Serge Claudet TE-CRG-OA (LHC Cryo OP)

Transcription

1 LHC Cryogenics for BE/OP shutdown lectures Serge Claudet TE-CRG-OA (LHC Cryo OP)

2 Content Introduction and LHC requirements Helium refrigeration and distribution for LHC Cool-down, tuning, quench and availability Controls, and tools towards AB interfaces LHC Cryo OP team Conclusion

3 LHC accelerator p-p collision cm -2.s -1, 14 TeV, 0.5 GJ stored energy Early requirements for the LHC cryogenic system 24 km of superconducting K, 8.33 T

4 Critical Current Density of Technical Superconductors 4.5 K 1.8 K 4.5 K LHC Spec Cable 1 LHC Spec Cable 2 A/mm2] Jc [A

5 Useful ranges of cryogens

6 Phase diagram of helium SOLID 1000 SUPER- CRITICAL Pa] Pressure [k 100 He II PRESSURIZED He II (Subcooled liquid) He I CRITICAL POINT SATURATED He I 10 VAPOUR SATURATED He II Temperature [K]

7 Layout of cryogenics Pt 5 Pt 4 Pt 6 8 x 4.5 K sc magnets 24 Cryoplant km & 20 Distribution 1.8 K Present Version K Pt 3 Pt t He inventory Pt 2 Pt 8 Pt 1.8 Cryogenic plant Pt 1

8 LHC Cryogenics architecture Point 1.8 Point 2 Point 4 Point 6 Point 8 Storage Storage Storage Storage Storage QSCB QSRB QSCC QSCA QSCC QSCC QSCA QSCB QSCC QSCC QSCB QSCA QSCC QSCC QSCA QSCB QSCC QSRA QSRA QSRB QSRB QSRA QSRA QSRB face Surf Shaft QUIB QURA QUIA QURA QUIC QURA QUIC QURA QUIC QURC QURC QURC QURC QURC QURC QURC QURC Cavern Sector 1-2 Sector 2-3 Sector 3-4 Sector 4-5 Sector 5-6 Sector 6-7 Sector 7-8 Sector 8-1 Legend Cryogenic Distribution ib ti Line QSC_(A,B,C): Warm Compressor Station QSR_(A,B): Surface 4.5 K Refrigerator Cold Box QURA: Underground 4.5 K Refrigerator Cold Box QURC: 1.8 K Refrigeration Unit Cold Box QUI_(A,B,C): Cryogenic Interconnection Box Electrical Feed Box Superconducting Link Commisionned & accepted Delivered / Under installation Ordered (Contract placed) Large variety of large scale refrigerators, Under commissioning Under fabrication Under definition AND Large variety of cryogenic transfer lines including large scale lines Tunnel

9 How does it compare? [to onnes] P [kpa] SOLID HeII Pressurized He II Saturated He II λ line Superfluid Helium 1.8 K HeI CRITICAL POINT GAS T [K] Virtual Liquid 2 MPa Helium Inventory 180 LHC, ATLAS, CMS Cooling capacity ITER LEP2 OMEGA, ALEPH, Tevatron, RHIC, BEBC, DELPHI, ISR Jlab, Low-Beta SNS, LEP HERA, Low-Beta Tristan, LHC LEP Year LHC: 144 kw 50 0 Tevatron HERA CEBAF RHIC LEP2 LHC (SSC) Unprecedented! (1.8K - scale x10)

10 Magnet cooling scheme SOLID 1000 P [kpa] 100 HeII Pressurized He II λ line HeI CRITICAL POINT GAS 10 Saturated He II T [K] Thermo-hydraulics of two-phase flow in He II (and limitations!) ( 1W/m)

11 Content Introduction and LHC requirements Helium refrigeration and distribution for LHC Cool-down, tuning, quench and availability Controls, and tools towards AB interfaces LHC Cryo OP team Conclusion

12 Experience over decades 180 LHC, ATLAS, CMS Refrigeration LEP2 OMEGA, ALEPH, BEBC, DELPHI, ISR Low-Beta LEP Low-Beta LHC LEP Year LHC: kw Cryogenic distribution lines LHC LEP CERN made lines km LHC: 2 From mostly CERN home-made hardware, To industry (with CERN support) for large projects

