1. Facility Layout and Infrastructure Requirements Rich Stanek (on behalf of CMTF facility team) PXIE Program Review January 16-17, 2013

2. Outline Introduction Goals and associated scope of work Primary technical challenges Progress to date Reutilization of components Major milestones Summary 2PXIE Review, R. Stanek

3. Introduction Decision made to site PXIE inside the existing CMTF building –Share this facility with the Cryomodule Test Stand 1 (CMTS1) Original plan was for two cryomodule test stands in CMTF building –PXIE can serve as a test stand for 162.5 MHz HWR and 325 MHz SSR1 Use of an existing building accelerates the pace for PXIE installation and saves resources Sharing a building with another facility, adds some complexity but offers several benefits –Plan floor space and infrastructure such that both facilities can be installed and operated efficiently –Share common infrastructure (elect. power, cryoplant, LCW system…) –Same team of people working on both facilities (schedules mesh well) Page 3PXIE Review, R. Stanek

4. CryoModule Test Facility CMTF Page 4 CMTF is a new set of buildings (adjacent to NML) built using SRF ARRA funds Was  CMTS1 & CMTS2 Now  CMTS1 & PXIE PXIE Review, R. Stanek

5. SRF Test Facility Complex 5 Cryomodule Test Facility (CMTF) Compressor Bldg. 5,300 sq. ft. high bay Cryomodule Test Stand 1 PXIE Accelerator Cleanroom Cryogenic Cold Boxes Existing NML Building Tunnel Expansion Beam Absorbers Test Beam Lines IOTA Ring Proposed ASTA Accelerator (nominal 3 CM up to 6 CM) Pass Thru Line PXIE Review, R. Stanek CMTF Main Bldg. 14,700 sq. ft. high bay 5,000 sq. ft. low bay

6. Goals and Scope of Work Prepare for PXIE (inside the CMTF building) –Create a layout and prepare infrastructure such that PXIE components can be installed as they become available PXIE and CMTS1 can coexist and operate simultaneously Scope of Work for Facility/Infrastructure –Building and cave layout Radiation shielding including penetrations and labyrinths –AC Power –HVAC –Compressed Air –Cooling Water –Cryogenics –Connections and cable routing Have recent experience with NML & HINS to guide design choices Page 6PXIE Review, R. Stanek

7. Functional Requirements for General Facility CMTF will house two distinct facilities, PXIE and CMTS1 and be able to be maintained, commissioned and operated independently so that the operation of one does not impact the operation of the other –Access labyrinths designed to allow entry into either cave independent of operation of the other –Removable shielding blocks on the cave roofs should allow for installation and removal of components (including cryomodules) without interference in the operation of the other facility –RF power, controls, instrumentation, water, air and cryogenic systems should be able to be operated either for one or both of the facilities Space for two cryogenic plants (Superfluid Cryogenic Plant and CTI-4000) as well as a local control room area and clean room should be provided Follow requirements of ES&H Manual (FESHM) for all components and systems (Hazard Analysis, LOTO, cryogenics, pressure vessel, flammable gas, piping,,.) ODH protection system should be designed to maintain ODH 0 classification outside caves Cave radiation shielding assessment should be consistent with the Fermilab Radiological Control Manual and allow unrestricted access to the CMTF building area outside the cave Placement of RF power equipment, cooling skids and other large auxiliary equipment as well as open aisle ways should be done in a way that allows easy crane or forklift access for replacement/repair procedures Requirements for maximum cable length should be incorporated into the rack layout so as to assure proper operation of instrumentation and controls Equipment should be positioned/mounted to minimize vibration effects on the beamline 7PXIE Review, R. Stanek

8. Functional Requirements for PXIE PXIE PXIE is designed to test and validate critical technologies for the first ~30 MeV of acceleration in continuous wave (CW) mode including operation of two cryomodules (162.5 MHz HWR and 325 MHz SSR1) Cave layout should allow for some reasonable variation of beamline length and component width as final component designs emerge Cave layout should minimize the length of RF power distribution components and critical control and instrumentation cables Cave layout should be able to accommodate PXIE staging scenarios and various commissioning activities (although this may require temporary shielding or alternate shift operation) Support stands should meet all component requirements including vibration isolation and allow for required alignment precision 8PXIE Review, R. Stanek

9. Technical Challenges Technical challenges include –Fitting all the equipment into the building properly With current cave configuration: ~5 ft. of additional beamline length available If cave is extended south to CMTF building wall: ~20 ft. available Respecting the requirements for cable length, min. RF coax length… Having NML as an example to follow is a big plus! –Final design and layout of the cryogenic system Complicated by flexibility of CMTS1 test stand Cryo system has tight operational parameters (pressure and temperature stability, minimize vibration inside cryomodule…) –Having facility/infrastructure ready for use when required (mostly funding driven, but…) Reuse of existing equipment (Mycom compressors, SLAC CTI-4000, pumps, valves, piping, instrumentation, controls…) 9PXIE Review, R. Stanek

10. Page 10 CMTF Layout CMTS1 PXIE Beamline RF Power/LLRF Chillers & Instrumentation racks Mezzanine space for controls racks Control Room underneath He Cryoplants Cleanroom Class 10,100,10,000 PXIE Review, R. Stanek

11. Page 11 PXIE cave dimensions –Length = 129’ (w/o labyrinths) – CMTF crane hook height = 24’ Beamline position in cave –From west wall = 9’ –From floor = 4.265’ (1.3 m) T Blocks Header Blocks PXIE Review, R. Stanek

