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ZONE 18 CRYOGENICS
M. SanmartiOn behalf of AT-ACR-OP section
Outline
• What is the Cryo in Zone 18
• Who is the Cryo in Zone 18
• Cryo Zone 18 and TCR links
• Recovery and performances
• Conclusions
What is the Cryo in Zone 18
• Production: – Refrigerators
• 18 kW @ 4.5K Air Liquide (PM18)• 6 kW @ 4.5K Linde (SM18)
– Infrastructure: recovery and purification
• Clients: – “Cryo” clients:
• LHC Magnets test benches (ACR-MT section)• LHC Cold compressors units BA7 (ACR-PI section)• String2• High Temperature Current Leads (ACR-IC section)
– “Non-Cryo” clients: RF modules & cavities, GreC
• Utilities– Electricity, Cooling Water, Compressed Air, Controls
STRING
18kW AirLiquide
POL18g/s
WPU1 Magnets
25.000 lDewar
6kW Linde
Clients
6kWHeliumTanks
Ballons
RE
CO
VE
RY
LIN
E
Valve Box
WPU2 String
Warmreturns
Warmreturns
HP Purificator2x200m³/h
CP's Recup3x100m³/h
Heater
18kWHeliumTanks
Heater
Test BenchCCU, CB
1.8 K
CPprecooling
TeststationHTS
RFCryostatModule
Magnetstest
bench
What is the Cryo in Zone 18
RefrigeratorsPM18-Air Liquide 18 kW @
4.5K• Compressor station
– 5 He compressors (1600 g/s, 4.2 MW)
– Oil system (5 oil pumps)
– Cleaning helium system
• Cold Box– Vacuum vessel
– 8 Turbines, heat exchangers
– 1 Nitrogen Precooler (80K)
• Controls(ABB):1100 I/O
• Connected to the Dewar
SM18-Linde 6 kW @ 4.5K
• Compressor station– 3 He compressors (350 g/s, 1.5
MW)
– Cleaning helium system
• Cold Box– Vacuum vessel
– 6 Turbines, heat exchangers
– 1 Nitrogen Precooler (80K)
• Controls (ABB): 800 I/O
• String2/back up
Infrastructure (750 Input/Output)
Helium storage
• 9 helium tanks of 80 m3 each, dedicated to the 6kW Linde cryoplant for GHe storage
• 12 helium tanks of 250m3 each, dedicated to the 18 kW Air Liquide cryoplant, for GHe storage
• A 25000 liters dewar for LHe storage
• A mobile 10000 liters dewar for LHe storage
LN2 supply
• 1 dewar of 50000 liters dedicated to the 6kW Linde cryoplant and the HP purification system (+ infrastructure SM18)
• 1 dewar of 50000 liters dedicated to the magnet test benches
• 2 dewars of 50000 liters dedicated to the 18kW Air Liquide cryoplant and BA7.
• All warm return gases (pure) can be sent either to the 18kW Air Liquide plant or to the 6kW Linde plant.
• The return gases are analysed for impurities (air/humidity) and can be sent to the balloons if necessary (not all return gases – flow too high)
HP Purification system:• 5 balloons of 80 Nm3, total capacity of 400 Nm3• 3 Burckhart compressors with 100 Nm3/h at 200 bar each• 2 HP purificators of 200 Nm3/h at 200 bar eachLP Purification system:18 g/s on-line purification system (freeze-out) at the outlet of the warm pumping unit
Clients The magnet test benches (Dewar-PM18) The RF-cavities and modules (Dewar-PM18) The 1.8K Cold Compressor Unit – test facility at BA7 (PM18) STRING2 (a full-size model of a regular cell of an LHC arc)
(Linde) A test station for testing High Temperature current leads 600A and
13kA (Dewar-PM18) The GREC experiment, Grands Reynolds Cryogéniques (Linde)
The clients take Liquid Helium from the 25000 liters dewar at 4.5K and send backpure gaseous helium - cold or warm - to the low pressure side of the compressors of the cryoplant (18kW/6kW) or impure to the balloons.
