56 MHz Cryogenic System R. Than J. Huang P. Orfin T. Tallerico Jan. 19, 2011.

56 MHz Cryogenic System

R. ThanJ. HuangP. Orfin

T. TallericoJan. 19, 2011

56 MHz Quiet Cryogenic Delivery Subsystem

• Transfer lines from S and R line taps plus 1st phase separator

• Cryostat with Boiler/Condenser Heat exchanger• Local Booster compressor • Heating System for return vapor + warm piping• Relief Header to outside (not required)• Instrumentation & Controls

Process Flow Diagram

Process & Instrumentation DiagramHelium tap-ins and Phase Separator

Process & Instrumentation DiagramBoiler and Condenser

Process & Instrumentation DiagramCavity

Haug Compressor

• Type QTOGX 180 LM-L• Oil free compression of dry, filtered Helium • 4 cylinders, 1-stage, air-cooled, gastight with

magnetic couplingMedium Helium, dry and filteredDew point - 80 ° C. Operating conditions min normal maxSuction temperature °C 20 20 20Suction pressure p1 bar(abs) 0.9 1.0 1.2Discharge pressure p2 bar(abs) 2.0 2.0 2.0Free gas delivery Nm3/h 240 270 330(referred to 1013 mbar, 0° C.)Massflow kg/h 43.0 48.5 59.5

11.9 g/s

Condenser Vapor Space Volume

vapor

condenser

liquid

Condenser Vapor Space Volume

Heat transfer gradient across condenser/boiler set pressure change in cavity volume between 0 load to full load, e.g. 100W

Condenser Vapor Volume sets the pressure rise rate dP/d

Condenser/Boiler• Designed heat load 100 W• Proposed heat transfer surface area 20 m2

• Average heat flux across heat transfer surface area 5 W/m2

• Condenser side temperature 4.4 K• Boiler side temperature 4.3 K• Proposed heat exchanger type Plate and fin• Heat exchanger material Al 3003• Condenser vapor volume 250 Liters

Condenser/Boiler• DT1 , Condenser side condensed liquid helium

film 10 mK• DT2 , Fin on condenser side 6 mK• DT3 , Parting plate wall 0.2 mK• DT4 , Boiler side, natural convection 59 mK• DT5 , Fin on condenser side 6 mK• DT6 , Helium column at bottom of the heat

exchanger 9 mK• DTtotal 90.2 mK• DTbudget 100 mK (100 mbar, condenser side)

Transfer lines from S and R line taps plus 1st Separator

• Transfer lines• Tap from S main header

– Warmer Liquid helium than M main header

– 3.5 atm, 5.3K– Pressure variation– 10Hz source

• Tap back into R header– Vapor return from 1st

phase separator

• 1st Separator– Operates at 1.45 atm– Takes warmer S line

helium and produce 4.65K liquid

– Recycles vapor back to R main header

– Vapor from warm S header liquid, + Heat leak from supply transfer line

Cryostat with Boiler/Condenser

• Boiler loop (PFD)• Some Vapor used for

shield flow• Bayonet for Portable

dewar fill

• Condenser Volume– 250 Liters– Pressure change ~ 64

mbar

Booster Compressor

• Oil free compressor• 4 cylinder piston• 11 - 12 g/s helium• Leak tightness: 1E-3T-L/s• P_suction: 0.9 bar• P_discharge: < 2.0 bar • Air cooling • Power: < 20 HP• < 15 psig: not ASME VIII• European CE/PED Code

