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

2. 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

3. 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

4. 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

5. 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

6. 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.

7. 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

8. 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

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

10. 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
EHTR 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
~ 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

11. 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

12. 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.

13. 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

14. 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

15. 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

16. 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

17. Design Calculation

18. Design Calculation

19. Pressure Drop Test for the Heater

20. 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.

21. 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

22. 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.

23. THANK YOU FOR KIND ATTENTION

24. Backup Slides

25. 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

26. 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
~ 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

27. 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

28. Vendor Provided Pump-Down Speed Profiles