1. Thomas Jefferson National Accelerator Facility Page 1 Dana Arenius Cryogenics Control Account Manager 12 GeV Upgrade Project X Collaboration September 8, 2010 JLab 12 GeV Cryogenics Upgrade WBS 1.3.3

2. Thomas Jefferson National Accelerator Facility Page 2 Outline Work structure and requirements Work scope to meet requirements Work Plan (Schedule) Cost Status Risks/problems Encountered Quality Control Check-out Commissioning

3. Thomas Jefferson National Accelerator Facility Page 3 Cryo SRD Costing info & backup Drawings 95% Complete Cryogenics detailed req & spec doc’s Cryo DSD Accelerator DSD WBS dictionary Cryomodules DSD ICD’s P3 System Function & Requirements In place Cryo DCD Procedures Power DSD ICS DSD Cryomodules SRD Power SRD ICS SRD In place or under development, as built

4. Thomas Jefferson National Accelerator Facility Page 4 Accelerator and Hall D Requirements Install Hall D Refrigerator Procure & Install 2nd CHL Refrigerator

5. Thomas Jefferson National Accelerator Facility Page 5 Requirements From System Functions & Requirements Document (Accelerator DSD document) CHL: (Forms the Systems Requirements Document for the Accelerator cryogenics, SRD) Provide, install and commission 2K and 35K refrigeration capacities for 10 additional linac cryomodules (5 per linac) Hall D: (Forms the Systems Requirements Document for Hall D cryogenics, Hall D DSD document) Install and commission the existing Hall D 200W, 4.5K refrigerator for magnet and target cooling

6. Thomas Jefferson National Accelerator Facility Page 6 Requirements Key refrigeration technical parameters Each New Cryomodule (CHL) Load 300W @ 2K (0.0375 atm at return 2K bayonet, +/- 0.1 mbar standard pressure regulation 300W @ 35K shield cooling Hall D Refrigerator Load 100W @ 4.5K refrigeration 0.7 liters/hr 4.5K liquefaction (lead cooling, etc.)

7. Thomas Jefferson National Accelerator Facility Page 7 Requirements From Interface Control Documents SRF Cryomodules: 2K and 35K process interface RF Provides…. Cryomodule Heater Control and Interlocks Hall D Provides…. Transfer line 4K & LN2 Process Interface Controls Group Provides… No external requirements Civil Provides….. Building, ventilation, electric, cooling water

8. Thomas Jefferson National Accelerator Facility Page 8 Scope Needed to Implement the DSD CHL Provide, Install, and Commission 4600W 2K and 12000W 35K Helium Refrigerator System, Use much of the existing infrastructure as possible (Ex: existing cold compressors) Hall D Install and commission an in-house Hall D 200W, 4.5K refrigerator for magnet and target cooling

9. Thomas Jefferson National Accelerator Facility Page 9 Meeting the Requirements Cryo Design Solution Document (DSD) CHL….Provide, Install, and Commission 4600W 2K Helium Refrigerator System  New Major Components Warm Helium Compressors (5 compressors) 4600W @ 2.1K Helium Refrigerator (2 piece) Oil Removal Coalescer Vessels and Filter LHe Dewar, 10,000 liter Gas Management Valve Rack 4KV Motor Control Center Instrumentation and Controls Instrument Air System

10. Thomas Jefferson National Accelerator Facility Page 10 Meeting the Requirements Design Solution Document (unchanged since IPR09) CHL….Provide, Install, and Commission 4600W 2K Helium Refrigerator System  Existing Major Components Cold compressor cold box Linac cryogen transfer lines Guard Vacuum System 4.5K Refrigerator building Central Control Room 20,000 gallon LN2 dewar (2) 4000 cf gaseous helium storage vessels (7)

11. Thomas Jefferson National Accelerator Facility Page 11 Meeting the Requirements Design Solution Document (DSD) Hall D: Install and commission 200W, 4.5K helium refrigeration system New Major Components 4,000 cf Gaseous Helium Storage Vessel LN2 Dewar, 10,000 liter Instrumentation and Controls Gas Management Valve Rack Gaseous Helium Process Piping Instrument Air System Existing Major Components 4.5K 200W Refrigerator Warm Helium Compressors w/starters LHe Dewar, 1,000 liter

12. Thomas Jefferson National Accelerator Facility Page 12 Work Plan

13. Thomas Jefferson National Accelerator Facility Page 13 WBS 1.3.3 Construction Cost Overview

14. Thomas Jefferson National Accelerator Facility Page 14 WBS 1.3.3 Construction Cost Overview

15. Thomas Jefferson National Accelerator Facility Page 15 WBS 1.3.3 Cryogenics Cost Methodology Basis of Estimate (BOE) 1-Sept-091-Sept-10 Costed0%59% Obligated0%31% Quotes from vendors0%5% Catalog prices0% Estimates from vendors/consultants74%0% Previous JLab experience26%5% Information from other labs, universities, etc.0% Engineering judgment0%

16. Thomas Jefferson National Accelerator Facility Page 16 Risks/Problems Encountered Wide variation of foreign exchange rate (1.29-1.65) over the project duration Hall D Model 2800 refrigerator physical condition, non- useable (provided to cryogenics for installation and commissioning by physics division) Vendor adherence to the specifications/design requirements

17. Thomas Jefferson National Accelerator Facility Page 17 Current Status All major equipment and materials procured Total Material/Equipment $19.1M Percentage purchased90% CHL building civil construction completed, 5/2010 CHL utility construction started, completion date 2/2011 CHL equipment installation work started, completion date 8/2011 Capacity of Hall D refrigerator verified Major equipment arriving daily 2 months ahead of schedule and near cost for this planned point of the project (~$30K over, July 2010) Current CHL#2 refrigerator design supports goal of 2/3rds of the electric power and LN2 requirements of the existng CHL#1

