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SRF Vertical Test Cryostat Design Review. 16 May 2006 IB1. Introduction. Welcome and introductions Charge to the committee: Assess the technical design of the ILCTA IB1 SRF Vertical Cryostat and its readiness for the procurement/fabrication process

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Presentation Transcript
slide2

Introduction

  • Welcome and introductions
  • Charge to the committee:
    • Assess the technical design of the ILCTA IB1 SRF Vertical Cryostat and its readiness for the procurement/fabrication process
    • Comment on all technical aspects of the Cryostat design, including integration to the IB1 cryogenic system
    • Provide a written report.

ILCTA-VTC Design Review

slide3

…not a facility safety review

  • Focus on
    • Cryostat technical specifications
    • Readiness for procurement
  • Review outline
    • Location of and purpose of facility in IB1 (Joe Ozelis)
    • Cryostat system requirements (Mayling Wong)
    • Integration with IB1 Cryogenic System, P&ID, and Cryogenic Design Parameters

(Roger Rabehl and Yuenian Huang)

    • 3D model overview (Clark Reid / Mayling Wong)
    • Documentation requirements (Mayling Wong)
    • Cost estimate, procurement plan, and schedule (Cosmore Sylvester)

ILCTA-VTC Design Review

slide4

Goals of the ILC Vertical Cavity Test Program

  • Verify cavity processing improvements by quantifying cavity performance in a reliable, reproducible, and efficient manner.
    • Measure Q0 vs Temperature
    • Measure Q0 vs E
    • Measure Field Emission (radiation)
    • Investigate effect of low temperature externally performed bakeout on Q-drop
  • Initial throughput expected to be ~ 2 cavities/month, increasing to ~ 2 cavities/week. Multiple tests/cavity (Q-drop) increase this.
  • System is to be capable of testing cavities designed for the ILC Main Linac cryomodule.
  • Baseline Design: Tesla cell shape, 9 cells, 1.3 GHz. Alternate geometries, # cells, superstructures, may also be evaluated.

ILCTA-VTC Design Review

slide5

Cavity Test Facility Location

ILCTA-VTC Design Review

slide6

Cavity Test Facility Location

Existing cryogenic services

Approx size/location of cryostat pit/hole

ILCTA-VTC Design Review

slide7

Cavity Test Facility Cryostat/Cryogenic Requirements

  • LHe bath capable of operation between 4.3 and ≤ 1.6K
  • Cooldown rate from 300K to 4K that minimizes Q–disease susceptibility (minimize time spent between 100-150K)
  • Sufficient volume of LHe above cavity to preclude need for active LHe level control during testing (190-200cm – 165cm to top cavity flange)
  • Instrumentation to provide readout of Dewar pressure, temperature, and LHe level
  • Fast turnaround –
    • Cooldown & fill : 4-6 hours
    • Pumpdown : 2-4 hours (can be concurrent w/ fill if not performing Q0 vs T measurements)
    • Remnant LHe boiloff : 3-5 hours (150-180W for 800L)
    • Warmup to 300K : 10-12 hours (400K He gas at ~2g/s)

ILCTA-VTC Design Review

slide8

Example Test Cycle (w/ Q0 vs T measurement)

Insert stand into Dewar

Leak check Dewar seal

Leak check test stand

Attach RF & instrumentation cables

Pump/purge Dewar w/ GHe, check for contamination

Cooldown

Fill @ 4K

Cable calibrations @ 4K

Measure cavity frequencies (all modes)

Perform low field (2-3 MV/m) Q0 measurement (1W amplifier)

Begin pumpdown to ~1.5K, take low field Q0 data

Warm back up to 2K

Perform Q vs E measurements at 2K

Boiloff remnant LHe

Warm Dewar

0.5hr

0.5hr

1hr

0.25hr

1hr

1.5hrs

4hrs

0.5hr

0.25hr

0.5hr

3hrs

0.5hr

2hrs

4hrs

12hrs

Total warm-warm cycle time = 31.5hrs

ILCTA-VTC Design Review

slide9

Example Test Cycle (w/o Q0 vs T measurement)

