sphenix infrastructure and facility upgrade · 17+ years in cryogenics group, 35+ years experience...

Director’s Cost, Schedule and Status Review of thesPHENIX Infrastructure and Facility Upgrade

SC-Magnet Cryogenics

Paul Orfin

Oct 16-17, 2019

BNL

Oct 16-17, 2019 Director's Cost, Schedule and Status Review 1

PRESENTATION OVERVIEW• Main Presentation– WBS breakdown

– Project Team & Collaborators

– Recap of SC Solenoid & SC bus extension to accommodate Detector

– Technical Overview: Cryo system Layout Systems components

– Technical Challenges

– Schedule

– Cost

– Status and Highlights

– Issues and Concerns

– Summary


• Additional Backup Material

divided in Subsections– Piping and Instrumentation Diagrams

– Technical summary for each subsystem section

– ES&H and QA section

– Recommendation section

– Important Technical issues section

– Cost section

– Past reviews section

– Piping and Instrumentation section

– Model views section

2.02.03 Magnet Cryogenic Systems• WBS: 2.02 SC Magnet

• 2.02.03 Magnet Cryogenic Systems

• 2.02.03.01 Helium System: 1008B Cold box, Transfer lines, & 1008 IR Cold box

• 2.02.03.02 LN2 Supply Transfer Line System

• 2.02.03.03 Warm Piping System

• 2.02.03.04 Cryo Controls Hardware

• 2.02.03.05 Cryo Controls Software

The Cryogenic system under MOU arrangement with Collider Accelerator Department to supply a completed installed and operational system for the SC solenoid.

The CAD Cryogenics Group is responsible for engineering and design, procurement, installation of cryo equipment, and electrical and controls system for it, plus controls interfacing with: Magnet quench detection / power supply system; RHIC-MCR and SPHENIX control room; commissioning and operation of the cryogenic system for the sPHENIX Superconducting Solenoid.

3Oct 16-17, 2019 Director's Cost, Schedule and Status Review

4

Technical Overview: SC-Solenoid with existing valvebox

Oct 16-17, 2019 Director's Cost, Schedule and Status Review

Coil return helium cools exiting leads

Flexible (laminated copper) connections to accommodate thermal contraction

SC Bus/Crylines extensionSolenoid Valve box &

5 kA Current leads

Re-use Existing solenoid valve box with vapor cooled leadsCooling method: Forced Flow: 7 g/s back return separator“SC buss and cryoline extension” tested for the full current/field in bldg. 912 cryo test facility

SC Splice joint verticalHelium Vertical loop up/down

Cryogenic jumper lines to Solenoid Valve BoxCryogenic jumper lines between West

Wall and IP8 ColdBox/Platform Cryogenic jumper lines from RHIC Cryo & 1008B coldbox

5 Segment multiline cryo transferline system

IP8 Coldbox

LN2 Supply

Technical Overview: Layout


West Wall spool segment

System Components


Helium System: Transfer lines & Cold boxes

RHIC interconnects– S-Line interconnect - Vacuum Jacketed spool – 1”– H-Line interconnect - Vacuum Jacketed spool – 1”– U-Line interconnect - Vacuum Jacketed spool – 1”– Field joint closures and couplers

1008B Service building Cold box– Control valves, reliefs, instrumentation– Heater Port with electric heater bundle – Venturi Flow meter– Thermal Shield

Multiple line transfer line spools – (Cryo-duct)– 5 Segments– Field joint closures and couplers– West wall Manifold transition to bayonets

Jumpers from manifold to IP8 Valve Box– S-Line Vacuum Jacketed Jumper with Bayonets– R-Line Vacuum Jacketed Jumper with Bayonets– Shield Return-Line Vacuum Jacketed Jumper with Bayonets– LN2 Vent Vacuum Jacketed Jumper

1008 IR Cold Box– Heater Port with electric heater bundle [Electric heater by BNL]– Liquid helium storage, 400L– Liquid Nitrogen heat exchangers [Providing a baseline design]– LN2 Supply male bayonet– Cryogenic Control valves– Bayonetted jumper interfaces

Jumper lines to Solenoid Valve Box– S-Line Vacuum Jacketed Spool with field joints

– Field joint closures and couplers– R-Line Vacuum Jacketed Spool with Bayonets– Shield Return-Line Vacuum Jacketed Spool with Bayonets– Warm gas line

LN2 supply line system from 6000 Gal Storage DewarTie-in Interface into LN2 Dewar liquid linePressure control valve, relief valves and instrumentationMulti segment spools, into the IP8 HallJumper transfer line into IP8 Cold box

Warm Piping systemReturn line from return flow of the vapor cooled current leadsQuench dump line to outside of buildingVacuum jacketed GN2 vent line to outside of building1008B Shield return line into RHIC cryo distribution WR Warm Return headerInstrument Air from 1008B Cryo Air system

CRYO CONTROLSCryo Controls Racks located in 1008BJunction Panel on platformBulkhead disconnect to disconnect cryo cables at junction panel

