2 K Cold Box Process Design Vishy Ravindranath
2 K Cold Box Process Design Vishy Ravindranath LCLS-II 2 K Cold Box FDR Mar 28, 2018
Outline 1. Introduction 2. Process Requirements 3. 2 K CB P&ID 4. 2 K CB Major Components: § § § Control Valves 2 K CB Flowmeters 2 K CB Relief Valves 2
Introduction LCLS-II (x 1 CP) 4. 5 K CB 2 K CB C 1 2 K CB C 2 2 K CB IB IB DB DB L 0, L 1 & L 2 L 3 LCLS-II (1 CP) Welded Interface § 37 CM: 1. 3 GHz, (x 35) + 3. 9 GHz (x 2) § Single CP Operation § U-Tubes between Interface Boxes 3
2. Process Requirements: 4 K CB & 2 K CB Maximum Capacity 2 K CB Capacity (Ref: 2 K CB Technical Specification, 79222 -S 001) Mode Flow [g/s] Inlet Temp. [K] Inlet Press. [mbar] Outlet Temp. [K] Outlet Press. [bar] Max 215 3. 5 27 < 30 1. 2 Min 150 3. 6 28 < 30 1. 2 4 K CB Capacity Ref: 4. 5 K CB Technical Specification, LCLSII-4. 8 -CT-0284 Cavities (2 K) Warm Shields (35 -55 K) Intercepts (5 -8 K) 4 K CB Max Cap. 4. 0 k. W (200 g/s) 15 k. W 1. 30 k. W Linac Heat Load (Qo = 2. 7 E 10) 15 k. W 1. 39 k. W 3. 7 k. W (180 g/s) q Max 2 K Ref Cap. = 200 g/s q Limited by 4 K CB Capacity Liq. 15 g/s q 15 g/s Liq. : Provides additional margin for the Intercept and the Warm Shield Loads 4
2 K Heat Load [k. W] 2. Process Requirements: Linac 2 K Heat Load (Mass Flow) Cavity Qo (x 10^10) Cryoplant Capacity = 4 k. W 5
2. Process Requirements: Heat Loads & Pressure Drops Line A C 1 -2 K CB Line B C 1 -4 K CB QDis Ø Heat Load and Pressure Drop compiled in LCLS-II-4. 8 -EN-0804 -R 0 “LCLS-II 2 K Cold Box Process Analysis” QDis QCM 6
3. 2 K CB PID LHe Dewar Clean up return Safety Reliefs To 4. 5 K CBX CC Bypass 2 K RET From LINAC CM 7
3. 2 K CB P&ID: Interfaces Int No. Interface Bayonet Size Component Pressure Rating [psig] Operating Temperature He-504 CC 5 Discharge 5 -3/16” 75. 1 4 -300 He-505 CC 6 Suction 5 -3/16” 75. 1 4 -300 He-506 CC 6 Bypass 5 -3/16” 75. 1 4 -300 He-507 30 K return from 2 K Cold Box to 4 K Cold Box 5 -3/16” 75. 1 4 -300 He-508 4 K vapor supply from LHe storage dewar to CC 1 suction 3 -1/8” 83. 2 4 -300 8
3. 2 K CB P&ID: Interfaces Int No. Interface He-501 CC 1 suction He-510 Connection Component Rating [psig] Operating Temperature [K] 10” pipe welded 45 4 -300 Cleanup return ½” pipe weld 150 300 He-511 3 Atm He supply 1” pipe weld 150 300 GV-512 Guard vacuum 1” pipe weld Vacuum-15 300 IA-513 Instrument air 1” pipe weld 150 300 He-515 Relief Valve Discharge Collector 3” KF Flange 15 4 -300 CW-517 Cooling water Supply 2” pipe weld 100 300 CW-518 Cooling water return 2” pipe weld 100 ~300 9
4. 2 K CB Major Components: Control Valves Valve Tag Valve Descr. PV 41500 Dewar 4 K Supply PV 41212 Valve Size NPS Max Sizing Scenario Req. Cv Max. Cv 1. 5 Pump Down 1. Mass flow = 300 g/s 2. Inlet Pressure = 1. 25 bara 3. Inlet Temperature = 4. 5 K 40 52 2 K Bypass 2 4 K Linac Operation 1. Mass flow = 490 g/s 2. Inlet Pressure = 1. 5 bara 3. Inlet Temperature = 4. 7 K 43 52 PV 41160 CC Discharge 4 202 302 PV 41565 CC Discharge 4 202 302 PV 41170 CC Discharge 4 Pump Down 1. Mass flow = 300 g/s 2. Inlet Pressure = 1. 2 bara 3. Inlet Temperature = 30 K 202 302 1. Control Valves are sized in accordance with Flow Equations For Sizing Control Valves - ANSI/ISA 75. 01 (IEC 60534 -2 -1 Mod)-2007. 2 K CB Bypass Valve –PV 41212 size was increased from 1” to 2” valve. q 2” valve allows 9 k. W of Ref. Capacity for 4. 5 K Linac Operation (with RF) 3. 2 K CB Control Valve Data Sheet documented in JLAB Spec: 79720 -S 007, Technical Specs for LCLSII Cryogenic Control Valves (PV 41212 updated spec communicated to Valve vendor by JLAB) 10
4. 2 K CB Major Components: Flowmeter Tag Description F 41200 CC Discharge F 41500 Dewar 4 K Supply Size NPS Throat Size Max Sizing Scenario ∆P_cal (mbar) ∆P_FS (mbar) 4 1. 8 1. m 2. P_in 3. T_in = 260 g/s = 1. 25 bara = 30 K 66 100 2 1. m 2. P_in 3. T_in = 300 g/s = 1. 25 bara = 4. 5 K 38 50 Flows considered for the sizing are based on CHLII 2 K Cold Compressor Flow Data 280 g/s CC mass flow 200 g/s The flowmeters are sized in accordance with : “Measurement of Fluid flow by means of pressure differential devices-Part 1: ISO 5167 -1 (1991)”. CC 5 Discharge Pressure = 1. 2 atm 2 K CB Flowmeter Datasheets documented in JLAB Spec: 79420 -S 010, Technical Specs for LCLS-II Venturi Flow Elements CC 5 Discharge Temperature 30 K 6 K 11
