1. ZONE 18 CRYOGENICS M. Sanmarti On behalf of AT-ACR-OP section

2. Outline What is the Cryo in Zone 18 Who is the Cryo in Zone 18 Cryo Zone 18 and TCR links Recovery and performances Conclusions

3. What is the Cryo in Zone 18 Production: –Refrigerators 18 kW @ 4.5K Air Liquide (PM18) 6 kW @ 4.5K Linde (SM18) –Infrastructure: recovery and purification Clients: –“Cryo” clients: LHC Magnets test benches (ACR-MT section) LHC Cold compressors units BA7 (ACR-PI section) String2 High Temperature Current Leads (ACR-IC section) –“Non-Cryo” clients: RF modules & cavities, GreC Utilities –Electricity, Cooling Water, Compressed Air, Controls

4. What is the Cryo in Zone 18

5. Refrigerators PM18-Air Liquide 18 kW @ 4.5K Compressor station –5 He compressors (1600 g/s, 4.2 MW) –Oil system (5 oil pumps) –Cleaning helium system Cold Box –Vacuum vessel –8 Turbines, heat exchangers –1 Nitrogen Precooler (80K) Controls(ABB):1100 I/O Connected to the Dewar SM18-Linde 6 kW @ 4.5K Compressor station –3 He compressors (350 g/s, 1.5 MW) –Cleaning helium system Cold Box –Vacuum vessel –6 Turbines, heat exchangers –1 Nitrogen Precooler (80K) Controls (ABB): 800 I/O String2/back up

6. Infrastructure (750 Input/Output) Helium storage 9 helium tanks of 80 m 3 each, dedicated to the 6kW Linde cryoplant for GHe storage 12 helium tanks of 250m 3 each, dedicated to the 18 kW Air Liquide cryoplant, for GHe storage A 25000 liters dewar for LHe storage A mobile 10000 liters dewar for LHe storage LN 2 supply 1 dewar of 50000 liters dedicated to the 6kW Linde cryoplant and the HP purification system (+ infrastructure SM18) 1 dewar of 50000 liters dedicated to the magnet test benches 2 dewars of 50000 liters dedicated to the 18kW Air Liquide cryoplant and BA7. All warm return gases (pure) can be sent either to the 18kW Air Liquide plant or to the 6kW Linde plant. The return gases are analysed for impurities (air/humidity) and can be sent to the balloons if necessary (not all return gases – flow too high) HP Purification system: 5 balloons of 80 Nm3, total capacity of 400 Nm3 3 Burckhart compressors with 100 Nm3/h at 200 bar each 2 HP purificators of 200 Nm3/h at 200 bar each LP Purification system: 18 g/s on-line purification system (freeze-out) at the outlet of the warm pumping unit

7. Clients  The magnet test benches (Dewar-PM18)  The RF-cavities and modules (Dewar-PM18)  The 1.8K Cold Compressor Unit – test facility at BA7 (PM18)  STRING2 (a full-size model of a regular cell of an LHC arc) (Linde)  A test station for testing High Temperature current leads 600A and 13kA (Dewar-PM18)  The GREC experiment, Grands Reynolds Cryogéniques (Linde) The clients take Liquid Helium from the 25000 liters dewar at 4.5K and send back pure gaseous helium - cold or warm - to the low pressure side of the compressors of the cryoplant (18kW/6kW) or impure to the balloons. The client can decrease the temperature to 1.8K by pumping on the helium bath. A refrigeration capacity of 360W @ 1.8K is available via a warm pumping group in series with a one- stage Cold Compressor Unit. The outlet of the pumping group passes an « on line low pressure purification system » and is sent back to the low pressure side of the compressors.

