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.