october, 2009 cryogenics system roberto than october, 2009 internal review
TRANSCRIPT
October, 2009
Cryogenics System
Roberto Than
October, 2009
Internal Review
October, 2009
Cryogenics System
• Cavity cooling: 1.9K @ cavities 1.8K @ HX / cold compressor bath Quiet System: Vibration & microphonics Heat transfer: SFTC or local evaporation
Quad cooling: 1.8K: Leads: HTS with shield flow as lead flow 4.5K: Leads: Normal leads.
• Sub-atmospheric system type/configuration
•Hybrid: Cold compression/ warm compression
•100% cold compression• New 4.5K plant @ 2 O’clock; Existing RHIC plant (1005) for Collider
• Use existing RHIC Plant for MeRHIC & RHIC
• New plant for both RHIC and MeRHIC
October, 2009
3
Cryogenics System
SUPERFLUID HEAT TRANSFER:– SFT Conduction via pressurized superfluid
Heat exchanger every 3 cavities ~ 8 inch Superfluid line 8 inch 12 Torr Vapor return line outside cryostat
– 2- flow boiling (LHC) heat transfer from pressurized superfluid Continuous heat exchanger / two-phase flow / vapor return
– Saturation Line central vapor recondensing unit per 6 cavities
October, 2009
Cryogenics System
LOADS DUTY carnot Wcarnot POWER
1.8K REF 5500 W 0.18 0.9 5 MW
SHIELD, 20K 3000 W 0.23 0.06 0.3 MW
LIQUEFACTION 12 g/s 0.23 0.08 0.4 MW
5.7 MW
LOADS DUTY5-cell CAVITY 1.8 K 5000 W
SHIELD 19-20 K 3000 W
FPC’s LIQ 10 g/s
QUAD LEADS LIQ 2 g/s
QUADS 1.8 or 4.5K ~ 140 W
October, 2009
Cryogenics System-EXISTING RHIC PLANT
LIFE CYCLE ISSUES
Constructed in 1982-1985
15 MW compressors
4600 g/s flow
Oil bearing turbo-expanders
2 Redundant Trains
2 x 6 expanders (T1-T6)
Phase 3 upgrade (2006-07)
Added new JT-loop gas bearing expander T7
+ new cold end HX’s
• Compressor bodies regular overhaul
• Life cycle issues– Motors (600 HP, 2200HP)– Oil cooler / aftercooler
heatexchangers– MCC / Breakers
• Main Cooling Towers,qty 6– (15 MW)
• Liquid helium storage • Gas storage
October, 2009
Cryogenics System
EXISTING PLANT BURDENED with Contingency
SUB ATMOSPHERIC SYSTEM @ 1002 26M
RHIC PLANT UPGRADE @ 1005 8 M
RHIC PLANT LIFE CYCLE ISSUES 8 MNEW 4.5K PLANT BURDENED with
Contingency SUB ATMOSPEHRIC SYSTEM @ 1002 26 M
NEW PLANT @ 1002 39 M
NEW PLANT @ 1005 for RHIC 26 M
October, 2009
Estimate by phase with contingency
WBS 1.2Cryogenics
Direct Labor
Direct Material
Contingency $
Contingency %
Total Direct dollars
Burdened Labor
Burdened Material
Contingency $ Burdened
Total Burdened
dollars
PED/EDIA 1,564 200 670 38% 2,435 2,262 231 947 3,440
Construction 1,278 35,860 14,484 39% 51,621 1,541 37,357 15,170 54,068
Installation 4,103 700 1,873 39% 6,676 4,662 807 2,133 7,601
Total 6,945 36,760 17,027 39% 60,732 8,466 38,394 18,250 65,110
with New PlantFY09 Direct K dollars FY09 Burdened K dollars
WBS 1.2Cryogenics
Direct Labor
Direct Material
Contingency $
Contingency %
Total Direct dollars
Burdened Labor
Burdened Material
Contingency $ Burdened
Total Burdened
dollars
PED/EDIA 1,262 200 555 38% 2,017 1,825 227 780 2,832
Construction 1,169 14,260 6,017 39% 21,446 1,383 15,251 6,488 23,122
Installation 4,775 700 2,135 39% 7,611 5,302 796 2,378 8,476
Total 7,205 15,160 8,708 39% 31,073 8,510 16,274 9,645 34,430
FY09 Direct K dollars FY09 Burdened K dollarswith Existing Plant
October, 2009
Labor hours, FTEs, $
WBS 1.2Cryogenics
total hours
Building Trades
StandardCentral Shops Designer Engineer
Direct dollars
Burdened dollars
