Techniques and diagnostics for the reliability, maintainability and safety of large cryogenic systems:
state-of-the-art and perspectivesLuigi SERIO
14th IMEKO TC10 WorkshopMilan, June 2016Technology Department
Outline
Luigi SERIO CERN 3
IntroductionCryogenics and superconductivityDevices and technologiesReliability, availability and safetyFurther developmentsConclusions
14th IMEKO TC10 Workshop, Milan, June 2016
Outline
Luigi SERIO CERN 4
IntroductionCryogenics and superconductivityDevices and technologiesReliability, availability and safetyFurther developmentsConclusions
14th IMEKO TC10 Workshop, Milan, June 2016
Introduction
14th IMEKO TC10 Workshop, Milan, June 2016 Luigi SERIO CERN 5
Cryogenic systems for particle physics and thermonuclearfusion superconducting applications are: Large Distribution of kWs of cooling power over several km
Complex Millions of components to monitor and control
Continuous processes Running 24h/24h – 365 day year uninterrupted
Operation requires adequate techniques, diagnostics andinstrumentation to achieve the highest levels of availabilityrequired by multibillion investment research programs
Outline
Luigi SERIO CERN 6
IntroductionCryogenics and superconductivityDevices and technologiesReliability, availability and safetyFurther developmentsConclusions
14th IMEKO TC10 Workshop, Milan, June 2016
7
cryogenics, that branch of physics whichdeals with the production of very lowtemperatures and their effects on matter
Oxford English Dictionary
2nd edition, Oxford University Press (1989)
cryogenics, the science and technology oftemperatures below 120 K
New International Dictionary of Refrigeration
3rd edition, IIF-IIR Paris (1975)
Temperature in Celsius (C): unit defined with 0 C (ice) and 100 C (vapour)
Temperature in Kelvin (K): 1 K = 1 C, but 0 K = -273.15 C (absolut zero)
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Useful range of cryogens, and potential applications
0 20 40 60 80 100 120 140 160 180
Oxygen
Argon
Nitrogen
Neon
Hydrogen
Helium
T [K]
Below PatmAbove Patm
Low temperature sc (LTS)
Nb-Ti Nb3Sn MgB2 YBCO Bi-2223
High temperature sc (HTS)
14th IMEKO TC10 Workshop, Milan, June 2016 Luigi SERIO CERN
The “Claude” or “Von Linde” cycle
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1014th IMEKO TC10 Workshop, Milan, June 2016 Luigi SERIO CERN
H. KammerlighOnnes liquefiesOxygen (1894) Helium (1908)
Karol Olszewski and Zygmunt Wróblewskiair, nitrogen, oxygen liquefaction in 1883
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1845-1888
1846-1915
Jagiellonian University, Cracow, Poland
~102 of components
Equipment of H. Kamerlingh Onnes (1908)first liquefaction of Helium
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Leiden « cascade » to produce liquid hydrogen
Helium liquefaction stage
~103 of components
First HeliumLiquefier
Onnes and van der Waals (1913)
LHC and ITER cryogenic systems
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106 - 107 of components
Complex processes requiring high levels of reliability, availability, maintanability and safety
Development of techniques, diagnostics and instrumentation
14
Cooling of superconducting devices
LHC Accelerator
ITER Reactor
Power cables
medical imaging
14th IMEKO TC10 Workshop, Milan, June 2016 Luigi SERIO CERN
Basic components of particle acceleratorsand fusion devices
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Role of superconductivity and cryogenics in accelerators and fusion devices
Compactness and high fields Superconducting magnets and acceleration cavities
Saving Energy Power consumption (only cryogenics) independent of the magnetic field
Electrical consumption per unit length reduced by a factor 10
Transport current efficiently over long distances High Temperature Superconductor with low thermal conductivity
Power consumption (inclusive of cryogenics) reduced by a factor 3
Efficient vacuum insulation Cryoabsorption and cryocondensation / machinery free devices
1614th IMEKO TC10 Workshop, Milan, June 2016 Luigi SERIO CERN
Outline
Luigi SERIO CERN 17
IntroductionCryogenics and superconductivityDevices and technologiesReliability, availability and safetyFurther developmentsConclusions
14th IMEKO TC10 Workshop, Milan, June 2016
Particle accelerators
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The CERN Flagship: The Large Hadron Collider (LHC)
LHC accelerator(24 km of superconducting magnets operating at 1.9 K)
ATLAS detector
CMS detector
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Highlights of a Remarkable Year : 2012 30 fb-1
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The specifications of manysystems were over the state ofthe art. Long R&D programswith many institutes andindustries worldwide werenecessary.
