technical specification for helium cryogenic … · web viewsolenoid valve box. the weld joint will...

TECHNICAL SPECIFICATION for Helium cryogenic transfer lines CeC

BROOKHAVEN NATIONAL LABORATORY

Brookhaven Science Associates

Collider-Accelerator Department

Upton, New York 11973

CAD-1343

Feb 28, 2019

Rev. A

TECHNICAL SPECIFICATION FOR

Helium Cryogenic system for sPHENIX superconducting solenoid

Prepared by

Prepared by

Paul Orfin / Cryogenic Systems Project Eng, C-AD

Date

Approved by

Roberto Than / Cryogenic Systems GL, C-AD

Date

Tom Tallerico, Cryogenic Controls&Instrum GL, C-AD

Date

Approved by

Approved by

Dave Passarello / Quality Assurance, C-AD

Date

Joe Tuozzolo / Chief M.E., C-AD

Date

Approved by

Kin Yip / Magnet Level 2 Manager, C-AD

Date

Approved by

Ed O’Brien / Project Director, sPHENIX

Date

CAD-1343 Rev APage 3 of 18

Contents1.INTRODUCTION52.APPLICABLE DOCUMENTS52.1.BSA Piping & Instrumentation Diagrams (P&ID) and General Arrangement drawings52.2.Codes Compliance62.3.Codes and Standards73.TECHNICAL SPECIFICATIONS73.1.System description73.2.RHIC interconnect cryogenic helium Vacuum Jacketed (VJ) piping83.2.1.Inner pipe design requirements83.2.2.Vacuum jacket design requirements83.2.3.Cryogenic Helium Lines Segments/ Spools Table83.2.4.Interconnect to existing blue valve box93.2.5.Field weld joint to 1008B cold box93.3.1008B Service Building Cold Box93.3.1.Cryostat vacuum vessel93.3.1.1.Vacuum vessel design requirements93.3.1.2.Vacuum breaks93.3.1.3.Vessel supports93.3.1.5.Flanged ports on the vacuum vessel103.3.1.6.Penetration port list103.3.2.Inner pipe design requirements113.3.3.Pressure relief requirements113.3.4.Heater port and assembly113.3.5.Venturi flow meter123.3.5.1.Venturi sizing123.3.5.2.Differential pressure transducer133.3.7.Valve list133.3.7.1.Helium valves133.3.7.2.Vacuum valves143.5.3.Cryogenic Helium Lines Segments/ Spools Table163.6.1.1.Vacuum breaks173.6.1.2.Vessel supports – Drip pan173.6.1.4.Flanged ports on the vacuum vessel183.6.1.5.Penetration port list183.6.6.Heater port and assembly233.6.9.1.Fluid valves243.6.10.Vacuum valves243.7.4.Cryogenic Helium Lines Segments/ Spools Table254GENERAL REQUIREMENTS274.1Materials274.2Bi-Metallic joints274.3Transfer Line Heat Leak274.4Multi-Layer Insulation284.5Thermal heat shield284.5.1Heat stationing284.6Bellows and Braided Flexible Metal Line284.6.1Bellows/ Braided Flex Lines for Vacuum Jacket Lines284.6.2Bellows / Braided Flex Lines for Internal Process Lines284.7Vacuum Spaces, Vacuum pump-out Valve, Vacuum gauging, and Getter System294.8Vacuum Breaks and Thermal Transitions294.9Pressure Loss from Flow Resistance294.10Cryogenic Piping Supports294.10.1Internal supports294.10.2External supports304.11Cryogenic Valves304.11.1Radiation or Sub-atmospheric Operation304.11.2Helium Valves Heat Leak314.11.3Helium Valve Seat Leakage Rates314.12Valve Positioner I/P Unit314.12.1Valve Positioner Readback314.12.2Valve limit switch Readback314.13Purge, Relief, and Instrumentation Branch Lines314.13.1Line requirements314.13.2Instrument/purge lines324.13.3Purge line path324.14Purge and Instrumentation Valves324.15Vacuum Valves324.16Safety Pressure Relief Valves324.17Bayonets334.18Lifting Lugs334.19Nameplate and Markers334.20Instrumentation344.20.1In-stream temperature sensors344.20.2Temperature Sensors344.20.3Pressure Sensors and Gauges344.20.4Liquid Level Indicator344.20.5Differential Pressure Transducer (DPT)354.20.6RHIC catastrophic failure vacuum warning switch354.20.7Vacuum Electrical Feed through354.20.8Vacuum Sensors on Vacuum Jacket Volume354.21Instrumentation and Equipment Protection354.22Earth Electrical Ground connection364.23Installation Instructions365VERIFICATION365.1Pipe Stress Analysis365.1.1Piping Connections375.1.2Analysis Requirements375.2Vessel Code analysis375.3Leak Checking37

1. INTRODUCTION

This specification covers the design, fabrication, leak checking, pressure testing, and delivery of the cryogenic system for the sPHENIX superconducting solenoid at Brookhaven National Laboratory (BNL). Brookhaven Science Associates (BSA) is the operator of the BNL facility.

2. APPLICABLE DOCUMENTS

The following specifications, standards, and drawings form a part of this specification to the extent specified herein. General arrangement drawings are conceptual only and are not build-to print drawings. Unless otherwise specified, the issues of these documents shall be that in effect on the date of the solicitation or contract.

2.1. BSA Piping & Instrumentation Diagrams (P&ID) and General Arrangement drawings

DRAWING NUMBER

DESCRIPTION

USED ON LOCATION

30150000

SITE MAIN ASSY,

SITE

30150001

SERVICE BUILDING 1008B MAIN ASSY.

1008A

30150002

SERVICE BUILDING 1008B, REWORK PIPING MAIN ASSY.

1008B

30150003

S-LINE INTERCONNECT, LHE SUPPLY T.L. ASSY.

1008B

30150004

H-LINE INTERCONNECT, COOLDOWN T.L. ASSY.

1008B

30150005

U-LINE INTERCONNECT, VAPOR RETURN T.L. ASSY.

1008B

30150006

INTERCONNECT, FIELD JOINT SLEEVE, 8 NPS V.J.

1008B

30150007

INTERCONNECT, FIELD JOINT SLEEVE, 5 NPS V.J.

1008B

30150008

INTERCONNECT, VACUUM BREAK, MAIN ASSY.

1008B

30150009

INTERCONNECT, FIELD JOINT TEE, 6 NPS V.P.

1008B

30150010

SEVICE BUILDING, COLD VALVE BOX MAIN ASSY.

1008B

30150011

SERVICE BUILDING, COLD VALVE BOX, 20 KW HEATER ASSY.

1008B

30150012

SERVICE BUILDING, COLD VALVE BOX FLW METER ASSY

1008B

30150013

MULTIPLE TRANSFER LINE MAIN ASSY.

SITE

30150014

MULTIPLE TRANSFER LINE, SPOOL NO. 1 ASSY.

1008B

30150015

MULTIPLE TRANSFER LINE, SPOOL NO.2 ASSY.

RHIC RING BURM 1008A-1008B

30150016


RHIC RING BURM 1008A-1008B

30150017


1008A

30150018


1008A

30150019


10008A

30150020

MULTIPLE TRANSFER LINE, FIELD JOINT SLEEVE, 8NPS V.J.

1008B & 1008A

30150021

MANIFOLD JUMPER, TRANSFER LINE, LHE SUPPLY ASSY.

1008A

30150022

MANIFOLD JUMPER, TRANSFER LINE, VAPOR RETURN ASSY.

1008A

30150023

MANIFOLD JUMPER, TRANSFER LINE, SHIELD RETURN ASSY.

1008A

30150024

LN2 JUMPER, TRANSFER LINE, SUPPLY ASSY.

1008A

30150025

LN2 JUMPER, TRANSFER LINE, VENT RETURN ASSY.

1008A

30150026

LN2 TRANSFER LINE, SUPPLY SPOOL ASSY.

1008A

30150027

LN2 TRANSFER LINE, VENT RETURN SPOOL ASSY.

1008A

30150028

MAJOR FACILITY HALL 1008A, VALVE BOX, MAIN ASSY.

1008A

30150029

MAJOR FACILITY HALL 1008A, VALVE BOX, LN2 HEAT EXCHANGER ASSY.

1008A

30150030

MAJOR FACILITY HALL 1008A, VALVE BOX, WARM HELIUM SUPPLY SPOOL NO. 1 ASSY.

1008A

30150031

MAJOR FACILITY HALL 1008A, VALVE BOX, VACUUM VESSEL RELIEF SPOOL ASSY.

1008A

30150032

MAJOR FACILITY HALL 1008A, VALVE BOX, LHE 400 LITER STORAGE TANK RELIEF SPOOL ASSY.

1008A

30150033

MAJOR FACILITY HALL 1008A, VALVE BOX, LN2 VENT RETURN SPOOL ASSY.

1008A

30150034

MAJOR FACILITY HALL 1008A, VALVE BOX, LN2 VENT RELIEF SPOOL ASSY.

