July 9-11 2014 LEReC Review 9 - 11July 2014 Low Energy RHIC electron Cooling Roberto Than CRYOGENICS SYSTEM.

July 9-11 2014

LEReC Review 9 - 11July 2014

Low Energy RHIC electron Cooling

Roberto Than

CRYOGENICS SYSTEM

July 9-11 2014

Outline

• Cryogenic System Scope and Interface• System Description• Cryogenic loads and system requirements• Procurements• Relocated equipment

– used/shared/repurposed– Moved to make space

• Equipment installation location and conventional facilities requirements

• Timeline• Risk list• Summary

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July 9-11 2014

Scope

• Provide 2K cooling to SRF e-Gun and 2K SRF 5-cell Accelerating cavity

• Provide 3 bar, 5K cooling for heat intercepts for FPC’s and beam line bores.

• Provide 5K cooling for HTS solenoid inside SRFGun cryostat

• Provide cooling to high heat load Cold Cathode– Supercritical, single phase, helium cooling

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July 9-11 2014

High Level Systems Description: Process Diagram

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….SUBCOOLER

CeC

2 - 4K

      2 - 4K

WR

M

CATHODE

HTR

HTR

HTR

HTR

HTR

HTR

HTR

HTR

HTR

HTR

HTR

SH

IELD

/TU

NE

R

July 9-11 2014

High Level Systems Description: SRF-Gun

PROCESS SUMMARY4.8K, 3.8 bar Helium from M-line tap for CeC–Supply transfer line. –Flow to cathode / Subcooler

Subcooler (Re-use 912 ERL) Remove transfer line heat, cool to 4.5K. Subcooled 4.5K, 3.5 bar to SRFGUN Return heater, then to 1 atm helium comp. Mass flow controller

2K COOLING– 4.5K, 3.5 bar feeds top fill / bottom fill – 2K-4K recovery heat exchanger– Top fill into 2K bath, level control valve– Vapor exits recovery heat exchanger– Back pressure control valve, bath at 23 Torr

– Returns to 20 Torr heaters (CeC equipment)– Sub-atmospheric pumps (CeC equipment)

Heat Intercept Piping in Gun cryostat– FPC’s, Beam line flanges– Return heaters– Mass flow controllers– HTS Solenoid magnet/Current Leads– Heat Shield cooling– Mass flow controller

Small helium compressor (CeC equipment)

RHIC WR (warm return to RHIC plant)

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July 9-11 2014

High Level Systems Description: CATHODE COOLING

PROCESS SUMMARY

4.8K, 3.8 bar Helium from M-line tap (CeC)–Supply transfer line tee off to: –6K, 3.8 bar Flow to cathode–Control valve supply side–Supply to: Flexible Transfer line–Isolation valve–Bayonet interface to cathode cart–Cathode loop: 700W heat load–Return: Flexible Transfer line–Return pressure control / isolation valve–To Common Return heater

• Subcooler boil-off• Cathode cooling return

CONTINGENCY

(Need LN2 dewar system at RHIC 02:00)

Existing CATHODE COOLING @ ERLChange back to LN2 cooled• Forced convection boiling heat transfer• 15- 30 g/s of flow• 3.5 g/s vapor generation at 700W• 10% vapor mass fraction for flow boiling

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July 9-11 2014

High Level Systems Description: 5-Cell Cryostat

PROCESS SUMMARY4.5K, 3.5 bar subcooler to:

5 CELL CAVITY CRYOSTAT & VALVEBOX– To 5K Intercepts in 5-cell cryostat– To 2K Cooling Loop

2K Cooling Loop– 4.5K, 3.5 bar feeds top fill / bottom fill – 2K-4K recovery heat exchanger– Top fill into 2K bath, level control valve– Vapor exits recovery heat exchanger– Back pressure control valve, bath at 23 Torr– Returns to 20 Torr heaters (CeC equipment)– Sub-atmospheric pumps (CeC equipment)

