ILC Mechanical Electrical Review Conventional MECHANICAL System Design

ILC Mechanical & Electrical Review Conventional MECHANICAL System Design Summary Emil Huedem, FNAL Lee Hammond, FNAL Parsons Mechanical Team (Tim Sheehan, Jerome Burke, Michael Painter) March 21, 2012 1

INTRODUCTION • Process cooling water, ventilations, and sump system • Cryogenic system is not included but only it’s final heat rejection (cooling towers) • Sizing (&costing) for full power first (adjustment to lower powerbaseline will be done later) • Criteria/Load tables used was before July 2011. Many changes since • Parsons did the concept & costing for both KCS-ML and DRFS-ML. Only KCS is considered in this review • Costed each system-bottoms up, per shaft, per system (in RDR scaled from shaft 7) • Some items just have cost ($/m fire suppression, $ target ventilation, $laser room HVAC, $compressed air from RDR) 2

WBS • Follows the RDR WBS system • Specific wbs only 1. 7. 3 AIR TREATMENT (HVAC) 1. 7. 4 PIPED UTILITIES 1. 7. 5 PROCESS COOLING WATER 3

Load Table progress – Basis for current Concept design RECENT CHANGES ARE NOT INCLUDED HERE 4

CRITERIA / TECHNICAL LOADS In Central Region Some key criteria/input Various area system heat load tables (except e-) Various delta T per users Machine design to run all year or anytime in a year DR & BDS has tight space (air) stability Lcw/process water supply stability not critical 150 gpm per mile inflow for groundwater ML loads comes from RF system & racks For KCS, more than 60% of ML loads are in the surface RECENT CHANGES ARE NOT INCLUDED HERE 5

PROCESS WATER PLANT LOCATIONS & LOADS-KCS (Technical components only shown) PM-12 PM-11 PM-10 PM-9 PM-8 PM-7 PM 7 cr PM+7 PM+8 PM+9 PM+11 PM+10 PM+12 5876 Central Region 570 1976 2092 1046 2092 RECENT CHANGES ARE NOT INCLUDED HERE 2092 570 1823 DR T F A 11 0 2 9/ em 7/1 E. Hue d 6

ML-KCS Process water System SURFACE (per RF) ~62. 5 KW to LCW 3 KW to CRAC ~10. 2 KW to air (ventilation) 12 11 10 9 8 7 7 8 9 10 11 12 RECENT CHANGES ARE NOT INCLUDED HERE 7

ML-KCS Process water System SURFACE RF MAIN CW SYSTEM TUNNEL CAVERN 8

ML-KCS Process water System (simplified) 83/98 F (28/37 C) (15 F DT) 85/100 F (29/38 C) (15 F DT) LCW 85/107 F (29/41. 7 C) (22 F DT) FCU 85/95 F (29/ 35 C) (10 F DT) 104 F (40 C) Space 9

INTERFACE (KCS) (ONLY THE SUPPLY PIPE ARE SHOWN FOR CLARITY) ONE 1” VALVE TAP FOR RACKS PER RF (5 KW PER RF) @ 10 F dt 3. 4 GPM [ from RLarsen Mar 252010 GDE presentation & RLarsen MAY 162011 email confirmation] 1 -1/4” (4. 5 GPM) TO FANCOILS 1 qty/RF LCW BOOSTER PUMP (1 PER 2 RF) 24 GPM, 1 BHP, 1 -1/2”PIPE 12” LCW MAIN SUPPLY PIPE 1 RF ( 3 CRYOMODULES) ~ 38. 75 m 1 -1/4” PIPE HEADERS AFTER BOOSTER PUMPS INCLUDED (assumed qty VALVE TAPS) SEP 23 2011 10

Central Region Process water System COOLING TOWERS CHILLERS To MAU MAIN CHW SYSTEM PROCE WTR PUMPS CAVERN LCW SKID TUNNEL 11

Central Region Process water System (simplified) 85/100 F (29/38 C) (15 F DT) 60/82 F (15 / 28 C) (22 F DT) PW 65/85 F (18/13 C) (20 F DT) LCW 70/92 F (21/33 C) (22 F DT) FCU 65/75 F (18/24 C) 85 F Space (10 F DT) 12

D R A F T SEP 2 2010 Central Region LCW SKID LOCATIONS & FEED Length shown are approximate for process water distribution purposes only & doesn’t reflect the actual beamlength PL er KW hold 0 50 lace p ir W W to A LC K 40 oad L at He PM-7 END OF MAIN LINAC 270 m 234 m 270 m Fast Abort Pre. Undulator 683 m 2, 023 KW LCW (excl dumps) 101. 5 KW Heat Load to air Beam Tunnel 204. 1 KW Heat Load to air Service Tunnel Auxiliary Source 74 m 310 KW LCW (excl dumps) Target 17 m 104 KW LCW TR 35 m Positron Capture 70 m 657 KW LCW (excl dumps) 400 Me. V Pre-Acc 35 m 193 KW LCW 512 m 480 m 353 m PTran 1 434 m 5 Ge. V Booster Section 512 m 313 m 14. 7 KW LCW 84. 9 KW LCW 90. 2 KW 0 KW Heat Load to air 0. 9 KW Heat Load to air 8. 6 KW Beam Tunnel Heat Load to air 0 KW 7. 4 KW Beam Tunnel Heat Load to air 0 KW Beam Tunnel 0 KW Heat Load to air Service Tunnel 2. 3 KW 25. 5 KW 86. 8 KW 21. 4 KW Heat Load to air Beam Tunnel Heat Load to air 34. 5 KW Service Tunnel Rack Heat Load 92 KW At Service tunnel Rack Heat Load At Service tunnel 487 m 431 m PTran 2 1, 010 m 29 KW LCW (excl dumps) 1. 8 KW Heat Load to air Beam Tunnel 4. 6 KW Heat Load to air Service Tunnel 13