Insert stand into Dewar

Leak check Dewar seal

Leak check test stand

Attach RF & instrumentation cables

Pump/purge Dewar w/ GHe, check for contamination

Cooldown

Fill @ 4K, begin pumping to 2K when LHE collects

Cable calibrations @ 2K

Measure cavity frequencies (all modes)

Perform Q vs E measurements at 2K

Boiloff remnant LHe

Warm Dewar

0.5hr

0.5hr

1hr

0.25hr

1hr

1.5hrs

4hrs

0.5hr

0.25hr

2hrs

4hrs

12hrs

Total warm-warm cycle time = 27.5hrs

ILCTA-VTC Design Review

slide10

Example Test Schedule (includes Q0 vs T msmt)

Day 1 : Load test stand, all checkouts, cooldown & fill to 4K

Day 2 : Q0 vs T, Q0 vs E, boiloff Lhe and begin Dewar warmup

Day 3 : Remove test stand, setup for 120° C bake – 24 hours

Day 4 : Load test stand, all checkouts, cooldown & fill to 4K

Day 5 : Q0 vs T, Q0 vs E, boiloff LHe and begin Dewar warmup

This scenario supports 2 tests per week of the same cavity, with a 24hr 120° C bake between tests.

If Day 3 is a Friday, can do a 48hr bake over a weekend.

ILCTA-VTC Design Review

slide11

Example Test Schedule (w/o Q0 vs T msmt)

Day 1 : Load test stand, all checkouts, cooldown, fill, pump to 2K, Q vs E, start boiloff & warmup script (long day)

Day 2 : Remove test stand, setup for 120° C bake – 48 hours, swap cavities

Day 3 : Load test stand, all checkouts, cooldown, fill, pump to 2K, Q vs E, start boiloff & warmup script (long day)

Day 4 : Remove test stand, setup for 120° C bake – 48 hours, swap cavities (baked one)

Day 5: Load test stand, all checkouts, cooldown, fill, pump to 2K, Q vs E, start boiloff & warmup script (long day)

This scenario supports 3 tests per week, 2 different cavities, one of

which gets a 48hr 120° C bake between tests.

ILCTA-VTC Design Review

slide12

Conclusions

  • The aggressive test schedules described here can be fully supported by a
  • cryostat/cryogenic system that provides:
  • LHe bath capable of operation between 4.3 and ≤ 1.6K
  • Cooldown rate from 300K to 4K that minimizes Q–disease susceptibility (minimize time spent between 100-150K)
  • Fast turnaround –
    • Cooldown & fill : 4-6 hours
    • Pumpdown : 2-4 hours (can be concurrent w/ fill if not performing Q0 vs T measurements)
    • Remnant LHe boiloff : 3-5 hours (150-180W for 800L)
    • Warmup to 300K : 10-12 hours (400K He gas at ~2-4g/s)
  • The present design will be shown to meet these requirements.
  • Additionally, it does not preclude testing of alternate cavity designs or
  • more extensive (R&D) testing.

ILCTA-VTC Design Review

cryogenic system requirements
Cryogenic System Requirements

ILCTA-VTC Design Review

cryogenic system requirements14
Cryogenic System Requirements

ILCTA-VTC Design Review

ib1 refrigeration capability
IB1 Refrigeration Capability
  • Calculated cooling capacity of 125 W at 2 K.
    • Assumes 88-90% efficient J-T heat exchanger pre-cooling the supplied LHe. This HX is identical to one used in the MTF LHC quadrupole feed box.
    • Assumes 3 Torr pressure drop through the pumping line between the new test facility and the Kinney pumps.

ILCTA-VTC Design Review

ilcta ib1 vertical dewar p id
ILCTA-IB1 Vertical Dewar P&ID

ILCTA-VTC Design Review

integration with ib1 refrigerator
Integration with IB1 Refrigerator
  • LHe supplied across the roof of IB1 through the existing transfer line from the 10 kl dewar. Drawn off a phase separator, 5 K boiloff will cool a dewar intercept and a baffle.
  • GHe pumped away via Kinney pumps, returned directly to compressor suction, or vented to atmosphere. The first option requires a new pumping line, the last two options will use existing VMTF piping.
  • LN2 supplied from 10 kgal dewar, tying into existing VMTF piping.
  • GN2 vented to atmosphere, tying into existing VMTF piping.

