LERF Readiness Review Ed Daly / Matt Marchlik Pressure System, Cryo Processes November 12 - 13, 2018

Outline Section 1: Pressure System Section 2: Cryo Process Outline Introduction Analysis Summary Section 2: Cryo Process Processes 11/12/2018

Pressure Systems - Outline Introduction Analysis Leak Testing Summary 11/12/2018

Pressure Systems - Introduction JLAB established the ES&H Chapter 6151 Pressure and Vacuum Systems Safety Supplement (PVSSS) to comply with the requirements of 10 CFR 851 “Worker Safety and Health Program” All JLAB pressure systems constructed on or after January 4, 2016 shall meet the requirements of the PVSSS 11/12/2018

Pressure Systems - Introduction Pressure System # PS-SRF-18-001 PS Folder located in DocuShare Calculations PS-1 Form (Cover Sheet) PS-3 Form (Technical Review) PS-6 Form (Final Mechanical Examination) PS-7 Form (Leak Test record) PS-8 Form (Final Walkthrough) PS-9 Form (System Turnover → Kevin Jordan, System Owner) 11/12/2018

Pressure Systems - Introduction All PS folders will be populated with the required documentation before energizing/commissioning the system Calculations WPSs & WPQs Material certs Inspection/examination reports Leak tests reports PS Forms 11/12/2018

Pressure Systems - Introduction 11/12/2018

Pressure Systems - Introduction P&ID JL0043630 In approval process Nomenclature: CEVCM03_12 is within zone 03. CM 2 CM 1 Zone 00 Zone 03 Zone 02 Zone 01 11/12/2018

Pressure Systems - Analysis ASME B31.3-2016 - Process Piping is the code of record for this system Analysis number PS-SRF-18-001-A1 Reviewed/Approved Located in the Document Repository 11/12/2018

Pressure Systems - Analysis System parameters Normal Fluid Service Design Pressures 4 K Supply: 165 psig Shield Supply: 165 psig Shield Return: 165 psig 2 k Return: 58 psig 300 K Supply: 150 psig Cooldown Circuit: 58 psig 11/12/2018

Pressure Systems – Leak Testing Leak testing performed per ASME B31.3 requirements. Positive pressure helium sensitive leak test The Cryo can’s process piping lines and vacuum boundary have been leak tested at the manufacturer Transfer line segments (2 ea) have been leak tested at the manufacturer LCLS-II CMs are already tested 11/12/2018

Pressure Systems – Leak Testing Transfer line shield and 4 K supply process piping field welds have been leak tested 11/12/2018

Pressure Systems – Leak Testing Cryo can to transfer line welds will be tested when completed in the near future. Currently being welded. Shield supply, shield return, 4 K supply, 2 K return process piping welds 300 K supply circuit Fast cooldown line 11/12/2018

Pressure Systems – Summary Analysis complete PS-1 PS-3 PS-6 PS-7 PS-8 PS-9 Installation in progress Leak testing in progress 11/12/2018

Cryo Processes - Outline Introduction Procedures Risk Mitigation Summary 11/12/2018

Cryo Processes - Introduction LERF LCLS-II CM testing procedures were established in collaboration with JLAB’s Cryogenic Group to ensure safe operation and to mitigate impact to CEBAF operations U-tube Stabbing procedure based upon existing procedures Cooldown procedure Temperature Bump procedure Warm Up procedure 11/12/2018

Cryo Processes - Introduction Prerequisites Process lines cleaned and purged CHL shall be at 4 K during u-tube operations to manage potential contamination Signal verification of all instrumentation according to procedures FL02 is cold and providing additional heat (200W) to establish stable return pressure Approved ATLis for each process ensuring all relevant parties are informed 11/12/2018

Cryo Processes – Procedures - Cooldown Initial CM cooldown from 300 K Simultaneously cool both CMs Preliminary Steps: Instrumentation signal verification Valves, vac, LL-gauges, P-transducers, T-diodes, and flow meters Strip Charts GHRP diodes LL gauges Helium pressures Valve positions U-tube installation Create ATLis and ensure it has been reviewed by Cryo Group 11/12/2018

Cryo Processes – Procedures - Cooldown Shield Cooldown ~ 3 g/s at operating T Operating temperature of 35 – 60 K 11/12/2018

Cryo Processes – Procedures - Cooldown Primary Cooldown RT valve closed Both CMs simultaneously CMCD and JT valves open CD bypass valve open Flow controlled to limit CM pressure to 1.5 atm JT valves closed when 4 K lines at 50 K GHRP Tavg < 80 K, primary supply full open Liquid formation – Close CMCDs JTs set to 78% upsLL After soak (24hr), Close JTs 11/12/2018

