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Session 2 - Shutdown 2012. Consolidations of Cryogenic Systems Review of the consolidation works scheduled for the cryogenic installations during a long shutdown. Olivier Pirotte on behalf of TE/CRG. OUTLINE. Non conformities (ECRs) / Repairs - PowerPoint PPT Presentation
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Session 2 - Shutdown 2012 Consolidations of Cryogenic Systems Review of the consolidation works scheduled for the cryogenic installations during a long shutdown Olivier Pirotte on behalf of TE/CRG
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Page 1: Session 2 -  Shutdown  2012

Session 2 - Shutdown 2012

Consolidations of Cryogenic Systems

Review of the consolidation works scheduled for the cryogenic installations during a long

shutdown

Olivier Pirotte on behalf of TE/CRG

Page 2: Session 2 -  Shutdown  2012

Session 2 - Shutdown 2012 - Consolidations of Cryogenic Systems - O. Pirotte on behalf of TE/CRG

OUTLINE Non conformities (ECRs) / Repairs

DFBs safety valves : DFBA (S23/S78/S81), DFBM (Q6R2 & Q6L8) Air leak DFBAO & DFBMC abnormal thermal load Replacement of flexible in DFBA (leak prevention) IT safety valve DN300 collector (safety) He level gauge on Standalone Magnets (see JPh Tock’s

talk) Leaks in “Y”-lines (see JPh Tock’s talk) Instrumentation of the tunnel (Recommendation #12, TF Report) HRL sectorization (Recom. #13, TF Report) DFBA CLs : TT channels 1.9 kV

consolidation(EDMS 919146)

Quench lines

Page 3: Session 2 -  Shutdown  2012

Session 2 - Shutdown 2012 - Consolidations of Cryogenic Systems - O. Pirotte on behalf of TE/CRG

OUTLINE Consolidations & new proposals

Decoupling of adjacent cryogenic sectors(reminder of G. Ferlin’s presentation, Chamonix 2009)

Access platforms to the QRL Service Modules

QRL service module compressed air distribution

Insert of flowmeters on Beam Screen circuits

Upgrade of DFBX Current Leads control Addition of a pressure measurement on header B ATLAS consolidations DFBAO: improvement of LHe level control (idem DFBAC) QURC P6 : change CV241 valves (idem P4, reduce

downtime)

Page 4: Session 2 -  Shutdown  2012

Session 2 - Shutdown 2012 - Consolidations of Cryogenic Systems - O. Pirotte on behalf of TE/CRG

OUTLINE

Mandatory maintenance activities Major overhauling planning

Upgrade / new installation Additional refrigerator at P4 (cavities)

Page 5: Session 2 -  Shutdown  2012

Session 2 - Shutdown 2012 - Consolidations of Cryogenic Systems - O. Pirotte on behalf of TE/CRG

HRL sectorization

Motorization of the HRL sector valves

Cost : 100 kCHF Installation : 1w/sect. + cabling

Allow safe interventions in the tunnel and improve

cryogenic consignations

Page 6: Session 2 -  Shutdown  2012

Session 2 - Shutdown 2012 - Consolidations of Cryogenic Systems - O. Pirotte on behalf of TE/CRG

DFBA CLs : TT channels 1.9 kV consolidation

• Prevent destruction of TT on 13kA CLs (major downtime risk)

• Restore conformity with LHC specification (Tests @ 1.9 kV)

• Cancel 5 TeV limitation

Cost : material already supplied Duration : 2-3 w / DFBA (cards CRG, cables EN/EL, connectors MPE)

Change :•Connectors•Cables•DAQ Cards

Page 7: Session 2 -  Shutdown  2012

Session 2 - Shutdown 2012 - Consolidations of Cryogenic Systems - O. Pirotte on behalf of TE/CRG

QUENCH LINES CONSOLIDATION

• Restore the operation of quench lines (quench sector issue : He -> atm.)

