HC review, A. Perin, 12-MAY DFB Project LHC hardware commissioning review May 2005 Hardware commissioning of the DFBs and DSLs and connection cryostats A. Perin, AT-ACR on behalf of R. van Weelderen, V. Benda AT/ACR, S. Marque, AT-CRI and of the DFB, DSL and connection cryostats project teams Acknowledgements: C. Davison, V. Fontanive, T. Goiffon, S. Koczorowski, R. Marie, L. Metral, AT-ACR R. Folch, M. Genet, Ph. Trilhe, TS-MME D. Bozzini, AT-MEL

HC review, A. Perin, 12-MAY DFB Project Outline  Main characteristics of the DFBs & DSLs  From workshop to operation  Commissioning the DFBs  Commissioning the DSLs  Commissioning of the connection cryostats  Conclusions Scope for DFB and DSL commissioning  DFB & DSL are powering LHC magnets, therefore the commissioning of the LHC circuits will involve their operation.  This presentation focuses on aspects specific to DFBs and DSLs that are not covered during the commissioning of the cryogenic instrumentation and the superconducting circuits.  System commissioning

HC review, A. Perin, 12-MAY DFB Project Location and types of DFBs in the LHC DFBA DFBM DFBL

HC review, A. Perin, 12-MAY DFB Project Main characteristics of the DFBs: variants 16 DFBA: powering the LHC arcs 23 DFBM: powering standalone magnets 13kA6kA600A120 A Chimneys Leads and chimneys 5 DFBL: powering the superconducting links

HC review, A. Perin, 12-MAY DFB Project Commissioning the DFBs: tunnel access Instrumentatio rack Transformers Water cooled cables DFBAO IR 8 L

HC review, A. Perin, 12-MAY DFB Project Main characteristics of the DFBs: global  44 DFBs, 3 main families 13kA6kA600A120 A Chimneys Leads Lead instrumentation / voltage taps / equipment 3 thermometers / lead 1 control valve / lead 8 voltage taps / lead 1 transformer / lead 1 heater / lead Other cryogenic instrumentation 2-3 level gauge / module 2-5 thermometers /module 2 pressure sensors / module 1 heater / module

HC review, A. Perin, 12-MAY DFB Project Main characteristics of the DFBs  Cryogenics –Current leads operation in 4.5 K saturated LHe bath –Controls: liquid helium and helium gas flow for the current leads –Max. pressure for DFBs current lead modules 0.35 MPa –DFBA supply/exit of GHe for E line  Electrical –Concentration of all types of busbars in very small space –Significant quantity of electrical interconnects: 1200 current leads to busbars, 1800 busbar to busbar, ranging from 120A to 13’000A  Insulation vacuum –No vacuum barrier: DFB share the vacuum of the magnets they power  Beam vacuum (DFBAs only) –Actively cooled beam pipes with beam screens –Cold-warm transitions

HC review, A. Perin, 12-MAY DFB Project Installation of the DFBs: the dates –DFBs will be installed during the interconnection period of the corresponding sector – on average 1 sector / 6 weeks (2 DFBA and 3 to 5 DFBM/L)

HC review, A. Perin, 12-MAY DFB Project DFBs from workshop to operation  Global strategy –Test as much as possible before installation in order to limit tunnel time –31 variants: no spare unit  Ancillary equipment –The DFBs will be produced and validated as complete systems including, all instrumentation, proximity piping and warm control valves, electrical splitting boxes etc. –As far as possible the units will be transported with all accessories installed  Testing –Extensive warm testing will be performed on all DFBs: vacuum, electrical, geometry, pre-alignment, etc. –Warm pressure/ mechanical/ electrical tests will be performed on complete units –All current leads will be cold tested and powered –No test in operational conditions will be performed before commissioning  Warm commissioning  Cooldown  Cold commissioning –Specific commissioning for first DFBAs Production / testing Commissioning  Installation –Specific tests, ELQA, interconnects etc. Installation

HC review, A. Perin, 12-MAY DFB Project Equipment around the DFBs to be commissioned DFBAO, IR 8L