18. Thomas Jefferson National Accelerator Facility Page 18 Procurement Status WBSSystemStatus 1.3.3.1CHL 1.3.3.1.1Warm Helium CompressorsAwarded 1.3.3. 1.24.5K Cold BoxAwarded Helium VaporizersAwarded LHe Storage DewarAwarded 1.3.3.1.3Oil Removal VesselsAwarded 1.3.3.1.6 Gas Management Valve RackInstalled 1.3.3.1.7Instrumentation and ControlReceived 1.3.3.1.8Instrument Air SystemInstalled 1.3.3.1.94160V MCCInstalled 1.3.3.1.10 Installation MaterialsReceived 1.3.3.1.11 CommissioningScheduled for FY12 1.3.3.1.12 Linac Transfer LineScheduled for FY11 1.3.3.2Hall D Refrigeration System 1.3.3.2.2Hall D Cold BoxIn House, Tested Warm Helium CompressorsIn House, Tested 1.3.3.2.3Refrigerator Piping DistributionScheduled for FY11 Gaseous Helium StorageReceived LN2 DewarReceived LHe StorageDewarIn House 1.3.3.2.4Instrumentation and ControlReceived 1.3.3.2.5U-TubesScheduled for FY12 1.3.3.2.6Field Installation MaterialsScheduled for FY11-12 1.3.3.2.7CommissioningScheduled for FY12

19. Thomas Jefferson National Accelerator Facility Page 19 CHL Major Equipment Procurements CHL Warm Helium Compressors (5) Awarded, PDR Pending Major subcomponents on order CHL 4.5K Cold Box Awarded, PDR Complete, Major Components on order, PDR Complete, FDR Pending Compressors & 4.5K Cold Box Represents ~73% of 1.3.3.1

20. Thomas Jefferson National Accelerator Facility Page 20 Other CHL Major Procurements Gas Management Rack Installed 4160V MCC Installed Oil Removal Vessels Oct 2010 Delivery LHe Storage Dewar Sept 2010 Delivery New Photo

21. Thomas Jefferson National Accelerator Facility Page 21 CHL Compressor Building Ready for Equipment CHL Building (August 09) CHL Building (July 09) New Photo Needed

22. Thomas Jefferson National Accelerator Facility Page 22 CHL Compressor Installation Piping Warm Helium Compressor Room Piping Underway

23. Thomas Jefferson National Accelerator Facility Page 23 Hall D Refrigerator Evaluation 2009 plan was to install existing Model 2800 refrigerator for Hall D Refrigerator failed incoming leak testing, both heat exchanger cross leaks and heat exchanger to vacuum leaks 2010 plan replaced the original with another existing Model 2800 refrigerator The replacement refrigerator was performance tested successfully in its current location, achieved 110% of required capacity

24. Thomas Jefferson National Accelerator Facility Page 24 Hall D Major Refrigeration Equipment Model 2800 Refrigerator On Site, Capacity Tested Helium Compressors On site, Capacity Tested

25. Thomas Jefferson National Accelerator Facility Page 25 Other Hall D Major Components Hall D GHe 4K cf Storage Delivered New Photo Hall D 6K Gal LN2 Dewar, Delivered

26. Thomas Jefferson National Accelerator Facility Page 26 Quality Control During Material Delivery Incoming material inspection/documentation and purchase compliance During assembly Weld Inspections, electrical and mechanical material certifications, weld documentation, assembly and traveler documentation compliance, workmanship, worker qualifications, safety training and procedures in place, special component qualification tests, final assembly inspection and certification During installation Weld Inspections, electrical and mechanical material certifications, weld documentation, installation traveler documentation compliance, workmanship, worker qualifications, safety training and procedures in place, as-built installation documentation

27. Thomas Jefferson National Accelerator Facility Page 27 Check-out Without power Point to Point Wiring Continuity, instrument and control calibrations, compressor and oil pump motor alignments, electrical megger tests, mechanical pressure and leak checks, compressor oil charging, operator and maintenance/repair training, safety training With power Utility verification, motor rotation direction verification, MCC functional tests, insulating vacuum verification, cooling water distribution balancing, full control system functional test, safety interlock functional tests, system decontamination, compressor oil charging, turbine cartridge installations, operation readiness reviews, helium compressor performance test, CHL 4.5K and Hall D refrigerator performance test, certification of readiness to support the accelerator linacs and Hall D. With beam Operation of the Accelerator CHL and Hall D refrigerators

28. Thomas Jefferson National Accelerator Facility Page 28 Commissioning Pre-Ops/Testing CHL Refrigerator Startup and cool down CHL#2 refrigerator Operate CHL#2 at or above 3500W @ 2K and 800W @ 50K for 12 hours. Operate CHL#2 at or above 4000W @ 2K and 10,000W @ 50K for 12 hours. Operate CHL#2 at or above 4600W @ 2K and 12,000W @ 50K for 12 hours. Hall D Refrigerator Operate Hall D refrigerator at 100W @ 4K and 0.7 g/s liquefaction for 12 hours

29. Thomas Jefferson National Accelerator Facility Page 29 Summary 12 GeV cryogenics is slightly ahead of schedule and is on cost All major equipment has been ordered Remaining cost associated with installation labor, check- out and commissioning and minor purchases Risks encountered include foreign exchange and Hall D refrigerator performance validation Substantial reduction in electrical power and LN2 usage