Cryo AIP

Muon Campus AIP Review

Arkadiy Klebaner

January 23, 2012

Scope

• Compressor system• Refrigeration system• Cryogenic storage and inventory management• Muon g-2 cryogenic distribution system• Mu2e cryogenic distribution system• Auxiliary systems

2

Design Options1. Procure new refrigerators and compressors2. Procure new refrigerators and reuse Tevatron

compressors3. Reuse Tevatron compressors and refrigerators

a) F0 or b) A0 compressor building

Value Engineering Option “3b” is chosen

3

Functional Requirements

• Detailed requirements are listed in the “ Muon Campus Cryogenics: Functional Requirements Specification” document #4248 in DocDb, initial release October 2, 2012

https://beamdocs.fnal.gov/AD-private/DocDB/ShowDocument?docid=4248

• The document is agreed upon and signed by both experiments and management

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Key Requirements• The Cryogenic System shall support

simultaneous steady state operation of both experiments, Muon g-2 and Mu2e. It shall provide for independent operation of the two experiments, including transient modes, e.g. warm-up, cooldown, etc.

• It should be possible to connect and/or isolate Mu2e magnets from the transfer line while under cold conditions

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Cryogenic loads:• Muon g-2

– Liquefaction load – 1.4 [g/sec]– Refrigeration load – 300 [W]– LN2 Shield flow rate – 1.6 [g/sec]

• Mu2e– Liquefaction load – 0.8 [g/sec]– Refrigeration load – 350 [W]– LN2 Shield flow rate – 20 [g/sec]

Key Requirements (cont.)

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0 1 2 3 4 5 6 7 8 90

200

400

600

800

1,000

1,200

1,400

Two Tevatron Satellite Refrigerators Operating Field

Liquefaction, [g/sec]

Ref

riger

atio

n, [W

atts

]

Theoretical Two Plants Capacity

Delivered Capacity

7

0 1 2 3 4 5 6 7 8 90

200

400

600

800

1,000

1,200

1,400

Mu2e

Two Tevatron Satellite Refrigerators Operating Field

Liquefaction, [g/sec]

Ref

riger

atio

n, [W

atts

]

Theoretical Two Plants Capacity

Delivered Capacity

8

0 1 2 3 4 5 6 7 8 90

200

400

600

800

1,000

1,200

1,400

Mu2eg-2

Two Tevatron Satellite Refrigerators Operating Field

Liquefaction, [g/sec]

Ref

riger

atio

n, [W

atts

]

Theoretical Two Plants Capacity

Delivered Capacity

Theoretical Two Plants Capacity

Delivered Capacity

Theoretical Two Plants Capacity

Delivered Capacity

9

0 1 2 3 4 5 6 7 8 90

200

400

600

800

1,000

1,200

1,400

Mu2eg-2

Two Tevatron Satellite Refrigerators Operating Field

Liquefaction, [g/sec]

Ref

riger

atio

n, [W

atts

]

Theoretical Two Plants Capacity

Delivered Capacity

Theoretical Two Plants Capacity

Delivered Capacity

Theoretical Two Plants Capacity

Delivered Capacity

Single RefrigeratorDelivered Capacity

10

0 1 2 3 4 5 6 7 8 90

200

400

600

800

1,000

1,200

1,400

Mu2eg-2

Two Tevatron Satellite Refrigerators Operating Field

Liquefaction, [g/sec]

Ref

riger

atio

n, [W

atts

]

Theoretical Two Plants Capacity

Delivered Capacity

Theoretical Two Plants Capacity

Delivered Capacity

Theoretical Two Plants Capacity

Delivered Capacity

Single RefrigeratorDelivered Capacity

Uncertainty factor = 1.5

Uncertainty factor covers underestimated heat load that is result of unknown heat leaks during components assembly or simply overlooked heat sources during design phase.

11

0 1 2 3 4 5 6 7 8 90

200

400

600

800

1,000

1,200

1,400

Mu2eg-2

Two Tevatron Satellite Refrigerators Operating Field

Liquefaction, [g/sec]

Ref

riger

atio

n, [W

atts

]

Theoretical Two Plants Capacity

Delivered Capacity

Theoretical Two Plants Capacity

Delivered Capacity

Theoretical Two Plants Capacity

Delivered Capacity

Overcapacity factor covers degradation of system top performance capacity due to a variety of factors including contamination, components wear and tear, etc.

Single RefrigeratorDelivered Capacity

Uncertainty + Overcapacity factor = 2.0

12

0 1 2 3 4 5 6 7 8 90

200

400

600

800

1,000

1,200

1,400

Mu2eg-2

Two Tevatron Satellite Refrigerators Operating Field

Liquefaction, [g/sec]

Ref

riger

atio

n, [W

atts

]

Theoretical Two Plants Capacity

Delivered Capacity

Theoretical Two Plants Capacity

Delivered Capacity

Theoretical Two Plants Capacity

Delivered Capacity

Single RefrigeratorDelivered Capacity

mar

gin

Uncertainty + Overcapacity factor = 2.0

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Current Design Concept

• Reuse TeV compressors and heat exchangers– A0 compressors– Four (4) Satellite refrigerators

• Two dedicated refrigerators per experiment

• Reuse TeV valve boxes, transfer lines, expansion boxes, dewars, storage tanks, etc.

