Testing/Commissioning of 2 K Cold Box Ritendra Bhattacharya LCLS-II 2K CB FDR March 28, 2018

Outline Charge 2 K Cold Box Test Process and Commissioning Scope Commissioning Requirement Responsibility Matrix Commissioning Readiness Flow Chart – DRAFT Test Plan and Controls Schedule –DRAFT Summary

FDR Charge 4. TESTS AND ACCEPTANCE Does the mechanical and instrumentation design allow adequate Performance Tests of the Cryoplant? NOTE: Test of 2 K Cold Box, Cold Compressors with the help of 4.5 K Cold Box

2 K Cold Box Test 4.5 K Commissioning Complete 2 K CB Installation Complete Pre - Commissioning Electrical & Control Checks Mechanical Checks Leak check & Flushing Motor Cartridge Integrations & Checks Local Leak check Electrical Checks (CC Cartridge only) Mechanical Checks(CC Cartridge only) System Cleanup & Cool down Acceptance Test for Cold Compressors with 2 K Cold Box 4.5 K Commissioning Complete U-Tubes reconfigured suitable to 2K CB Test

2.0 K Cold Box – Process & Commissioning Scope 2K Cold Box Cold Compressor – Process Parameters 2K Cold Box (Without LINAC) Commissioning - Scope Helium filling and cleanup Test heaters Insulation vacuum system Guard vacuum Magnetic bearing tuning at 4 K Level (if necessary) Cold compressors (1 through 5) Performance test of cold compressors (1 through 5) Modes Mass Flow Suction Discharge Maximum Capacity ≥ 215 g/s 3.5 K, 27 mbar < 30 K, 1.2 bara Nominal Capacity ≥157 3.6 K, 28 mbar Minimum Capacity ≤150 g/s 2 K Cold Box

2 K Cold Box Commissioning – Requirement Recall Final acceptance testing is to occur after the integration of 2 K cold box is completed. The Vendor to verify that all the CC instruments and controls associated with the provided equipment are properly indicating throughout each portion of the acceptance test. Process data (temperatures, pressures, mass flows, speeds, and gas purity) will be recorded by the SLAC’s archival system. The entire system shall operate stably at each of the operating conditions for 24 hours. Final test operational procedures to be provided by the Vendor 4 weeks prior to the start of acceptance testing for review and approval. The Vendor to provide the services of competent engineers and technicians to participate and conduct the initial startup and operations for the acceptance tests. JLab and SLAC: to provide competent and qualified support personnel to man stations as required during operations and testing for the purpose of training; to assign additional engineers to observe and evaluate the testing.

Commissioning Responsibility Matrix for 2 K Cold Box SRR ERR Installation Commissioning Readiness Commissioning Performance Test Handoff Sub-Systems 2 K Cold Box Main Transferline (MCB-IB-TL) Interface CAN –A Test Equipment Responsibility Matrix shall be prepared to identify specific roles & responsibilities JLAB engineering & commissioning support personnel Equipment and installation vendor’s personnel SLAC Pre-Commissioning, Commissioning and operations support personnel SRR System Readiness Review ERR Equipment Readiness Review

2 K Cold Box - Commissioning Readiness Installation completion System Pressure Tested and Leak Tested Loop check Continuity (up-to Terminal block) Circuit filled with air or N2 Cold compressor Cartridges not installed Accessibility ensured Installation Test Reports Pressure Safety System (pressure tests, relief valve/device test/check) Leak tests Electrical checks including on-site calibration of pressure transmitters/gauges and differential pressure transmitters/gauges – Need based Control checks including operator screens Communication check for all networks systems Availability of Facility provided Electric power availability (Step –by-step lock out/tag out for availability check at each equipment) Helium Gas Liquid Nitrogen Tower Cooling Water Measure to safeguard Co-occupancy of CP2 Installation and CP1 Commissioning. (Idea is to reduce the down time for resource) Safety System reviewed and verified Tooling, Consumables and spares available Resources available

