1. Cryomodule Specifications and Design Overview Tom Peterson 12 May 2015 LCLS-II 1.3 GHz Cryomodule

2. 2 Outline Production Cryomodule Final Design Review, 12 May 2015 Introduction, configuration and layout Documentation status FDR, differences from prototype High Q0 retention, cool-down Liquid helium management Thermal design, heat loads, pressure drops Cryomodule interfaces Prototype tests Summary

3. 3 LCLS-II Linac Production Cryomodule Final Design Review, 12 May 2015 Physics Requirements Document: “SCRF 1.3 GHz Cryomodule,” LCLSII-4.1-PR-0146-R0, 4/30/2014 Original Release. Thirty-five 1.3 GHz 8-cavity cryomodules Two 3.9 GHz 8-cavity cryomodules Four cold segments (L0, L1, L2 and L3) which are separated by warm beamline sections.

4. 4 The Cryogenic System Production Cryomodule Final Design Review, 12 May 2015 Figure from LCLS-II-4.9-EN-0300 (ED0001995) LCLS-II CDS Relief System Analysis

5. 5 LCLS-II cryomodules: top level parameters Production Cryomodule Final Design Review, 12 May 2015 Cryomodule (CM) ParametersSymbolnom.valueUnits Cavity operating temperatureT­ cryo 2K # 9-cell cavities per cryomodule (1.3 GHz)N cav 8- # installed cryomodules (1.3 GHz)N CM 35- # 3.9-GHz cavities per 3.9 GHz CM-8- # 3.9 installed GHz cryomodules-2- # installed 1.3 GHz cryomodules in L0N CM0 1- # installed 1.3 GHz cryomodules in L1N CM1 2- # installed 3.9-GHz cryomodules as linearizerN CMLH 2- # installed cryomodules in L2N CM2 12- # installed cryomodules in L3N CM3 20- Physics Requirements Document: “SCRF 1.3 GHz Cryomodule,” LCLSII-4.1-PR-0146-R0, 4/30/2014 Original Release.

6. 6 LCLS-II Cryomodule Documentation, page 1 (more up-to-date list is LCLS-II-CryomoduleDocumentationList-10May2015-Links.xlsx) Production Cryomodule Final Design Review, 12 May 2015 Reference NumberDocument Title Physics requirements LCLSII-1.1-PR-0133-R0LCLS-II Parameters LCLSII-4.1-PR-0146-R01.3 GHz Cryomodule LCLSII-2.4-PR-0136Beam Position Monitor General cryomodule requirements (in draft and/or under review) LCLSII-2.5-FR-0053-R0Functional Requirements Specification, "1.3 GHz Cryomodule" LCLSII-4.5-ES-0356-R0Engineering Specifications Document, “1.3 GHz Cryomodule Technical Description” LCLSII-4.5-EN-0179-R0Engineering Note, “Cryomodule Heat Load” LCLS-II-4.5-EN-0186-R0Engineering Note, “Cryogenic System – Cryomodule Design Methodology” LCLSII-2.5-IC-0056-R1Interface Control Document, “Accelerator Systems to Cryogenic Systems” LCLSII-4.5-IC-0372-R0Interface Control Document, "LCLS-II Cryomodule External Interfaces" (ED-0002307) SLAC-I-720-0A24E-001Seismic Design Specification for Buildings, Structures, Equipment and Systems: 2014

7. 7 LCLS-II Cryomodule Documentation, page 2 Production Cryomodule Final Design Review, 12 May 2015 Reference NumberDocument Title LCLSII-4.5-EN-0226-R0Engineering Note, “Cryomodule Seismic Design Criteria” LCLSII-4.9-IC-0058-R1Interface Control Document, "Cryogenic Distribution System" LCLSII-4.5-EN-0214Cryomodule Design Heat Flux for Vacuum Failures About cryomodule components LCLSII-4.5-ES-0411Fermilab Engineering Specification, "LCLS-II Cryomodule Vacuum Vessel" LCLSII-4.5-ES-0412Fermilab Engineering Specification, "LCLS-II Cryomodule HGRP" LCLSII-4.5-ES-0055-R0Engineering Specifications Document, “Fundamental Power Coupler" LCLSII-4.5-IC-0237-R0Interface Control Document, “Fundamental Power Coupler” LCLSII-4.5-EN-0221Engineering Note, “Tuner electro-mechanical design” LCLSII-4.5-ES-0385Cryomodule SRF Cavity Tuner LCLSII-4.5-EN-0222-R0Magnetic Shielding: Requirements and Possible Solutions LCLS-II-4.5-EN-0310-R0 Engineering Note, “A Study of Magnetic Shielding Performance of a Fermilab International Linear Collider Superconducting RF Cavity Cryomodule”

