conceptual design of the cryogenic electrical feedboxes...

A. Perin AT-ACR, 1ICEC20 11 May 2004

DFB Project

Cryogenic Electrical powering for the LHC

Conceptual Design of the Cryogenic Electrical Feedboxes and the Superconducting Links of

LHC A. Perin, R. van Weelderen, L. Metral, T. Goiffon, P.Trilhe

DFB & DSL project team: C. Davison, V. Fontanive, T. Goiffon, J. Lyngaa, R. Marie, L. Metral, AT-ACR

L. Baliev, P. Issiot, V. Kleimenov, H. Nemoz, Ph. Trilhe, EST-ME

P. Cruikshank, R. Veness, AT-VACJ.C. Guillaume, ST-ELY. Muttoni, G. Trinquart, M. Mrzyglod, EST-MEG. Vandoni, AT-ECR

Acknowledgements

A. Ballarino, R. Herzog, C. Urpin, J. L. Perinet-Marquet, AT-MEL

J. Beltron-Sanchez, R. Orfila, P. Portier, AT-ACR

O. Capatina, Claude Hauviller, EST-IC

B. Skoczen, A. Jacquemod, F. Schauf AT-CRI

Contributions of Groups: Contributions of Groups: AT-ACR, AT-ECR, AT-MEL, AT-MAS, AT-VAC, AT-CRI,

EST-IC, EST-SU, EST-ME, ST-CV, ST- EL, TIS-TE, TIS-GS, AB-AP


DFB Project

Superconducting linksDSL

Cryogenic ElectricalFeedboxes DFBs

Cryomagnet powering

Outline


DFB Project

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Aerial view of CERN


DFB Project

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UA4 7

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LHC PROJECT

N

Point 5UNDERGROUND WORKS

CMS

Point 6

Point 7

Point 8

LHC ‘B’ATLAS

Point 1Point 1.8

SPS

Point 2

Point 3.3

Point 3.2

Point 4

ST-CE/ljr18/09/2000

Existing Buildings

LHC Project Buildings

ALICE

The Large Hadron collider

Superconducting magnets


DFB Project

Layouts of the LHC IR 1 - 4

Optics ver. 6.4DFBMDFBL

DFBA


DFB Project

Powering of the LHC cryomagnets

Supply of current to LHC superconducting magnetsSupply of current to LHC superconducting magnets��

RequirementsRequirementsSupply high current to 1.9K or 4.5K magnets reliable operation using existing cryogenicsTunnel integration & transportcompatible with the power converters & cabling integrationvarious types of magnets & busbars

Current supplyCurrent supply

Tunnel integrationTunnel integration

End of arcEnd of arc

Standalone magnetsStandalone magnets

Inconvenient/impossibleTunnel integration

Inconvenient/impossibleTunnel integration

Remote cryo supplyRemote cryo supply

Electrical feedbox: DFBAElectrical feedbox: DFBA

Electrical feedbox: DFBMElectrical feedbox: DFBM

Inner tripletInner triplet

CC correctors CC correctors Direct supply: DFBADirect supply: CryostatDirect supply: Cryostat

Electrical feedbox: DFBXElectrical feedbox: DFBX

DSL + DFBLDSL + DFBL


DFB ProjectDFBs : Functionalities & interfaces

QRL

cryogenics

WRL

heliu

m

Control &supervision

DC powering & protection

MagnetsBeam pipes

forces

cryogenics

currentcryogenics

alignment

interfaces

interfaces

Supports

DFB


DFB Project

Functionalities of the DFBs

Current supply to the LHC cryomagnetsCurrent supply to the LHC cryomagnets��

applies to: all DFBssubfunctionalities

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Cryogenic fluids for the superconducting linksCryogenic fluids for the superconducting links

• applies to : only for DFBLs


DFB Project

List of DFBs & circuits

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IR Position 6 kA 600 A 120 ANo of

