1. LCLS-II CMTF@LERF For LCLS-II Cryomodule Testing at JLab
E. Daly / K. Jordan / C. Hovater / M. Wiseman with help from Accel Ops and Engineering
03-AUG-2017

2. LERF Vault as Cryomodule Test Facility (CMTF) Phasing
Outline
Overview
Introduction
LERF Vault as Cryomodule Test Facility (CMTF)
Phasing
Cost / Schedule / Staffing
Assumptions / Constraints
Impacts / Risks
Summary
REV3, 03-AUG-2017

3. Using LERF as Cryomodule Test-Bed - Overview
A detailed scope, cost and schedule estimate for installing and testing LCLS-II cryomodules (two-at-a-time) as an assembly in the LERF has been developed in response to possible LCLS-II project needs.
Estimate considers four phases of increasing scope - short term limited testing (microphonics & technical characterization) up to a full test bed (a possible mitigation for schedule recovery) to operate in parallel with the CMTF in the Test Lab.
Phase 1 – Set Up LERF for CM testing
Phase 2 – First pair of CMs - Initial Full Power Testing
Phase 3 – Three Production CM testing cycles
A typical test cycle is 5-8 weeks
Phase 4 – Restore LERF
REV3, 03-AUG-2017

4. Using LERF as Cryomodule Test-Bed - Opportunity
The LCLS-II project has discovered issues with microphonics during the prototype cryomodule testing phase at FNAL and JLab
Development on-gooing to demonstrate closed-loop RF control due to microphonics
Need to achieve expected cryogenic conditions in testing facilities
In the longer term, a place to conduct integrated RF/Cryo testing and an additional place to test cryomodules could be very useful for both LCLS-II and JLab
LERF has existing utilities (water, electrical, cryogenic, waveguides, radiation shielding, personnel protection, etc.) and is situated near a large-scale cryogenic plant
Similarity to actual LCLS-II machine conditions – large Cryoplant located near operational cryomodules
Address microphonics and large-scale issues which cannot be assessed in smaller cryogenic testing facilities
REV3, 03-AUG-2017

5. Approach
Phase I – Convert the FEL vault into a cryomodule testing facility to conduct integrated RF testing of CM/LLRF/HPRF (using Solid State Amplifiers)
Phase II / Phase III – Utilize facility to expand capability to test multiple cryomodules in order to mitigate possible schedule delays caused by late CM assembly activities.
Phase IV – Restore LERF
REV3, 03-AUG-2017

6. LCLS-II CM Layout in LERF – Testing 2 CMs per Cycle
CM Slot
CM Slot
CM Slot
Access
Storage
Current machine contains slots for 3 full CMs and 1 Injector CM
Shielded vault
Existing PSS including radiation and ODH monitoring
Utilities include cryo, water, electrical
Propose 2 CMs installed in middle of FEL machine
REV2, 03-AUG-2017

7. Preliminary Detailed P6 Cost Estimate
Set Up
First Test
Three Tests
Restoration
Full cost recovery Including operating cost estimates for LERF
Operating costs - $10.8K/week while CM is cold
Path forward assuming JLab approval
Proposal brought into the LCLS-II project baseline via baseline change request – expect some minor cost adjustments
Subsequently managed using EVMS to monitor and report on progress
REV3, 03-AUG-2017

8. P6 Schedule (1/2)
REV3, 03-AUG-2017

9. P6 Schedule (2/2)
REV3, 03-AUG-2017

10. CEBAF Operations – Constraints on LERF Ops
CEBAF Operation Plan
FY18 Q1 – 10 wks (Oct/Nov/Dec) – Highly Likely
FY18 Q2 – 6 wks (Feb/Mar) – Highly Likely
FY18Q3 – 8 wks at 6 GeV - TBC
CHL Configurations
FY18 Q1/Q2 – 2 x (CHL + Cold Boxes)
Transition by May 6th to 1 CHL
FY18 Q3/Q4 – 1 x (CHL + Cold Box) – Two week transition at 4K (cold down opportunity)
Transition by Sep 10th to 2 CHLs
Cryogenics
U-tube ops required at 4K
Integrate with maintenance plans on SC1 (Ops on SC2 – FY18Q3)
Power Consumption
Off-peak running will save on power bill
Mitigates the demand charge for the next year
REV3, 03-AUG-2017