INTERFACE (Central Region)(ONLY THE SUPPLY PIPE ARE SHOWN FOR CLARITY) 14” PROC WATER (PW) MAIN SUPPLY PIPE HX FANCOILS LCW SKID SERVICE TUNNEL 1 -1/2” PW FANCOILS 4” LCW (298 gpm) 2” LCW PIPE 2” PW 2” LCW PIPE (to Power Supplies) VARIOUS VALVE TAPS assumed 1 -1/2” PW BEAM TUNNEL 3” LCW PIPE (to Magnets) 3” LCW PIPE VARIES SEP 23 2011 14

Damping Ring Process water System (PMB shaft) 15

Damping Ring Process water System (PMC shaft) 16

Damping Ring Process water System (Simplified) PMC-0 18/41 o. C Wiggler LCW 65/105 F (40 o. F DT) Wiggler 84 o. F Space Tower 83/98 F (15 o. F DT) 28/37 o C Chiller 60/90 F (30 o. F DT) 15. 6/32 o C RF LCW 17/41 o C 63/106 F (43 o. F DT) Wiggler 29 o. C ~23 o. C 73 F return 11/17 o. C 52/62 F to FCU 18/34 o. C 65/94 F magnet&PS 18/41 o C (65/105 magnets) 11/23 o C HX 52/73 o. F (21 o. F DT) Chiller 50/71 o. F (21 o. F DT) 10/22 o. C PMB-0 17

INTERFACE (Damping Ring)(ONLY THE SUPPLY PIPE ARE SHOWN FOR CLARITY) 6” (52 F) LCW FANCOILS 4” (65 F) LCW Will assume minimum number of valves taps Feed from PMB-0 to beam tunnel (approx 1. 3 Km) 6” (52 F) LCW from PMB-0 FANCOILS Will assume minimum number of valves taps 8” LCW TO WIGGLERS from PMC-0 Feed from PMC-0 to wiggler area (approx 204 m x 2) 18

IR & Main Dump Process water System (simplified) 19

AIR TREATMENT SCHEME 20 Kcfm 40 Kcfm 80 Kcfm 60”x 54” supply & return duct in shaft Typical Ventilation Equipment on each shaft Supply air to use the space below floor (non-ducted) Ducted supply air to each “Refuge Area Alcove” • ~1 mph airspeed (~2 ac/hr) 20

PLUMBING SCHEME • 150 gpm per mile inflow 21

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OVERHEAD (full power loads) 0. 08 w/w at peak 23

ADJUSTMENT TO FINAL NUMBERS • • Separate cost by Area systems Add missing wbs Adjust IR water plant cost Adjust Ventilation cost Add laser rooms Add Fire suppression etc • Scale per new load/criteria • Adjust cost to low power PARSONS’s MECH COST EXCEL PARSONS’s ELEC COST EXCEL ADJUSTED MECH COST EXCEL ADJUSTED ELEC COST EXCEL CIVILCOST EXCEL OVERALL CFS COST EXCEL (AMERICAs) Add EDMS references Add other mandatory input Risk Basis (high & low %) LINK or INPUT ? GERRY DUGAN’s EXCEL FILE ( CEM)

28 F dt • Stacking of loads in surface RF considered but not used • Not much first cost savings, (10” to 8” pipe mains) vs effect of high space temperature 25

Chiller vs w/out chiller on DR 26

POST RDR • About 50+ list from V. E. in Nov 2007, List from value engineering sessions in Nov 2007. Some appear to have real good cost reduction potentials. • Project focus on “first-cost” reduction • Talks located in http: //ilcagenda. linearcollider. org/conference. Display. py? conf Id=2328 • Description of each list, but no detailed evaluation • Specific items selected by project to be evaluated in 2008 o Elimination of centralized chilled in ML o Higher RF water delta T o Warmer tunnel temperature during operation and local cooling during maintenance o Other pipe materials • E Huedem, June 5 2008 discussions during this effort o Centralized LCW vs processwtr/skid o Tunnel booster pump footprint=2/rf o (stacking of loads) Surface RF High delta T 28 Fdt vs 15 F = not much cost savng o Surface RF ventilate or part of rack 27 o DR chilled water or not

BACKUP SLIDES some LOAD TABLES Backup Slides SEP 29 2011 Conv Mechanical Updates E. Huedem / L. Hammond 28

MAIN LINAC KCS Mar 23 2011 Backup Slides Load to LCW per Ray 29

POSITRON SOURCE Backup Slides (1 of 3) 30

POSITRON SOURCE Backup Slides (2 of 3) 31

POSITRON SOURCE (3 of 3) Updates recently Added ~200 KW New totals = 6460 Backup Slides 32

BDS Backup Slides 33

Backup Slides 34

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