• Avoid major downtime risk (use of He strategic storage)• Avoid extra cost risk : ~700 kCHF / sector

Point 5

Figures : • New integration solutions to be studied• Issue : sections with vacuum insulated TL ?• Cost estimate : ~500 kCHF• Installation : 10 weeks / Point• 2012->2013 ?: no consequence if E ~3.5/4 TeV

HOW : Restore the functionality of QLs

Test of QLs at P5

Many conflicts with neighbouring equipements during shrinkage

Destruction of the insulation / Liquid air on cable trays

Page 8: Session 2 -  Shutdown  2012

Session 2 - Shutdown 2012 - Consolidations of Cryogenic Systems - O. Pirotte on behalf of TE/CRG

OUTLINE Consolidations & new proposals

Decoupling of adjacent cryogenic sectors(reminder of G. Ferlin’s presentation, Chamonix 2009)

Access platforms to the QRL Service Modules

QRL service module compressed air distribution

Insert of flowmeters on Beam Screen circuits

Upgrade of DFBX Current Leads control Addition of a pressure measurement on header B ATLAS consolidations DFBAO: improvement of LHe level control (idem DFBAC) QURC P6 : change CV241 valves (idem P4, reduce

downtime)

Page 9: Session 2 -  Shutdown  2012

Session 2 - Shutdown 2012 - Consolidations of Cryogenic Systems - O. Pirotte on behalf of TE/CRG

Decoupling of adjacent sectors

Allow exchanging a magnet or a QRL SM in a sector while

keeping the adjacent sector in nominal cryogenic operation

• Cost : 130 kCHF / sector (QUI)• Installation : 4-6 w / sector

Add a submarine

DN250 valve on header B

C

D

B

F

E

B

C

D

C

D

B

F

E

B

C

D

F E D C F E D C

QRL(5-6)

QURCB

QSRB QSRA - QURA

QURCA

QRL(6-7)

QUI

Page 10: Session 2 -  Shutdown  2012

Session 2 - Shutdown 2012 - Consolidations of Cryogenic Systems - O. Pirotte on behalf of TE/CRG

Platforms for QRL Service Module

Allow safe intervention on instrumentation of a QRL SM (arc, SAM, DFBs)

Study with EN/MEF of a retractable platform to access a standard QRL

Service Module in the arcs

HOW : Install access platforms

Page 11: Session 2 -  Shutdown  2012

Session 2 - Shutdown 2012 - Consolidations of Cryogenic Systems - O. Pirotte on behalf of TE/CRG

QRL Service Module Access Issue – Arc

Maintenance activities +

interventions on cryogenic

systems required

access to instrumen-

tation

How to get and work on the instrumentation of the SM ?

Safety issue with

maintenance personnel

Page 12: Session 2 -  Shutdown  2012

Session 2 - Shutdown 2012 - Consolidations of Cryogenic Systems - O. Pirotte on behalf of TE/CRG

QRL Service Module Access Issue - DFBs

How to get and work on the DFBs ?

Unsafe access conditions : risks of injuries and collateral damage to neighbouring equipements

Page 13: Session 2 -  Shutdown  2012

Session 2 - Shutdown 2012 - Consolidations of Cryogenic Systems - O. Pirotte on behalf of TE/CRG

Platforms for QRL Service Module

Allow safe intervention on instrumentation of a QRL SM (arc, SAM, DFBs)

Figures : • 310 QRL Service Modules• Standard config. : ~200 SM in the arcs• Non standard config. :

SAMs / DFBs (DFBX?) / RMs• Cost estimate : 850 kCHF• Installation : 4-6 weeks / sector• Shift from 2012 to 2013 : no consequence

HOW : Install access platformsStudy of a retractable platform to access a standard QRL Service Module in the arcs

Page 14: Session 2 -  Shutdown  2012

Session 2 - Shutdown 2012 - Consolidations of Cryogenic Systems - O. Pirotte on behalf of TE/CRG

He guard

QV

PV, CV

6 barAir

QRL SM - Compressed air distribution

Improve performance and life time of cryogenic control

valves

• Cost : 25 kCHF / sector (manpower)• Installation : 2-3 w / sector (ideally after access platforms installation)

