LCLS-II Cryomodules Production Plans at Fermilab Tug Arkan

Introduction 2 partners labs are collaborating with SLAC for the LCLS-II project: Fermilab: Assemble 1 prototype 1.3 GHz CW module (May – December 2015) Assemble 16 production 1.3GHz CW modules (mid FY16 - mid FY18) Assemble 2 3.9GHz CW modules (late FY18) JLAB: Assemble 1 prototype 1.3 GHz CW module Assemble 17 production 1.3GHz CW modules Total: 35 Cryomodules (1.3GHz CW) 2 Cryomodules (3.9GHz CW)

LCLS-II Prototype Module Assembly Use existing ILC R&D 1.3GHz cavities: Process and test bare cavities Helium vessel welding to the cavity Test some of dressed cavities in HTS and some in VTS post helium vessel welding Cavity String Assembly Cold Mass Assembly Phase-I Cold Mass Assembly Phase II, III Cryomodule test (CMTF)

Planned LCLS-II Production Module Workflow at Fermilab Receive dressed, ready to be tested in vertical test stand (VTS) cavities from the vendors (Beamline under vacuum) Visual Incoming Inspection at IB4 Install, leak check and test the cavities in VTS at IB1 Qualified Cavities go to CAF-MP9 cleanroom for cold end coupler assembly. Non qualified cavities will be HPR'ed and re-tested. Some Cavities are then outfitted with tuner and magnetic shielding outside of the cleanroom at MP9 and then go to HTS at MDB for horizontal test. Other cavities will stay in the cleanroom and ready to be assembled into a cavity string. 8 qualified cavities, Magnet Spool Tube, BPM, Gate Valves, Interconnecting Bellows: Cavity String Assembly at CAF-MP9 Cleanroom Cold Mass Assembly Phase-I at CAF-MP9 Cold Mass Assembly Phase II, III and prep for transport to CMTF at CAF-ICB Cryomodule Test at CMTF Prepare and Ship Module to SLAC at CAF-ICB

Parts Inventory Management Partner labs has agreed on a joint procurement plan to acquire the cryomodule components. Each lab is responsible for the procurement of a certain part required for the modules Fundamental power couplers: Receive ready to be room temp conditioning or ready to be assembled onto qualified cavities All vacuum parts will be 100% leak checked Stainless steel parts and hardware will be checked for permeability (10% sampling) Hardware mechanical QC with gauge thread etc. (10% sampling) Critical dimensions checks for all the parts and sub-assemblies (CMM, optical, laser tracker etc.) Responsible engineer will sign off the incoming parts routing form with conformance and non conformance reports attached. Accepted parts go to storage. Rejected Parts require decision for further action. Accepted parts will be sent to the production floor as kits. Parts/Hardware will be cleaned (UHV, UHV&particle free, standard) and sorted at the production areas.

Parts / Fixture / Hardware Cleanroom Preparation Continuous work Assembly hardware: Wash/Rinse in the ultrasonic bath Blow clean with ionized nitrogen under the Class 10 hood Dry in Class 10 hood Transport into the Class 1000 ante clean room Blow clean with ionized nitrogen while monitoring the particulates count in the Class 100 sluice area Transport into the Class 10 assembly Class 10 Hood US cleaner

Assembly Workflow @ CAF-MP9 Receive dressed Cavities Receive peripheral parts Assemble cold end of the coupler to cavities in WS0 Assemble dressed Cavities to form a String in WS1 Install String Assembly to Cold Mass in WS2 Transport the Cold Mass to CAF-ICB

Assembly Workflow @ CAF-ICB Install the Cold Mass back to the Cold Mass Assembly Fixture in WS3 Align Cavity String to the Cold Mass Support in WS3 Install the String assembly with the cold mass into the Vacuum vessel WS4 Final assembly and QC at WS5 Prepare in WS6 & Ship Completed Cryomodule to CMTF for testing

CAF-MP9 Clean Room Cavity String Assembly Clean Room A ~250 square-meter clean room: Class 1000 ante clean room area: Preparation of the dressed cavities for transportation into the assembly clean room. Class 10/100 sluice area Parts and Fixtures final preparation to enter the Class 10 assembly area. Class 100 area Parts and Fixtures preparation for assembly. Class 10 assembly clean room area Class 100 Class 10 Class 1000 Rail

Cleanroom Infrastructure Vacuum / Gas Manifold Class 1000 cleanroom for the dressed/qualified cavity preparation to enter the cleanroom

Cold Mass Assembly Spreader bar fixture is used to support, lower and raise the GRHP String assembly rail is aligned to the center of the spreader bar fixture. We plan to add a second rail in WS2

Cold End Coupler Assembly (WS0) Leak check the dressed qualified cavity (received beamline under vacuum) Backfill the cavity Leak check the coupler pair in the processing stand as delivered from SLAC (or as received from the vendor) Backfill Remove a cold end coupler from the stand Assemble cold end coupler to the cavity using particle free flange assembly (PFFA) procedures. Pump down, leak check, RGA Total duration: 7 days 2 cleanroom techs, ~0.7 day per 1 cavity/coupler Goal: 2 cavities/couplers assembly per day, 4~5 days to complete 8 cavities + 2 days for extra QC

String Assembly-I (WS1) Align 8 cavities for string assembly: 1 day Gate Valve (GV1) to Cavity Assembly: 1 day Sub-assembly of the right angle valve Installation to the support post and vacuum hose assembly Leak check Alignment to the cavity beam line flange Particulate free flange assembly (PFFA) procedures Assemble the gate valve to the cavity

