FCC cryogenics status, layout, and implementation studies - PowerPoint Presentation

1. FCC cryogenics status, layout, and implementation studiesB. Naydenov, L. Delprat, B. Bradu, K. BrodzinskiOn behalf of the CERN cryogenics groupFCC Week 23’ – London – June 5th-9th 20231B. Naydenov, L. Delprat, B. Bradu, K. BrodzinskiThis project has received funding from the European Union's Horizon 2020 research and innovation programme under grant agreement No 951754.boyan.kaloyanov.naydenov@cern.ch

2. 2B. Naydenov, L. Delprat, B. Bradu, K. BrodzinskiCurrent statusSRF heat loads – FCC-ee machine focusCryoplants layoutPoint H cryo layoutPoint L cryo layoutCryomodules arrangementHe InventoryElectrical power requirementsConclusion and upcoming activitiesTable of contents

3. Status3New baseline PA31-3.0 (25-01-23)Long Straight Section (LSS) reduced from 2160 m to 2032 m.New cryomodules (CM) distribution: all booster CMs at point L and all collider CMs at point H.Four scenarios for point L – shaft at 0 m, 300 m, 600 m and 1000 m of the IP – see slide 8.Point H changed from asymmetric to symmetric – see slide 7.FCC-ee cryoplants design and staging are being adapted – see slides 6 and 10.Narrowing down, together with SRF team, operating scenarios, heat loads (slide 4) and CM design concept with its integration implications (slide 11).Understanding machine booster operation, its differences with the collider and its impacts on the cryogenics system.Soon starting a second iteration of exchanges with industrial partners where focus will be put on FCC-ee.M. BenediktSTATUS | SRF HEAT LOADS | OVERALL CRYO LAYOUT | PH LAYOUT | PL LAYOUT | CM ARRANGEMENT | HE INVENTORY | ELECTRICAL | CONCLUSIONS B. Naydenov, L. Delprat, B. Bradu, K. BrodzinskiPoint L – RF BoosterPoint H – RF ColliderFirst surface estimation requirements for cryo (buildings, alcoves, and caverns) system provided to civil engineering team.Collaboration with FNAL.

4. FCC-ee SRF heat loads4ZWHttbarPoint H - ColliderPoint L - Boosterx66 – 48 kW at 4.5 K x122 – 20 kW at 2 K x28 – 4.1 kW at 4.5 K x66 – 48 kW at 4.5 K x66 – 48 kW at 4.5 K x6 – 0.3 kW at 2 K x14– 0.8 kW at 2 K x27– 1.7 kW at 2 K x150 – 8.6 kW at 2 K 400 MHz cavities : = 2.7E+9 800 MHz cavities : = 3.0E+10 Assumptions30 % margin on heat loads, today AsymmetricTotal of 1300 m SymmetricTotal of 1950 m Last update of above values 12/05/2023B. Naydenov, L. Delprat, B. Bradu, K. BrodzinskiSTATUS | SRF HEAT LOADS | OVERALL CRYO LAYOUT | PH LAYOUT | PL LAYOUT | CM ARRANGEMENT | HE INVENTORY | ELECTRICAL | CONCLUSIONS

5. FCC-ee machine cryoplants layout5→ Technical Point→ Sector RF Cryoplant→ Experiment PointPGPAPDPJPLPBPFPHRF Booster pointRF Collider pointB. Naydenov, L. Delprat, B. Bradu, K. BrodzinskiSTATUS | SRF HEAT LOADS | OVERALL CRYO LAYOUT | PH LAYOUT | PL LAYOUT | CM ARRANGEMENT | HE INVENTORY | ELECTRICAL | CONCLUSIONS MDI magnets linked to detector position definition – not considered hereStagePoint H - ColliderPoint L - BoosterZ1x 5 kWeq @ 4.5 K1x 1.5 kWeq @ 4.5 K(98% @ 2K)W2x 25 kWeq @ 4.5 K1x 3.5 kWeq @ 4.5 K(98% @ 2K)H2 x 30 kW eq @ 4.5 K1x 6.5 kWeq @ 4.5 K(98% @ 2K)tt2x 60 kWeq @ 4.5 K (60% @ 2K)1x 32 kWeq @ 4.5 K(98% @ 2K)RF points – PH and PL