Heat Intercept piping in 5-CELL cryostat– FPC’s– Beam line flanges– Tuner – Heat shield cooling

Return heater

Mass flow controllers

Small helium compressor (CeC equipment)

RHIC WR (warm return to RHIC plant)

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July 9-11 2014

High Level Systems Description: Equipment List

• Supply Transfer Line existing DX-tap for CeC project.• Interconnecting VJ lines between subcooler and SRFGun valvebox• Interconnecting VJ bundle between Gun valvebox and 5-cell valvebox• Subcooler• ERL SRFGUN Valve box• ERL SRFGUN Cryostat• Flexible VJ Helium lines Cathode cooling • 20 Torr cold vapor return VJ line to CeC Return heaters• Common return heater for subcooler bath / cathode cooling• ERL SRF 5-cell Valve box• ERL SRF 5-cell Cryostat• Return heater 5-cell Tuner/Thermal shield return flow

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July 9-11 2014

Parameters: SRF cryostats

• SRF Gun– 2.00K, CW– Static heat leak: 14 W– Dynamic load: 10 W– Heat Intercept/ cooling:

FPC x 2: 0.15 to 0.3 g/s Beam line Flanges: Cathode side /

downstream. 2 x 0.3 g/s– HTS Solenoid cooling: 10 W– HTS current leads: ~ 16 W– Heat shield cooling: ~ 25 W

• Gun Cathode– Cooling Duty: 700W– Cathode temperature: <90K– Flexible transfer lines retract

cathode. – Cooling method: Supercritical

helium 3 bar,5K, 6 grams/sec

• SRF 5-Cell– 2.00K, CW– Static heat leak: 21 W– Dynamic load: 5 W [25 W]– Heat Intercept/ cooling:

FPC : 0.15 g/s Beam line Flanges: 0.15 g/s Tuner/Shield: 0.1 g/s

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July 9-11 2014

Parameters: Cathode Cooling

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• Updated design of cathode: 650W heat dissipation• Supercritical Helium Cooling• Preliminary analysis shows that this is feasible• Detail ANSYS model: Copper temperature profile

Lumped modelChannel Flow cross section Area 0.000047 m2

Hydraulic Diameter 0.0008 m

Heat transfer Area 248 cm2

k, @ 14K, 3.5bar 0.0218 W/m-K

Viscosity @ 14K, 3.5bar 3.0E-6 Pa-s

Prandtl @ 14K, 3.5bar 0.76

Helium Flowrate 6 g/s

Reynolds 35700

Nusselt 92

Heat transfer coefficient 2400 W/m2-K

LMTD 13 K

July 9-11 2014

Parameters: RHIC CRYO PLANT LOADING

4.5K Ref

Load

Liquefaction loadg/s

Carnot WorkkW

ActualComp.

kW

Supply lineSubcooler load

[46 W] 2.57 17.6 93

SRFgun Cathode cooling 6 41.2 217

SRFgun intercepts coolingHTS solenoid

1.4 9.4 52

SRF Gun 2K, 39W 2.3 15.8 83

SRF 5-cell 2K 2.7 18.5 97

SRF 5-cell intercept coolingThermal shield

0.6 4.1 22

0.562

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All loads returns as liquefaction loads on main RHIC Plant

July 9-11 2014

Procurements

1. 20 Torr cold vapor return VJ transfer line 2.5”x 4 VJ

2. Cryogenic transfer line, ½”Tx 2”VJ

3. Cryogenic transfer line jumpers between subcooler & valve boxes.

4. Flexible Cryogenic transfer lines set for cathode cooling loop 3.5bar, 5K helium.

5. Return heater for cathode cooling / subcooler boil-off

6. Control system I/O cards (Quantum series) and instrumentation cables, rack components

7. Platform around SRF Cryostats/valveboxes

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July 9-11 2014

Relocated Equipment

Relocated• Subcooler from ERL cryosystem• Cryogenic valves from ERL cryosystem• Valvebox for SRFGun• Valvebox for SRF 5-cell• Mass flow controllers and manifold for Intercepts cooling circuits