Cryo Processes – Procedures - Cooldown Primary Cooldown cont’d Open RT- Cryo Group monitors return pressure When return-P < .045 atm, JTs set to 90% upsLL Cryo Group to assist in RT valve setup for steady state ops Cryo Group to perform RT pumpdown to 2 K Primary supply 100% upper limit once stable JTs set to 90% upsLL 11/12/2018

Cryo Processes – Procedures – Temperature Bump To expel remanent magnetic field from the cavities One CM at a time, up to 40K and back down to 4K Preliminary Steps: Strip Charts Diodes LL gauges Helium pressures Valve positions Create ATLis and ensure it has been reviewed by Cryo Group 11/12/2018

Cryo Processes – Procedures – Temperature Bump RT closed CD bypass valve open Cryo Group – Open SLINAC CD valve (transfer line CD header to recovery) CM2 CD heater on CHL recovery 1.08<P<1.09 atm Cavity HV at 40 K → Heater off HEATER 11/12/2018

Cryo Processes – Procedures – Temperature Bump FCD Cryo Group to monitor SLINAC Cold compressor speed Open CM2CD valve Cavities at 4 K, close CM2CD and set CM2JT for 80% upsLL 11/12/2018

Cryo Processes – Procedures – Temperature Bump CM2JT is closed and the same steps are then performed for CM1 CD bypass valve is closed and the RT valve is opened The opening of the RT valve is controlled by the Cryo Group as they monitor return pressure and cold compressor stability RT valve is fully opened and disconnected from controls JT valves are set to maintain 90% upsLL 11/12/2018

Cryo Processes – Procedures – Warm Up To warm the CM back up to 300 K after testing Both CMs simultaneously at a rate acceptable to Cryo Group Preliminary Steps: Strip Charts Diodes LL gauges Helium pressures Valve positions Create ATLis and ensure it has been reviewed by Cryo Group 11/12/2018

Cryo Processes – Procedures – Warm Up Close the 4 K supply valve Close the RT valve Open CD bypass valve Maintain return line P<1.05 atm Close JT valves Open CMCD valves HV heaters on until dwnsLL<20% Maintain CHL recovery P<1.09 atm Open 300 K supply valve ~1.5g/s Incrementally increase insulating vacuum space pressure GHRP T>285 K, heaters off Close 300 K supply valve HEATER 11/12/2018

Approach for Risk Mitigation Design modified after review to require only one set of u- tube operations at initial 4K cooldown and removal after warm-up Fast cooldown down via atmospheric return (4K) Max flow rate dictated by stable operations of vacuum No plans for FCD thru 2K return transfer line Majority of operations is single cavity testing (up to 20 W dynamic) with FL02 heater energized at 200W Multi-cavity operations will happen only after all cavities have been characterized individually and ATLis is approved

Cryo Processes – Risk Mitigation (1/2) PROCESS/STEP RISK MITIGATION(S) Primary cooldown/Open RT valve-step 11c Overpressurization of return header, trip CHL Cryo Group will monitor parameters and direct opening rate during pumpdown Temperature bump/heater warm up-step 9 Cryo Group will monitor recovery pressure. Heater power dialed back Temperature bump/Open CM CD valve-step 15-17, 29-31 Cryo Group will monitor the cold compressor speed. Adjust CM-CD valves All/State of EV and Manual valves on Cooldown header Potential connection between subatmospheric and atmospheric return paths if RT is open simultaneously Administrative tag on manual valve with state change requiring Cryo Group concurrence. CEVCD disconnected; Consider disconnecting atm return line 11/12/2018

Cryo Processes – Risk Mitigation (2/2) PROCESS/STEP RISK MITIGATION(S) CM steady operations Instability in 2K return TL causing pressure oscillations at Cold Compressors Require 200 W heater heat in FL02 CM steady operations / Cavity Testing / RF ON Excessive power into primary return due to dynamic heating Single cavity testing with constant heat (200 W) in FL02 Overfilling helium volume with spill-over into return piping causing pressure oscillations “A” loop on primary JT closes when pressure exceeds specified limits Overloading SLINAC cold compressor Cryo Group will monitor the cold compressor speed. Adjust CM-JT valves CM steady operations / 2K RT Valve operations Instability in 2K return TL causing pressure oscillations at Cold Compressors leading to trip Calibrate RT valve actuator LVDT; Consider verifying leak tightness of RT valve 11/12/2018

Processes – Summary Preliminary Cooldown procedure developed Preliminary Temperature Bump procedure developed Preliminary Warm Up procedure developed Scenarios that could negatively impact CEBAF CHL operation are understood and able to be mitigated Cryogenics Group has collaborated in the development of the procedures 11/12/2018

Summary Pressure System Program Analysis complete Completed PS-forms filed Installation and leak testing in progress Procedures Preliminary procedures written Cryogenics Group has collaborated in the development of the procedures Procedures will continue to be updated based on feeback from initial testing observations 11/12/2018