HC review, A. Perin, 12-MAY DFB Project Equipment around the DFBs to be commissioned CL control valve 600A current lead CL heaters transformers CL instrumentation cabling

HC review, A. Perin, 12-MAY DFB Project Commissioning the DFBs: global picture  Required commissioning rate will be approx. 1 sector / 6 weeks with parallel commissioning of 2 DFBAs and 3 to 5 DFBMs/L  DFBs are tightly integrated with magnets and powering system: commissioning of the DFBs will be done mostly in parallel with ELQA and powering commissioning. (DFB and DSL must be operational to perform power tests!) QRL cryogenics WRL helium Control & supervision DC powering & protection Magnets Beam pipes forces cryogenics current cryogenics alignment interfaces Supports DFB  Cold tests in operating conditions will not performed on surface: DFBs will be operated the first time in the tunnel: specific testing will be needed for at least 1 DFB of each type  Commissioning starts when installation is finished, i.e.: –DFB is installed and aligned –all connections (busbar, vacuum, cryogenics, etc.) are closed and leak checked –Pressure test is successfully performed

HC review, A. Perin, 12-MAY DFB Project Commissioning the DFBs: warm Goal: ensure that the the DFBs are ready to start the cooldown –Testing of local equipment and instrumentation is performed as far as possible in the workshop before installation operations –Insulation vacuum commissioning: performed in parallel with the corresponding magnets –Operation of all control valves and instrumentation (see presentation 2 ) –Electrical commissioning: continuity and High Voltage (see presentations 9 & 21) –Precise alignment of beam pipes after pumping and pressure tests –Beam vacuum commissioning: cold and warm sides ( see presentations 15 & 16)

HC review, A. Perin, 12-MAY DFB Project Commissioning the DFBs: cooldown  Cooldown –Specificities (with respect to arc components) Cooldown to 70K cannot be done in parallel with the magnets because of pressure in header D (1 MPa) is not compatible with DFB/current leads design pressure (0.35 MPa) Shuffling module cooldown will be the same as the corresponding arc Sequence shall be defined in coordination with magnet cool down Cool down time depending on DFB type and local conditions (varying from 2 to 5 days) Commissioning of the DFBL should be performed in parallel with the superconducting links –Control of the alignment of beam pipes after cooldown

HC review, A. Perin, 12-MAY DFB Project Type cold commissioning of DFBs  GOALS: –check the functionalities –determine the operational parameters and behavior of each type of DFB –determine the behavior in most probable non nominal cases  Applies to: 1 (at least) DFB for each type DFBA, DFBM, DFBL  Operational parameters : estimated time: min. 3 weeks (possibly in parallel with some other commissioning operations) Determine cool down/warm up time and parameters Determination of PID parameters for all operating conditions LHe level maximum and minimum LHe level stability, particularly in case of unbalanced powering Operational parameters in transient condition  Non nominal operating conditions and interlocks: estimated time: min. 1 week (will required dedicated commissioning time) Failure of CL heater & recovery Loss of liquid level Loss of cooling gas for CL  Optional: parameters confirming the technical choices: estimated time: possibly in the shadow of the other commissioning operations Temperature measurement (shield etc.) Temperature measurement of GHe leaving CL (icing & condensation – HV test problem) Stop CL heating and restart with ice on it Deformation of the beam pipes in case of quench

HC review, A. Perin, 12-MAY DFB Project Default cold commissioning of DFBs  Goals: –Apply the operating parameters from type tests –check the proper operation of the equipment and tuning if needed –prepare for normal operation  Commissioning operations will be integrated and dependent on ELQA and powering commissioning operations  Most specific commissioning operations can be performed in parallel with other systems commissioning  Parallel operation of 2 DFBAs and 3 to 5 DFBM/L Operations  Commissioning of instrumentation and control loops (see presentation 2 )  Control of stability of LHe levels and temperatures  Electrical commissioning: ELQA (see presentations 9 & 21)  Commissioning of DC power system (see presentation 8)  Commissioning of beam vacuum (see presentation 15 & 16)  Validation of operational parameters during power tests and other transient conditions