8. 8 LCLS-II Cryomodule Documentation, page 3 Production Cryomodule Final Design Review, 12 May 2015 Reference NumberDocument Title LCLSII-4.5-ES-0413Fermilab Engineering Specification, "LCLS-II Prototype Cavity Magnetic Shield Specification" LCLSII-4.5-ES-0355-R0Engineering Specifications Document, "Cryomodule Magnet" LCLSII-EN-0286-R0Engineering Note, “Vacuum System Safety Plan” LCLSII-4.5-ES-0414Engineering Specifications Document, “CM Coaxial Cable and Connectors Specification" LCLSII-4.5-ES-0415Engineering Specifications Document, “Prototype Cryomodule Sensors Specification" LCLSII-4.5-ES-0416Engineering Specifications Document, “Multi-pin Connectors" LCLSII-4.5-ES-0417Engineering Specifications Document, “Prototype Cryomodule Sensor Wiring" LCLSII-4.5-ES-0418LCLS-II 1.3 GHz Cryomodule Stand Design LCLSII-4.5-ES-0419LCLS-II 1.3 GHz Cryomodule Transport System Fermilab documentLCLS-II Magnet Package Design, Fabrication, and tests, May 6, 2014 LCLSII-4.5-ES-0403Cold Button Beam Position Monitor F10023160LCLS-II Cold BPM Assembly Drawing

9. 9 LCLS-II Cryomodule Documentation, page 4 Production Cryomodule Final Design Review, 12 May 2015 Reference NumberDocument Title Cryomodule engineering details, analyses, and compliance documents F10009945Assembly, 1.3GHz Cryomodule LCLS-II (model) F10022915LCLS-II Prototype Cryomodule P&ID (drawing) F10040796LCLS-II Production Cryomodule P&ID (drawing) ED0001152Master Spreadsheet 1.3GHz CM-LCLS-II (cryomodule dimensional details) ED0001995LCLS-II CDS Relief System Analysis ED0002339Fermilab Engineering Note, LCLS-II Cryomodule Vacuum Vessel (FESHM conformance) ED0002337Fermilab Engineering Note LCLS-II Vacuum Vessel FEA Structural Analysis ED0002396Cryomodule vacuum vessel venting calculation ED0002383Procedure for Support Post Traction Test (Draft) ED0002112Fermilab Engineering Specification, LCLS-II Cryomodule Beam Pipe Copper Plating ED0002026Assembly Procedure for LCLS-II Support Post (Draft) ED0002454LCLS-II 1.3GHz Prototype Cryomodule Instrumentation List ED0002638P&ID (instrumentation) tag name list

10. 10 LCLS-II Cryomodule Documentation, page 5 Production Cryomodule Final Design Review, 12 May 2015 Reference NumberDocument Title ED0002593Inter-connect assembly procedures ED0002453JT valve sizing and flow calculation ED0002406Cool-down valve sizing and flow calculation ED0002405Cryomodule two phase pipe pressure, vapor velocity, and venting calculation ED0002404Cryomodule cooldown line pressure, flow, and venting calculation 5500-ES-371043 Fermilab Specification: 1.3 GHz Cryomodule (Type IV) Interconnect Bellows Assembly Engineering Note EN0001803Cryomodule piping engineering note (FESHM piping standard) Fermilab draft documentElectric heater sizing, design, implementation engineering note ANL/Fermilab documentThermal intercept analyses (ANL effort) LCLSII-4.5-EN-0430Stress Analysis of LCLS II Cryomodule for Seismic Load LCLSII-4.9-EN-0253CDS/Cryomodule What-If Analysis LCLSII-4.9-EN-0255CDS/Cryomodule Failure Mode and Effects Analysis EN01774Dressed cavity helium vessel engineering note (cavity AES035, FESHM conformance)