INSULATING VACUUMTurbo pump on solenoid valve box and Turbo on IP8 Cold boxRough pump off platform

Technical Challenges• Technical challenge: Minimize risk of losing cooling flow on vapor cooled current leads

– Differential Pressure budget across vapor cooled lead > sufficient

Difference between operation at BABAR/SLAC and Test in bldg. 912 versus RHIC IP8

IR8 no local plant: Return pressure for warm gas return is 1.2 bar instead of 1.05 bar

Solution: Operate 400L reservoir at 1.65 bar; Solenoid at 1.45 bar, Helium Temperature 4.65K

*Option approved by team to operate at slight higher temperature

• Revisit of radiation hardness of electronic components: see Radiation slide in backup material

– Components reviewed and deemed safe for radiation and magnetic environments

– Helium mass flow controllers for current leads cooling – move to 1008B service building

– Pressure Transducer may require a power cycle

– Fail last position controller – investigating impact; bench testing planned; move to 1008B


8

Subsystem Team & Collaborators

Oct 16-17, 2019 Director's Cost, Schedule and Status Review

• Key Personnel:

• Collider Accelerator Dept: Cryogenics Group

• Roberto Than: Cryo Group Head for 11 years. Cryogenic

Plant process engineer. 29 years cryogenics experience.

• Paul Orfin [Lead]: Project Engineer. 9+ years experience

with Cryogenics group

• Tom Tallerico: Group leader Cryo Controls/Instrumentation,

17+ years in Cryogenics group, 35+ years experience in controls and instrumentation.

• Brian Van Kuik: Cryo Instrumentation engineer. 10+ years

RHIC Main Control Room Operation Coordinator

– 4+ yrs PLC and HMI programmer for cryo controls for sPHENIX solenoid low/high power test

• Patrick Talty: Cryo Controls and Instrumentation engineer.

• 18+ years, PLC, SCADA, HMI control system engineer for cryogenic group

• Cryo Group: Mechanical and electrical technicians with

20+ years cryogenic equipment and cryogenic instrumentation experience

• Robert Meier: Senior Designer. 15+ years

designing for cryogenic group.

• Support and interface with:– Infrastructure sPHENIX

• Jim Mills– Facilities and Experimental Support Group; C-AD

• Brian Streckenbach– Electrical Power Distribution Group;

– C-AD : Communications and Electronic Support;

– C-AD Electrical Systems: Electrical Power Supplies Group;

• Carl Schultheiss– C-AD Controls systems: Front End Systems; C-AD Controls

systems: Access Controls;

– BNL Central shops: Welding support

Charge: Management: Is there a capable team in place to effectively manage the two projects as defined in the approved baselines for each? Does the management team have the resources and management tools necessary for the size and complexity of this overall effort?

Schedule /Schedule drivers

Director's Cost, Schedule and Status Review 9Oct 16-17, 2019

Helium System LN2 supply Warm Piping Controls/Instruments

Eng & Design, RFP pkg. 03/2019 1/2020 02/2020 present - 7/2020

Procure. Readiness Review Mar 11 2019

Procurement Bids 7/2019 – 9/2019 1/2020-2/2020 Order componentsManufacturing by Vendoror Order Materials

10/2019 – 2/202112 / 18 months

2/2020-10/20208 months

12/2019 – 6/2020 3/2020 – 6/2021Rack builds

RHIC RUN 20 12/2019 to 6/2020

Equipment Delivery Group-1 10/2020Group-2 3/2021

10/2020 6/2020

Install 1008B/Outside/West wall 9/2020-12/2020 10/2020-12/2020 9/2020-12/2020

RHIC RUN 21 12/2020 to 5/2021

Float for manufacturing 0 / 5 months 10 months In house In house

Late startInstall 1008B/Outside/Westwall

7/2021 - 3/2022 7/2021 - 3/2022 7/2021 - 3/2022 7/2021 - 3/2022

Schedule /Schedule drivers

April 9-11, 2019 sPHENIX Director's Review 10

Cost Drivers Cost Risk


Subsystem Material Cost $Estimate

Contingency Budget $ Actual

Cryo Transfer line system & Interface Cold boxes 1,100 K 30% 1,430 K 1,565 K

LN2 supply transfer line 233 K 30% 303 K Bid in 1/20-2/20

Warm Piping System [In-house by cryo staff and central shop welders]

65 K 30% 85 K Purchase components4/2020 to 4/2021

Controls Hardware 213 K 10% 225 K

TOTALS 1,524 K 1,981 K

Resource Hours Resource Hours

Cryo Eng 3900 Carpenter 160

Cryo control Eng 1800 Rigging 220

Designer 1800 Welder 720

Cryo Mechanical Techs 1200 Electrician 480

Cryo Electronic Techs 800 Surveyer 80

Cable puller 160

Cost Drivers/ Cost Risk• Cost Risks: 30% Contingency• CRYOGENIC EQUIPMENT MATERIAL COST

– HELIUM SUBSYSTEM: Contract award in a few weeks.