11. Schedule Integrated with CEBAF Operations
Testing cycles could occur three times per FY at the conclusion of planned CEBAF runs
First testing cycle most likely in Jul-2018 contingent upon actual FY2018 run schedule and staffing availability
REV3, 03-AUG-2017

12. P6 Labor Profile (1/2) – Incremental Labor Required
Incremental labor required to convert LERF and support testing (doesn’t include actual testing labor)
CM Tests
REV3, 03-AUG-2017

13. P6 Labor Profile (2/2) – Incremental + Testing Labor
Total labor required to convert LERF and support testing (includes actual testing labor time-phased)
CM Tests
REV3, 03-AUG-2017

14. Assumptions Priority for JLab is 12 GeV Operations
Schedule for testing CMs will be coordinated with FY2018 & FY2019 run schedules
CM testing windows will be adjusted to minimize impact on NP program
Full cost recovery from LERF operations is required
Defined boundaries between laboratory program and WFO
Cost includes specific LERF facility charges
Draft cost and schedule presented in parallel to LCLS-II and JLab management.
Updates and revisions based on discussions are included
Staffing requirements will be considered as part of overall FY2018/2019 laboratory planning. Priority consistent with WFO vs. CEBAF operations.
Recommend meeting with LCLS-II Project Director, Lab Director and Chief Planning Officer to review and discuss overall plan
REV3, 03-AUG-2017

15. Impacts & Risks
Cryogenics: present 2K issues complicate near term scheduling. Contamination is a concern that could affect availability.
Can’t stab U-tubes during CEBAF ops (need 4K for 1 week)
Repeated stabbing adds potential contamination problems
Cooldown and warm-up : overall cryo load must be handled properly with controls.
CEBAF Operations:
Phase I no impact.
Phase II & III requires PSS Control and interface. Cannot keep two of the FEL CMs cold as CEBAF spares. Coordination is required with other cryo activities.
Phase II & III need coordination with CEBAF 12 GeV operations.
LERF Operations: Phase II and Phase III would eliminate all other LERF operations.
Staffing: Initial plan utilizes combination of in-house staff and possibly term hires. Higher priority work might limit available staff.
Schedule: Working towards July test cycle (April if all goes very well.)
REV3, 03-AUG-2017

16. LERF Vault as Cryomodule Test Facility
Summary
LERF Vault as Cryomodule Test Facility
Full Cost Recovery - ~ $4M over 18 to 24 months
Provide parallel testing facility to reduce testing bottleneck (12 to 15 CMs may need to be tested in FY2018/FY2019) and mitigate schedule delays due to cavity supply and CM design issues
Seeking decision from LCLS-II management regarding proposal for LERF facility
REV3, 03-AUG-2017

17. Back Up
REV3, 03-AUG-2017

18. JLab Proposed Layout for LCLS-II CM Production
CM Testing
Phase II CM Assembly (2X)
Clean Room String Assembly
Phase I CM Assembly (2X)
Final Assembly / Prep for Testing
Vacuum Vessel Installation
REV3, 03-AUG-2017

19. JLab Facilities Improvements : Testing in CMTF
Draft FRS for CMTF in Progress (LCLSII-4.6-FR-0285); Similar to FNAL CMTS1 FRS
Ability to run 8 cavities simultaneously
End Cans (2 sets to support CM production rate)
Engineering Specification JL S in Review/Approval Process
Connects CM to CTF valve box via u-tubes
Interfaces for valves, LL and diodes to monitor and control helium flow/inventory
Provides reliefs for primary circuit, shield circuit and insulating vacuum space
HPRF
Receive 1.3 GHz 3.8 kW Solid-State Amplifiers (SSAs)
Procure Circulators
Modify Waveguide and Interlocks
Run line power to SSA/Circulators
Provide controls in CMTF Control Room
LLRF
RF Instrumentation (arc detectors, IR sensors, etc.)
Provide digital controls in CMTF Control Room
Software development
Cryogenic Test Facility (CTF)
Improve return side piping to reduce overall pressure drop from CMTF
Ensure recovery system (pumping, compression) provides base pressure of atm (23 torr) in the CM helium bath
Improve/replace aging instrumentation such as arc cells, flow meters and temperature sensors
REV3, 03-AUG-2017

