Review of the consolidation works scheduled for the …...All CRG colleagues (J. Casas, S. Claudet, G. Ferlin, A. Perin, G. Perinić, L. Tavian, …) ATLAS team (H. Ten Kate) Inputs

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

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

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

OUTLINE


Consolidations & new proposalsDecoupling of adjacent cryogenic sectors

(reminder of G. Ferlin’s presentation, Chamonix 2009)

Access platforms to the QRL Service ModulesQRL service module compressed air distributionInsert of flowmeters on Beam Screen circuitsUpgrade 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)

OUTLINE


Mandatory maintenance activitiesMajor overhauling planning

Upgrade / new installationAdditional refrigerator at P4 (cavities)

HRL sectorization


Motorization of the HRL sector valves

Cost : 100 kCHFInstallation : 1w/sect. + cabling

Allow safeinterventions in the tunnel and improve

cryogenicconsignations

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 suppliedDuration : 2-3 w / DFBA (cards CRG, cables EN/EL, connectors MPE)

Change :• Connectors• Cables• DAQ Cards

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

Restore the functionality of QLs

Test of QLs at P5

Many conflicts with neighbouringequipements during shrinkage

Destruction of the insulation /Liquid air on cable trays

OUTLINE


Consolidations & new proposalsDecoupling of adjacent cryogenic sectors

(reminder of G. Ferlin’s presentation, Chamonix 2009)

Access platforms to the QRL Service ModulesQRL service module compressed air distributionInsert of flowmeters on Beam Screen circuitsUpgrade 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)

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 onheader B

C

D

B

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E

B

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B

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B

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D

QRL(5-6)

QURCB

QURCA

QRL(6-7)

QUI

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

Install access platforms

QRL Service Module Access Issue – Arc


Maintenance activities +

interventions on cryogenic

systemsrequired

access to instrumen-

tation

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

Safety issue with

maintenance personnel

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

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

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

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 (ideallyafter access platforms installation)

Split air distribution :add a 2 bar collector for CV

in // of the 6 bar one2 bar

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 interconnections


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

DFBX: 600 A and 120 A CLcontrol 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 currentleads (19 x flowmeters / DFBX)• Consolidate temporary local control system of heaters on DFBXsinstalled in 2008

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

Courtesy H. Ten Kate

OUTLINE


Mandatory Maintenance activitiesMajor overhauling planning

Upgrade / new installationAdditional refrigerator at P4 (cavities)

Mandatory Maintenance activitiesMajor 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 preventivemaintenance tasks can becarried out in the shadowof the revisions : up to 6 weeks / installation (C199 contract)

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 levelas P6 & P8

• Cost : 300 kCHF• Duration : 6 weeks

Profit of LSD to install pipeworkin the shaft

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)


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


ADDITIONAL SLIDES


Non Conformities – Remaining work from2009


• 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.

Replace metallic flexible hose in DFBAs


Replace potentiallydamaged metallic flexible

hose in DFBAs.

Installation : 1 week / DFBA (12 remaining)

Replace the flexible hosewith a suitably

dimensionned and shapedsmaller diameter pipe

4

Line N in DFBAH HCM

CL line

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 evaporatethe liquid that accumulatesat a low point.

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

Level gauges

Capillary withinstrumentation wires

Connector

LHeconnec-tion

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

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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

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LN2

Warm recovery line

4.5 Krefrigerator

Coldcompressor

system


box Lowestpoint




Helium ring line

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D C BFE C D

LN2

Warm recovery line

4.5 Krefrigerator

Coldcompressor

system


box Lowestpoint




Helium ring line

Addition of a pressure measurement on header B


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

TEST OF QUENCH LINES AT P5


Destruction of the insulation

Many conflicts with neighbouring equipements during shrinkage

Liquid airon cable trays

Point 5

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

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

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


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


Documents

Review of the consolidation works scheduled for the …...All CRG colleagues (J. Casas, S. Claudet, G. Ferlin, A. Perin, G. Perinić, L. Tavian, …) ATLAS team (H. Ten Kate) Inputs