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16 DFBA

23 DFBM

5705701961966926922582586464

Chimneys120 A600A6kA13kA

Totals

8L C4.L8 3 12 68R C4.R8 5 12 88R C5.R8 3 12 68R C6.R8 3 3

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DFB Project

Tunnel integration

Ø3800 tunnel

Ø4400 tunnel

Beam pipes

Reservedfor transport

Reservedfor transport


DFB Project

Basic configurations

3 types of DFBs16 DFBA24 DFBM5 DFBL

• One current lead integration type

• 2 current leads modules types

� high current: 13kA + 6 kA (600A IR 3 &7)

� low current: 6kA + 600 A

• Interface variants

Low current moduleIR1,2,4,5,6,8

DFBA

High current moduleAll IR Shuffling module

current leads modules Magnet interface

Low current module

DFBMcurrent leads module Magnet interface

Low current module

DFBLcurrent leads modules DSL interface

Low current module

DSL feedbox

DSL feedboxIR3

IR 3DSL interface

Driving factors

1. Functionality, availability, quality of beam

2. Optimization of design & validation time

3. Limited design and R&D resources

4. Standardization, simplification


DFB ProjectDFBA configuration

Low current module 6kA & 600A leads

High current module 13kA & 6kA leads

Shuffling module

Vacuum equipment VAA

Connection to magnets

Jumper cryoconnection to QRL

SHM/HCMinterconnect

HCM/LCMinterconnect

Configuration of DFBAO IR8 left

Supporting beam

600A leads

6kA leads

6kA leads

13kA leads

Current lead chimneys

Removable door


DFB Project

DFBA support system

Connection to magnets

Jack

DFBA support system

Warm beam pipes

Vacuum equipment

13kA busbars

Jack

Longitudinalsupport

DFBA shuffling module

Beam screen system

Alignment targets

Beam pipes

Thermal screen


DFB Project

connection to magnet5x6kA CLs

12x120A CLsservice chimney

removable door

DFBMA

DFB configurations

11x6kA CLs12x120A CLs

service chimney

removable door

interface to DSL

interface to QRL

DFBLA


DFB ProjectIntegration of current leadsDFB Project

50 K outlet

20 K supply

current lead

Flexible hose/busbar

interconnect sleeve busbar interconnect

plug/ lambda plate

LHe level

level measurement

50 K collector


DFB Project

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Tunnel integration of DFBAs


DFB Project

Specifications & documentsReference drawingsDetailed design of DFBA

Specification drawingsManufacturing drawings

QAPTest procedures

Raw materials Parts

Components

Preassembly of CL module

Assembly of CL modules

CL cartridge

Busbar system

Preassembly of SHM

Preassembly of DFB

Busbar & 1.9Ksystem

Assembly of SHM modules

Assembly of DFB

Chimneys

Busbars & piping

Superinsulation

Cold supports

Thermal screen

Vacuum tank parts

Non busbar piping

Vacuum tank

Thermal screen

I beam

Plugs components

Current leads

Beam pipes system

Shuffling box

Busbars

Instrumentation

Subassemblies Modules assembly

Reception tests

DFB assembly Finalization & installation

Design & preparation

contractor at CERN

CERN

contractor at own premises

Legend

Transport

Installation

CL

mod

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Production & assembly scheme of a DFBA


DFB ProjectDevelopments for the DFB project

Lambda Plates

DFBM type vacuum shell

Thermal tests for chimneys

Tests of cold foot

DFBM cryo prototype Transport system for DFBAs


DFB ProjectPlanning


DFB ProjectSuperconducting Links

• What– Space constraints in the LHC tunnel, cost and

locally high risks associated with specific excavation works � adoption of the principle to employ superconducting power transmission lines (DSLs) in parts of the powering layout of the accelerator magnets.

– The DSLs are essentially comprised of cryogenic, vacuum insulated, transfer lines housing one or more superconducting cables. DC currents will be in the range of 120 A to 6000 A. Nominal operation temperatures will be from 4.5 K to 6 K for the part which houses the cable, and about 70 K for the heat shielding.