• Positive isolation for Mu2e and hard connection to g-2

• New controls (hardware)

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15

Compressor system• A0 compressors (four skids)

• Each skid consists of the following:• Two-stage oil injected screw compressor• 300 kW motor• 60 g/s capacity• Compression from 1 atm to 20 atm• Slide valve for capacity control• 6 kW oil pump• Oil cooler heat exchanger• Aftercooler heat exchanger• Oil separator• Oil removal system• Entire system is contained on a single,

fabricated steel base skid, oil removal on separate skidTwo-stage compound oil flooded

screw compressor Mycom 2016C

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Slide 17

Helically grooved rotorsMycom 2016C Two-Stage

Compressor system (cont.)

Slide 18

Four skidsConsists of:• Oil Separator (located on compr skid)• Oil Coalescers (3 stages)• Charcoal Adsorber

• Removes oil vapor• Molecular Sieve

• Removes water vapor• Final Filter

• Contains 1 micron filter element

Oil Removal System

Slide 19

Heat Exchanger• 35 ft. long heat exchanger• Consists of four heat exchangers housed in a single cryostat• Nitrogen precooling• U-tube connections for high pressure, low pressure helium and gas expander

Slide 20

Refrigerator Valve Box

• Connects all refrigerator components together using u-tubes• Provides positive isolation between different components by removing u-tubes• Distributes cryogens to and from load and includes necessary control valves• Contains 130 liter subcooling dewar

Slide 21

Expansion Engines

• Two engine types• Liquid “wet” expansion engine• 30K gas “dry” expansion engine• 3 in and 2 in piston sizes• 2 hp and 7.5 hp respectively

Slide 22

Gas Storage• Two gas storage consists of 30,000 gal nominal capacity storage

tanks• Overall length of 66 ft with an outside diameter of 9 ft

Nitrogen Tank

• 15,000 gal• MAWP 150 psig• 10' outside diameter• 30' tall• 65,000 # empty

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Controls

24

Piping headers

Towards A0 25

Mu2e Connection

26

Refrigerator room

27

Refrigerator room (cont.)

28

Refrigerator room (cont.)

29

Refrigerator room (cont.)

30

Refrigerator room (cont.)

31

Transfer line

32

Transfer line (cont.)

33

Transfer line (cont.)

34

Gas Management Panel

35

Slide 36

Plant and g-2

g-2 cryo distribution

CY 2017CY 2015CY 2014CY 2013 CY 2016

Compressors

g-2

Mu2e distribution

Mu2e cryo distribution

Mu2e

Refrigerators

g-2

Refurbishment and installationProcurement and installation CooldownEngineering and design

Project Plan: Timeline

Project funds available Building beneficial occupancy

$ $

MC-1 Mu2e

$ $ $

Project Plan

Baseline Costs

WBS Name Base cost

with escalation

Contingency Indirect costs Total

1 Muon Campus Cryogenics - AIP $5,356,750 $1,905,238 $2,519,607 $9,781,595 1.01 Interface milestones - - - - 1.02 Project management $166,614 $81,799 $160,582 $408,996 1.03 System engineering $77,967 $38,278 $75,145 $191,390 1.04 Cryogenic plant sub systems $2,353,671 $836,530 $1,082,744 $4,272,945 1.05 Experiment interfaces $2,589,448 $865,635 $1,038,206 $4,493,289 1.06 Safety documents $93,061 $45,688 $89,692 $228,442 1.07 Commissioning $75,989 $37,307 $73,238 $186,533

TPC ~ $9.8M

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Basis of Estimate• Basis of estimates for key project elements are

completed• Prior experience is dominant costing method

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Escalation and Contingency

• Escalation– M&S= 2.7% /year – SWF= 2.7 % /year

• Contingency– Average 25%– Exception on items similar to the currently

procured for other projects. The smallest contingency is 20%.