Split air distribution : add a 2 bar collector for CV

in // of the 6 bar one2 bar

Page 15: Session 2 -  Shutdown  2012

FT

Proposal following last operation issues:add flowmeters on BS circuits

Aim : measurement of BS heat load (e-clouds, ?) How : add Coriolis FT to measure mass flow in BS Proposal : 1 FT / 400 m (8/sector) Cost : 64 x (15 kCHF + 5kCHF for cabling) = 1.3

MCHF Issue : integration in the interconnectionsSession 2 - Shutdown 2012 - Consolidations of Cryogenic Systems -

O. Pirotte on behalf of TE/CRG

CEH

Support posts & 60 A CL

TT

C'm2, T2

m1, T1

D

QRL side

Magnet side

Aperture 1

Aperture 2

Ib

Ib

Basic cooling scheme of beam screens : ~ 53m

mt, Tt

TT

Page 16: Session 2 -  Shutdown  2012

Session 2 - Shutdown 2012 - Consolidations of Cryogenic Systems - O. Pirotte on behalf of TE/CRG

DFBX: 600 A and 120 A CL control upgrade & control of

heaters Improve performance and

reduce risk of downtime due to the operation of DFBXs

• Cost : 130’000 CHF / DFBX• Installation : 3 w / DFBX

• Replace 2008 consolidation by a more reactive and robust control strategy of 120A and 600A current leads (19 x flowmeters / DFBX)

• Consolidate temporary local control system of heaters on DFBXs installed in 2008

Page 17: Session 2 -  Shutdown  2012

Session 2 - Shutdown 2012 - Consolidations of Cryogenic Systems - O. Pirotte on behalf of TE/CRG

ATLAS consolidations

Cryogenics kCHF Compressors 1450 Cryocontrols 470 Small spares 50 He pumps 175 11kL return line 80 PCS pipe extension 70 7kL buffer 340 He dryers 360

Total ~ 3 MCHF Courtesy H. Ten Kate

Page 18: Session 2 -  Shutdown  2012

Session 2 - Shutdown 2012 - Consolidations of Cryogenic Systems - O. Pirotte on behalf of TE/CRG

OUTLINE

Mandatory Maintenance activities Major overhauling planning

Upgrade / new installation Additional refrigerator at P4 (cavities)

Page 19: Session 2 -  Shutdown  2012

Session 2 - Shutdown 2012 - Consolidations of Cryogenic Systems - O. Pirotte on behalf of TE/CRG

Mandatory Maintenance activities Major overhauling planning

The full revision of the 74 compressors is the determining factor in the planning : up to 18 weeks for compressor station with 8 CPs (QSCA)

Cost :- CP major overhauling : 5.2 MCHF- Preventive maint. : 1.6 MCHF

All other preventive maintenance tasks can be carried out in the shadow of the revisions : up to 6 weeks / installation (C199 contract)

Page 20: Session 2 -  Shutdown  2012

Session 2 - Shutdown 2012 - Consolidations of Cryogenic Systems - O. Pirotte on behalf of TE/CRG

HL-LHC : new refrigerator at P4

Decouple the operation of the cavities from the

magnets (Sensitive control of the LP

cavities performance)

&Improve P4 cryogenic

margins to equivalent level as P6 & P8

• Cost : 300 kCHF• Duration : 6 weeks

Profit of LSD to install pipework in the shaft

Page 21: Session 2 -  Shutdown  2012

Session 2 - Shutdown 2012 - Consolidations of Cryogenic Systems - O. Pirotte on behalf of TE/CRG

In summary The list of consolidations and maintenance activities scheduled for the next

long SD has been presented. The total cost is about 12.15 MCHF.

