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Session 2 - Shutdown 2012

Session 2 - Shutdown 2012. Consolidations of Cryogenic Systems Review of the consolidation works scheduled for the cryogenic installations during a long shutdown. Olivier Pirotte on behalf of TE/CRG. OUTLINE. Non conformities (ECRs) / Repairs

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Session 2 - Shutdown 2012

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  1. Session 2 - Shutdown 2012 Consolidations of Cryogenic Systems Review of the consolidation works scheduled for the cryogenic installations during a long shutdown Olivier Pirotte on behalf of TE/CRG

  2. OUTLINE Session 2 - Shutdown 2012 - Consolidations of Cryogenic Systems - O. Pirotte on behalf of TE/CRG • Non conformities (ECRs) / Repairs • DFBssafety valves : DFBA (S23/S78/S81), DFBM (Q6R2 & Q6L8) • Air leak DFBAO & DFBMC abnormal thermal load • Replacement of flexible in DFBA (leakprevention) • IT safety valve DN300 collector (safety) • He level gauge on StandaloneMagnets (seeJPhTock’s talk) • Leaks in “Y”-lines (seeJPhTock’s talk) • Instrumentation of the tunnel (Recommendation #12, TF Report) • HRL sectorization(Recom. #13, TF Report) • DFBA CLs : TT channels 1.9 kV consolidation (EDMS 919146) • Quenchlines

  3. OUTLINE Session 2 - Shutdown 2012 - Consolidations of Cryogenic Systems - O. Pirotte on behalf of TE/CRG • Consolidations & new proposals • Decoupling of adjacent cryogenicsectors(reminder of G. Ferlin’spresentation, Chamonix 2009) • Access platforms to the QRL Service Modules • QRL service module compressed air distribution • Insert of flowmeters on BeamScreen circuits • Upgrade of DFBX CurrentLeads control • Addition of a pressure measurement on header B • ATLAS consolidations • DFBAO: improvement of LHelevel control (idem DFBAC) • QURC P6 : change CV241 valves (idem P4, reducedowntime)

  4. OUTLINE Session 2 - Shutdown 2012 - Consolidations of Cryogenic Systems - O. Pirotte on behalf of TE/CRG • Mandatory maintenance activities • Major overhauling planning • Upgrade / new installation • Additionalrefrigeratorat P4 (cavities)

  5. HRL sectorization Allowsafe interventions in the tunnel and improvecryogenic consignations AIM Motorization of the HRL sector valves Cost : 100 kCHF Installation : 1w/sect. + cabling HOW Session 2 - Shutdown 2012 - Consolidations of Cryogenic Systems - O. Pirotte on behalf of TE/CRG

  6. DFBA CLs : TT channels 1.9 kV consolidation • Prevent destruction of TT on 13kA CLs (major downtimerisk) • Restore conformitywith LHC specification (Tests @ 1.9 kV) • Cancel 5 TeV limitation AIM • Change : • Connectors • Cables • DAQ Cards HOW Cost : materialalreadysupplied Duration : 2-3 w / DFBA (cards CRG, cables EN/EL, connectors MPE) Session 2 - Shutdown 2012 - Consolidations of Cryogenic Systems - O. Pirotte on behalf of TE/CRG

  7. QUENCH LINES CONSOLIDATION Test of QLsat P5 • Restore the operation of quench lines (quench sector issue : He -> atm.) • Avoid major downtimerisk (use of He strategicstorage) • Avoid extra costrisk : ~700 kCHF / sector Point 5 AIM Destruction of the insulation /Liquid air on cabletrays HOW : Restore the functionality of QLs • Figures : • New integration solutions to bestudied • Issue : sections with vacuum insulated TL ? • Costestimate : ~500 kCHF • Installation : 10 weeks / Point • 2012->2013 ?: no consequence if E ~3.5/4 TeV Manyconflictswithneighbouringequipementsduringshrinkage Session 2 - Shutdown 2012 - Consolidations of Cryogenic Systems - O. Pirotte on behalf of TE/CRG

  8. OUTLINE Session 2 - Shutdown 2012 - Consolidations of Cryogenic Systems - O. Pirotte on behalf of TE/CRG • Consolidations & new proposals • Decoupling of adjacent cryogenicsectors(reminder of G. Ferlin’spresentation, Chamonix 2009) • Access platforms to the QRL Service Modules • QRL service module compressed air distribution • Insert of flowmeters on BeamScreen circuits • Upgrade of DFBX CurrentLeads control • Addition of a pressure measurement on header B • ATLAS consolidations • DFBAO: improvement of LHelevel control (idem DFBAC) • QURC P6 : change CV241 valves (idem P4, reducedowntime)

