1. Dana Arenius LCLS-II 4.5K Cold Box Director’s Review November 16, 2016
4.5K Cold Box Overview
Dana Arenius
LCLS-II 4.5K Cold Box Director’s Review
November 16, 2016

2. Contractual Milestones Design Schedule Delays
Outline
4.5K Cold Box Function
Contractual Milestones
Design Schedule Delays
Schedule Recovery Actions
Summary
LCLS-II 4.5K Cold Box Director’s Review, November 16, 2016

3. Cryoplant First Light & Normal Beam Operations
2 Cryomodule Strings
U-Tube Connections
14 MV/m Gradient
2.0≤ Qo ≤3.0
Compressor System
4.5 K
Coldbox
LHe
Dewar
2.0 K
Normal Beam Operations
2 Cryoplants
2 Cryomodule Strings
U-Tube Connections Removed
Gradient - 16 MV/m
2.0≤ Qo ≤3.0
Compressor System
He Gas Tanks
4.5 K
Coldbox
LHe
Dewar LN 2
Dewar
2.0 K
Coldbox
U-TUBE JUMPER CONNECTIONS - IB IB
Upstream Distribution Box
Downstream Distribution Box
Downstream
Distribution
Upstream String
Box
Downstream String LH BC 1 L L 1 L 2 L 3 FC 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 IB
Cryogenic
Cryogenic Transfer 3 . 9
GHz Cryomodule 1 . 3
GHz Cryomodule
End /
Feed Cap
Vacuum
Barrier
Bypass
Line
Cryoplant
Gas Header
Interface Box
LCLS-II 4.5K Cold Box Director’s Review, November 16, 2016

4. Cryoplant Layout Overview
LN2 storage
CP1 4.5K Cold Box
GHe storage
CP1 Oil Removal
CP2 4.5K Cold Box
CP2 Oil Removal
CP2 Compressors
CP1 Compressors
Oil
processor
2K CBX
Guard Vacuum
CDS Interface Boxes
LHe
Dewar
LHe
Dewar
Instrument Air
Motor Control
Center 4
LCLS-II 4.5K Cold Box Director’s Review, November 16, 2016

5. Single Plant Operation (CP-1) for First Light, 14 MV/m
First Light Design Heat Loads with Qo=2.7x1010 Steady State CW 14 MV/m
Mode 1: Max Capacity of the Cryoplant
Temp Level
Heat Load [kW]
High Temperature
Thermal Shield, (35K)
15.3
Low Temperature
Thermal Shield, (5K)
1.3
Primary Temperature 2K 4
Variation in the 2.0 K Heat Loads of First Light for the Selected First Light Gradient with Qo
Source: Jlab Refrigerator Specification S001
One cryoplant is sufficient to support the First Light Operation
(Ref: SLAC LCLSII-4.5-EN-0179-R2)
LCLS-II 4.5K Cold Box Director’s Review, November 16, 2016

6. Two Plant Operation (CP-1 & CP-2) For Design Heat Loads
Design Heat Loads with Qo=2.7x1010 Steady State CW 16 MV/m
Mode 1: Max Capacity of the Cryoplant
Temp Level
Heat Load [kW]
High Temperature
Thermal Shield, (35K)
15.3
Low Temperature
Thermal Shield, (5K)
1.3
Primary Temperature 2K 4
Variation in the 2K Design Heat Loads with Variable Gradient and Qo
Source: Jlab 4.5K Cold Box Specification S001
(Ref: SLAC LCLSII-4.5-EN-0179-R2)
Two cryoplant operation to support variation in gradient and Qo
LCLS-II 4.5K Cold Box Director’s Review, November 16, 2016

7. 4.5K Cold Box Design Challenges
Included in plant performance analysis:
Large variation of operational design parameters
First Light single plant load (heavy load) vs. Normal two plant operation (~50% load for each plant)
Unknown final Qo determination, design basis 2.7x1010
Required extensive heat exchanger/turbine performance analysis for wide possible load variation
Level of Seismic design criteria for California
Subcontract requirement for CA Seismic licensed PE
LCLS-II 4.5K Cold Box Director’s Review, November 16, 2016

8. JLab/SLAC/Air Liquide Engineering Coordination
Weekly status and issue resolution meetings
Attended by
AL/SLAC/JLab engineering, vendor PM
JLab procurement
Not attended by AL subcontractors
PHPK (cold box assembly engineering and fabrication)
Sumitomo (heat exchanger manufacturer)
Hopper (Seismic PE, Subcontractor to PHPK)
LCLS-II 4.5K Cold Box Director’s Review, November 16, 2016

9. 4.5K Cold Box Contractual Milestone Schedule
FDR Completion Plan: Nov 28th, Seismic Analysis
Last Long Lead Item Ordered: 1-Nov-16
LCLS-II 4.5K Cold Box Director’s Review, November 16, 2016

10. 4.5K Cold Boxes, 1.04.08.06/.16 Preliminary design review completed
Heat exchanger sizing
Absorber Beds
Process cycle design verification
Final Design Review 7-8th Sept
~90% of 92 required documents delivered
3-D modeling of internal piping completed
Missing Piping Stress & Seismic Design
Hold on top plate (upper cold box) and both cold box vacuum shells until analysis of piping stress and seismic analysis is complete (Note: Internal piping/vessel structure attached to vacuum shell)
Missing analysis scheduled to be delivered ~28th November
LCLS-II 4.5K Cold Box Director’s Review, November 16, 2016

11. Schedule Recovery Action Items Implemented
Notification of unsatisfactory schedule performance to vendor senior management
Vendor schedule optimization study of remaining work to recover schedule implemented
Continuation of weekly AL/Jlab/SLAC engineering coordination meetings
Invitation by AL to JLab to attend weekly AL/Subcontractor coordination meeting for direct stakeholder communication
PHPK
Hopper
LCLS-II 4.5K Cold Box Director’s Review, November 16, 2016