The following consolidations should strongly be considered :

Consolidations involving safety issues for the personnel : HRL sectorization : 100 kCHF, 1 w / sector Access platforms to the QRL SMs : 850 kCHF, 6 w / sector

Consolidations needed for 14 TeV or to avoid major downtime risk : DFBA Current Leads TT channels 1.9 kV consolidation : 3 w / DFBA Quench lines : 500 kCHF, 10 w / sector Upgrade of the DFBX CLs control : 1 MCHF, 3 w / DFBX Mandatory maintenance activities (CP major revision) : 6.8 MCHF, 14 months (18

w / LHCA)

Page 22: Session 2 -  Shutdown  2012

Session 2 - Shutdown 2012 - Consolidations of Cryogenic Systems - O. Pirotte on behalf of TE/CRG

Acknowledgements

All CRG colleagues (J. Casas, S. Claudet, G. Ferlin, A. Perin, G. Perinić, L. Tavian, …)

ATLAS team (H. Ten Kate)

Inputs from EN/MEF

Thanks for your attention

Page 23: Session 2 -  Shutdown  2012

Session 2 - Shutdown 2012 - Consolidations of Cryogenic Systems - O. Pirotte on behalf of TE/CRG

ADDITIONAL SLIDES

Page 24: Session 2 -  Shutdown  2012

Session 2 - Shutdown 2012 - Consolidations of Cryogenic Systems - O. Pirotte on behalf of TE/CRG

Non Conformities – Remaining work from 2009

• DN230 SV on DFBA (S23/S78/S81)• DN160 SV on DFBM (Q6R2 & Q6L8)• Deflectors for safety of persons• Duration : 3 weeks / Point• 2012->2013 ? : no consequence if E ~3.5/4 TeV

IT DN300 SV collector : • Cost estimate : 25 kCHF / IT• Installation : 2-3 weeks / IT• 2012->2013 ? : no consequence.

Mitigation measures remain in force.

Page 25: Session 2 -  Shutdown  2012

Session 2 - Shutdown 2012 - Consolidations of Cryogenic Systems - O. Pirotte on behalf of TE/CRG

Replace metallic flexible hose in DFBAs

Replace potentially damaged metallic

flexible hose in DFBAs.

Installation : 1 week / DFBA (12 remaining)

Replace the flexible hose with a suitably

dimensionned and shaped smaller diameter

pipe

Flexible hose LHCDFBA_0114

Line N in DFBAH HCM

CL line

Fixed pointapprox 3.2 m

Page 26: Session 2 -  Shutdown  2012

Session 2 - Shutdown 2012 - Consolidations of Cryogenic Systems - O. Pirotte on behalf of TE/CRG

DFBAO: improve LHe level control

To improve the liquid He level control

• Cost : 5 kCHF + 10 kCHF manpower• Duration : 2-3 weeks

Install additional level gauge in non perturbated chimney.Add a heater to evaporate the liquid that accumulates at a low point.

Pressure equilib / evap. to 6kA chimney exhaust(Ø8)

Level gauges

Capillary withinstrumentation wires

Connector

LHe connec-tion

Page 27: Session 2 -  Shutdown  2012

Session 2 - Shutdown 2012 - Consolidations of Cryogenic Systems - O. Pirotte on behalf of TE/CRG

DFB Burkert valves CV891 consolidation

120/600 A Consolidation strategy:• Use newly developed bearing-less

valves• 1000 valves for 600A & 120A valves

already delivered• 10 x 13 kA + 64 x 6 kA valves delivered.

Remaining March 2011• Installation during technical stops• 2010-2011 Xmas break : all DFBX + 600