  9. Decoupling of adjacent sectors Allow exchanging a magnet or a QRL SM in a sector while keeping the adjacent sector in nominal cryogenic operation AIM • Add a submarine DN250 valve on header B HOW • Cost : 130 kCHF / sector (QUI) • Installation : 4-6 w / sector • QUI Session 2 - Shutdown 2012 - Consolidations of Cryogenic Systems - O. Pirotte on behalf of TE/CRG

  10. Platforms for QRL Service Module Allow safe intervention on instrumentation of a QRL SM (arc, SAM, DFBs) AIM • HOW : Install accessplatforms Studywith EN/MEF of a retractableplatform to access a standard QRL Service Module in the arcs Session 2 - Shutdown 2012 - Consolidations of Cryogenic Systems - O. Pirotte on behalf of TE/CRG

  11. QRL Service Module Access Issue – Arc How to get and work on the instrumentation of the SM ? Maintenance activities + interventions on cryogenicsystemsrequiredaccess to instrumen-tation Safety issue with maintenance personnel Session 2 - Shutdown 2012 - Consolidations of Cryogenic Systems - O. Pirotte on behalf of TE/CRG

  12. QRL Service Module Access Issue - DFBs How to get and work on the DFBs ? Unsafeaccess conditions : risks of injuries and collateral damage to neighbouringequipements Session 2 - Shutdown 2012 - Consolidations of Cryogenic Systems - O. Pirotte on behalf of TE/CRG

  13. Platforms for QRL Service Module Allow safe intervention on instrumentation of a QRL SM (arc, SAM, DFBs) AIM • HOW : Install accessplatforms Study of a retractableplatform to access a standard QRL Service Module in the arcs • Figures : • 310 QRL Service Modules • Standard config. : ~200 SM in the arcs • Non standard config. : SAMs / DFBs (DFBX?) / RMs • Costestimate : 850 kCHF • Installation : 4-6 weeks / sector • Shift from 2012 to 2013 : no consequence Session 2 - Shutdown 2012 - Consolidations of Cryogenic Systems - O. Pirotte on behalf of TE/CRG

  14. QRL SM - Compressed air distribution • Improve performance and life time of cryogenic control valves AIM • Split air distribution :add a 2 bar collector for CV in // of the 6 bar one QV HOW Air 6 bar 2 bar PV, CV • Cost : 25 kCHF / sector (manpower) • Installation : 2-3 w / sector (ideallyafteraccessplatforms installation) He guard Session 2 - Shutdown 2012 - Consolidations of Cryogenic Systems - O. Pirotte on behalf of TE/CRG

  15. Proposalfollowing last operation issues:addflowmeters on BS circuits Basic cooling scheme of beam screens : ~ 53m m1, T1 Aperture 1 Ib • Aim : measurement of BS heatload (e-clouds, ?) • How : add Coriolis FT to measure mass flow in BS • Proposal : 1 FT / 400 m (8/sector) • Cost : 64 x (15 kCHF + 5kCHF for cabling) = 1.3 MCHF • Issue : integration in the interconnections TT TT D Ib mt, Tt EH m2, T2 Aperture 2 C C' Magnet side QRL side Support posts & 60 A CL FT Session 2 - Shutdown 2012 - Consolidations of Cryogenic Systems - O. Pirotte on behalf of TE/CRG

  16. DFBX: 600 A and 120 A CL control upgrade & control of heaters Improve performance and reducerisk of downtime due to the operation of DFBXs AIM • Replace 2008 consolidation by a more reactive and robust control strategy of 120A and 600A currentleads (19 x flowmeters / DFBX) • Consolidatetemporary local control system of heaters on DFBXsinstalled in 2008 HOW • Cost : 130’000 CHF / DFBX • Installation : 3 w / DFBX Session 2 - Shutdown 2012 - Consolidations of Cryogenic Systems - O. Pirotte on behalf of TE/CRG

  17. ATLAS consolidations Courtesy H. Ten Kate • Cryogenics kCHF • Compressors 1450 • Cryocontrols 470 • Small spares 50 • He pumps 175 • 11kL return line 80 • PCS pipe extension 70 • 7kL buffer 340 • He dryers 360 • Total ~ 3 MCHF Session 2 - Shutdown 2012 - Consolidations of Cryogenic Systems - O. Pirotte on behalf of TE/CRG

