HC review, A. Perin, 12-MAY-2005 1 DFB Project LHC hardware commissioning review 11-13 May 2005 Hardware commissioning of the DFBs and DSLs and connection

HC review, A. Perin, 12-MAY-2005 1

DFB ProjectDFB Project

LHC hardware commissioning review

11-13 May 2005

Hardware commissioning of the DFBs and DSLs

and connection cryostats

A. Perin, AT-ACR

on behalf of R. van Weelderen, V. Benda AT/ACR, S. Marque, AT-CRI

and of the DFB, DSL and connection cryostats project teams

Acknowledgements: C. Davison, V. Fontanive, T. Goiffon, S. Koczorowski, R. Marie, L. Metral, AT-ACRR. Folch, M. Genet, Ph. Trilhe, TS-MMED. Bozzini, AT-MEL


DFB ProjectDFB ProjectOutline Main characteristics of the DFBs & DSLs

From workshop to operation

Commissioning the DFBs

Commissioning the DSLs

Commissioning of the connection cryostats

Conclusions

Scope for DFB and DSL commissioning

DFB & DSL are powering LHC magnets, therefore the commissioning of the LHC circuits will

involve their operation.

This presentation focuses on aspects specific to DFBs and DSLs that are not covered during

the commissioning of the cryogenic instrumentation and the superconducting circuits.

System commissioning



Location and types of DFBs in the LHC

DFBA

DFBA

DFBA

DFBA

DFBA

DFBA

DFBA

DFBADFBM DFBM DFBM DFBM

DFBM DFBM

DFBMDFBMDFBM

DFBL DFBL



Main characteristics of the DFBs: variants

IR

Equip.