A

6 / 13 kA

New Test Bench

Page 28: Session 2 -  Shutdown  2012

D

C

B

F

D

C

B

F

D

C

B

F

E

D

C

B

F

E

D

C

B

F

D

C

B

F

E

D

C

B

F

D

C

B

F

E

B C D

LN2

Warm recovery line

4.5 Krefrigerator

Coldcompressor

system

Cryogenicinterconnection

box Lowestpoint

4.5 K standalonemagnet or cavities

Distributionfeed box Standard cell pair Mid sector Return module

to adjacentcryogenic system

Helium ring line

D

C

B

F

D

C

B

F

D

C

B

F

E

D

C

B

F

E

D

C

B

F

D

C

B

F

E

D

C

B

F

D

C

B

F

E

D C BFE C D

LN2

Warm recovery line

4.5 Krefrigerator

Coldcompressor

system

Cryogenicinterconnection

box Lowestpoint

4.5 K standalonemagnet or cavities

Distributionfeed box Standard cell pair Mid sector Return module

to adjacentcryogenic system

Helium ring line

D

C

B

F

D

C

B

F

D

C

B

F

E

D

C

B

F

E

D

C

B

F

D

C

B

F

E

D

C

B

F

D

C

B

F

E

D C BFE C D

LN2

Warm recovery line

4.5 Krefrigerator

Coldcompressor

system

Cryogenicinterconnection

box Lowestpoint

4.5 K standalonemagnet or cavities

Distributionfeed box Standard cell pair Mid sector Return module

to adjacentcryogenic system

Helium ring line

Addition of a pressure measurement on header B

Session 2 - Shutdown 2012 - Consolidations of Cryogenic Systems - O. Pirotte on behalf of TE/CRG

Aim : assess line B operation + redundancy How : add a PT on each Return Module Cost : = 100 kCHF (12 kCHF/sector) Issues : precision (0.2 mbar) & range (1

barg), He guard, radiation

PT

PT

Page 29: Session 2 -  Shutdown  2012

Session 2 - Shutdown 2012 - Consolidations of Cryogenic Systems - O. Pirotte on behalf of TE/CRG

TEST OF QUENCH LINES AT P5Destruction of the insulation

Many conflicts with neighbouring equipements during shrinkage

Liquid air on cable trays

Point 5

Page 30: Session 2 -  Shutdown  2012

Session 2 - Shutdown 2012 - Consolidations of Cryogenic Systems - O. Pirotte on behalf of TE/CRG

ATLAS MR COMPRESSOR STATION

Courtesy of J Metselaar & N Delruelle

New C6

C2 upgraded

Consolidated ATLAS MR compressor station

C1

C3

C4

C5

INTRODUCE REDUNDANCY AND ENERGY SAVING

Cost : 1.55 MCHFInstallation : 12-14 w

Page 31: Session 2 -  Shutdown  2012

Session 2 - Shutdown 2012 - Consolidations of Cryogenic Systems - O. Pirotte on behalf of TE/CRG

ATLAS – He : decouple solenoid-toroid

During Toroid Fast Dump recovery, also Solenoid is down since MR in use for cooling down the toroids, thus 4d-loss of detector time

Cure:

Install a new ~7kL He buffer dewar to continue solenoid operation during the 5 days of Fast Dump recovery of the toroid

Few options to be studied and engineered

Cost estimate : 350 kCHF Courtesy H. Ten Kate

Page 32: Session 2 -  Shutdown  2012

Session 2 - Shutdown 2012 - Consolidations of Cryogenic Systems - O. Pirotte on behalf of TE/CRG

ATLAS : prevent He pollution

Avoid risk of He pollution, clogging of filters and interruption of SR and MR refrigerator operation for 1-2 weeks/cleaning cycle

Cure:Install He water dryers in SH1 and cold He air dryers in

USA15, twin bed absorber units with auto switching and recovery

Page 33: Session 2 -  Shutdown  2012

Session 2 - Shutdown 2012 - Consolidations of Cryogenic Systems - O. Pirotte on behalf of TE/CRG

Non Conformities – Remain from 2008

DFBs safety valves (material in stock) Installation : 3 weeks / point Shift from 2012 to 2013 : no consequence if E ~3.5/4

TeV Flexible in DFBA (material in stock)

Installation : 1 w / DFBA Shift from 2012 to 2013 : no consequence if E ~3.5/4

TeV IT safety valve DN300 collector

Design and integration to be done : 2 months (1 w / IT) Installation : 2 weeks / IT Cost estimate : 25 kCHF / IT Shift from 2012 to 2013 : no consequence. Mitigation

measures remain in force


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