  18. OUTLINE Session 2 - Shutdown 2012 - Consolidations of Cryogenic Systems - O. Pirotte on behalf of TE/CRG • Mandatory Maintenance activities • Major overhauling planning • Upgrade / new installation • Additionalrefrigeratorat P4 (cavities)

  19. Mandatory Maintenance activities Major overhauling planning • The full revision of the 74 compressors is the determining factor in the planning : up to 18 weeks for compressor station with 8 CPs (QSCA) • All otherpreventive maintenance taskscanbecarried out in the shadow of the revisions: up to 6 weeks / installation (C199 contract) • Cost : • CP major overhauling : 5.2 MCHF • Preventive maint. : 1.6 MCHF Session 2 - Shutdown 2012 - Consolidations of Cryogenic Systems - O. Pirotte on behalf of TE/CRG

  20. HL-LHC : new refrigeratorat P4 • Decouple the operation of the cavitiesfrom the magnets(Sensitive control of the LP  cavities performance)&Improve P4 cryogenicmargins to equivalentlevel as P6 & P8 AIM Profit of LSD to installpipework in the shaft • Cost : 300 kCHF • Duration : 6 weeks Session 2 - Shutdown 2012 - Consolidations of Cryogenic Systems - O. Pirotte on behalf of TE/CRG

  21. In summary • The list of consolidations and maintenance activitiesscheduled for the next long SD has been presented. The total costis about 12.15 MCHF. The following consolidations shouldstronglybeconsidered : • Consolidations involvingsafety issues for the personnel : • HRL sectorization : 100 kCHF, 1 w / sector • Access platforms to the QRL SMs : 850 kCHF, 6 w / sector • Consolidations needed for 14 TeV or to avoid major downtimerisk : • DFBA CurrentLeads TT channels 1.9 kV consolidation : 3 w / DFBA • Quenchlines : 500 kCHF, 10 w / sector • Upgrade of the DFBX CLs control : 1 MCHF, 3 w / DFBX • Mandatory maintenance activities (CP major revision) : 6.8 MCHF, 14 months (18 w / LHCA) Session 2 - Shutdown 2012 - Consolidations of Cryogenic Systems - O. Pirotte on behalf of TE/CRG

  22. Acknowledgements • All CRG colleagues(J. Casas, S. Claudet, G. Ferlin, A. Perin, G. Perinić, L. Tavian, …) • ATLAS team (H. Ten Kate) • Inputs from EN/MEF • Thanks for your attention Session 2 - Shutdown 2012 - Consolidations of Cryogenic Systems - O. Pirotte on behalf of TE/CRG

  23. ADDITIONAL SLIDES Session 2 - Shutdown 2012 - Consolidations of Cryogenic Systems - O. Pirotte on behalf of TE/CRG

  24. Non Conformities – Remainingworkfrom 2009 • DN230 SV on DFBA (S23/S78/S81) • DN160 SV on DFBM (Q6R2 & Q6L8) • Deflectors for safety of persons • Duration : 3 weeks / Point • 2012->2013 ? : no consequence if E ~3.5/4 TeV • IT DN300 SV collector : • Costestimate : 25 kCHF / IT • Installation : 2-3 weeks / IT • 2012->2013 ? : no consequence. Mitigation measuresremain in force. Session 2 - Shutdown 2012 - Consolidations of Cryogenic Systems - O. Pirotte on behalf of TE/CRG

  25. Replace metallic flexible hose in DFBAs • Replace potentiallydamagedmetallic flexible hose in DFBAs. AIM • Replace the flexible hosewith a suitablydimensionned and shapedsmallerdiameter pipe HOW Installation : 1 week / DFBA (12 remaining) Session 2 - Shutdown 2012 - Consolidations of Cryogenic Systems - O. Pirotte on behalf of TE/CRG

  26. DFBAO: improveLHelevel control Connector Capillary with instrumentation wires Pressure equilib / evap. to 6kA chimney exhaust(Ø8) Level gauges LHeconnec-tion To improve the liquid He level control AIM • Install additionallevel gauge in non perturbatedchimney. • Add a heater to evaporate the liquidthataccumulatesat a low point. HOW • Cost : 5 kCHF + 10 kCHFmanpower • Duration : 2-3 weeks Session 2 - Shutdown 2012 - Consolidations of Cryogenic Systems - O. Pirotte on behalf of TE/CRG