11. FNAL Team Center numbering for important components of 1.3 GHz CM (Preproduction & Production) LCLS-II, 1.3GHz pCMLCLS-II, 1.3GHz Production CM Cryomodule AssemblyF10009945F10041183 Vacuum VesselF10026609 Cold Mass AssemblyF10009950F10041120 Assembly Cold Mass Upper F10009954 Assembly cavity StringF10009887F10041166 Assembly 1.3GHz dressed Cavity F10027807 (short-short)F10041087 (short-long) Assembly magnet package F10009375 Assembly lever tuner (FNAL) F10008766 Production Cryomodule Final Design Review, 12 May 2015 11

12. 12 1.3GHz pCM-design and drawings status, May 2015 Top-level assembly drawing is F10009945 3D NX model of 1.3GHz preproduction cryomodule ~98% Status of drawings which are not approved and released yet: instrumentation flanges (Done) liquid level with instrumentation (Done) finishing model of the magnet current leads (in progress) HTC test in June will verify current lead design some thermal intercepts (in progress) Analyses to confirm intercept sizing are nearly complete finalize lower 50K shield (Done) magnetic shielding-new design (Done) 2D drawings total: 936 of ~1043 total released 2D drawings: 664 (some released drawings need to be revised) need to finalize 2 of 4 “top level drawings”: Cold mass Assembly- F10009950 and 1.3GHz Cryomodule Assembly-F10009945 Production Cryomodule Final Design Review, 12 May 2015

13. 13 Some major requirements in terms of driving design Production Cryomodule Final Design Review, 12 May 2015 Series configuration, TESLA style Continuous insulating vacuum No external parallel transfer line 300 mm OD helium gas return pipe (HGRP) is “backbone” support Helium vessel modified from ILC-style (including short end beam tube at both ends in the prototype cryomodule) for end-lever tuner Modified tuner design Thermal performance in CW operation High heat loads, heat transport, helium flow rates Input coupler for CW operation 0.5% longitudinal tunnel slope Liquid helium management Retention of very high cavity quality factor (Q0) Magnetic shielding Cool-down constraints Pressure safety A cryogenic system issue of which cryomodules play a major part

14. 14 SLAC Tunnel with 1.3GHz Cryomodule Production Cryomodule Final Design Review, 12 May 2015 Tunnel size: 10x11 Feet Tunnel slope: ~0.5%

15. 15 ILC / XFEL CM Modifications for LCLS-II (components) Production Cryomodule Final Design Review, 12 May 2015 Component design – based on TESLA / ILC / XFEL designs Cavities – XFEL identical Helium vessel – XFEL-like (modified ILC with bellows at end for end lever tuner) HOM coupler – XFEL-like Magnetic shielding – increased from XFEL to maintain high Q0 Tuner – XFEL-like end-lever style Magnet – Fermilab/KEK design split quadrupole BPM – DESY button-style with modified feedthrough Coupler – XFEL-like (TTF3) modified for higher QL and 7 kW CW Concerns based on global experience Tuner motor and piezo lifetime: included access ports Maintain high Q0 by minimizing flux trapping: new requirement – constraints on cool-down rate through transition temperature Functional Requirements Document: “1.3 GHz Superconducting RF Cryomodule,” LCLSII-4.5-FR-0053-R0, 6/23/2014 Original Release.