13 Cryogenic architecture Typical LHC even point 1.8 K Refrigeration Unit New 4.5 K Refrigerator Ex-LEP 4.5 K refrigerator 1.8 K Refrigeration Unit Warm Compressor Station Warm Compressor Station Warm Compressor Station Warm Compressor Station Surface Cold Box Upper Cold Box Shaft Cold Compressor box Lower Cold Box Interconnection Box Cold Compressor box Cavern Distribution Line Magnet Cryostats Distribution Line Magnet Cryostats Tunnel LHCS Sector (33k (3.3 km) LHCS Sector (3.3 (33k km)

14 Cryogenic sub-systems Point 8 Storage QSCC QSCA QSRA QSCB QSRB QSCC Shaft Sur rface QURA QURC QUIC QURC Cavern Sector 7-8 Sector 8-1 Tunnel

15 Helium storage Gex 2 for CMS Point 4 Point 5 LHC: 130t Point 6 Point t: 50 x 250 m x 76 m3 Cold masses QRL, header C QRL, other headers Cryoplants Storage tanks Point 7 To be completed by (Ph. 1): (R) Point 2 Ferney Voltaire St Genis-Pouilly P 1.8 P 1 Point 8 Geneva A good basis, but rather long logistics 25 t: 2 x 15 t for Spring 2008!

16 Follow-up of Helium inventory LHC Cryogenics - Helium Inventory Tons Initial Inventory Deliveries Final Inventory Losses External storage Similar (reduced?) losses expected for 2009 due to purges/leak tests

17 K Refrigerators K to 75 K K to 20 K - 41 g/s liquefaction Pinput : 4.2 MW COP 250 W/W Carnot Limit

18 LHC K Refrigerator Compressor stations

19 LHC K Refrigerator Process cycle for one type Expansion turbines Heat exchanger blocks

20 1.8 K issues Sub-atmospheric compressor MP 1 CC CC CC 3 2 LP LHe HX HP 4.5 K refrigerator r Heat load Mixed Compression P ratio K under atmo osphere Co old under Active magnetic bearings vacuumoutlet Pressure ratio 2 to 4 Stainless Steel Plate Inlet CC: Cold Compressor 3-phase induction Electrical motor (rotational speed: 200 to 700 Hz) 200 to 800 Hz) Fixed-vane diffuser Spiral volute Axial-centrifugal Impeller (3D) - 3D wheels - Bearings (300K) HX: - Very Low Pressure

21 K units K refrigeration units 1st Pump-down in final LHC configuration Pump-down 15 mbar P8-7 April 2005 Installed mode K Suction Pressure 712 7: : :36 10:48 12:00 Time Set point 1.8K Cooling Power ling Power [W] Coo Isentropic efficiency [%] Diam: 250mm 80 LHC Tore Supra CEBAF S. Claudet LHC Cryogenics - BE/OP Year of lectures construction - 17Mar'09

22 Interconnecting valve boxes 35 cryogenic valves 2 x 600 kw heaters To 6 compound cryo lines A Nightmare for designers, as well as for site operation and maintenance

23 LHC vertical cryo lines 4 headers in 600mm Diam Belows free in shafts

24 LHC underground cryo lines 3 headers in 500mm Diam 4 headers in 600mm Diam Thermal compensation Difficult external supports, In order to limit efforts at interface (No load) Specific design for each line

25 Main cryo distribution line (QRL)

26 QRL elements

27 QRL: Thermal performance Heat inleaks [W] E+F (50-75 K) B+C+D (4-20 K) Calculated Measured / /- 50 (~ 2.8 W/m) (~0.2 W/m)

28 Electrical Feed Boxes (DFB s) Connection to magnets x 16 Shuffling modu odule Vacuum equipment VAA Current lead chimneys 6kA leads 13kA leads + many others for stand-alone magnets (Q4-Q5-Q6) High current module 13kA & 6kA SHM/HCM interconnect Jumper cryo connection to QRL ka leads Supporting beam 6kA leads Removable door 600A leads HCM/LCM interconnect ect Low current module 6kA & 600A leads LHC: 3.4 MAmp 1.9K 45K 4.5K

