Crab Cavities SPS cryogenics progress and requirements Fermilab - - PowerPoint PPT Presentation

Crab Cavities SPS cryogenics – progress and requirements

Fermilab visit at CERN 02 August 2013

Krzysztof Brodzinski

(on behalf of CERN cryogenic team)

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Contents

• Cryogenics for Crab Cavities project – technical aspects and status
• Circuits
• Heat load
• Capacity limitations with existing infrastructure + possible solutions
• BA4 work progress
• 2 K pumping units test
• Available space – integration brief
• Cryogenics for SPS cryostat design
• Process and instrumentation
• Safety devices
• Pumping collector sizing
• Superfluid helium layer
• Conclusions
• K. Brodzinski - Fermilab visit_2013.08.02

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Cryogenic circuits

• K. Brodzinski - Fermilab visit_2013.08.02

3 CC x 2

Service module

Coupler intercept CTW CTW Screen Screen

R

LT TT PT

JT

EH TT

black –> existing 4.5 K red –> to be constructed 2 K

Regarding 2 K refrigeration

CC cryostat

EH

Buffer tank

LN2

Additional He source

Heat loads and TCF20 capacity

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Equipment Heat load Source of capacity cryostat Static HL @ 2K ~ 8-10W Dynamic @ 2 K ~ 5-10 W HL @80 K ~40-60 W TCF20 -> 0.4-0.5 g/s TCF20/Buffer tank LN2 Service module ~2.5 W @ 2K ~30 W @ 80 K TCF20 -> 0.13 g/s LN2 Buffer tank* ~1.5 W @ 4.5 K ~ 19 W@ 80 K TCF20 -> 0.08 g/s LN2 Transfer lines ~3.4 W @ 4.5 K ~26 W @ 80 K TCF20 -> 0.17 g/s LN2 Flash at 2 K ~20% of liquefaction flow TCF20 -> 0.2 g/s

The below values are calculated/estimated – no exact calculation is available yet depending on design Total net value: 0.98-1.08 g/s Total with 1.5 safety factor: ~1.5 g/s

• V. Parma and colleagues

TCF20 cold box capacity discussion

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0.7 0.85 1.2 Liquefaction capacity line [g/s] Static heat load -> 0.98-1.08 *1.5 =~1.5 g/s

Conclusions:

• Existing TCF20 without LN2 boost is not sufficient to cover requirements (even upgraded as liquefier)
• Plan B: LN2 boost to be installed and liquefaction capacity tested
• Plan C: install new TCF20 liquefier + install LN2 boost (difficult because of safety and a lot of work – transfer

lines to be installed, possible problems with instabilities of LN2 flow – info from G. Passardi)

• Plan D: on the surface: Install a 10000 L dewar with link to 200 L buffer as an “emergency boost”

Target: The cold box should cover at least the static heat load, the buffer tank dynamic operation of the cavity.

1.56 0.76

CERN isentropic equiv. recalculated (20 l/h) CERN isentropic equiv. recalculated with guaranteed refrigeration capacity (85 W) CERN isentropic equiv. recalculated with measured refrigeration capacity (120 W) LEGNARO guaranteed liquefaction capacity (22 l/h) LEGNARO guaranteed liquefaction capacity with LN2 (45 l/h)

Work done in BA4

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• Inventory list, GMAO new naming definition list and PID update done by ~15.09.2012
• All SVs re-qualified and installed – done by ~15.09.2012
• Electrical motor and compressor maintenance – done by ~30.09.2012
• Oil separation refurbished (coalescers cartridge replaced, ADS charcoal replaced) – done

by ~30.09.2012

• Storage – He tank re-qualified as pressure recipient – done on 12.09.2012
• All other pressure recipients re-qualified – done by ~15.10.2012
• Purging system on compressor station refurbished
• Cooling water and air ventilation installations for compressor station – refurbished
• Cold box vacuum system revised and partially refurbished
• Compressor station and cold box (partially) instrumentation revised
• Compressor station new electrical supply system with documentation done and tested by

~15.11.2012

• Control system well advanced (partially ready)
• He tightness test done on compressor station
• First run of compressor station done by 30.11.2012 – milestone (OK operational, HP@6

bara)