4. 2 K CB Major Components: Relief Valves 2 K Cold Box Safety Reliefs are designed to: 1. Adequately relieve the system and protect the process pipes/components within the 2 K Cold Box against worst case failure scenarios. 3. All reliefs vent into a common relief header which is routed outside the building to vent the gas in a safe manner ha 4” li Re ef c Dis Co e rg tor c lle 2. Relief Valves mounted within Guard Vacuum Enclosure: (protected by parallel plate with 2 psig set pressure): Prevents contamination of subatmospheric process lines during normal operations 12
4. 2 K CB Major Components: Codes for Relief Valve Sizing Calculations documented in: “ 79222 -P 0001 2 K Cold Box Relief Valves” Standards & References: • API 520 – Part I 2014, “ Sizing, Selection, and Installation of Pressure Relieving Devices on Refineries, Part I-Sizing and Selection” • CGA S-1. 3 -2008 “Pressure Relief Device Standards” • ASME Code Section VIII, Division I, Appendix 11, Mandatory Capacity Conversions for Safety Valves 13
4. 2 K CB Relief: Heat Leak Assumption Nominal Length Node# Pipe Size [in] [m] #1 2 9 10 6 8 6 #2 6 11 4 11 2 1/2 5 #3 4 11 #4 4 7 #5 4 5 #6 4 6 Surface Area Heat Leak [m 2] 2 [k. W] 2. 4 20 30 4 2. 7 2. 0 2. 7 6 4 3 4 For 2 K CB thermal relief valve sizing based on heat flux assumption of 1500 W/m 2 q “Safety Aspects for LHe Cryostats and LHe Transport Containers, ” W. Lehman and G. Zahn, ICEC 7, London, 1978 (Fig 7): • 6000 W/m 2 for cryostat with 10 layers of MLI (super insulation) • 1300 W/m 2 for cryostat 1” thick layer of MLI q 2 K CB process pipes have 60 layers of MLI 14
4. 2 K CB Major Components: Reliefs Failure Scenario: q Loss of 2 K CB Insulating Vacuum q Heat Inleak into Process Lines due to air condensation Tag Mass Flow [g/s] Req. Orifice Size [in] Sel. Orifice Size [in] RV 41500 79 0. 18 0. 29 RV 41530 1340 0. 80 0. 92 RV 41540 274 0. 36 0. 44 RV 41550 133 0. 29 RV 41565 94 0. 19 0. 29 RV 41560 136 0. 23 0. 29 15
4. 2 K CB Major Components: Relief Valve Vent Line Pressure Drop Ins. Vac Seg#1: 3” relief discharge manifold = ΔP 1. 4 ΔP = 2 psi i ps PL = 66 psia ΔP = 2. 4 psi Seg#2: 4” Parallel Plate Vent f elie : g#3 Se Vents to outside the Bldg. 6” R ΔP r ade e H . 4 =0 psi ΔP = 6 psi Pr = 45 psig = (45 + 14. 7 + 6) Air Leak Pv = 14. 7 psia A. Flow Rate = 2 kg/s - All reliefs vent simultaneously B. Pressure Drop in Vent Line (Back Pressure) = 6 psid C. Differential Pressure on the Process Line = 51 psid D. Cold compressor casing design pressure = 60 psid. 16
Summary q The cold compressor design accommodates the anticipated variation in the heat load. q The design & interface requirements for the 2. 0 K Cold Box have been identified on the P&ID. q Relief Valve calculations have been performed for the 2 K cold box. The calculation details have been documented and reviewed q Detailed supporting calculation documents been developed: Document No. Title Status LCLSII-4. 8 -EN-0804 LCLS-II 2 K Cold Box Process Analysis Released JLAB-79720 -S 007 Tech. Spec for LCLS-II Cryogenic Valves Released JLAB-79120 -S 010 Tech. Spec for LCLS-II Venturi Under Review JLAB-79222 -P 0001 2 K CB Relief Valve Sizing Under Review 79222 -0000 2 K Cold Box P&ID Released 17
Background LCLS-II 2 K CBX FDR, Mar 9, 2017 18
Non Cryomodule-Heat Loads Document No. Title LCLSII-4. 8 -EN 0804 -R 0 LCLS-II 2 K Process Analysis LCLSII-4. 5 -EN 0179 -R 2 Cryogenic Heat Load LCLSII-4. 9 -EN 0299 -R 1 LCLS-II CDS Heat Leak Analysis 19
Line B Pressure Drop for LCLS-II (1 CP) Int. Box 30 m 50 m g/s 107. 5 Pressure Drop [mbar] 11 m 2 ∆P = ~ 4 mbar @ 215 g/s 1. 6 1. 5 1. 2 0. 8 0. 4 0. 8 0. 7 Head 2 K HX 0. 7 0. 2 0 Tunnel TL Surface TL Ø Pressure Drop in Line B for LCLS-II Baseline ~ 4 mbar 2 K CB TL 20
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