  27. DFB Burkert valves CV891 consolidation 120/600 A • Consolidation strategy: • Use newly developed bearing-less valves • 1000 valves for 600A & 120A valves already delivered • 10 x 13 kA + 64 x 6 kA valves delivered. Remaining March 2011 • Installation during technical stops • 2010-2011 Xmas break : all DFBX + 600 A 6 / 13 kA New Test Bench Session 2 - Shutdown 2012 - Consolidations of Cryogenic Systems - O. Pirotte on behalf of TE/CRG

  28. Cold Cold Cold compressor compressor compressor system system system 4.5 K 4.5 K 4.5 K refrigerator refrigerator refrigerator LN2 LN2 LN2 B B B C C C D D D D D C C E E F F Cryogenic Cryogenic Cryogenic interconnection interconnection interconnection box box box Lowest Lowest Lowest 4.5 K standalone 4.5 K standalone 4.5 K standalone Distribution Distribution Distribution point point point magnet or cavities magnet or cavities magnet or cavities feed box feed box feed box Standard cell pair Standard cell pair Standard cell pair Mid sector Mid sector Mid sector Return module Return module Return module F F F F F F F F F F F F F F F F F F F F F F F F B B B B B B B B B B B B B B B B B B B B B B B B C C C C C C C C C C C C C C C C C C C C C C C C D D D D D D D D D D D D D D D D D D D D D D D D E E E E E E E E E E E E to adjacent to adjacent to adjacent cryogenic system cryogenic system cryogenic system Warm recovery line Warm recovery line Warm recovery line Helium ring line Helium ring line Helium ring line Addition of a pressure measurement on header B • Aim : assess line B operation + redundancy • How : add a PT on each Return Module • Cost : = 100 kCHF (12 kCHF/sector) • Issues : precision (0.2 mbar) & range (1 barg), He guard, radiation PT PT Session 2 - Shutdown 2012 - Consolidations of Cryogenic Systems - O. Pirotte on behalf of TE/CRG

  29. TEST OF QUENCH LINES AT P5 Destruction of the insulation Point 5 Liquid air on cabletrays Manyconflictswithneighbouringequipementsduringshrinkage Session 2 - Shutdown 2012 - Consolidations of Cryogenic Systems - O. Pirotte on behalf of TE/CRG

  30. ATLAS MR COMPRESSOR STATION INTRODUCE REDUNDANCY AND ENERGY SAVING AIM C4 C3 C2 upgraded C1 C5 New C6 Cost : 1.55 MCHF Installation : 12-14 w ConsolidatedATLAS MR compressor station Courtesy of J Metselaar & N Delruelle Session 2 - Shutdown 2012 - Consolidations of Cryogenic Systems - O. Pirotte on behalf of TE/CRG

  31. ATLAS – He : decouple solenoid-toroid During Toroid Fast Dump recovery, also Solenoid is down since MR in use for cooling down the toroids, thus 4d-loss of detector time Cure: Install a new ~7kL He buffer dewar to continue solenoid operation during the 5 days of Fast Dump recovery of the toroid Few options to be studied and engineered Costestimate : 350 kCHF Courtesy H. Ten Kate Session 2 - Shutdown 2012 - Consolidations of Cryogenic Systems - O. Pirotte on behalf of TE/CRG

  32. ATLAS : prevent He pollution Avoid risk of He pollution, clogging of filters and interruption of SR and MR refrigerator operation for 1-2 weeks/cleaning cycle Cure: Install He water dryers in SH1 and cold He air dryersin USA15, twin bed absorber units with auto switching and recovery Session 2 - Shutdown 2012 - Consolidations of Cryogenic Systems - O. Pirotte on behalf of TE/CRG

  33. Non Conformities – Remainfrom 2008 • DFBssafety valves (material in stock) • Installation : 3 weeks / point • Shift from 2012 to 2013 : no consequence if E ~3.5/4 TeV • Flexible in DFBA (material in stock) • Installation : 1 w / DFBA • Shift from 2012 to 2013 : no consequence if E ~3.5/4 TeV • IT safety valve DN300 collector • Design and integration to bedone : 2 months (1 w / IT) • Installation : 2 weeks / IT • Costestimate : 25 kCHF / IT • Shift from 2012 to 2013 : no consequence. Mitigation measuresremain in force Session 2 - Shutdown 2012 - Consolidations of Cryogenic Systems - O. Pirotte on behalf of TE/CRG

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