1. LERF as Cryomodule Testing Facility Set-Up and Installation Logistics
Kevin Jordan PE

2. Bio Kevin Jordan PE CEBAF
FermiLab 1978 – 1985
Worked on DC power, Vacuum controls, RF, Managed switchyard
DESY 1985 – 1987
Went to Europe instead of SSC
Worked on SRF cavity instrumentation for HERA
CEBAF
Founding member SRF team 1987 – 1993
Worked in diagnostics group
Founding member / Chief Engineer FEL team 1996 – 2015
CASA Diagnostics team 2015 – current
Associates electronics technology 1977 Madison Tech
BSEE ODU 1990
Licensed Professional Engineer 1993

3. Outline Scope LERF Facility LLRF/SSA Location & Utilities
Personnel Safety System
Cryomodule Installation
Cryomodule and Cryogenic Controls
Interfaces
Questions/Concerns/Comments

4. 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

5. Scope Install: Test Removal:
Remove existing waveguide tophats and circulators from gallery
Remove 4 quad girders from FEL back leg for access to center of ring
Remove 2 existing CMs & store in back of LERF vault
Remove and store Darklight solenoid & baseplate in LERF vault
Install:
16 SSAs & LLRF in LERF Gallery
Connect to SSAs to existing waveguide that routes to tunnel
Install new cables in existing penetrations
Duplicate and install (2) AC distribution/PSS/VVU from Test Lab facility
Design & build new supply/return ‘U-Tubes’ for both 2K & shield
Develop EPICS based CM testing & commissioning tools
Install & commission 16 sets of LCLS LLRF hardware & software
Install & commission LCLS based cryo, vacuum & interlock systems
Test
Remove shield blocks, roll in 2 modules, reinstall shield blocks (~8 hours)
Connect 2 CMs together, tie into cryo, hookup tunnel waveguide
Cooldown & test
Repeat…
Restore LERF once CM commissioning is complete

6. Gallery Layout for 1 of 2 Zones
Voltage Verification Unit (VVU)
480 VAC Breaker panel
Personnel Safety System (PSS)
Solid State Amps
Equipment Racks
400 Amp service re-routed
To new breaker panel

7. New AC Distribution PSS & VVU
Existing HPA has 480 VAC/400 Amp service
Identical to Test Lab installation
Duplicate Test Lab PSS installation and tie into LERF PSS

8. Waveguide Layout Upstairs
Waveguides will route out the top of the existing rack to the SSA
All connections will be done using waveguide
Waveguide will go out the top of the rack (one set of 4 shown)

9. Ample Space in Penetrations for new Cables
Waveguides are in place and easily accessed for new routing
Open penetrations for new cables
Can project provide pre-made cable assemblies?

10. Cryomodule Instrumentation
As much as possible, instrumentation will be LCLS-II standard
Software
Temperature diodes
Magnetic Field monitoring
Vacuum controls (insulating, coupler beam line)
Decarad system for radiation monitoring
Faraday cups
SC Magnet Test
Duplicate existing magnet test stand
BPM cables and monitor (VNA).

11. LERF Vault Preparation for CM Testing
Remove the Dark Light Solenoid and floor plate
Remove 4 quad girders for CM access to center of ring
Remove two LERF cryomodules – store in LERF vault
Need access to cryogenic supply/return lines

12. New U-Tube Design
New design must take into account the location of the cable tray

13. Moving & Installing Cryomodules
A crane will first remove 27 shield blocks (2 rows deep) from the truck entrance then remove the tested CMs and replace with the next two CMs and replace the blocks. Need assessment from RADCON if all of the blocks are required.

14. Connecting Cryomodules in the Vault
Interface Connections to Cryogenics via u-tubes and flex lines
Supply transfer line has two stub ups – one each for primary and shield flow
Return transfer line has two stub ups with integrated control valves – one each for primary and shield flow
Cooldown header returns helium gas to the recovery system
Used for slow and fast cooldown, warm up
CM Cooldown/JT control valve with operators
Bayonet box cooldown and 5K circuit control valves with operators
Interface between CMs
Beamline connection – spool piece, particulate-free, UHV under cleanroom
Cryo-piping – conflat flanges with bellows
Insulating vacuum – large bellows with O-rings (like at SLAC)

15. Bayonet Box & U-tubes Concept

16. Logical Ties Removal / Design Installation Testing Restoration
Review of plan
Staff availability
Identify storage locations in LERF User lab & Vault
Assess CM/WG layout, design cryo hardware
Installation
CMs availability
Cryogenic hardware availability (Bayonet box, End Cap & U tubes)
Cable plant – I&C, Cryo, HPRF, LLRF, Vacuum
Delivery of SSAs and other SLAC provided hardware
Waveguide/Isolators/Directional Couplers
Testing
Training Operations & possibly SLAC personnel
EPICS software for LLRF & performance testing
Restoration
Completion of LCLS-II CM testing program

17. Risks
Staff availability – commitment from laboratory for project, however coordination of many skill sets over relatively short time frame
Software – ready for use when needed; leverage SLAC development for LCLS-II
Hardware – delivery dates meeting required schedule; cryogenic components design, procurement and delivery

18. Summary
The detailed scope includes Removal, Install, Testing, and Restoration
Majority of infrastructure at FEL vault facilitates relatively straightforward set up of CM test stand
Planning covers installation of all sub-systems needed for testing
All CM interfaces have been considered in order to support testing of two CMs at a time
Questions/Concerns/Comments?