1. FNAL Cryomodule Assembly and Installation Plans Tug Arkan May 22, 2015

2. Introduction 2 partners labs are collaborating with SLAC for the LCLS-II project: Fermilab: -Assemble 1 prototype 1.3 GHz CW module -Assemble 16 production 1.3GHz CW modules 3 modules assembled in series (ramp-up) 13 modules are assembled with a throughput of 1 module per 4 weeks -Assemble 2 3.9GHz CW modules JLAB: -Assemble 1 prototype 1.3 GHz CW module -Assemble 17 production 1.3 GHz CW modules Total: 35 Cryomodules (1.3GHz CW) 2 Cryomodules (3.9GHz CW) 2

3. 3 Assembly Workflow @ CAF-MP9 Receive dressed Cavities Receive peripheral parts Assemble dressed Cavities to form a String in WS1 Install String Assembly to Cold Mass in WS2 Transport the Cold Mass to CAF-ICB Assemble cold end of the coupler to cavities in WS0

4. 4 Assembly Workflow @ CAF-ICB Install the String assembly with the cold mass into the Vacuum vessel WS4 Install the Cold Mass back to the Cold Mass Assembly Fixture in WS3 Align Cavity String to the Cold Mass Support in WS3 Prepare in WS5 & Transport Completed Cryomodule to CMTS for testing

5. 5 Parts / Fixtures / Hardware Cleanroom Preparation Assembly hardware: Wash in the ultrasonic bath Dry under Class100 hood Move into the Class 1000 ante clean room Blow clean with ionized nitrogen while monitoring the particulates count in the sluice area (Class 100) Transport into the Class 10 assembly area Class 10 Hood US cleaners Electro-polished, rolled thread 316L stainless steel studs; silicon bronze nuts Class 1000 softwall cleanroom

6. Cold End Coupler Assembly (WS0) Leak check the dressed qualified cavity (received beamline under vacuum) Backfill the cavity Leak check the coupler pair in the processing stand as delivered Backfill Remove a cold end coupler from the stand Assemble cold end coupler to the cavity using particle free flange assembly (PFFA) procedures. Pump down, leak check, RGA Total duration: 7 days for 8 couplers assembly 6

7. 7 String Assembly-I (WS1) Align 8 cavities for string assembly: 1 day Gate Valve (GV1) to Cavity #1 Assembly: 1 day Check the particle free cleanliness of the GV and clean as needed Sub-assembly of the GV peripherals Installation to the support post and vacuum hose assembly Leak check Alignment to the cavity beam line flange Particulate free flange assembly (PFFA) procedures Assemble the gate valve to the cavity Leak Check

8. 8 Cavity Alignment in the clean room X-Y Alignment Fixture: Cavities beam line flanges are aligned to ~0.5mm for the interconnect bellows assembly in the clean room Rotational Alignment Fixture: Coupler position: parallel to earth with respect to the cavity helium vessel lugs

9. 9 String Assembly-II (WS1) Cavity to Cavity Assembly with the interconnect bellows: Assemble vacuum hose to the cavity. Pump down and Leak check. Backfill Align the interconnect bellows to the cavity field probe end beampipe flange Assemble with PFFA Align the bellows to the cavity coupler end beampipe flange Assemble with PFFA 1 day per interconnecting bellows, 8 cavities, 7 bellows total = 7 days

10. String Assembly-III (WS1) BPM+Magnet Spool Tube+GV2+Beamline monitoring manifold assembly and leak check (1 day) Magnet subassembly to the 8 cavity string (1 day) Pump down, bag the bellows, leak check. Backfill (2 days) Roll out of the cleanroom to WS2 Total duration: 13 days 10

11. 11 Cold Mass Assembly – Phase I (WS2) Spreader bar fixture is used to support, lower and raise the GRHP sub-assembly. GHRP sub-assembly is rough aligned in the spreader bar fixture to the rails center. (See Virgil’s talk) A second rail system is setup at WS2. WS2 assembly tasks are the most critical ones and have potential to be schedule drivers therefore if needed, cavity string can be transferred from first rail system to second rail system in order to free up cleanroom access

12. Cold Mass Assembly at CAF-MP9 (WS2) 12 Tasks outside of the clean room before the string was lifted off the cleanroom posts to GHRP sub-assembly (Phase-I): 2-phase helium pipes cutting to length & bellows welding with orbital cutting and welding machines (1 day) Cavity magnetic shields installation (0.25 day) Cavity insulation installation (0.25 day) Temperature sensors instrumentation and RF cables installation (1.5 days) Cavity helium vessel lugs to needle bearings and housings installation (1 day) Cool down lines to helium vessel welding (1 day) Various leak checks / pressure tests of the helium circuit (2 days) Various electrical checks (1 day) Various RF checks & HOM notch frequency tuning (2 days) Total duration : 10 days

13. 13 Cold Mass Transport After the cavity string is picked up off the rail and partially assembled to GRHP sub-assembly, the cold mass assembly is transported to CAF-ICB (~5 km from CAF-MP9).