– LN2 SUPPLY LINES: Vendor ROM quotes

• Vendor 1: 90K for lines + 49K installation = 139K

• Vendor 2: $250/ft + add for interface/control valve at Dewar: 150K+50K: 200K

• Vendor 3: $250,000 ± 10%

– WARM PIPING SYSTEM:

– In house field assembly/welding:

– Purchase parts/components

– CONTROL SYSTEM HARDWARE:

– In house rack builds and assemblies

– Purchase parts/components


ES&H and Quality Assurance • ODH: 1008IR sPHENIX Detector Hall From NONE to ODH-0 classification

– Submit USI to the BNL Laboratory for cryogenic system addition and ODH change in IP8 for revision in the RHIC ASE/SAD.

• Helium subsystem and LN2 subsystem external procurement– ASME BPVC VIII Div-1

– Piping: ASME B31.3 piping code

• Warm piping and Installation work welding:– BNL central Shop welders: ASME Section IX welder cert.

– Piping: ASME B31.3 piping code: 5% radiograph, pressure test.

• Document control & Engineering change– CAD document control system Windchill


Status and Highlights• Helium subsystem:

– Bid process completed, vendor selected– Contract award in 2 weeks– Vendor manufacturing 10/2019 to 2/2021

• Group 1 : 10/2020• Group 2: 2/2021

• LN2 Supply subsystem:– Design: 10/2019 - 1/2020– SOW, Technical Specification, Layout

underway– Drawing package TBC– Request For Quote TBC– Out for bid: Jan/Feb 2020– Vendor manufacturing 2/2020 to 10/2020

• Warm Piping subsystem:– In-house: built to print– drawing package TBC Feb 2020 Mar 2020– Materials purchases Apr 2020 – into 2021

• Cryo Controls– Material purchases underway– Major equipment to be purchased:

• Electrical Control UL Panels for heaters• Cables

– Rack build:• To be started• Will be integrated with RHIC cryo controls Rack

upgrades of new PLC systems.

– Software logic:• To be started• Logic from 912 test ported/rewritten into new

PLC system• new logic for the IP8 cold box & 1008B cold

box



Status and Highlights:LN2 SUPPLY LINE LAYOUT

Recommendations

Oct 16-17, 2019 16Director's Cost, Schedule and Status Review

Review Item Solution, implementation, resolution Status

Dec 18, 2018 LESHC-PCSS/ Final Technical

Failure Mode Effect Analysis for the system to be carried out This will be carried prior PDR with vendor in the event any changes are to made to the system. Upcoming for November 2019

TBC


Submit USI to the BNL Laboratory ES&H Safety Committee for cryogenic system addition and ODH change in IP8 for revision in the RHIC ASE/SAD.

This item will be done by CAD ES&H Group TBC by CAD ES&H

Mar 112019 Procurement Readiness Review

Review radiation and magnetic field influence on equipment Radiation: Valve positioners for high radiation area, current lead cooling helium flow controllers option to move to 1008B service building.Magnetic field: Solenoid valve box valve and instrumentation no issues during bldg. 912 High power/Field test

√


Update of Specifications and SOW [for the helium system procurement] per comments from the review

The procurement for the Helium system is underway. Quotes received and a vendor has been selected. Contract award in a few weeks. √

Apr 9-11 2019 AL D Cost & Schedule Review

Add Risk to registry for magnet not meeting operating current performance for stability i.e. holding at full current for >24 hour was not demonstrated.

The probability of the magnet quenching after holding for 1 hour is low, but is registered as a risk.

√

*Closed Recommendations are in back up slides

Issues and Concerns:Risk Registry


1: Delay in support platform construction

2: Magnet temperature sensors too far to read: RETIREDNew signal conditioning boards: Tested 900 ft cable length

3: Vendor Delay in fabrication: 5 month float

RETIRED

SUMMARY and Looking ahead• THANK THE SUB-COMMITTEE FOR HELPING WITH THE

REVIEW!• Procurement of helium subsystem awarded

• FMEA analysis to be completed winter 2019

• Submit USI for reclassification of 1008IR to ODH-0 for approval to change the RHIC Accelerator Safety Envelope and Safety Assessment Document

• Complete design and start procurement for LN2 supply subsystem

• Complete design and start procurement warm piping subsystem

• Continue work on cryo controls hardware and software

• System is ready for baseline approval


Background & support material• Backup & Support Material

divided in Subsections– SCHEDULE

– Piping &Instrumentation Diagrams section

– Technical summary for each subsystem section

– ES&A and QA section

– Recommendation section

– Important Technical issues section

– Cost section

– Past review section

– Model views section


SCHEDULE


1008B Coldbox & RHIC Interconnects

April 9-11, 2019 Director's Cost, Schedule and Status Review 23

TECHNICAL OVERVIEW CRYOGENIC SYSTEM REQUIREMENTS

MODS/CONSTRAINST

I. Re-use Existing solenoid valvebox with vapor cooled leads

II. Added “SC buss and cryoline extension” : Tested at full current/field in bldg. 912 cryo test facility

III. Cooling method: Forced Flow: 7 g/s

[No thermo-syphon]

