1. ESS Programme Plan and Schedule Update C. Darve, Deputy WP05 and WP04 leader Acknowledgement: N. Elias, WP05 and WP04 P. Bosland, WP05 leader https://ess-ics.atlassian.net/wiki/display/CRYOM/Cryomodules+Collaboration+space

2. Headline ESS Programme Plan  Scope –Life-cycle flow for the cavities and cryomodules –Interface requirements between cavities and cryomodules  see afternoon Workshop –Acceptance criteria and NC  see afternoon Workshop –Use lessons-learned from ECCTD (and XFEL)  Schedule (time) ESS Technical Annex (“schedule”) –PDR –CDR –Data packages –Tracking progress Communication channels: –Follow-up –Collaboration Space web site –Video-conferences 2

3. Headline ESS Programme Plan  Scope –Life-cycle flow for the cavities and cryomodules –Interface requirements between cavities and cryomodules  see afternoon Workshop –Acceptance criteria and NC  see afternoon Workshop –Use lessons-learned from ECCTD (and XFEL)  Schedule (time) ESS Technical Annex (“schedule”) –PDR –CDR –Data packages –Tracking progress Communication channels: –Follow-up –Collaboration Space web site –Video-conferences 3

4. Scope: Cavities and Cryomodules life-cycle Cavity Cryomodule Technology Demonstrators: 1 x Medium-beta, M-ECCTD<= FR-SW agreement 1 x High-beta, H-ECCTD<= CEA/CNRS Early In-Kind Production of cavities of the series with RF tests: 36 x operating Medium-beta cavities<= LASA In-Kind 84 x operating High-beta cavities<= STFC In-Kind Production of all other cryomodule components (incl PC, CTS):<= CEA In-Kind Cryomodule assembling:<= CEA In-Kind Low-power tests of 3 first medium and high-beta cryomodules<= CEA FR In-Kind RF and cryogenics for low power testing Transport of cryomodules from assembly hall to ESS: 9 x Medium-beta cryomodules <= STFC In-Kind 21 x High-beta cryomodules <= STFC In-Kind 4

5. 5 NameDescriptionClarification Plug- compatible cavity design The cavities installed in the MBL cryomodules shall be designed such that they are plug- compatible with the cryomodule designed for the MB-ECCTD "Plug compatible" means that no alterations to the design of the remainder of the cryomodule components are necessary, e.g. Anchoring system. Note that design alterations resulting from the results of the MB-ECCTD are not ruled out by this requirement. R/QThe R/Q of the cavities designed for the MBL cryomodules shall not differ from that of the ECCTD cavity by more than +/-3.5% R/Q should be calculated at a beam velocity of beta = 0.705. Note that no alteration of the geometric beta of the cavity is suggested by the use of this value for beta. Epeak/EaccThe ratio of the peak surface electrical field (Epeak) to the accelerating gradient (Eacc) for the cavities installed in the MBL cryomodules shall not exceed that of the ECCTD cavities Eacc should be calculated for a beam velocity of beta = 0.705. Note that no alteration of the geometric beta of the cavity is suggested by the use of this value for beta. Interface requirements between cavities and cryomodules Cavity design shall be compatible with : Cold tuning system Power coupler Cryomodules component, e.g. thermal and magnetic shield, tie-rod system Assembly procedures Tooling handeling Use the technologies demonstrated via the ECCTD Preliminary

6. Cryomodule & main components 6  Similar to CEBAF/SNS cryomodule concept with 4 cavities per cryomodule  Common cryomodule design for medium and high beta cavities  Similar to CEBAF/SNS cryomodule concept with 4 cavities per cryomodule  Common cryomodule design for medium and high beta cavities MediumHigh Geometrical beta0.670.86 Frequency (MHz)704.42 Maximum surface field in operation (MV/m)45 Nominal Accelerating gradient (MV/m)16.719.9 Nominal Accelerating Voltage (MV)14,318,2 Q 0 at nominal gradient> 5e9 Cavity dynamic heat load (W)4,96,5 Power Coupler (HIPPI type coupler) Diameter 100 mm 1.1 MW peak power Antenna & window water cooling Outer conductor cooled with SHe Doorknob transition equipped with a bias system Cold Tuning System (Saclay V5 type modified for ESS cavities) stepper motor + gear box at cold Max tuner stroke: ± 3 mm Max tuning range: ~ 600 kHz Tuning resolution: ~1 Hz 2 piezo staks Cavities without HOM coupler 5 cells high beta (0,86) cavity 6-cells medium beta (0,67) cavity