The technological challenges of the LHC
the largest superconducting magnet system ~10’000 magnets
the highest field dipole accelerator magnets 8.3 T
the largest 1.9 K cryogenics installation
superfluid helium, 150 tons of LHe to cool down 37’000 tons ofStSt
ultra-high cryogenic vacuum for the particle beams
10-13 atm, ten times lower than on the Moon
the highest currents controlled with high precision up to 13 kA
the highest precision ever demanded from the power converters
ppm level over several orders of magnitude
a sophisticated and ultra-reliable quench detection and magnet protection system
energy stored in the magnets ~10 GJ,
energy stored in the beams > 700 MJ
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Pt 3
Pt 4
Pt 5
Pt 6
Pt 7
Pt 8
Pt 1
Pt 2
Pt 1.8
Cryoplant DistributionPresent Version
Cryogenic plant
LHC cryogenic system
LHC
8 sectorsUpper
Cold Box
Interconnection Box
Cold Box
WarmCompressor
Station
LowerCold Box
Distribution Line Distribution Line
Magnet Cryostats, DFB, ACS Magnet Cryostats, DFB, ACS
ColdCompressor
box
Shaf
tSu
rface
Cav
ern
Tunn
el
LHC Sector (3.3 km) LHC Sector (3.3 km)
1.8 KRefrigeration
Unit
New4.5 K
Refrigerator
Existing4.5 K
Refrigerator
1.8 KRefrigeration
UnitWarm
CompressorStation
WarmCompressor
Station
WarmCompressor
Station
ColdCompressor
box
Even pointOdd point Odd point
MP StorageMP Storage MP Storage
UpperCold Box
Interconnection Box
Cold Box
WarmCompressor
Station
LowerCold Box
Distribution Line Distribution Line
Magnet Cryostats, DFB, ACS Magnet Cryostats, DFB, ACS
ColdCompressor
box
UpperCold Box
Interconnection Box
Cold Box
WarmCompressor
Station
LowerCold Box
Distribution Line Distribution Line
Magnet Cryostats, DFB, ACS Magnet Cryostats, DFB, ACS
ColdCompressor
box
Shaf
tSu
rface
Cav
ern
Tunn
el
LHC Sector (3.3 km) LHC Sector (3.3 km)
1.8 KRefrigeration
Unit
New4.5 K
Refrigerator
Existing4.5 K
Refrigerator
1.8 KRefrigeration
UnitWarm
CompressorStation
WarmCompressor
Station
WarmCompressor
Station
ColdCompressor
box
Even pointOdd point Odd point
MP StorageMP Storage MP Storage
UpperCold Box
Interconnection Box
Cold Box
WarmCompressor
Station
LowerCold Box
Distribution Line Distribution Line
Magnet Cryostats, DFB, ACS Magnet Cryostats, DFB, ACS
ColdCompressor
box
UpperCold Box
Cold Box
WarmCompressor
Station
LowerCold Box
Magnet Cryostats, DFB, ACS Magnet Cryostats, DFB, ACS
ColdCompressor
box
Shaf
tSu
rface
Cav
ern
Tunn
el
LHC Sector (3.3 km) LHC Sector (3.3 km)
1.8 KRefrigeration
Unit
New4.5 K
Refrigerator
Existing4.5 K
Refrigerator
1.8 KRefrigeration
UnitWarm
CompressorStation
WarmCompressor
Station
WarmCompressor
Station
ColdCompressor
box
Even pointOdd point Odd point
MP StorageMP Storage MP Storage
UpperCold Box
Interconnection Box
Cold Box
WarmCompressor
Station
LowerCold Box
Distribution Line Distribution Line
Magnet Cryostats, DFB, ACS Magnet Cryostats, DFB, ACS
ColdCompressor
box
Total 8 sectors:Warm Compressors: 64Turbines: 74Cold Comp.: 28Leads: 1’200I/O signals: 60’000PID loops: 4’000
23
Compressor stationof LHC 18 kW@ 4.5 K helium refrigerator
MotorsOil/Helium Coolers Compressors
4.2MW input powerBldg: 15m x 25m
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LHC 18 kW @ 4.5 K helium cryoplants
Diameter: 4 mLength: 20 mWeigth: 100 tons600 Input/Output signals
Air Liquide Linde
33 kW @ 50 K to 75 K, 23 kW @ 4.6 K to 20 K, 41 g/s liquefaction
14th IMEKO TC10 Workshop, Milan, June 2016 Luigi SERIO CERN
Centre: 15,000,000º CSurface:
6,000º C
The sun fuel compressed by G Hydrogen is "burned" to form He
Thermonuclear Fusion reactors
1026 W, 10 mW/m3
5.108 W, 500 kW/m3
neutronfusionD
T He
Lithium (laptop battery) plus a bathtub of water produces 200’000 kWh of electricity45 liters of water + 0.5 kg of Lithium = 40 t of coal
neutron + Li T + He
14.1 MeV
3.5 MeV
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The Core of ITER
Toroidal Field CoilNb3Sn, 18, wedged
Central SolenoidNb3Sn, 6 modules
Poloidal Field CoilNb-Ti, 6
Vacuum Vessel9 sectors
Port Plugheating/current drive,
test blanketslimiters/RHdiagnostics
Cryostat24 m high x 28 m dia.
