6th International Workshop on Cryogenics Operations Bernd Petersen DESY 6th International Workshop...

6th International Workshop on Cryogenics OperationsBernd Petersen DESY

6th International Workshop on Cryogenic

Operations

Bernd Petersen DESY MKS

presenting the work of many colleagues:

IFJ-PAN (Poland)

WUT(Poland),BINP(Russia),

Linde/Cofely and several DESY groups

Full cryogenic operation of AMTF

– the first year

XFEL WP10 Accelerator Module Test Facility

2Outline

AMTF - purpose & objectives (TDR) AMTF – layout AMTF- main cryogenic components Refrigerator availability Main cryo operation problems General safety requirements Cryogenic safety Safety of work organisation Some preliminary test results for XFEL cavities & modules (Preliminary) conclusions



3

AMTF: purpose & objectives (TDR)

- Complete cold performance test of all XFEL cryomodules before tunnel installation (RF, vacuum,cryo-losses)

103 cryomodules, rate: 1/week

- Cold RF test of all XFEL superconducting cavities before cryomodule assembly

824 cavities, rate 6/week

- Cold test of all superconducting magnet packages before cryomodule assembly

103 magnets, 1/week

- ( Assembly and tests of RF Waveguides (WP1) at Waveguide Assembly and Test Facility WATF)



4

Three test benches (XATB1, XATB2 and XATB3) for testing assembled modules and for high power tests of assembled cavities

Two test cryostats (XATC1 and XATC2) for RF performance tests of the cavities (One magnet test stand XMTS (located in the Magnet Test Hall Building 55) for testing

magnets)

AMTF layout (TDR)

84m x 48m



AMTF Hall - Cavity 5

Vertical Cryostat Radiation protection shielding Cavity preparation area

Cavity storage area Cavity incoming check area Clean room



AMTF Hall - Cryomodule 6

Unloading of the cryomodule after transport

Cryomodule preparation area Cryomodule test stand

Cryomodule test stand – module inside

Cryomodule test stand – front view



7XMTS: Test stand for sc XFEL Quadrupoles

Formal part of AMTF but installed and in operation since July 2008

Status November 2014:

96 (of 103) Quadrupols tested

For the development and series tests of superconducting magnet packages & current leads (in MTH-bldg 55)



8Cryogenic operation of AMTF

AMTF is supplied by the FLASH-Helium-Refrigerator (former refrigerator 42 of the HERA plant)

For the operation of the AMTF 3 KW at 40/80K, 0.5 KW at 4.5K and a peak liquifaction rate of 33 g/s

have to be delivered. The peak liquifaction is buffered by means of a 1oooo ltr liquid helium

storage dewar (XAST.)

Capacity limit:

return gas peak

screw compressor capacity during cool down/warm-up

2 dynamic procedures in parallel



9AMTF – cryogenics contributions

Red = WUT

Wroclaw University of Technology-> Kriosystem

Blue = DESY MKS

Acting for XFEL company

(no in-kind !) -> DEMACO

Green= BINP

Budker Institute Novosibirsk



10 AMTF components (utilities etc./DESY in-kind)

Pump station – completed in September 2010 Compressor station – completed in August 2010 Control building – completed in October 2010 Test Hall – erected in May 2010 Piping bridge – completed in October 2010

0 10m

Control building

Test hallCompressor station

Pump station

Piping bridge

Water towers

HERA Kälteanlage Halle



11Transfer line XATL1

The ~170m long DN400 transfer line XATL1 supplies the test stands with cryogenic power from HERA refrigerator. WUT/Poland in-kind.

Spec DESY: Short specification in August 2008 Full specification in August 2009 Commissioning August 2012

– in continuous operation since December 2012

DESY (in-kind):

Valve box for XATL1 at refrigerator



12Helium compressors (DESY in-kind)

2 sets of compressors for 2K operation at AMTF ( 2 x 20 g/s helium at 20 mbar)

1 set = 13 x parallel (WS 2001 RUVAC roots blower + SOGEVAC SV750B )

– simple, (robust), modular, redundant

SOGEVAC:

4 unscheduled repairs,

complete replacement of bearings & packing rings (all SOGEVAC)

RUVAC: 4 repairs,

complete exchange of bearings ongoing (all RUVAC)

No impact for AMTF operation

Very reliable service & support from manufacturer

In average: about 5000 h operation (status November 2014)


Manifacturer: Oerlikon Leybold

SOGEVAC

RUVAC


13 AMTF Vertical Cryostats

SPEC DESY

April 2009

Design & Construction

WUT&Kriosystem

Poland in-kind

Delivery & installation:

July 2012 – April 2013

Cavity Frame Design:

DESY FLA

6 inserts for AMTF

~Ø

Concrete cylinder 140mm thick

Vacuum vessel

Thermal shield

LHe vessel

Stainless steel ring 30mm thickConcrete floor

Soil

Warm magneticshields

PVC pipe DN200

Support

Concrete

~

A-A

The lowestradiation shield

Cold magneticshield (MHF-sl)

Cold magneticshield (MKS1)

Space for heaters

Vacuum lid Vacuum flange

max.Ø

3xM20

Ø

Ø

Ø

min

.

