Cryomodule Safety Approvals Jay Theilacker LCLS-II Production Cryomodule Final Design Review May 12-14, 2015

2 Introduction LCLS-II Production Cryomodule Final Design Review, May 12, Theilacker Fermilab Safety Program Multi-Laboratory Safety Program Comparison Pressure Safety Electrical Safety Seismic Safety FMEA / What-If Analysis Summary

3 Design Basis LCLS-II Production Cryomodule Final Design Review, May 12, Theilacker Derived from the DESY TESLA cryomodule design Design modified at Fermilab for ILC development using Fermilab Engineering, QA and ES&H policies Cryomodule further modified at Fermilab to satisfy LCLS- II project requirements As a result, it was necessary to ensure that Fermilab policies also satisfy the requirements of SLAC and JLAB

4 Fermilab Safety Program LCLS-II Production Cryomodule Final Design Review, May 12, Theilacker Fermilab ES&H Manual (FESHM) applied to the cryomodule ChapterTitleLCLS-II Application Piping SystemsCryomodules and cryogenic distribution system piping Dressed Niobium SRF Cavity Pressure Safety SRF cavities 5034Pressure TestingCryomodules and cryogenic distribution system. 5033Vacuum Vessel SafetyCryomodules and cryogenic distribution system. 4240Oxygen Deficiency HazardFormerly Input for SLAC ODH analysis. 5032Cryogenic System Review Lists documents we generate to receive an operational readiness clearance. Applies to cryomodules and cryogenic distribution system. First application will be CMTS. 9100Fermilab Electrical Safety ProgramCryomodules in general 9140 Protection Against Exposed Electrical Bus Cryomodule magnet power leads 9150High Voltage Coaxial ConnectorsCryomodule coupler vacuum ion pump 9160 Low Voltage, High Current Power Distribution Systems Cryomodule magnet and power leads 10110Below the Hook Lifting DevicesIn case SLAC chooses to use a Fermilab lift fixture engineering design

SLAC reviewed the safety and QA programs at the partner laboratories o Common areas determined to be consistent with the SLAC program and therefore the LCLS-II project requirements o Unique areas were addressed o Seismic (FNAL and JLAB) o ODH (SLAC) 5 Multi-Laboratory Safety Program Comparison LCLS-II Production Cryomodule Final Design Review, May 12, Theilacker

Partner labs (FNAL and JLAB) have pressure vessel, pressure piping and vacuum vessel policies in place o Reviewed to be equivalent to SLAC policies and LCLS-II Project requirements [LCLSII-1.2-EN-0020]LCLSII-1.2-EN-0020 Special SRF pressure vessel considerations o Unable to comply directly with ASME B&PV Code o Governing regulation becomes 10 CFR 851 “When national consensus codes are not applicable”...“contractors must implement measures to provide equivalent protection and ensure a level of safety greater than or equal to the level of protection afforded by the ASME” 6 Pressure Safety LCLS-II Production Cryomodule Final Design Review, May 12, Theilacker

Fermilab equivalent level of safety method o Chose to address the pressure safety at the source (the cavity) as opposed to containment at the vacuum vessel boundary o Fermilab Dressed Niobium SRF Cavity Pressure Safety  ES&H Manual Chapter  References “Guidelines for the Design, Fabrication, Testing and Installation of SRF Niobium Cavities” o Using the Fermilab method made the most sense since the cavity was already designed using this method o JLAB has a different system for ensuring 10 CFR 851 compliance  JLAB has reviewed the Fermilab policy and engineering note and accepted it for cavity testing at JLAB.  The first dressed LCLS-II cavity has been approved and operated at JLAB 7 SRF Pressure Safety LCLS-II Production Cryomodule Final Design Review, May 12, Theilacker

FNAL and SLAC review pressure systems differently Both systems have advantages and disadvantages Project is working toward meeting requirements of both systems 8 Pressure Safety Review Differences LCLS-II Production Cryomodule Final Design Review, May 12, Theilacker FermilabSLAC Scope of Review Individual components Overall system Time of Review After implementation (ORC) After design, before implementation Code Stamped Vessels Considers stamp to be proof of design Requires vendor calculations, material certifications and weld/welder information

DocumentDocument # 1. Cryomodule Piping Engineering NoteEN01803EN Cryomodule Cavity Engineering NoteEN01774EN Cryomodule Vacuum VesselED ED Cryomodule Vacuum Vessel FEAED ED Cryomodule Vacuum Vessel VentingED ED LCLS-II CDS Relief System RequirementsED ED LCLS-II CDS Gas Return Pipe Pressure Drop AnalysisED ED LCLS-II CDS HT Shield and LT Intercept ∆P AnalysisED ED Pressure System Review LCLS-II Production Cryomodule Final Design Review, May 12, Theilacker

