Project Oversight Board Review of Accelerator Upgrade Project – Vertical Test Cryogenics Andy Marone June 4, 2018
OUTLINE • 1.9K Vertical Test operation diagram. (slide 3) • Program to stockpile critical spares. (slides 4-8) • Cryogenic operation requirements for AUP testing. (slide 9) • Plant production capacity. ( slide 10) • Basis for estimating cost of testing. (slides 11-12) • Quench gas recovery (Phase II & III). (slides 13-15) • Improve cryo system response to the high pressure pulse of helium that follows a quench.
1.9K Vertical Test Operation To Quench recovery tanks Cold Helium Return Koch Wet Expander 2 more storage tanks available 7500L CTI 4000 Refrigerator
CTI Model 4000 Refrigerator/Liquifier Description: Primary unit, 250 (net) L/hr. uses (2) reciprocating engine expanders @ 250 RPM Use in conjunction with Koch wet expander BNL Contribution: Rebuild expansion engines New LN 2 heat exchanger, Doubling # of inline purifiers to four New diagnostic and control software (LabVIEW). 4
Mycom and Sullair 350 Compressors • Mycom Compressor (primary unit, 2 stage, 800 hp, 597 KW, 160 g/s) • BNL Contribution Purchased & received critical spares: new 2 nd stage compressor head new 400 hp motor new oil heat exchanger new helium heat exchanger • New Oil pump installed • Old pump to be refurbished • Sullair 350 Compressor (single stage, 350 hp, 261 KW, 51 g/s) • BNL Contribution Purchased & received critical spares: new compressor screw new oil pump 5
Sullair 500 - Compressor BNL Contribution • Repurpose and move to Magnet Division cryo area • Skid modified to fit into available area • Electrical panel removed • Frame cut/shortened/re-welded • 500HP Motor rebuilt • Motor & compressor head realigned • 4160V transformer relocated 6
High capacity pump (Nash-Kinema) Pumps on LHe in heat exchanger - down to 16 mbar for 1.8 K operation Delivers 2.7 g/s @ 1.8 K Cooling capacity = 40 W @ 1.8 K BNL Contribution Purchased spare blower Purchased new Spare NASH liquid ring pump ( now in operation). Connected helium exhaust gas line to new 100 hp compressor and inline purifier, to reclaim helium gas (was previously routed to dirty gas facility) Purchased new 100 hp Sullair compressor New control software (Labview), replacing SSC-era controls. 7
Additional Items Required Risk reduction and increased efficiency. • CURL funding requested in 2019 for the following; 1. Remanufacture our used NASH pump. 2. Purchase spare 100HP electric motor ( can be used for either NASH pump or Blower. 3. Replace several leaking and inefficient transfer lines ( this will increase efficiency). 4. Increase instrumentation of critical components ( this will allow for earlier detection of potential problems to avoid major damage). Meeting 3 quench per day project testing requirement. • Linde 1610 refrigerator and compressors being packaged up at PNNL for shipment to BNL later this month which will provide an additional liquefaction of 80 l/hr. (on top of the 250 l/hr. from the CTI 4000).
AUP Upcoming Vertical Tests • 2 nd prototype vertical test (July 2018) Will implement “phase II” to increase quench gas recovery (more on this later). • 2 more prototype tests (July 2019) • 20 production Cold Masses (plus 3 retests if necessary) ending in 2024. 1. Each cold mass will require approximately 25 training quenches. 2. Schedule requires 3 quenches per day.
J. Muratore: Operating stored energy (at B nom , I nom ): E max = 4.6 MJ assuming L=34 mH and I nom = 16.470 kA Ultimate stored energy (at B ult , I ult ) E max2 = 5.5 MJ assuming L=34 mH and I ult = 18 kA Achieved / expected energy extraction = 25% Marone / W. McKeon: Present LIQUID helium storage capacity = 17,500 liters (3 dewars) Present WARM helium gas storage capacity = 11,000 liter equivalent Present Liquefaction capacity (MAGCOOL-HEUB CTI Model 4000) = 250 L/hr. (65 gal/hr.) (max. output = 300 L/hr.) Future additional Liquefaction capacity (Linde PNNL L1610) = 80 L/hr. ◦ This will allow BNL to meet AUP’s 3 quench/day testing requirement.
