2K Cold Box Mechanical Design Nate Laverdure LCLS-II 2K Cold Box FDR March 28, 2018

Status of design outputs Outline Status of design outputs Complete subsystem design Complete technical specifications for build-to-print fabrication, shipping, installation, and integration Outline plan for configuration change

Documentation list Title Status 79222-S003 Technical Specification for Initial Construction of LCLS-II 2K Cold Box Released 79420-S004 Technical Specification for SLAC LCLS-II Cryogenic Multi-Layer Superinsulation (MLI) Requirements and Installation 79222-D6001 LCLS-II 2K Cold Box Drawing Index 79222-0000 LCLS-II 2K Cold Box with Cold Compressor (SCB) Flow Diagram (P&ID) Released Rev J 79222-0020 LCLS-II 2K Cold Box Complete Assembly and all mechanical and electrical sub-assemblies Released Rev A 79222-A0003 LCLS-II 2K Cold Box Valve Panel Anchorage & Structural Analysis 79222-A0002 LCLS-II 2K Cold Box Vacuum Skid Anchorage & Structural Analysis

Design documentation 79222-S003 Technical Specification for Initial Construction of LCLS-II 2K Cold Box

Design documentation 79222-D6001 LCLS-II 2K Cold Box Drawing Index

Mechanical drawing package structure 79222-0020 Complete Assembly 79222-0021 Instrumentation Installation 79222-0022 Utility Installation 79222-0026 Anchor Installation Gauge panel and two electrical enclosures Valve panel and several utility piping spools 79222-0139 Insulating Vacuum System 79222-0027 Shipped Assembly Structured to minimize mechanical reassembly work on SLAC site

Mechanical drawing package structure 79222-0020 Complete Assembly Includes all installation, outfitting of all external piping and external instrumentation 79222-0021 Instrumentation Installation 79222-0022 Utility Installation 79222-0026 Anchor Installation Gauge panel and two electrical enclosures Valve panel and several utility piping spools 79222-0139 Insulating Vacuum System 79222-0027 Shipped Assembly

Mechanical drawing package structure 79222-0020 Complete Assembly 79222-0021 Instrumentation Installation 79222-0022 Utility Installation 79222-0026 Anchor Installation GC scope Offloading Anchoring in place Gauge panel and two electrical enclosures Valve panel and several utility piping spools 79222-0139 Insulating Vacuum System 79222-0027 Shipped Assembly

Mechanical drawing package structure 79222-0020 Complete Assembly Complete 2K Cold Box vessel including vacuum shell, internal piping, internal instrumentation In shipping configuration for transport to SLAC 79222-0021 Instrumentation Installation 79222-0022 Utility Installation 79222-0026 Anchor Installation Gauge panel and two electrical enclosures Valve panel and several utility piping spools 79222-0139 Insulating Vacuum System 79222-0027 Shipped Assembly

Review of mechanical details General arrangement, location of interfaces Configurations and bayonet installation/removal Mechanical design details Thermal reliefs Cold compressor installation Bellows/straightener assembly Heater assembly Central support column

Interface locations – main cryogenic process interfaces He-505 CC6 suction He-504 CC5 discharge He-506 CC6 bypass He-501 2k suction from linac He-507 30K to 4KCB He-508 4K fom LHe dewar

Interface locations – warm utility interfaces He-515 Relief valve discharge collector He-511 3 atm He supply GV-512 Guard vacuum IA-513 Instrument air CW-517 & 518 Cooling water supply & return He-510 Cleanup return to recovery system

Interface locations – warm utility interfaces

Design considerations for future configuration change Changes to two piping spools U-tube configuration change

Future configuration change – affected piping spools CC1 INLET FROM TRANSFER LINE CC2

Future configuration change – affected piping spools Abandoned in place Removed spool Cut locations Replacement spool Cut locations 79222-0061 79222-0062

Future configuration change – proposed sequence Process conditions Linac warm, 1 atm Backfill insulating vacuum and make entry Peel back insulation, cut piping, remove spools All cuts are in vertical orientation for cleanliness Spools can be removed through manway No instrumentation on removed spools CC1 suction and discharge piping abandoned in place, can be secured to vacuum shell

Future configuration change – proposed sequence Insert new spool, weld Spool can be inserted through manway No instrumentation located on new spool QC checks ASME B31.3 pneumatic leak check Sensitive helium leak check Insulate Clean up Blowdown, pump, & backfill process piping Pump down insulating vacuum

Cold box configurations – u-tubes Size Both SCB-MCB-CCR 5-3/16” LHD-SCB-VAP-03 3-1/8” High flow - CC-1 through CC-5 SCB-CC6-BYPASS Low flow - CC-2 through CC-6 SCB-CC5-CC6

Cold box configuration control Bayonet installation/removal procedure

Bayonet installation/removal procedure

Thermal relief assembly All 2K Cold Box cryogenic reliefs are: Thermal reliefs ASME reliefs Protected against air contamination via guard vacuum enclosure Exhausted to header which is protected against moisture entry and vented outdoors

Thermal relief assembly

Thermal relief assembly Relief inspection/replacement process: Warm up 2K Cold Box and bring to 1 atm Backfill relief exhaust header with 3 atm He purge Break fittings around relief shroud and remove Disconnect relief flange and install blank while under purge Inspect/test relief on bench or replace Disconnect blank and install relief while under purge Re-install relief shroud Pump relief exhaust header to guard vacuum and backfill with 3 atm He purge

Mechanical details – cold compressor installation

Mechanical details – cold compressor installation

Mechanical details – bellows/straightener assembly Used in CC-1 and CC-2 inlet piping spools

Mechanical details – bellows/straightener assembly Cleanup of stagnant annular volume Recommendation: Large virtual leak exists between flex ID and process piping. Need to address this. Response: 12x 1/8” holes to facilitate pump and backfill of annular space

Mechanical details – heater assembly Scaled from SNS and earlier heater designs

Mechanical details – control valves

Mechanical details – internal piping support Only 1 permanent support required for the design Located on the heater assembly (small heat in-leak has no adverse effects)

Mechanical details – insulation

Mechanical details – manway Based on 30” design used at JLab 4K Cold Box

Mechanical details – central support column Maintains flatness of top plate during assembly Threaded rods and nuts for leveling during installation Shims inserted between flanges to carry large compression load And during operation Encased in passive copper conductor Insulated with MLI Thermal deflection limited to a few thousandths

Mechanical details – vacuum pumping system

ES&H design considerations – ODH 2K Cold Box located in the cold box building, a class 1 ODH area Mitigations: Warning Signs Installed Oxygen Monitor Ventilation Training for personnel

ES&H design considerations – noise DOE standard: no personnel exposure to noise above 85 dBA without hearing protection Noise generated by all cold compressors is expected to be lower than 85 dB when measured from 1 m distance from equipment No hearing protection needed inside the cold box room

ES&H design considerations – fall protection Cold Box top plate height: 12.5 feet Safe access to components located on the top plate is provided by a work platform

ES&H design considerations – egress & work access 180-degree access around bayonets for system configuration changes Access on at least 1 side of control valves, relief valves, cold compressors, and feedthroughs for maintenance ~24” aisle width or more for egress from work areas

ES&H design considerations – confined space Design minimizes the requirement to work within the 2K CBX insulating vacuum enclosure Cold compressor motor cartridges installed via bolted flange connections on the top plate Flange provided on top plate for ventilation

Maturity of design is commensurate with FDR Summary Maturity of design is commensurate with FDR All design outputs are complete and approved Mechanical and electrical drawing set Technical specification and included references Proceeding with approved procurement of 2K Cold Box vessel