IV. Jumpers ±3” flex to allow final Cradle adjustment and fabrication tolerance


IMPLEMENTATIONa. Quench handling:• Downstream Pressure controlled to protect RHIC return line

operations. Excess will be handled by quench dump valve / Mechanical Relief valve.

b. Controlled cooldown/warmup• Heater system will be used to heat cold gas from RHIC to control

the supply temperaturec. 100K Hold during shutdown• LN2 supply with exchangers, helium circulation with a

compressor at 10 o’clock bldg. 1010B• LN2 supply from existing 6000 Gallon dewar

d. Vapor cooled current Leads DP budget• Operate solenoid higher bath pressure 1.45bar [and

temperature] and 400L reservoir at higher pressure, 1.65bare. Failure modes events

Magnet rampdown: Loss of 4.5K supply400 L local reservoir with heaterAllows slow ramp down

Loss of control signal/ pneumatic supply to valvesImplement Fail in Last position for critical valves [F.L.] to keep helium flowing

Radiation triggered electronics interruptionImplement radiation tolerant hardware: valve positioners, temperature sensors, pressure sensors

REQUIREMENTSa. Provide cooling from RHIC main

cryogenic systemi. Hold Magnet at (4.55K) 4.65K

[dictated by RHIC vapor return line pressure]

ii. Provide Current leads cooling flows; Ramp with current

iii. Provide Thermal Shield Flow

b. Controlled cooldown/warmup gradient of 40K or less

c. Cooldown time: approx. 7-10 days• Cooldown from 300K to 50K

occurs during the RHIC collider’s 4 weeks 45K cooldown wave using 45K, 4bar flow. Budget 10 g/s.

d. Handle Quenche. Hold magnet at approximately

100K during summer shutdownf. Permissive and interlocks control

for magnet protection: Fast and slow discharges

TECHNICAL OVERVIEW HELIUM CRYOGENIC SYSTEM

• 1008B Coldbox:▪ Manufactured ASME B31.3 Piping code

▪ 3 cryo interconnects to RHIC “BLUE” valvebox

▪ 7 Helium cryogenic valves:

▪ Venturi: with 2 DP ranges for cooldown flow and LHe flow monitoring

▪ Reliefs:

▪ Temperature sensors Silicon diodes DT-670

▪ Pressure sensors

▪ Instrumentation isolation valves:

▪ Thermal shield:

▪ Insulating vacuum: actively pumped by turbo vacuum pump

▪ Insulating vacuum vessel relief plate

▪ Electric Heater with overtempt protection

▪ Transferline system 5-spools▪ 3 line thermal shielded transfer line system

▪ 3 bayonetted Jumpers:


• IP8 Coldbox– 400L ASME VIII Div-1 reservoir:

• Removes the heat leak from the supply flow from RHIC cryo distribution

• Provides reservoir for rampdown

– LN2/GN2/Helium Heat-exchangers ASME VIII Div-1 :

– 7 cryogenic valves:

– 6 Reliefs

– Dual switch over valve for ASME UV reliefs for the vessel

– Instrumentation isolation valves:

– Electric Heater with overtempt protection

– Bayonet interfaces for the Westwall to coldbox jumpers

– Bayonet interfaces for the solenoid valvebox jumpers

• Flexible jumpers: West wall to IP8-coldbox– Bayonetted jumpers with ±3” flex range x,y,z directions

• Jumpers IP8 coldbox to solenoid valvebox

TECHNICAL OVERVIEW LN2 SUPPLY SYSTEM


• LN2:▪ about 600 ft

▪ ½” NPS x 2 Vacuum jacketed line

▪ Sized to supply about 40 g/s LN2 with a dewar operating pressure of 60 psig

▪ Bayonnetted spools

▪ Manufactured to ASME B31.3 Piping code

▪ Cryogenic valve to control supply pressure in line

▪ Reliefs:

▪ Pressure sensor

▪ Insulating vacuum: Static

▪ “Keep full” device for vapor relief at high point

▪ Field joint at storage dewar to tie-into LN2 liquid line

▪ I/O to bring dewar pressure and level back to cryo controls

TECHNICAL OVERVIEW WARM PIPING SYSTEM

• Return line from return flow of the vapor cooled current leads– Sized to handle the return flow with the other components given overall pressure budget

• Quench dump line to outside of building– Sized to handle the quench flow with upstream pressure below solenoid bath volume relief valve pressure

• Vacuum jacketed GN2 vent line to outside of building– Sized to handle the vent flow for cooldown from 300K to 90K and steady hold of the solenoind below 100K

– Check valve /relief device to prevent moisture collection further inside of line

• 1008B Shield line warm gas return into RHIC cryodistribution WR Warm Return header– Sized to handle the return flow with the other components given overall pressure budget