String Assembly-II (WS1) 1 day per interconnecting bellows, total = 7 x 1 = 7 days Cavity to Cavity Assembly with the interconnect bellows: Assemble vacuum hose to the cavity. Pump down and Leak check. Backfill Align the interconnect bellows to the cavity field probe end beampipe flange Assemble with PFFA Align the bellows to the cavity coupler end beampipe flange

String Assembly III (WS1) Magnet+BPM+GV2 assembly and leak check (1 day) Magnet subassembly to the 8 cavity string (1 day) Pump down, bag the bellows, leak check. Backfill (1 day) Total duration: 13 days 4 techs direct hands-on assembly 2 techs cleaning parts/hardware (UHV & Particle free) All 6 cleanroom techs fully qualified to do hands-on assembly

Cold Mass Assembly at CAF-MP9 (WS2) Work outside of the clean room before the string was lifted off the rail to the cold mass support: (Phase-I) Transport the cavity string to the adjacent rail (0.5 day) 2-phase helium pipes & bellows cut/welding (1 day) Cavity magnetic shields installation (0.5 day) Tuner installation (2 days) Cavity insulation installation (0.5 day) Temperature sensors instrumentation and RF cables installation (1 day) Cavity helium vessel lugs needle bearings and housings installation (1 day) Various leak checks / pressure tests of the helium circuit (1 day) Various electrical checks (1 day) Various RF checks (2 days) Total duration : ~10 days

Cold Mass Transport (1~1.5 days, 4 mechanical techs) After the cavity string is picked up off the rail and partially assembled to the cold mass support, the cold mass assembly is transported to the Vacuum Vessel Assembly Area at CAF-ICB (~5km from CAF-MP9). (1~1.5 days, 4 mechanical techs)

Cold Mass Assembly at CAF-ICB (WS3) Assembly Tasks: (Phase-II) Put the cold mass on the 4 support spreader bar fixture (0.25 day) Assemble Magnet (0.5 day) Align cavity string (laser tracker) (2.5 days) Complete the interconnect magnetic shielding assembly (1 day) Complete the coupler heat shields intercepts assembly (0.25 day) Complete cooling straps assembly to the cavities HOM (0.25 day) Complete the harnessing of the instrumentation wires & RF cables (0.5 day) RF Checks (1 day) Various electrical checks (0.25 day) Weld the magnet current leads to the magnet instrumentation box (0.25 day) Various leak checks of the helium circuit (1 day) Total duration : ~8 days

Assembly on Big Bertha at CAF-ICB (WS4) Assembly tasks: (Phase-II) Install and weld lower 50K aluminum shields (1 day) 30 layers of MLI as blankets (1 day) Trim insulations around main couplers, magnet and cold mass support posts (1 day) Electrical checks (0.5 day) RF checks (1 day) Slide vacuum vessel onto the cold mass (0.25 day) Align cold mass to the vacuum vessel (laser tracker) (2 days) Weld magnet flanges and JT valve (0.5 day) Various leak checks (1 day) Total duration : ~7 days

Final Assembly Phase-III (WS5) Install warm part of the main power couplers (8 days) Route & terminate instrumentations wires and RF cables to the feedthrough flanges (3 days) Install coupler pumping lines/pumps & leak check (1 day) Pump down and leak check insulating vacuum (2.5 days) Total duration : ~15 days

Cryomodule Transport Preparation (WS6) Transport completed Cryomodule from CAF-ICB to the CMTF : 1 days Shipping preparation to SLAC: 3 days

Module Transportation to SLAC Shipping fixture and end cans need to be designed and fabricated. (similar to XFEL design). Use the prototype modules for shipping tests Ship Modules with cavity string under vacuum; insulating vacuum backfilled with nitrogen slightly above atmospheric pressure; warm end couplers under vacuum

LCLS-II 1.3 GHz Module Assembly at CAF WS2:10 days WS1: 13 days WS0: 7 days WS3: 8 days WS5: 15 days WS4:7 days WS6: 1~3 days Total = ~60 days (peak rate)

Module Assembly Weekly Workflow Module #n Module #n+1 Module #n+2 Cleanroom Assembly: Start: Week #1 Complete: Week #4 Cleanroom Assembly: Start: Week #5 Complete: Week#8 Cleanroom Assembly: Start: Week #9 Complete: Week #12 Cold Mass Assembly: Start: Week #5 Complete: Week #12 Cold Mass Assembly: Start: Week #9 Complete Week #16 Cold Mass Assembly: Start: Week #13 Complete Week #20 4 weeks throughput 4 weeks throughput It takes ~12 (60 days) weeks to assemble a module. Excluding any sick modules that need to be reworked, there will be max 3 modules in the production line at the same time

CAF Mechanical Tech Workforce for LCLS-II Cleanroom Techs (Total of 6 are needed) Current: 3 cleanroom techs, fully trained and experienced Goal: Hire 3 new contract mechanical techs and train them Cold Mass Techs (Total of 8 are needed) 2 cold mas techs, fully trained and experienced Hire 6 new contract mechanical techs and train them

Summary Cryomodule Assembly Facility (CAF) infrastructure require minor upgrades for LCLS-II modules assembly. We are in the process of making the necessary upgrades. Some of the existing fixtures need to be modified. Some new fixtures need to be designed and fabricated. CAF core mechanical technician group is small but very well trained and experienced. Qualified manpower especially touch labor shortage is a major issue. Current plan is to hire contract mechanical technicians and train them. Training period is ~1 year for a fully qualified cleanroom tech and ~6 months for a cold mass assembly tech. Contract tech high turnover rate is a risk Support groups (electrical, QC, material handling) are also understaffed We are in the process of hiring full time and contract staff to remedy understaffing problem We will test the CAF infrastructure feasibility during the prototype module assembly