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6th International Workshop on Cryogenics OperationsBernd Petersen DESY
6th International Workshop on Cryogenic
Operations
Bernd Petersen DESY MKS
presenting the work of many colleagues:
IFJ-PAN (Poland)
WUT(Poland),BINP(Russia),
Linde/Cofely and several DESY groups
Full cryogenic operation of AMTF
– the first year
XFEL WP10 Accelerator Module Test Facility
2Outline
AMTF - purpose & objectives (TDR) AMTF – layout AMTF- main cryogenic components Refrigerator availability Main cryo operation problems General safety requirements Cryogenic safety Safety of work organisation Some preliminary test results for XFEL cavities & modules (Preliminary) conclusions
6th International Workshop on Cryogenics OperationsBernd Petersen DESY
XFEL WP10 Accelerator Module Test Facility
3
AMTF: purpose & objectives (TDR)
- Complete cold performance test of all XFEL cryomodules before tunnel installation (RF, vacuum,cryo-losses)
103 cryomodules, rate: 1/week
- Cold RF test of all XFEL superconducting cavities before cryomodule assembly
824 cavities, rate 6/week
- Cold test of all superconducting magnet packages before cryomodule assembly
103 magnets, 1/week
- ( Assembly and tests of RF Waveguides (WP1) at Waveguide Assembly and Test Facility WATF)
6th International Workshop on Cryogenics OperationsBernd Petersen DESY
XFEL WP10 Accelerator Module Test Facility
4
Three test benches (XATB1, XATB2 and XATB3) for testing assembled modules and for high power tests of assembled cavities
Two test cryostats (XATC1 and XATC2) for RF performance tests of the cavities (One magnet test stand XMTS (located in the Magnet Test Hall Building 55) for testing
magnets)
AMTF layout (TDR)
84m x 48m
6th International Workshop on Cryogenics OperationsBernd Petersen DESY
XFEL WP10 Accelerator Module Test Facility
AMTF Hall - Cavity 5
Vertical Cryostat Radiation protection shielding Cavity preparation area
Cavity storage area Cavity incoming check area Clean room
6th International Workshop on Cryogenics OperationsBernd Petersen DESY
XFEL WP10 Accelerator Module Test Facility
AMTF Hall - Cryomodule 6
Unloading of the cryomodule after transport
Cryomodule preparation area Cryomodule test stand
Cryomodule test stand – module inside
Cryomodule test stand – front view
6th International Workshop on Cryogenics OperationsBernd Petersen DESY
XFEL WP10 Accelerator Module Test Facility
7XMTS: Test stand for sc XFEL Quadrupoles
Formal part of AMTF but installed and in operation since July 2008
Status November 2014:
96 (of 103) Quadrupols tested
For the development and series tests of superconducting magnet packages & current leads (in MTH-bldg 55)
6th International Workshop on Cryogenics OperationsBernd Petersen DESY
XFEL WP10 Accelerator Module Test Facility
8Cryogenic operation of AMTF
AMTF is supplied by the FLASH-Helium-Refrigerator (former refrigerator 42 of the HERA plant)
For the operation of the AMTF 3 KW at 40/80K, 0.5 KW at 4.5K and a peak liquifaction rate of 33 g/s
have to be delivered. The peak liquifaction is buffered by means of a 1oooo ltr liquid helium
storage dewar (XAST.)
Capacity limit:
return gas peak
screw compressor capacity during cool down/warm-up
2 dynamic procedures in parallel
6th International Workshop on Cryogenics OperationsBernd Petersen DESY
XFEL WP10 Accelerator Module Test Facility
9AMTF – cryogenics contributions
Red = WUT
Wroclaw University of Technology-> Kriosystem
Blue = DESY MKS
Acting for XFEL company
(no in-kind !) -> DEMACO
Green= BINP
Budker Institute Novosibirsk
6th International Workshop on Cryogenics OperationsBernd Petersen DESY
XFEL WP10 Accelerator Module Test Facility
10 AMTF components (utilities etc./DESY in-kind)
Pump station – completed in September 2010 Compressor station – completed in August 2010 Control building – completed in October 2010 Test Hall – erected in May 2010 Piping bridge – completed in October 2010
0 10m
Control building
Test hallCompressor station
Pump station
Piping bridge
Water towers
HERA Kälteanlage Halle
6th International Workshop on Cryogenics OperationsBernd Petersen DESY
XFEL WP10 Accelerator Module Test Facility
11Transfer line XATL1
The ~170m long DN400 transfer line XATL1 supplies the test stands with cryogenic power from HERA refrigerator. WUT/Poland in-kind.
