Cryogenic refrigeration for the XFEL facility Current status

Cryogenic refrigeration for the XFEL facility. Current status of the commissioning. Wilhelm Hanspeter Grenoble, June 4 th, 2015

Content. 1. Introduction 2. Refrigeration Process 3. Commissioning Concept 4. Results 5. Status and open issues 2

Content. 1. Introduction 2. Refrigeration Process 3. Commissioning Concept 4. Results 5. Status and open issues 3

Introduction. New experiment: the European XFEL: X-ray Free-Electron Laser — Ultra short X-ray flashes: 27 000 times/s — The brilliance is a billion times higher than that of the best conventional X-ray radiation sources Key figures: — Length of accelerator: 1700 m — Length of facility: 3400 m — Accelerator modules: 100 — Max. electron energy: 17. 5 Ge. V — Max. wavelength : 0. 5 nm — Start of commissioning: 2016 4

Content. 1. Introduction 2. Refrigeration Process 3. Commissioning Concept 4. Results 5. Status and open issues 5

Refrigeration process. Requirements. Cooling loop Unit Min. required wo overcapacity Specified incl overcapacity 2 K k. W 1. 46 1. 896 Cold Comprs. g/s 74. 0 96. 0 5 -8 K shield k. W 2. 40 3. 2 40 -80 K shield k. W 16. 0 24. 0 6

Refrigeration p rocess. Main features. Compressor System 1 Coldbox CB 41 Compressor System 3 Coldbox CB 43 Distribution Box DB 54 Dewar C. Comp CB 44 XFEL Main features — 2 coldboxes supplying cold Helium in single or parallel operation — 2 thermal shields, isothermal cooling at 2. 0 K — In coldbox 41/43: 7 gas beared expansion turbines in 4 turbine strings ld — 4 cryogenic cold compressors with a compression ratio of > 45 K 80 e hi rn S - TU str LP ing s Co ld 5 -8 eld Co hi KS mp res sor s HP su pp ly 40 tu re Dewar a He 2 K Load l t in ea K k 2 TL main process flows cold turbomachines cryogenic cooling loads 7

Content. 1. Introduction 2. Refrigeration Process 3. Commissioning Concept 4. Results 5. Status and open issues 8

Phase 1. Commissioning concept. Compressor System 1 Coldbox CB 41 Compressor System 3 Coldbox CB 43 Distribution Box DB 54 Dewar 51 Testbox 51 Phase 1 scope of supply Purpose: Comissioning & test of «over-atmosheric» components with testbox with jumper lines & simulation heaters. Functional tests: — Initial controller setup, system stabilisation. — Verification of modified components. Performance tests: — Single coldbox operation CB 41 & CB 43. 9

Phase 2. Commissioning concept. Compressor System 1 Compressor System 3 Coldbox CB 41 Coldbox CB 43 Phase 2 Distribution Box DB 54 Dewar 51 Distance: ~10 m ΔHeight: 0 m Cold Testbox Compressor 44 CB 44 Purpose : test of complete refrigeration plant wo the influence of cryolines, installation of cold compressor CB 44 and testbox 44 at coldbox hall Functional tests: — Controller setup, test of CC startup & pumpdown — Establish stable operation at nominal conditions of CC Performance tests: — None 10

Phase 3. Commissioning concept. Compressor System 1 Compressor System 3 Coldbox CB 41 Coldbox CB 43 Phase 3 Distribution Box DB 54 Dewar 51 Distance: 150 m Height: -22 m Cold Testbox Compressor 44 CB 44 Purpose: Performance test of complete plant. CB 44 installed at final location. Functional tests: — Controller setup, adaption to changed geometries — Normal & part load operation of cold compressors Performance tests: — Single coldbox operation CB 43 and CB 41 with cold compressors — Double coldbox operation with cold compressors 11

Content. 1. Introduction 2. Refrigeration Process 3. Commissioning Concept 4. Results 5. Status and open issues 12