6. FCC-ee cryoplants at point H - staging6Staging at point HIncreased staging complexity.ZWHttbarRef. ~25 kW eq @ 4.5 K10 kW @ 2 K included&Feasibility TBC ! Ref. ~5 kW eq @ 4.5 KRef. ~25 kW eq @ 4.5 KRef. ~60 kW eq @ 4.5 KRef. ~60 kW eq @ 4.5 KUpgrade10 kW @ 2 Kincluded // Replacement of cryoplantB. Naydenov, L. Delprat, B. Bradu, K. BrodzinskiSTATUS | SRF HEAT LOADS | OVERALL CRYO LAYOUT | PH LAYOUT | PL LAYOUT | CM ARRANGEMENT | HE INVENTORY | ELECTRICAL | CONCLUSIONS

7. FCC-ee cryo layout at point H (ttbar)7QRL Header& Process valuesDiameter (mm)A : 1.3 bar , 2.2 K (∆P=25 mbar)72B : 30 mbar , 2 K (∆P=2 mbar)320C: 3 bar, 4.6 K (∆P=130 mbar)110D: 1.3 bar, 4.5 K (∆P=70 mbar)185E: 20 bar, 50 K (∆P=10 mbar)80F: 18 bar, 75 K (∆P=15 mbar)80Vacuum jacket (400MHz)550* Vacuum jacket (800 MHz)750* * +100 mm for bellows and flangesService cavern & LSS center are alignedCM are shared symmetricallyCM organized to optimize QRLLSS total length is of 2032 m. DN850 DN850 DN650 DN650 B. Naydenov, L. Delprat, B. Bradu, K. BrodzinskiSTATUS | SRF HEAT LOADS | OVERALL CRYO LAYOUT | PH LAYOUT | PL LAYOUT | CM ARRANGEMENT | HE INVENTORY | ELECTRICAL | CONCLUSIONS

8. Point L8PGPAPDPLPBPFPHRF Booster pointRF Collider pointPA31-3.0: shaft location is uncertain. Different scenarios to be assessed:S1: Shaft at nominal point S2: Shaft at 300 m S3: Shaft at 600 m S4: Shaft at 900 mDifficult point containing the booster SRF section – limited integration spaceS1S2S3S4B. Naydenov, L. Delprat, B. Bradu, K. BrodzinskiSTATUS | SRF HEAT LOADS | OVERALL CRYO LAYOUT | PH LAYOUT | PL LAYOUT | CM ARRANGEMENT | HE INVENTORY | ELECTRICAL | CONCLUSIONS

9. FCC-ee cryo layout at point L (ttbar) 9DN650 DN650  DN650 DN650 DN800 DN600 DN700 S1S2S3S4B. Naydenov, L. Delprat, B. Bradu, K. BrodzinskiSTATUS | SRF HEAT LOADS | OVERALL CRYO LAYOUT | PH LAYOUT | PL LAYOUT | CM ARRANGEMENT | HE INVENTORY | ELECTRICAL | CONCLUSIONS Line A – 1.3 bar / 2.2 K: 80 mmLine B – 30 mbar/ 2 K: 360 mmLine E – 20 bar / 50 K: 90 mmLine F – 18 bar / 75 K: 90 mm

10. FCC-ee cryoplants at point L / S4: staging10ZWHttbarRef. 2 K (~1 kW)Ref. 2 K (~0.5 kW)Ref. 2 K (~9 kW)Ref. 2 K (~2 kW) B. Naydenov, L. Delprat, B. Bradu, K. BrodzinskiSTATUS | SRF HEAT LOADS | OVERALL CRYO LAYOUT | PH LAYOUT | PL LAYOUT | CM ARRANGEMENT | HE INVENTORY | ELECTRICAL | CONCLUSIONS

11. FCC-ee collider/booster CM sectorization at RF points11Cryo-RF working group has been set in January 2024 to address the cryomodule design of the cavities. Current discussions are focused on the sectorization concept of the 2 K Cryomodules for the 800 MHz bulk Nb cavities.Several options are being weighted:Fully segmented approachEx: ESS or PIP-IIContinuous/Integrated cryostat approachEx: XFEL or LCLS-II Hybrid approach (vacuum not addressed)RefrigeratorExternal transfer lineIndividual service moduleRefrigeratorIntegrated transfer lineMain service moduleRefrigeratorExternal transfer lineCombined service moduleB. Naydenov, L. Delprat, B. Bradu, K. BrodzinskiSTATUS | SRF HEAT LOADS | OVERALL CRYO LAYOUT | PH LAYOUT | PL LAYOUT | CM ARRANGEMENT | HE INVENTORY | ELECTRICAL | CONCLUSIONS