1008A

30150035

SOLENOID VALVE BOX, REWORK, MAIN ASSY.

1008A

30150036

SOLENOID VALVE BOX, REWORK, MULTIPLE COAX CONNECTION ASSY.

1008A

30150037

SOLENOID VALVE BOX, REWORK, HEAT SHIELD RETURN CONNECTION ASSY.

1008A

30150038

SOLENOID VALVE BOX, REWORK, WARM HELIUM RETURN CONNECTION ASSY.

1008A

30150039

SOLENOID VALVE BOX, TRANSFER LINE, LHE SUPPLY ASSY.

1008A

30150040

SOLENOID VALVE BOX, TRANSFER LINE, VAPOR RETURN ASSY.

1008A

30150041

SOLENOID VALVE BOX, TRANSFER LINE, HEAT SHIELD RETURN ASSY.

1008A

30150042

SOLENOID VALVE BOX, JUMPER , WARM HELIUM SUPPLY SPOOL ASSY.

1008A

30150043

SOLENOID VALVE BOX, TRANSFER LINE, FIELD JOINT SLEEVE, 4 NPS V.J.

1008A

30150044

SOLENOID VALVE BOX, TRANSFER LINE, FIELD JOINT SLEEVE, 3 NPS V.J.

1008A

30150045

SOLENOID VALVE BOX, VACUUM SYSTEM, REWORK, MAIN ASSY.

1008A

30150046

SOLENOID VALVE BOX, VACUUM SYSTEM, REWORK, TURBO PUMPS ASSY.

1008A

30150047

SOLENOID VALVE BOX, VACUUM SYSTEM, REWORK, VACUUM PUMPS ASSY.

1008A

2.2. Codes Compliance

The contractor shall ensure that the project meets or exceeds the standards set forth in the listed codes and standards below. The contractor shall use the latest version of these items when possible or indicate what version of the standard they shall be using. The contractor shall have a copy of these items in the facility, particularly for the design standards and codes, and shall have a working knowledge of them for proper application in this project. The contractor shall indicate any deviation from these standards and submit them for BSA approval before any work on the project is done. Any additional codes or standards the contractor would like to apply to the design shall also be submitted to BSA for written approval.

2.3. Codes and Standards

API 520 PT I

Sizing, Selection, and Installation of Pressure-relieving Devices in Refineries Part I - Sizing and Selection – Eighth Edition

API 520 PT II

Sizing, Selection, and Installation of Pressure-Relieving Devices in Refineries Part II— Installation - Fifth Edition

ASME BPVC

Section VIII - Rules for Construction of Pressure Vessels, Division 1‚ Rules for Construction of Pressure Vessels and Division 2‚ Alternative

ASME BPVC

Section IX - Qualification Standard for Welding and Brazing Procedures‚ Welders‚ Brazers‚ and Welding and Brazing Operators

ASME B16.5

Pipe Flanges and Flanged Fittings NPS 1/2 through NPS 24 Metric/Inch Standard\

ASME B16.9

Factory-Made Wrought Buttwelding Fittings

ASME B31.3

Process Piping

ASME B30.26

Rigging Hardware

ASTM A240

Standard Specification for Chromium and Chromium-Nickel Stainless Steel Plate, Sheet, and Strip for Pressure Vessels and for General Applications

ASTM A269

Standard Specification for Seamless and Welded Austenitic Stainless-Steel Tubing for General Service

ASTM A312

Standard Specification for Seamless, Welded, and Heavily Cold Worked Austenitic Stainless-Steel Pipes

ASTM A380

Standard Practice for Cleaning, Descaling, and Passivation of Stainless-Steel Parts, Equipment, and Systems

ASTM A403

Standard Specification for Wrought Austenitic Stainless-Steel Piping Fittings

ASTM E498

Standard Practice for Leaks Using the Mass Spectrometer Leak Detector or Residual Gas Analyzer in the Tracer Probe Mode

ISO 21013-3

Cryogenic vessels - Pressure-relief accessories for cryogenic service Part 3: Sizing capacity determination

ASME MFC-3M

Measurement of Fluid Flow in Pipes Using Orifice, Nozzle, and Venturi

3. TECHNICAL SPECIFICATIONS3.1. System description

The cryogenic system for the sPHENIX superconducting solenoid shall consist of several major component groups described in the following sections. The system will provide liquid helium to the superconducting solenoid as well as return cold vapor. The supply and return shall connect to the existing cryogenic valve box at 1008B of the Relativistic Heavy Ion Collider (RHIC). The system will control the flow of the helium to maintain superconducting temperatures for the solenoid’s operation. The system will also incorporate a liquid nitrogen heat exchanger to cool helium when RHIC is off as to keep the solenoid from going above 100K.

The follow table summarize the major pieces of spools and cold boxes:

Major item grouping

Function

Insulating Vacuum boundary

RHIC interconnects: 3 x single line interconnects interfacing to RHIC valve box

Interconnects RHIC valve box and 1008B Cold box

Shares insulating vacuum with the existing RHIC Valve box. The vacuum breaks for the interconnects are part of 1008B cold box

1008B Cold box

Local cold box containing valves that controls supply and return flow back to RHIC valve box

Shares insulating vacuum with the 5 segment multi-line transfer spools

5 segment multi-line transfer spools system

Transfer line between 1008B cold box and IP8 Cold box and terminates with manifold with bayonets inside the IP8 Hall West wall

Shares insulating vacuum with

3 flexible interconnecting jumpers

Interconnects multi-line transfer spools line to the IP8 Cold box

Static self-contained insulating vacuum volume

IP8 Cold box

Contains the liquid helium hold up reservoir, the LN2 exchangers, and controls valves

Insulating vacuum volume not shared with connecting spool jumpers. Dynamic pumped with vacuum turbopump

3 interconnecting jumpers:

1 field joint connected [LHe supply]

2 bayonetted [Shield return & 4.5K Vapor return]

Interconnects the IP8 Cold box with the existing Solenoid valve box

1: Liquid helium supply line share insulating vacuum with solenoid valve box

2x: Static self-contained insulating vacuum volume

3.2. RHIC interconnect cryogenic helium Vacuum Jacketed (VJ) piping

The cryogenic helium transfer lines shall consist of an inner pipe (core pipe), designed to handle the flow of liquid helium, surrounded by an outer pipe that shall provide insulating vacuum space for the inner line. The inner line shall be wrapped with Mylar Multi-Layer Insulation (MLI) to meet the heat leak specification for a helium transfer line as specified in 4.2-Transfer Line Heat Leak. The lines will have a common insulating vacuum space with the existing blue valve box, which is actively pumped.

3.2.1. Inner pipe design requirements

The inner pipe shall be designed and manufactured in accordance with ASME B31.3 piping code.

Material: Type 304/304L (dual graded), austenitic Stainless Steel as per ASTM A312 or ASTM 269

Design pressure

Internal: 273 psid@ 120°F. [18.8 bar@322K]

External: minimum 14.7 psid or higher. If the relief pressure of the jacket is higher than 14.7 psig, then the external design pressure shall be consistent with this relief pressure. For single line spools, this is not applicable since the source of the pressurization is the line itself.

MDMT: -452°F @ 276 psig. [[email protected] bar]

3.2.2. Vacuum jacket design requirements

The vacuum boundary or jacket piping shall be designed and manufactured in accordance with ASME B31.3 piping code.

Material: Dual graded Type 304/304L, austenitic Stainless Steel as per ASTM A312 or ASTM 269

Design pressure: Internal: 15 psig at 120°F; External:14.7 psid.

MDMT: -452°F @ 15 psig. Design temperature shall be 120°F at the highest pressure.

The vacuum jacket shall be designed for external pressure of 14.7 psi (full vacuum) and 15 psig internal.

3.2.3. Cryogenic Helium Lines Segments/ Spools Table

The table below indicates the inner lines (core lines) and their ends.

Line Segment

Process Line Size

End 1

End 2

S-Line interconnect

1” SCH5

Field weld joint to helium supply tap blue valve box

Field weld joint to 1008B cold box

H-Line interconnect

1” SCH5

Field weld joint to helium heat shield tap blue valve box


U-Line interconnect

1” SCH5

Field weld joint to helium utility tap blue valve box


3.2.4. Interconnect to existing blue valve box

The contractor shall provide interfacing parts to complete the connection to the blue valve box taps. The parts will interface with the existing blue valve box’s process and vacuum jacket to complete the tap in connection. The existing process lines are all 2” NPT SS304 and the vacuum jackets are 4” NPT SS304. The contractor supplied taps shall tee off the stub end of the blue valve box. The horizontal leg will connect to the contactor provided cryogenic lines by means of a field weld joint. The vertical leg will continue up to provide thermal isolation for the reliefs that will move up at least 30 inches. The contractor shall provide the vacuum jacket, process line, 2” 150# flange for the relief as well as any vacuum closure parts. All components shall have the ability for field length adjustment of at least 6” to be cut onsite to ensure proper fit.