Phase 1. Single Coldbox Operation. Cooling Loop Unit Measured CB 41 2 K Loop 1 k. W Cold Comprs 1 g/s 99. 9 5 -8 K shield k. W 40 -80 K shield k. W Measured CB 43 Min. required wo overcapacity Specified incl overcapacity 1. 46 1. 896 99. 9 74 96 2. 71 2. 77 2. 40 3. 2 18. 32 18. 02 16. 0 24 TU s s 2) As sor res mp ld Co 5 -8 simulation of cold compressors by heaters from 4 -20 K. Massflow acc. Q=mdh per specification, for 17. 5 Ge. V case, without overcapacity Co eld hi KS — Initial system controller setup as basis for first performance tests 1) Thermal tu re ing su pp ly str LP — Test run time: ≥ 24 hours Functional tests: rn HP — Minimum requirements 2 of DESY achieved d el -8 40 Performance tests: 0 K i Sh Dewar a He t in 2 K Load k lea 2 K main process flows cold turbomachines cryogenic cooling loads 13

Phase 2. Single Coldbox Operation. 0 K i Sh d el rn -8 40 str ing s Functional test: eld — CC Startup time < 1 h ld 5 -8 hi KS Co — Fully automated sequence for CC Startup & pumpdown Co mp res sor HP s su pp ly TU LP tu re Dewar a He t in 2 K Load k lea 2 K main process flows cold turbomachines cryogenic cooling loads 14

Phase 3. Single Coldbox Operation. Cooling Loop Unit Measured CB 41 2 K Loop 1 k. W Cold Comprs g/s 99. 6 5 -8 K shield k. W 40 -80 K shield k. W Measured CB 43 Min. required Specified w/o overcapacity incl overcapacity 1. 46 1. 896 99. 9 74 96 2. 79 2. 77 2. 40 3. 2 18. 09 18. 02 16. 0 24 TU s s 1) Thermal 2) As simulation of 2 K Loop by heaters per specification, for 17. 5 Ge. V case, without overcapacity sor res mp Co eld ld 5 -8 hi KS Co — Pressure stability = +/- 0. 2 mbar @ 24 mbar suction tu re ing su pp ly str LP — Test run time: ≥ 24 hours Functional tests: rn HP — Minimum requirements 2 of DESY achieved d el -8 40 Performance tests: 0 K i Sh Dewar a He t in 2 K Load k lea 2 K main process flows cold turbomachines cryogenic cooling loads 15

Content. 1. Introduction 2. Refrigeration Process 3. Commissioning Concept 4. Results 5. Status and open issues 16

Status & open issues. Performance tests: — Single coldbox performance test with CB 43 and cold compressors. — Single coldbox performance test with CB 41 and cold compressors. — Parallel coldbox operation incl. max. performance test in progress. — Demonstrate long term reliability of refrigerator plant: test run of 800 consecutive hours. outstanding Functional tests: — Part load operation of cold compressors with CB 41 in progress. — Functional tests refrigerator & compressor system in progress. — Functional tests cold compressor in progress. 17

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Refrigeration process. Plant concept. Compressor System 1 Compressor System 3 Coldbox CB 41 Coldbox CB 43 Distribution Box DB 54 Dewar 51 Distance: 150 m Height: -22 m Cold Compressor CB 44 Overhaul Modify XFEL New 19

Refrigeration process. Requirements. Compressor System 1 Coldbox CB 41 Compressor System 3 Coldbox CB 43 Distribution Box DB 54 Dewar C. Comp CB 44 Cooling loop Unit Min. required wo overcapacity incl overcapacity 2 K k. W 1. 46 1. 896 CC g/s 74 96 5 -8 K shield k. W 2. 40 3. 2 40 -80 K shield k. W 16. 0 24 XFEL Specified 20

Refrigeration p rocess. Main features. Compressor System 1 Coldbox CB 41 Compressor System 3 Coldbox CB 43 Distribution Box DB 54 Dewar C. Comp CB 44 XFEL Main features — 2 coldboxes supplying cold Helium in single or parallel operation — 2 thermal shields, isothermal cooling at 2. 0 K — In coldbox 41/43: 7 gas beared expansion turbines in 4 turbine strings ld — 4 cryogenic cold compressors with a compression ratio of > 45 K 80 e hi - TU str ing s ld hie S K 5 -8 Dewar a He 2 K Load LP tu re Co ld Co mp res sor s HP su pp ly 40 rn S l t in ea K k 2 TL main process flows cold turbomachines cryogenic cooling loads 21