Flow Chart of Commissioning Tasks - DRAFT 2.0 K Cold Box Acceptance Sub-Systems Step-by Step Remarks

2 K Cold Box Commissioning & Cold Compressor Acceptance Test Scheme FT41200 4.5 K Cold Box: Mode: 50% Turn down (CC Pump-Down) Mode: Nominal, Max. (CC Performance) FT PV41170 HE Recovery System MV41162 PV41160 CC6 PV41565 PT CC5 PV22393 PT PV22195 PV22194 CC4 CC3 U-Tubes CC2 CC1 U-Tube U-Tube U-Tube F E D C A EHTR41521-4 PT TT PV41500 Heater3 kW LHe Supply ~ 200 g/s U-Tube LHe Withdrawal B 2 K Cold Box GHe Return U-Tube 10 kL LHe Dewar JT ~ 2 - 5 g/s U-Tube A Heater 6 kW C Adaptation TEST-2kW-HTR LT Dummy TAO Load Heater Adaptation EHTR31000 D TT Adaptation TEST-16kW-HTR PT Main Transferline E Adaptation F

Test Equipment Equipment Function B C-D Loop E-F Loop Dummy TAO Load with Guard Vacuum Separates Liquid and vapor phases Keeps the Line B Cold with a small flow to the suction of Cold Compressor diminishing possible Thermo Acoustic Oscillation (TAO). 4.5 K CB Test Heaters Acts as a Jumper in order to provide a flow paths for C-D Loop and E-F loop Adaptation (Female Bayonets) Match the physical geometry C-D Loop A B Test Equipment E-F Loop

Process Control (1/2) – During Test Assumption Heater at LHe Dewar always produces surplus gaseous helium mass flow w.r.to demands from CC in order to keep the non-zero return flow back to 4.5 K Cold Box. This will prevent sub-atmospheric condition in the LHe Dewar. Cold Compressor Control The speed of the first 4 of the 5 stages of Cold Compression will be controlled by the 5th stage’s speed through “gear ratio”* The speed of the 5th stage is adjusted via. a process control loop to maintain a CC mass flow based on inlet pressure [look-up table: Pi Vs mi] The 5th stage speed seeks to maintain either a specified pressure difference (discharge minus suction) or a specified suction pressure. ----ALTERNATE CONTROL---- The speed of the first 3 of 5 stages of CC will be controlled by the 4th stage’s speed using “gear ratio”* The speed of the 4th stage is adjusted via. a process control loop to maintain a CC mass flow based on inlet pressure [look-up table: Pi Vs mi] The 4th stage speed seeks to maintain either a specified pressure difference (discharge minus suction) or a specified suction pressure The speed of 5th stage CC controls its own suction pressure (0.95 ATM) NOTE: *Look-up table (Inlet Pressure Vs Gear Ratio) applied PV41500 opens more -> allows more flow and less head for a iso-speed operation and vice versa.

Process Control (2/2) – During Test PV41500 Functions Adjust to the fixed flow characteristic to reduce oscillation Manual operation preferred during the test condition Isolate the 10 kL Dewar to protect sub-atmospheric condition CC Suction side Heater – EHTR4152X Maintains the CC suction temperature, TD41530 at the user provided input (~ 3.6 K) Heater at LHe Dewar – EHTR31000 Manually adjusted to establish the necessary mass flow Insufficient Flow w.r.t. CC ( ) Surplus Flow w.r.t. CC ( ) LHe Dewar Return Flow - PV22194 Maintains back pressure in LHe Dewar, PT31005 ~ 1.4 ATM LHe Dewar Supply Flow – PV22393 Maintains the Turbine – 4 discharge pressure ~ 3.2 ATM. Head – Flow Characteristic – Schematic only n3 n2 n1 Head – Flow Characteristic – Schematic only n3 n2 n1

