low energy rhic electron cooling (lerec) filedec 6/7, 2017 low energy rhic electron cooling internal...

Dec 6/7, 2017

Low Energy RHIC electron Cooling

Internal Readiness Review December 6-7, 2017

Low Energy RHIC electron Cooling (LEReC)

Roberto Than

Cryogenic Operations, Hazards and Control Roberto Than

Dec 6/7, 2017


OVERVIEW

• INSTALLATION STATUS: IN PROGRESS • CRYOGENIC SYSTEM OVERVIEW

– Equipment and Plan View – Piping & Instrumentation Diagram

• HAZARDS & CONTROLS – Safety Reviews – Oxygen Deficiency Hazard [ODH] – Cryogenic & Pressure Safety – Electrical – Noise

• OPERATIONS – Cryo Group Org Chart / Shift – Operating Procedures Manuals – LEREC Operations

2

Dec 6/7, 2017


Cryogenics Installation Status: In progress

Timeline Update • Nov 13: Cryostat rigged into location. Survey • Nov 17- Nov 22: Platform install, Dry fit cryo line assemblies; continue warm piping welding • Dec 1: Cryostat final 2 inch translation: DC Gun to Booster Beamline section close-up. • Nov 27- Dec 2: Dry fit assemblies and Field joint welding • Dec 4 – 16: Field joint welding. Install controls junction box, cable and wiring work. • Dec 18 – 22: Finish vacuum boundaries and final pressure and mass spec leak check • Dec 22 - Jan 5: Complete controls and instrumentation wiring and check out

3

LHe Sub-cooler

20kW, 1 Atm. Return Heater

2K Vapor, 20Torr Helium Return VJ Transfer Line

SRF Booster Cryostat

Dec 6/7, 2017


Cryogenic System Overview: Equipment Scope • LEREC Equipment

– Cryogenic Transfer lines system – 4.5K Subcooler [re-use from Bldg 912 system] – Refrigeration Recovery Heatexchanger [Joule-Thomson Loop exchanger] / Relief Stack – Qty 5 x 5K heat intercepts return heaters and flow control system – 1 atm Return heater – Warm piping system – FPCs’ inner conductor cooling water loop freeze-protection [blowdown] system

• CeC Equipment being shared: – 20 Torr Return Heater [3K to 290K] – 20 Torr warm return line – Helium Vacuum Pumping System – Recovery compressor and gas management control valves

4

Dec 6/7, 2017


Cryogenic System Overview: Shared Equipment with CEC

• Helium compressor, cryogenic controls • 2K, 20 Torr, Helium bath warm vacuum pumps • 20 Torr Helium return heater

5

CEC: 20kW

20 Torr Vacuum Return Heater Skid

CEC: Helium Vacuum

Pumping skids (3)