• First helium flow through the cold box done on 18.12.2012 – milestone (OK, no leak into

the vac)

Work done in BA4

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At SPS BA4 there is a 4.5 K cryogenic infrastructure used last time about 8 years ago for COLDEX experiment. It is foreseen to test its capacity and upgrade it for 2 K refrigeration – refurbishment is underway Cold box TCF20

2 K pumping groups recovered from AMS Renovated compressor + elec. motor – run test done New power supply panel for compressor station Revised, labeled and qualified pressure control system / oil removal system TCF20 Cold box

SPS LS1 time frames: Open Access : 25/03/13 Close Access : 27/06/14

2 K pumping units performance test

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Both pumps were run to check their capacity – probably 2 pumps will have to be integrated in the tunnel – analysis underway.

2 stage pumping group 2 batteries of He gas bottles

<200 bar

2 stage pumping group (Leybold: RUVAG WS2001 and SV630) PT01: pressure transmitter, Rosemount, 0… 2000 mbara TT01: Pt100 FT: flow transmitter, Brooks, 0… 1.5 g/s PT02: pressure transmitter, GE, 0… 100 mbara Recuperation line towards liquifier

FT

Cryo integration in SPS

• K. Brodzinski - Fermilab visit_2013.08.02

9 TCF20

SM heater

Very tight integration if going behind the beam line (more details in Th. Renaglia presentation).

Buffer

Pump

Tentative SPS CC cryogenic schedule

• K. Brodzinski - Fermilab visit_2013.08.02

10 Work planned for 2013:

• 2 K pumping group to be transported and integrated in the SPS tunnel in Autumn 2013 – AMS groups will be used
• Low pressure He recovery heating system to be transported and integrated in the SPS tunnel in Autumn 2013 – probably AMS elements

could be adapted

• Electrical and control systems for 2 K cryogenics to be done (cables pulling included) – underway
• Refurbishment of the cold box 4.5 K – vacuum system and turbine circuits – done
• Cold box control system to be completed – done
• Cold box instrumentation revision/update to be completed – underway
• Cold run of the cold box – in September May 2013 – milestone – almost ready, conditioning done, waiting for cooling water circuit ON
• Liquefaction test of 4.5 K cold box (potentially with boost at 80 K stage, if yes, this boosting system is to be developed and

bought/constructed), some hardware modifications are required as preparation for this test – to be done by 15.10.2013 – milestone

• Refurbishment of the supply/recovery system between BA4 and North Area is to be done or procurement of additional buffer tank to

fulfil requirements of helium availability for CC testing – to be analysed and confirmed – spring/autumn 2013 – milestone

• LN2 system for cooling of screen circuits to be developed and bought – to be defined
• Buffer tank to be designed and bought
• 2 K cryogenics: transfer line system to be designed and ordered (installation in 2014)
• 2 K cryogenics: Service module to be to be designed and ordered (installation in 2014)

Main task for 2013/2014 is the distribution system development and installation

Process & instrumentation 1/2

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helium tank crab cavity common pumping collector thermal screen at ~80 K cryostat interface CWT Power coupler intercept CWT

The cryostat will house 2 crab cavities and will be operated at 2 K (saturated helium bath  ~30 mbar). The design should be done in the way to minimize the static heat load at 2 K (important!) It will be equipped with two circuits 2 K and 80 K. The main interface should be provided from the top with 4 main lines (LHe IN, GHe pumping, LN2 80 K IN and 80 K OUT).

• Proposed piping should cover nominal operation and transients (cool down and warm up),
• Interface to the cryostat: internal pipes welded, external envelope bolted (allowing opening of the

jacket by means of sliding it up or down). Power couplers and Cold/Warm Transitions will be intercepted with LN2 at 80 K.

