ZONE 18 CRYOGENICS M. Sanmarti On behalf of AT-ACR-OP section

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



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



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



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



250 kg envoyé au zone nord 170 kg envoyé au ZN

05.06.02Livraison de 3700 Kg

10.07.02Livraison de 2325Kg



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

[email protected]

AL

[email protected] 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

Documents

ZONE 18 CRYOGENICS M. Sanmarti On behalf of AT-ACR-OP section