Water drain pipe DN100(PVC or stainless steel)

~Ø

~



14AMTF: 3 cryomodule test stands & cryostat adapters

Spec DESY (February 2010)

Design, Construction, Installation: BINP in-kindFirst test stand delivered & installed May 2013 (cold commissioning July 2013)

Cold commissioning of 3rd test stand December 2013

2 cryostat adapters for the test of single dressed cavities at AMTF



15XAST,XAVB, XAVB

L Helium Dewar XAST Valve Box XAVBSub Cooler Box XASB

DESY is acting for the XFEL company

Manufacturer: DEMACO NL


Wessington Cryogenics Ltd UK


Cool down and Warm up16

XATC1, XATC2Pump and purge manualCool-down to 4K, liquid helium transferand warm-up process automatized by use of SNL scriptsPump-down to 2K manual

XATB1, XATB2, XATB3•Pump and purge manual•Complete cool-down and warm-up process performed manually by cryo-operators

Cool-down to

100K

Liquid helium

transfer to the cryostat

Pump-down to 2K

Warm-up to 300K

Liquid helium

transfer from the cryostat

Pressure rise to 1 Bar

Pump and purge

Measurement at 2K

Cool-down to

70K

Cool-down to 4K, helium liquefaction

Pump-down to 2K

Warm-up to 300K

Liquid helium

evaporation

Pressure rise to 1

Bar

Pump and purge

Measurement at 2K

Cryogenics operation sequence for vertical cryostat

Cryogenics operation sequence for cryomodule test stand



Vertical Cryostats Operation Cycles17

Example: July 2014 -> September 2014

About 180 cycles since start of AMTF operation in 2013

Courtesy of

J.Zajac Linde/Cofely



XFEL Cryomodule tests operation Cycles18

About 20 cycles since September 2013 (now 13th XFEL cryomodule under test)

Courtesy of




Refrigerator Avialability 201319

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CRYOGENIC PLANT OPERATION 2013

Availability 2013 = 98,80%

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Refrigerator Avialability 201420

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CRYOGENIC PLANT OPERATION 2014

Availability 2014 = 98,4%

02.11.2014

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Main Cryo Operation Problems in AMTF21

Mixing of serial tests with installation work and commissioning

Problems with warm 2K helium compressors (see transparency) Mixing of warm&cold gas for controlled cool-down/warm upLHe level measurements affected by electrical heaters 2K supply JT-valve in module test stand 3 (XATB3) out of shape Misalignment of process tube flanges (feed-caps) -> adapters‚Digital‘ operation of valve positioners -> change type of positioners Thermal contact of electrical heaters -> use of ‚CMTB-type‘ heaters Liquid level measurements -> increase current Mix-up of thermometers (calibration) -> try to sort, some re-

calibration


-> Several problems with well known and ‚mature‘ components !


Cryogenic safety22

no general risk of oxygen deficiency within the AMTF hall (about 50 000 m3 volume) oxygen deficiency monitors in each module test stand radiation protection cave design of helium safety valves and venting systems according to our cryomodule ‚crash-tests‘ on CMTB or – on default- according to ‚Lehmann-Zahn‘ values 5K and 40/80K helium release systems separated from 2K release systems (20 bar vs. 4 bar) all safety valves vent into helium volumes – venting to atmosphere outside the hall


Oxygen monitor


23AMTF: general design & safety requirements

EU/German law ‚Betriebssicherheitsverordnung‘ DESY safety rules Rules&procedures for buildings & utilities General safety & radiation safety rules Pressure vessels: PED (AD2000,EU harmonized code)

This means in advance of technical commissioning: Third party interlock approvals PVI(=appoval before operation) by third party

(the complete procedure took several months for AMTF) … (list is not complete)



AMTF safety at work - organisation 24

Safety officers for different working areas Electronic access control for AMTF (‚DACHS‘) Safety instructions checked by electronic access control (general safety, cryogenic safety, radiation safety)


‚DACHS‘

electronic access control


25

Analysis of vertical acceptance tests includes Series Cavities + “ILC HiGrade”-Cavities NO infrastructure commissioning tests

So far delivered: 488 cavities (status November 2014) Total RF tested: 450 cavities

Vertical acceptance tests

Average:> 9 tests per weeksince Oct 2013 (full operation of AMTF)

Manufacturer 1

Manufacturer 2

Status of plot: July 2014

Courtesy of

J.Swierblewski IFJ-PAN details see LINAC 2014



Yield of usable and maximum gradient of 339 cavities “as received”

Yield of gradients: “As received” 26

Average maximum gradient:

(30.4 ± 7.6) MV/mM1: (28.4 ± 7.1) MV/mM2: (32.4 ± 7.6) MV/m

Average usable gradient:

(26.6 ± 7.6) MV/mM1: (24.8 ± 7.0) MV/mM2: (28.6 ± 7.9) MV/m

given errors are standard deviation

M1

M2

M1

M2

Courtesy of




Summary of preliminary module results 27

average max. gradient

module[MV/m]

average max. gradient

vertical[MV/m]

Average operational

gradientmodule[MV/m]

Average usable gradient

vertical[MV/m]

XM-2 27.2 28.1 24.5 26.5

XM-1 28.2 30.8 25.1 29.4

XM1 30.3 32.5 27.6 29

XM2 27.7 32.7 25.5 28.6

XM3 30.4 32.0 28.8 29.3

XM4 28.6 33.3 23.8 30.5

XM5 27.8 28.9 24.9 26.9

All results above XFEL specs. 23.6 MV/m

Status November 2014: XM13 is under test, 18 modules at DESY

Courtesy of




28 Some (preliminary) conclusions

Deliveries & installation of XATCs,XATB,XAVB,XATL

were ‚just-in-time‘ for start-up of cavity production Deliveries & installation of XATBs

were ‚just-in-time‘ for start-up of cryomodule production No dedicated de-bugging of cryo-supply (and other systems) XATCs design capacities demonstrated Complexity of XATBs commissioning underestimated General effort for installation & commissioning underestimated To be demonstrated: 1 cryomodule test/week So far: in budget and almost ‚in time‘ (not ‚on schedule‘)

Thank you for your attention !


6th International Workshop on Cryogenics Operations Bernd Petersen DESY 6th International Workshop...

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