16. 16 Differences between prototype and production CMs Production Cryomodule Final Design Review, 12 May 2015

17. 1.3 GHz cavity (Preproduction & Production) pCM Cavity String configuration Production CM Cavity String Configuration Production Cryomodule Final Design Review, 12 May 2015 17 More about dressed cavity from Chuck Grimm

18. 18 Cryomodule Thermal and Hydraulic Design Production Cryomodule Final Design Review, 12 May 2015 LCLS-II CM is a modified TESLA/XFEL CM for CW mode operation Thermal shields, intercept flow, and cryogenic supply and return flow in series through a string of cryomodules Heat load range (design within the cryomodule includes generous margins) 80 to 150 W per cryomodule at 2 K depending on local HOM deposition and cavity Q0 A cavity may see as much as 25 W Cost savings: Omit 5 K thermal shield Simplification since large dynamic heat at 2 K makes such a thermal shield of marginal value Retain 5 K intercepts on input coupler Two-phase pipe is 100 mm diameter and closed at each end 0.5% slope or 6 cm elevation difference over 12 m 100 mm diameter two-phase pipe is nearly full at one end, nearly empty at the opposite end Cryomodule (CM) thermal and hydraulic design is well advanced Steady-state flows and upset conditions with venting analyses Liquid supply valve for 2-phase liquid level, cool-down valve for “fast” cool-down

19. 19 Cryomodule flow scheme Production Cryomodule Final Design Review, 12 May 2015 Cool-down valve for “fast” cooling is a BCR for high Q0 preservation

20. 20 LCLS-II Cryomodule (CM) Cryogenic Circuits Production Cryomodule Final Design Review, 12 May 2015 A.2.4 K subcooled supply B.Gas return pipe (GRP) C.Low temperature intercept supply D.Low temperature intercept return E.High temperature shield supply F.High temperature shield return G.2-phase pipe H.Warm-up/cool-down line Circuit (Line) Operating ParametersABCDEFGH Pressure, [bar]30.0313.22.23.52.50.0313 Temperature, K2.42.05835552.0

21. 21 Cryomodule image from 3-D model Production Cryomodule Final Design Review, 12 May 2015

22. 22 High Q0 requirement drives some new design features Production Cryomodule Final Design Review, 12 May 2015 We assume Q0 = 2.7E10 in our design Magnetic shielding to keep < 5 mGauss Probable new features necessary such as active external coils High rate of cool-down looks necessary VTS results were best with much as 2 – 3 Kelvin/minute through 9.2 K transition temperature Key is high delta-T within Nb to “sweep out” magnetic flux For fast cool-down, cool one cryomodule at a time Create a closed-ended warm-up/cool-down manifold (line H) for each cryomodule so as to provide a cool-down/warm-up valve on each cryomodule Design for 30 grams/sec of 5 Kelvin helium flow into cryomodule during cavity transition through 9.2 K -Analysis in backup slides Retain original plan for uniform cooling of bimetallic joints

23. Cool-down requirements We must cool slowly from 300 K until most thermal contraction is complete (around 80 K). Cool-down rates (dT/dy and dT/dt) based on DESY measurements and analysis, in order to limit stresses on the support posts, must be limited in the Gas Return Pipe (GRP) GRP vertical gradient is < 15 K GRP longitudinal gradient is < 50 K GRP cool-down rate is 10 K/hr May start fast cool-down at 80 K or colder “Fast” means 2 – 3 K/minute (“slow” < 0.5 K/minute) (reference: Anna Grassellino’s presentation) Since thermal shield is ~35 K – 55 K, in the following analysis use 40 K delta-T at 3 K/minute = 13 minutes for transition from thermal shield temperature to below the niobium 9.2 K critical temperature Production Cryomodule Final Design Review, 12 May 2015 23

24. 24 LCLS-II Cryomodule Volumes Production Cryomodule Final Design Review, 12 May 2015 Fast cool-down of one cryomodule implies replacing 200 liters of helium volume as quickly as possible. From the previous slide, we want to replace those 200 liters, starting at 40 K, with helium at ~ 5 K in 13 minutes. Flow into the cryomodule at 15 liters/minute = 31 grams/sec liquid helium in liquefier mode. (~2 liters/min for each helium vessel) 31 g/s sets cool-down valve size

25. 25 Cryogenic plant capacity (Cryo Plant Performance Sheet from Dana Arenius, August 5, 2014) Production Cryomodule Final Design Review, 12 May 2015 In liquefier mode (supplying 4.5 K, receiving back warm helium gas), 31 grams/sec is no problem. However, 4 cryomodules would require 4 x 31 = 124 gr/sec, about the limit of cryogenic plant production L3 has 20 cryomodules cooled in parallel -31 grams/sec per cryomodule would not be available Need to focus cooling on a few cryomodules

