1. R. Than J. Huang P. Orfin T. Tallerico Jan. 19, 2011
56 MHz Cryogenic System
R. Than
J. Huang
P. Orfin
T. Tallerico
Jan. 19, 2011

2. 56 MHz Quiet Cryogenic Delivery Subsystem
Transfer lines from S and R line taps plus 1st phase separator
Cryostat with Boiler/Condenser Heat exchanger
Local Booster compressor
Heating System for return vapor + warm piping
Relief Header to outside (not required)
Instrumentation & Controls

3. Process Flow Diagram

4. Process & Instrumentation Diagram Helium tap-ins and Phase Separator

5. Process & Instrumentation Diagram Boiler and Condenser

6. Process & Instrumentation Diagram Cavity

7. Helium, dry and filtered
Haug Compressor
Type QTOGX 180 LM-L
Oil free compression of dry, filtered Helium
4 cylinders, 1-stage, air-cooled, gastight with magnetic coupling
Medium
Helium, dry and filtered
Dew point
- 80 ° C.
Operating conditions
min
normal
max
Suction temperature °C 20
Suction pressure p1 bar(abs)
0.9
1.0
1.2
Discharge pressure p2 bar(abs)
2.0
Free gas delivery Nm3/h
240
270
330
(referred to 1013 mbar, 0° C.)
Massflow kg/h
43.0
48.5
59.5
11.9 g/s

8. Condenser Vapor Space Volume
liquid

9. Condenser Vapor Space Volume
Heat transfer gradient across condenser/boiler set pressure
change in cavity volume between 0 load to full load, e.g. 100W
Condenser Vapor Volume sets the pressure rise rate dP/dt

10. Condenser/Boiler Designed heat load 100 W
Proposed heat transfer surface area 20 m2
Average heat flux across heat transfer surface area 5 W/m2
Condenser side temperature  4.4 K
Boiler side temperature  4.3 K
Proposed heat exchanger type  Plate and fin
Heat exchanger material  Al 3003
Condenser vapor volume  250 Liters

11. Condenser/Boiler
DT1 , Condenser side condensed liquid helium film  10 mK
DT2 , Fin on condenser side  6 mK
DT3 , Parting plate wall  0.2 mK
DT4 , Boiler side, natural convection  59 mK
DT5 , Fin on condenser side  6 mK
DT6 , Helium column at bottom of the heat exchanger  9 mK
DTtotal  90.2 mK
DTbudget  100 mK (100 mbar, condenser side)

14. Transfer lines from S and R line taps plus 1st Separator
Tap from S main header
Warmer Liquid helium than M main header
3.5 atm, 5.3K
Pressure variation
10Hz source
Tap back into R header
Vapor return from 1st phase separator
1st Separator
Operates at 1.45 atm
Takes warmer S line helium and produce 4.65K liquid
Recycles vapor back to R main header
Vapor from warm S header liquid, + Heat leak from supply transfer line

15. Cryostat with Boiler/Condenser
Boiler loop (PFD)
Some Vapor used for shield flow
Bayonet for Portable dewar fill
Condenser Volume
250 Liters
Pressure change ~ 64 mbar

16. Booster Compressor Oil free compressor 4 cylinder piston
g/s helium
Leak tightness: 1E-3T-L/s
P_suction: 0.9 bar
P_discharge: < 2.0 bar
Air cooling
Power: < 20 HP
< 15 psig: not ASME VIII
European CE/PED Code
Gas Management
Suction pressure control
Bypass valve High to Low
Return back to WR header at 1.25 bar

17. Vapor Heating System + warm piping
Ambient Air Exchanger
Dual exchangers for defrost cycling, continuous duty
~ g/s
Rate 15 psig
Non Jacketed Piping:
Helium Boiler Cryostat to ambient heat exchanger to compressor suction, ~ 120 ft
Compressor discharge to WR header, ~ 120 ft

18. Relief System 5 psig Small Process Relief Burst disk 7-8 psig
Piped to WR header
Handles cooldown, fill, warmup excursions
Burst disk 7-8 psig
Discharge to IP volume
Vacuum switch to isolate supply valve
Relief Header (not required) catastrophic failure release scenario
Finite inventory

19. 56 Mhz Cryogenic Instrumentation
Instrumentation Count
Proportional Valves – Qty 9.
Digital Valves – Qty 2.
Pressure Transducers – Qty 3.
Level Monitoring – Qty 3.
Temperature – Qty 26. (22 ordered)
7 high temperature range (1.4k – 420K)
19 standard temp range. (1.4k – 325K)
Vacuum* – Qty 3. (2 insul. And 1 beam)
*Supplied by vacuum group

20. 56 Mhz Cryogenic Instrumentation
Instrumentation Cables – Pulled by Cryo Group.
Will use upgraded Square D system to read signals. In process of upgrading now on AIP.
*Supplied by vacuum group

21. Major Equipment Jan VJ Lines Supply/Return+ 1st separator:
BNL Eng +Design: Jan thru Feb 2011 (2 months)
PPM + RFQ +Award Mar April 2011 (2 months)
Manufacturing: May June July Aug September (5 months)
Install: Sept/Oct ( field joints 2 welds plus jacket welds)
Oil-free air cooled compressor + warm piping + small shack
BNL Eng +Design: Jan thru April 2011 (4 months)
PPM + RFQ +Award May June July 2011 (3 months)
Manufacturing+ delivery:  Aug 2011 thru Mar 2012  (6 months)
Install : May 2012 thru June 2012  (Outside tunnel, Just outside rad control fence)
Condenser:
PPM + RFQ +Award Mar April 2011(2 months)
Manufacturing: May 2011 thru April 2012  (11 months)
Delivery to cryostat manufacturer for install (see below)
Install at Manufacturer: May 2012 thru June 2012 (2 months)
Cryostat:
BNL Eng +Design: Jan thru April 2011 (4 months)
PPM + RFP +Award May, June July 2011 (3 months)
Manufacturing: Aug 2011 thru July 2012  (11 months) (get condenser in May)
Install: July/Aug 2012
Ambient vaporizer 15 kW
BNL Eng +Design: Feb 2011 (1 months)
Manufacturing: Aug 2011 thru Nov 2011  (4 months)
Install: July/Aug piping
Controls & Instrumentation
PLC rack upgrade from Symax to Modicon Quantum (underway)
Cernox TT’s ordered.
Level, PT, etc. TBD
Cables +tray + rack TBD

22. Major Equipment 2011 VJ S/R Comp Conde Cryost Jan E&D Feb Mar Apr B&P
May
Jun
Manu
Jul
Aug
Sep
Oct
Install
Nov
Dec
2012
VJ S/R
Comp
Conde
Cryost
Jan
Manu
Feb
Mar
Apr
May
Install
Jun
Jul
Aug
Sep
Oct
TEST
Nov
Dec

23. Budget: FY11:300K, FY12: 1200K Unburdened Burdened VJ S&R Lines 80K
Requested
VJ S&R Lines
80K
Compressor +Shack+ Elec
180K
Warm Piping +Ambient HX
75K
Condenser
60K
Cryostat
650K
Instr. & Controls
Relief Stack
50 K
Trades
120K
1295
1500
1664