3.2.5. Field weld joint to 1008B cold box

The contractor shall provide interfacing parts to complete the connection to the 1008B cold box. The weld joint will connect the process lines as well as close the vacuum boundary. All components will have the ability for field length adjustment of at least 6” to be cut onsite to ensure proper fit.

3.3. 1008B Service Building Cold Box3.3.1. Cryostat vacuum vessel 3.3.1.1. Vacuum vessel design requirements

The vacuum boundary or jacket vessel shall be designed and manufactured in accordance with ASME BPVC Div-1 or 2 but won’t need to be code stamped. Any ancillary piping connections shall be designed and manufactured in accordance with ASME B31.3 piping code.





3.3.1.2. Vacuum breaks

The vacuum boundary for the cold box must be isolated from other systems. To achieve this on the RHIC side interconnect interfaces, a low heat leak vacuum break shall be used. The cold box will share insulating vacuum with the multi-line transfer line thus the cold box transfer line side field joint will not have a vacuum break. The vacuum breaks will follow the specifications listed in 4.6 Vacuum Breaks and Thermal Transitions.

3.3.1.3. Vessel supports

The vessel shall be supported by legs from the bottom of the vessel resting on the building floor. The supports shall consist of at least 3 vertical contacts with the ground, each with a minimum 0 to 1-inch height adjustment to allow for leveling on an uneven surface as well as any vertical tolerance make up. The legs will have a flat surface so that they can be bolted to the concrete floor. Each support leg shall have a minimum strength to support 3 times the entire weight of the entire vessel divided by the number of legs.

The supports must be able to resist corrosion for the effective life of the product or at least 20 years. This can mean the use of corrosion resistant materials or a surface coating such as paint. Dissimilar materials connected to each other, must review the potential for galvanic corrosion. The vessel support shall have provision for fork lift and pallet jack forks to move the vessel into its final location. At a minimum, a flat surface will be provided 4” above the ground level to rest the forks safely under the vessel without tipping.

The vessel will be located in Long Island, New York which is in seismic zone 2A and it must be designed to handle that seismic conditions.

3.3.1.4. Vacuum relief requirements

Relief of insulating vacuum vessel volume shall have a vacuum rated ASME UV relief, or ASME UD stamped burst disk (FIKE Axius disc, XL holder assembly G with O-ring groove, critical leakage design version) or one or more MDC 420033 BDA-275-ASME. To prevent accidental release of a burst disc, a pressure relief devise will be provided to vent well below the set point of the burst disc.

Relief shall be sized to handle the larger of the following two cases:

a.The relief device disk shall be sized to at a minimum handle the free convection heat transfer from the jacket wall to cold helium vapor in the event of a helium large leak/catastrophic failure of a line. A minimum heat flux of 5000W/m2 shall be used for this case.

b.The maximum practical flow delivered by the pressurized inventory of helium through the broken line is 700 g/s (1/2-inch tube x 10 ft) at a temperature of 50K. This temperature is derived from the heat transfer from the vacuum vessel walls to the gas at the listed mass flow rate.

The reaction force from the venting of the device must be taken into consideration when designing the vessel and its piping. Sizing calculations as well as reaction force values and strength calculations shall be submitted to BSA. The relief device outlet ports must have a means of connection to a pipe so that external venting of the gases can be done.

3.3.1.5. Flanged ports on the vacuum vessel

All flanged ports on the vacuum vessel shall use conflat flange connections as indicated on the schematic drawing. The size of the port and flanges will be determined by the contractor to meet the vessel’s requirements.

3.3.1.6. Penetration port list

Below is a list of the require penetrations to the vacuum vessel. These nozzle numbers must correspond to the pressure vessel analysis nozzle designation. These penetrations are consistent with the P&ID and require BSA notification and approval before they can be changed.

Nozzle/Penetration

Description

Connection/Flange type

A

Return (upper) experiment line

Pipe Line Set

B

Supply (lower) experiment line

Pipe Line Set

C

Instrumentation line for Helium Vessel

2.75” Conflat

D

Helium Vessel pressure relief

Flange, TBD

E

Electrical Feed Thru

1.33” Conflat

F

RHIC catastrophic failure vacuum warning switch

2.75” Conflat

G

Vacuum sensor port

2.75” Conflat

H

Heater and Warm helium vapor outlet

Pipe; ANSI 150 at heater for 2” pipe

I

Vacuum Vessel primary relief

Flange, TBD

J

Vacuum Vessel secondary relief

2.75” Conflat

K

Vacuum roughing pump down valve

8” Conflat

L

Vacuum turbo pump down valve

8” Conflat

M

QHS supply line, manifold and valves

Pipe Line

N

Helium Pump down line

2” Bayonet




Design pressure



Minimum Design Metal Temperature: -452°F@internal 273 psid [[email protected]]

3.3.3. Pressure relief requirements

The helium pressure vessel shall have an ASME UV relief. The relief device will be sized to at a minimum handle the loss of insulating vacuum to air with 40 layers of Multi-Layer Insulation (MLI) around the vessel. A minimum heat flux of 6,000 W/m2 shall be used for this scenario. The relief will be set at 250 PSIG. The reaction force from the venting of the devise must be taken into consideration when designing the vessel and its piping. Sizing calculations as well as reaction force values and strength calculations shall be submitted to BSA. The relief device outlet ports must have a means of connection to a pipe so that external venting of the gases can be done.

Relief valve tag

Setpoint

Design Temperature

H3734R

250 psig

-452°F

H3736R

250 psig

-452°F

H3738R

250 psig

-452°F

H3740R

250 psig

-452°F

3.3.4. Heater port and assembly

A cold gas heater will be required as part of the cold box to ensure that the helium outlet is as room temperature. BSA will provide the heater. The contractor shall design and fabricate the heater assembly in accordance with ASME B31.3 piping code to handle the proper pressure and temperature of the system. The inlet for the heater will come from the cold box and will be determined by the contractor. The outlet port must have a 2” ANSI 150 flange. The heater assembly should be designed such that the immersion heat elements can be removed for service or inspection. This can be accomplished by mounting the heater to a flanged connection which would allow for the heater to be removed with the flange. The assembly shall use at 5” 150# flange to interface with the heater. The flange shall have a Viton O-ring with a mating groove to complete the pressure seal. The main body of the heater assembly shall consist of a 5” schedule 10 pipe whose inner diameter shall be inspected to ensure smooth insertion of the heater. The contractor must ensure that the heater can be removed and inserted in its final installation location. The contractor shall supply a blank flange to cap the heater port for pressure testing and shipping.

3.3.5. Venturi flow meter

The cold box shall have a venturi flow meter to measure the helium supply. Based on the flow conditions indicated in the sizing section below, the helium can be in the liquid or gaseous state. The design of the venturi shall be based on ASME MFC-3M, Measurement of Fluid Flow in Pipes Using Orifice, Nozzle, and Venturi. This shall include, but not limited to, the minimum straight pipe length required before and after the venturi based on the piping configuration.

3.3.5.1. Venturi sizing

The venturi selection shall be based on the major flow characteristics listed in the table below. Final selection of the venturi shall be confirmed by BSA prior to procurement.

Service

Fluid

Helium-4

Fluid ID

10

Meter Type

Low Loss Venturi

Pipe size

Pipe ID

0.87

0.87

0.87

0.87

inch

Pipe ID

0.0221

0.022098

0.0221

0.0221

m

DP sensor Range

0

0

mm H2O

Nominal Mass Flow [ kg/s]

0.0120

0.0100

0.0030

0.0088

kg/s

Nominal Mass Flow [ g/s]

12.0000

10

3

8.8

g/s

0

Flowing Temperature [Kelvin]

4.7

50

288

288

K

Flowing Pressure [kPa]

358.62

358.62

206.90

810.00

kPa

Flowing Pressure [atm]

3.538

3.538

2.041

9.867

atm

Flowing Pressure [psia]

52

52

30

145

psia

Density at flowing conditions [kg/m^3]

128.39

3.42

0.35

1.35

kg/m3

Viscosity at flowing T/P [ Centipoise]

0.0035

0.0064

0.0194

0.0194

Centipoise

Viscosity at flowing T/P [ Pa-s]

0.000003

0.000006

0.000019

0.000019

Reynolds No at nominal flow

199565726

89891328

8916534

26123389

Ratio of specific heats (Cp/Cv)

1.918

1.671

1.666

1.666

Beta

0.300

0.300

0.300

0.300

Throat ID

0.0066

0.0066

0.0066

0.0066

m

Throat Area

0.0000345174

0.0000345174

0.0000345174

0.0000345174

m2

DP

472.920

12354.523

11253.033

24392.555

Pa

DP

1.90

49.63

45.21

97.99

in H2O

DP

4.729

123.545

112.530

243.926

mbar

DP

0.069

1.791

1.632

3.537

psid

DP

0.05

1.26

1.15

2.49

m water

Permanent/Non-recoverable Pressure loss]

0.014

0.358

0.326

0.707

psid

Permanent/Non-recoverable Pressure loss]

94.584

2470.905

2250.607

4878.511

Pa

3.3.5.2. Differential pressure transducer

Based on the flow rate range, two differential pressure transducers shall be needed. The differential pressure of the two sensors will be 5” and 50” of water column. The contractor shall specify and purchase these transducers once approved by BSA. The contractor will be responsible for mounting the sensors on the exterior of the vessel as well as provide the connections to the internal pressure taps on either side of the venturi.