17.9KA Ultimate Current Quenches, 25% Energy Extraction – 3 QUENCHES/DAY, PRODUCTION; 16 hour cryo Task Name Duration (hr) Helium Usage (gal) Helium Usage (L) refill 4.5K liquid 1.5 250 946 pump down to 1.9K 3 150 568 ramp #1 (17.9KA @20A/s) 0.5 refill 4.5K liquid 2 300 1136 pump down to 1.9K 3 150 568 ramp #2 (17.9KA @20A/s) 0.5 refill 4.5K liquid 2 300 1136 pump down to 1.9K 3 150 568 ramp #3 (17.9KA @20A/s) 0.5 partial refill 4.5K liquid 1 200 757 total cryo tech (CT) * 17 1105 4183 total test tech (TT) 11.5 total helium 2605 9861 17.9KA Ultimate Current Quenches, 25% Energy Extraction – 2 QUENCHES/DAY, PROTOTYPE; no 16 hour days Task Name Duration (hr) Helium Usage (gal) Helium Usage (L) refill 4.5K liquid 1.5 250 946 pump down to 1.9K 3 150 568 ramp #1 (17.9KA @20A/s) 0.5 refill 4.5K liquid 2 300 1136 pump down to 1.9K 150 568 3 ramp #2 (17.9KA @20A/s) 0.5 partial refill 4.5K liquid 1 200 757 total cryo tech (CT) * 11.5 747.5 2830 total test tech (TT) 6 total helium 1798 6804 * boil-off of 250 L/hr. is calculated based on cryo tech time for full day
PROTOTYPES ‐ 2 QUENCHES PER DAY PRODUCTION ‐ 3 QUENCHES PER DAY PRESENT CAPACITY, 12 HR. CRYO FUTURE CAPACITY, 16 HR. CRYO Task Name Task Name Helium usage, L/d 6804 Helium usage, L/d 9861 Prototype testing based on 1/10/17 Functional helium use (L) helium use (L) # of 25% Energy # of 25% Energy 17.9KA Quenches quenches Extraction 17.9KA Quenches quenches Extraction start 11000 start 11000 end of day 1 2 10,096 end of day 1 3 8939 end of day 2 4 9,191 end of day 2 6 6878 end of day 3 6 8,287 end of day 3 9 4817 end of day 4 8 7,383 end of day 4 12 2756 end of day 5 10 6,479 end of day 5 15 695 Test Requirements of 50 quenches weekend / day 6 10 11,000 weekend / day 6 15 8495 weekend / day 7 10 11,000 weekend / day 7 15 11000 end of day 8 12 10,096 end of day 8 18 8939 end of day 9 14 9,191 end of day 9 21 6878 end of day 10 16 8,287 end of day 10 24 4817 end of day 11 18 7,383 end of day 11 27 2756 end of day 12 20 6,479 end of day 12 30 695 weekend / day 13 20 11,000 weekend / day 14 20 11,000 end of day 15 22 10,096 end of day 16 24 9,191 end of day 17 26 8,287 end of day 18 28 7,383 end of day 19 30 6,479 weekend / day 20 30 11,000 weekend / day 21 30 11,000 end of day 22 32 10,096 end of day 23 34 9,191 end of day 24 36 8,287 end of day 25 38 7,383 end of day 26 40 6,479 weekend / day 27 40 11,000 weekend / day 28 40 11,000 end of day 29 42 10,096 end of day 30 44 9,191 end of day 31 46 8,287 end of day 32 48 7,383 end of day 33 50 6,479 WORKING DAYS 25 WORKING DAYS 10 maximum liquefaction capacity maximum liquefaction capacity 5900 Liters/day 7800 Liters/day 1. Days in red denote testing does not occur; liquefaction only to rebuild inventory
Phase 1 Improvement (Jan.-Feb. 2018) Phase I Relief Stack • Venting to quench tanks • Cash Relief Valve limited by 3” piping. (1380g/s @ 33 PSIG) • Approximately 60% of • 3” Burst Disk (40 PSIG) the 19,000 S.C.F of • 2” Solenoid Valve (1400 g/s @ 30 PSIG) helium needed to be • 3” Solenoid Valve (2700 vented to atmosphere. g/s @ 30 PSIG) 12
Phase 2 Improvement for July 2018 Prototype Test (Addition of 2 nd Dewar as a cold buffer) Existing dewar connected to test dewar with a vacuum jacketed transfer line 14
Phase II & III Goals 1) By implementing phase II the expectation is to reduce venting to a maximum of 20% of the 19,000 S.C.F of He in the test dewar at the time of quench. • (15,200 S.C.F. = 72 Kgs.) 2) Current error band allows the possibility of full Helium retention especially at lower current quenches. • Slower boil off rates at lower energies give more time for additional He to make it into the recovery tanks. 3) If current estimates play out and full retention is not achieved, analysis of MQXFAP2 may show that a modest increase in piping size out to the recovery tanks (from 3”IPS to 4 or 6 IPS) could allow the retention of all helium. 15
Summary • Cryogenic system will be able to support: • 3 quenches / day • Minimal venting of helium • Cost of testing is well-established from prior experience
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