Hongyu Bai LCLS-II 2 K Cold Box PDR September 27, 2016 Safety and ESH Hongyu Bai LCLS-II 2 K Cold Box PDR September 27, 2016

Outline 2K coldbox and interfaces Pressure safety Design pressure Pressure relief in the 2K coldbox Pressure relief at the interfaces Other safety issues What-if analysis Summary LCLS-II 2 K Cold Box PDR, Sept 27, 2016

2 K Cold Box Components 5 CC + 1 CC with motors and magnetic bearing Process piping Bayonets Flow straightener Vacuum Jacket With manhole Vacuum pumps Relief devices Control valves MLI Instruments LCLS-II 2 K Cold Box PDR, Sept 27, 2016

2 K ColdboxInterfaces LHe dewar To 4.5K CBX U-tube Clean up return From Interface Box Vacuum Break Instrument Air Cooling water 3 atm He Guard Vac.

Design pressure requirement Component Normal operating Design Pressure Pressure Temperature Vacuum jacket ~ 0 bara ~ 300 K External 1 bara Internal 0.2 barg Discharge piping to 4.5 K coldbox 1.2 bara ~ 27 K 6.2 bara Suction piping and CCs piping 0.027 bara 3.4 – 27 K 4.1 bara LHe dewar vapor return piping 1.25 bara 4.5 K 3 atm Helium supply 4 bara 300 K 11.2 bara LCLS-II 2 K Cold Box PDR, Sept 27, 2016

Pressure rating of components 3-1/8” bayonets (LHe dewar 4.5K Vapor return) 12.4 bara [1] 5-3/16” Bayonets (30K discharge U-tube) 6.2 bara [1] 9-1/4” female bayonets (on Interface Box) 5.1 bara [1] CC motor cartridge 47 bara [2] CC wheel housing 4.1 bara [2] Cryogenic valves > 10 bara [1] LCLSII-4.8-EN-0791-R0, Jlab bayonet gate valves [2] LCLS-II cold compressor technical proposal, ALAT LCLS-II 2 K Cold Box PDR, Sept 27, 2016

Operating Temperature Interfaces No. Interface Connection Operating pressure Operating Temperature 1 30 K discharge to 4.5K CBX 5-3/16” bayonet ~ 1.2 bara 25-30 K 2 3.5K suction line 10” internal pipe weld connection ~ 27 mbara ~3.5 K 3 4.5K vapor from LHe dewar 3-1/8” bayonet ~ 4.5 K 4 Cleanup return 1/2“ internal pipe weld 300 K 5 RT He supply 1” pipe 4 bara 6 Guard vacuum Weld < 10 Torr 7 Instrument air ~ 7 bara 8 Cooling water 1” pipe weld ~ 5 bara ~ 300K LCLS-II 2 K Cold Box PDR, Sept 27, 2016

Utilities 1. Cooling water (For CC and Diffusion Pump) Pressure drop: <1bar Pressure head of water pump at SLAC: ~ 70 psi 2. Vacuum guard (For CC and bayonets) Vacuum will be used for the sealing intercept instead of helium. Helium guard is provided as an option. Relief plate set pressure: 1.2 bara 3. Instrument air For 6 pneumatic control valves Required pressure of 7 bara Safety valve set pressure: 11.2 bara LCLS-II 2 K Cold Box PDR, Sept 27, 2016

The reliefs are designed to: Safety Relief System The reliefs are designed to: Ensure safety in all modes (normal, failure, partial maintenance, etc.) Adequately relief system for all types of failures Prevent contamination during normal operations Reseal to maintain system integrity, minimize helium loss Vent outdoors for process piping Safety valve in guard vacuum LCLS-II 2 K Cold Box PDR, Sept 27, 2016

Sub-atmospheric pressure Line B U-tube Safety relief setting 2 K Coldbox: Safety valves are installed at suction and discharge U-tube Vacuum Break CM process lines are protected at DB (FNAL): Safety valve relief at 2 bara Burst disk relief at 4 bara LCLS-II 2 K Cold Box PDR, Sept 27, 2016