TECHNICAL OVERVIEW CRYOGENIC CONTROL SYSTEM


REQUIREMENTSControl logic:Control cooldown of solenoid given temperature gradient limitControl stedy state operation at 4.5KAlarmsImplement alarms for critical process variablesInterlockImplement interlocks for critical processes to protect current leads/ magnet for 2 protection modes:

Slow discharge Fast discharge

Able to disconnect the able to allow the cradle to translate out of IP8 Hall

Provide redundancy or similar availability for critical components

Laboratory and Code requirements

IMPLEMENTATION

• Control racks located in 1008B service building• Redundant power supply for instrument loop• Redundant power supply for PLC chassis• Cable trays and cable runs from 1008B service building control

racks through the West wall adjacent to cryo transfer lines

• Junction box located on the platform• Bulk head connector to disconnect cables coming from the west

wall side

• Failure modes:• Radiation hard valve positioners substituted in• Critical valves inside IP8 are made Fail-in-Last position [F.L.] on

both loss of air or loss of signal to positioner.• Temperature: Cernox and Platinum RTD sensors are okay• SC Level probe are okay• Capacitance level probe, conditioning electronics needs to be

close by. Only used during shutdown mode• Pressure and DP sensors option version available for nuclear

industry. Redundant pressure sensor.• Heater control panels: Built to UL508 and UL listed.• Rack components and power supplies: UL listed or NRTL certified• Grounding lugs for each coldbox

ES&H and QA: Are the ES&H and QA aspects being properly addresses given the current state of the project?


Item Status

Pressure and cryogenic safety

Review: BNL LESHC PCSS committeeLHe and LN2 exchangers manufactured to ASME BPVC VIII Div1&2Manufactured to ASME B31.3 piping codeNew York state Mechanical codeSeismic Area: Long Island NY

√

Egress Egress around cryogenic equipment meets BNL, and OSHA and NY state

√

Oxygen Deficiency Hazards Review: BNL LESHC PCSS committeeODH sensors will be installed in IP8 Hall.GN2 Vent and helium quench dump line will be vented to outside of building.

√USI for modification to the RHIC ASE/SAD

Radiation1 Rad/year

Materials reviewed for use in cryogenic system. No Teflon used except where used, annual inspection and replacements. Valve stem seals are metal bellows sealed.

Some instrumentation components selection to be finalized.

Magnetic field From our High current/High field test in building 912 no issues for cryogenic equipment.

√

Rigging Installation in of coldbox in 1008B, Transfer line spools between 1008B and IP8 Hall, transfer line through IP8 West Wall, and Coldbox on the platform has been worked out with facilities support

CHARGE: ES&H and QA: Are the ES&H and QA aspects being properly addresses given the current state of the project?

RADIATION: Radiation in the IP8 hall: 1 Rad per year


Item Type / Model Status

Valve positioners Fischer 6200 radiation hard Tested 2.x104 Rad

√

Temperature Cernox & Platinum (RTD) √

Pressure TransducersDifferential Pressure Trans.

Standard or Rosemount 3150 / 3051N series

May occasionally need to be powered cycledNuclear most likely not necessary

Liq. Helium Level 1 Liq. Helium Level 2

Superconducting wire probeLiquid head using DPT

√ Only wires, Controller in service building√ Standard or Rosemount 3150/3051N series

LN2 sensor 1 and controller LN2 sensor 2:

Capacitive level [Controller needs to be nearby]

Liquid head using DPT Rosemount 3150 / 3051N series

Remove controller for run. Only used during

shutdown

Solenoid valves Coil √

Allicat helium mass flow controllers for Current lead flows

TBD [Low differential DP budget] TBDOption: Move into service building

Current monitor for fail last valve position implementation

[Phoenix switch MCR-2SP/UI] TBD

CHARGE: ES&H and QA: Are the ES&H and QA aspects being properly addresses given the current state of the project?

Recommendations: Have recommendations from past review been appropriately addressed?



Jan 12 2018 External Review

Care must be used in the warm-up of the magnet. There should be monitoring and controls to limit the differential temperature across magnet

This is currently part of the control logic for a controlled cooldown and warmup, with alarms and interlocks, which has been functioning properly during the bldg 912 low field and high field test. The new system will have a new supply and supply condition and the new equipment will have the same control logic to mix cold and warm streams to get the desired gradient across the magnet.

√


The lead flow may not have sufficient flow [pressure drop operating budget] due to the return pressure. The use of a small compressor may be required.