3.3.6. Thermal heat shield

To minimize heat leak on the cryogenic lines, a thermal heat shield shall be incorporated around the process lines as indicated in 4.4-Thermal heat shield.

3.3.7. Valve list3.3.7.1. Helium valves

The contractor shall include the following cryogenic liquid helium control valve in the transfer lines:

Valve Tag

Description

Trim sizeCv / Kv

Trim profile

Trim Turndown ratio

Pipe size

Fail position

Actuator type

Actuation direction

Stem seal

Positioner

Position Feedback

Position Limit switches

Heat station

@100K

H3692A

R to RHIC-WR

6.0 / 5.2

EQ%

>35

1½”NPS

F.C.

Air/Spring

Air to open

Packing

I/P

Analog

Yes

X

H3693A

Shield to RHIC-WR

3.0 / 2.6

EQ%

>35

½”NPS

F.C.

Air/Spring

Air to open

Packing

I/P

Analog

Yes

H3694A

Shield Return to RHIC-U

2.0 / 1.7

EQ%

>35

½”NPS

F.C.

Air/Spring

Air to open

Packing

I/P

Analog

Yes

H3695A

R to RHIC-U

3.4 / 3.0

EQ%

>35

1”NPS

F.O.

Air/Spring

Air to close

Packing

I/P

Analog

Yes

X

H3696A

RHIC-H to Supply

1.0 / 0.9

EQ%

>35

½”NPS

F.C.

Air/Spring

Air to open

Packing

I/P

Analog

Yes

X

H3697A

RHIC-H to Supply, Isolation

6.0 / 5.2

Q.O.

>35

1”NPS

F.C.

Air/Spring

Air to open

Packing

solenoid

Yes

H3698A

RHIC-S to Supply

4.0 / 3.5

EQ%

50

1”NPS

F.L.

Air/Spring

Air to open/close

Packing

I/P

Analog

Yes

X

3.3.7.2. Vacuum valves

Each vacuum space shall have a valve to pump down to the desired vacuum on site as indicated in Section 4.5: Vacuum Spaces, Vacuum pump-out Valve, Vacuum gauging, and Getter System. Transfer line jackets shall use a vacuum seal-off valve. The vacuum seal-off valves shall be selected or designed so that the sealing plug cannot violently eject in the event of a rapid pressurization. This can be inherited in the design of the valve or through the use or a protective shroud.

The contractor shall supply the corresponding operator for the selected seal-off valve provided.

3.4. Multiple process line cryogenic spools with heat shield – (Cryo-duct)







The vacuum space shall be common with the 1008B cold box and actively pumped from there.

3.4.2. Vacuum relief requirements

The vacuum jacket lines will have a pressure relief device installed in each vacuum space to prevent over pressurization. Common vacuum space among multiple segments is allowed and preferred, with the relieve device being place on any external segment that is easily accessible. The insulating vacuum space shall have a vacuum tight ASME UV stamped certified relief device (for capacity). The relief pressure shall be set at 15 PSIG. At a minimum, the reliefs shall be sized to handle a 4-atmosphere leak of helium into the vacuum space with a convective heat transfer value of 5000 W/m2 from the inner wall of the jacket pipe. This case shall dictate unless another case can be identified that would require a larger relief size.

The contractor will size the relief valves and provide them with the lines. Relief valve reaction forces must be calculated and factored into the design of the pipe lines. Relief sizing and reaction force calculations shall be submitted to BSA.




Design pressure




3.4.3.1. Lines sizes

The individual process fluid line sizes shall match the P&ID and the list below

Line

Size

Liquid Supply

1” NPT – sch 10

Vapor Return

1-1/2” NPT – sch 10

Shield Return

1/2” NPT – sch 10



3.4.5. LHe Lines Segments/Spools Table

The table below indicates the spool pieces and their ends.

Line Segment #

Size

End 1

End 2

Spool #1

Multiple core pipe bundle

Field joint with 1008B cold box

Piping field joint

Spool #2


Piping field joint

Piping field joint

Spool #3


Piping field joint

Piping field joint

Spool #4


Piping field joint

Piping field joint

Spool #5 - Manifold


Piping field joint

Bayonet with warm end ball valves

3.4.6. Manifold Spool #5

3.4.6.1. Bayonets with warm end ball valves

Bayonets shall be used to terminate the cryo-duct and create discrete connections for each of the internal process lines. The bayonets shall be the low heat leak helium service type. Each one shall utilize a warm end ball valve to allow for isolation of each line should the bayoneted transfer line be removed. The orientation of the valve handle shall be confirmed with BSA to ensure it will not block access to the walk ways around the equipment.

3.4.6.2. Additional Supports for jumper lines

The bayonets will support jumper lines that span the gap to the IP8 cold box. Due to the limited space requirements, the contractor shall create a self-supporting interface for the jumpers. The interface must be able to take the additional moment and bending force loads from the jumper lines acting on the manifold bayonets. The contractor shall account for the loads by increasing the vacuum jacket diameter or through the addition of gusset braces to ensure the jacket and internal lines are not overstressed. The loads shall be included in the ASME B31.3 piping analysis and any necessary structural calculations.

3.4.7. Lifting lugs

Each spool shall have lifting lugs to facilitate rigging of the lines on site. Multiple lugs may be necessary to hold the spool properly. If a spreader bar is needed, the contractor shall indicate that in the drawing and installation instructions. The Center of Gravity (CG) mark shall be permanently marked on the spool.

3.5. Cryogenic Jumpers from manifold spool #5 to IP8 cold box








Any static vacuum jacket lines will have a pressure relief device installed in each line to prevent over pressurization. The insulating vacuum space shall have a vacuum tight ASME UV stamped certified relief device (for capacity). Full bore vacuum port operators can be used considered as an adequate relief device but must be approved by BSA. The operators must show to the meet the relieving capacity and retain the end plug to prevent injury from its release. The relief pressure shall be set at 15 PSIG. At a minimum, the reliefs shall be sized to handle a 4-atmosphere leak of helium into the vacuum space with a convective heat transfer value of 5000 W/m2 from the inner wall of the jacket pipe. This case shall dictate unless another case can be identified that would require a larger relief size.





Design pressure






Line Segment

Process Line Size

End 1

End 2

Liquid supply

1” SCH10

Male bayonet

Male bayonet

Vapor return

1-1/2” CH10

Male bayonet

Male bayonet

Shield return

1/2” SCH10

Male bayonet

Male bayonet

3.5.4. Flexible section

The spool sections will need to allow for a large tolerance adjustment in the final location of the IP8 cold box bayonets. The adjustment needs to be +/- 3” in all directions; X, Y, & Z. To facilitate this adjustment, the contractor shall integrate a vacuum jacketed flexible hose section on the horizontal portion of the spools.

3.5.5. Additional Supports

The jumper lines span the gap to the IP8 cold box. Due to the limited space requirements, the contractor shall create a self-supporting design for the jumpers. The lines must be able to take the additional moment and bending force loads from the jumper lines acting on the bayonets ends. The contractor shall account for the loads by increasing the vacuum jacket diameter or through the addition of gusset braces to ensure the jacket and internal lines are not overstressed. The loads shall be included in the ASME B31.3 piping analysis and any necessary structural calculations.

3.6. Intersection Point 8 (IP8) cold box

3.6.1. Vacuum vessel design requirements






3.6.1.1. Vacuum breaks

The vacuum boundary for the cold box must be isolated from other systems. To achieve this on the solenoid supply interface, a low heat leak vacuum break shall be used. The vacuum breaks will follow the specifications listed in 4.6 Vacuum Breaks and Thermal Transitions.

3.6.1.2. Vessel supports – Drip pan

The vessel shall be supported by legs from the bottom of the vessel resting on the building floor. The supports shall consist of at least 3 vertical contacts with the ground, each with a minimum 0 to 1-inch height adjustment to allow for leveling on an uneven surface as well as any vertical tolerance make up. The legs will have a flat surface so that they can be bolted to the concrete floor. Each support leg shall have a minimum strength to support 3 times the entire weight of the entire vessel divided by the number of legs.

The supports must be able to resist corrosion for the effective life of the product or at least 20 years. This can mean the use of corrosion resistant materials or a surface coating such as paint. Dissimilar materials connected to each other, must review the potential for galvanic corrosion. The vessel support shall have provision for fork lift and pallet jack forks to move the vessel into its final location. At a minimum, a flat surface will be provided 4” above the ground level to rest the forks safely under the vessel without tipping.

The vessel will be located in Long Island, New York which is in seismic zone 2A and it must be designed to handle that seismic conditions.

