1. Baseline Change Request
BCR Title: LERF as CM Testing Facility
(LERF = Low Energy Recirculation Facility)
Presenter’s Name: Ed Daly
CCB Presentation Date:

2. BCR Summary
Documents the work scope increase for an additional CM testing facility at JLab
Update the cost and schedule to include:
Set up of the LERF as a CM testing facility
Include additional labor to support facility
Net Impact:
Cost: Increase of $3,690K
Technical:
Using LCLS-II HPRF/LLRF provides early feedback on RF/SRF system integrated performance
Schedule:
Enables acceleration of CM testing by increasing testing through-put
CCB Presentation –

3. Using LERF as Cryomodule Test-Bed - Opportunity
The LCLS-II project has discovered issues with CM performance (microphonics, achieving high Qo, Field Emission) during the prototype cryomodule testing phase at FNAL and JLab
Resulting in some re-work of CMs
Need 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
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4. 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.
Estimate considers four phases – to achieve 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
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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, Isolators and other equipment loan)
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
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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
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7. BCR Form
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8. Cost Estimate Baseline Proposed Delta
Description
M&S
Hours
Burdened Costs
Infrastructure
$1,985,710
5,093
$8,602,787
$3,241,660
22,219
$12,292,894
$1,255,950
17,126
$3,690,107
Total
Full cost recovery Including operating cost estimates for LERF
Operating costs - $10.8K/week while CM is cold
Path forward
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
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9. Coordination of Project Supplied Equipment
RF High Power (Dian Yeremian)
16 Solid State Amplifiers, Isolators and Dual directional couplers
Low Level RF (Matt Boyes)
Four complete LLRF Racks (fully dressed with chassis and internal cables)
RF EPICS Software
LO Distribution and Reference Distribution*
Cryo Controls (Kevin Mattison)
Two complete cryo controls racks (fully dressed with equipment)
Cryo EPICS Software
Vacuum Controls (Sung Kwon)*
Beam line, coupler and insulating vacuum control racks (fully dressed with equipment). Note: Pumps are supplied by JLAB.
Vacuum EPICS Software
*Budgeted in the BCR, but could be supplied by project if available.
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10. P6 Schedule (1/2)
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11. P6 Schedule (2/2)
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12. 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
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13. 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
Can test at least 6 CMs by mid-2019
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14. CM Testing Schedule Considerations
Project needs GHz successful tests out of 40 CMs built
Assume that all CMs require at least one test
JLab pCM will be re-tested at FNAL in Sep-2017
One additional test cycle added in Schedule Re-alignment BCR
Doesn’t consider 3.9 GHz CM testing needs
Expect acceptable results from test with sixth CM at FNAL and sixth CM at JLab that includes all design improvements to mitigate microphonics
Current project plan includes testing 1 CM per month per partner lab
5 CMs have been tested as of end of July (2 pCMs + 2 FNAL CMs and 1 JLab CMs)
Estimate 20 CMs tested between Aug-2017 and May-2018 (10 months) without interruptions due to supply chain or cryogenics availability
Up to 15 more required by March 2019
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15. 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
Phase 1
Phase 2
Phase 3
Phase 4
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16. Key Staff Have Been Identified that report to CM CAM
Kevin Jordan leads Removal / Installation / Restoration activities that occur until CMs are ready to test
Technical lead for coordination of installation and removal activities planned to convert the LERF to a CM testing facility
Responsible for planning the work, reviewing it with stakeholders, and coordinating activities with groups providing resources.
Ensures that the full scope of work is completed in accordance with best and safe work practices through the use of the ATLis work planning system
Curt Hovater coordinates SLAC-provided hardware, supports installation activities and leads integration of RF/SRF systems
Jim Henry (Cryo Hardware, Overall Layout) leads design efforts with support from Joe Gubeli (RF system layout, Waveguides)
Supporting Staff
Groups within Engineering, Facilities and Accelerator Divisions that provided cost estimates will provide staff to perform activities
Operations committed to provide staff to conduct CM testing during CEBAF down-times
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17. 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.
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18. Impacts & Risks
Cryogenics: present 2K issues complicate near term scheduling. Contamination is a concern that could affect availability.
U-tubes operations add 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.)
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19. Stakeholder Input Received JLab Cryomodule CAM and STL PMCS group
Stakeholder Review
Stakeholder Input Received
JLab Cryomodule CAM and STL
PMCS group
Cryogenic System Manager, SRF Group Leader and CM Chief Engineer
Accelerator System Manager and AS Group Leads
LCLS-II Project Manager
LCLS-II Project Director
JLab Laboratory Director, Chief Planning Officer and ADs
JLab SMEs, Technical Review Team and Division Heads
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20. Review Agenda https://www.jlab.org/indico/event/233/
Reviewers
Tom Peterson (SLAC, chair and report) George Biallas (JLab)
Andrew Burrill (SLAC)
Chris Cuevas (JLab)
Harry Fanning (JLab)
Bob May (Jlab)
Attendees
SLAC: J. Galayda, M. Ross, A. Burrill (at Jefferson Lab), J. Chan, G. Hays M. Reichenadter (remote)
JLAB: E. Daly, K. Jordan, C. Hovater, J. Preble, J. Leung, J. Henry, G. Neil, J. Fitzpatrick, K. Macha, D. Hamlette
FNAL: R. Stanek, C. Ginsburg (remote)
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21. Strongly recommend of LERF as additional CMTF
Summary
Strongly recommend of LERF as additional CMTF
Additional in-parallel testing station adds test cycles that can be used for re-testing reworked CMs and other unplanned tests
Mitigates schedule slippage caused by unscheduled down-time of existing cryogenic testing facilities at Partner Lab
Schedule has been integrated with CEBAF Operations
Funding enables starting design and removal/installation activities in August
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22. Back Up
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23. 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
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24. 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
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25. 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
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26. Assumes Phase III completed
Phase IV – Restore LERF
Assumes Phase III completed
Remove any LCLS-II specific hardware from vault
Replace LERF specific hardware
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