Thomas Jefferson National Accelerator Facility Page 1 UITF Progress meeting UITF Project Status Meeting Matt Poelker October 21, 2015

Thomas Jefferson National Accelerator Facility Page 2 UITF Progress meetingOutline Purpose: to inform Lab Leadership of the UITF status Action Items (from previous meetings) Project Update –Progress Update –Milestones Update –Budget Update –Highlights & Concerns –Next meeting agenda

Thomas Jefferson National Accelerator Facility Page 3 UITF Progress meeting To refresh your memory… What we started with… UITF as imagined

Thomas Jefferson National Accelerator Facility Page 4 UITF Progress meeting Action Items – From August 31, 2015 Minutes New Action Items: Matt will provide the UITF Oct/Nov/Dec spend plan to Allison & Lyn ASAP Andy will provide information at the next meeting on the Physics Division response to his updated request for resources

Thomas Jefferson National Accelerator Facility Page 5 UITF Progress meeting Major components Facilities Engineering Mech Design Cryo Safety Systems I&C DC Power Low Level RF systems High Power RF Survey & Alignment SRF Commission with RF Operations Network and communications Progress Update Green means we can see progress

Thomas Jefferson National Accelerator Facility Page 6 UITF Progress meeting Major components Source Group Reliable 350kV ops Beam to cup in front of ¼ CM Beam to cup in front of HDIce EHSQ Shielding approval, ODH assessment  Global hazard review FSAD Accel Readiness Review Commissioning Plan HDIce Installation at Cave Beam on HDIce Progress Update Green means we can see progress

Thomas Jefferson National Accelerator Facility Page 7 UITF Progress meeting Cave 1 cleared out

Thomas Jefferson National Accelerator Facility Page 8 UITF Progress meeting Installation Group LCW, compressed air, and GN2 plumbing installed Cave1 Platforms for Electronics racks Shielding plates beneath penetrations Attach PSS conduit Cable trays above beamline

Thomas Jefferson National Accelerator Facility Page 9 UITF Progress meeting Cave 2

Thomas Jefferson National Accelerator Facility Page 10 UITF Progress meeting Facilities Electricity to top of Cave1, and inside Cave1. Procurement Dept. setting up site visit for contractors, who will submit bids. Site visit within 2 weeks, work complete by end of November. Jason W. estimates $109k

Thomas Jefferson National Accelerator Facility Page 11 UITF Progress meeting Rack layout clearly defined 11 Electricity to racks by end of November Plus outstanding PR for $18k for communications conduit… Brad would then install communications network, IOCs Pam loads software… System owners can then populate the racks

Thomas Jefferson National Accelerator Facility Page 12 UITF Progress meeting Control Room Facilities added carpet, relocated air conditioner, moved a door (thanks) Work station purchased and installed Terminals can now be installed Electricity and network connections coming soon, then IOCs, then software

Thomas Jefferson National Accelerator Facility Page 13 UITF Progress meeting Simple ODH solution? vent pipes Large entry/exit with chain-link gate Install elbow-shaped vent pipes inside pre-cast concrete Can Cryo/EHS&Q specify vent dimensions? How many? Radcon must approve from shielding perspective Two 30” vent pipes in Cave1 Six 10” dia. cable penetrations

Thomas Jefferson National Accelerator Facility Page 14 UITF Progress meeting Big Chimney near HDIce Helium source terms identified for ¼ CM and CTF, and also HDIce Strategy still focused on using passive exhaust vents to maintain ODH0 (or ODH1) conditions Large vent 30 ft 2 near HDIce, 10 ft 2 vents inside Cave1, ceiling penetration with chimney, chain link gate, Test Lab high bay equivalent to “outside” Will Oren working with Cryo, SRF, HDIce to complete the assessment

Thomas Jefferson National Accelerator Facility Page 15 UITF Progress meeting

Thomas Jefferson National Accelerator Facility Page 16 UITF Progress meeting Combine the two features that provided incremental success: shed and doped insulator Next test late September

Thomas Jefferson National Accelerator Facility Page 17 UITF Progress meeting Tedious polishing complete. Next: vacuum degas electrode components, assemble on insulator and install on gun at GTS, align photocathode puck manipulator, bake gun, patiently high voltage process the gun Repeat when black, mildly conductive insulator arrives late November Next test late October