3.6.1.2.1. Drip Pan

Since the area below the IP8 cold box will house sensitive electronic equipment, it is important to prevent any excessive water from dripping off the cold box. The contractor will provide a drip pan to contain any moisture that could develop from cold flow on unjacketed lines from external frost or condensation. The largest risk of frost comes from the outlet of the heater in the event of a failure while cold fluids are flowing. The drip pan can be a sperate component or integrated into the design of the support stand. If it is separate and floor penetrations are required to bolt the cold box, provisions must be included by the contractor to seal any holes.


Relief of insulating vacuum vessel volume shall have a vacuum rated ASME UV relief, or ASME UD stamped burst disk (FIKE Axius disc, XL holder assembly G with O-ring groove, critical leakage design version) or one or more MDC 420033 BDA-275-ASME. To prevent accidental release of a burst disc, a pressure relief devise will be provided to vent well below the set point of the burst disc.

Relief shall be sized to handle the larger of the following two cases:

a.The relief device disk shall be sized to at a minimum handle the free convection heat transfer from the jacket wall to cold helium vapor in the event of a helium large leak/catastrophic failure of a line. A minimum heat flux of 5000W/m2 shall be used for this case.

b.The maximum practical flow delivered by the pressurized inventory of helium through the broken line is 700 g/s (1/2-inch tube x 10 ft) at a temperature of 50K. This temperature is derived from the heat transfer from the vacuum vessel walls to the gas at the listed mass flow rate.

The reaction force from the venting of the device must be taken into consideration when designing the vessel and its piping. Sizing calculations as well as reaction force values and strength calculations shall be submitted to BSA. The relief device outlet ports must have a means of connection to a pipe so that external venting of the gases can be done.

3.6.1.4. Flanged ports on the vacuum vessel

All flanged ports on the vacuum vessel shall use conflat flange connections as indicated on the schematic drawing. The size of the port and flanges will be determined by the contractor to meet the vessel’s requirements.

3.6.1.5. Penetration port list

Below is a list of the require penetrations to the vacuum vessel. These nozzle numbers must correspond to the pressure vessel analysis nozzle designation. These penetrations are consistent with the P&ID and require BSA notification and approval before they can be changed.

Nozzle/Penetration

Description

Connection/Flange type

A

Return (upper) experiment line

Pipe Line Set

B

Supply (lower) experiment line

Pipe Line Set

C

Instrumentation line for Helium Vessel

2.75” Conflat

D

Helium Vessel pressure relief

Flange, TBD

E

Electrical Feed Thru

1.33” Conflat

F

RHIC catastrophic failure vacuum warning switch

2.75” Conflat

G

Vacuum sensor port

2.75” Conflat

H

Heater and Warm helium vapor outlet

Pipe; ANSI 150 at heater for 2” pipe

I

Vacuum Vessel primary relief

Flange, TBD

J

Vacuum Vessel secondary relief

2.75” Conflat

K

Vacuum roughing pump down valve

8” Conflat

L

Vacuum turbo pump down valve

8” Conflat

M

QHS supply line, manifold and valves

Pipe Line

N

Helium Pump down line

2” Bayonet




Design pressure

Internal:

RHIC side of helium vessel valves: 273 psid@ 120°F. [18.8 bar@322K]

Solenoid side of helium vessel valves: 87psid@ 120°F. [6bar@322K]


Minimum Design Metal Temperature:

RHIC side of helium vessel valves: -452°F@internal 273 psid [[email protected]]

Solenoid side of helium vessel valves: -452°F@internal 87 psid [4.2K@6bar]

3.6.2.1. Thermal isolation on inner spools

The contractor shall give special consideration to the inner spools connecting to the LN2 sub-system to ensure proper thermal isolation and stratification of gases in the lines. Such spools include the lines connection to valves H3664A, H3665A and H3667A. When routing those spools, length and vertical orientation of the spools must be considered to isolate the warm end from the 4K helium system. Route for these as well as other internal lines will be subject to approval by BSA.



3.6.4. Liquid helium reservoir

The reservoir is needed to supply liquid helium to the superconducting solenoid in the event of losing the RHIC supply. With the solenoid as full current, it can take over 30 minutes to slowly discharge the magnet to a safe current level. The 400 liter is the minimum amount of liquid needed to keep the magnet superconducting during that time.

3.6.4.1. Design requirements for helium pressure vessel

Design Code: Designed and manufactured in accordance with ASME BPVC VIII Div-1 or 2. 2017 edition.

Design pressure:

Internal: 87 psig at 120°F (322K)

External: minimum 30 psi or higher. If the relief pressure of the jacket is higher than 15 psig, then the external design pressure shall be consistent with this relief pressure.

MDMT: 4.2K @ 87 psig

Minimum vessel volume: 400 Liters at 80% full

Material: SS304L per ASTM A240

Seismic Zone: Long Island NY, Zone 2A

Vessel elevation: 35 ft above ground level

3.6.4.2. Demisting element

The vapor outlet connection to the Return line must be designed with a demister element in place to minimize liquid carryover, while not presenting significant impedance to the helium flow. The demister element must have a 0.005” mesh diameter or smaller and be noncorrosive stainless steel. The demister must have a minimum area of 3.914 square inches or an outlet pipe inner diameter of 2.25 inches or more. The maximum flow rate will be 10 g/s and the pressure drop must be below 0.2 PSI.

3.6.4.3. Inlet connection

The liquid inlet connection from the Supply line must be designed with an open troth fill line to prevent splashing of the liquid in the vessel. An example of an acceptable troth uses a longitudinally cut pipe to allow fluid to flow down but allow any vapor to escape. This fill line must go down to within a third of the bottom of the vessel. The line must be supported properly to prevent damage during shipping and to prevent vibration during operation. The troth design will be reviewed at the preliminary review and require BSA approval.

3.6.4.4. Outlet connection

The liquid outlet at the bottom of the vessel must have an anti-vortex breaker drain that does not create significant impedance to the helium flow.

3.6.4.5. Vessel penetration list

Below is a list of the required penetrations to the helium vessel using the “N” designation to represent nozzle. These nozzle numbers must correspond to the pressure vessel analysis nozzle designation. These penetrations are consistent with the P&ID and require BSA notification and approval before they can be changed.

N1 – Helium supply line coming into vessel

N2 – Helium Vapor Return line going out of the vessel

N3 – Vessel Pressure relief line

N4 – Level probe sensor

N5 – Pressure sensor line

N6 – Vessel liquid drain line going out of vessel

3.6.4.6. Differential pressure transducer

A differential pressure transducer will be used to measure the helium liquid level in the vessel. A sensing line will be placed at the bottom of the vessel with a minimum of 3 loops to prevent thermo-acoustic oscillations. The other sensing line will be off the upper vapor space of the vessel. The contractor will provide the sensor as well as a mounting bracket for the sensor assembly.

3.6.4.7. Warm up heater

The contractor will mount heaters on the vessel to allow for a controlled warm up and pressurization of the vessel. The flexible Kapton type heaters will be provided by BSA as well as installation instructions. The heater must be secured to the vessel using a mechanical feature or clamp and ensure good thermal conductivity. The wire leads from the heater will be routed to the electrical feed through. The location of the heater shall be placed as low as possible on the vessel to ensure all liquid can be boiled off. The vessel temperature sensor should be mounted close to this heater to provide some feedback on the heater’s temperature. The locations of these devices and the mechanical holding feature for the heater shall be presented to BSA for final approval at the Final Design Review (FDR).

3.6.4.8. Relief requirements for liquid reservoir

3.6.4.8.1. Relief criteria

The helium pressure vessel shall have an ASME UV reliefs. The relief device will be sized to at a minimum handle the loss of insulating vacuum to air with 40 layers of MLI around the vessel. A minimum heat flux of 6,000 W/m2 shall be used for this scenario. The relief will be set at 72 PSIG. The reaction force from the venting of the device must be taken into consideration when designing the vessel and its piping. Sizing calculations as well as reaction force values and strength calculations shall be submitted to BSA.

3.6.4.8.2. Dual reliefs with valve switch over

The contractor shall provide 2 reliefs with a remote aire actuated switch over valve. The valve will be used to switch reliefs in the RHIC tunnel while there is no access to the area. Venting could result in the relief not fully seating from the cold temperatures. Being able to remotely switch over will allow the relief to warm up and safely reseat while still maintaining a pressure relief on the vessel.

3.6.4.9. Vessel internal supports

The helium vessel must be supported so that it can be safely shipped. The contractor has the option to create a support system that would be permanent and allow for shipping of the vessel or a temporary support that would be removed before final installation. The final approval for the design will be made by BSA.

3.6.5. Liquid nitrogen/helium heat exchanger

The heat exchanger will consist of a liquid nitrogen bath with a finned coil wrapped around an inner mandrel. The liquid nitrogen will fill the bottom portion of the vessel, submerging the lower windings of the finned coil. The nitrogen vapor travels up and cools the warm helium in the finned tube. Helium enters the top of the coil and exits cooled at the bottom.