14. Cold Mass Assembly at CAF-ICB (WS3) Assembly Tasks: (Phase-II) Assemble Magnet / Current Leads (1 day) Align cavity string to cold mass (laser tracker) (2.5 days) (see Virgil’s talk) Remove helium vessel safety brackets & Assemble end lever tuner system (2 days) Complete the interconnect magnetic shielding assembly (1 day) Complete the harnessing of the instrumentation wires & RF cables (0.5 day) Electrical & RF Checks (1 day) Total duration : 8 days 14

15. Assembly on Big Bertha at CAF-ICB (WS4) Assembly tasks: (Phase-II cont.) Install and weld lower 50K aluminum shields (1 day) 30 layers of MLI as blankets (1.25 day) Electrical & RF checks (1 day) Slide vacuum vessel onto the cold mass (0.25 day) Weld magnet flanges and JT/Cooldown valves (0.5 day) Leak checks & pressure test (1 day) Align cold mass to the vacuum vessel and transfer to external fiducials (laser tracker) (2 days) (See Virgil’s talk) Total duration : 7 days 15

16. Final Assembly Phase-III (WS5) Install warm part of the fundamental power couplers (8 days) Route & terminate instrumentations wires and RF cables to the feedthrough flanges (3 days) Install coupler pumping lines, pumps & leak check (1 day) Pump down and leak check insulating vacuum (3 days) Total duration : 15 days 16

17. 17 Cryomodule Transport Preparation (WS6) Prep & Transport completed Cryomodule from CAF-ICB to the CMTS : 2 days CM1 & 2 Transport Fixture 10 tons capacity Module Lifting Girder LCLS-II module shipping fixture which can also be used for on- site transport

18. CAF-MP9 during LCLS-II Production WS1: 13 days WS2:10 days WS0: 7 days 18

19. CAF-ICB during LCLS-II Production WS3: 8 days WS4:7 days WS5: 15 days WS6: 2 days 19

20. Schedule WS0: Cold End Coupler Assembly - 7 days WS1: Cavity String Assembly – 13 days WS2: Cold Mass Assembly Phase I – 10 days WS3: Cold Mass Assembly Phase II – 8 days WS4: Vacuum Vessel Assembly – 7 days WS5: Final Cryomodule Assembly – 15 days WS6: Prep & Shipping – 2 days Total duration for assembly: ~60 days (12 weeks) 20 pCM assembly duration: ~ 6 months CM2-CM4 assembly duration: 12~14 weeks per module, assembled in series CM5-CM16 assembly duration: 12 weeks per module, assembled with the required throughput

21. Module Assembly Weekly Workflow 21 Cleanroom Assembly: Start: Week #1 Complete: Week #4 Cold Mass Assembly: Start: Week #5 Complete: Week #12 Module #n Module #n+1 Cleanroom Assembly: Start: Week #5 Complete: Week#8 Cold Mass Assembly: Start: Week #9 Complete Week #16 Module #n+2 Cleanroom Assembly: Start: Week #9 Complete: Week #12 Cold Mass Assembly: Start: Week #13 Complete Week #20 It takes ~12 (60 days) weeks to assemble a module. Excluding any sick modules that need to be reworked, there will be max 3 modules in the production line at the same time to satisfy the required throughput (1 module per 4 weeks) 4 weeks throughput

22. Installation Plans Mechanical installation to SLAC tunnel: -1.3 GHz Cryomodule External Physical Interfaces, LCLSII-4.5-IC- 0372-R0 -LCLS-II 1.3GHz Cryomodule Inter- connection Assembly Procedure, Teamcenter # ED0002593 22

23. Cryogenic Pipes Interconnect Assembly Cryogenic pipes need to be interconnected: Cut Flanges (orbital cutting machine with customized jaws) Weld bellows (orbital welding machine with customized weld heads) Leak Checks (reverse leak check setups to minimize helium background contamination and better sensitivity) Pressure test (special attention to the helium circuit where the SRF cavities reside) or x-ray post welding quality assurance for ASME 31.3 code compliance 23

24. Beamline Interconnect Assembly Particle free UHV working protocols in a softwall cleanroom (Class 10/100): Ensure gate valves are closed Uninstall manifolds from the gate valves (needs to be done before putting the modules in place at the tunnel) Move the modules in place at the tunnel (Distance between two gate valves is ~300 mm) Follow particle free UHV working protocols to assemble HOM absorber Leak check Establish common beamline vacuum 24

25. Cryomodule Schedule Highlights A full P6 schedule has been developed Takes into account the CD milestones, facility throughput, lead time on procurements Prototype CM – current “baseline” P6 status Begin assembly July 2015 – driven by dressed cavities & couplers Complete assembly Jan 2016 Cryomodule testing in 2016 Production CM – current “baseline” P6 status Cavity prep/test Mar 2016 (dressed cavities from industry) Begin prod CM assembly Apr 2016; end prod assembly Dec 2017 -Nominally one CM per month once steady state is reached Final FNAL 1.3 GHz CM delivered to SLAC May 2018 Some modifications will be made prior to CD-2 baselining Camille Ginsburg 25