7. 7 Cavity Production Transport to CEA Assembly in Cryomodule Acceptance Test in VC Acceptance Test @ CEA- in * Possible “partner’s transfer flagpoint” * Transport to ESS Acceptance Test @ CEA- out * Acceptance Test @ ESS-in High Power Test @ ESS Acceptance Test  Tunnel Ready For Installation In tunnel INFN/STFC ESS/STFC CEA Scope: Cavities and Cryomodules Life-cycle Ready For Assembly in CM

8. 8 Cavity Production Transport to CEA Assembly in Cryomodule Acceptance Test NC Report NC Minor NC Minor NC Repairable at CEA NC Repairable at CEA NC Report NC Not Repairable at CEA NC Not Repairable at CEA Repair Out of Work Data management and dealing with non-conformance * “partner’s transfer flagpoint” * * NC Minor NC Minor NC Repairable at STFC/LASA NC Repairable at STFC/LASA NC Not Repairable at STFC/LASA NC Not Repairable at STFC/LASA

9. 9 Data management Action items: -Define a general Data management system, based on a simplified version of the XFEL DB, to be implemented at the ESS. Study: system functionality and select data to store. -Define simplified Data management system at ESS, CEA, LASA, STFC, Desy, Zanon, RI, etc..

10. M&H Technology Demonstrators 10 Engineering studies completed Fabrication of the components in progress Assembly infrastructure and procedures Preparation of the test stands (coupler processing & cryomodule tests)

11. Technology Demonstrators: ECCTD The goals of the ECCTD are to verify/validate the design to initiate the series production. It shall verify (but not necessarily be limited to): Fabrication process and industrialization of ALL cryomodule components: e.g. Fabricate successfully the SRF 704 MHz cavities, chemical and heat treatments, power couplers, CTS, cryomodule equipment, assembly procedures, etc Validate RF design: e.g. performance of cavities in vertical cryostat and on the test stand; power coupler performance, test slow tuning system, fast tuning System, LLRF Validate thermal and vacuum cryomodule design: eg. cool-down rate, operating conditions; heat loads; cooling scheme efficiency, leak tightness; Validate the alignment techniques. Validate the toolings design: e.g. handling and transportation Validate the verification procedure and threshold: e.g. Acceptance criteria process, SAT, FAT Verify the non-conformity tracking process. Control command: e.g. Validate the PLC sequences and the fast acting system, verify the operating algorithms ES&H e.g. Complete risk analysis, Cavities and CM mechanical relief sizing. Training: e.g. fabrication follow-up, testing procedure, assembly, operation, 11

12. Ex: “HoA - ANNEX C: H-ECCTD Test Plan” Before installation: vacuum tightness checks alignment measurements After installation / RF power OFF: Cryogenics and vacuum connections leak checks Temperatures measurement during cool down Static losses measurement RF resonant frequencies measurement (fundamental and HOMs) Alignment measurement at room temperature and at cold temperature At cold temperature with RF power (limited to 3 months) Measurement of every cavity from 1 to 4 at low power: external coupling factors measurements: Q i, Q t Tuning operations study Test of every cavity from 1 to 4 at high power in pulsed mode Maximum accelerating gradient measurement Lorentz force detuning compensation study Dynamic losses at 2 K measurement Field emission thresholds and quench limits determination Cryogenic behaviors study Temperature measurements Couplers: variation of He mass flow and CM consumption as a function of RF power (to optimize coupler static losses) 12

13. 1 st April 2015TAC1113 M-ECCTD CDR review decision H-ECCTD CDR review decision 2) Power couplers contract awarded RF power source ready for coupler processing Cryomodule components contract awarded Planning Ready For Installation OK with ESS schedule: 03/09/18 => 02/05/19 1CM/month Planning Ready For Installation OK with ESS schedule: Q1 + Q2 2021: installation of HBL n° 1 to 11 Q1 + Q2 2022: Installation of HBL n° 12 to 21 Overall WP5 planning 1) Mb cavities contract awarded 1) Hb cavities contract awarded Mb – CDR – 15/09/16 Hb – CDR – 15/09/17 CDR – 23/12/16 CDR – 13/10/17