3.6.5.1. Design requirements for nitrogen pressure vessel

Design Code: Designed and manufactured in accordance with ASME BPVC VIII Div-1 or 2.

Design pressure:

Internal: 275 psig at 120°F (322K)

External: minimum 30 psig or higher. If the relief pressure of the jacket is higher than 30 psig, then the external design pressure shall be consistent with this relief pressure.

MDMT: 4.2K @ 275 psig

Minimum vessel volume: 53.3 Liters at 100% full (3,254 in3; 14.1 gallons)

Inner diameter of vessel: 23.5 inch

Minimum height of cylindrical portion of the vessel: 33.75”

Material: SS304L per ASTM A240

Seismic Zone: Long Island NY, Zone 2A

Vessel elevation: 35 ft above ground level

3.6.5.2. Demisting element

The vapor outlet connection to the Return line must be designed with a demister element in place to minimize liquid carryover, while not presenting significant impedance to the helium flow. The demister element must have a 0.005” mesh diameter or smaller and be noncorrosive stainless steel. The demister must have a minimum area of 3.914 square inches or an outlet pipe inner diameter of 2.25 inches or more. The maximum flow rate will be 32 g/s and the pressure drop must be below 0.2 PSI.

3.6.5.3. Inlet connection

The liquid inlet connection from the Supply line must connect to the bottom of the vessel. The design will be reviewed at the preliminary review and require BSA approval.

3.6.5.4. Vessel penetration list

Below is a list of the required penetrations to the helium vessel using the “N” designation to represent nozzle. These nozzle numbers must correspond to the pressure vessel analysis nozzle designation. These penetrations are consistent with the P&ID and require BSA notification and approval before they can be changed.

N1 – Warm helium coming into vessel

N2 – Cold helium going out of the vessel

N3 – Nitrogen inlet

N4 – Nitrogen outlet

N5 - Vessel Pressure relief line

N6 – Level probe sensor

N7 – Pressure sensor line

N8 – Vessel liquid drain line going out of vessel

3.6.5.5. Warm up heater

The contractor will mount heaters on the vessel to allow for a controlled warm up and pressurization of the vessel. The flexible Kapton type heaters will be provided by BSA as well as installation instructions. The heater must be secured to the vessel using a mechanical feature or clamp and ensure good thermal conductivity. The wire leads from the heater will be routed to the electrical feed through. The location of the heater shall be placed as low as possible on the vessel to ensure all liquid can be boiled off. The vessel temperature sensor should be mounted close to this heater to provide some feedback on the heater’s temperature. The locations of these devices and the mechanical holding feature for the heater shall be presented to BSA for final approval at the Final Design Review (FDR).

3.6.5.6. Level probe

The nitrogen fluid level needs to be monitored. The contractor will design a removable level probe system with the interfaces listed in 4.20.3-Liquid Level Indicator. The probe can be inserted in the center of the design as shown in the reference design drawings, ensuring that none of the vapor is bypassed that would result in the loss of cooling capacity of the heat exchanger.

3.6.5.7. Relief requirements for liquid nitrogen reservoir

The pressure vessel shall have an ASME U relief. The relief device will be sized to at a minimum handle the loss of insulating vacuum to air with 40 layers of Multi-Layer Insulation (MLI) around the vessel. A minimum heat flux of 500 W/m2 shall be used for this scenario. The relief will be set at 72 PSIG. The reaction force from the venting of the devise must be taken into consideration when designing the vessel and its piping. Sizing calculations as well as reaction force values and strength calculations shall be submitted to BSA. The relief device outlet ports must have a means of connection to a pipe so that external venting of the gases can be done.

3.6.5.8. Inner pipe design requirements [Exchanger coil and tubing inside exchanger]


Material: C122 SB75 LA Copper as per ASTM B224

Isolation section between copper exchanger coil segments and transition segments to outside of heat exchanger boundaries: Type 304/304L (dual graded), austenitic Stainless Steel as per ASTM A312 or ASTM 269

Design pressure


External: 87 psid @ 120°F [6.0bar@322K] .

Minimum Design Metal Temperature: -320°F@internal 87 psid [[email protected] bar]

Overall length: 31.3 meters (102.5 feet)

3.6.5.8.1. Heat exchanger coil

The contractor shall provide the coiled heat exchanger and integrate it into their design. The inner piping of the heat exchanger will be a coiled copper line with 0.500” tall circular fins with a 0.020” thickness. The fins will be spirally wrapped around the tubing with 7 fins per inch pitch. The tubing and the fins shall be tin solder coated to ensure good thermal contact between those parts. The finned tubing shall then be coiled around a mandrel diameter to fit within the vessel, ensuring a tight fit to prevent any vapor bypassing. The heat transfer calculations used the DuraFin- DURA-IS: Edge Tension Soldered Finned from Energy Transfer (www.finnedtube.com) as the basis. Alternative product lines can be used but will require BSA approval to ensure proper capacity.

3.6.5.8.2. Rope spacers

In order to prevent vapor from bypassing the heat exchanger, natural cotton rope must be used to fill voids in the coil. The tangency of circular fins creates voids that would minimize the interaction time between the vapor and the heat exchanger. The rope shall be used by the contractor to fill those voids on the inner and outer side of the coil, allowing for maximum interaction time and therefore improved heat transfer. The contractor shall ensure the ropes stay in place during assembly and shipping.

3.6.5.8.3. Coil bare sections from manufacturing

The manufacturing of a long continuous finned coil will eventually require coupling sections to join the sections of coils. The contractor will minimize the length of these regions when possible and provide a spacer to minimize vapor bypass.

3.6.5.8.4. Thermal isolation coil section

To ensure the lowest level of the submerged coil reaches the nucleate boiling regime, a stainless-steel thermal isolation section will be used. The single spiral of this material will isolate the highly thermally conductive copper from influencing the temperature of the lowest coils. Bi-metallic joints will be used on either side of this isolation section.

3.6.5.9. Inner mandrel design

The inner mandrel will be used to prevent any vapor bypass. The mandrel will act as a spacer. The contractor shall provide the mandrel and can integrate it in their design to facilitate the heat exchangers manufacturing and support of other internal components. The outer diameter of the mandrel must be a tight fit against the inner diameter of the fined coils. The end of the mandrel must be sealed to prevent vapor bypassing the coils. The mandrel shall not trap any vapor or hold any substantial amount of liquid by the nature of its design. The ideal representation of this mandrel would be a solid block of material, but given its diameter, that would be impractical.

3.6.6. Heater port and assembly

A cold gas heater will be required as part of the cold box to ensure that the helium outlet is as room temperature. BSA will provide the heater. The contractor shall design and fabricate the heater assembly in accordance with ASME B31.3 piping code to handle the proper pressure and temperature of the system. The inlet for the heater will come from the cold box and will be determined by the contractor. The outlet port must have a 2” ANSI 150 flange. The heater assembly should be designed such that the immersion heat elements can be removed for service or inspection. This can be accomplished by mounting the heater to a flanged connection which would allow for the heater to be removed with the flange. The assembly shall use at 5” 150# flange to interface with the heater. The flange shall have a Viton O-ring with a mating groove to complete the pressure seal. The main body of the heater assembly shall consist of a 5” schedule 10 pipe whose inner diameter shall be inspected to ensure smooth insertion of the heater. The contractor must ensure that the heater can be removed and inserted in its final installation location. The contractor shall supply a blank flange to cap the heater port for pressure testing and shipping.

3.6.7. Bayonets

3.6.7.1. Bayonet list

The following list of bayonets shall be provided by the contractor as indicated.

Bayonet

Size

Connecting to:

Provided as:

BC-01

1”

Supply jumper from IP8 manifold

Part of jumper spool and cold box

BC-02

1-1/2”

Return jumper from IP8 manifold


BC-03

1/2"

Shield jumper from IP8 manifold


BC-04

3/4"

LN2 supply line

Female part of IP8 cold box; male loose for LN2 system

BC-05

1-1/4”

LN2 vent line

Female part of IP8 cold box; male loose for LN2 system

BC-06

1-1/2”

Return jumper from solenoid


BC-07

1/2"

Shield jumper from solenoid


3.6.7.2. Unattached bayonets (LN2 supply and vent)

There will be two unattached male bayonets provided by the contractor. Those bayonets are for the liquid nitrogen portion of the system. The unattached bayonets will mate with their respective female counterpart and confirmed with an insertion test. These bayonets shall be provided to BSA as soon as possible to ensure connections can be made to the LN2 system.

3.6.8. Field weld joint to existing solenoid valve box jumper

The contractor shall provide interfacing parts to complete the connection to the IP8 cold box. The weld joint will connect the process line as well as close the vacuum boundary. All components will have the ability for field length adjustment of at least 6” to be cut onsite to ensure proper fit.

