1. SC1R Cold Box PDR Overview
SC1R Cold Box Preliminary Design Review
K Dixon
Monday, November 12, 2018

2. Review Committee Charge
Does the process design meet the stated Accelerator requirements?
Is the cold compressor design requirements documentation ready for procurement?
Is the heat exchanger design requirements doc ready for procurement?
Are the planned modifications to the infrastructure suitable for cold compressor operations?
Does the commissioning strategy presented have a favorable chance of success?
Is the plan for removing the existing cold box sound?
Is the plan for installing the new cold box reasonable?
Does the vessel look like it can be easily fabricated at a reasonable cost and structurally sound?
Does the internal piping allow room for access to the critical components?
Are the technical risks accounted for and suitably addressed for a preliminary design?
SC1R PDR Overview

3. SC1 History
Delivered by CVI using 4 LN-cooled Cold Compressors (CC’s) in 1990
Commissioned in 1994
Isolated from system in 1999
Reconfigured to include 5 CC’s, increased HX NTU’s, thermosiphon cooling, volumetric and flow stability, etc.
Re-commissioned in fall of 2013
CC4 failure in spring of 2015
Recovered in fall of 2015
CC5 failure in spring of 2017
Cold Compressor Advisory Team (Rode, Oren, Arenius, Howell, Freyberger, Ganni, Klebaner) unanimously recommended replacing SC1 during June ‘17 meeting.
Presently supporting 2K operations.
SC1R PDR Overview

4. CHL1 SC1 Cold Compressor 4 Failure
Compressor 4 failed
Magnetic bearing cabinet control problem resulted in hard rotor landing at high speed that damaged back up ball bearings, rotor, etc.
Spare compressor borrowed from SNS and modifications performed to be ready to install it for fall FY15 run
Failed compressor sent to France
Manufacturer repairing using spare parts
Unit returned after two years
Finishing a test program to verify health
Readiness uncertain
SC1R PDR Overview

5. CHL1 SC1 Cold Compressor 5 Problem
Problem traced to internal broken wire for bottom rotor radial position sensor
Least operating hours
Wire repaired and others checked
Compressor tested warm
Bearings energized
Properly levitated
Rotor spun at high speed
Compressor installed and running successfully
SC1R PDR Overview

6. Overview of SC1R DOE Science Lab Infrastructure (SLI) Funded Schedule
$8M
Includes design, cold box and spare cold compressors
Installation, interfacing piping and electrical wiring/panels not presently included
Schedule
Conceptual Design Complete 9/30/17
CB Design Completion 6/29/18
Cold Compressor Delivery 12/21/18
CB Assembly Complete 12/20/19 Critical Path
Project Complete?? 12/23/20
Conceptual Design
Use present location
Use 5 external water-cooled CC motors with VFD’s and long-life bearings
Could use similar/same size as MSU & LCLS2
Maintain Bayoneted Connections incl 2K Return Header
Keep large 2K/4K HX inside cold box
Vacuum break at LP Return header considered but eliminated
Platform for upper shell access
SC1R PDR Overview

7. Overview of SC1 (cont.) Cold Box Structural Shell Internals
Contracted build to print
ASME BPVC design requirements
Painted carbon steel, SA-517, Gr 70
Inverted st. steel nozzles & flat plates with domed heads
Allows room for discharge nozzles
Avoids large flat head
Internals
Contracted build to print along with shell
ASME B31.3 design requirements
Use similar HX specification as SC2
Bellow-sealed control valves
Partial LN2 shielding for 2K piping
Overall Dimensions
17’ tall x 10.5’ dia
<28 T weight
SC1R PDR Overview

8. SC1R P&I Diagram
SC1R PDR Overview

9. Cold Compressor Requirements
General
5 CC’s in series
Mass flow controlled by adjusting fixed- ratio speeds in CC’s 1-4 during steady state operations
CC5 speed controlled using its suction pressure
Casings
Design per ASME BPVC and API 617
K design pressure
Motors
VFD controlled
Externally accessible
Design conforming to NEC
Bearings
Long-life, 5 yr
5-axis support
Fully instrumented
SC1R PDR Overview

10. Cold Compressor Requirements (cont.)
Operating Conditions
Maximum
250 g/s flow
≤ K, inlet conditions
1.2 < 30 K discharge
Nominal
200 g/s flow
K, inlet conditions
SC1R PDR Overview

11. ‘2K/4K’ Heat Exchanger Requirements
General
1.5 kW duty, 3 NTU
Brazed aluminum plate-fin constr.
Includes Al/SStl transition joints
Design conforming to API Std 662
Constructed to ASME BPVC— ‘U’ stamped
Parameter
Supply Stream
Return Stream
Flow
250 g/s
Inlet Temperature
4.5 K
2.2 K
Outlet Temperature
2.5 K
3.3 K
Max Dif Pres
1.7 mbar
2 mbar
Design Temp
340 K
2 K
Design Pressure
350 psi
100 psi
Inlet/Outlet Nozzle
≤ 3 NPS
≤ 10 NPS
SC1R PDR Overview

12. Safety Considerations
Removal and Installation will be performed in close coordination with ESH&Q personnel
Most equipment will be designed/procured using national consensus codes
Safety related analyses will be included in the Final Design Review
The Installation and Removal, including safety aspects, will be included in the Final Design Review OR Installation Design Review
SC1R PDR Overview

13. Cold Compressor Reqmts Heat Exchanger Reqmts Safety
Charge
History
Failures
Overview
Cold Compressor Reqmts
Heat Exchanger Reqmts
Safety
Monday, November 12, 2018