14. Proposed Milestones for LASA IKC “Technical Annex” 14

15. Proposed Milestones for LASA IKC “Technical Annex” 15

16. Proposed Milestones for STFC IKC “Technical Annex” 16

17. Proposed Milestones for STFC IKC “Technical Annex” 17

18. Headline ESS Programme Plan  Scope –Life-cycle flow for the cavities and cryomodules –Interface requirements between cavities and cryomodules  see afternoon Workshop –Acceptance criteria and NC  see afternoon Workshop –Use lessons-learned from ECCTD (and XFEL)  Schedule (time) ESS Technical Annex (“schedule”) –PDR –CDR –Data packages –Tracking progress Communication channels: –Follow-up –Collaboration Space web site –Video-conferences 18

19. Technical Annex - TOC SCHEDULE AIK [ACCSYS WP NUMBER. ACCSYS IKC REGISTER NUMBER] TO THE IN-KIND CONTRIBUTION AGREEMENT SIGNED BETWEEN ESS and [name of partner] on DATE 1.Scope 2.Related documents 2.1Applicable Documents 2.2Reference documents 3.Terms and Definitions 4.Project definition 4.1Deliverable Item definition 4.2Project Stages Definition 4.2.1Stage 1: Design Stage 4.2.2Stage 2: Realization and Verification 4.2.3Stage 3: Installation, Commissioning and Initial Operations 19

20. PDR - Definition “Preliminary Design Review(s) reviews preliminary design, sometimes referred to as conceptual design. A PDR assesses preliminary design options and decisions in comparison with ESS input baseline reference design including requirements. A successful PDR demonstrates that design is sufficiently developed, clear and agreed between ESS and the Partner. Preliminary design updates the baseline reference design which was agreed at Kick-off, and a successful PDR establishes a new baseline, described in [CMP] The ‘Allocated Baseline’ from which the Partner may proceed to detailed design, including any agreed pre-series prototyping. For planning purposes, a PDR should be limited to no more than one working day.” 20

21. PDR - Deliverables The contents of the technical data package for PDR(s) shall include but not be limited to: Requirements, agreed or proposed updates to documents comprising the baseline reference design. Design Reports, including reports of prototyping and other preliminary design-related analyses, tests, simulations. Design Data, (preliminary design level of detail) including 3D CAD models and CAD drawings, general arrangement drawings, P&ID, FE models, etc., and interface descriptions including at least interface identification and any preliminary design definition. RAMI Report, an initial version of a report of the estimation of the probability and consequences of failures in equipment as well as main maintenance tasks and proposed spare parts. Safety Report, an initial version of the safety risk assessment report (including identifying hazards and evaluating likelihood of incidents occurring and severity of potential consequences, also list of existing control measures). [PQP], any outline draft for the Project Quality Plan including initial identification of Standards to be applied, initial planning for compliance testing and inspection, and initial planning for verification. 21

22. CDR - Definition “Critical Design Review(s) conclude Stage 1. The CDR assesses if the design meets all facility element requirements with acceptable risk and within the cost and schedule constraints. The CDR demonstrates that the maturity of the design is appropriate to support proceeding with full-scale fabrication, assembly, integration, test, and future operation and decommissioning. The CDR should also review initial planning for verification. Detailed design updates the baseline reference design which was agreed at Kick-off, and any ‘Allocated Baseline’ of preliminary design established by PDR. A successful CDR establishes a new baseline, described in [CMP] as the ‘Design Baseline’ from which the Partner may proceed to Stage 2 Realisation and Verification. “ 22

23. CDR “The contents of the technical data package for CDR(s) shall include but not be limited to: Requirements, agreed or proposed updates to documents comprising the baseline reference design. Design Reports, including reports of prototyping and other design-related analyses, tests, simulations. Design Data, (detailed design level) including 3D CAD models and CAD drawings, general arrangement drawings, P&ID, FE models, etc., and detailed interface descriptions including interface identification and definition for controlling interface design. RAMI Report, a report of the estimation of the probability and consequences of failures in equipment as well as main maintenance tasks and proposed spare parts. Safety Report, safety risk assessment report (including identifying hazards and evaluating likelihood of incidents occurring and severity of potential consequences, also list of existing control measures). Verification Plan, (including planned FAT and SAT activities) [PQP], a full draft for the Project Quality Plan including identification of Standards applied in design, procurement, manufacture and assembly, and planning for compliance testing and inspection.” 23

