O Pirotte, HMTS WG meeting, 11.06.2020, INDICO 924259

O Pirotte, HMTS WG meeting, 11.06.2020, INDICO 924259 2

Cryogenic Test Benches in B180

O. Pirotte (TE-CRG)


Content

• Introduction

• B180 test facility project

• Comments


SM18

CERN Large Cryogenic Test Facilities

B180

Cryolab - B163

AD


B180

B36

B279

B180 2001-2007:

ATLAS assembly and cryogenic test area for huge cryogenic

components of the detector : SC magnets + LAr calorimeters


2 BT magnet test benches + End Cap test bench (outside)

1.2 kg/s LHe pump Test Facility

Cryogenic Area :TCF200, Precooler, DVB, LHe pump cryostat


GSI-FAIR Super-FRS magnet tests at CERN

Courtesy CGSI-FAIR & A. Kosmicki

Type # Total

mass

Cold

mass

[kg] [kg]

dipole 24 50’000 2’000

multiplet 1 24 70’000 45’000

multiplet 2 9 25’000 20’000

In the framework of a collaboration agreement between CERN and GSI, 57 Super-FRS

magnets will be tested at CERN at 4.5 K: 48 multiplets and 9 dipoles.

Mass up to 70 tons and dimensions up to 5 m high

Total testing expected period about max 3 years

A new test facility for large and heavy devices !

There are three type of magnets:


Architecture and dimensioning parametersThe S-FRS magnet test sequence is the

major driver for defining the architecture and

dimensioning parameters.

Test Phase Requirement

Cool-down 293 K – 90 K 5.6 kW cooling power, 21.4 g/s at 10 bar

Cool-down 90 K – 4.5 K 6.2 m3 of saturated LHe at 4.5 K

Filling of magnet with LHe 1.7 m3 of saturated LHe at 4.5 K

Cold tests heat loads 30 W static at 4.5 K + 35 W dynamic during 10 minutes,

160 W at 60 K – 90 K (screen)

1.6 g/s at 4.5 K – 300 K (liquefaction load for CLs)

Warm-up 90 K – 293 K 5.4 kW heating, 20 g/s at 10 bar

The test sequence is planned to last about 42 days

for each magnet.

The required test rate is 21 magnets / year :

• three test benches

• two cool-down/warm-up

Dimensioning parameters for performing the test

sequence for a multiplet 1 (heaviest magnet)


Summary of main requirements

Parameter Specification

Magnet design pressure 20 bar

Maximum magnet cold mass 45’000 kg

Operating temperature cold mass 4.5 K (LHe at 1.3 ± 0.1 bar)

Maximum cool-down / warm-up rate 80 K – 4.5 K No limitation

Maximum allowable temperature difference over the

magnet in 80 K – 300 K range (cool down and warm up) 40 K

Maximum nominal heat in-leak to magnet cold mass 30 W

Maximum dynamic heat in-leak to magnet cold mass 35 W for 10 min

Maximum heat shield in-leak 160 W

Maximum GHe flow for current lead cooling 1.6 g/s

Maximum LHe volume of magnet 1.60 m3

LHe level stability ± 10 mm

Maximum pressure drop magnet helium circuit cool down 1.5 bar

Magnet test speed 2 magnets/month


Configuration of cryogenic system

DVB: Distribution Valve Box SVB: Satellite Valve Box

CVB: Connection Valve Box CWU: Cool down / Warm up Unit


3D overview of test facility

Preparation area

Test area

LHC dipole storage

Power converters

OfficesControl room

Control racks

Control racks

Magnetic measurement racks

Cold BoxDVB

Dewar




Contracts

9 major contracts

in 7 member states

Compression station refrigerator

Mayekawa Italy SRL

Helium refrigerator

Linde Kryotechnik

LHe dewar: Cryoworld BV

LN2 distribution: Demaco Holland BV

Cool down / warm up unit

AS Scientific Products

LN2 storage tank

Cryocan

Cryo distribution

Kriosystem

Cryogenic valves: Flowserve

Warm control valves: Stohr Armaturen


B180 test facility: overview

Panorama photos of B180Before: January 2015

April 2019


B180 Helium refrigeratorAn existing Sulzer TCF200 helium refrigerator of 1979 was

fully refurbished by Linde Kryotechnik in 2016.

Brayton cycle with two turbines in series. Third turbine for

boosting performance.

Original performance: 1.2 kW refrigeration or 5.6 g/s

liquefaction with 1.0 kW shield between 60 – 90 K.

Main refurbishment work included:

- Adding a GHe return to 300 K;

- New purge and instrumentation rack;

- New cooling water distribution panel and turbine bearing

gas supply panel;

- New turbine coolers;

- Maintaining all cryogenic valves;

- Repairing thermometers;

- Repainting the box.Helium refrigerator after refurbishment

Helium refrigerator before refurbishment


Helium refrigerator compression stationA new compression station from Mayekawa Italy S.R.L. is

used for driving the helium refrigerator.

Main components:

- Two stage compound screw compressor;

- One 3.3 kV AC electrical motor;

- Oil separation system with oil separator, 3

coalescing filters and a charcoal adsorber.