Spec DESY: Short specification in August 2008 Full specification in August 2009 Commissioning August 2012
– in continuous operation since December 2012
DESY (in-kind):
Valve box for XATL1 at refrigerator
6th International Workshop on Cryogenics OperationsBernd Petersen DESY
XFEL WP10 Accelerator Module Test Facility
12Helium compressors (DESY in-kind)
2 sets of compressors for 2K operation at AMTF ( 2 x 20 g/s helium at 20 mbar)
1 set = 13 x parallel (WS 2001 RUVAC roots blower + SOGEVAC SV750B )
– simple, (robust), modular, redundant
SOGEVAC:
4 unscheduled repairs,
complete replacement of bearings & packing rings (all SOGEVAC)
RUVAC: 4 repairs,
complete exchange of bearings ongoing (all RUVAC)
No impact for AMTF operation
Very reliable service & support from manufacturer
In average: about 5000 h operation (status November 2014)
6th International Workshop on Cryogenics OperationsBernd Petersen DESY
Manifacturer: Oerlikon Leybold
SOGEVAC
RUVAC
XFEL WP10 Accelerator Module Test Facility
13 AMTF Vertical Cryostats
SPEC DESY
April 2009
Design & Construction
WUT&Kriosystem
Poland in-kind
Delivery & installation:
July 2012 – April 2013
Cavity Frame Design:
DESY FLA
6 inserts for AMTF
~Ø
Concrete cylinder 140mm thick
Vacuum vessel
Thermal shield
LHe vessel
Stainless steel ring 30mm thickConcrete floor
Soil
Warm magneticshields
PVC pipe DN200
Support
Concrete
~
A-A
The lowestradiation shield
Cold magneticshield (MHF-sl)
Cold magneticshield (MKS1)
Space for heaters
Vacuum lid Vacuum flange
max.Ø
3xM20
Ø
Ø
Ø
min
.
Water drain pipe DN100(PVC or stainless steel)
~Ø
~
6th International Workshop on Cryogenics OperationsBernd Petersen DESY
XFEL WP10 Accelerator Module Test Facility
14AMTF: 3 cryomodule test stands & cryostat adapters
Spec DESY (February 2010)
Design, Construction, Installation: BINP in-kindFirst test stand delivered & installed May 2013 (cold commissioning July 2013)
Cold commissioning of 3rd test stand December 2013
2 cryostat adapters for the test of single dressed cavities at AMTF
6th International Workshop on Cryogenics OperationsBernd Petersen DESY
XFEL WP10 Accelerator Module Test Facility
15XAST,XAVB, XAVB
L Helium Dewar XAST Valve Box XAVBSub Cooler Box XASB
DESY is acting for the XFEL company
Manufacturer: DEMACO NL
6th International Workshop on Cryogenics OperationsBernd Petersen DESY
Wessington Cryogenics Ltd UK
XFEL WP10 Accelerator Module Test Facility
Cool down and Warm up16
XATC1, XATC2Pump and purge manualCool-down to 4K, liquid helium transferand warm-up process automatized by use of SNL scriptsPump-down to 2K manual
XATB1, XATB2, XATB3•Pump and purge manual•Complete cool-down and warm-up process performed manually by cryo-operators
Cool-down to
100K
Liquid helium
transfer to the cryostat
Pump-down to 2K
Warm-up to 300K
Liquid helium
transfer from the cryostat
Pressure rise to 1 Bar
Pump and purge
Measurement at 2K
Cool-down to