Blanket440 modules
Torus Cryopumps, 8
Major plasma radius 6.2 m
Plasma Volume: 840 m3
Plasma Current: 15 MA
Typical Density: 1020 m-3
Typical Temperature: 20 keV
Fusion Power: 500 MWMachine mass: 23350 t (cryostat + VV + magnets)
- shielding, divertor and manifolds: 7945 t + 1060 port plugs- magnet systems: 10150 t; cryostat: 820 t
Divertor54 cassettes
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Plant bridge
Tokamak (11)
The Cryogenic system
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Cryogenic instrumentation
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Courtesy Ch Balle.
Complexity of flow distribution: e.g the LHC
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Beam tube 1Beam tube 2
(4.6 K, 3 bar)
(20 K, 1.3 bar)
(75 K, 19 bar)
(4 K, 16 mbar)
(50 K, 20 bar)
D Q DD D Q DD D Q
Header C
Header D
Header B
Header F
Header E
Line N, Bus-Bars
T
T
T
T
T
T T
X
T
TY Y
T
T
T
L
T
T
X
T
PP
PP
T
T T
P
X
P
T
TT T T T T T T T T
YY Y Y Y Y Y Y Y Y
Beam screen
Support Posts
Warm Instrumentation
Under Evaluation
Cryogenic Instrumentation, vacuum type
X Cryogenic Instrumentation, insertion type
MAGNETSCryogenic Distribution Line
L: Liquid Helim LevelP: PressureT: TemperatureY: Electrical Heater
Type "A" Service Module Type "B" Service Module
L L
HX HX
FT: Flowmeter
FT FT
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Instrumentation: Turn-key procurementSensors, actuators, electronics, etc. what is available from industry
Courtesy J Casas.
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Instrumentation: Requirements
• Most measurement requirements can be satisfied by standard industrial apparatus
• However some applications require specific developments:• Modified instrument for cryo-operation (e.g.: Coriolis mass flowmeters)• Temperature measurement concerns:
• Platinum thermometers without an “official” conversion below 72 KClass A ± 0.3 K @ 73 KSensors with little literature concerning accuracy (e.g.: CLTS)
• Long term drift
• Specificity of radiation environment and remote diagnostics
• Actual measurement performance difficult to assess
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Instrumentation: LHC thermometry
LHC temperature readout is of “laboratory” quality in spite:• Very hostile environment, worse than typical industrial installation• Sheer quantity of measuring channels (9’000) • Individual calibration => require QA during manufacturing• Once installed difficult/impossible to exchange
Cross-check possible for superfluid pressurized bath => dispersion within ± 0.005 K
Courtesy J Casas.
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Instrumentation: CERN thermal anchoringMost challenging LHC measurement channel is temperature:
• Superconducting magnet temperature is a key control parameter• Accuracy has a direct impact in regulation band
• Accuracy budget is 0.01 K split in the sensor & electronics
Temperature sensors followed a very strict selection and QA procedureThermal anchoring compatible with large series production was designed to provide
calibration in “final” conditions & provide reliable measurement under vacuum.
Courtesy J Casas.
Temperature sensors
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Courtesy Ch Balle.
Pressure sensors
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Courtesy Ch Balle.
Level sensors
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Courtesy Ch Balle.
Flow sensors
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Pressure drop
Thermal
CoriolisPositive displacement Other flow properties
Venturi flow rate meter Designed and constructed following ISO 5167 Measuring pressure drop with a DP-10 Valydine cold
pressure sensor (diaphragm) Accuracies below 3 % with calibration at exact operating
conditions Issues: Zeroing and drift Maintanace Reliability
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Courtesy Rivetti et al.