3.6.9. Valves

3.6.9.1. Fluid valves

The contractor shall include the following cryogenic control valve in the transfer lines:

Valve Tag

Description

Trim size

Cv / Kv

Trim profile

Trim Turndown ratio

Pipe size

Fail position

Actuator type

Actuation direction

Stem seal

Positioner

Position Feedback

Position Limit switches

Heat station

@100K

H3664A

Warm bypass

6.0 / 5.2

EQ%

>35

1”NPS

F.C.

Air/Spring

Air to open

Bellows

I/P

Analog

Yes

H3665A

90K Supply

4.0 / 3.5

EQ%

>35

1”NPS

F.C.

Air/Spring

Air to close

Bellows

I/P

Analog

Yes

H3667A

S to LN2 Exchanger circuit

9.0 / 7.8

EQ%

>35

1”NPS

F.C.

Air/Spring

Air to open

Bellows

I/P

Analog

Yes

H3668A

S to 400L Fill

0.8 / 0.7

EQ%

>35

0.5” T

F.L.

Air/Spring

Air to open/close

Bellows

I/P

Analog

Yes

X

3669A

400L to Return

0.8 / 0.7

EQ%

>35

½”NPS

F.L.

Air/Spring

Air to open/close

Bellows

I/P

Analog

Yes

X

H3670A

Shield Return

2.0 / 1.7

EQ%

>35

½”NPS

F.C.

Air/Spring

Air to open

Bellows

I/P

Analog

Yes

N6248A

LN2 Supply to LN2 Boiler

2.0 / 1.7

EQ%

>35

½”NPS

F.C.

Air/Spring

Air to open

Bellows

I/P

Analog

Yes

3.6.10. Vacuum valves

Each vacuum space shall have a valve to pump down to the desired vacuum on site as indicated in Section 4.5: Vacuum Spaces, Vacuum pump-out Valve, Vacuum gauging, and Getter System. Transfer line jackets shall use a vacuum seal-off valve. The vacuum seal-off valves shall be selected or designed so that the sealing plug cannot violently eject in the event of a rapid pressurization. This can be inherited in the design of the valve or through the use or a protective shroud.

The contractor shall supply the corresponding operator for the selected seal-off valve provided.

3.7. Cryogenic piping to Solenoid Valve Box







3.7.2. Vacuum relief requirements

Any static vacuum jacket lines will have a pressure relief device installed in each line to prevent over pressurization. The insulating vacuum space shall have a vacuum tight ASME UV stamped certified relief device (for capacity). Full bore vacuum port operators can be used considered as an adequate relief device but must be approved by BSA. The operators must show to the meet the relieving capacity and retain the end plug to prevent injury from its release. The relief pressure shall be set at 15 PSIG. At a minimum, the reliefs shall be sized to handle a 4-atmosphere leak of helium into the vacuum space with a convective heat transfer value of 5000 W/m2 from the inner wall of the jacket pipe. This case shall dictate unless another case can be identified that would require a larger relief size.





Design pressure

Internal: 87 psid@ 120°F. [6 bar@322K]


Minimum Design Metal Temperature: -452°F@internal 87 psid [4.2K@ 6 bar]



Line Segment

Process Line Size

End 1

End 2

Liquid supply

1” SCH10

Field joint to IP8 cold box

Field joint to solenoid valve box

Vapor return

1-1/2” CH10

Bayonet to IP8 cold box

Bayonet to solenoid valve box; unattached female bayonet to be included

Shield return

1/2” SCH10

Bayonet to IP8 cold box

Bayonet to solenoid valve box; BSA to provide the male bayonet

3.7.5. Bayonets

The cryogenic lines connecting the IP8 cold box and the solenoid valve box will use bayonets in some locations.

3.7.5.1. Unattached bayonets

The vapor return line will need an unattached female bayonet to interface with the solenoid valve box. The interface for that connection is not fully defined so it can accommodate the contractor supplied bayonet. That female bayonet shall be delivered in a timely manner for integration into the solenoid valve box by BSA. The contractor will supply all interfacing parts and seals to complete this unattached bayonet.

3.7.5.2. Government Furnished Equipment (GFE) – Bayonet

One bayonet will the provided by BSA and treated as Government Furnished Equipment (GFE). The bayonet will be provided to easily mate with the existing connection on the solenoid valve box. The bayonet is attached to an existing spool that can be sent to the contractor to ensure adequate room exists for their integration into the shield return line.

3.7.6. Flexible section

The spool sections will need to allow for a large tolerance adjustment in the final location of the IP8 cold box bayonets. The adjustment needs to be +/- 3” in all directions; X, Y, & Z. To facilitate this adjustment, the contractor shall integrate a vacuum jacketed flexible hose section on the horizontal portion of the spools.

3.7.7. Additional Supports

The jumper lines span the gap from the solenoid valve box to the IP8 cold box. Due to the limited space requirements, the contractor shall create a self-supporting design for the jumpers. The lines must be able to take the additional moment and bending force loads from the jumper lines acting on the bayonets ends. The contractor shall account for the loads by increasing the vacuum jacket diameter or through the addition of gusset braces to ensure the jacket and internal lines are not overstressed. The loads shall be included in the ASME B31.3 piping analysis and any necessary structural calculations.

3.7.8. Supply line design

The supply line connecting the IP8 cold box and the existing solenoid valve box requires additional considerations for its design. It is a heat leak sensitive line and its design needs to minimize any external heat from entering. By the nature of its location, using an active heat shield is not practical. Furthermore, the final location tolerance of the end bayonets cannot be fully determined until the end of the entire project. This will require a means to adjust the final length on site.

3.7.8.1. Split design

To account for the tolerance in this rigid line, the major length of the line will need to have an additional field joint provided. The joint will have to allow for adjustment in the horizontal portion of the line. The vertical tolerance will be adjusted at the field joint at either end on the IP8 cold box and the existing solenoid valve box. The horizontal adjustment must be able to account for a 12” range of adjustment. Mating components, MLI, and closure parts must have this built into the parts so that they can be trimmed to fit in the field.

3.7.8.2. Low heat leak

Minimizing heat leak for this line is important. As a result, field joints shall be used in place of bayonets due to their added heat leak. The contractor shall take special attention to minimize heat leak in this supply line during design and fabrication.

3.7.8.3. Field joint closures

The contractor shall provide interfacing parts to complete the connection to the IP8 cold box and the existing solenoid valve box. The weld joint will connect the process lines as well as close the vacuum boundary. All components will have the ability for field length adjustment of at least 6” to be cut onsite to ensure proper fit. The contractor will provide the components to complete the vacuum jacket at the existing solenoid valve box. This shall include core line couplings, MLI, and vacuum shell closure pieces as well as any pieces needed to connect or complete the solenoid jacket. The recommendations for the field joint can be made by the contractor but the current configuration will use a 2” pipe as the vacuum jacket.

4GENERAL REQUIREMENTS

To insure proper field installation, the dimensions on the drawings shall be followed. They are specified to ensure such items as proper mating for pipe ends, avoiding interferences, and structural support locations. The selection of specific components and materials for the final design shall minimize heat leak, cool-down cold-mass, and fluid flow resistance.

The contractor is responsible for the engineering design of this system. All aspects of the contractor’s proposed design shall be reviewed and approved by BSA prior to beginning fabrication. The contractor shall have the responsibility for all aspects of the final design, such as: thermal and mechanical performance, safety, reliability, quality, ease of installation and assembly, etc., in accordance with this specification. The contractor is responsible to show that the design meets all analytical requirements through the use of hand calculations, computer simulations, and code calculations which shall be documented in reports submitted to BSA.

4.1 Materials

All internal lines and vacuum jackets (including weld attachments) shall be constructed of dual graded Type 304/304L, austenitic Stainless Steel as per ASTM A-312 or ASTM 269. In addition, all internally pressurized piping and vacuum jackets shall be of a welded construction. Contractor shall identify all materials of construction during the conceptual design review. All other cryogenic components such as valves, flexible hose, bayonets, etc., shall be constructed of cryogenic engineering industrial standard 300 Series Stainless Steel. Application of epoxies or other similar materials shall be rated for cryogenic service, specified in the proposal, and used only upon written approval of BSA. Material certifications for all material used in the final fabrication shall be included with the final deliverable packet submitted to BSA.

When building assemblies or components of dissimilar materials the vender will review the interfaces to remove or minimize the effects of any potential galvanic corrosion. In such cases, there must not be more than 0.25 V difference in the "anodic index."

4.2 Bi-Metallic joints

When transitioning from different materials, bi-metallic joints are needed. These components are typically susceptible to damage from thermal shock due to the difference in the material’s thermal expansion coefficients. The contractor shall ensure these joints are properly secured in their design and shown not to be stressed in their piping and structural analysis. When such components are to be used, they must be full thermally cycled at least 5 times from room temperature to 80K. After the temperature cycling, the joints will be helium mass spectrum leak check to verify that there were no manufacturing defects. The contractor will provide photographs, indicating the time elapsed, for each thermal cycle as well as results of the leak checking in a single report. Equivalency reports from a component supplier shall be considered by BSA, in lieu of such testing if the supplier can show that their testing exceeds the requirements listed.