70K
Cool-down to 4K, helium liquefaction
Pump-down to 2K
Warm-up to 300K
Liquid helium
evaporation
Pressure rise to 1
Bar
Pump and purge
Measurement at 2K
Cryogenics operation sequence for vertical cryostat
Cryogenics operation sequence for cryomodule test stand
6th International Workshop on Cryogenics OperationsBernd Petersen DESY
XFEL WP10 Accelerator Module Test Facility
Vertical Cryostats Operation Cycles17
Example: July 2014 -> September 2014
About 180 cycles since start of AMTF operation in 2013
Courtesy of
J.Zajac Linde/Cofely
6th International Workshop on Cryogenics OperationsBernd Petersen DESY
XFEL WP10 Accelerator Module Test Facility
XFEL Cryomodule tests operation Cycles18
About 20 cycles since September 2013 (now 13th XFEL cryomodule under test)
Courtesy of
J.Zajac Linde/Cofely
6th International Workshop on Cryogenics OperationsBernd Petersen DESY
XFEL WP10 Accelerator Module Test Facility
Refrigerator Avialability 201319
0
10
20
30
40
50
60
70
80
90
100
1 2 3 4 5 6 7 8 9 10111213141516171819202122232425262728293031323334353637383940414243444546474849505152
[ A
vail
ab
ilit
y p
er
we
ek
in %
]
[ Week ]
CRYOGENIC PLANT OPERATION 2013
Availability 2013 = 98,80%
Mai
nten
ance
Mai
nten
ance
Mai
nten
ance
Cool
ing
wat
er fa
ilur
e -c
ryop
lant
shut
dow
n
Volt
age
drop
-cr
yopl
ant
shut
dow
n
CBX
Mai
nten
ance
Courtesy of
J.Zajac Linde/Cofely
6th International Workshop on Cryogenics OperationsBernd Petersen DESY
XFEL WP10 Accelerator Module Test Facility
Refrigerator Avialability 201420
0
10
20
30
40
50
60
70
80
90
100
1 2 3 4 5 6 7 8 9 10111213141516171819202122232425262728293031323334353637383940414243444546474849505152
[ A
vail
ab
ilit
y p
er
we
ek
in %
]
[ Week ]
CRYOGENIC PLANT OPERATION 2014
Availability 2014 = 98,4%
02.11.2014
IOC
M
aint
enan
ce
12K2
Fre
quen
cy c
onve
rter
fai
lure
-cr
yopl
ant
shut
dow
n52
CVC3
10 V
alve
posi
tion
er
mal
func
tion
IOC
Mai
nten
ance
IOC
M
aint
enan
ce
CBX
Mai
nten
ance
Courtesy of
J.Zajac Linde/Cofely
6th International Workshop on Cryogenics OperationsBernd Petersen DESY
XFEL WP10 Accelerator Module Test Facility
Main Cryo Operation Problems in AMTF21
Mixing of serial tests with installation work and commissioning
Problems with warm 2K helium compressors (see transparency) Mixing of warm&cold gas for controlled cool-down/warm upLHe level measurements affected by electrical heaters 2K supply JT-valve in module test stand 3 (XATB3) out of shape Misalignment of process tube flanges (feed-caps) -> adapters‚Digital‘ operation of valve positioners -> change type of positioners Thermal contact of electrical heaters -> use of ‚CMTB-type‘ heaters Liquid level measurements -> increase current Mix-up of thermometers (calibration) -> try to sort, some re-
calibration
6th International Workshop on Cryogenics OperationsBernd Petersen DESY
-> Several problems with well known and ‚mature‘ components !