29 Electrical Feed Boxes (DFB s) LT836 LT837 LT866 LT867 5 m LT864 LT865

30 LHC Sector 4-5 scheme 3.3 km K 10t/15tHe 4.5 K 1.9 K

31 Content Introduction and LHC requirements Helium refrigeration and distribution for LHC Cool-down, tuning, quench and availability Controls, and tools towards AB interfaces LHC Cryo OP team Conclusion

32 Cooldown of Sectors From RT to 80K: Precooling with LN tons of LN2 (64 trucks of 20 tons) [Three weeks] [Timing i early 2008] From 80K to 4.5K: Cooldown with He turbines 4700 tons of material to be cooled [Two weeks] From 4.2K 42K to 19K:Cold 1.9K: compressors (15 mbar) More than 15 tons of helium inventory [One week] Tuning before powering: Instrumentation, Electrical feed-boxes (DFB s), global process [One week]

33 LHC sector First cool-down

34 300 First cool-down of LHC sectors First beams around LHC Tempe erature [K] Short in connection cryostats and repairs Christmas and water maintenance shut-down Open Days Simultaneous Cryo start/maintain All sectors at nominal temperature UX85 Ph1 works Nov Dec Jan Feb Mar Mar Apr May Jun Jul Aug Sep ARC56_MAGS_TTAVG.POSST ARC78_MAGS_TTAVG.POSST ARC81_MAGS_TTAVG.POSST ARC23_MAGS_TTAVG.POSST ARC67_MAGS_TTAVG.POSST ARC34_MAGS_TTAVG.POSST ARC12_MAGS_TTAVG.POSST ARC45_MAGS_TTAVG.POSST Cooling sectors + Cryo tuning + Powering activities

35 Corrected cool-down curves Cool-down curves corrected from external aleas or cryo failures Température e moyenne du secteur [K] K/d x 13 d Secteur 7-8 #1 Secteur 4-5 Secteur K/d x 8 d 25 days for 20K Secteur 7-8 #2 Secteur 8-1 Spécification 12 K/d x 4 d Temps [jour] + 3 days for Filling + 2 days for 1.9K 30 days (4 to 5 wks)

36 1.8K Units: Global significant progress! Sector 12 - Cold Compressor inlet 1.0E+00 Bearings/Drive communication problems inlet P [Bar] CC 1.0E-01 Re-connection at lower pressures ( mbar) Two Months before manual stop! 1.0E Better than 2wks MTBF Spring 08!

37 Tuning LSS components Electrical Feed Boxes (DFBs): We could operate all of them close to nominal conditions (maximum scenario required so far during HWC) Few delicate cases (heat loads, levels measurements, levelling of sc link to magnets, valves for cooling current leads, thermometers and noise, High Voltage perturbation on instrumentation cards) Stand alone Magnets (SAM): Might come back! Difficult Level measurements due to Cold GHe capillary with too small diameter and possible low points, most delicate cases being treated Triplets: DFBX: Commissionned with moderate ramp rates on some leads (Cu) NC found on some Q1 (Missing Cu braid), being treated on critical cases in R1 and 5L Superconducting links (DSLs): No problem encountered on four DSLs (<80m), except for DSLC_P3 DSLC design/installation weak point being treated

38 Recovery Time after Limited Resistive Transitions (Predictions at design stage) Without loosing helium, and powering permit on other powering subsectors Achieved or achievable From x3 down to x1.5 w.r.t design values More than 14 cells or full sector: recovery up to 48 hours In case of fast discharge (even w/o quench): 2 h recovery (heating due to eddy currents).