• Gas Management– Suction pressure control– Bypass valve High to Low

– Return back to WR header at 1.25 bar

Vapor Heating System + warm piping

• Ambient Air Exchanger• Dual exchangers for

defrost cycling, continuous duty

• ~ 14 kW @ 10 g/s• Rate 15 psig

• Non Jacketed Piping:– Helium Boiler Cryostat to

ambient heat exchanger to compressor suction, ~ 120 ft

– Compressor discharge to WR header, ~ 120 ft

Relief System

• 5 psig Small Process Relief – Piped to WR header– Handles cooldown, fill,

warmup excursions

• Burst disk 7-8 psig– Discharge to IP volume– Vacuum switch to isolate

supply valve

• Relief Header (not required) catastrophic failure release scenario

• Finite inventory

56 Mhz Cryogenic Instrumentation

• Instrumentation Count• Proportional Valves – Qty 9.• Digital Valves – Qty 2.• Pressure Transducers – Qty 3.• Level Monitoring – Qty 3.• Temperature – Qty 26. (22 ordered)

7 high temperature range (1.4k – 420K)19 standard temp range. (1.4k – 325K)

• Vacuum* – Qty 3. (2 insul. And 1 beam)

*Supplied by vacuum group

56 Mhz Cryogenic Instrumentation

• Instrumentation Cables – Pulled by Cryo Group.

• Will use upgraded Square D system to read signals. In process of upgrading now on AIP.

*Supplied by vacuum group

Major Equipment

• Jan VJ Lines Supply/Return+ 1st separator: • BNL Eng +Design: Jan thru Feb 2011 (2 months)• PPM + RFQ +Award Mar April 2011 (2 months)• Manufacturing: May June July Aug September (5 months)• Install: Sept/Oct ( field joints 2 welds plus jacket welds)• • Oil-free air cooled compressor + warm piping + small shack • BNL Eng +Design: Jan thru April 2011 (4 months)• PPM + RFQ +Award May June July 2011 (3 months)• Manufacturing+ delivery: Aug 2011 thru Mar 2012 (6

months)• Install : May 2012 thru June 2012 (Outside tunnel, Just

outside rad control fence)• • • Condenser: • BNL Eng +Design: Jan thru Feb 2011 (2 months)• PPM + RFQ +Award Mar April 2011(2 months)• Manufacturing: May 2011 thru April 2012 (11 months)• Delivery to cryostat manufacturer for install (see below)• Install at Manufacturer: May 2012 thru June 2012 (2 months)• • •

• Cryostat: • BNL Eng +Design: Jan thru April 2011 (4 months)• PPM + RFP +Award May, June July 2011 (3 months)• Manufacturing: Aug 2011 thru July 2012 (11 months) (get

condenser in May)• Install: July/Aug 2012• Ambient vaporizer 15 kW• BNL Eng +Design: Feb 2011 (1 months)• PPM + RFP +Award May, June July 2011 (3 months)• Manufacturing: Aug 2011 thru Nov 2011 (4 months) • Install: July/Aug 2012 + piping• • • Controls & Instrumentation• PLC rack upgrade from Symax to Modicon Quantum

(underway) • Cernox TT’s ordered.• Level, PT, etc. TBD• Cables +tray + rack TBD

Major Equipment2011 VJ S/R Comp Conde Cryost

Jan E&D E&D E&D E&D

Feb E&D E&D E&D E&D

Mar E&D E&D E&D E&D

Apr B&P E&D B&P E&D

May B&P B&P B&P E&D

Jun Manu B&P B&P B&P

Jul Manu B&P Manu B&P

Aug Manu Manu Manu B&P

Sep Manu Manu Manu Manu

Oct Install Manu Manu Manu

Nov Manu Manu Manu

Dec Manu Manu Manu

2012 VJ S/R Comp Conde Cryost

Jan Manu Manu Manu

Feb Manu Manu Manu

Mar Manu Manu

Apr Manu Manu

May Install Manu Manu

Jun Install Manu

Jul Install Manu

Aug Install

Sep Install

Oct TEST

Nov

Dec

Budget: FY11:300K, FY12: 1200K Unburdened Burdened Requested

VJ S&R Lines 80K

Compressor +Shack+ Elec

180K

Warm Piping +Ambient HX

75K

Condenser 60K

Cryostat 650K

Instr. & Controls

80K

Relief Stack 50 K

Trades 120K

1295 1500 1664