DSLProject


DFB Project

• Where– Five DSLs will be needed. One of them will be exceptionally long,

about 500 m in length without any intermediate branches. It willlink the 3 km long continuous cryostat of accelerator magnets ofArc 3-4 of the LHC to a current feed box located in UJ33 some 500 m away. Besides its power transmission function, the link will also need to provide the cryogens for this current feed box. An additional four, significantly shorter, links will be used at points 1 and 5 of the LHC machine to bring power from current feed boxes to individual magnet cryostats (Q6, Q5 and Q4D2). Each of those four links will be about 70 m in length with two intermediate branches, roughly 3 m in length, to individual magnet cryostats.

Superconducting Links DSLProject


DFB Project

Superconducting Links

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UJ 5 6 1

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UJ 5 6

P M5 6

UL5 6TU5 6

LHC PROJECT

N

Point 5UNDERGROUND WORKS

CMS

Point 6

Point 7

Point 8

LHC ‘B’ATLAS

Point 1Point 1.8

SPS

Point 2

Point 3.3

Point 3.2

Point 4

ST-CE/ljr18/09/2000

Existing Buildings

LHC Project Buildings

ALICE

DSLProject


DFB Project

Superconducting Links DSLProject

pt1 & pt5

DFBL plug

Radiation screen

6 K3 bar

5.5 K3 bar

:LHe subcooler

Connectionbox

DFBA

4.5 K3 bar

DFBL

~ 540 m

65 K19.4 bar

75 K18.8 bar

DFBL plug

DFBL

Current leads

Q6 Q5 Q4 D2interconnectionplug

5.5 K3.5 bar

interconnectionpluginterconnectionplug

Radiation screen

60 K19 bar

6 K3.5 bar

:LHe subcooler

SC cable

~20 m ~30 m ~20 m

4.5 K3.5 bar

6 K3.5 bar

6 K3.5 bar

pt3


DFB Project

DSLProject

Configuration of the DSLs

Branch of a DSLAPowering the DSLC



• When (time window for installation)

Before the magnets and DFBLs, avoiding QRL installation and commisioning

DSLA: IP1L, RR13-UJ13………………Jan 2005DSLE: IP5R, RR57-UJ57……………..April 2005DSLD: IP5L, RR53-UJ53……………...May 2005DSLB: IP1R, RR17-UJ17………..Nov-Dec 2005DSLC: IP3, UJ33, UP33 & R34….Jan-Feb 2006

DSLProject


DFB ProjectSuperconducting Links• How: transfer lines (DSLA,B,D,E)

DSLProject

SC link 30m model


DFB ProjectTunnel integration• How: transfer lines (DSLC routing tunnel->trench-> UP33->DFBL)

DSLProject



• Challenges

– Time• integration studies, interfaces, IT, December

finance committee

– Manufacturing• Quality of detailed design, and manufacturing

– In situ installation• Long cable lengths to be inserted in the DSLs

in the tunnel

DSLProject


DFB Project

Global approach of Cryomagnet powering

DFB when possible

DSL + DFB when impossible/inconvenient

Tunnel integration

• 3D integration studies

Situation: Technical solutions frozen, production of specification

Summary

DSL & DFB at pt3DFBA at pt8 right

CryoPower Project


DFB Project

Operations at CERN

Production of DFBs

Design input definitionFunctional spec., etc. Reference drawings Specification drawings

Layouts

detailed drawings Parts manufacturing

Raw materials

DFB Integration

Components Components

Transport to CERNIntegration of current

leads

End of productiontesting

Testing

Components

Assembly &integration

Subassemblies

Transport to tunnel Tunnel installation

CommissioningExternal supplier participation

Mostly CERN

Acceptance testing Tunnel testing

conceptual design of the cryogenic electrical feedboxes...

Documents