Subatmospheric System Relief Name Cryomodules & CDS (FNAL Scope) 2K CBX suction 2K CBX discharge Operating pressure 31 mbar ( normal operation) 1.2 bara (Cooldown) 27 mbara ( normal operation) <= 1.2 bara (Cooldown) 1.2 bara Safety Relief Pressure 2 bara (at RT) 4 bara (at LT) 4.1 bara 6.2 bara Location DB 2 K CBX 2 K VBX Type Spring loaded valve Burst disk ASME, guard vac. enclosure ASME, guard vac. enclosure Vents to Outdoors LCLS-II 2 K Cold Box PDR, Sept 27, 2016

Preserve inventory in the event of total power failure Blowdown “Low pressure” relief for long term power outage. Preserve inventory in the event of total power failure LCLS-II 2 K Cold Box PDR, Sept 27, 2016

Safety valves Primary relief valve requirements RV41712: static heat in-leak cavities at 4.5 K liquid RV41722: Thermal expansion in the case of loss of vacuum in 2K CBX RV41175/RV41200/RV41500:Thermal expansion in the case of loss of vacuum in 2K CBX RV41000: Vacuum Jacket protection Standards: ASME B31.3-2014 “Process Piping” ASME BPVC Section VIII Div. 1 – 2015 “Rules for construction of Pressure Vessels” API 520 – Part I 2014, “ Sizing, Selection, and Installation of Pressure Relieving Devices on Refineries, Part I-Sizing and Selection” CGA S-1.3-2008 “Pressure Relief Device Standards” LCLS-II 2 K Cold Box PDR, Sept 27, 2016

Oxygen Deficiency Hazard (ODH) Fluid: Helium colorless, odorless, tasteless, non-toxic, inert Helium volume: Normal operation: < 10 Liter LHe (equivalent) Cooldown: < 100 liter LHe (equivalent) (~ 15000 liters in CMs.) ODH in the coldbox room has been analyzed and reviewed. SLAC ES&H Program Manager Concurrence. ODH class of Cryo building: class I Warning Signs Installed Oxygen Monitor Ventilation Training for personnel LCLS-II 2 K Cold Box PDR, Sept 27, 2016

Electrical Electricity 480 VAC +/-24V 3 phase – 60Hz +/-1Hz, 13 kW/16 kVA for each CC motor. The electrical components will follow the following standards: IEC 60204-1: 2005 / A1:2008, Safety of machinery – Electrical equipment of machines IEC 61000-6-2: 2005 , Electromagnetic compatibility (EMC) – Part6: Generic standards – IEC 61000-6-4: 2006 / A1: 2011 Electromagnetic compatibility (EMC) – Part6: Generic standards IEC 61010-1 Safety requirements for electrical equipment for measurement, control, and laboratory use LCLS-II 2 K Cold Box PDR, Sept 27, 2016

Noise The expected noise generated by the cold compressors will be lower than 85 dB when measured from 1 m distance from equipment [1]. The National Institute for Occupational Safety and Health (NIOSH) Allows all worker exposures to noise no more than 85 dBA for eight hours to minimize occupational noise induced hearing loss. The standards for occupational noise exposure adopted by the DOE State that personnel without hearing protection must not be exposed to an intensity of noise exceeding 85 dBA. [1] LCLS-II cold compressor technical proposal, ALAT LCLS-II 2 K Cold Box PDR, Sept 27, 2016

Cold burn, etc Cold burn: Lowest temperature: 3.5 K The cryogenic pipes and equipment are vacuum insulated. Fall protection Height: 12.5 feet A platform will be built around the 2 K coldbox for maintenance. Confined space: A manhole on the side and a ventilation hole on the top provided for installing upgrade/downgrade piping spools inside. Any maintenance inside 2 K CBX jacket will be planed, reviewed and approved according to ESH manual Chapter 6. Seismic: to be completed LCLSII-4.8-EN-0227 “LCLS-II Engineering Note on Cryogenic Plant Seismic Design Criteria” LCLS-II 2 K Cold Box PDR, Sept 27, 2016

What-if analysis What-if analysis for the 2 K CBX has been performed and an EN was drafted.

Summary The related ES&H aspects are identified and addressed in the 2 K cold box design. Integrated pressure safety relief is designed in the 2 K cold box, cryoplant and CDS. What-if analysis was performed for the 2 K coldbox. LCLS-II 2 K Cold Box PDR, Sept 27, 2016

Thank you!