Code 6 kA 600 A

Spare

600 A 120 A

N

chimney

s

IR1 Left DFBLA 11 12 14

IR1 Right DFBLB 11 12 14

IR3 Right DFBLC 44 4 12

IR5 Left DFBLD 11 12 14

IR5 Right DFBLE 11 12 14

44 44 4 48 68TOTAL

IR Code 13 kA 6 kA 600 A

Spare

600 A 120 A

N

chimneys

IR1 Left DFBAA 2 12 28 8 0 23

IR1 Right DFBAB 2 12 28 8 0 23

IR2 Left DFBAC 6 15 46 8 8 36

IR2 Right DFBAD 6 15 46 8 4 36

IR3 Left DFBAE 2 0 44 4 0 14

IR3 Right DFBAF 2 0 0 0 0 2

IR4 Left DFBAG 6 12 46 8 4 33

IR4 Right DFBAH 6 12 46 8 4 33

IR5 Left DFBAI 2 12 28 8 0 23

IR5 Right DFBAJ 2 12 28 8 0 23

IR6 Left DFBAK 6 9 46 8 4 30

IR6 Right DFBAL 6 9 46 8 4 30

IR7 Left DFBAM 2 0 44 4 0 14

IR7 Right DFBAN 2 0 44 4 0 14

IR8 Left DFBAO 6 15 46 8 4 36

IR8 Right DFBAP 6 12 46 8 4 33

64 147 612 108 36 403TOTAL

16 DFBA: powering the LHC arcs

23 DFBM: powering standalone magnets

13kA 6kA 600A 120 A Chimneys

64 258 692 196 570

Leads and chimneys

5 DFBL: powering the superconducting links



Commissioning the DFBs: tunnel access

Instrumentatio rack

Transformers

Water cooled cables

DFBAO IR 8 L



Main characteristics of the DFBs: global

Low current module 6kA & 600A leads

High current module 13kA & 6kA leads

Vacuum equipment VAA

Connection to magnets

Jumper cryoconnection to QRL

SHM/HCMinterconnect

HCM/LCMinterconnect

Configuration of DFBAO IR8 left

Supporting beam

600A leads

6kA leads

6kA leads

13kA leads

Current lead chimneys

Removable door

Low current module 6kA & 600A leads

High current module 13kA & 6kA leads

Vacuum equipment VAA

Connection to magnets

Jumper cryoconnection to QRL

SHM/HCMinterconnect

HCM/LCMinterconnect

Configuration of DFBAO IR8 left

Supporting beam

600A leads

6kA leads

6kA leads

13kA leads

Current lead chimneys

Removable door

11x6kA CLs12x120A CLs

service chimney

removable door

interface to DSL

interface to QRL

DFBLA

connection to magnet5x6kA CLs

12x120A CLsservice chimney

removable door

DFBMA

connection to magnet5x6kA CLs

12x120A CLsservice chimney

removable door

DFBMA

44 DFBs, 3 main families

13kA 6kA 600A 120 A Chimneys

64 258 692 196 570

Leads

Lead instrumentation / voltage taps / equipment• 3 thermometers / lead• 1 control valve / lead• 8 voltage taps / lead• 1 transformer / lead• 1 heater / leadOther cryogenic instrumentation• 2-3 level gauge / module• 2-5 thermometers /module• 2 pressure sensors / module• 1 heater / module



Main characteristics of the DFBs

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

4.5 K standalonemagnet or cavities

Electricalfeed box Standard cell pair Return module

Electricalfeed box

Cryogenics– Current leads operation in 4.5 K saturated LHe bath– Controls: liquid helium and helium gas flow for the current leads– Max. pressure for DFBs current lead modules 0.35 MPa– DFBA supply/exit of GHe for E line

Electrical– Concentration of all types of busbars in very small space– Significant quantity of electrical interconnects: 1200 current leads to busbars, 1800 busbar to busbar,

ranging from 120A to 13’000A Insulation vacuum

– No vacuum barrier: DFB share the vacuum of the magnets they power Beam vacuum (DFBAs only)

– Actively cooled beam pipes with beam screens– Cold-warm transitions



Installation of the DFBs: the dates

Sector IR Code N chim.

Inst.

Date Sector IR Code N chim.

Inst.

Date

7-8 60 Sep 05 5-6 69 Jun 067R DFBAN 13 Jan 06 5R DFBAJ 21 Jun 068L DFBAO 34 Nov 05 6L DFBAK 29 Jun 068L DFBMA 7 Sep 05 5R DFBLE 13 Jun 068L DFBMC 5 Sep 05 6L DFBMM 3 Jun 067R DFBMH 1 Jan 06 6L DFBMM 3 Jun 06

8-1 80 Jan 06 6-7 49 Jul 061L DFBAA 21 Jan 06 6R DFBAL 29 Jul 068R DFBAP 31 Jan 06 7L DFBAM 13 Jul 061L DFBLA 13 Jan 06 6R DFBMM 3 Jul 068R DFBMB 7 Jan 06 6R DFBMM 3 Jul 068R DFBMI 5 Jan 06 7L DFBMH 1 Jul 068R DFBMJ 3 Jan 06 1-2 80 Sep 06

4-5 77 Mar 06 1R DFBAB 21 Sep 064R DFBAH 32 Mar 06 2L DFBAC 34 Sep 065L DFBAI 21 Mar 06 1R DFBLB 13 Sep 065L DFBLD 13 Mar 06 2L DFBMA 7 Sep 064R DFBMG 3 Mar 06 2L DFBMC 5 Sep 064R DFBMK 3 Mar 06 2-3 60 Nov 064R DFBML 5 Mar 06 2R DFBAD 34 Nov 06

3-4 57 Apr 06 3L DFBAE 13 Nov 063R DFBAF 2 Apr 06 2R DFBMB 7 Nov 064L DFBAG 32 Apr 06 2R DFBMC 5 Nov 063R DFBLC 11 Apr 06 3L DFBMD 1 Nov 063R DFBMD 1 Apr 064L DFBME 3 Apr 064L DFBMF 5 Apr 064L DFBMG 3 Apr 06

–DFBs will be installed during the interconnection period of the corresponding sector– on average 1 sector / 6 weeks (2 DFBA and 3 to 5 DFBM/L)



DFBs from workshop to operation

Global strategy– Test as much as possible before installation in order to limit tunnel time– 31 variants: no spare unit

Ancillary equipment – The DFBs will be produced and validated as complete systems including, all instrumentation, proximity

piping and warm control valves, electrical splitting boxes etc.– As far as possible the units will be transported with all accessories installed

Testing– Extensive warm testing will be performed on all DFBs: vacuum, electrical, geometry, pre-alignment, etc.– Warm pressure/ mechanical/ electrical tests will be performed on complete units– All current leads will be cold tested and powered– No test in operational conditions will be performed before commissioning

Warm commissioning Cooldown Cold commissioning

– Specific commissioning for first DFBAs

Pro

du

ctio

n /

te

stin

gC

om

mis

sio

nin

g

Installation– Specific tests, ELQA, interconnects etc.