Process & instrumentation 2/2

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12 The cryostat should be equipped with the following instrumentation:

• Helium level measurement – each helium tank should be equipped with a level gauge allowing for helium level measurement from the

bottom through the phase separator (LT x 2, each gauge should allow for helium level regulation in the phase separator collector),

• Pressure measurement on the saturated helium bath is to be provided (PT x 1),
• Temperature measurement on each cavity helium tank is to be provided, installed on the bottom of each helium tank (suggested

CERNOX type transducer, TT x 2),

• Electrical heaters of 50 W are to be installed on each helium tank (EH x 2)
• Temperature measurement on 80 K screen line is to be provided (TT x 2 on inlet and outlet)
• JT valve and sub-cooling HX are foreseen to be installed out of the cryostat
• (instrumentation for 80 K intercept circuits – definition underway)

All sub atmospheric instrumentation/safety devices with ambient air interface will have to be equipped with appropriated helium guard.

helium tank crab cavity common pumping collector thermal screen at ~80 K cryostat interface CWT Power coupler intercept CWT

LT PT EH TT EH TT LT TT TT

Safety devices

• K. Brodzinski - Fermilab visit_2013.08.02

13 Assembly of cavity with helium tank have to be designed to withstand pressure of at least 2.6 bar (deltaP of 2.6 bar) without plastic deformation at ambient temperature. Design pressure for the cryostat assembly should be based on installed safety devices according to design rules (cryostat equipped with a safety valve set at 1.8 bara* and a rupture disc set at 2.2 bara*, possibly one device could be installed … - analysis underway)

• both safety devices will be installed in the way to avoid potential projection of helium towards the passages or transport areas

(deflectors installation to be analyzed, preliminary position for the rupture disc and safety valve have been proposed on transfer line close to the cryostat interface),

• Both safety devices should protect the cavity and the cryostat from pressure rise causing plastic deformations,
• Both safety devices should be equipped with appropriate helium guards.
• sizing of the devices -> to be done

helium tank crab cavity common pumping collector thermal screen at ~80 K cryostat interface CWT Power coupler intercept CWT Rupture disc @ 2.2 bara SV @ 1.8 bara

* Value compatible with recommendations given by T. Peterson on December 2012 Fermilab meeting

Pumping collector sizing

• K. Brodzinski - Fermilab visit_2013.08.02

14 0.00 1.00 2.00 3.00 4.00 5.00 6.00 7.00 8.00 20 40 60 80 100 120 He gas speed [m/s] Level of liquid in the double phase line [mm]

Pumping collector gas speed *

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Requirements: gas speed lower than 5 m/s*, min 50 mm for level regulation, additional buffer for ~ 20 min of operation, compatibility with safety devices for pressure limit requirements. Indications: Diameter of 100 mm (recommended) allows for:

• return gas speed below 5 m/s up to ~90 mm of liquid level in the collector (operation

regulation level to be set at ~50 mm of LHe in the collector),

• buffer volume for transients/unexpected process perturbations (half filled collector allows for

~20-30 min of operation assuming collector length of ~1.6 m and 20 W of thermal load),

• compatibility with safety valves sizing is still to be checked !

* Calculation done assuming: collector diameter of 100 mm, He mass flow = 2 g/s, GHe temp = 2 K, GHe press = 20 mbar.

100 mm ~90 mm 0 mm

Liquid level

~50 mm

Regulation maxi: 5 m/s * Value compatible with recommendations given by T. Peterson on December 2012 Fermilab meeting

Superfluid Helium layer

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Requirements: superfluid helium layer must cover whole surface of the cavity and provide correct

• peration of the cavity at required conditions (2 K). The heat transfer capability for superfluid

helium layer have to be evaluated, typically between 0.95 - 1 W/cm2 Exercise – indication: assuming round cavity from below sketch; dimensions D=175 mm x L=700 mm and heat load of 20 W, the required minimum superfluid helium layer is ~ 2.5 mm. Applied production technology will require more …. It should not be enlarged without the limits in order to minimize reasonably the liquid helium volume (max. 40 L/cavity if possible).

helium tank crab cavity common pumping collector cryostat interface

180 185 ~300 700 710 Units: [mm]

Conclusions

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• Work is progressing well, cold run of the cold box to be done in September with dedicated

liquefaction test,

• Boost of the cold box is mandatory (LN2 system to be built + additional 10000 L He dewar

connection possibility to be take into consideration,

• 2 K pumping units – capacity test done -> 2 units to be integrated in the tunnel,
• Tight planning with still a lot of work on the infrastructure to fulfill requirements -> LN2 line to

be installed, probably He line to be installed through the shaft to connect the buffer tank,

• Close collaboration with regular working sessions is needed to merge between CERN

requirements and the modules suppliers.

Thank you! Questions?