39 Analysis of stops sector 56 origin (hrs) stop p( (hrs) 1 29-Feb-08 Elec 2.0 Stop 400V (Pb AUG loop) stop CC Mar-08 Cryo 0.0 Controls CC (AL) stop CC not applicable 3 14-Mar-08 Cryo 48.0 Leak in 18kW Cold Box stop CC Apr-08 Cryo Controls CC (AL) stop CC not applicable 5 04-Apr-08 Cryo Stop 18kW Comp. (LS oil) stop entire sector not applicable 6 04-Apr-08 Water Stop 400V P5 (water) partly blind not applicable 7 06-Apr-08 Cryo Stop 18kW Comp. (LS oil) stop entire sector not applicable 8 18-Apr-08 Elec 0.0 Low 400kV stop CC Apr-08 Elec 0.0 CERN 400kV failure stop entire sector May-08 Elec US65 400V stop stop CC not applicable May-08 Elec US65 400V stop stop CC not applicable May-08 Elec US65 400V stop stop CC not applicable May-08 Elec VDC power unit down stop entire sector May-08 Elec 0.0 US65 400V 264 stop stop CC May Elec 2.0 US65 400V stop stop CC stop sector sector Apr-08 Controls 3.0 stop PLC communication stop CC Apr-08 Cryo 0.0 Control CC stop CC Apr-08 Elec 0.0 CERN 400kV 168 failure stop entire sector May-08 Cryo 0.0 Drive CC elec failure stop CC May-08 Cryo Drive CC elec 144 failure stop CC not applicable 6 26-May-08 Cryo Drive CC elec failure stop CC not applicable 7 29-May-08 Elec + Water 2.0 VAR + water perturbations stop entire sector Le earning - ex xperience sector Apr-08 Elec 0.0 CERN 400kV failure stop entire sector 240 g 2 06-May-08 Cryo 0.0 Control CC stop CC May-08 Elec + Water 1.0 VAR + water perturbations stop entire sector Jun-08 Cryo CC instrum problem stop CC not applicable 120 Target Autumn 08: 72 < 12 h for stop CC < 36 h for full sector stop stop CC LEP Bonus/Malus LHC estimates Original failure [hrs]

40 LHC Cryogenics: towards beams 30 Target for global (8 sectors) Cryo OK for Powering Beams!!! 25 LHC Cryo Main ntain UX85 Ph1 works Electrical Transformers 5 19 Sept May Jun Jun Jun Jun Jul Jul Jul Jul Aug Aug Aug Aug Aug Sep Sep Sep- 08

41 LHC Cryogenics: just after beams 30 A bit frustrating!!! 25 LH HC Cryo Ma aintain Sept 08 Target for 4 sectors tested with calorimetry Switch EL network Sep Sep Sep Oct Oct Oct Oct Nov- Nov- Nov- Nov- Dec- Dec- Dec

42 Content Introduction and LHC requirements Helium refrigeration and distribution for LHC Cool-down, tuning, quench and availability Controls, and tools towards AB interfaces LHC Cryo OP team Conclusion

43 Controls Ethernet backbone (IT-CS) SH6 4 x 30 PLC s 4 x I/O SHM6 230v LHCC a SCADA data servers DS1 LHCA DS2 OS1 OS2OS1 OS2 1.8K 4.5K 4.5K 1.8K LHCB SD6 LHCC b OS3 OS4OS3 OS4 EW1 EW2 Ethernet local connection (LHC-IAS/IT CS) Ethernet surface Infrastucture (IT-CS) SUH6 QSCCa Comp 1.8K QSCA- 1/2 Comp 4.5K QSA(a) Main Dryer QSV Ghe Buffer QSCC b QSCB QSA(b) Comp 1.8K Comp 4.5K Main Dryer QSRA-1/2 UCB 4.5K QSKA QSRB-1/2 Cold Box 4.5K QSDN LN2 Buffer US IP5(b) DF B Alcov e Alcov e QURA-2 QURCa-1 Secto r LCB 4.5K CB 1.8K QURA-1 QURCa-2 DF B QUI Connection Box QURCb-1 US IP6 Ethernet underground Infrastucture (IT-CS) PLC s Alcov Alcov US Industrial s, Ethernet based e e IP7(a) communications and object QURCb-2 oriented sofware: High potential, reliability being Secto r improved DF B CB 1.8K DF B

44 Cryogenics P&F diagram More than 500 PID control loops per sector S. Claudet A large and complex fluid distribution LHC Cryogenics -system BE/OP lectures - 17Mar'09

45 Application SW The UNICOS (UNified Industrial COntrol System) Industrial based control systems for the LHC Supervision layer implemented in PVSS Front-end layer implemented in PLC-Schneider High level of detail in the application available in CCC Possible to navigate through the Cryogenic system. Four access levels (the first three with password): Administrator: control system engineer Expert login: for experts only, can modify interlocks, logic settings, etc. Operator: can operate the system, access the equipment. Monitor: Read access only