Inst

alla

tion



Equipment around the DFBs to be commissioned

DFBAO, IR 8L



Equipment around the DFBs to be commissioned

CL control valve600A current lead

CL heaters transformers

CL instrumentation cabling



Commissioning the DFBs: global picture

Required commissioning rate will be approx. 1 sector / 6 weeks with parallel commissioning of 2 DFBAs and 3 to 5 DFBMs/L

DFBs are tightly integrated with magnets and powering system: commissioning of the DFBs will be done mostly in parallel with ELQA and powering commissioning. (DFB and DSL must be operational to perform power tests!)

QRL

cryogenics

WRL

hel

ium

Control &supervision

DC powering & protection

MagnetsBeam pipes

forces

cryogenics

currentcryogenics

alignment

interfaces

interfaces

Supports

DFB

Cold tests in operating conditions will not performed on surface: DFBs will be operated the first time in the tunnel: specific testing will be needed for at least 1 DFB of each type

Commissioning starts when installation is finished, i.e.:– DFB is installed and aligned– all connections (busbar, vacuum, cryogenics, etc.) are closed and leak checked– Pressure test is successfully performed



Commissioning the DFBs: warm

Goal: ensure that the the DFBs are ready to start the cooldown

– Testing of local equipment and instrumentation is performed as far as possible in the workshop before installation

operations– Insulation vacuum commissioning: performed in parallel with the corresponding

magnets– Operation of all control valves and instrumentation (see presentation 2 )– Electrical commissioning: continuity and High Voltage (see presentations 9 & 21) – Precise alignment of beam pipes after pumping and pressure tests– Beam vacuum commissioning: cold and warm sides ( see presentations 15 & 16)



Commissioning the DFBs: cooldown

Cooldown– Specificities (with respect to arc components)

• Cooldown to 70K cannot be done in parallel with the magnets because of pressure in header D (1 MPa) is not compatible with DFB/current leads design pressure (0.35 MPa)

• Shuffling module cooldown will be the same as the corresponding arc• Sequence shall be defined in coordination with magnet cool down• Cool down time depending on DFB type and local conditions (varying from 2 to 5

days)• Commissioning of the DFBL should be performed in parallel with the

superconducting links

– Control of the alignment of beam pipes after cooldown



Type cold commissioning of DFBs

GOALS: – check the functionalities– determine the operational parameters and behavior of each type of DFB– determine the behavior in most probable non nominal cases

Applies to: 1 (at least) DFB for each type DFBA, DFBM, DFBL

Operational parameters: estimated time: min. 3 weeks (possibly in parallel with some other commissioning operations)

• Determine cool down/warm up time and parameters• Determination of PID parameters for all operating conditions • LHe level maximum and minimum• LHe level stability, particularly in case of unbalanced powering• Operational parameters in transient condition

Non nominal operating conditions and interlocks: estimated time: min. 1 week (will required dedicated commissioning time)

• Failure of CL heater & recovery• Loss of liquid level• Loss of cooling gas for CL

Optional: parameters confirming the technical choices: estimated time: possibly in the shadow of the other commissioning operations

• Temperature measurement (shield etc.)• Temperature measurement of GHe leaving CL (icing & condensation – HV test problem)• Stop CL heating and restart with ice on it • Deformation of the beam pipes in case of quench



Default cold commissioning of DFBs

Goals:– Apply the operating parameters from type tests– check the proper operation of the equipment and tuning if needed– prepare for normal operation

Commissioning operations will be integrated and dependent on ELQA and powering commissioning operations

Most specific commissioning operations can be performed in parallel with other systems commissioning

Parallel operation of 2 DFBAs and 3 to 5 DFBM/L

Operations Commissioning of instrumentation and control loops (see presentation 2 ) Control of stability of LHe levels and temperatures Electrical commissioning: ELQA (see presentations 9 & 21) Commissioning of DC power system (see presentation 8) Commissioning of beam vacuum (see presentation 15 & 16) Validation of operational parameters during power tests and other transient conditions