Solution proposed: Operate the solenoid bath at higher pressure, which means higher bath temperature.Technical committee magnet expert has reviewed the new proposed operating conditions and concluded that the magnet should be able to operate at the higher bath temperature of 4.65K at 1.45bar. The Current Sharing Temperature Tcs, i.e. the temperature at which a defined electric field is detected in the cable due to the superconducting-to-normal state transition. This temperature depends on the magnetic field and on the ratio between operating current and critical current. At 4600 A the peak field in the winding is at 2.3T. When considering the Ic(B) curve of the conductor, one find Tcs=7.28 K. The temperature margin between the Tcsand the operating temperature T0 = 2.78K. The real parameter is the enthalpy margin defined as the energy for unit volume (J/m^3) which can be dissipated in the winding without causing a transition. For this conductor the margin is 3635 J/m^3 if T0=4.5 K. If the coolant temperature increases, the enthalpy margin decreases. At a T0= 4.65 K, the enthalpy margin only decreases by 2.5 %.We will be able to operate, with the return valve and control logic, the solenoid return separator at a higher boiling point pressure, e.g. 1.45 bar which will give us 250 mbar DP budget for the current lead flow circuit and warm return piping. We will swap to “Low Pressure Drop” Allicat: Sierra Whisper series Mass flow Controllers from the current MKS brand mass flow controller.The 400 Liter supply reservoir will be operated at 1.65 bar. 4.85K

√


The quench pressure transient should be analyzed to ensure the burst disk does not rupture before the opening of mechanical and pneumatic controlled valves.

We have done a full energy quench during the high field test, and the fast dump valve, set at a pressure of 2.2 atm opened; burst disk did not rupture.

Use of burst disks will be eliminated. Implement dual spring relief valves with switch over valve

√

CHARGE: Recommendations: Have recommendations from past review been appropriately addressed?




The burst disks should be arranged in an assembly that allows the replacement of a burst disk while another is in an operations state.

Implement dual switch over valve √


Temperature sensors should be installed on the relief devices exit line to monitor helium leakage.

Planned implementation for major reliefs √


It should be determined if the Quench Pressure Dump valve should be directly interlocked with the fast shutdown or quench interlock.

The dump valve operated on pressure interlock, [at 2.2bara] performed okay during the high field quench test, but this interlock with the quench detection system can be implemented easily. The quench dump valve is set to respond quickly to the pressure rise and it may not be necessary to open faster than the pressure response of the system.

√


It should be analyzed if the fast discharge rate will be sufficient to protect the gas cooled leads from damaged if cooling flow is stopped.

The burn out time that the manufacturer of the vapor cooled leads give is 87 seconds. A fast discharge duration is 37 sec. A MIITS calc shows 60 sec of reaction time. A TIME LIMIT has been set for 20 sec to initiate interlock[An in-house calculation check of the temperature of the copper lead to reach 250F gives 115 seconds]

√

Recommendations: Have recommendations from past review been appropriately addressed?

CHARGE: Recommendations: Have recommendations from past review been appropriately addressed?




The design and process of removing the cryogenic transfer lines jumpers between the shield wall to the IP8 coldbox should be reviewed in detail.

The transfer line jumpers will each have flexible section with an adjustment range of ±3 inches, in all directions, to allow for final adjustment of the cradle carriage location. The jumpers will have lifting lugs for removal with the small building crane.

√


RHIC cryogenics system operations [return line] should be protected from a quench disturbance

The Control valves for the RHIC’s R/U header and WR header will be throttled based on pressure and temperature Control loops √


Failure Mode Effect Analysis for the system to be carried out This will be carried prior PDR with vendor in the event any changes are to made to the system. Upcoming for November 2019

TBC


Submit USI to the BNL Laboratory ES&H Safety Committee for cryogenic system addition and ODH change in IP8 for revision in the RHIC ASE/SAD.

This item will be done by CAD ES&H Group TBC by CAD ES&H

Dec 18, 2018 LESHC-PCSS/ Final Technica

Voltage tap measurement system will be calibrated prior to each run

Standard Procedure to be implemented once system is commissioned and running by Power Supply Group

TBC by P. S.


Review radiation and magnetic field influence on equipment Radiation: Valve positioners for high radiation area, current lead cooling helium flow controllers option to move to 1008B service building.Magnetic field: Solenoid valvebox valve and instrumentation no issues during bldg. 912 High power/Field test

√


Update of Specifications and SOW [for the helium system procurement] per comments from the review

The procurement for the Helium system is underway. Quotes received and a vendor has been selected. Contract award in a few weeks. √

Apr 9-11 2019 AL D Cost & Schedule Review

Add Risk to registry for magnet not meeting operating current performance for stability i.e. holding at full current for >24 hour was not demonstrated.

The probability of the magnet quenching after holding for 1 hour is low, but is registered as a risk.

√

Recommendations: Have recommendations from past review been appropriately addressed?CHARGE: Recommendations: Have recommendations from past review been appropriately addressed?

Gas Cooled Leads Burn Out Time


• American Magnetics spec “The burnout time at full current

(5000 amps) is 87 seconds”.

