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O Pirotte, HMTS WG meeting, 11.06.2020, INDICO 924259 2
Cryogenic Test Benches in B180
O. Pirotte (TE-CRG)
O Pirotte, HMTS WG meeting, 11.06.2020, INDICO 924259 3
Content
• Introduction
• B180 test facility project
• Comments
O Pirotte, HMTS WG meeting, 11.06.2020, INDICO 924259 4
SM18
CERN Large Cryogenic Test Facilities
B180
Cryolab - B163
AD
O Pirotte, HMTS WG meeting, 11.06.2020, INDICO 924259 5
B180
B36
B279
B180 2001-2007:
ATLAS assembly and cryogenic test area for huge cryogenic
components of the detector : SC magnets + LAr calorimeters
O Pirotte, HMTS WG meeting, 11.06.2020, INDICO 924259 6
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
O Pirotte, HMTS WG meeting, 11.06.2020, INDICO 924259 7
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:
O Pirotte, HMTS WG meeting, 11.06.2020, INDICO 924259 8
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)
O Pirotte, HMTS WG meeting, 11.06.2020, INDICO 924259 9
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
O Pirotte, HMTS WG meeting, 11.06.2020, INDICO 924259 10
Configuration of cryogenic system
DVB: Distribution Valve Box SVB: Satellite Valve Box
CVB: Connection Valve Box CWU: Cool down / Warm up Unit
O Pirotte, HMTS WG meeting, 11.06.2020, INDICO 924259 11
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
O Pirotte, HMTS WG meeting, 11.06.2020, INDICO 924259 12
O Pirotte, HMTS WG meeting, 11.06.2020, INDICO 924259 13
O Pirotte, HMTS WG meeting, 11.06.2020, INDICO 924259 14
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
O Pirotte, HMTS WG meeting, 11.06.2020, INDICO 924259 15
B180 test facility: overview
Panorama photos of B180Before: January 2015
April 2019
O Pirotte, HMTS WG meeting, 11.06.2020, INDICO 924259 16
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
O Pirotte, HMTS WG meeting, 11.06.2020, INDICO 924259 17
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
O Pirotte, HMTS WG meeting, 11.06.2020, INDICO 924259 18
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
Supply pressure: 17.2 bar
Suction pressure: 1.0 bar
Max flow rate: 185 g/s
Consumed electrical power: 637 kW
Helium refrigerator compression station Helium refrigerator
Supply pressure: 17.2 bar
Suction pressure: 1.0 bar
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
O Pirotte, HMTS WG meeting, 11.06.2020, INDICO 924259 19
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
O Pirotte, HMTS WG meeting, 11.06.2020, INDICO 924259 20
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
O Pirotte, HMTS WG meeting, 11.06.2020, INDICO 924259 21
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
O Pirotte, HMTS WG meeting, 11.06.2020, INDICO 924259 22
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
O Pirotte, HMTS WG meeting, 11.06.2020, INDICO 924259 23
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
O Pirotte, HMTS WG meeting, 11.06.2020, INDICO 924259 24
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.
O Pirotte, HMTS WG meeting, 11.06.2020, INDICO 924259 25
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
O Pirotte, HMTS WG meeting, 11.06.2020, INDICO 924259 26
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
O Pirotte, HMTS WG meeting, 11.06.2020, INDICO 924259 27
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
O Pirotte, HMTS WG meeting, 11.06.2020, INDICO 924259 28
Cool down flow scheme
O Pirotte, HMTS WG meeting, 11.06.2020, INDICO 924259 29
LHe distribution
O Pirotte, HMTS WG meeting, 11.06.2020, INDICO 924259 30
Synoptic
O Pirotte, HMTS WG meeting, 11.06.2020, INDICO 924259 31
B180 Test stationBus bars (few 100 kA, air cooling)
Satellite VB
Jumper SVB / Magnet
O Pirotte, HMTS WG meeting, 11.06.2020, INDICO 924259 32
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