The client can decrease the temperature to 1.8K by pumping on the helium bath. A refrigeration capacity of 360W @ 1.8K is available via a warm pumping group in series with a one-stage Cold Compressor Unit. The outlet of the pumping group passes an « on line low pressure purification system » and is sent back to the low pressure side of the compressors.
Courtesy L. Tavian
Utilities needed for Cryogenics
• Electricity:
– 3.3kV Powering of main compressors– 400V Powering of heaters, pumps,...– 24V Instrumentation (relays, 500 mA)– 24V Control System & monitoring (4 –20 mA)
• Water: – Cooling of compressor station (motors, helium, oil), turbines, vacuum pumps...
• Compressed Air:
– Valves actuators
• Controls :– Networks– fieldbuses, PLC, SCADA
Cooling towers
Compressed air
Cooling and ventilationWater
Helium and nitrogen- LN2: 2/4 trucks per week (2003)
nominal 2/3) trucks per day
- LHe: ~60000 liters per years (02-07)
Electric power about 7 MW
Utilities for Cryogenics in SM18
CRYO
Controls:Networks, fieldbuses, PLC, SCADA
About 11,5 MW (1000 m³/h)
Who is the Cryo in Zone 18
ZONE 18W3
LHC POINTSW6
CCU / BA7W4
CRYOMAGNETS W5
ZONE 18W3
LHC POINTSW6
CCU / BA7W4
CRYOMAGNETS W5
L. HERBLIN
M. SANMARTI
JP. LAMBOY
A. TOVAR
C. CALZAS D. CHANAT G. FERLIN
Y. COLLOMBET
J. AXENSALVA
S. KNOOPS
N. QAZI
N. ZELKO
L. MOURIER
J.C. ROGEL
R. BECK
G. EVRARD
G. FISCHER
V. LAVELLE
C. ROBIN
S. AMOMO
F. ANTONIOTTI
N. BALIN
V.SOUTO-GOMES
N. NAVION-MAILLOT
B. BARRIAPt 6
S. MASSONPt 8
A. EYCHENNE
E.MILLET
JC. DE SOUSA
ALLS OPERATIONS ACR H. BERG
M. CHARVIN G. VINCENT
CERN OPERATION ACRACR/OP - L. SERIO
ACR/MTB. VULLIERME
ACR/PIS. CLAUDET
ACR-OPL. Serio
zone 1818 kW, infra, cavities
zone 186 kW, String 2
LHC pointsLHC Cryo systems
Commissioning
Operation TeamALLS
cryoplants zone 18
Operation TeamALLS
cryoplants zone 18
Operation TeamALLS/CERN
Cryoplants LHC
ACR-MTB. Vullierme
Test Bench SM18
OperationTeam ALLS
Test Benches
JR
C C U tes tsS . C lau d etG . F erlin
W P 4
A C R -P IS . C lau d et
Who is the Cryo in Zone 18
Who is the Cryo in Zone 18
VIDE MECANIQUE ELEC. & INSTRUM.SUPPORT
TECHNIQUEZONE 18
W3LHC POINTS
W6CCU / BA7
W4CRYOMAGNETS
W5
J. MORENO J. BOUTTAZ J. KASPRZYCKI D. JOUVE
G. CLERC S. CALLEJA C. MIZRAHI
L. MURAT B. DEFINOD
N. QAZI
N. ZELKO
L. MOURIER
J.C. ROGEL
R. BECK
G. EVRARD
G. FISCHER
V. LAVELLE
C. ROBIN
S. AMOMO
F. ANTONIOTTI
N. BALIN
V.SOUTO-GOMES
N. NAVION-MAILLOT
B. BARRIAPt 6
S. MASSONPt 8
A. EYCHENNE
E.MILLET
JC. DE SOUSA
OPERATIONS ACR H. BERG
MAINTENANCEF. BARACCO
M. CHARVIN G. VINCENT
Who is the Cryo in Zone 18• ACR-OP: production, infrastructures and String2
– CERN: C. Calzas, D. Chanat, Y. Collombet, S. Knoops, M. Sanmarti and L. Serio**
– ALLS: H. Berg**, M. Charvin, A. Eychenne, E. Millet*, N. Navion-Maillot, JC de Sousa*, V. Souto-Gomes.