Design performance:

Supply pressure: 18.7 bar

Suction pressure: 0.9 bar

GHe flow rate: 160 g/s

Electrical power: 706 kW

Helium refrigerator compression station

Helium refrigerator oil separation system


6.9 g/s

0

1

2

3

4

5

6

7

0 200 400 600 800 1000 1200 1400

Liq

ue

factio

n r

ate

[g

/s]

Refrigeration power [W]

data 1997

Theoretical curve

data 2018

Helium refrigerator: commissioning results



Max flow rate: 185 g/s

Consumed electrical power: 637 kW

Helium refrigerator compression station Helium refrigerator



Refrigeration power: 1300 W @ 160 g/s

Liquefaction power: 6.9 g/s @ 125 g/s

No shield cooling

300

400

500

600

700

800

0

20

40

60

80

100

120

140

160

180

200

40 50 60 70 80 90 100

Ele

ctr

ica

l p

ow

er

[kW

]

GH

e flo

w r

ate

[g

/s]

Slide valve position [%]

185 g/s

637

1300 W


B180: cryogenic distribution system5 m3 LHe dewar delivered by Cryoworld BV

Preliminary measured evaporation rate:

~2.6% / day of total capacity or 3.7 W

Cryo distribution installation

LHe dewar installation

Cryodistribution delivered by Kriosystem

First cool down in autumn 2017 to test:

• Mechanical integrity

• Leaks

• Vacuum jacket temperature

No major non-conformities found.

~ 3.7 W


Precooling & warming up systemPurpose cool-down / warm up units:

• precool devices to 80 K;

• warm up devices from 4.5 K to room

temperature.

50 g/s GHe circulation at 10 bar

15 kW cooling capacity with ΔT of 50 K (LN2)

15 kW heating capacity

Includes 80 K adsorber to remove gas impurities

50 m3 LN2 storage tank

Measured evaporation rate:

0.24%/day of total capacity

CWU1 CWU2


Compression station building 279: overview

Compression building B279 was built in 1971.

The building is fully renovated to fulfil current standards

with respect to safety and environmental aspects.

March 2016

May 2016

October 2016


B279: oil spillage measuresOil spillage measures taken to:

- collect the total amount of oil (2000 L)

- prevent leakage outside the building (through cracks, drainages etc.)

Resign on floor Profiles at corners Steps at doors and openings

Gutters

Mapping floor level

Collector pipe at lowest point of floor

Retention tank 1: 1900 L Retention tank 2: 1900 L


B279: noise measuresNoise outside the building needs to stay below 60 dB(A)

due to proximity of offices.

A study determining the noise damping coefficients showed

that we need below 90 dB(A) inside the building.

Noise sources:

Helium refrigerator compression station: 98 dB(A)

CWU compression station: 88 dB(A)

Two options:

1) Isolating the building -> complex and costly

2) Noise hood around compressor stages helium

refrigerator compression station

Option 2 selected. Noise hood reduces noise to 90 dB(A)

at 1 m of compression station.

Helium refrigerator compression station

Noise hood

Noise study


B180 Overall project timeline

The orders for the cold box compressor and for the liquid helium system were placed in

2015.

All main components of the cryogenic infrastructure were installed between June 2016

and August 2018.

As the delivery of the magnets was delayed, the resources allocated to the project were

reduced from end of 2016 and allocated to more urgent projects.


B180 Project status - OverviewAll equipment required for testing the 1st super-FRS magnet in May is operational and commissioned

Main sub-systems

LHe system: commissioned

Pre-cooling system: operational, CWU1 commissioned

• CWU2: non-conformity corrected in April 2019

• Leak in insulation vacuum of the LN2 dewar. Investigation ongoing, not blocking.

• CWU regeneration system to be completed by June 2019

Cryogenic distribution system: commissioned


Documents for handover to operation

Review of P&IDs and instrumentation list: CDS completed, LHe & pre-cooling system ongoing

Project and equipment documentation: stored in EDMS

Electrical schemes: stored in EDMS

Control specifications: stored in EDMS, CWU2 and pre-cooler re-generation circuit will be

validate following equipment commissioning


S-FRS magnet test schedule 2019 - 2020

Test of 1st super-FRS magnet from 30 May to 13 November

Next

Delivery of 1st Long Multiplet magnet – November 2019

Delivery of 1st Dipole magnet – April 2020

Series test of Short Multiplet magnets – start in 2020


Cool down flow scheme


LHe distribution


Synoptic


B180 Test stationBus bars (few 100 kA, air cooling)

Satellite VB

Jumper SVB / Magnet


Comments

• No Quench recovery : no magnet quench expected. In case of quench, helium will be lost via safety devices

• Test at saturated LHe 4.5 K. Possibility of Supercritical He

• For tests at 1.9 K, it is necessary to invest in a warm pumping unit and special low pressure heaters.

• No CLs feedbox : CLs are part of the magnet assembly and not controlled via the cryogenic system. The interface is a unique return line to the LP with a flow meter

• The SVB will need to be replaced by an equivalent CFB like in SM18 (more complex)

• Power converters and bus bars are dimensioned for a few 100 kA, air cooled.

• If case 20 kA bus bars (water cooled) are needed, it is necessary to invest in a new deminelarized water cooling station

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