XFEL WP10 Accelerator Module Test Facility
Cryogenic safety22
no general risk of oxygen deficiency within the AMTF hall (about 50 000 m3 volume) oxygen deficiency monitors in each module test stand radiation protection cave design of helium safety valves and venting systems according to our cryomodule ‚crash-tests‘ on CMTB or – on default- according to ‚Lehmann-Zahn‘ values 5K and 40/80K helium release systems separated from 2K release systems (20 bar vs. 4 bar) all safety valves vent into helium volumes – venting to atmosphere outside the hall
6th International Workshop on Cryogenics OperationsBernd Petersen DESY
Oxygen monitor
XFEL WP10 Accelerator Module Test Facility
23AMTF: general design & safety requirements
EU/German law ‚Betriebssicherheitsverordnung‘ DESY safety rules Rules&procedures for buildings & utilities General safety & radiation safety rules Pressure vessels: PED (AD2000,EU harmonized code)
This means in advance of technical commissioning: Third party interlock approvals PVI(=appoval before operation) by third party
(the complete procedure took several months for AMTF) … (list is not complete)
6th International Workshop on Cryogenics OperationsBernd Petersen DESY
XFEL WP10 Accelerator Module Test Facility
AMTF safety at work - organisation 24
Safety officers for different working areas Electronic access control for AMTF (‚DACHS‘) Safety instructions checked by electronic access control (general safety, cryogenic safety, radiation safety)
6th International Workshop on Cryogenics OperationsBernd Petersen DESY
‚DACHS‘
electronic access control
XFEL WP10 Accelerator Module Test Facility
25
Analysis of vertical acceptance tests includes Series Cavities + “ILC HiGrade”-Cavities NO infrastructure commissioning tests
So far delivered: 488 cavities (status November 2014) Total RF tested: 450 cavities
Vertical acceptance tests
Average:> 9 tests per weeksince Oct 2013 (full operation of AMTF)
Manufacturer 1
Manufacturer 2
Status of plot: July 2014
Courtesy of
J.Swierblewski IFJ-PAN details see LINAC 2014
6th International Workshop on Cryogenics OperationsBernd Petersen DESY
XFEL WP10 Accelerator Module Test Facility
Yield of usable and maximum gradient of 339 cavities “as received”
Yield of gradients: “As received” 26
Average maximum gradient:
(30.4 ± 7.6) MV/mM1: (28.4 ± 7.1) MV/mM2: (32.4 ± 7.6) MV/m
Average usable gradient:
(26.6 ± 7.6) MV/mM1: (24.8 ± 7.0) MV/mM2: (28.6 ± 7.9) MV/m
given errors are standard deviation
M1
M2
M1
M2
Courtesy of
J.Swierblewski IFJ-PAN details see LINAC 2014
6th International Workshop on Cryogenics OperationsBernd Petersen DESY
XFEL WP10 Accelerator Module Test Facility
Summary of preliminary module results 27
average max. gradient
module[MV/m]
average max. gradient
vertical[MV/m]
Average operational
gradientmodule[MV/m]
Average usable gradient
vertical[MV/m]
XM-2 27.2 28.1 24.5 26.5
XM-1 28.2 30.8 25.1 29.4
XM1 30.3 32.5 27.6 29
XM2 27.7 32.7 25.5 28.6
XM3 30.4 32.0 28.8 29.3
XM4 28.6 33.3 23.8 30.5
XM5 27.8 28.9 24.9 26.9
All results above XFEL specs. 23.6 MV/m
Status November 2014: XM13 is under test, 18 modules at DESY
Courtesy of
J.Swierblewski IFJ-PAN details see LINAC 2014
6th International Workshop on Cryogenics OperationsBernd Petersen DESY
XFEL WP10 Accelerator Module Test Facility
28 Some (preliminary) conclusions
Deliveries & installation of XATCs,XATB,XAVB,XATL
were ‚just-in-time‘ for start-up of cavity production Deliveries & installation of XATBs
were ‚just-in-time‘ for start-up of cryomodule production No dedicated de-bugging of cryo-supply (and other systems) XATCs design capacities demonstrated Complexity of XATBs commissioning underestimated General effort for installation & commissioning underestimated To be demonstrated: 1 cryomodule test/week So far: in budget and almost ‚in time‘ (not ‚on schedule‘)
Thank you for your attention !
6th International Workshop on Cryogenics OperationsBernd Petersen DESY