Turbine magnetically levitated Rotor made of YBCO and magnetically levitated below 100 K (Meissner effect)
Stronger forces are obtained permitting high angular speed
A highly axi-symmetric magnet and accurate positioning are required
Angular speed measured by the passive distortion of the originally toroidal shape of themagnetic field generated by the rotor.
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A positioning system hold the rotorin the right position untilsuperconductive
Eliminating contact and thereforefriction, the K factor of the turbineis much more stable Higher repeatability and accuracy
In industrial conditions it proved tobe unreliable Courtesy Rivetti et al.
Coriolis flowmeter
Two electromagnetic sensor
Manifold that splits the flowinto two parallel tubes
Transmitter (up to 1 km distance)outside the cryostat
Sensing element (inside the cryostat)
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Coriolis flowmeter principle of operation Start the flow and observe the twisting of the tube The fluid momentum coupled with the oscillatory motion created by the
vibration induces a Coriolis force The higher the flow, the greater the twist due to the Coriolis effect
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Coriolis performances
CMF025 (6 mm size, 140 g/s f.s.) Coriolis flowmeter:
relative deviation and calculated pressure drop vs. mass flow
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Instrumentation: Radiation DesignRadiation maps required to set experimental qualification dosesLHC case:• Cold devices need to be rad-hard• Electronics can be “radtol” (< 1 kGy) if placed at centre & below the dipoles.• Long straight areas: radiation far too high => electronics in protected areas=> Use as much radtol electronics to save cable cost
44
4 x 30 PLC’s4 x 15’000 I/O
8 x 500 PID loops
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Dynamic process simulationsModel each cryo
component individually + fluid properties
Build your complete model by assembling elementary components
+ Parametrize each component with your specifications (pipe diameter, valve size, etc.)
Simulate
Include basic control in model OR: couple it to real control system
Define boundary conditions over timeEach refrigeration system10’000 Algebraic equations1’000 Differential EquationsSimulation speed: x3 – x80
Courtesy B. Bradu
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CERN: Control improvements Control improvements using simulations Rotating machinery
Control loops regulations Linear and non linear
Comparison of different control techniques for the LHC beam screen temperature control during beam injection (B. Bradu, ICEC, 2016)
Slow PI Fast PI + FF IMC+FF
Comparison of different control techniques for the LHC P6 warm compression station pressures (B. Bradu, Aussois 2012) Comparison of different PID tunings for the output temperature regulation of GreC
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ITER: handling of large pulsed loads
Cryoplants + Distribution + Magnets cooling Cryoplant validation under pulsed heat loads
Analysis of parallel cryoplants operation
Evolution of the refrigeration power provided by the three refrigerators(L. Gomez, ICEC, 2014)
Variation of heat load to Cryoplant in the case of plasma disruption (R . Maekawa, Cryogenics, 2014)
Outline
Luigi SERIO CERN 48
IntroductionCryogenics and superconductivityDevices and technologiesReliability, availability and safetyFurther developmentsConclusions
14th IMEKO TC10 Workshop, Milan, June 2016
14th IMEKO TC10 Workshop, Milan, June 2016 Luigi SERIO CERN 49
Criticality analysis of the Cryogenic System
Courtesy J Martin.
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Functional analysis of the Cryogenic System
Courtesy J Martin.
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Criticality analysis of the Cryogenic Process
Courtesy J Martin.
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Criticality determination
Courtesy J Martin.
Availability improvement by design/operation mitigation
Initial criticality matrix Revised criticality matrix
He turbines
He circulatorsHe CompressorsOil circulators
N2 turboexpenders
(86 failure modes)
Initial criticality matrix Revised criticality matrix Ball bearings, AMB
coils, AMB controllers, statoriccoils, rotor & binding band and VFD electronics.
CRM shaft failure. Erroneous design
or manufacturing of cryolines.
(141 failure modes)
C = O x S
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Effective maintenance program Computer Aided Maintenance Management System Infor EAM™ Assets inventory and management Maintenance Procedures and documentation management Spare parts analysis and management Work management, control and optimization via KPIs
Partnership with industry to perform the preventive and corrective maintenance
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Preliminary
Overall availability
Courtesy G Ferlin.