Normal operation and piquet service (CERN/ALLS)
• ACR-MT: LHC magnets tests bench– CERN: J. Axensalva, L. Herblin, JP Lamboy, A. Tovar, B.
Vuillerme**– ALLS: 3x8 shifts (1 STL, 3 TL, 8 operators)24 hours operation from control room (ALLS)
OPERATION OPERATION OPERATION
SM18 - LHC - STRING SM18 - LHC - HTS SM18- LHC - AIMANTS
CRYO_COLDBOX_ 6KW CRYO REFRIGERATEUR CRYO_STRING_LHC TEST_HTS_LHC CRYO_GENERAL_PRE
(CRYO-7) (LHC 4.5K_Refrig. ) (CRYO14) (CRYO) (TEST_LHC_MAGNET)
not in service
|
Responsable Responsable
Natel : TEST_LHC_AIMANTS| | | | B. Vullierme 75477
Responsables technique Natel : 160775
Natel : | | | |
Salle de contrôle String Salle de contrôle
B. 2173 SM18
Tel.79557/79558/79559|
| | | | |
not in service Voir les consignesclasseur piquet
Natel : 16 03 54
at CERN 16 0125
Tel.78016/78210/78211
Responsable
L. Serio
Natel : 160130
OPERATION
SM 18-LHC-REFRIG
Salle de contrôle cryo
Voir consignes classeur piquet
Responsables technique
Piquet CERNNatel : 16 47 60
GSM 0-079 201 0125
B. 2173 SM18
Cryo and TCR links
Defaut Liste Cryogénie SM18 CRYOSUBSYS MEMBER MNEM BUILDING DESCRIPTION
CRYO_COLDBOX_6KW CRYO-7 SM18 2173 DEFAUT CRYO BF 6KW
ANS, APRES 15 MIN. SANS CONFIRMATIONSalle de contrôle Piquet : GSM 0-79 201 01 25
B. 2173 SM18 at CERN 16 01 25Tel.78016 Si non reponse ingenieur support ALLS (voir planning)
voir consigne classeur piquet Si non reponse piquet CERN (GSM 16 47 60)
Default CRYO REFRIGERATEUR 4.5K PM18 SUBSYS MEMBER MNEM BUILDING DESCRIPTION
CRYO REFRIG LHC 4.5K_REFRIG SD18 DEFAUT CRYO REFRIG.R 4.5 K PM18
ANS, APRES 15 MIN. SANS CONFIRMATIONSalle de contrôle STRING Piquet : GSM 0-79 201 0125
B. 2173 SM18 at CERN 16 01 25Tel.79557 Si non reponse ingenieur support ALLS (voir planning)
voir consigne classeur piquet Si non reponse piquet CERN (GSM 16 47 60)
Defaut Liste SM18-LHC-STRINGSUBSYS MEMBER MNEM BUILDING DESCRIPTION
CRYO_STRING_LHC CRYO-14 SM18 2173 DEFAUT CRYO STRING LHC
ANS, APRES 15 MIN. SANS CONFIRMATIONSalle de contrôle STRING Piquet : GSM 0-79 201 0125
B. 2173 SM18 at CERN 16 01 25Tel.79557 Si non reponse ingenieur support ALLS (voir planning)
voir consigne classeur piquet Si non reponse piquet CERN (GSM 16 47 60)
Defaut Liste Cryogénie SM18-LHC HTS ********NOT IN SERVICE*******SUBSYS MEMBER MNEM BUILDING DESCRIPTION
TEST_HTS_LHC CRYO SM18 2173 DEFAUT CRYO HTS
Not in servicePiquet :
Defaut Liste Cryogénie SM18-LHC-AIMANTSSUBSYS MEMBER MNEM BUILDING DESCRIPTION
CRYO_GENERAL_PRE TEST_LHC_AIMANTS SM18 2173 DEFAUT CRYO AIMANTS LHC