20. JLab CMTF
HPRF system suitable for individual cavity testing or 8 cavities in short duration steady state
TBD system for testing SC magnet – need PS & leads info
Magnetic shielding encloses testing volume reducing external fields to less than 50 mG
Cryogenic capacity for testing up to 8 cavities in CW mode
End Caps – specific for LCLS-II CM testing
Interface to CM piping and existing junction box using u-tubes
REV3, 03-AUG-2017

21. JLab CMTF Conceptual Layout
JUNCTION BOX
* = New Hardware
BAYONET BOX*
END CAP*
BAYONET U-TUBE*
CAVE DOOR
(CLOSED)
HEAT EXCHANGER
End view of CM with bayonets connecting JB, HX and BB
REV3, 03-AUG-2017

22. Approval Process
THE PROCESS INVOLVES FOUR STAGES: STAGE 1 – INITIAL EXPLORATION WITH POTENTIAL PARTNERS STAGE 2 – EVALUATION BY PRIMARY DIVISION MANAGER STAGE 3 – DECISION BRIEFING TO LABORATORY LEADERSHIP STAGE 4 – APPROVAL BY DOE
REV3, 03-AUG-2017

23. STAGE 3 –DECISION BRIEFING TO LABORATORY LEADERSHIP*
Prepare a decision briefing, using the information from the Proposal Information Form (PIF), to obtain lab approval. The briefing must include the following elements: a. Outside Work Opportunity Title and Partner b. Overview of opportunity: description of work with deliverables and milestones c. Details of the opportunity: duration; resources needed, key skills, infrastructure needs, partner contribution d. Complete Budget Estimate form through the Budget Office (By FY, FTEs by skill, and non-labor) e. Benefit to Lab (how does opportunity supports JLab’s mission and scientific goals, core competencies, etc.) f. Proposed method for receiving funds (FOA, Grants, proposals, CRADAs in support of SBIR/STTR proposals, Work for Others, IAA, CRADAs, IWOs, etc.) Lab Leadership recommends that the Laboratory Director approves the initiative. Some initiatives may need DOE approval. The preparation of relevant documents is described under Stage 4, below. If approved, the PI has an actual commitment from the Lab to continue to Stage 4. If the proposal does not include new funds into the Lab then it can be approved without moving to Stage 4.
*Taken directly from Lab Approval Process
REV3, 03-AUG-2017

24. Phase I – Configure LERF for Testing
Removal of 20’ of back leg of existing machine to install/position CMs
Removal of u-tubes from two existing CMs in FEL vault
Can remove two high performing CMs to augment CEBAF
Requires a set of u tubes to connect CMs to existing cryogenic transfer line bayonet connections
Review design; procure cryogenic hardware
Requires one set of CM testing end caps (same design as CMTF)
Requires two sets of stands (same design as CMTF)
Requires one set of interconnect hardware including HOM BLA, bellows
Install cryogenic controls (Cryocon temp readbacks, heaters, JT and cooldown valves, etc.)
Pull cabling
Install SLAC-provided SSAs and HPRF hardware
Install SLAC-provided LLRF controls
Review and approve any updates to OSP for FEL vault operations
Decarad and Faraday cups for radiation monitoring
REV3, 03-AUG-2017

25. Phase II – Initial Full Power RF/Cryo Testing
Assumes all hardware from Phase I available
Schedule allows for more time and resources for initial testing cycle
Install pair of CMs in LERF
Connect RF, instrumentation and cryo controls
Coordinate cooldown with CEBAF operations
Evaluate procedures for cooldown, RF testing and warm up
Coordinate warm up with CEBAF operations
Remove pair of CMs from LERF
REV3, 03-AUG-2017

26. Phase III – CM Acceptance Testing
Assumes Phase II completed
Schedule considers logistics for installing multiple CMs in LERF vault
Staffing estimate will be based on current project baseline
Assumes one test cycle in CMTF / 5 wks
Potential impact - CMTF & LERF testing is conducted in parallel
REV3, 03-AUG-2017

27. Assumes Phase III completed
Phase IV – Restore LERF
Assumes Phase III completed
Remove any LCLS-II specific hardware from vault
Replace LERF specific hardware
REV3, 03-AUG-2017