Cold Compressor – Active Magnetic Bearing Stability of Active Magnetic Bearing (Not a requirement) CC operation at constant speed Can be tested by adjusting (closing) PV41500 manually CC operating point moves closer to the Surge Line ABM operation may be verified by Checking the rotor vibration (displacement) Head – Flow Characteristic – Schematic only n3 n2 n1

2 K Cold Box and Cold Compressor Acceptance Criteria Pressure Ratio Calculated from the inlet and outlet pressure fulfilling process requirements Flow Rate Measured by the venturi flow meter fulfilling process requirements Overall return temperature to 4.5 K Cold Box Measured by temperature diode to ensure below 30 K. Overall Isentropic Efficiency (requirement in terms of overall return temperature) Ratio of isentropic enthalpy difference to the actual enthalpy rise Can be measured by inlet and outlet temperature and pressures (Pin, Tin, Pout, Tout) 2 K Cold Box Insulation Vacuum Measured by vacuum pressure transmitters

Nusair Hasan LCLS-II 2K CB FDR March 28, 2018 2 K Cold Box Test Heater Nusair Hasan LCLS-II 2K CB FDR March 28, 2018

Design Calculation

Design Calculation

Pressure Drop Test for the Heater

Estimation Methodology Measure Δp for different flow rates. Establish f vs. Re relationship. Re-calculate Δp at process conditions. Data will validate design. Also help commissioning efforts.

Schedule – 2 K Cold Box Commissioning – DRAFT P6 Schedule Duration: CP-1: Jan 2019 to Dec 2019 [Current] Present Assessment for CP-1: 57 weeks 2.0 K Cold Box: 11 weeks DRAFT

Summary 4a. Does the mechanical and instrumentation design allow adequate Performance Tests of the Cryoplant? 2 K Cold Box design includes all the necessary equipment, sufficient instruments and process flexibility within the boundary of 2 K CB. Commissioning scopes are well defined Preliminary Commissioning Procedure for the 2 K Cold Box has been defined by adding test equipment. [Detailed Cold Compressor Test Plan will be provided by the Vendor] Draft commissioning schedule has been prepared Test plan heater pressure drop estimation is in place. Documentations preparation is the near term objective These allows adequate performance tests of 2 K cold box and cold compressors with the 4.5 K Cryoplant.

THANK YOU FOR KIND ATTENTION

Backup Slides

LCLS II Cryoplant – Commissioning Scope CP1 Oil Removal LN2 storage CP1 4.5K Cold Box GHe storage Recovery Compressor CP2 4.5K Cold Box CP2 Oil Removal CP2 Compressors CP1 Compressors Oil processor 2K CBX Guard Vacuum CDS Interface Boxes LHe Dewar LHe Dewar Instrument Air Motor Control Center

2 K Cold Box Commissioning & Cold Compressor Acceptance Test Scheme (OPTION-1) FT41200 4.5 K Cold Box: Mode: 50% Turn down (CC Ramp-up) Mode: Nominal (CC Performance) FT HE Recovery System PT CC5 PT CC4 CC3 U-Tubes CC2 CC1 U-Tube U-Tube U-Tube F E D C A PT PV41500 Heater3 kW LHe Supply ~ 245 g/s U-Tube LHe Withdrawal B Operation Main Transferline is not intended the fashion shown in the schematic above; because E-F line provides the shield cooling for the Main transferline. Having A-B loop cooled and E-F cooled, it is not further intended to keep C-D at warm condition in order to GHe Return U-Tube 10 kL LHe Dewar JT ~ 2 - 5 g/s U-Tube A No Shield Cooling via E-F for Main Transferline –> Not Intended U-Tubes are not connected to Interface CAN Heater 6 kW C LT Dummy TAO Load Heater D TT PT Main Transferline E F

Performance Test of 4.5K coldbox Ref: H. Bai 15 kW heater for HTTS 2 kW heater for LTTI (new) 35 kW heater for CC

Vendor Provided Pump-Down Speed Profiles