1. Felix Wamers, CSCY@GSICERN-GSI Technical Coordination Meeting, 12 th -13 th of May 2015 1 CERN-GSI Technical Coordination Meeting Felix Wamers, Yu Xiang, Holger Kollmus, and CSCY @ GSI Result from a Design Study with Cryotherm GmbH on the Cryo-Interface for SuperFRS-Magnet Testing at CERN Mid-term meeting with and pre-final documents from F. Carovani and J. Singavarapu from Cryotherm GmbH on two technical solutions for the SFRS Cryoline-Cryostat Interconnection * Introduction * Concepts of the Two Proposed Designs * Mechanical Aspects * Reaction Force Calculations (Cool-Down) * Safety Valves * Pressure Drop Calculations * Thermal Analysis (Heat In-leak) * Summary & Outlook

2. Felix Wamers, CSCY@GSICERN-GSI Technical Coordination Meeting, 12 th -13 th of May 2015 2 SFRS Cryo-Interface: Introduction Situation: Hydraulics and mechanics of the cryo-magnet-interface need to be specified and communicated to CERN, so that they can - design and tender their cryo feed boxes - design and tender their jumper connections  Reminder: GSI-CERN Committee Meeting 05.12.2014  Deadline: Next Committee Meeting 26.06.2015 CSCY Action: Industry Design-Study on the SFRS Cryo-Interface - 03.02.2015: Kickoff Meeting with Cryotherm - 25.02.2015: Offer from Cryotherm for Design Studies on 1) Jumper-Line, and 2) Feedbox - 20.03.2015: Order of item 1) by GSI - 24.04.2015: Mid-term review: Cryotherm visit at GSI - 13.05.2015: Delivery of design report and all documents

3. Felix Wamers, CSCY@GSICERN-GSI Technical Coordination Meeting, 12 th -13 th of May 2015 3 JumperLine: Goals for the Design Study Goals for the external study at Cryotherm: Suggest a JL Design fulfilling the desired mechanical, hydraulic, and thermal specs: +/-20 mm installation tolerance minimize forces on cold mass and FB keep heat in-leaks low enough keep pressure drop (cool-down) low enough coupling and dimensioning of the cryostat (and shield-lines) safety valves

4. Felix Wamers, CSCY@GSICERN-GSI Technical Coordination Meeting, 12 th -13 th of May 2015 4 Cryotherm Design: General Concept Open and Close Sliding Jackets for Cutting and Welding ClosedOpen

5. Felix Wamers, CSCY@GSICERN-GSI Technical Coordination Meeting, 12 th -13 th of May 2015 5 Cryotherm Design: General Concept Contents of Design Study: Design of Jumper-Line as such until vacuum barrier to feed box (similar to KIT, Fermilab) Suggestion of two different options in terms of alignment and shrinkage compensation via hoses Concept for process lines and SV line in cryostat Calculation/estimation of reaction forces onto cold mass during cool-down and feedbox due to loss of vacuum Pressure drop and heat in-leak calculations Sizing for LHe-vessel and shield-line safety valves Open Spacer

6. Felix Wamers, CSCY@GSICERN-GSI Technical Coordination Meeting, 12 th -13 th of May 2015 6 Cryotherm Design: Option 1 Two bellow systems for installation tolerance (2x20mm) Sliding jackets to access the process lines for welding 50 K shield moves within vacuum tube on wheels He process lines are fixed transversally within spacers, but can slide longitudinally via ‘noses’ in spacers Rigid spacers slabs (G10) can slide within shield on wheels Flexible hoses on process lines compensate for vacuum bellows and for thermal contraction Flexible 90° hoses within knee take up thermal contraction Vacuum barrier towards feedbox Closed Jackets

7. Felix Wamers, CSCY@GSICERN-GSI Technical Coordination Meeting, 12 th -13 th of May 2015 7 Cryotherm Design: Option 2 One bellow system for installation tolerance (20 mm) - further away from magnet Flexible hoses on process lines compensate for vacuum bellow and for thermal contraction Closed Jackets Shield piece flexibly connected via six thermal straps Fixed vertical part of jumper line, fix-flanged to feed box

