1. Overview of Mechanical Design
Nate Laverdure
LCLS-II 2 K Cold Box FDR
March 9, 2017

2. Design overview and interfaces
Outline
Design overview and interfaces
Configurations and bayonet installation/removal
Design details
Thermal reliefs
Cold compressor installation
Bellows/straightener assembly
Heater assembly
Central support column
Mechanical drawing package
LCLS-II 2 K CBX FDR, Mar 9, 2017

3. Mechanical design overview
LCLS-II 2 K CBX FDR, Mar 9, 2017

4. Mechanical design overview
LCLS-II 2 K CBX FDR, Mar 9, 2017

5. Cold box configurations
High flow configuration (CC-1 through CC-5)
From linac
To 4KCB
From
LHe dewar
LCLS-II 2 K CBX FDR, Mar 9, 2017

6. Cold box configurations
Low flow configuration (CC-2 through CC-6)
From linac
To 4KCB
From
LHe dewar
LCLS-II 2 K CBX FDR, Mar 9, 2017

7. Cold box configurations – u-tubes
Size
High flow
CC-1 through CC-5
IBX-CC1I-2KPR-1
9-1/4”
CC1O-CC2I-2KPR-1
CC5O-2KCB-CCR-1
5-3/16”
2KCB-4KCB-CCR-1
LHD-2KCB-4KVAP-1
3-1/8”
Low flow
CC-2 through CC-6
IBX-CC2I-2KPR-1
CC5O-CC6I-2KPR-1
Used in both configurations
LCLS-II 2 K CBX FDR, Mar 9, 2017

8. Top plate and work platform
Access requirements
Around bayonets for system configuration changes
Around control valves, relief valves, and feedthroughs for maintenance
Sufficient aisle width for egress from work areas
LCLS-II 2 K CBX FDR, Mar 9, 2017

9. Cold box configuration control
Bayonet installation/removal procedure
LCLS-II 2 K CBX FDR, Mar 9, 2017

10. Bayonet installation/removal procedure
LCLS-II 2 K CBX FDR, Mar 9, 2017

11. Thermal relief assembly
All 2K Cold Box cryogenic reliefs are:
Thermal reliefs
ASME reliefs
Protected against air contamination via guard vacuum enclosure
Exhausted to header which is protected against moisture entry and vented outdoors
LCLS-II 2 K CBX FDR, Mar 9, 2017

12. Thermal relief assembly
LCLS-II 2 K CBX FDR, Mar 9, 2017

13. Thermal relief assembly
Relief inspection/replacement process:
Warm up 2K Cold Box and bring to 1 atm
Backfill relief exhaust header with 3 atm He purge
Break fittings around relief shroud and remove
Disconnect relief flange and install blank while under purge
Inspect/test relief on bench or replace
Disconnect blank and install relief while under purge
Re-install relief shroud
Pump relief exhaust header to guard vacuum and backfill with 3 atm He purge
LCLS-II 2 K CBX FDR, Mar 9, 2017

14. Mechanical details – cold compressor installation
LCLS-II 2 K CBX FDR, Mar 9, 2017

15. Mechanical details – bellows/straightener assembly
Used in CC-1 and CC-2 inlet piping spools
LCLS-II 2 K CBX FDR, Mar 9, 2017

16. Mechanical details – bellows/straightener assembly
Cleanup of stagnant annular volume
Recommendation: Large virtual leak exists between flex ID and process piping. Need to address this.
Response: 12x 1/8” holes to facilitate pump and backfill of annular space
LCLS-II 2 K CBX FDR, Mar 9, 2017

17. Mechanical details – heater assembly
Based on SNS and earlier heater designs
LCLS-II 2 K CBX FDR, Mar 9, 2017

18. Mechanical details – control valves
LCLS-II 2 K CBX FDR, Mar 9, 2017

19. Mechanical details – internal piping support
Configurable support
Pinned in 2 places for shipping
Pinned in 1 place for normal operation
LCLS-II 2 K CBX FDR, Mar 9, 2017

20. Mechanical details – internal piping support
LCLS-II 2 K CBX FDR, Mar 9, 2017

21. Mechanical details – manway
Based on 30” design used at JLab 4K Cold Box
LCLS-II 2 K CBX FDR, Mar 9, 2017

22. Mechanical details – central support column
Maintains flatness of top plate during assembly
Threaded rods and nuts for leveling during installation
Shims inserted between flanges to carry large compression load
And during operation
Encased in passive copper conductor
Insulated with MLI
Thermal deflection limited to a few thousandths
LCLS-II 2 K CBX FDR, Mar 9, 2017

23. Mechanical details – vacuum pumping system
LCLS-II 2 K CBX FDR, Mar 9, 2017

24. Mechanical drawing package structure
Final integration
top level assembly
Assembled on SLAC site
Includes all installation, outfitting of all external piping and external instrumentation
Responsibility of final construction subcontractor
Initial construction
top level assembly
Shipped to SLAC
Includes vacuum shell, internal piping, internal instrumentation
Responsibility of initial construction subcontractor
LCLS-II 2 K CBX FDR, Mar 9, 2017

25. Mechanical drawing package
LCLS-II 2 K CBX FDR, Mar 9, 2017

26. Mechanical drawing package
LCLS-II 2 K CBX FDR, Mar 9, 2017

27. Mechanical drawing package
LCLS-II 2 K CBX FDR, Mar 9, 2017

28. Mechanical drawing package
LCLS-II 2 K CBX FDR, Mar 9, 2017

29. Documentation Document No. Title Author Status 79222-D6001
2K Cold Box Drawing List
D. Rath
Under review
LCLS-II 2 K CBX FDR, Mar 9, 2017

30. 2K Cold Box design documentation
Summary
2K Cold Box design documentation
P&ID released
Mechanical drawings for initial construction of the 2K Cold Box primarily in checking or released
Drawings to be complete by 10 Apr 2017
Access requirements are well defined
Maturity of design is commensurate with FDR
LCLS-II 2 K CBX FDR, Mar 9, 2017

31. Overview of Mechanical Design
Nate Laverdure
LCLS-II 2 K Cold Box FDR
March 9, 2017

32. 9-1/4” bayonet interference
Background
Used for subatm He connections at CC suction
SNS experience with this component: seized during installation
Outer male bayonet tube observed out-of-round
Interference between OD of outer male bayonet tube and ID of lantern ring or valve flange body
Not observed at JLab
LCLS-II 2 K CBX FDR, Mar 9, 2017

33. 9-1/4” bayonet interference
Mitigation
Purchase tube meeting ASTM A269
From this tubing, select and use only sections meeting additional imposed tolerance
Verify clearance using purpose designed gauge or lantern ring
Inspect ID of all lantern rings and valve flange bodies
LCLS-II 2 K CBX FDR, Mar 9, 2017