CEC: Helium

Recovery Compressor

Dec 6/7, 2017

Low Energy RHIC electron Cooling 6

Cryogenic System Overview: Piping & Instrument Diagram

Dec 6/7, 2017


Cryogenic System Overview: Equipment

7

Work Platform & Clean Room

below

704MHz SRF Booster Cavity

5K Intercepts Heaters. Qty: 5


LHe Sub-cooler

2K Vapor, 20Torr Helium Return VJ

Transfer Line

Liquid Helium Supply Transfer Line

Warm Return 1 Atm to RHIC

2K/4K Ref. Rec. Heat Exchanger

Dec 6/7, 2017


Cryogenic System Overview: Equipment layout

8

Work Platform & Clean Room

1-atm Return pipe to 18 g/s compressor

704MHz SRF Booster Cavity

5K Intercepts Heaters. Qty: 5


LHe Sub-cooler

2K Vapor, 20Torr Helium Return VJ Transfer Line

CEC: 20Torr Vacuum

Return Heater Skid

Liquid Helium Supply Transfer Line

CEC: Phase separator 4.5K

CEC: 4.5K System

CEC: 2K, SRF 5-cell

Cavity

CEC: Return to Warm Vacuum Pumps

Warm Return 1 Atm to RHIC

Dec 6/7, 2017


1002B

Tunnel

1002F

1002D

1002A

Tunnel

IR2 Area

CEC-CRYO: Helium Vacuum

Pumping skids (3) Recovery Compressor

LEREC SRF/CRYO

CEC SRF/CRYO

Cryogenic System Overview: Equipment

ODH

ODH Laser Building

Rack/P.S. Building

Cryo valveboxes RHIC Power Supplies LEREC RF Amps Building

ODH

Dec 6/7, 2017


Reviews: LESHC-PCSS[Laboratory Enviromental Safety Health Committee:Pressure&CryogenicSafetySubcommittee] ASSRC: Accelerator System Safety Review Committee Aug 25, 2016, ASSRC, LEREC SRF Booster Cavity and Cryogenic distribution system Oct 4, 2016, LESHC-PCSS #16-04: ERL SRF eGun/LEReC SRF Booster Conversion Modifications Aug 21, 2017 LESHC-PCSS #17-05: Review of the LEREC Cryogenic System for SRF Booster Cavity

OPEN ITEMS 9324.1.1: Finding 1: Document tripping time for the booster cavity MPS [Cryointerlock <400W, BLM >400W] 9324.1.2: Finding 2: Pipe beam burst disks outside cleanroom Cryostat vacuum and beamline burstdisks 9324.1.3: Finding 3: Investigate use of 02 monitor inside cleanroom. Stand-alone sensor with local alarm PureAir

Nov 17, 2017, ASSRC: LEREC System

Walkthroughs: Grounding inspections, EEI inspections labels on controls rack and electrical equipment Hazards & caution signs for: Trips, sharp edges, hot surface, cold surface, high voltage, startle hazard, etc, pipe labeling, relief devices, exposed conductor, cable runs.

Week of Dec 27-29 ASSRC/ LESHC-PCSS Final Walkthrough or Week of Jan 3-5 ASSRC/ LESHC-PCSS Final Walkthrough

10

Hazards & Controls: Reviews and Walkthroughs

Dec 6/7, 2017


IR2 Area ODH Classification: ODH 0 RHIC ODH SYSTEM: Sensors throughout tunnel and the ceiling of IR2 Area

ODH sensor system and alarming and ventilation fans turn-on RHIC VODH system: Early warning system redundunt vacuum switches in RHIC cryostat vacuum volumes. add CEC and LEREC Cryostat volumes to system. turns on ODH-Ventilation Fans and [Restricted ACCESS mode] isolates sextant cryogen inventory from remaining sextants. Annual testing per OPM 7.1.76 LEREC CRYO Control PLC: Locally parallel vacuum switches connected to cryo controls to close CEC/ LEREC supply valves.

RHIC Sextant inventory: 9000 liquid liter

Hazards & Controls: ODH, IR2 Area

LEREC Inventory CEC Inventory Subcooler 80 Liters Phase separator 80 Liters

SRF Cryostat 170 Liters 4.5K QHS/112MHz 670 Liters

704MHz 5-cell 250 Liters

TOTAL 250 Liters 1070 Liters

Dec 6/7, 2017


RHIC Cryodistribution • Relief valves piped to outside of tunnel • Relief plates of magnet-cryostats’ insulating vacuum volume: Reliefs vents into tunnel

CEC Cryostats: Helium Relief devices vent into the tunnel/IR2 Area

LEREC Cryostat: Helium Relief devices vent into the tunnel/IR2 Area All relief are above the platform level

LEREC SRF Booster Cleanroom [below platform] o Local ODH sensor installed inside cleanroom enclosure o Cryostat insulating vacuum volume: Pipe to outside the cleanroom o Cryostat’s Beamline UHV burtsdisk: Pipe to outside the cleanroom

Building 1002A: ODH Classification: ODH 0 CEC Helium Compressor Room. Sensor/Alarm and ventilation fans

Building 1002B: ODH Classification: ODH 0 RHIC Valveboxes Sensor/Alarm and ventilation fans