Thomas Jefferson National Accelerator Facility Page 18 UITF Progress meeting Milestones Update WBSItemMilestone DescriptionStart Date Projected Finish % Complete Days Float? Change (%) Change (Days) 1.04.xx x FacilitiesCivil work complete6-4-15Feb %10 to 50% GunDemonstrate gun ok at 350 kW at FEL GTS Dec %0 CMCommission cold ¼ CM, no beam Jan %10 to 20% Beam from Gun to Cup in front of ¼ CM Mar %10 to 20% Beam thru MeV energy delivered to cup in front of HDIce Jun Beam to HDIceAug Tom Renzo happy with ODH vent plans, now working on aspects of Cave2 structure, taking credit for Electricity procurement Not as much progress on Gun Plan Y: my guys working on LERF, bubble chamber and CEBAF

Thomas Jefferson National Accelerator Facility Page 19 UITF Progress meeting Carryover = $81k Cancelled $71k trim card PR

Thomas Jefferson National Accelerator Facility Page 20 UITF Progress meeting Month by Month Spending Profile

Thomas Jefferson National Accelerator Facility Page 21 UITF Progress meeting Schedule Ramifications Current status: Responding to CR Working to resolve some lingering Cryo-related issues: 2K vs 4K red-herring, how best to provide LHe to HDIce, “parking” the ¼CM when not in use, 4K cold box upgrade schedule, ODH assessment Next month activities (November) Perimeter of Cave2 complete Tom Renzo finalizing Cave2 structural design (precast concrete, bracing, anchoring, roof planks) Electricity delivered to racks Find a way to purchase Communications conduit, so network and IOCs can be installed (or done by in-house folks?) ODH assessment complete, ideally with ODH0 assignment Old cryo transfer lines removed Voltage applied to gun at GTS, plan Y

Thomas Jefferson National Accelerator Facility Page 22 UITF Progress meeting Schedule Ramifications In two months (December): Source group building keV beamline Klystron rack finished, R. Nelson building control panel Low level rf boards complete, installation in racks begins IOCs installed, Software group installing software Installation group working opportunistically: shield plates, PSS conduit, cable trays, some demolition Safety System Group working on ODH system Cryo group installing new transfer lines… Procurements for Cryo controls approved Recall, next big milestone…commission ¼ CM (no beam), scheduled for Feb (cryo, ODH, LL and HP RF, software, adequate shielding, EHS&Q approvals)

Thomas Jefferson National Accelerator Facility Page 23 UITF Progress meeting Schedule Ramifications Commission ¼ CM (no beam), scheduled for Feb 2016 Electric/FM – ($109k + $23k for com. conduit) 132 k$ Control room – - SRF checkout of ¼ CM present condition – - Low Level RF – 16 k$ High Power RF – 25 k$ Network controls – 33 k$ Software control of RF – - adequate shielding (Cave2 with a roof) – - Cryo – (controls and pipe) 68 k$ Installation group 9 k$ ODH - SSG 2 k$ EHS&Q approvals… - Total 285 k$

Thomas Jefferson National Accelerator Facility Page 24 UITF Progress meeting Status Cryo Related to ¼ Cryomodule Poelker’s suggestion to operate at 4K was a distraction A challenge: appreciating the best way to connect to CTF, so as not to do it again How to cool HDIce (need to downselect) “Parking” the ¼ CM can influence design Anticipated CTF upgrades Related to HDIce Purchase LHe (expensive), Cryo group provides dewars (was our Plan A), connect HDIce to CTF Message1: Need to stop thinking and start marching Message2: 4K cold box work scheduled for August 2016

Thomas Jefferson National Accelerator Facility Page 25 UITF Progress meeting Labor-focused Tasks Installation Group Cable trays, PSS conduit, penetration shielding, rack prep in advance of electric work, removal of rails and LCW piping Cave2, silver solder the quad magnet cooling tubes Have our electricians install communications conduit Have Ops staff install network switch and IOCs Magnet Mapping, quads and solenoids Mechanical Design: finish keV region, resume MeV region design DC Power: refurbish the racks for trim cards, re-install trim cards Low Level RF – finish construction of rf control boards High Power RF – work on the control panel and klystron rack Cryo: remove old transfer lines

Thomas Jefferson National Accelerator Facility Page 26 UITF Progress meeting Design work was stopped…would like it to continue

Thomas Jefferson National Accelerator Facility Page 27 UITF Progress meetingSummary Despite CR, there is continued progress and it is becoming more obvious, visible But the schedule is slipping… Appreciating the impact of CTF 4K cold box replacement. Scheduled start date is our scheduled “beam on HDIce” target date, August 2016 BNL has asked “me” to demonstrate their high current, long lifetime, polarized beam milestone for eRHIC. Could we use this to our advantage?