26. 26 Conclusion for cool-down concept Production Cryomodule Final Design Review, 12 May 2015 Required cool-down rate can be provided with our design “Fast” cool-down comparable to single cavity tests can be provided in a cryomodule Cryogenic plant can provide the flow for a few cryomodules at a time Capillary tubes and other pipes can carry the flow Note that line H (cool-down / warm-up line) exists only in the cryomodules and is eliminated from the distribution system. Implementation... Isolate Line H (cool-down / warm-up line) for each cryomodule and provide each cryomodule with its own cool- down valve, supplied from Line A (helium supply)

27. 27 Liquid helium management Production Cryomodule Final Design Review, 12 May 2015 High heat loads (~80 Watts per cryomodule at 2.0 K) 0.5% tunnel slope downward in beam direction Careful design for liquid helium management Keep liquid helium out of the 300 mm HGRP Be sure cavities are covered with liquid with plenty of allowance for liquid level control in the 2-phase pipe

28. All the dimensions, for reference Production Cryomodule Final Design Review, 12 May 2015 28

29. Production Cryomodule Final Design Review, 12 May 2015 29

30. Totally full 2-phase pipe just starts to spill into the 300 mm HGRP. But the connection from 2-phase pipe to HGRP is only at the center of the cryomodule, where the 2-phase pipe is half full. Liquid level there is 17 mm below the bottom of the 300 mm HGRP. (See next slide for dimensions.) 30 Keep liquid helium out of HGRP Production Cryomodule Final Design Review, 12 May 2015

31. Bottom of the 2-phase pipe ID is 25 mm above the helium vessel ID top. Helium vessel is full to the top with any liquid in the 2-phase pipe. Center of the 2-phase pipe is 17 mm below the bottom of the HGRP. 31 But also be sure cavity is covered with liquid helium Production Cryomodule Final Design Review, 12 May 2015

32. 32 Connection from 2-phase pipe to 300 mm HGRP Production Cryomodule Final Design Review, 12 May 2015 Connection from 2-phase pipe to 300 mm HGRP is 650 mm upstream (in beam direction) from center, up hill from center

33. 33 System Pressure Drops Production Cryomodule Final Design Review, 12 May 2015 Pressure drops must be analyzed for each helium flow path to ensure that steady-state operation matches system design and that non-steady conditions (cool-down, emergency venting, warm-up) are properly handled Input variables include line size, Allowable temperature rise, Allowable pressure drop Heat load (temperature rise and heat load  mass flow) Maximum allowable pressure for emergency venting Matching cryomodule/distribution system to the cryogenic plant

34. 34 Pressure drop analysis for cool-down lines Production Cryomodule Final Design Review, 12 May 2015

35. 35 Two phase pipe pressures and vapor velocities Production Cryomodule Final Design Review, 12 May 2015

36. 36 Heat loads and cryogenic plant size Production Cryomodule Final Design Review, 12 May 2015 Heat loads are carefully evaluated Input from various groups including beam dynamics, RF cavity performance, input couplers, cryomodule design, magnets and current leads, distribution system These are tabulated as “best estimates” meaning no margin added. These are the expected values Then also an uncertainty factor must be applied Heat load x uncertainty factor = maximum anticipated Uncertainty factor evaluation should be quantitatively based on measurements and statistics These then provide input to the cryogenic plant design and sizing Temperature and pressure constraints agreed upon by various cryogenic system designers provides additional input Combinations of heat loads (e.g., static only, static +RF, static + RF + beam) provide various “modes” for cryogenic plant operation

37. 37 Simplified Heat Load Diagram Production Cryomodule Final Design Review, 12 May 2015

38. 38 CM Static Heat Load Production Cryomodule Final Design Review, 12 May 2015 Basis of estimate: Carlo Pagani, 2nd ILC Acc. Workshop, 8/16/2005 (TTF measurements at DESY) X.L. Wang, et. al., TTC 2011 (CMTB measurements at DESY) B. Petersen et. al., XFEL predicted based on measurements and analyses N. Ohuchi, S1-G-report(Thermal Test).doc (S1-Global measurements at KEK) Then add static heat estimate for items unique to LCLS-II such as cool-down valve, increased copper coating on input coupler, heavier HOM cables, etc.