Hazards & Controls: ODH, IR2 Area

Dec 6/7, 2017


Hazards & Controls: Pressure Safety ENGINEERING & MANUFACTURING: • SRF Booster cavity and Helium vessel: – Equivalent safety ASME BPVC Section VIII Div.1/2

• Subcooler [from bldg. 912] [Manufactured by vendor] – U-stamped vessel: ASME BPVC Section VIII Div.1

• Cryogenic Transfer lines [Manufactured by vendor] – Built to ASME B31.3 Process Piping code INSTALLATION:

• Warm piping and Cryolines field joints [Central shop welder] – ASME B31.3 Process Piping code – Central Shop welder/ Weld inspector. ASME IX qualified. – Cryo Mechanical Techs – Weld inspection, Pressure and leak tests

Dec 6/7, 2017


Hazards&Controls: Noise and Hearing Protection Safety • IR2 AREA – Startle Hazards Reliefs and burstdisks of cryogenic systems located above the platform Booster cavity cryostat vacuum relief, piped to outside cleanroom Sign/Labels posted at/near the relief devices

• 1002A Building: Helium Compressor & Helium Vacuum Pumps – Loud Noise Greater then 85 dB when Vacuum pumping systems are running Double hearing protection, 8 hours

– Startle Hazards Reliefs

– Compressor relief piped to outside – Vacuum pump reliefs piped to outside

Dec 6/7, 2017


Hazards & Controls: Electrical Safety • Instrumentation & Controls, & Electric Power – Inside Cryostat or above cryostat: Grounding of cryostat FPC’s window and flange heaters, 25W, 120VAC, PLC control SRF cavity bath heater: 50W, 24V, PLC control 5 x 1.5 kW, 208VAC heaters for 5K intercept returns flow

– On platform around cryostat: 480VAC 20 kW, 1 atm return heater assembly. Grounding of heater

– 1002D trailer building Heater Control Cabinet [UL508] UL listed 480VAC heater. Grounding Heater Control Cabinet [UL508] UL listed 208VAC heaters. Grounding Control Racks: PLC chassis & 120 VAC controllers. Grounding

– Instrumentation: 28 VDC [ 4-20 mA loops]

Dec 6/7, 2017


Hazards & Controls: Machine Protection.Sys SRF 704MHz Booster SRF Cryostat: • Beam Losses Monitors can detect losses to 200W. • Beamlosses < 400W and cavity’s dynamic / field emissions loads: Cryo-Interlocks to SRF MPS and to LEREC MPS

– Cavity bath pressure – Cavity bath Liquid helium level – Cavity bath Temperature – FPC’s flanges temperatures – Downstream beamline flange temperature

Cryo-Interlock to LEREC MPS – Upstream stainless reducer choke area pipe temperature

– Beamlosses > 400W: [Defocusing loss and beam hit] Beam Losses Monitors will shutdown beam.

• SRF MPS: Interlock trips on RF losses, arc detectors, vacuum level, Cryo interlock and FPC’s cooling water flow switches, HOM adsorber Temperature

Dec 6/7, 2017


MPS: FPC inner conductor water loop • 704MHz Booster SRF Cryostat Fundamental Power Coupler’s Waveguide

surfaces water cooled. • 2 x RF Power couplers • 5 Water cooling loops for each coupler • Inner-conductor-vacuum-side water loops blowdown freeze-protection

system [2 power couplers] – Automatic blowdown of water after loss of waterflow after 20 min

time-out. – Automatic gas purge to keep inner conductor warm – Expel gas before water loop returns to main loop – Normal Operation of Inner conductor water loop

Dec 6/7, 2017


OPERATIONS: Conduct of Ops: Cryo Group Org. Roberto Than

Head, Engineering Operations D. Lederle

Operation Manager Day to day operation of cryogenic system and

engineering support

Cryo-Controls & Instrumentation

T. Tallerico Group Leader / Engineering Manager

Cryogenics Engineering / Mechanical Engineering

R. Than Engineering Manager

A. Warkentien Mechanical Techician Supervisor

P. Talty Engineering Orfin Engineering

Shift Super-Plant operator

4

Plant operator Interface with MCR Interface with cryogroup specialists General mech maintenance