PED/EDIA 23,100 0 0 12,000 11,100 1,564 2,262
Construction 14,700 5,000 4,000 3,300 2,400 1,278 1,541
Installation 41,800 28,000 12,000 1,200 600 4,103 4,662
Total 79,600 33,000 16,000 16,500 14,100 6,945 8,466FTEs 45.2 18.8 9.1 9.4 8.0
with New Plant Labor (FY09$K) no contingencyHours estimated
WBS 1.2Cryogenics
total hours
Building Trades
StandardCentral Shops Designer Engineer
Direct dollars
Burdened dollars
PED/EDIA 18,500 0 0 9,000 9,500 1,262 1,825
Construction 13,000 5,000 4,000 2,000 2,000 1,169 1,383
Installation 48,400 31,100 16,000 1,000 300 4,775 5,302
Total 79,900 36,100 20,000 12,000 11,800 7,205 8,510FTEs 45.4 20.5 11.4 6.8 6.7
Labor (FY09$K) no contingencyHours estimated
with Existing Plant
October, 2009
Estimated Material $
WBS 1.2Cryogenics
Purchases<$25K
Purchases >$25K< $600K
Purchases > $600K Travel Total
FY09 Burdened K dollars
PED/EDIA - 200 - - 200 231
Construction - 29,310 6,550 - 35,860 37,357
Installation - 700 - - 700 807
Total Dollars 0 30,210 6,550 0 36,760 38,394
FY09 Direct K dollarswith New Plant
WBS 1.2Cryogenics
Purchases<$25K
Purchases >$25K< $600K
Purchases > $600K Travel Total
FY09 Burdened K dollars
PED/EDIA - 200 - - 200 227
Construction - 4,910 9,350 - 14,260 15,251
Installation - 700 - - 700 796
Total Dollars 0 5,810 9,350 0 15,160 16,274
with existing PlantFY09 Direct K dollars
October, 2009
BACKUP MATERIAL
10
October, 2009
11
Cryogenics System
MeRHIC5500 W@ 1.8K
10 g/s LIQ3000 W Shield
• SUPERFLUID SYSTEMS
1
10
100
1000
10000
1.6 1.7 1.8 1.9 2 2.1
Temperature [K]
Ca
pa
cit
y [
W]
WARM COMPRESSION
HYBRID COMPRESSION
COLD COMPRESSION
1/8 of LHC (sector)
TORASUPRA
ELBE Rossendorf
NHMFLMTF
A0
M e R H I C TJNL CEBAF
SNS
E R L
Stanford
October, 2009
12
SUB-ATMOSPHERIC SYSTEM
4
100% COLD COMPRESSION2K 4600 W Thomas Jefferson National Lab 2K 2400 W Spallation Neutron Source
HYBRID COMPRESSION1.8K 2400 W LHC –CERN1.8K 5000 W BNL MeRHIC
SUBATMOSPHERICSYSTEM
4.5Kplant
4.5Kplant
SUBATMOSPHERICSYSTEM
October, 2009
13
SUB-ATMOSPHERIC SYSTEM
4
SHIELD
FPC INTERCEPT
4.5KPLANT
LN2
October, 2009
14
Cryogenics System.2
• LOADING 4.5K PLANT & SUB-ATMOSPHERIC SYSTEM RHIC RHIC RHIC MeRHIC MeRHIC MeRHIC
REF LIQ SHIELD LOAD LIQSUBATM-
WARM
LOAD W 7735 25074 29908
T K 4.5 4.5 45 4.5 4.5 300
P atm 4 4 14 4 4 0.5
Ex J/g 1043.1 1043.1 4610 1043 1043 8334
T K 4.5 300 85 19 300 300
P atm 1.28 1 9 1.3 1 9
Ex J/g 2395.5 7901.8 5681.0 4888.3 7901.8 6530.2
REF LIQ SHIELD COLDCOMP LIQ VACCOMP
Ex J/g 1352.4 6858.7 1071.0 3845.2 6858.7 1803.6
flow g/s 420 44 120 296 12 296
Wcarnot MW 0.568 0.302 0.129 1.138 0.082 0.534
carnot 0.225 0.225 0.225 0.225 0.225 0.450
Wactual MW 2.52 1.34 0.57 5.06 0.37 1.19 10.68
October, 2009
15
Cryogenics System
• System Level Design:• 1.8K system
– 1.8K SUB-ATMOSPHERIC SYSTEM Cold compressors single point failure
– Redundant train– On shelf spare
– Cryogenic distribution system / Superfluid heatexchangers
• Interface / Integration to 4.5K Plant– Return lines to RHIC Collider cryolines– Integration with RHIC main cryo plant– RHIC main cryo plant upgrade
October, 2009
16
Cryogenics System
• RHIC CRYO PLANT UPGRADE:
– Rotoflow Expanders 5/6 to gas bearing expander
– Cold (<10K) Heatexchanger stack HX-21-24 upgrade (Phase 3 HX’S too small)
– JT-Expander T7 upgrade / or 2nd JT-expander configuration
– Tee-in for 20K return flow from 2 O’Clock CR/ U lines.