1. Hongyu Bai LCLS-II 2 K Cold Box FDR March 9, 2017
Test of the 2 K Cold Box
Hongyu Bai
LCLS-II 2 K Cold Box FDR
March 9, 2017

2. 2K cold box commissioning
Outline
2K cold box test steps
2 K cold box factory test
CC factory acceptance test
2K cold box factory test
2K cold box commissioning
Operation modes
Requirements
Process
Performance data
Documents
Summary
LCLS-II 2 K CBX FDR, Mar 9, 2017

3. 2 K Cold Box Tests 120 days 60 days 15 days Factory Test of CCs
Delivery of CCs Cartridges
Installation (Anchoring, Piping, Wiring)
Integration of cartridges & Check out (Vendor&JLab)
Factory Test
of 2K Cold Box
Delivery of 2K Coldbox
120 days
4.5K Cold Box Commissioning Completed
Cold Compressor commissioning
Full CP System Commissioning
LINAC
Commissioning
60 days
15 days
LCLS-II 2 K CBX FDR, Mar 9, 2017

4. CC Factory Acceptance Tests
Cartridge assembly tests
The natural frequencies of the rotor will be determined and compared to the calculated values. This will enable Vendor to check the safe operation of the compressor for the entire operation range.
Perform a Helium leak test on the cartridge.
Test the AMB and the AMB controller at ambient temperature in workshop.
Perform a test at 105% of nominal rotation speed under vacuum
Casing assembly tests
A helium leak test will be performed using a flat flange at compressor inlet and outlet and the dummy cartridge (less than 1 x 10-6 atm cc/s)
Electrical cabinet tests
The electrical cabinet will be tested during the cartridge test at 105% nominal rotation speed under vacuum at workshop.
“Testing procedures and reports (done by Vendor)” to be provided at CC Delivery.
LCLS-II 2 K CBX FDR, Mar 9, 2017

5. Cold Box Factory Tests Pressure test
The pressure test will be performed on the process piping, utility piping according to code B31.3.
Leak test
A helium leak test will be performed on the process piping (less than 1 x 10-8 atm cc/s) and vacuum jacket (less than 1 x 10-6 atm cc/s)
“Testing procedures and reports” to be provided by the Vendor.
LCLS-II 2 K CBX FDR, Mar 9, 2017

6. 2 K cold box commissioning - Operation Modes
The high flow configuration of the 2 K coldbox will be tested in CP1 first. The specified operation modes to be tested.
1. Maximum Capacity
≥215 g/s; Suction: 3.4 K, ≤27 mbar; Discharge: 1.20 bar, ≤30 K
This condition forms the basis for the maximum volume flow and maximum operating speeds.
2. Nominal Capacity
≥157 g/s, Suction: 3.5K, 28 mbar; Discharge: 1.20 bar, ≤30 K.
3. Minimum Capacity
≤ 150 g/s, Suction: 3.5K, 28 mbar; Discharge: 1.20 bar, ≤30 K.
4. Pump-down (Start , peak)
suction pressure: 1.2 bar to 27 mbar.
Speed: minimum increases to normal
This configuration will be used for the first light.
LCLS-II 2 K CBX FDR, Mar 9, 2017

7. 2 K cold box commissioning - Operation Modes
The low flow configuration of the 2 K coldbox will be tested in CP2 first. The specified operation modes to be tested:
1. Maximum Capacity
135 g/s; Suction: 3.5 K, 27 mbar; Discharge: 1.20 bar, ≤30 K
This condition forms the basis for the maximum volume flow and maximum operating speeds.
2. Nominal Capacity
120 g/s, Suction: 3.6K, 28 mbar; Discharge: 1.20 bar, ≤30 K.
3. Minimum Capacity
100 g/s, Suction: 3.6K, 28 mbar; Discharge: 1.20 bar, ≤30 K.
4. Pump-down (Start , peak)
suction pressure: 1.2 bar to 27 mbar.
Speed: minimum increases to normal
This configuration for CP1 and CP2 will be used for future normal operation.
LCLS-II 2 K CBX FDR, Mar 9, 2017

8. 2 K cold box commissioning - Requirements
Final acceptance testing is to occur after the integration of 2 K cold box is completed.
The Vendor to verify that all the CC instruments and controls associated with the provided equipment are properly indicating throughout each portion of the acceptance test.
Process data (temperatures, pressures, mass flows, speeds, and gas purity) will be recorded by the SLAC’s archival system.
The entire system shall operate stably at each of the operating conditions for 24 hours.
Final test operational procedures to be provided by the Vendor 4 weeks prior to the start of acceptance testing for review and approval.
The Vendor to provide the services of competent engineers and technicians to participate and conduct the initial startup and operations for the acceptance tests.
JLab and SLAC: (1) to provide support personnel as required during operations and testing for the purpose of training; (2) to assign additional engineers to observe and evaluate the testing.
LCLS-II 2 K CBX FDR, Mar 9, 2017

9. 2 K cold box commissioning - Process in 4.5 K CBX and LHe Dewar
LHe Buffer
35 kW Heater for simulation of 2 K Coldbox load during 4.5 K coldbox commissioning
2 K coldbox will be connected after 4.5K coldbox commissioning is completed.
LHe Dewar
6 kW
LCLS-II 2 K CBX FDR, Mar 9, 2017

10. 2 K cold box commissioning - Process in 2 K cold box
Flow meter
Flow meter CV
3 kW Heater
To control the suction temperature of the first CC.
LCLS-II 2 K CBX FDR, Mar 9, 2017

11. 1st Stage Suction Pressure
Pump Down Path for CHL2
1st Stage Suction Pressure
Mass Flow
Sequences:
Back-fill
Pumpdown- 2K CBX
Pumpdown -4.5K CBX
Heaters in CM
Control CM pressure
1st Stage Suction Temp
1st Stage Speed

12. 2 K coldbox and CC performance
Pressure ratio
calculated by inlet and outlet pressure
Flow rate
Measured by venturi flow meters
The overall isentropic efficiency of the CCs will be calculated based on the data value measured during the acceptance test.
2 K refrigeration power
Calculated from 2 K coldbox flow rate and temperature
Suction pressure stability
LCLS-II 2 K CBX FDR, Mar 9, 2017

13. Documents Document No. Title Author Status 1
CC Final acceptance test – equipment operation procedure
Vendor
4 weeks prior to acceptance testing 2
CC Final acceptance test report
4 weeks after final acceptance test completion 3
2 K Cold Box commissioning procedure
JLab
Prior to Commissioning readiness review 4
2 K Cold Box commissioning report
4 weeks after acceptance test
LCLS-II 2 K CBX FDR, Mar 9, 2017

14. Summary
Does the the design allow adequate Performance Tests* of the Cryoplant? Note*: Test of Cold Compressors and overall Cryoplant with 2K Compressors Running.
The design of of the 2 K coldbox test is included in the 2 K coldbox and the cryoplant system design. It includes sufficient instruments to measure the performance of the CCs and 2 K coldbox, and specific heaters and transfer lines/U-tubes for the tests. These allow adequate performance tests of 2 K cold box with the 4.5 K cryoplant.
The test procedures will be provided by the Vendor and JLab prior to the commissioning readiness review.
LCLS-II 2 K CBX FDR, Mar 9, 2017

15. Thank you!
LCLS-II 2 K CBX FDR, Mar 9, 2017

16. Cryoplant Layout Overview
CP1 4.5K Cold Box
CP2 4.5K Cold Box
2K CBX 16

17. Performance Test of 4.5K coldbox
15 kW heater for HTTS
2 kW heater for LTTI (new)
35 kW heater for CC