12. FCC-ee 800 MHz CM bi-phase tube study12Nominal levelUpper dynamic levelLower dynamic levelBi-phase tubeWith inclinationWith inclination7.5 mQRL1 cryo cell0.25%Cryo distribution line can be both external or internal to CM vacuum chamber – study in progressThe analysis aims to answer:What is an optimum cell length? What is the right bi-phase tube size for such cell, given the heat loads?B. Naydenov, L. Delprat, B. Bradu, K. BrodzinskiCryo Distribution Linebi-phase tubeSTATUS | SRF HEAT LOADS | OVERALL CRYO LAYOUT | PH LAYOUT | PL LAYOUT | CM ARRANGEMENT | HE INVENTORY | ELECTRICAL | CONCLUSIONS

13. FCC-ee 800 MHz CM bi-phase tube study13ColliderBoosterPosition (m)Position (m)B. Naydenov, L. Delprat, B. Bradu, K. BrodzinskiSTATUS | SRF HEAT LOADS | OVERALL CRYO LAYOUT | PH LAYOUT | PL LAYOUT | CM ARRANGEMENT | HE INVENTORY | ELECTRICAL | CONCLUSIONS Bi-phase line [m]g/s] Gas speed [m/s]Gaseous cross-section [m2]Bi-phase line [m]g/s] Gas speed [m/s]Preliminary proposal:A cryo cell length of 52 m (6 CM per cell) – coherent with warm quadrupoles spacingA bi-phase tube diameter of 25 cmFirst results:If supply fails, the highest module will dry in about 30 minEvacuation gas speed does not exceed 1.5 m/s (within limits)Bi-phase line diameter for booster will be refined once transients are better understoodGaseous cross-section [m2]

14. 14Total helium inventory for technical points at FCC-ee (ttbar) ~ 25 tonPoint HZWHttbarCryomodules2.2 ton2.6 ton2.6 ton7.5 tonDistribution (QRL)4.3 ton4.3 ton4.3 ton4.3 tonCryoplants0.2 ton1.7 ton1.7 ton4.5 tonTotal6.7 ton8.6 ton8.6 ton16.3 tonPoint L/S4ZWHttbarCryomodules0.3 ton0.6 ton1.1 ton6 tonDistribution (QRL)1.4 ton1.4 ton1.4 ton1.4 tonCryoplants0.1 ton0.1 ton0.2 ton1.1 tonTotal1.8 ton2.1 ton2.7 ton8.5 ton Baseline CM assumption with a two-phase helium pipe and a bath around the cavity:Points H and L He InventoryB. Naydenov, L. Delprat, B. Bradu, K. BrodzinskiSTATUS | SRF HEAT LOADS | OVERALL CRYO LAYOUT | PH LAYOUT | PL LAYOUT | CM ARRANGEMENT | HE INVENTORY | ELECTRICAL | CONCLUSIONS

15. Electricity power requirements – Installed power15Three scenarios are considered:Conservative: 230 Wel/W or 28.8 % of Carnot efficiency (LHC-like – CDR values) the baseline!Intermediate: 210 Wel/W or 31.5 % of Carnot efficiency (With an optimized process) appears not achievableOptimistic: 170 Wel/W or 39 % of Carnot efficiency (With centrifugal compressors) strong R&D effort needed-26% of consumption with centrifugal compressors - R&D needed.PH [MW]PL [MW]Total [MW]Z1.2 / 1.1 / 0.90.35 / 0.32 / 0.261.6 / 1.4 / 1.2W11.5 / 10.5 / 8.50.8 / 0.7 / 0.612.3 / 11.2 / 9.1H11.5 / 10.5 / 8.51.5 / 1.4 / 1.113 / 11.9 / 9.6ttbar27.6 / 25.2 / 20.47.4 / 6.7 / 5.435 / 32 / 26In “high” modeB. Naydenov, L. Delprat, B. Bradu, K. BrodzinskiSTATUS | SRF HEAT LOADS | OVERALL CRYO LAYOUT | PH LAYOUT | PL LAYOUT | CM ARRANGEMENT | HE INVENTORY | ELECTRICAL | CONCLUSIONS