• I2t = 50002*87 = 2175 MIITS

• For an exponential decay; MIITS = I2*(tau/2)

tau = 2.36 H/ 0.068 Ohms = 34.7 sec. then

50002*(34.7/2) = 434 MIITS

• 2175 – 434 = 1741. MIITS remaining

• That leaves 1741.E6/ 50002 = 69.6 seconds to detect the no flow condition and engage interlock to quench detection system

• Action: Time limit setpoint: 20 seconds

• Sustain DP across current lead flow circuit

– Supply pressure into lead pot and return pressure into RHIC-WR

COST• CRYOGENIC EQUIPMENT MATERIAL COST

– The cost estimate for the helium system is assessed by the following method: major component cost x 2.5 factor = finished equipment. Excludes installation

– Vendor ROM quotes for custom design cryostats and coldbox are typically in very wide range due to no time spent on given ROM price, without a finished technical spec and drawings.

• Engineering and cryosystem hardware and controls install by cryogenic group

• Field joints and warm piping welding by BNL central shop welder

• Rigging support by CAD rigging


COST HELIUM CRYOGENIC SYSTEM Material/Direct

• 1008B Coldbox:▪ 7 Helium cryogenic valves: 94K

▪ Venturi: 5K; 5 Reliefs: 10K

▪ 20 Instrumentation isolation valves: 8K

▪ Thermal shield: 15K

▪ Total major component: 132K.

▪ Completed cryostat: 2.5 factor x 132K = 330K

• Transferline system 5-spools▪ 180 ft x 500/ft= 90K

▪ 3 bayonetted Jumpers: 6 x 8 = 48K

▪ Total major equipment: 138K

▪ Completed transfer system: 183K x 2.5 = 345K

• IP8 Coldbox– 400L ASME reservoir: 80K

– LN2/GN2/Helium Heat-exchanger: 30K

– 7 Helium cryogenic valves: 94K

– 6 Reliefs: 12K

– Switch over valve: 8K

– 20 Instrumentation isolation valves: 8K

– Total major equipment: 232K

– Completed cryostat: 2.5 factor x 232K = 580K

Shipping & Crating: 20K

– Helium System cost: 330K+345K+580K +20K= 1,275K

• REQUEST: 1100K +30% CONTINGENCY = 1430K

• ACTUAL: 1597K


COST LN2 SUPPLY LINE Material/Direct; Warm piping Sys

• LN2 SUPPLY LINE– About Qty 30 bayoneted spools segments

– 600 FT x $200/ft = 120K

– 1 control valve: 8K x 2.5 = 20K

– 30 pair bayonets x 2K/pair: 60K x 2.5= 150K

– System total = 290K

– ORIGINAL REQUEST: 233K +30% CONTINGENCY

• Warm Piping– REQUEST: 65K +30% CONTINGENCY


Cryo Mechanical Manpower


Cryo Elec/Controls/Instr: Materials


$215,236 126,000$ (Cryo Controls Hardware procurement) PLC I/O cards & expansion chassis 20,000$ 20,000$

(Cryo Controls Hardware procurement) Rack components 12,000$ 12,000$

(Cryo Controls Hardware procurement) Lakeshore Temperature Controller/conditioners 8,000$ 8,000$

(Cryo Controls Hardware procurement) Lakeshore Temperature sensors 30,000$ 30,000$

(Cryo Controls Hardware procurement) SC level probes 3,000$ 3,000$

(Cryo Controls Hardware procurement) PresSure transmitters 6,400$ 6,400$

(Cryo Controls Hardware procurement) Flowmeters 8,000$ 8,000$

(Cryo Controls Hardware procurement) Vacuum gages and cables 6,000$ 6,000$

(Cryo Controls Hardware procurement) 32 conductor cables, IP8 to 1008B racks 20,000$ 20,000$

(Cryo Controls Hardware procurement) 8 conductor cables, IP8 to 1008B racks 8,000$ 8,000$

(Cryo Controls Hardware procurement) Heaters 480VAC 17,000$ 17,000$

(Cryo Controls Hardware procurement) Heater UL listed 480VAC Control Panel 24,000$ 24,000$

(Cryo Controls Hardware procurement) Switch, 480 VAC 1,220$ 1,220$

(Cryo Controls Hardware procurement) Network switch and Ethernet fiber drop 3,500$ 3,500$

(Cryo Controls Hardware procurement) Cable tray and supports 6,000$ 6,000$

(Cryo Controls Hardware Procurement) 20 watt heater on relief valve 600$ 600$

(Cryo Controls Hardware Procurement) Large interface box on Platform 500$ 500$

(Cryo Controls Hardware Procurement) interface box in Service Building 400$ 400$

(Cryo Controls Hardware Procurement) heater power cable 480 VAC 1,416$ 1,416$

(Cryo Controls Hardware Procurement) Roughing pump power cable 480 VAC see above see above

(Cryo Controls Hardware Procurement) Roughing pump see turbo see turbo

(Cryo Controls Hardware Procurement) Turbo pump and Controller 25,000$ 25,000$

(Cryo Controls Hardware Procurement) Vacuum gauges & connectors see turbo see turbo

(Cryo Controls Hardware Procurement) 32 conductor cable LN2 6,500$ 6,500$

(Cryo Controls Hardware Procurement) Plastic general 32 conductor connectors (pairs) 300$ 300$

(Cryo Controls Hardware Procurement) Acopian 24V power Supply 2,000$ 2,000$

(Cryo Controls Hardware Procurement) +/- 15 volt Power Supply 500$ 500$

(Cryo Controls Hardware Procurement) 72 inch enclosure 1,500$ 1,500$

(Cryo Controls Hardware Procurement) LN2 Conduit/couplings 3,400$ 3,400$

Cryo Elec/Controls/Instr/Trade: Labor


Previous Reviews


Reviews Date Description Outcome

Directors Review Mar 7, 2014 Directors Review sPHENIX project Recommend full current high

power test.