8. Felix Wamers, CSCY@GSICERN-GSI Technical Coordination Meeting, 12 th -13 th of May 2015 8 Cryotherm Design: Mechanical Tolerances Option 1: - Two pairs of bellows: 2 times +/- 20 mm - One 90 deg hose, two 0 deg hoses Option 2: - One pair of bellows: 1 time +/- 20 mm - Two 0 deg hoses

9. Felix Wamers, CSCY@GSICERN-GSI Technical Coordination Meeting, 12 th -13 th of May 2015 9 Cryotherm Design: Reaction Forces LHe vessel (cold mass): Option 1: Zero (horizontal hoses) Option 2: 721 N = (621(A)+43(B)+57(C)) N Feed-Box (5 kN, insulation vacuum loss) Option 1: no problem Option 2: no problem Cool-down shrinkage in dome (3.5 + 0.5 mm) 3.5 mm 0.5 mm Safety Relief (11 kN, insulation vacuum loss) 15 kg/s He mass flow (no MLI) Vacuum enclosure pipeline strong enough No data from suppliers (Witzenmann) on force compensation of hoses

10. Felix Wamers, CSCY@GSICERN-GSI Technical Coordination Meeting, 12 th -13 th of May 2015 10 Cryotherm Design: Safety Valve Concept Central vertical relief line in dome Two flexible hoses for thermal compensation Relief line outside dome parallel to floor, parallel to beam line if possible Actual calculation of reaction forces, e.g. during He blow-off, cannot be calculated by Cryotherm, since the hose producer, Witzenmann, does not provide the corresponding force-response data for the hoses when bending.

11. Felix Wamers, CSCY@GSICERN-GSI Technical Coordination Meeting, 12 th -13 th of May 2015 11 Cryotherm Design: Safety Valve Sizing SV dimensioning according to AD 2000-A2 LHe vessel: 6 kW/m 2, 33 m 2  mass flow at 20 K: 10 kg/s  discharge diameter: 50 mm  mass flow from spec: 15 kg/s  discharge diameter: 62 mm Shield line (80K): 0.5 kW/m 2, 40 m 2  mass flow at 100 K: 1 kg/s  discharge diameter of 24 mm Discharge Line (19 bar * 3% = 0.57 bar) 15 kg/s: DN 125, ∆p = 173 mbar 10 kg/s: DN 100, ∆p = 298 mbar

12. Felix Wamers, CSCY@GSICERN-GSI Technical Coordination Meeting, 12 th -13 th of May 2015 12 Cryotherm Design: ∆p (Cool-Down) CERN specification: Max.: 5 bar Current design value: 1.3 bar (magnet) + 570 / 400 mbar (JL) Option 1: ~ 570 mbar in addition to 1.3 bar Option 2: ~ 400 mbar in addition to 1.3 bar

13. Felix Wamers, CSCY@GSICERN-GSI Technical Coordination Meeting, 12 th -13 th of May 2015 13 Crytherm Design: ∆T, Heat In-Leak Current design value: 22 W on shield (50 K), in total 1280 W for the whole SFRS (58 JLs) 1.0 W (+ G10 spacer contribution  GSI) on LHe (4.5 K), in total 58 W + spacers for the whole SFRS Heat Load at 80 K Shield MaterialHeat Load at 4.5 K

14. Felix Wamers, CSCY@GSICERN-GSI Technical Coordination Meeting, 12 th -13 th of May 2015 14 Summary and Outlook Summary on the Jumper Connection Design Major Aspects of SFRS cryo jumper connection mechanical design done - process lines within jacket fixed via wheel-spacers (2 v, 2 h) - two vertical and two horizontal bellows for mechanical tolerances - one corresponding vertical and horizontal flex. hose on each process line to compensate for the external bellows internally - for each process line one 120 degree (15-90-15) flex hose in the 90 degree knee of the jumper the thermal contractions during cooldown Outlook We will obtain the final documents (report, drawings, step files,...) this week. We still can ask questions. DONE NEXT Cryostat-internal piping design and safety valve connection. Mechanical stress on cold mass due to cool-down and He-loss calculated. Pressure loss calculations, thermal calculations, and safety valve sizing have been done. Cryotherm suggests to go for option 2.