12. Progress to Date Outfitting of CMTF and installation of infrastructure is going well –Biweekly meetings to coordinate installation work and equipment layout –Sharing information with all members of the project team –Assembling a PXIE equipment list with detailed information for components Size, weight, and rigging requirements Power and cooling requirements Amount of support equipment, relay racks, etc. –Sharing personnel with NML team (as appropriate) –Working on 3D CAD model of beamline and enclosure Allows accurate representation and easy identification of interferences 12PXIE Review, R. Stanek

13. Page 13 Pictures PXIE Review, R. Stanek

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16. Support Infrastructure Page 16 Reuse equipment designs from NML –Component support stand Current design uses 8020 Al channel –Load & vibration tested –Perform FEA for deflection and resonant frequencies –Portable clean rooms Design works well in NML PXIE Review, R. Stanek

17. CMTF Cryogenics Cryogenic systems should have the following functionality –Operate PXIE with 1 HWR and 1 SSR1 Cryomodule (CW mode) –Operate CMTS1 capable of testing 1 Cryomodule 1.3 GHz Cryomodules - Pulsed or CW 325 MHz SSR or 650 MHz Cryomodules CW –Pressure stability goal 0.1 mbar (rms) Helium cryoplants in CMTF (nominal capacities) –New Superfluid Refrigerator 250W @ 1.8K or 500W @ 2K Under fabrication (Linde) due to arrive May 2013 Commissioning complete by end of CY13 –Repurposed SLAC CTI-4000 Refrigerator - supplies LHe to NML/ASTA 1000W @ 4.5K Refurbished in-house (new absorber vessel, added wet engine capability, refurbished turbines…) Expect installation at CMTF in FY14 Page 17 Courtesy of A. Klebaner PXIE Review, R. Stanek

18. CMTF Cryo Block Diagram Page 18 PXIE cryo distribution Courtesy of A. Klebaner PXIE Review, R. Stanek

19. Preliminary Cryo Distribution Scheme Page 19 DRAFT Courtesy of T. Peterson PXIE Review, R. Stanek

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21. Conventional Infrastructure HVAC  meets requirements –FESS worked with technical contacts to determine loads for system during initial construction Using standard methodology for equipment sizing –Heat Loads to Air have not changed substantially from first estimates 230 - 250 KW in Compressor Bldg. and 50 - 70 KW in Test Hall Operation of Mycom compressors (major heat load) well understood AC Power  meets requirements for Max Loads –PXIE Estimated Power ~800 kVA –CMTS1 Estimated Power ~450 kVA –CMTF Infrastructure Estimated Power ~3,165 kVA –CMTF Available Power (using 80% factor) ~4,800 kVA 21 4,415 kVA PXIE Review, R. Stanek

22. Conventional Infrastructure Cooling Water  Looking for alternatives for LCW to reduce cost –ICW Flow Required ~1620 GPM (mostly for compressors) ICW strainer and piping sized accordingly (common Lab system) –LCW Flow Required~800 GPM –LCW Flow Available (still to be procured) 1000 GPM (90 o F +/- 1 o F) There are also multiple stand-alone chillers in the PXIE system –Offer more precise temperature control and isolation »RFQ body and vane tip »Cryoplant uses two 12 ton chillers with remote condensers –Used during initial commissioning Compressed Air  meets requirements –Air Flow Required 105 SCFM –Air Flow Available160 SCFM 100 psig pressure, -40 o F dew point Using air compressor that was originally used at NML 22PXIE Review, R. Stanek

23. Reutilization of Components Cryogenic system –Seven Mycom compressors with associated oil removal skids –Helium gas and LN2 storage vessels –LN2 purifier and gas purity monitoring –Valves, instrumentation, control chassis parts… –SLAC CTI-4000 and 4,000 liter LHe dewar (for CMTS1 and/or NML) Tevatron wet expander for CTI-4000 –SNS Kenney-Tuthill vacuum pump for warm Helium pumping –Tevatron bayonet boxes and expansion cans for CMTF to NML transfer line Shielding cave –Various sizes of concrete blocks (A, B, E, F, and H) Electrical outfitting –Three 1500 kVA electrical transformers (from Tevatron) –Relay racks, cable trays, wiring… Water systems –Several chillers and various parts of water systems (pumps, filters…) Air system –NML air compressor system PXIE Review, R. Stanek23

24. Major Milestones PXIE Enclosure Ready for IS/LEBT18-Feb-13  progressing well PXIE Enclosure Safety System Tested20-Aug-13  performed in stages PXIE Enclosure Ready for RFQ01-Oct-14  should not be a problem PXIE Enclosure Complete01-Oct-14  should not be a problem Main LCW System Installed at CMTF11-Mar-15  funding driven looking for alternatives Cryogenic System Installed at CMTF26-Oct-15  cryoplant commissioned in CY13 Cryogenic System Fully Tested26-Jul-16  should not be a problem 24PXIE Review, R. Stanek

25. Summary Layout work, CMTF building outfitting & PXIE-specific infrastructure are all progressing Placing PXIE inside existing CMTF building accelerated progress –PXIE shares the CMTF building with CMTS1 –Working on optimizing the equipment layout –Common infrastructure and PXIE shielding cave are being installed –Cryogenics is one of the driving issues when operating SRF Superfluid cryogenic plant in fabrication, installed in FY13 CMTF cryogenics capable of delivering required capacity Work is gaining momentum and expect infrastructure and cave to be ready for start of installation of components starting in February 2013 Page 25PXIE Review, R. Stanek