1. Cooling Water and Heat Recovery system Thomas Hjern Harald Bäck Design Leader Process systems Conventional Facilities Accelerator Review November 3-4, 2014

2. NSS design teams Equipment design Vendor contacts In-king deliveries Target design teams Equipment design Vendor contacts In-king deliveries CF Process design task Accelerator design teams Equipment design Vendor contacts In-king deliveries “Work package 16” CW requirement coordination CW interface to “machine” Contaminated CW systems Local CW systems CF Process Cooling Water production (CUB) Site distribution Main headers in buildings Heat recovery systems CF HVAC Heating Cooling ESS Energy Team District Heating

3.  Reliability“..never cause shutdown of accelerator..”  Availability6500 hours per year at full load “..never have total CW shutdown..”  StabilitySupply temperature +/- 1 °C Supply pressure +/- 0,1 bar  FlexibilityWide operating range Design margins for critical components  R ecyclingRecover waste heat  R esponsibleHigh energy efficiency Design objectives ! ! !

4. Cooling water station (CUB)

5. Simplified Cooling water block diagram

6. Cooling water site distribution CUB expansion area ? To Campus area

7. Distribution piping

8. Accelerator layout

9. 3D CAD view

10. Isolated sub-systems Sub-system Main CW system to/from CUB Contaminated systems To low design pressure To high operating pressure

11. Example – Interface to CW consumers Constant flow consumersVariable return temperature

12. Reliability Chillers, heat pumps and pumps have standby units Redundancy for critical control components Competent monitoring and alarm functionality Backup power for critical components (Operator training and operational procedurs) Design objectives (cont.)

13. Availability Backup air coolers (reduced capacity) Service & maintenance of machinery at low load periods Pressure vessels inspection at low load periods Online tuning and reconfiguration of control system Two independent power supplies Design objectives (cont.)

14. Stability Pressure control for CW distribution Buffer tanks for CWM & CWL Advanced control capacity -Feed forward -Multi variable controls -Variable PID gain -Online tuning & configuration Design objectives (cont.) PC CWL Buffer tank 150m3 CWM Buffer tank 150m3 HEAT PUMPS PC CHILLERS CW return <30⁰C CW return 30-50⁰C CW supply 25⁰C CW supply 10⁰C CW supply 50⁰C CW return >50⁰C

15. Flexibility Expandability for additional heat pump and chillers Over-sizing of distribution piping Reserved space for future distribution piping Advanced control capacity Design objectives (cont.)

16. R ecycling Heat recovery from CW to Lund DH Heat recovery from CW to internal DH Heat recovery at ESS is both sustainable and profitable! Design objectives (cont.)

17. R esponsible Energy efficient heat pumps and chillers -Ammonia screw compressors Low temperature internal district heating (55°C) Integrated design “from klystrons to district heating” -Use high supply temperature -Produce high return temperature -Maximize direct cooling from CUB to Accelerator Design objectives (cont.)

18. Conductivty ~1µS/cm (0,5-2) Slip-stream to de-mineralizers in CUB Oxygen <15 ppb Slip-stream to degassers in CUB High pH prel – Polishing with cat-ion exchanger after de-mineralizers “Particle free” Full flow filtration at 1000 µm out of CUB Slip-stream filtration at 100 µm in CUB Local filtration at sensitive equipments Online control of conductivity, oxygen and pH Cooling water specifications

19. CF design standard -Common design standard for all design projects by CF -Design pressure 12 bar g / PN16 -Diff. pressure supply/return 3 bar g(2-4 bar g) -316L for piping, valves and equipments -Condensation protection for CWL supply and return -Strict manufacturing procedures Recommendations to CW consumers -Use 316L as much as possible (304 might be OK) -Use copper only when absolutely required -Don’t use brass, elastomers, plastic, etc CW Design standards

20. Examples – 316L components Pipes and tubing Heat transfer

21. Examples – 316L components Fittings Hoses and quick couplings

22.  Recent major changes have major impact on system design -Collector cooling 80-55°C -HVAC dehumidification -DHL capacity 6->30MW  Risk of new requirements 2015-2025 Mitigation Re-design and/or Re-build Risk - New requirements

23.  Low conductivity increase corrosion rate!  Very high corrosion rate on copper at medium oxygen levels  Transition between Cu(I) and Cu(II) release particles  (Risk of copper hydroxide precipitation?) Mitigation Online monitoring Expandability for deminerilizing, degassing and filtering Large water volume => stable conductivity, oxygen and pH Gather external experiences and knowledge -Accelerators -Power industry Risk - Corrosion, fouling & plugging

24. Thank you!