16. Conclusions and Upcoming activities16Cryogenics study is on track in collaboration with RF and TIWG colleaguesStaging of the machine cryoplants and concept of the cryogenic distribution were defined following Z, W, H and ttbar machineCryo for detectors/MDI under study -> main assumptions still to be transmitted to cryogenics for further study of the design conceptSurface needs (on ground, alcoves and caverns) have been transmitted to civil engineeringFurther study the operation modes of the booster and the related heat loads with RF/optics expertsDefine the operation modes of the cryoplants according to the machine modes (e.g. Economic mode, maintaining a wide range of operability)Conclude on RF points (H & L) layout:PL position of the access shaft wrt the LSS-center to be confirmedNumber of CMs, heat loads and sectorization strategyUpdate the feasibility study with industryInvestigate open points : safety aspects, installation and waste heat management.B. Naydenov, L. Delprat, B. Bradu, K. BrodzinskiSTATUS | SRF HEAT LOADS | OVERALL CRYO LAYOUT | PH LAYOUT | PL LAYOUT | CM ARRANGEMENT | HE INVENTORY | ELECTRICAL | CONCLUSIONS

17. Thank you for your attention

18. SPARES18B. Naydenov, L. Delprat, B. Bradu, K. Brodzinski

19. Booster cycles impact on cryogenics19B. Naydenov, L. Delprat, B. Bradu, K. Brodzinski

20. 20Last booster cycle specifications fromK. Oide (24th Nov. 2022)B. Naydenov, L. Delprat, B. Bradu, K. Brodzinski

21. 21Cycle modes and shapesFilling from scratch(only few times/day)Top-Up filling (usual steady-state operation)Collider energy(Max 182GeV)LINAC energy (20 GeV)Collider top-up interval between e+ and e- (4 IP)2 * collider filling time from scratch(electrons and positrons)BR ramp time (shape is unknown)n injections are needed = 2 * # of BR ramps up to ½ stored current + 2* #of BR ramps for bootstrap Collider filling time for top-upB. Naydenov, L. Delprat, B. Bradu, K. Brodzinski

22. 22Result for Z & W machinesProbably the flat top time will be increased to few seconds for Z. Significant impact on the integral !α (from scratch) = 1% α (top-up) = 1%α (from scratch) = 7% α (top-up) = 2% B. Naydenov, L. Delprat, B. Bradu, K. Brodzinski

23. 23Result for H & tt machinesα (from scratch) = 25% α (top-up) = 11%α (from scratch) = 46% α (top-up) = 13% B. Naydenov, L. Delprat, B. Bradu, K. Brodzinski

24. 24Implication for cryogenicsCryogenic dynamic heat load is varying during ramp-up/downHow cryo power evolves during the transient? If we assume that it is proportional to the square of particle energy:We must consider the filling from scratch modeThe relationship between the energy cycle and the dynamic heat load could be refinedAllow to not oversize the cryo system.Allow to better understand the dynamics.Next stepsCryo team will perform some dynamic simulations to evaluate the impact of the filling from scratch.Some additional helium buffers at the cryomodule level and at the refrigerator level could be mandatory.Machineα for filling from scratch (Energy / cryo power)α for top-up mode(Energy / cryo power)Z1% / 1 %1% / 1%WW7% / 6%2% / 2%ZH25% / 19%11% / 8%ttbar46% / 34%13% / 9%B. Naydenov, L. Delprat, B. Bradu, K. Brodzinski

25. FOCUS on RF Points25B. Naydenov, L. Delprat, B. Bradu, K. Brodzinski

26. 26Updated RF heat loads for FCC-eeO. Brunner, F. PeaugerB. Naydenov, L. Delprat, B. Bradu, K. Brodzinski

27. FCC-ee cryoplants at point H (ttbar)2733 CM @ 4.5 K11.4 m/CM4 cavities/CM8 cells/CM33 CM @ 4.5 K11.4 m/CM4 cavities/CM8 cells/CM61 CM @ 2 K7.5 m/CM4 cavities/CM20 cells/CM61 CM @ 2 K7.5 m/CM4 cavities/CM20 cells/CMDiagrams not to scale B. Naydenov, L. Delprat, B. Bradu, K. Brodzinski

28. FCC-ee cryogenics at point L/S4 (ttbar) 28150 CM @ 2 K7.5 m/CM4 cavities/CM20 cells/CMDiagrams not to scale B. Naydenov, L. Delprat, B. Bradu, K. Brodzinski