12. Summary
Heat exchanger analysis was longer than expected in completing PDR per contractual date and heat exchanger ordering
Heat exchanger delay affected 3-D piping, piping stress and seismic analysis completion dates for FDR
Lacking stress/seismic analysis, formal approval for cold box shell ordering (needed for CB fabrication) was delayed
FDR Seismic analysis completion is scheduled for Nov 28th
Schedule study implemented to recovery schedule slip
Expanded JLab interaction with vendor subcontractors
LCLS-II 4.5K Cold Box Director’s Review, November 16, 2016

13. MAY I ANSWER ANY QUESTIONS?
LCLS-II 4.5K Cold Box Director’s Review, November 16, 2016

14. LCLS-II 4.5K Cold Box Director’s Review, November 16, 2016

15. Cryoplant Modes of Operation (1)
*Tables from 4.5K Cold Box Procurement Specification S001
Table 3.4(A) – Mode 1, Max. Capacity
Table 3.4(C) – Mode 3, Max. Liquefaction
Supply
Return
Load w p T q
[g/s]
[atm]
[K]
[kW]
Warm Shield
146
Note 1 35
2.5 55
15.2
Cold Intercept 37
3.25
5.5
1.29
7.50
1.3
4-K Refrigeration
4-K Liquefaction 15
3.2
4.5
1.10
300.0
Sub-Atmospheric
200
1.20
30.0
Supply
Return
Load w p T q
[g/s]
[atm]
[K]
[kW]
Warm Shield
155
Note 1 44
2.3
56.5
10.1 
Cold Intercept 20
3.2
5.8
1.23
10.8
0.9
4-K Refrigeration
4-K Liquefaction 40
4.5
1.10
300.0
Sub-Atmospheric
Table 3.4(B) – Mode 2, Nominal turn down
Table 3.4(D) – Mode 4, Max. Refrigeration
Supply
Return
Load w p T q
[g/s]
[atm]
[K]
[kW]
Warm Shield
96.7 
Note 1  35
2.5 55
10.10
Cold Intercept 27
3.2
5.5
1.29
7.50
0.9
4-K Refrigeration
4-K Liquefaction
Sub-Atmospheric
157
4.5
1.20
30.0
Supply
Return
Load w p T q
[g/s]
[atm]
[K]
[kW]
Warm Shield
146
 Note 1 35
2.5 55
15.2
Cold Intercept 31
3.2
5.3
1.23
9.0
1.3
4-K Refrigeration
481
4.5
4.45
4-K Liquefaction
Sub-Atmospheric
The specification requires the cryoplant to support a wide operational variable domain while maintaining plant efficiency.
LCLS-II 4.5K Cold Box Director’s Review, November 16, 2016

16. Cryoplant Modes of Operation (2)
Table 3.4(E) – Mode 5, Max. Fill
Table 3.4(F) – Mode 6, Standby
Supply
Return
Load w p T q
[g/s]
[atm]
[K]
[kW]
Warm Shield
146
 Note 1 35
2.7 55
15.2
Cold Intercept
3.2
5.3
1.23
7.8
1.3
4-K Refrigeration
4-K Liquefaction
45 
4.5
1.10
300.0
Sub-Atmospheric
157
1.20
30.0
Supply
Return
Load w p T q
[g/s]
[atm]
[K]
[kW]
Warm Shield
96.7 
 Note 1 35
2.7 55
10.1
Cold Intercept 25
3.2
5.3
1.23
7.5
0.9
4-K Refrigeration 27
4.5
0.5
Mode 7, 50% Turn Down
Supply
Return
Load w p T q
[g/s]
[atm]
[K]
[kW]
Warm Shield
[Note 2]
35.0 [±5]
2.5 55
[±5]
7.5
Cold Intercept
3.2
5.0
[±0.5]
1.29
8.0
0.7
4-K Liq.
4.5
1.1
300
Sub-Atm.
100
1.2 30
1.9 
A seventh operating point was checked and validated by the vendor for operation at 50% of maximum single plant operation mode as an additional operating point within the domain
*Tables from 4.5K Cold Box Procurement Specification S001
LCLS-II 4.5K Cold Box Director’s Review, November 16, 2016

17. Process Model Validation- JLAB/SLAC Calculation (Example: Mode 1- Max Capacity), All 7 Modes completed
LCLS-II 4.5K Cold Box Director’s Review, November 16, 2016

18. Validation of Heat Exchanger UAs
Heat Exchanger Cooling Curve
For the heat exchanger sizing, the mode yielding the maximum UA value is considered (highlighted in yellow).
Integrated UAs were calculated and compared with the vendor calculated values.
Good agreement in the UA and the NTU values
LCLS-II 4.5K Cold Box Director’s Review, November 16, 2016

19. Safety Margin on UAs
“A uniformly applied UA safety margin of 15% is required for all heat exchangers for the operating mode requiring the highest UA”.
The UA provided by the Vendor is in compliance with the requirement for the Heat Exchangers
LCLS-II 4.5K Cold Box Director’s Review, November 16, 2016

20. 4.5K CB Pressure Drop in Heat Exchangers-Vendor Data
Pressure Drops in HXs for Mode 1: Max Capacity (Example for each Mode)
“The ratio of the core pressure drop to the distributor pressure drop > 3.”
“The ratio of the sum of the core and distributor pressure drops to the sum of the header and nozzle pressure drop > 3.”
The pressure drop values provided by the vendor satisfy the above requirements
LCLS-II 4.5K Cold Box Director’s Review, November 16, 2016