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Funding Profile FY13 FY14 FY15 FY16 FY17 Total Labor

SWF base escalated $230,492 $967,862 $231,222 $330,566 $95,613 $1,855,756 SWF indirect costs $222,148 $932,826 $222,852 $318,600 $92,152 $1,788,577 Subtotal $452,640 $1,900,688 $454,074 $649,166 $187,764 $3,644,333 SWF Contingency $113,160 $475,172 $113,519 $162,292 $46,941 $911,083 Total $565,801 $2,375,860 $567,593 $811,458 $234,706 $4,555,416 M&S

M&S base escalated $334,000 $1,853,158 $0 $1,154,855 $158,981 $3,500,994 M&S indirect cost $68,103 $417,122 $0 $213,388 $32,416 $731,029 Subtotal $402,103 $2,270,280 $0 $1,368,243 $191,397 $4,232,023 M&S Contingency $77,953 $567,570 $0 $300,783 $47,849 $994,155

Total $480,055 $2,837,850 $0 $1,669,026 $239,247 $5,226,178 Total

SWF+M&S base esc $564,492 $2,821,020 $231,222 $1,485,421 $254,594 $5,356,750 SWF+M&S Indirects $290,251 $1,349,948 $222,852 $531,988 $124,568 $2,519,607 Subtotal $854,743 $4,170,968 $454,074 $2,017,410 $379,162 $7,876,356 SWF+M&S contingency $191,113 $1,042,742 $113,519 $463,074 $94,790 $1,905,238 Total $1,045,856 $5,213,710 $567,593 $2,480,484 $473,952 $9,781,594

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FY13 FY14 FY15 FY16 FY17 Total

Cryo Engineer 0.18 1.20 0.73 0.46 2.57 Cryo Tech 0.95 0.16 0.27 0.19 1.57 Designer and drafter 0.40 0.27 0.16 0.64 1.47 Electrical Engineer 0.26 0.77 0.09 0.38 1.51 Electrical Tech 0.54 1.51 0.16 1.05 0.07 3.33 Mechanical Task Manager 1.92 1.92 Mechanical Tech 0.45 2.06 2.93 0.61 6.06 Project Manager 0.15 0.19 0.20 0.20 0.11 0.85

Total FTEs 1.99 8.87 1.51 5.94 0.98

Labor by Categories

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FY 13 M&S• Long lead items procurement• Removing equipment and refurbishing TeV equipment (1

FTE)• Engineering &Design (1 FTE)

WBS Name FY13 1 Muon Campus Cryogenics - AIP $ 334,000 1.04 Cryogenic plant sub systems $ 334,000 1.04.04 Refrigerator system $ 334,000 1.04.04.02 Heat exchangers $ 60,000 1.04.04.04 Engines $ 85,000 1.04.04.09 Controls $ 159,000 1.04.04.10 Distribution system $ 30,000

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FY14 M&S

• Installing TeV equipment• Running headers from A0• Connecting to g-2• Cooling down g-2

WBS Name FY14 1 Muon Campus Cryogenics - AIP $ 1,853,158

1.04 Cryogenic plant sub systems $ 1,278,038 1.04.01 LN2 system $ 184,860 1.04.02 Gas management system $ 62,583 1.04.03 ODH system $ 10,270 1.04.04 Refrigerator system $ 640,335 1.04.05 Compressor System $ 379,990

1.05 Experiment interfaces $ 575,120 1.05.01 Interconnect electrical & controls $ 10,270 1.05.02 Interconnect piping $ 462,150 1.05.04 g-2 interface connection $ 102,700

9 FTE

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FY15

• No M&S• Mu2e E&D work (1.5 FTE)• Will need g-2 operational funds

44

FY16

• Procuring Mu2e transferline components• Refurbishing and installing TeV transferline,

expansion box and headers• Refurbishing and installing AP10 bayonet can

WBS Name FY16 1 Muon Campus Cryogenics - AIP $ 1,154,855

1.05 Experiment interfaces $ 1,154,855 1.05.03 Mu2e interface connection $ 1,154,855 1.05.03.01 Mu2e interface connection Cooldown return $ 118,070 1.05.03.02 Mu2e interface connection Distribution box $ 704,087 1.05.03.03 Mu2e interface connection Expansion box $ 54,161 1.05.03.04 Mu2e interface connection Transfer line w/expansion joints $ 224,378 1.05.03.05 Mu2e interface connection Bayonet cans $ 54,161

5.94 FTE

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FY17

• Connecting Mu2e• Cooling down Mu2e

WBS Name FY17 1 Muon Campus Cryogenics - AIP $ 158,981

1.05 Experiment interfaces $ 158,981 1.05.03 Mu2e interface connection $ 158,981 1.05.03.04 Mu2e interface connection Transfer line w/expansion joints $ 158,981

0.8 FTE

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Milestones

MILESTONE DEFINITION BASELINE

Start Project Directive signed, funding available Month 0

Basic engineering is completed System detailed engineering is complete, installation

drawings and specifications are finished

Month 14

Begin refrigerator building installation Refrigerator building and A0 to MC1 piping support

beneficial occupancy

Month 14

Compressor system is ready All compressors are refurbished Month 19

Refrigeration system commissioned Heat exchangers, expanders, gas management system,

storage are installed

Month 22

Muon g-2 acceptance tests The Muon g-2 distribution system is cold Month 22

Mu2e acceptance tests The Mu2e distribution system is cold Month 57

Project Complete Project Closed Month 58

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Thank you!

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