B. Van Kuik Engineering Soria Engineering

Mech Techs 5

General Mech Techs maintenance

L. Masi Electrical Techician Supervisor

(Lederle) Engineering

Specialist 2

Compressor, Expander, Gas analysis, control valves, machinist

Electrical Techs 4

General Electrical Techs

Cryo Control Room Shift Super-Plant Operator

Mech Tech

RHIC Main Controls Room Operation Coordinator /

LEREC Shift Leader

Cryo Engineering support Cryo Electrical Tech

Cryo Mechanical Specialist

e.g. Magnet Power Supply Vacuum

Cooling Water

Dec 6/7, 2017


Cryogenics Control Room, 1005S next to cryoplant [5 o’clock location ring] SHIFT: Shift-Supervisor-Cryo-Plant-Operator with + Mech Tech Cryo shift rounds

• Inspection Rounds RHIC cryogenics system and service buildings. • Includes 1002A and 1002B cryo equipment

Interface with LEREC Shift Leader or MCR Operations Coordinator • Any cryogenic equipment issues on RHIC or other experiments • Overloading of local system and trips • Cryogenic system interlock trips to SRF MPS • ODH alarms

Interface with cryo staff specialists • Cryogroup-Electrical Tech, Cryogroup-MechTech Specialist, • Cryogroup-Controls Engineer, Cryo-Engineer • External groups: Water, Vacuum, Power-Supply group

OPERATIONS: Conduct of Ops

Dec 6/7, 2017


LOCATIONS: Cryogenics Control Room, 1005S next to cryoplant [5 o’clock location ring] RHIC Main Control Room: 2 CryoControls stations next to LEREC Controls stations LEREC COMMISSIONING: Jan-Feb 2018 BLUE SEXTANT: 4/5, 2/3, 12/1@ 4.5K

Overnight shift: 2 man, Plant Operator [Shift supervisor] + Tech Daytime shift: Plant Operator, with daytime staff Training: CEC system operation for 2 years. Plant operators have previous experience with almost the same equipment from testing this cryostat in Bldg 912. LEREC OPM ready. Operational training during commissioning.

RHIC RUN: MAR-JUNE 2018 24 hour, 2 shifts: 2 man, Plant Operator + Tech LEREC COMMISSIONING: JUNE-SEP 2018.

Overnight shift: 2 man, Plant Operator [Shift supervisor] + Tech Daytime shift: Plant Operator, with daytime staff

OPERATIONS: Shift and Support

Dec 6/7, 2017


• Operating Procedures Manual: OPM 7.1.81. Operating procedures CeC Cryogenics System Operation OPM 7.1.85. Operating procedures LeREC Cryogenic System Operation

OPERATIONS: Operating Procedures

Dec 6/7, 2017


OPERATIONS: LEREC Operator Interface

Dec 6/7, 2017


SUMMARY • Safety reviews completed with open actions items to be finished during installation. • Cryogenics system installation to be completed during December with final Safety

walk-throughs and inspections to follow. • Standard industrial hazards and Non standard industrial hazards have been

addressed. Pipe labeling Warning Labels and Signs to be posted at end of system installation.

• Machine Protection System in place for SRF Booster Cryostat for beam losses below 400W handled locally by Cryo system trips, above 400W protection by Beam Loss Monitors.

• LEREC Cryogenic system OPM completed. Cryogenic system operation very similar to SRF Booster cavity testing in building 912.

23

Dec 6/7, 2017


BACK UP SLIDES

24

Dec 6/7, 2017


CRYO OPERATIONS: Human Machine Interface, SCADA

25

Dec 6/7, 2017


LEREC Operator Interface: Cryostat Temperatures

Dec 6/7, 2017


CEC FPCs Inner conduct. water loops blowdown system

Dec 6/7, 2017


CEC: Cryo Operator Interface

28

low energy rhic electron cooling (lerec) filedec 6/7, 2017 low energy rhic electron cooling internal...

Documents