8. Courtesy L. Tavian Utilities needed for Cryogenics Electricity: –3.3kV Powering of main compressors –400V Powering of heaters, pumps,... –24V Instrumentation (relays, 500 mA) –24V Control System & monitoring (4 –20 mA) Water: –Cooling of compressor station (motors, helium, oil), turbines, vacuum pumps... Compressed Air: –Valves actuators Controls : –Networks –fieldbuses, PLC, SCADA

9. Cooling towers Compressed air Cooling and ventilation Water Helium and nitrogen - LN2: 2/4 trucks per week (2003) nominal 2/3) trucks per day - LHe: ~60000 liters per years (02-07) Electric power about 7 MW Utilities for Cryogenics in SM18 CRYO Controls: Networks, fieldbuses, PLC, SCADA About 11,5 MW (1000 m³/h)

10. Who is the Cryo in Zone 18

11. ACR-MT B. Vullierme Test Bench SM18 Operation Team ALLS Test Benches Who is the Cryo in Zone 18

13. ACR-OP: production, infrastructures and String2 –CERN: C. Calzas, D. Chanat, Y. Collombet, S. Knoops, M. Sanmarti and L. Serio** –ALLS: H. Berg**, M. Charvin, A. Eychenne, E. Millet*, N. Navion-Maillot, JC de Sousa*, V. Souto-Gomes. Normal operation and piquet service (CERN/ALLS) ACR-MT: LHC magnets tests bench –CERN: J. Axensalva, L. Herblin, JP Lamboy, A. Tovar, B. Vuillerme** –ALLS: 3x8 shifts (1 STL, 3 TL, 8 operators) 24 hours operation from control room (ALLS)

14. Cryo and TCR links

16. 5 Juin 200316 File on webpage of our section: http://lhc-div-acr-op.web.cern.ch/lhc-div-acr-op/ Link: Piquet

17. Performance in 2002 For PM18: only taken into account distribution to clients in SM18 for 2002, with buffer of 25000 litres dewar. For 2003, also taking into account BA7, without buffer … if level in phaseseparator of cryoplant decreases below 30%, production- stop for BA7.

18. Non Conformity Report ALLS - summary Coldbox 6kW Linde: 20 Beeps: 5 utility-cuts resulting in production-stop For example: powercut with as consequence blow-up of several balloons 1 cryogenic problem resulting in a production-stop 4 cryogenic problems in planified period (cooling down or warming up of STRING) 4 due to cold coming from STRING (turbines stopped) 2 due to pure gas storage (MP) too high 1 due to pure gas storage (MP) too low 3 due to stop of CP2 only (no production stop) Bonus-Malus-file: 5 utility-cuts; 1 cryogenic problem with beep 5 cryogenic problems without beep (during working hours) For example: Turbine 4 broken STRING: 18 Beeps: 12 for HTS OFF 6 due to problems STRING (e.g. errors in control) -> none of them in Bonus-Malus-file as they were not resulting in a production-fault for STRING Bonus-Malus -file: Total number of quenches provoked: 17 Total number of stops: 13 utility: 9 controls STRING: 1 Test Kickers: 2 HTS off without BEEP: 1

19. Helium Zone 18 - 2002

20. Conclusions (??) http://lhc-div-acr-op.web.cern.ch/lhc-div- acr-op/default.htm

21. Salle des machines

22. Boite froide

24. General layout of the zone 18 InfraFrigos

25. Some figures of zone 18 - Available LHe: 6 kW Linde: 16-30 g/s 18kW AL: 150-250 g/s (SM18 + BA7) -Transfer Line SD-SM: LHe: 60 g/s (120 g/s) GHe: 60 g/s @ 80K (90 g/s @ 50K) - Consumption: - Magnets: LHe: 60 g/s (120 g/s) GHe: 35 g/s (120 g/s) - Cryostats/Modules: 10-15 g/s intermittent -BA7: 40-45 g/s equiv. liq. (130 g/s) -String: Lhe: 6-10 g/s norm. op 30 g/s transients Cryogenic fluids-consumption: 2/4 trucks per week and later on 2/3 trucks per day of LN2 About 60000 litres of LHe per year During the coming 5 years

26. Dewar and connections to clients