Upgrade of the vertical test station with new improved inserts for existing cryostats

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Upgrade of the vertical test station with new improved inserts for existing cryostats

Technical seminar - 5th June 2014

Vincent Roger - TE-MSC-TF

OutlookIntroduction

Part I – General description

Part II – The new insert of the Long station

2.1 Design stage

2.2 Safety file

2.3 Follow up of the production

Part III – The future inserts

3.1 Projects progress

3.2 The insert of the Cluster D

Conclusions3Upgrade of the vertical test station in SM18

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Introduction

In order to increase our capacity of testing magnets, current leads and diode stacks, several projects have been set up to realise new insert or to update them. With these new inserts we will gain also in :

• Flexibility• Cooling Time• Handling & operation

In a general way, the purpose of an insert is to :

• Support mechanically the magnet or other devices• Connect electrically this device to the power supply via the current leads• Cool down the device from 293 K to 4.2 K or 1.9 K

Upgrade of the vertical test station in SM18

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• Inserts already in use in SM18

The insert used to test the diode stacks The insert used to test current leads

The design of these inserts were simple since they work at 4.2 K :No exchangers and instrumentationsNo λ plateNo tie holdings and helium guards


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• Inserts in progress The second insert of the long station The insert of the Siegtal station The insert of the Auxiliary station The insert of HFM The insert of the Cluster D


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Part I – General description

Magnet

λ plate

Top plate

LHe / LHe exchanger

4.2 K helium bath

1.9 K helium bath

GHe / LHe exchanger


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• Cryogenic devices

To reach 1.9 K, two thermal exchangers are needed :

• The GHe / LHe exchanger used to reach 1.9 K (using gaz helium at very low pressure vapour saturised and JT valve)

• The LHe / LHe exchanger used to cool the main helium bath to 1.9 K by conduction

GHe pumpingCommand of the Joule Thomson

valve

GHe / LHe exchanger

LHe / LHe exchanger

Instrumentations


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• Use of a PLC & Operation

A PLC (Programmable Logic Controller) has been set up in order to manage automatically cryogenic devices for standard operations as cool down or warm up but especially to guarantee facilities and staff safety.


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Part II – The new insert of the Long station

2.1 Design stage

In order to reduce the delay between two magnet tests on the long station, it has been decided to design a new insert. This insert is NOT a copy of the existing insert, cryogenic performance have been improved, and instrumentations have been automatized.

Group project of 9 peoples:

Follow up : TE-MSC-TFDesign : EN-MME-EDMManufacturing : EN-MME-FSCryogenic devices : TE-CRG-MESafety : DGS-SEE-SI


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• Design of the existing insert


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• Main improvements

A new GHe / LHe exchanger to increase the helium flow

A new LHe / LHe exchanger to increase its surface

A new GHe outflow on the safety line

Automatize the safety valve on the λ plate

Use new instrumentation boxes

Use an helium guard on the tie holdings to prevent leak

Use of a new standard valves for the LHe inflow


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• Design of the new insert


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One of the main difficult part was to design a bigger LHe / LHe exchanger by keeping a good handling.

To decrease the cooling magnet time from 4.2 K to 1.9 K, the exchange’s surface has

been increased from 0.3 m2 to 1.0 m2


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More than 200 elements have been modelled and 120 drawings have been realised !!! There are hundreds of welds which will be done and controlled by the main workshop !!!

From 600 to 700 hours of work !!!


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2.2 Safety file

The maximum allowable pressure (PS) of the insert has been defined. From this the opening pressure of safety valves and the pressure tests are defined.


Working pressure : around 0.2 barg0.9 barg : opening of the valve to the balloonPS = 1.5 barg1.1 * PS = 1.7 barg (primary safety system)1.2 * PS = 1.8 barg (secondary safety system)Test pressure : 2.5 barg

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According to the Pressure Equipment Directive 97/23/EC (PED), this insert belongs to a risk category III.


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Therefore a safety file need to be set up in which all the following information have to be documented.


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Moreover the percentage of radiographic tests on butt‐welds shall be in agreement with the following table.

All non standard welds need to be calculated, and the workshop needs also to be certified for all weld types.

Electron beam welds

BrazingCopper / Stainless steal


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For this safety file, an EDMS structure has been set up.


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2.3 Follow up of the commands & the manufacturing

To certify the insert, it is needed to check rigorously the material certificate of each part even if these parts are ordered on the CERN store.

At the main workshop, each material pieces are identified and attached to one element of one drawing to keep the material traceability.


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The manufacturing has begun, and the weld process is going to start :


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2.4 Synthesis

It’s the first time that a such project is realised with regards to the new standards. The approach is now well defined, and based on this experience we can go ahead with the following new inserts.

Design stage

Safety file• Technical

description of the project

• Calculations• Weld

analysis• Definition of

the pressure tests

Design Validation

• With EN-MME

• With DGS-SEE

• Commands

Manufacturing process

&Definition of

the weld controls

Manufacturing

• Material traceability

• Weld control report


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Part III – The future inserts3.1 Projects progress

• The insert of the Siegtal station

• The insert of the Auxiliary station

• The insert of HFM

• The insert of the Cluster D

Design stage

Safety fileDesign

ValidationManufacturing process

Design stage

Safety fileDesign

ValidationManufacturing process

Design stage

Safety file

Design stage

11/2014

To be defined

12/2015

12/2015


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3.2 The Cluster D

New cryostatNew insertNew cryogenics devicesNew power supply & equipmentNew rack for the acquisition and new PLCNew control room


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A preliminary study has been done in order to choose a design strategy based on the Long test station or on the HFM test station.

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Based on this criteria, we estimated that HFM type design would fit better both in time and price estimate to our needs for serving HL-LHC magnet tests.

Design based on the design of the HFM test

station

Design based on design of the LONG test station

Price of the cryostat ×

Price of the insert ×

Time for fabrication of cryostat

×Time for fabrication of

insert×

Price of fabrication of cryogenic lines

×

Handling of the insert in operation

×

Adaptability ×


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Today a first design of the insert is done, to go further with the design stage we would need some inputs (design of the current leads, final geometry of the cryostat, magnet interface, …)


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Conclusions


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On behalf of

Design Office and Main workshop : EN-MMEVincent Maire, Emilien Rigutto, Luca Dassa

Magnet Test Facilities: TE-MSC-TFMarta Bajko, Christian Giloux, Patrick Viret

Cryogenic Team : TE-CRGVladislav Benda

Safety group: DGS-SEECecile Pinto

Cryostats & Machine Integration : TE-MSC-CMIArnaud Vande Craen


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Upgrade of the vertical test station with new improved inserts for existing cryostats

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