ILCTA-VTC Design Review

helium vessel thermal design
Helium Vessel Thermal Design
  • Heat load to 2 K helium bath is controlled 80 K shield and heat intercepts at 80 K and 5 K level
  • 80 K shield and intercept will be cooled by LN2
  • 5 K heat intercept will be cooled by GHe vapor from phase separator, 10 W heater to control vapor flow
  • Heat load to 2 K from other sources (pumping line and instrumentations wired) will be estimated later, however, it should be around 2 W or so level

ILCTA-VTC Design Review

helium vapor pressure drop
Helium Vapor Pressure Drop
  • The total vapor pressure drop will be about 3 torr and that’s our design goal
  • 2” line is 150 ft and 6” line is 300 ft
  • Total vapor pressure drop breaks down to three parts in the pumping line in our calculation
    • Pressure drop within JT heat exchanger, < 1 torr
    • Pressure drop along 150 ft, 2” insulated piping, 3.5 K inlet and 5 K outlet, the average pressure drop is 1.01 torr
    • Pressure drop along 300 ft, un-insulated 6” piping, 5 K inlet and 300 K outlet, the average pressure drop is estimated to be 0.843 torr

ILCTA-VTC Design Review

cryostat layout
Cryostat Layout

ILCTA-VTC Design Review

helium vessel
Helium Vessel
  • ASME BPVC vessel
  • Dimensions - 304SS shell
    • 28-inch OD
    • 0.094-inch thick
      • Thickness driven by external pressure (due to leak in insulating vacuum)
      • To minimize thickness (& conduction heat load) use Stiffeners every 30-inch along length
        • L1X1X1/4-inch angle bent & intermittently welded
    • 16-feet long

ILCTA-VTC Design Review

helium vessel cont d
Helium Vessel (cont’d)
  • Relief system
    • Burst disc
      • 65-psig set pressure
      • 1.5-inch - Sized assuming complete helium vaporization during leak of insulating vacuum (resulting flux of 0.6 W/cm2)
    • Code Relief valve
      • 50-psig set pressure
    • Connected to top plate of removable insert (not part of this assembly/procurement)
  • Heater for dewar warm-up
    • Temperature of helium 420K
    • Helium pressure 3-psig

ILCTA-VTC Design Review

top flange of helium vessel
Top flange of helium vessel
  • Thickness 1-inch
    • Sized to ensure welded joint to the helium vessel shell is adequate, following guidelines of ASME BPVC

Top flange of

Helium vessel

ILCTA-VTC Design Review

status of documentation
Status of Documentation
  • Engineering drawings
    • 75% exist for initial design iteration
  • Engineering notes
    • Helium vessel: 75% complete
    • Vacuum vessel
    • Pressure drop calculations
    • Heat load analysis
    • Relief valve sizing
    • Technical specification for vendor (required at the time the RFP is issued)

ILCTA-VTC Design Review

cost estimate
Cost Estimate

ILCTA-VTC Design Review

procurement plan
Procurement Plan
  • Complete the Design of the Cryostat assembly and release via. an RFP. Select the “best” qualified vendor based on a technical evaluation of the vendor’s proposal - not solely on lowest bid.

While cryostat Procurement is underway-

    • Continue to work towards a final design of the magnetic shielding and release these drawings for fabrication (estimated del: 6 weeks ARO)
    • Continue to work on the final design of the top plate and suspension components and then release these for fabrication
      • located a supplier of the Lead and has a quote and estimated delivery (6 weeks ARO)
      • located a supplier for an encapsulant (rated for 4.5K use) which could be used on the exposed lead surfaces

ILCTA-VTC Design Review

schedule
Schedule

ILCTA-VTC Design Review