46 Standard cells ( 27/sector) QRL Filling valves Magnets 1.9K control Beam screen T control Q D D D Q D D D Q D D D Q D D D Cool-down using mostly Flow controlers P, T, L controlers at operating conditions

47 Electrical feed boxes (4 to 8) Filling valve QRL Current leads control Cool-down using mostly Flow controlers T, L controlers at operating conditions

48 Cryo conditions for powering Cryo Start: set of conditions to allow powering of concerned sub-sector (rather strict = good stability of process) Cryo Maintain: Few important conditions checking integrity of HW, with slow power abort in case this signal is lost

49 LHC Cryo Overview LHC Cryogenics Overview T LHC CS CM CS CM Sector CV910 Max xx.xx % Beep Beep Beep W RC FS T Helium Mass QSV xxxxx Kg QSD xxxxx Kg Sectors xxxxxx Kg LHC xxxxxx Kg S T Elec Power P18 xx.xx MW P2 xx.xx MW P4 xx.xx MW P6 xx.xx MW P8 xx.xx MW LHC xxx.xx MW S T

50 LHC Points Overview

51

52 Content Introduction and LHC requirements Helium refrigeration and distribution for LHC Cool-down, tuning, quench and availability Controls, and tools towards AB interfaces LHC Cryo OP team Conclusion

53 LHC Cryogenics: who does what + Operation contract (C169, end Jul 09) and FSU s

54 Affectations LHC Cryo CRG-OA Ing. OP référents experts académiques Ing. production Encadrement site Opérateurs Sites + Shifts

55 Début des shifts Cryo LHC 2009: 15 Avril Ajustements en cours selon disponibilités Timing: 6h - 14h - 22h (+/- 1/4h consignes) Tel Cryo CCC: Confirmation des demandes faites Aut 08 pour horaires décalés ALLS en complément (suivi CCC, livraisons LN2)

56 Conclusion 2008 LHC Cryogenics is the largest and most complex cryogenic system worldwide Very solid basis thanks to thorough studies and RnD conducted in 90ies All sub-systems systems (except tunnel equipment) tested with performance assessed to requirements Operation of LHC Cryogenics for the needs of Machine Hardware Commissioning i i now demonstrated t d Experience gathered to improve availability, with procedures and tools being put in place We have to concentrate on cooling-down the eight sectors, giving best conditions for HWC, while preparing our interface with AB/OP for beams!

57 Summary 2009 LHC Cryogenic system has been put in operation with success and was ready for D-day With static heat loads and effect of resistive heating lower than specified, we have the foreseen global budget for expected dynamic loads, to be further checked at local levels Test programs were conducted to improve our understanding and tuning of sub-systems Nominal preventive maintenance and consolidation programs Services-Cryo-Machine are being implemented during this winter shut-down Operation with shift (1 x 5x8) to start spring 09, industrial support to help for big transients and possible others for specific cases

58 Two sectors on one cryoplant 1.8 K Refrigeration Unit Ex-LEP 4.5 K Refrigerator New 4.5 K refrigerator 1.8 K Refrigeration Unit 4.5K Ref.: 10% capacity left per sector for dynamic loads, after specific adjustments made Warm Compressor Station Warm Compressor Station 5MW of power input, instead of 8MW (2x4MW) Upper Cold Box Competitive for recovery after stops (<10hrs for CC, <24hrs after power Lower Cold Box failure for 2 sectors) Cold Compressor box Interconnection Box Warm Compressor Station Cold Box Warm Compressor Station 45K 4.5K 15 mbar Cold Compressor box Surfa ace Shaft C avern Distribution Line Powering tests Magnet Cryostats LHC Sector (3.3 km) OK P6, possible P8 (3Qx) P4? (RF/DSLC), P2/P18?!? (ex-lep, 3Qx) Distribution Line Powering tests Magnet Cryostats LHC Sector (3.3 km) Tun nnel Not valid for large transients, but an interesting feature for low beam loads, or validated fall-back scenario if serious problems with a refrigerator