ANS, APRES 15 MIN. SANS CONFIRMATIONvoir consigne classeur piquet Piquet : GSM 0-79 201 03 54
at CERN 16 03 54
Cryo and TCR links
5 Juin 2003 16
CERN
Date debut piquet
Week SK DC LS MS CC NNM BB AEY SM VSG MCh
24-01-03 5 7 731-01-03 6 7 707-02-03 7 7 714-02-03 8 7 721-02-03 9 7 v 728-02-03 10 7 707-03-03 11 7 7
TOTAL 49 70 70 70 63 7 0 7 0 0 0Téléphones:
nom init. tel. GSM domicile En cas de non-reponse de l'operateur De Sousa JCdS 78469 après 15 min. il faut contacter:Millet EM 78211
Barria BB 78205 Appeler Operateur ALLSCharvin MCh 78211 Si non-joignable: 160125Masson SM 78211 appeler Ingénieur de soutien ALLSEychenne AE 78211 160683Navion-Maillot NNM 78469 Si non-joignable:Souto-Gomez VSG 78211 appeler piquet CERN 164760
nom init. tel. GSM domicile Ing. ALLS SM18:Calzas CC 74098 init. domicileChanat DC 75676 HB 022/7822949
Knoops SK 76296
Sanmarti MS 74058
Serio LS 74669
163835
022/ 7869772160130
022/ 3407930
0450283722
0450418178
0450991676
164464
160777
160721
Opérateurs ALLS:
Soutien CERN:
0450389398
0613137336
0603169416
0450565774
Berg Hilmar
ALLS
nom
0450414477
Planning ZONE18 Cryo operation 2003
0620635608
163673 0450409048
File on webpage of our section:http://lhc-div-acr-op.web.cern.ch/lhc-div-acr-op/Link: Piquet
Performance in 2002
PM18 Linde String at 1.9K
Total hours of liquid helium production in 2002 Performance in %
6470
98.94%
5150
97.38%
4170
92.63%
Utilities-stop (electricity, water, compressed air)
For String: coldbox stop = utiliy-stop (watercut – impurities)
29h30 0.46% 33h36 0.65% 25h48
174h21
0.62%
4.18%
Cryogenic operation failures – tuning of new cryoplant
For String: problems with pumpinggroup
36h30 0.56% 33h18 0.65% 6h05
59h15
0.15%
1.42%
Automate/program – failures
For String: other causes (HTS – Kickertests)
2h38 0.04% 1h25 0.03% 30h45
11h15
0.74%
0.27%
Quench-recuperation Total hours of recuperation (<24h) 0h 0h 411h50 9.8%
Total hours >24h recuperation 30h50 0.74%
Accumulation of impurities - big quantities of impurities: total regeneration of cold box
0h 66h30 1.29%
- Without redundancy Linde
- With redundancy Linde
Liquid helium deliveries (4 deliveries of maximum 8 hours) (If reduction LHe distribution)
0h 0h 0h
For PM18: only taken into account distribution to clients in SM18 for 2002, with buffer of 25000 litres dewar. For 2003, also taking into account BA7, without buffer … if level in phaseseparator of cryoplant decreases below 30%, production-stop for BA7.