24. CDR “The CDR data package shall also contain documentation to initiate a competitive tender for the procurement of the facility element and to support the project activities. The CDR data package should additionally include but not necessarily be limited to: Procurement Package, a complete documentation package for the procurement of the facility element including as a minimum a statement of work, manufacturing follow-up description, applicable and reference documentation Project Plan, updated plan in Gant chart form, describing in detail remaining Stage 1 activities, describing in detail Stage 2 Realisation & Verification activities, and an outline of any Stage 3 Installation, Commissioning and Initial Operations activities for the Partner. Risks, Risk Register, showing identified project management risks and/or technical risks.” 24

25. Example of status/doc at CDR-phase To start stage 2 the necessary prerequisite are the following: The interface document of the cryomodules with the tests stations at CEA Saclay, with the transport to ESS-Lund, with the test stand at ESS-Lund and with the LINAC infrastructure is settled by the end of stage 1. The acceptance criteria for the cryomodule assembly are settled by the end of stage 1. The ESS acceptance management process is operational. The verification plan followed up all along the cryomodule assembly, at the test stand at Saclay until the shipment to ESS-Lund is settled by the end of stage 1. The configuration items for cryomodule is clearly defined. The cavity string configuration with individual cavity performance for each cryomodule is known 3 weeks before the assembly. The last version of all assembly drawings and P&ID is released at the end of stage 1. Each design change needs an acceptance from CEA and the assembly drawing has to be updated and released to CEA. The ESS change management process is operational. The ESS-“CHESS” interface is operational to upload the cryomodule assembly documentation. The ESS non-conformity management process is operational. Transport test is successfully performed. Could this sentence be more specific? Should we clearly refer to a “document management database”? 25

26. Headline ESS Programme Plan  Scope –Life-cycle flow for the cavities and cryomodules –Interface requirements between cavities and cryomodules  see afternoon Workshop –Acceptance criteria and NC  see afternoon Workshop –Use lessons-learned from ECCTD (and XFEL)  Schedule (time) ESS Technical Annex (“schedule”) –PDR –CDR –Data packages –Tracking progress Communication channels: –Follow-up –Collaboration Space web site –Video-conferences 26

27. Communication channels SRF collaboration Kick-off meeting at Saclay: 23 June 2015 SRF collaboration at STFC: 15 December 2015 Medium-beta cavity design: 2-3 November 2015 Weekly Vidyo meeting: Fridays mornings Monthly Project reports Collaborative Project Objectives: Freeze the cavities design List interfaces requirements CEA needs to analyse the impact on the cryomodule design and on the toolings before approval Track actions items Etc 27

28. Cryomodules Collaboration space Interface between Cryomodule and Cavities- Within EMR 2015-11-02 Interfaces Meeting @ LASA - Medium-beta cavity/cryomodules 2015-12-15 Interface Meeting @ STFC - Collaboration for SRF Elliptical Cavities Collaboration Interface with Radio-Frequences - RFS - WP08 Interface with RF sources Interface with RFS/LLRF 2015-06-10 - Interface Meeting between EMR and LLRF - Meeting notes (LLRF Interface) 2015-10-21 - Interface Meeting between EMR and RF systems - Meeting notes Interface with RFS/RFDS Interface with RFS/Interlocks Interface with Cryogenics (Cryoplant, Distribution System) - CRYO - WP11 2015-02-16: Interface Meeting - Cryogenic Instrumentation Minutes of meeting 16-Feb-2015 (Cryogenic Instrumentation) 2015-03-04: PED Meetings - Pressure Equipment Directive 2015-03-09: Interface Meeting - Cryomodule instrumentation Minutes of 2015-03-09 (Cryomodule instrumentation) 2015-08-31: Interface Meeting - Pressure Configuration

29. Cryomodules Collaboration space Interface with Vacuum - VAC - WP12 2015-07-21: Interface Meeting - Cryomodules vacuum 2015-10-12 Interface meeting - Cryomodules Vacuum Beam Vacuum Interface Requirements Insulation Vacuum Interface Requirements Interface with Cabling and Conventional Power - CNPW - WP15 Interface with Cooling support - WTRC - WP16 Interface with Power Supplies, HV Power Converters - PWRC - WP17 Interface with Proton Beam Instrumentation - PBI - WP07 Interface with Test Stands - WP10 Interface with Control and Command - Integrated Control System (ICS) Interface with Survey and Alignment