39. 2 K heat in first few cryomodules From LCLScryoHeat-27April2015-100percent.xlsx Production Cryomodule Final Design Review, 12 May 2015 39 94%

40. 40 Most recent estimate of heat loads Production Cryomodule Final Design Review, 12 May 2015 From: LCLScryoHeat-27April2015-100percent Spreadsheet based on recent beam dynamics analyses from Andrei Lunin and input from Chris Adolphsen. Not yet formally documented in requirements or engineering notes.

41. 41 Cold compressor flow versus average cavity Q0 Production Cryomodule Final Design Review, 12 May 2015 Underlying analysis is from an older heat load estimate, but changes are less than 10%, and this illustrates the impact of Q0. Approx limit for two cryogenic plants Approx limit for one cryogenic plant

42. 42 Two cryogenic plants, heat load limits Production Cryomodule Final Design Review, 12 May 2015 A design goal for cryomodules has always been that no part of a cryomodule be the “bottleneck” for heat transfer. In other words, we always design such that one can take full advantage of the maximum expected total cryogenic plant capacity. At project start, we selected a 100 mm OD nozzle from the helium vessel and 100 mm OD 2-phase pipe to accommodate large 2 Kelvin heat loads. We also retained the large thermal shield and thermal intercept lines corresponding to TTF/FLASH experience.

43. 43 Line sizes Production Cryomodule Final Design Review, 12 May 2015

44. 44 Helium II heat transport within the helium vessel Production Cryomodule Final Design Review, 12 May 2015

45. 45 Connection diameter versus heat flux Production Cryomodule Final Design Review, 12 May 2015 XFEL 55 mm XFEL 95 mm LCLS-II Helium vessel is designed for heat loads of up to around 40 Watts, well in excess of our maximum anticipated of 25 Watts.

46. Production Cryomodule Final Design Review, 12 May 2015 46 Conductive heat flow to helium vessel end must be removed via helium II heat transport so as to keep Nb end groups cold. Analysis and tests at HTS show more than sufficient heat removal throughout the helium vessel.

47. 47 "LCLS-II Cryomodule External Interfaces" (LCLSII-4.5-IC-0372-R0, ED-0002307, Yun He) Production Cryomodule Final Design Review, 12 May 2015

48. 48 Cryomodule interfaces – alignment fiducials Production Cryomodule Final Design Review, 12 May 2015 LCLSII-2.5-IC-0056-R1 (ED-0002307), Interface Control Document, “Accelerator Systems to Cryogenic Systems”

49. 49 Cryomodule interfaces – beam tube interconnect, HOM absorber Production Cryomodule Final Design Review, 12 May 2015 LCLSII-2.5-IC-0056-R1 (ED-0002307), Interface Control Document, “Accelerator Systems to Cryogenic Systems”

50. 50 Cryomodule interfaces – RF power input coupler Production Cryomodule Final Design Review, 12 May 2015 LCLSII-2.5-IC-0056-R1 (ED-0002307), Interface Control Document, “Accelerator Systems to Cryogenic Systems”

51. 51 Cryomodule interfaces – instrumentation connectors Production Cryomodule Final Design Review, 12 May 2015 More about instrumentation from Darryl Orris LCLSII-2.5-IC-0056-R1 (ED-0002307), Interface Control Document, “Accelerator Systems to Cryogenic Systems”

52. 52 Cryomodule interfaces – Vacuum Vessel Instrumentation Flanges Production Cryomodule Final Design Review, 12 May 2015 LCLSII-2.5-IC-0056-R1 (ED-0002307), Interface Control Document, “Accelerator Systems to Cryogenic Systems”

53. 53 Prototype cryomodule test plans (see Elvin Harms’ talk) Production Cryomodule Final Design Review, 12 May 2015 Commission the test stand as an integrated facility Coupler conditioning (couplers perform as expected) Cool-down & warm-up - maintain target Q0 Magnet operation Tuner operation/performance LFDC, LLRF Static and dynamic heat loads - single cavity plus entire cryomodule Develop and commission production testing protocols, procedures, and software Characterize field emission & dark current System calibrations Note that these tests occur in early 2016... while we are procuring production cryomodule parts. Nevertheless, we can react with changes in components as needed

