Upgrade - PowerPoint Presentation

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Upgrade of the vertical test station with new improved inserts for existing cryostats

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Technical seminar - 5

th

June 2014

Vincent Roger - TE-MSC-TFSlide3

Outlook

Introduction

Part I – General description

Part II – The new insert of the Long station

2.1 Design stage2.2 Safety file2.3 Follow up of the productionPart III – The future inserts3.1 Projects progress3.2 The insert of the Cluster DConclusions

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Introduction4

In order to increase our capacity of

testing magnets, current leads and diode stacks, several projects have been set up to realise new insert or to update them. With these new inserts we will gain also in :

Flexibility

Cooling TimeHandling & operationIn a general way, the purpose of an insert is to :Support mechanically the magnet or other devicesConnect electrically this device to the power supply via the current leadsCool down the device from 293 K to 4.2 K or 1.9 K

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Inserts already in use in SM18

The insert used to test the diode stacks

The insert used to test current leads

The design of these inserts were simple since they work at 4.2 K : No exchangers and instrumentations No λ plate No tie holdings and helium guards

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Inserts in progress

The second insert of the long station

The insert of the

Siegtal stationThe insert of the Auxiliary stationThe insert of HFMThe insert of the Cluster D

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Part I – General description

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Magnet

λ

plate

Top plate

LHe

/

LHe

exchanger

4.2 K

helium

bath

1.9 K

helium

bath

GHe

/

LHe

exchanger

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Cryogenic devices

To

reach 1.9 K, two thermal exchangers are needed :

The GHe / LHe exchanger used to reach 1.9 K (using gaz helium at very

low pressure vapour saturised and JT valve)

The

LHe

/

LHe

exchanger

used

to cool the main

helium

bath to 1.9 K by

conduction

GHe

pumping

Command of the Joule Thomson valve

GHe

/

LHe

exchanger

LHe

/

LHe

exchanger

Instrumentations

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Use of a PLC & Operation

A PLC (Programmable

Logic

Controller) has been set up in order to manage automatically cryogenic devices for standard operations as cool down or warm up but especially to guarantee facilities and staff safety.

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Part II – The new insert of the Long station10

2.1 Design stage

In order to reduce the delay between two magnet tests on the long station, it has been decided to design a new insert.

This insert is NOT a copy of the existing insert, cryogenic performance have been improved, and instrumentations have been automatized.

Group project of 9 peoples: Follow up : TE-MSC-TF Design : EN-MME-EDM Manufacturing : EN-MME-FS Cryogenic devices : TE-CRG-ME Safety : DGS-SEE-SI

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Design of the existing insert

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Main improvements

A new

GHe

/ LHe exchanger to increase the helium flowA new LHe / LHe exchanger to increase its surface A new GHe outflow on the safety lineAutomatize the

safety valve on the λ plateUse new instrumentation boxes

Use an helium guard on the tie holdings to prevent leak

Use of a new

standard

valves for the

LHe

inflow

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Design of the new insert

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14One of the main

difficult part was to design a bigger LHe / LHe

exchanger by keeping a good handling.

To decrease the cooling magnet time from 4.2 K to 1.9 K, the exchange’s surface has been increased from 0.3 m

2 to 1.0 m2

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More than 200 elements have been modelled and 120 drawings

have been

realised !!! There are hundreds of welds which will be done and controlled by the main workshop !!!

From 600 to 700 hours of work !!!

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2.2 Safety file

The maximum

allowable

pressure (PS) of the insert has been defined. From this the opening pressure of safety valves and the pressure tests are defined.Upgrade of the vertical test station in SM18Working pressure : around 0.2 barg0.9 barg : opening of the valve to the balloonPS = 1.5 barg1.1 * PS = 1.7 barg

(primary safety system)1.2 * PS = 1.8 barg (secondary safety system)Test pressure :

2.5

bargSlide17

17According to the Pressure Equipment Directive 97/23/EC (PED),

this insert belongs to a risk category III.

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18Therefore a safety file need to be set up in which all the following information have to be documented.

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19Moreover the

percentage of radiographic tests on butt‐welds shall be in agreement with the following table.

All non standard welds need to be calculated, and the workshop needs also to be certified for all weld types.

Electron

beam

welds

Brazing

Copper / Stainless steal

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20For this safety file, an EDMS structure has been set up.

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2.3 Follow up of the commands & the manufacturing

To certify the insert, it is needed to check rigorously the material certificate of each part

even if these parts are ordered on the CERN store.

At the main workshop, each material pieces are identified and attached to one element of one drawing to keep the material traceability.

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22The manufacturing has begun, and the weld process is going to start :

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2.4 Synthesis

It’s the first time that a such project is realised with regards to the new standards. The approach is now well defined, and based on this experience we can go ahead with the following new inserts.

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Part III – The future inserts

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3.1

Projects

progressThe insert of the Siegtal stationThe insert of the Auxiliary station

The insert of HFM

The insert of the Cluster

D

11/2014

To be defined

12/2015

12/2015

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3.2 The Cluster D

New cryostat

New insert New cryogenics devices

New power supply & equipment New rack for the acquisition and new PLC New control room

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A preliminary study has been done in order to choose a design strategy based on the Long test station or on the HFM test station.Slide27

27Based on this criteria, we

estimated that HFM type design would fit better both in time and price estimate to our needs for serving HL-LHC magnet tests.

Design based on the design of the HFM test station

Design based on design of the LONG test stationPrice of the cryostat

×

Price of the insert

×

Time for fabrication of cryostat

×

Time for fabrication of insert

×

Price of fabrication of cryogenic lines

×

Handling of the insert in operation

×

Adaptability

×

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Today a first design of the insert is done, to go further with the design stage we would need some inputs (design of the current leads, final geometry of the cryostat, magnet interface, …)

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Conclusions29

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On behalf of 30

Design Office and Main workshop : EN-MME

Vincent Maire, Emilien Rigutto, Luca Dassa

Magnet Test Facilities: TE-MSC-TF

Marta Bajko, Christian Giloux, Patrick Viret Cryogenic Team : TE-CRGVladislav BendaSafety group: DGS-SEECecile PintoCryostats & Machine Integration : TE-MSC-CMIArnaud Vande

Craen

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