DSLs: the superconducting links



Main characteristics of the DSLs: functionalities

Electrical– Connection of the DFBL to standalone magnets (DSLA, B, D,E), approx. 76m– Connection of the DFBL to the DFBA (DSLC), approx. 517m

Cryogenic (only for DSLC) : Supply of cryogenics to DFBLC, very limited instrumentation, no active components Specificities: long cryogenic lines, in particular at pt3 : very long reaction times (3 to 30 hours)

Installation dates– DSLA IR1L: 10.10.2005 - 02.12.2005– DSLB IR1R: 14.05.2006 – 07.07.2006– DSLC part1 UJ33-UP33-Tunnel: 16.04.2006 – 26.05.2006– DSLC part2 Tunnel: 09.07.2006 – 25.08.2006– DSLD IR5L: 15.01.2006 – 12.03.2006 – DSLE IR5R: 05.03.2006 – 30.04.2005



Commissioning the DSLs

Global test strategy Type-1 DSLs (76m)

– No particular tests, except for pressure and leak testing and HV tests during and after in-situ installation.

Type-2 DSLs (517m)– Pressure and leak testing and HV tests during and after in-situ installation – Type test by a ~30m long validation model:

• mechanical and LN2 to give production go-ahead to firm (fall 2005)• Optional: Cryogenic+ electrical (summer 2006).

– N.B. DSLC installation of critical cable part 09.07.2006 – 25.08.2006

Warm commissioning Essentially ELQA in parallel with corresponding DFB commissioning Insulation vacuum commissioning in parallel with corresponding DFBs

Cooldown Can be performed in parallel with corresponding DFBs and magnets

Cold commissioning: type testing for DSLA and DSLC ELQA Cryogenics: system characterized by very long reaction time No cold test on real size DSL on surface: 1 extended commissioning for each type:

– Necessary to perform tests to determine the operational parameters– Reaction time in transient conditions, optimization of operating temperature and

flows– Recovery after non-nominal conditions (loss of coolant, re-cooling parameters)– Will require at least 3 weeks of dedicated cold operation (necessitates cold

operation of corresponding DFBs)



Commissioning the connection cryostats (LE)

Cryogenics Layout: P&I Diagrams LHCLSQR_0022 - 0032

IR 1 left

General 16 LE in DS of LHC Ensure continuity of cold machine

Characteristics Similar hydraulic characteristics as magnets

(pressure drop, free cross section,…) Beam pipes and busbar lines are cooled by adjacent

magnets and by central shuffling module Specially placed thermometer at warmest point to

follow subcooling to 1.9K

Cryogenic test Performed on magnet test bench in SM18 Specially instrumented (40 thermometers) LE Goal: determine the cooldown rates and general

behavior at cold and in transient conditions Electrical insulation

Example: IR 1 leftMechanical Layouts

TT821

l L1 L2

Tmax

1.90 K 1.90 K S1 S2

Central Shuffling Module

Line M

ξ Heat Exchanger

Sketch of a cold bore cooling sleeve (in operation with beam). (document LHC-LE-ES-0002 rev. 1.0)

Illustrations courtesy S. Marque, AT-CRI



Commissioning the connection cryostats (LE)

Commissioning Cooldown

– Same time as DS cooldown– Tracking of temperatures and pressures in particular, pressure drop and temperature evolution

Subcooling to 1.9K– Tracking of temperature and comparison with test measurements and numerical estimations– Tracking of adjacent magnet temperatures



Conclusions

In order to reduce the commissioning time in the LHC tunnel, all ancillary equipment will be installed on the DFBs and tested before tunnel installation

As no operational cold test can be performed on surface, specific time (approx. 3 weeks) will be needed for the first DFB commissioning

As an integral part of the LHC arcs and of the powering systems, the DFBs will be involved in most commissioning operations. The specific commissioning operations dedicated to series DFB should require a limited dedicated time, most operations can be performed in parallel with other commissioning operations.

The DSLs will require dedicated specific time (approx. 2 weeks) to determine the operational parameters and optimize the control loops.

For the connection cryostats, the commissioning will consist essentially of a careful tracking of the parameters of the LE and of the adjacent magnets

Documents

HC review, A. Perin, 12-MAY-2005 1 DFB Project LHC hardware commissioning review 11-13 May 2005 Hardware commissioning of the DFBs and DSLs and connection