Thomas Jefferson National Accelerator Facility Page 28 UITF Progress meeting Backup Slides Backup slides from past meetings, P&C meetings

Thomas Jefferson National Accelerator Facility Page 29 UITF Progress meeting “Shed” triple- point protection Doped insulator SF6 R350 epoxy receptacle Combination of doped insulator and shed, SF6 and epoxy receptacle, plus added length Yan Wang has modeled the shed, a good design… …then in October

Thomas Jefferson National Accelerator Facility Page 30 UITF Progress meeting Original vs Current Cost Estimate Presented at UITF meeting May 13, 2015: Total cost estimate. The specific allocations for FY15 and 16 are not correct Original Est. by Hari Areti FTEsLaborProcTotalLaborProcTotal on FY , FY , FY Total , , , , , Revised Est. FTEsLaborProcTotalLaborProcTotal by Matt PoelkerFY % on FY , , , % FY , , , , % Total17.7 2, , , , , , Dfference from original estimate (11.5) (1,263.46) (645.93) (1,909.39) (1,719.10) (1,014.40) (2,919.25) Loaded $Direct $

Thomas Jefferson National Accelerator Facility Page 31 UITF Progress meeting Revised Estimates Breakdown Original request to DOE: $2.6M (loaded) Current estimate for completion: $5.6 M (loaded) Delta increase of $2.9M (loaded) Labor estimates Underestimated effort by 11.5 FTEs Increased labor by $1.7M (loaded) Procurements Underestimated by ~$1M (loaded) Several sub-system components were not included in the original estimate and later determined were necessary to complete the scope

Thomas Jefferson National Accelerator Facility Page 32 UITF Progress meeting Comparison Procurement Estimates (Direct $) SystemPrevNowDeltaComment Facilities (numbers are Proc and Labor) Safety System RF Systems rf control boards, klystron PS Cryogenics Pipe, heat exchanger Polarized Source Gun insulators, beamline parts I&C BPMs, viewers, picoammeters DC Power Trim cards and parts Magnets Addl. quads, correctors, dipoles SRF HDIce50-5 Network, IOCs CIS FY14 Actuals FY14 actuals Total1,0281,

Thomas Jefferson National Accelerator Facility Page 33 UITF Progress meeting FY14 and FY15 UITF Procurements FY14FY15 Addl. expected FY15 procurements Solid Works CAD2.2Insulator flange1 Contract Mech Designer~ kV HV power supply31.1bpm components7.6 stairs~ 20 semiconducting R30 insulators52.6 semiconducting R30 insulators_v222.3 trim cards~100 gun HV chamber7.8 Klystron HV power supply55.5 quad magnets (machine shop)70 to 130 ion pumps15.1concrete wall removal32 Chopper rf amplifiers (x2)44 beamline Y chamber5LLRF parts15.1 water skid for chopper3 photocathode prep chamber4.5steering magnets19.3 keV beamline support structure6.5 drill penetrations in concrete4.2SF6 tank11.3 Addl. FY15 procurement total303.5 assorted3.9waveguide3.8 Credit card21.8SSG sensor1 Machine shop40.8assorted9.4 total189total178.3 FY14 + FY15 Procurements: UITF Total Procurements 1682

Thomas Jefferson National Accelerator Facility Page 34 UITF Progress meeting FY16 Procurements? ~ required spent in FY14 FY15 To purchase in FY16 Facilities: Cryo90.80 waiting for update RF Gun includes beamline components + contract designer I&C Hope to reduce this number using PLC technology SSG DC power Trim cards… Magnets shop to make quads, assumed 100k but could be less Still need three dipoles Network58 0 Total Of course, hope the number comes in lower: 750 k$