Use/Share of CeC project equipment:• 20 Torr Return heaters• Sub-atmospheric pumps• Small helium compressor

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July 9-11 2014

Location in LEReC

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VALVEBOX

SRFGUN

SUBCOOLER

SEPARATOR/SRF-5CELL

SRF 5-cellVALVEBOX

LHe supply

20 Torr return

CEC 20 Torr Return heaters

Tap Existing LHe supply

July 9-11 2014

Conventional facilities requirements

• Instrument Air for valve actuators• 480 VAC, 3 phase for large return heaters• 208 VAC, 1 phase for small return heaters• DI water for FPC thermal loops• Cable trays: tunnel to racks in trailer/service bldg• Utilities for shared equipment from CeC experiment

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July 9-11 2014

Timeline

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Oct 2014 Cathode cooling helium lines, Design complete

Nov 2014 - April 2015 Cathode cooling helium lines: RFQ, Manufacture, deliver.

Jan – Jun 2015: Shutdown for gun modifications and LEReC test preparation (in 912 blockhouse).

Apr – Jun 2015 Re-install SRFGun into ERL

July- Dec 2015 Test new cathode with nitrogen coolingTest new Cathode with helium cooling

June 2015 Supply VJ line, Coldbox interconnects, subcooler jumpers, Design complete. 20 Torr Return VJ Line, Design complete. Return heater, 1 bar helium, Design complete.

Nov 2015 SRF Gun Valvebox mods/interface, Design and dwgs completeSRF 5-cell Valvebox mods/interface, Design and dwgs complete

July 2015 - Apr 2016 Supply VJ line, Coldbox interconnects, subcooler jumpers. RFQ, Manufacture, deliver. 20 Torr Return VJ Line. RFQ, Manufacture, deliver.Return heater, 1 bar helium. RFQ, Manufacture, deliver.

Feb 2016 SRF Gun Valvebox mods/interfaces, Parts procured. SRF 5-cell Valvebox mods/interfaces, Parts procured.

July 9-11 2014

Timeline

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July 2016 – Oct 2016 Install SRF 5-cell CryostatInstall SRFGun Valvebox 5-Cell valvebox, Subcooler, Return heaterInterface modifications, interconnecting VJ linesInstall Instrumentation/controls cables in cable tray

Nov 2016 - Dec 2016 Install Supply and 20Torr Return transfer lines

Nov 2016 Install SRFGun

Dec 2016 - Mar 2017 Install VJ transfer lines between SRFGun and valvebox

April 2017 Warm check out complete CRYOGENICS

May 2017 Cooldown SRF gun w/RHIC refrigerator

July 9-11 2014

Risk list

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WBS Risk Description Type of Risk

ConsequenceLikeli-hood

Cost Impact

(burdened $k)

Risk Expiration

Mitigation Plan

1.6

The present plan is to use He from the RHIC refrigertor to cool the cathode. If the heat load is too high then an LN2 cooling system will be need for the cathode to improve cooling performance. Cost Level 2 L 380 3QFY15

The new cathode design will be tested in 912 ERL . A cost estimate as been done for adding an LN2 cooling system at 02:00 in RHIC which will be installed if the heat load is too high or inefficient for the RHIC refrigerator.

Medium Risk

RISK / CONTINGENCYExisting CATHODE COOLING ERLChange to LN2 cooled• Forced convection boiling heat transfer• 15 - 30 g/s of flow• 3.5 g/s vapor generation at 700W• 10% vapor mass fraction for flow boiling

July 9-11 2014

Summary

• Re-use existing ERL equipment as much as possible• Cathode Cooling with helium will be tested in ERL 912 Fall ‘15• To minimize equipment and installation work no 4.5K return is

implemented. All loads are returned as liquefaction load to plant. ~ 0.25 MW higher operating power.

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