29. FCC-ee cryoplants at point L : staging29ttbarRef. 2 K (6 kW)Ref. 2 K (3 kW)Ref. 2 K (6 kW)Ref. 2 K (6 kW)orOp. 1Op. 2ZWHRef. 2 K (0.5 kW)Ref. 2 K (1 kW)Ref. 2 K (2 kW)upgrade 1upgrade 2S3ttbarRef. 2 K (4.5 kW)Ref. 2 K (4.5 kW)ttbarRef. 2 K (9 kW)S1/S2S4Symmetric SymmetricAsymmetric B. Naydenov, L. Delprat, B. Bradu, K. Brodzinski

30. Surface needsFor Civil engineering 30B. Naydenov, L. Delprat, B. Bradu, K. Brodzinski

31. 31Point A & GPoint B & FPoint D & JPoint HPoint Lee (ttbar)hhee (ttbar)hhee (ttbar)hhee (ttbar)hhee (ttbar)hhSurface in m2Compressor station building4304300x6400N/A6400640032006400Cold box buildingx400x800800800400800LN2 storage4242x4242424242GHe storage4002000x2900162029008102900LHe storagex1080x2200x2200x2200Total aboveground8727822x12342886212342445212342Surface requirements for cryoAboveground surface needs per point:Estimations based on industrial studies for FCC-hh @ CDR baseline and LHC experience.Compressor stationsCold boxbuildingLN2 StorageGHe StorageLHe StorageControl RoomLHC P8 total cryo area of about 4600 m2.B. Naydenov, L. Delprat, B. Bradu, K. Brodzinski

32. Surface requirements for cryo – Service Caverns32Service cavern sizes - Points B, F, H and L850 m2 for cryo.Driven by FCC-hh assumptions.Accounts for cold boxes, interconnection boxes and auxiliary racks.Does not account for instrumentation which will be located in:Alcoves (racks)Tunnel (crates)FCC-ee cryoplants should fit within.L. BromileyB. Naydenov, L. Delprat, B. Bradu, K. Brodzinski

33. 33Surface requirements for cryo - AlcovesCryogenic control system and instrumentation:Sensors - in the LHC it manages more than 16000 sensors (thermometers, pressure sensors and level gauges).PLCs running control loops, alarms and interlocks.Actuators:Control valves (analog), quench valves and pressure valves (digital) – more than 3000 in the LHC.Heaters – more than 2400 in the LHC.Racks and crates house electronic cards for: reading the temperature, pressure and liquid helium level measurementssupplying electrical power to the heatersreading the digital valves statusInstrumentation and Control – main alcoves requirements driverB. Naydenov, L. Delprat, B. Bradu, K. Brodzinski

34. Surface requirements for cryo - Alcoves347 alcoves per sector (EDMS - 2822196)16.5 m2 of surface in each alcove based on FCC-hh requirements.It is assumed that crates will be kept next to the magnets where radiation is expected to reach 200 Gr/yr (20 – 200 times the LHC values). R&D on radiation resistant ASIC chips and processors is required but deemed realistic.No requirements coming from FCC-ee at this stage as instrumentation will be mostly located in the Klystron galleries.Space for a rack and margins to open the door whilst a person is passing.RackL. BromileySector alcoves schematicB. Naydenov, L. Delprat, B. Bradu, K. Brodzinski

35. Utilities needs35B. Naydenov, L. Delprat, B. Bradu, K. Brodzinski

36. Water- and air-cooling needs for FCC-ee cryo36Air needs: Underground areas @ ttbar : 0.1 MW for point L (1 * 9 kW @ 2 K installed)0.2 MW for point H (2 * 10 kW @ 2 K installed)Surface areas @ ttbar:0.5 MW for point L (1 * 9 kW @ 2 K installed)2 MW for point H (2 * 60 kW eq @ 4.5 K installed)Water needs:Underground areas @ ttbar : 0.8 MW for point L (1 * 9 kW @ 2 K installed)1.8 MW for point H (2 * 10 kW @ 2 K installed)Surface areas @ ttbar:10 MW for point L (1 * 9 kW @ 2 K installed)40 MW for point H (2 * 60 kW eq @ 4.5 K installed)RF pointsWaste heat recovery assessment to be started with CV.13 MW per cryo-point in the LHCB. Naydenov, L. Delprat, B. Bradu, K. Brodzinski