54. 54 What we cannot test until linac operation Production Cryomodule Final Design Review, 12 May 2015 Beam dynamics effects HOM absorber loads HOM coupler performance BPM functioning Magnet package except for electrical checks Cryogenic operation of a long (up to 12 CM) string with full- sized cryogenic plant System with integrated heating, full flow rates, and pressure drops Long string on 0.5% slope Full cryomodule-to-cryomodule interconnect

55. 55 Alignment Production Cryomodule Final Design Review, 12 May 2015 Alignment design and procedures based on TESLA Test Facility experience at DESY CM1, CM2, and FLASH 3.9 GHz cryomodule experience at Fermilab Jlab experience for CEBAF and SNS Recent XFEL procedures An LCLS-II workshop on alignment with SLAC, Jlab and Fermilab participation is planned later in May Information added to backup slides Thermal contraction allowance 2-phase pipe closure, compensation for pressure loads Post-shipment survey mark

56. 56 Summary for cryomodule design Production Cryomodule Final Design Review, 12 May 2015 Design effort based on long history of design work Deviations from previous TESLA-style cryomodules are necessary, but structure and form are very much the TESLA concept with minimal modifications Component design effort and technical risk minimized by using existing designs with minimal modification Using prototypes to advance and confirm design concepts early Substantial Fermilab and partner lab experience and capabilities Emphasizing integrated system design

57. 57 Acknowledgments Production Cryomodule Final Design Review, 12 May 2015 This presentation includes information from many people at Fermilab, Jlab, and SLAC involved in cryomodule design, cryogenic distribution design, and overall cryogenic system design. Special thanks to Camille Ginsburg, Chuck Grimm, Yun He, Joshua Kaluzny, Arkadiy Klebaner, and Yuriy Orlov who provided information and slides for this presentation.

58. Backup slides, additional information Production Cryomodule Final Design Review, 12 May 2015 58

59. 59 Design team Production Cryomodule Final Design Review, 12 May 2015 An incomplete list of people working on LCLS-II cryomodule assembly design, with apologies to those not mentioned here Camille Ginsburg Yuriy Orlov Joshua Kaluzny Yun He Tug Arkan Zhijing Tang Design and drafting group On various components including dressed cavity and magnetic shielding (Chuck Grimm), tuner (Yuriy Pischanikov, Evgueni Borisov, Warren Schappert), RF power input coupler (Ken Premo, Oleg Prokofiev, others at Fermilab and at SLAC), magnet (Vladimir Kashikhin), current leads (Sergey Cheban, Valeri Poloubotko), instrumentation (Darryl Orris) – and in general others on each of these components On integration into the cryogenic system with interfaces via the cryogenic distribution system – Kaluzny and AD Cryogenics Department On plans for the Cryomodule Test Stand and testing, many others in TD and AD

60. TESLA-style cryomodules compared Production Cryomodule Final Design Review, 12 May 2015 60

61. 61 Cryomodule pipe pressures Production Cryomodule Final Design Review, 12 May 2015

62. 62 Chapter 5032, Cryogenic System Review – Required Documentation Production Cryomodule Final Design Review, 12 May 2015 System Design Documents A system equipment and operation description Complete and accurate (signed off and approved) flow sheets An active component list (instrument and valve summary). In the system, all of these devices will be tagged and identified with permanent tags. A list of the system control loops and interlocks and a description of normal operations of each loop or interlock. System Operating Documents Operating procedures Any checklists required for startup, shutdown or normal operation The qualification and training requirements of cryogenic personnel Safety Analysis Documents A FMEA (Failure Mode and Effect Analysis) A what-if analysis A hazards analysis (typically an ODH analysis per FESHM 5064) Documentation necessary to demonstrate that other sections of the ES&H Manual are followed. (This means pressure vessel, piping, vacuum vessel, etc.)