Non Conformity Report ALLS - summaryColdbox 6kW Linde:
20 Beeps:5 utility-cuts resulting in production-stop
For example: powercut with as consequence blow-up of several balloons
1 cryogenic problem resulting in a production-stop4 cryogenic problems in planified period (cooling down or warming up of STRING)4 due to cold coming from STRING (turbines stopped)2 due to pure gas storage (MP) too high1 due to pure gas storage (MP) too low3 due to stop of CP2 only (no production stop)
Bonus-Malus-file: 5 utility-cuts; 1 cryogenic problem with beep5 cryogenic problems without beep (during working hours)
For example: Turbine 4 broken
STRING:
18 Beeps:
12 for HTS OFF
6 due to problems STRING (e.g. errors in control)
-> none of them in Bonus-Malus-file as they were not resulting in a production-fault for STRING
Bonus-Malus -file:
Total number of quenches provoked: 17
Total number of stops: 13
utility: 9
controls STRING: 1
Test Kickers: 2
HTS off without BEEP: 1
Helium Zone 18 - 2002
0
1000
2000
3000
4000
5000
6000
7000
8000
13.0
3.02
23.0
4.02
23.0
5.02
21.0
6.02
19.0
7.02
19.
08.0
2
14.
09.0
2
12.
10.0
2
07.
11.0
2
05.
12.0
2
Kg
0
20
40
60
80
100
120
140
160
180
200
Quantité d'Helium total Perte moyenne par jour (kg) Purif ication Helium (kg/jour)
Total LHe livré au SM18:9655 kg
Perte moyenne par jour au SM18: 20 kg (0.4% sur stock moyenne; 20*30d*9m=5400kg)Stock moyenne au SM18: 4719 kg
700 kg envoyé au cryolab
Perte moyenne de50 kg/jour
Perte de 300 kg:Test HTS (CFB)
Envoi de 300 kgau cryolab + perte de 50 kg (arret P18)
10000 l envoyé au cryolab+ 200 kg au ZN
Perte moyenne de40 kg/jour
Perte moyenne de25 kg/jour
250 kg envoyé au zone nord 170 kg envoyé au ZN
05.06.02Livraison de 3700 Kg
10.07.02Livraison de 2325Kg
03.04.02Livraison de 2200Kg
03.09.02Livraison de 2950Kg
Livraison de 1000 kg venant du cryolab
Conclusions (??)
• http://lhc-div-acr-op.web.cern.ch/lhc-div-acr-op/default.htm
Salle des machines
Boite froide
Boite froide
General layout of the zone 18
SW18
SHM18
BA7
SD18
SH18
SM18STRING
POL
25000 lDewar
Magnets test bench
HPPurificator
HeliumTanks6kW
Ballons
LN2Dewars
Cryostats Modules
CCU1 CCU2
WPU1
WPU2
CP's 6kWLinde
CP'sRecup
CB 6kW Linde
AL
Test BenchCCU, CB
1.8K
HeliumTanks18kW
CPPreccoling
Test StationCurrent Leads
10000 lDewar
Warm part ofCB 1.8K
LN2
InfraFrigos
STRING
18kW AirLiquide
POL18g/s
WPU1 Magnets
25.000 lDewar
6kW Linde
Clients
6kWHeliumTanks
Ballons
RE
CO
VE
RY
LIN
E
Valve Box
WPU2 String
Warmreturns
Warmreturns
HP Purificator2x200m³/h
CP's Recup3x100m³/h
Heater
18kWHeliumTanks
Heater
Test BenchCCU, CB
1.8 K
CPprecooling
TeststationHTS
RFCryostatModule
Magnetstest
bench
Some figures of zone 18
- Available LHe:6 kW Linde: 16-30 g/s18kW AL: 150-250 g/s
(SM18 + BA7)-Transfer Line SD-SM:
LHe: 60 g/s (120 g/s)GHe: 60 g/s @ 80K
(90 g/s @ 50K) - Consumption:
- Magnets: LHe: 60 g/s (120 g/s)GHe: 35 g/s (120 g/s)
- Cryostats/Modules:10-15 g/s intermittent
- BA7: 40-45 g/s equiv. liq.
(130 g/s)- String:
Lhe: 6-10 g/s norm. op30 g/s transients
Cryogenic fluids-consumption:•2/4 trucks per week and later on 2/3 trucks per day of LN2 •About 60000 litres of LHe per yearDuring the coming 5 years
Dewar and connections to clients
Dewar and connections to clients