HC review, A. Perin, 12-MAY DFB Project DSLs: the superconducting links

HC review, A. Perin, 12-MAY DFB Project Main characteristics of the DSLs: functionalities  Electrical –Connection of the DFBL to standalone magnets (DSLA, B, D,E), approx. 76m –Connection of the DFBL to the DFBA (DSLC), approx. 517m  Cryogenic (only for DSLC) : Supply of cryogenics to DFBLC, very limited instrumentation, no active components  Specificities: long cryogenic lines, in particular at pt3 : very long reaction times (3 to 30 hours)  Installation dates –DSLA IR1L: –DSLB IR1R: – –DSLC part1 UJ33-UP33-Tunnel: – –DSLC part2 Tunnel: – –DSLD IR5L: – –DSLE IR5R: –

HC review, A. Perin, 12-MAY DFB Project Commissioning the DSLs Global test strategy  Type-1 DSLs (76m) –No particular tests, except for pressure and leak testing and HV tests during and after in-situ installation.  Type-2 DSLs (517m) –Pressure and leak testing and HV tests during and after in-situ installation –Type test by a ~30m long validation model: mechanical and LN 2 to give production go-ahead to firm (fall 2005) Optional: Cryogenic+ electrical (summer 2006). –N.B. DSLC installation of critical cable part – Warm commissioning  Essentially ELQA in parallel with corresponding DFB commissioning  Insulation vacuum commissioning in parallel with corresponding DFBs Cooldown  Can be performed in parallel with corresponding DFBs and magnets Cold commissioning: type testing for DSLA and DSLC  ELQA  Cryogenics: system characterized by very long reaction time  No cold test on real size DSL on surface: 1 extended commissioning for each type: –Necessary to perform tests to determine the operational parameters –Reaction time in transient conditions, optimization of operating temperature and flows –Recovery after non-nominal conditions (loss of coolant, re-cooling parameters) –Will require at least 3 weeks of dedicated cold operation (necessitates cold operation of corresponding DFBs)

HC review, A. Perin, 12-MAY DFB Project Commissioning the connection cryostats (LE) Cryogenics Layout: P&I Diagrams LHCLSQR_ IR 1 left General  16 LE in DS of LHC  Ensure continuity of cold machine Characteristics  Similar hydraulic characteristics as magnets (pressure drop, free cross section,…)  Beam pipes and busbar lines are cooled by adjacent magnets and by central shuffling module  Specially placed thermometer at warmest point to follow subcooling to 1.9K Cryogenic test  Performed on magnet test bench in SM18  Specially instrumented (40 thermometers) LE  Goal: determine the cooldown rates and general behavior at cold and in transient conditions  Electrical insulation Example: IR 1 left Mechanical Layouts TT821 l L1 L2 Tmax 1.90 K S1 S2 Central Shuffling Module Line M ξ Heat Exchanger Sketch of a cold bore cooling sleeve (in operation with beam). (document LHC-LE-ES-0002 rev. 1.0) Illustrations courtesy S. Marque, AT-CRI

HC review, A. Perin, 12-MAY DFB Project Commissioning the connection cryostats (LE) Commissioning  Cooldown –Same time as DS cooldown –Tracking of temperatures and pressures in particular, pressure drop and temperature evolution  Subcooling to 1.9K –Tracking of temperature and comparison with test measurements and numerical estimations –Tracking of adjacent magnet temperatures

HC review, A. Perin, 12-MAY DFB Project Conclusions  In order to reduce the commissioning time in the LHC tunnel, all ancillary equipment will be installed on the DFBs and tested before tunnel installation  As no operational cold test can be performed on surface, specific time (approx. 3 weeks) will be needed for the first DFB commissioning  As an integral part of the LHC arcs and of the powering systems, the DFBs will be involved in most commissioning operations. The specific commissioning operations dedicated to series DFB should require a limited dedicated time, most operations can be performed in parallel with other commissioning operations.  The DSLs will require dedicated specific time (approx. 2 weeks) to determine the operational parameters and optimize the control loops.  For the connection cryostats, the commissioning will consist essentially of a careful tracking of the parameters of the LE and of the adjacent magnets