56
Safety
Major risks associated with cryogenic fluids at low temperatures:
Asphyxia: Oxygen is replaced by helium Cold burns: in case of contact with cold surfaces Explosion: pressure rise in case of warm-up at
constant volume (1l Liq≈ 700 l gas) Confinement: pressure rise in case of warm-up at
constant volume (1l Liq≈ 700 l gas) make itdifficult to contain a potentially contaminated fluid
Embrittlement: Thermal contractions, potentialfragile at cold
14th IMEKO TC10 Workshop, Milan, June 2016 Luigi SERIO CERN
Definition, identification and location of the process nodes
Analysis of the potential failures and hazards
Determination of credible incidents
Analysis of potential causes and consequences
Remedial actions and/or mitigation of consequences
Main stages of the risk and safety analysis
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Main cryogenic transfer lines
Helium and nitrogen liquefiersin the cryoplant buildings
Cryodistributionlines and boxes in the tokamak building
Criticality rate of the failure
failure occurence rate(based on probability data and
numer of components)
PM SEVSEVOCCCRT 2
severity rate to the machine(based on the location of defected element)
severity rate to the personnel(based on oxygen deficiency hazard)
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Personnel access restrictions
Outline
Luigi SERIO CERN 59
IntroductionCryogenics and superconductivityDevices and technologiesReliability, availability and safetyFurther developmentsConclusions
14th IMEKO TC10 Workshop, Milan, June 2016
Caloric measurement
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Courtesy of Weka AG and KIT
Virtual flow rate meters Infer mass flow from the on-line measurement of valve opening, pressure drop, density measurement
Tested, calibrated and validated on CERN installations Used in the LHC for on-line measurement with about 20 % accuracy Improvement of the metrological performance (presently
RMSE ~ 7 %) by means of uncertainty analysis.
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Superconducting radio frequency cavities - imperfections
- Loss of superconductivity by exceeding critical surface: temperature, current, magnetic field,- The ac electromagnetic field causes heat dissipation at the normal conducting spot (defect),
=> can lead to a propagating quench.
Pictures courtesy of: S. Horvath-Mikulas, CERN BE/RF-SRF
1 mm 1 mm
- Stored energy of an acceleration cavity is in the range of 100 J.- Duration of a quench is typically in the range of milliseconds.- Typical defects are usually significantly smaller than 1 mm.
Q>10 kW/cm2.
Courtesy Torsten Koettig
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He II – Oscillating Superleak Transducers (OST)
Detection and localization of quench spots on superconductingRF cavities by the measurement of the second sound propagation
OST 1
OST 2
time
time
20 m
m
Courtesy Torsten Koettig
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Dynamic simulations During the design phase Validation of dynamic behaviour
Setup of control schemes
During the commissioning phase Virtual commissioning
Tuning of control loops
During the operation phase Operator training
Control improvements
Cryoplant optimization
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Root cause analysis and systems dependencies Review topology of intersystem networks Identify clearly and univocally functional dependencies Simulate the global functional network and physical interconnection Provide tools to easily identify interdependencies to assess technical interventions
feasibility and extent Improve availability for machine operation time by Adapting the topology Reducing intervention time Optimizating the protection parameters
Impact on Physics
Duration of No Beam
Fault Duration
Fault Root Cause
System
Sub‐System
Equipment Code
Failure Mode
Equipment Viewpoint
Operations Viewpoint
Cause1
Cause3
Cause5
Cause7
Cause2
Cause4
Cause6
Cause8Cause9Cause10
0 5 10 15 20 25 30Time [hours]
Outline
Luigi SERIO CERN 66
IntroductionCryogenics and superconductivityDevices and technologiesReliability, availability and safetyFurther developmentsConclusions
14th IMEKO TC10 Workshop, Milan, June 2016
Conclusions
14th IMEKO TC10 Workshop, Milan, June 2016 Luigi SERIO CERN 67
Significant efforts have been made over the years to develop instrumentationand techniques for large & complex cryogenic systems
This has lead to the improvement of the reliability, maintainability and safety ofthe systems and the increase in performances
Today large and complex systems are running at or above design target atCERN and are planned to operate in the coming years at ITER
The LHC cryogenic system istargeting an all inclusive 98%availability goal to ensure recordluminosity for the physics program
Techniques and instrumentationdeveloped for basic scienceapplications are now available forindustrial applications
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Something went bump in the nightBy ATLAS Collaboration, 16th June 2016
The observed and expected 95% confidence level (CL) limits on the cross-section times branching ratio to diboson final states for the Heavy Vector Triplet (W', Z') scenario, compared to the theoretical predictions for the HVT model-A (red line) and model-B (purple line). (Image: ATLAS Experiment/CERN)
With many valuable contributions from colleagues at CERN and ITER Organizations