4.3 Transfer Line Heat Leak

The heat leak into the vacuum jacketed transfer line shall be consistent with liquid helium application. The transfer line shall have a heat leak requirement of no more than 1.9 W/m2 using the Outer Diameter (OD) of the jacket piping. This is a combined radiation and conduction heat leak total. The contractor shall determine the total heat leak for their line, including conductive and radiation loads, in watts and divide it by the total external surface area of the pipeline in square meters. The external surface area shall be determined by the perimeter of the jacket piping multiplied by the total length of the line. The contractor shall include this calculation in their analysis and make a clear comparison to the required value for each pipe spool.

4.4 Multi-Layer Insulation

All process piping shall be individually wrapped with MLI (Multi-Layer Insulation). Blanket or spiral wrapped construction is acceptable. MLI design shall be adequate for low heat leak liquid helium temperature applications.

Multi-layer super-insulation with at least 40 layers shall be provided to insulate the surface of the helium vessel. This is to minimize the heat flux for the case of loss of insulating vacuum to air (to an MLI insulated helium vessel) and needed to use the minimum heat flux value of 6,000 W/m2.

When thermal shields are utilized, a minimum of 20 layers will be wrapped outside the shield.

4.5 Thermal heat shield

To minimize heat leak on the cryogenic lines, a thermal heat shield shall be incorporated around the process lines where indicated. Heat shield cooling will use 30K vapor originating from the outlet of the solenoid shield in the IP8 experiment building. The contractor shall determine the design to ensure it is able to meet the heat leak requirements. Typical installation includes, but are not limited to, aluminum shields with D-shaped tubes attached to them by solder to ensure full thermal contact. Typical material options include Aluminum D-tube on 1100 or 3003 sheets, with aluminum D-tube 6063/6061/3003 or Copper tube on copper sheet. Shields must have a uniform temperature profile that does not exceed a 10-degree temperature increase from the outlet temperature of that portion of the shield section.

4.5.1 Heat stationing

The heat shield will be used to station parts of the design to intercept heat leak. Heat stationing locations are indicated on the P&ID and can be placed at additional locations needed by the contractor to meet the heat leak requirements. Heat stationing include, but are not limited to, valves and vacuum breaks.

4.6 Bellows and Braided Flexible Metal Line

Flexible sections, both process flow and vacuum space, are required as part of the final design, and all flexible hoses shall meet ASME B31.3 requirements. The contractor shall submit Expansion Joint Manufacturers Association (EJMA) calculations to show that the active length of flexible line was sized correctly and that it meets pressure and temperature requirements.

4.6.1 Bellows/ Braided Flex Lines for Vacuum Jacket Lines

Bellows used for absorbing axial thermal displacements of the vacuum jacket shall be designed for the jacket temperature range of 266K to 320K and 5000 cycles. The quantity and location of internal bellows, their type, and guidance, shall be determined by the contractor to accommodate system pressure and temperature excursions. The bellows installation design shall prevent mechanical damage and thermal contact between the process piping and the vacuum jacket that can occur as the result of squirm, axial offset, deflection, etc. caused by pressure and/or temperature change.

Bellows and braided flexible lines shall be designed to handle external pressure (vacuum inside with pressure outside) as specified in the requirements section of this specification. As shown on the BSA provided drawings, some transfer lines require supports for the vacuum jacketed flex sections.

4.6.2 Bellows / Braided Flex Lines for Internal Process Lines

Bellows for internal process lines shall be supplied with an EJMA technical calculation summary specification sheet. Bellows used for absorbing axial thermal displacements of the inner process line shall be designed for the pipe temperature range of 4K to 320K and 5000 cycles. The quantity and location of internal bellows, their type, and guidance, shall be determined by the contractor to accommodate system pressure and temperature excursions. The bellows installation design shall prevent mechanical damage and thermal contact between the process piping and the vacuum jacket that can occur as the result of squirm, axial offset, deflection, etc. caused by pressure and/or temperature change.

Braided flexible lines shall be supplied with contractor’s pressure/temperature ratings technical data sheet. Bellows and braided flexible lines shall be designed to handle external pressure (vacuum inside with pressure outside) as specified in the requirements section of this specification.

4.7 Vacuum Spaces, Vacuum pump-out Valve, Vacuum gauging, and Getter System

The self-contained vacuum space shall contain a pump-out valve, pressure relief valve, and a conflat flange. The vacuum space shall each contain an appropriate getter system that shall remove residual gases, moisture, and hydrogen. A list of each size Vacuum Seal-Off /Valve Operators used shall be supplied to BSA. Transfer lines shall also have a thermocouple vacuum gage (DV-5) mounted to an isolation valve.

Getter System

Getter PdO (palladium oxide), molecular sieve, charcoal system, or BSA approved equivalent, shall be installed in sufficient quantities in each vacuum space of the cryogenic transfer lines as a completed sealed and leak checked system. Getters shall be packaged in a properly sealed system and shall be activated appropriately.

4.8 Vacuum Breaks and Thermal Transitions

When needed, vacuum breaks will be provided in the piping and vessel design to isolate vacuum spaces. Since such vacuum breaks typically connect the cold process lines to warm vacuum jackets, it is important to review the thermal transition for stress and heat leak. In order to minimize heat leak, it is necessary to review the thermal conduction path. The contractor will provide a calculation of the temperature distribution in such a break as well as a steady state heat leak. The vacuum break must also be included in any piping analysis to ensure the line is not over stressed.

At a minimum, the contractor will provide a double leg vacuum break to act as the thermal transition unless another configuration can be proven to meet the stress and minimal heat leak requirement. The double leg design uses two pipe lines of different sizes to step up from the process pipe diameter to the jacket diameter. Vacuum breaks will include heat stationing at the midpoint of the double leg unless analysis indicates a more optimal location.

4.9 Pressure Loss from Flow Resistance

Minimizing flow resistance or pressure drop in this system is critical for its function. Since all the line sizes and valve sizes have been specified, the contractor shall ensure the design is consistent with these requirements. This shall include the process piping and fittings, vacuum jacketed inlet piping, heater vessel, and outlet piping. Components that can produce flow restriction, such as bayonets, valves and flexible lines, in the process line shall be factored into the calculation. Inlet gas conditions shall be 4.5K at

3.5 atm with temperatures after the heater at 300K. To minimize the pressure drop, the contractor shall incorporate large radius elbows for the process piping and rounded or transitional entrances for the heater vessel. The contractor shall review the pressure drop calculation for all transfer lines and routing design and submit this for BSA verification and approval.

4.10 Cryogenic Piping Supports4.10.1 Internal supports

For proper cryogenic piping design, inner pipe supports are necessary to ensure that the inner pipe is not over stressed and that it does not directly contact the outer pipe (jacket piping). The vacuum jacketed cryogenic piping shall incorporate a pipe spider. Since minimizing resonant vibrations is critical for this design, the helium core pipes shall be supported at least every 5 feet with a pipe spider. The spider shall allow for longitudinal displacement of the core piping while supporting it laterally to the jacket pipe. Supports for this piping shall match the piping analysis, and their locations and types shall be indicated on the drawings created by the contractor and submitted to BSA.

The piping supports shall be included the heat leak requirement for the lines and the contractor’s calculations. The contractor shall provide a detailed drawing of the spider design as well as its thermal calculation to BSA prior to fabrication. This drawing shall be used to verify system level heat load calculations.

Spiders shall be secured to the piping to ensure that the spacing remains within 1 inch of the designed value and to ensure that the spiders do not jam, which would prevent longitudinal travel of the core pipe. When installing the spiders, the orientation shall be varied to minimize vibrations. For instance, square shaped spiders shall be installed with a 45-degree rotation relative to the previous spider to optimize the contact with the jacket pipe. To verify proper installation of spiders, the contractor shall submit photographs of the spiders on the core pipe prior to insertion into the jacket.

4.10.2 External supports

The contractor will include supports for the external piping vacuum jackets were indicated on their analysis and coordinated with BSA. The support shall be a guide type that allows for longitudinal displacement of the piping while supporting it laterally. Supports for this piping must match the piping analysis and their locations and types must be indicated on the drawings created by the supplier and submitted to BSA.

The supplier will supply all the brackets and hangers necessary to secure the piping to 1-5/8” Unistrut structural channel. The structural channel will be provided by BSA. Where applicable the channels will come out perpendicularly from the wall in the horizontal position with the open channel facing up. If necessary, ceiling or floor channels can be provided after coordination with BSA. The supplier will ensure that the strength of the support brackets provided exceeds the maximum possible loads from the pipe. BSA will be responsible for securing the pipe supports with the reaction force loads given by the supplier.

The supplier shall place a visible and permanent mark on the exterior of the piping to indicate where the supports shall be installed. Supports on the external vacuum jacket shall have a permanent marker to indicate the location of

technical specification for helium cryogenic … · web viewsolenoid valve box. the weld joint will...

Documents