BNL Internal Committee

Dec 16, 2014 NPP Review: sPHENIX magnet review:a. Acceptance tests/plans of the Magnet in Building 912b. Design modifications to the Magnet “Chimney” and its interfaces to subsystems hadronic calorimeterc. Verify that the hadronic calorimeter acts as a flux return and magnet can be operated without end plugs: asymmetric forces?d. Identified a technical and management team.

Magnet Chimney extension approved, and proceed with Low and High power test in 912

BNL Internal Committee

May 14 2015 Mechanical Design Review: Magnet Valve Box Extensiona. Is Extension design ready for fabricaction for full field test in 912 and final install in IP8?b. Mechanical design adequate and are new parts easiliy available.c. Good understanding between disciplines and responsibilities.

Mechanical Chimney extension approved for IP8 Integration

BNL LESHC 15-05: PCSS committee

May 22, 2015 Review the Magnet (testing) in Building 912SOLENOID History and Design, Documentation, Location and Assembly Work in Building 912 Cryogenic System to Cool Solenoid, Low Current <100A Test at 4.5K.

Approved for Low power testing in building 912. Determine burst pressure for lead pots and phase separator [for splice joint failure]

C-AD ASSRC Accelerator System Safety Review Committee

Dec 2015 Review sPHENIX Solenoid 912 Low power Test:Cryogenics and cooling, Power supply and quench detection.Magnet checkout: superconducting circuit and cryogenics is functioning

Approved for Low power testing in building 912

C-AD Internal Committee

Mar 15, 2017 sPHENIX Quench Detector Review Approved for High power testing in

building 912

CHARGE: Prerequisites: Have all the Prerequisites activities and documents necessary to support PD-2 and PD-3 approval been completed? Is the project ready for a PD-2/PD-3 review?Have recommendations from past review been appropriately addressed?

Previous Reviews

April 9-11, 2019 Director's Cost, Schedule and Status Review 46

Reviews Date Description Outcome

C-AD ASSRC July 2017 Review sPHENIX Solenoid 912 High Power Test Includes testing of the newly added SC bus/cryolines to extend the connection between the solenoid and valvebox and demonstrate magnet can go to full power.

Approved for High power testing in

building 912

External Committee[SLAC, Fermi, Ansaldo, NSLS2] with BNL staff.

Jan 18, 2018 Review of cryogenics system for IP8New cryogenic equipment to interface solenoid between RHIC cryo distribution: Review requirements, design and layout, operating modes, interfaces with RHIC.

Proceed with design. Address Action items

Internal Committee and LESHC-PCSS Committee

Dec 5, 2018 Final Technical Review & LESHC-PCSS Committee ReviewFinal technical review and Assess safety requirements and interfaces to other systems.

Proceed with finalizing design and proceed with procurement of Helium subsystem.Address Action items.

PEP Committee, C-AD technical & procurement staff, BNL Safety department

Mar 11, 2019 Procurement Readiness ReviewInterface and installation requirementsProcurement Readiness: SPEC and SOW, drawing packageCommittee and Evaluation criteria doc for RFP Procurement

CommitteeBNL and other labs

Apr 9-11, 2019 Directors Review for PD2/PD3 Readiness

Committee Oct 16-17, 2019

Directors Review sPHENIX 2.X Cost, Schedule and Status Review

CHARGE: Prerequisites: Have all the Prerequisites activities and documents necessary to support PD-2 and PD-3 approval been completed? Is the project ready for a PD-2/PD-3 review?Have recommendations from past review been appropriately addressed?

MODEL VIEWS


Detector with

Platform 1008BColdbox

IP8Coldbox

Existing RHIC valveboxes

BLUE & YELLOW

Transferline thru West

Wall labyrinth

Oct 16-17, 2019 sPHENIX Director's Review 48

IP8 Cold Box Main Platform


Vacuum Jacketed Spools

– tops clears hall opening

Coaxial modificati

on

Vacuum Port

IP8 Cold box

IP8 Cold Box


Transfer Line system


connects between 1008B-coldbox and the IP8-Coldbox

Service Building 1008B Cold Box


Interfaces to the RHIC Cryodistribution system

sphenix infrastructure and facility upgrade · 17+ years in cryogenics group, 35+ years experience...

Documents