30. Thanks for your attention 30

31. Compliance with European Pressure Equipment Directive (PED) 31 Volumes of the helium circuits and vessels < 48 l 1.431 bara < Working pressure Ps = 1.04 barg TUV Nord analysis report: The elliptical and Spoke cryomodules are classified according to PED article 3.3 Cryo pipes designed to reduce the overpressure in case of beam vacuum failure continuous diphasic pipe Ø=100 with large curvatures 2 Ø=100 bursting disks at each extremity

32.  S. Bousson, Workshop on Requirements Conformance for SRF Cryomodules, Lund, 15 th Oct. 2014 Spoke cryomodule overall life cycle Appro Niobium Fabrication Cavité Traitement surface Cavité Assemblage cavité Salle blanche Test en CV COMPONENT PHASE Export / delivery Test / validation Préparation/ assembly SUpply/ Production NiobiumCavitiesCouplers vessel Vacuum Cryomod. Full. compon.. Cryomod. string Cavity CTS… Transport -> site assemblage Transport -> Fabriquant cavités … … … … Fabrication Enceinte Cryomodule Transport -> site assemblage Appro Compos. cryomodule Transport -> site assemblage Assemblage train cavités Transport -> site assemblage Fabrication SAF Assemblage SAF Test à chaud SAF Transport -> site assemblage Assemblage cryomodule Test à chaud Transport -> Uppsala Fabrication Coupleur Préparation salle blanche coupleurs Conditionn- ement coupleurs Transport -> site assemblage

33. Charge to the Committee This review constitutes the principal technical and project review of the Work Package for this year. Additional specific design reviews may also be held. Keeping in mind the current status of the Accelerator Project, the committee is asked to review the information presented, answer to the extent possible the questions below and make specific recommendations to increase the likelihood of success of the Work Package. The result of the review will be a short report that includes recommendations. The committee serves in an advisory capacity to the Work Package Leader and the ACCSYS management team. Has the work package reached a level of technical maturity consistent with its current status on the schedule? Are there any technical concerns regarding the work package? Is any additional development or testing required for the work package to meet its goals? Are the requirements for the work package well understood and documented? Are all the interfaces between the work packages and other work packages and products properly defined, understood and agreed upon? Have all safety issues in the work package been properly identified and dealt with? Are there sufficient resources (funding, staff) assigned to the work package to allow the goals of the work package to be met? Are there decisions that need to be made in order to allow the work package to meet scope, cost and schedule? Are there any outstanding procurements or personnel actions that are limiting the progress on the Work Package? Is the Work Package on track to meeting its milestones? Are there any adjustments to the schedule and milestones that should be made? Are there any changes to the work package scope that should be made? Are additional reviews warranted before the next annual audit? 33

34. Technical Annex - TOC 4.3Project Schedule and Key Milestones 4.3.1Kick-off meeting 4.3.2Status meetings 4.3.3Design Review(s) in Stage 1 4.3.4Readiness / Acceptance Review(s) in Stage 2 4.3.5Review(s) in Stage 3 4.4Deliverables 4.4.1Status reports 4.4.2Technical Data Package(s) for Design Review(s), Stage 1. 4.4.3Technical Data Package(s) for Review(s), Stage 2 4.4.4Final report 4.4.5Documentation package for supply 34

35. Technical Annex - TOC 5.Tasks applicable to all project stages 5.1Project management and control 5.1.1Use of a Planning Tool 5.1.2Delivery Milestones 5.1.3Milestone Definition List 5.1.4Interim Milestones 5.1.5EV – Weighted MS value 5.1.6Monthly Forecasting 5.2Risk Management 5.2.1ESS Risk Management Process 5.2.2ESS risk criteria 5.2.3Risk register 5.2.4Risk status report 35

36. Technical Annex - TOC 5.3Configuration management 5.4Organization 5.5Product & Quality assurance and safety 5.5.1Applicable law, legislation and standards 5.5.2Safety 5.5.3Quality 5.5.4Licensing 6.Documentation format 7.Transportation and DELIVERY 8.Warranty 9.Excluded Background 36