63. 63 Chapter 5032, Cryogenic System Review – Required Documentation Continued Production Cryomodule Final Design Review, 12 May 2015 Engineering Documents Calculations and/or test results demonstrating the adequacy of the relief system Calculations and/or test results shall be prepared to verify that stress levels in materials are acceptable per the applicable FESHM chapter or ANSI Code. Material certifications, test data, or data sheets shall be provided for any unusual materials used in the system. Maintaining Safe Operation Documents shall be kept current. Plans for maintenance and operations shall be prepared before operations begin. Operator training and qualification records shall be kept. Inspections Inspections by the review panel shall be performed during the review in order to further acquaint the panel with the system and to clarify technical points concerning safety of the system. Inspections by the review panel shall be performed as required during operations to verify continued system safety.

64. 64 CM, Feed Cap and Bypass and Vertical Transferline Production Cryomodule Final Design Review, 12 May 2015 Horizontal Bypass Vertical Transferline Total transferline length is ~ 510 m

65. Cryomodule Design, LCLS-II DOE Review, April 7-9, 2015 65 TESLA design alignment verification

66. 0.24mm warm offset on cavities 0.24 mm cold contraction to “0” 1.97mm cold contraction. At cold the distance to the center is ~245mm y + x on Cavities Springs in x

67. Contractions offset for magnet No offset for warm vs cold 1.97mm cold shrinking. At cold the distance to the center is ~245mm Same as for cavities y + x on Quad/BPM No springs in x

68. Reasons of y + x offsets x on cavities The material of the He-vessels and the cold mass is different – Ti and Stainless steel different shrinking factor To compensate this the support have in x in direction to the couplers springs. The calculate Δ value of the shrinking is ~0.48mm To align the cavities with a offset of 0.24mm in warm the cavities will have in cold “0” because the springs are only on one side (coupler direction) installed. On the other side are fix screws installed in this case the cavities must move towards to the couplers x on Quad/BPM No offset in x for the Quad/BPM needed because the material of the Dummy vessel and the coldmass identical (both stainless steel) No springs installed at both sides on the x supports y on cavities and Quad/BPM The coupler ports in the vacuum vessel are 246mm to the center of the module vacuum vessel The module string is in warm align 247mm to the module vacuum vessel center In this case the coupler antennas go during the cool down from -1.0mm through 0.0mm to +1.0mm in cold (stress reduction) In cold the module string is 245mm to center of module vacuum vessel At Desy (Flash and XFEL) the beam lines in the Feed- a. End-boxes are align with 245mm to the center of the box vacuum vessels. If I remember right the specification of the NML Feed- a. End-boxes identical with the FLASH boxes? If the center of the module vacuum vessels and the Feed- a. End-box vacuum vessels in the same axis the string beam line in the module will in cold also in the axis of the beam line in the Feed- a. End-boxes During the beam line connection to the Feed- a. End-boxes you will have a offset of ~2.0mm

69. 69 2-phase pipe end supports – new for LCLS-II Cryomodule Design, LCLS-II DOE Review, April 7-9, 2015 Closed 2-phase pipe produces no load on cavity support structure. Bellows between 2-phase pipe sections. Tension rods carry pressure load. Sliding sleeve supports end section of 2-phase pipe and carries vacuum load if any (non-operational condition).

70. 70 Alignment – checking after shipping Cryomodule Design, LCLS-II DOE Review, April 7-9, 2015 XFEL info here from 3 Feb 2015 email from Georg Gassner For the XFEL production modules Measure the posts where the strings are mounted and the end of the strings Mount measurement points onto the valve assembly of the strings, which are accessible when the transport caps at the end of the module and the top flanges are removed. Before the initial production started (>10 years ago) DESY measured the position of the cavities directly through ports and they had stretched-wires setup to determine the straightness of the strings. For the new production of the XFEL cryo module in France They took the first few modules apart in Hamburg and checked the geometry of the strings. What they found was that measuring the position and orientation of the ends of the strings and the posts was sufficient to check for transport related movement as long as it is correctly mounted. This is also what we did for CM1 and CM2 Alignment features were installed with epoxy on the Gate Valve body for both sides of cavity string We measured the cavity string position on the support posts and at the gate valves relative to the vacuum vessel before and after shipping