Pressure SystemsScopeDesign Documents 2K ReturnSRF Cavities, Lines B, G and H1, 2, 6, 7 2K SupplyLine A1, 2 Low Temperature InterceptLines C and D1, 2, 8 High Temperature ShieldLines E and F1, 2, 8 Insulating Vacuum3, 4, 5 Status Cavity design and implementation Successfully reviewed internally at FNAL and JLAB prior to horizontal testing LCLS-II Linac pressure systems Documents were submitted to the SLAC Pressure System Program Manager and comments have been received and are being implemented Cryomodule Operational Readiness Clearance Reviewed internally at FNAL and JLAB prior to cryomodule testing 10 LCLS-II Linac Pressure Systems LCLS-II Production Cryomodule Final Design Review, May 12, Theilacker

The cryomodule electrical systems have been design in accordance to the Fermilab ES&H Manual [details in Darryl Orris presentation]. Electrical systems include: SystemFESHM Chapter Thermometry9100 Coupler vacuum ion pump9100, 9150 Slow tuner motor9100 Fast tuner piezo actuators9100 Superconducting magnet package9100, 9140, 9160 SLAC recently drafted a LCLS-II project technical standard for electrical safety requirements [LCLSII-1.1-TS-0435] which is consistent with the Fermilab policiesLCLSII-1.1-TS Electrical Safety LCLS-II Production Cryomodule Final Design Review, May 12, Theilacker 9100Fermilab Electrical Safety Program 9140Protection Against Exposed Electrical Bus 9150High Voltage Coaxial Connectors 9160Low Voltage, High Current Power Distribution Systems

Requirements LCLSII-4.5-EN Cryomodule Seismic Design Criteria Analysis LCLSII-4.5-EN Stress Analysis of LCLS-II Cryomodule for Seismic Load Status Under review by SLAC. Determined to meet SLAC requirements within the cryomodule. Some minor modifications will be recommended related to mounting to the tunnel floor. 12 Seismic Safety LCLS-II Production Cryomodule Final Design Review, May 12, Theilacker

The direct interconnection of the cryomodule and cryogenic distribution system made it prudent to generate combined FMEA and What-If documents. Requirements for Operational Readiness Clearance FESHM 5032 Cryogenic System Review [for FNAL] LCLSII-1.1-TS-0382 [Under development]LCLSII-1.1-TS Engineering Failure Analysis Procedure FMEA LCLSII-4.5-EN-0255 (ED )ED CDS and Cryomodule Failure Mode and Effects Analysis What-If LCLSII-4.5-EN-0253 (ED )ED CDS and Cryomodule What-If Analysis 13 FMEA / What-If Analysis LCLS-II Production Cryomodule Final Design Review, May 12, Theilacker

What-If analysis is used to identify maximum credible incidents. Two different types of maximum credible incidents are determined and mitigated. Internal cryogenic rupture Mitigated by vacuum relief sizing [ED ]ED Input to tunnel and gallery ODH analysis [LCLSII-1.2-PM-0379]LCLSII-1.2-PM-0379 Loss of vacuum (beam or cryostat) to air Mitigated by circuit relieving [ED , LCLSII-4.9-EN-0300]ED The CDS/Cryomodule What-If Analysis is an input to the SLAC tunnel and gallery oxygen deficiency hazard analysis. The CDS/Cryomodule groups have been supplying the SLAC personnel working on the ODH analysis with the required inputs. A preliminary ODH analysis has been prepared by SLAC. 14 ODH / What-If Analysis LCLS-II Production Cryomodule Final Design Review, May 12, Theilacker

15 Summary Partner Lab Engineering, Pressure Safety and QA processes have been reviewed and approved for use on the LCLS-II project Cryomodule/CDS pressure systems are under review by the SLAC Pressure System Program Manager with initial comments expected by this review LCLS-II dressed cavities have been reviewed and approved at FNAL and JLAB prior to horizontal testing Electrical safety being addressed through existing policies Seismic analysis has been successfully reviewed by the SLAC Seismic Program Manager and Building Inspection Office related to internal elements -Minor modifications to tunnel floor anchoring being discussed Cryomodule/CDS FMEA and What-If analyses are developed, identifying maximum credible incidents and tied into the SLAC tunnel/gallery ODH analysis LCLS-II Production Cryomodule Final Design Review, May 12, Theilacker