4.5K Cold Box Overview
Dana Arenius
LCLS-II 4.5K Cold Box Director’s Review
November 16, 2016
Outline
• 4.5K Cold Box Function
• Contractual Milestones
• Design Schedule Delays
• Schedule Recovery Actions
• Summary
LCLS-II 4.5K Cold Box Director’s Review, November 16, 2016
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Cryoplant First Light & Normal Beam Operations
First Light
1 Cryoplant
2 Cryomodule
Strings
U-Tube Connections
14 MV/m Gradient
2.0≤ Qo ≤3.0
He Gas Tanks
LHe
Dewar
LN2
Dewar
2.0 K
Coldbox
1
L1
2 3
BC1
U-TUBE
JUMPER
CONNECTIONS
2.0 K
Coldbox
Normal Beam
Operations
2 Cryoplants
2 Cryomodule Strings
LHe
U-Tube Connections
Dewar
Removed
Gradient - 16 MV/m
2.0≤ Qo ≤3.0
IB
Downstream
Downstream
Distribution
Distribution
Box
Box
Upstream
Distribution
Box
Upstream String
LH
4.5 K
Coldbox
4.5 K
Coldbox
IB
L0
Compressor System
Compressor System
L2
Downstream String
L3
FC
4 5 6 7 8 9 10 11 12 13 14 15
16 17 18 19 20 21 22 23 24 25
26 27 28 29 30 31 32 33 34 35
IB
3.9 GHz Cryomodule1.3 GHz Cryomodule End/Feed Cap VacuumBarrier
LCLS-II 4.5K Cold Box Director’s Review, November 16, 2016
Cryogenic
Bypass
Cryogenic Transfer
Line
Cryoplant Gas Header Interface Box
3
Cryoplant Layout Overview
CP1 4.5K Cold Box
LN2 storage
GHe storage
CP1 Oil Removal
CP2 4.5K Cold Box
CP2 Oil Removal
CP2 Compressors
CP1 Compressors
Oil
processor
2K CBX
Guard Vacuum
CDS Interface Boxes
LHe
Dewar
LCLS-II 4.5K Cold Box Director’s Review, November 16, 2016
LHe
Dewar
Motor Control
Center
Instrument Air
4
Single Plant Operation (CP-1) for First Light, 14 MV/m
First Light Design Heat Loads with Qo=2.7x1010
Steady State CW Operation @ 14 MV/m
Mode 1: Max Capacity of the
Cryoplant
Temp Level
Variation in the 2.0 K Heat Loads of First Light for
the Selected First Light Gradient with Qo
Heat
Load
[kW]
High Temperature
Thermal Shield, (35K)
15.3
Low Temperature
Thermal Shield, (5K)
1.3
Primary Temperature
2K
4
Source: Jlab Refrigerator
Specification 79220-S001
(Ref: SLAC LCLSII-4.5-EN-0179-R2)
LCLS-II 4.5K Cold Box Director’s Review, November 16, 2016
One cryoplant is sufficient to
support the First Light
Operation
5
Two Plant Operation (CP-1 & CP-2) For Design Heat Loads
Design Heat Loads with Qo=2.7x1010 Steady State
CW Operations @ 16 MV/m
Mode 1: Max Capacity of the
Cryoplant
Temp Level
Variation in the 2K Design Heat Loads with Variable
Gradient and Qo
Heat
Load
[kW]
High Temperature
Thermal Shield, (35K)
15.3
Low Temperature
Thermal Shield, (5K)
1.3
Primary Temperature
2K
4
Source: Jlab 4.5K Cold Box
Specification 79220-S001
(Ref: SLAC LCLSII-4.5-EN-0179-R2)
LCLS-II 4.5K Cold Box Director’s Review, November 16, 2016
Two cryoplant operation to
support variation in gradient
and Qo
6
4.5K Cold Box Design Challenges
Included in plant performance analysis:
• Large variation of operational design parameters
 First Light single plant load (heavy load) vs. Normal two plant
operation (~50% load for each plant)
 Unknown final Qo determination, design basis 2.7x1010
 Required extensive heat exchanger/turbine performance
analysis for wide possible load variation
 Level of Seismic design criteria for California
 Subcontract requirement for CA Seismic licensed PE
LCLS-II 4.5K Cold Box Director’s Review, November 16, 2016
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JLab/SLAC/Air Liquide Engineering Coordination
• Weekly status and issue resolution meetings
 Attended by
• AL/SLAC/JLab engineering, vendor PM
• JLab procurement
 Not attended by AL subcontractors
• PHPK (cold box assembly engineering and fabrication)
• Sumitomo (heat exchanger manufacturer)
• Hopper (Seismic PE, Subcontractor to PHPK)
LCLS-II 4.5K Cold Box Director’s Review, November 16, 2016
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4.5K Cold Box Contractual Milestone Schedule
Milestone Description
Completion of Kick Off Meeting
Preliminary Design Review (PDR)
Order Long Lead Items
Complete final design review (FDR)
Delivery of Long Lead Material
Cold Box 1 Manufacturing Complete
Factory acceptance of completed turbines
Cold Box 1 Received at SLAC
Cold Box 1 Assembled at SLAC
Cold Box 2 Manufacturing Complete
Cold Box 2 Received at SLAC
Cold Box 2 Assembled at SLAC
Commissioning, Train, & Accept (CB1)
Deliver Ops & Main Manuals
Commissioning, Train, & Accept (CB2)
Required
Date
08-Oct-15
10-Mar-16
08-Apr-16
11-Jul-16
11-Nov-16
11-Aug-17
25-Aug-17
11-Sep-17
11-Dec-17
12-Feb-18
12-Mar-18
11-Jun-18
11-Oct-18
11-Jan-19
11-Feb-19
Actual
Complete
8-Oct-15
10-Mar-16
1-Nov-16
FDR Completion Plan: Nov 28th, Seismic Analysis
Last Long Lead Item Ordered: 1-Nov-16
LCLS-II 4.5K Cold Box Director’s Review, November 16, 2016
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4.5K Cold Boxes, 1.04.08.06/.16
•
Preliminary design review completed



•
Heat exchanger sizing
Absorber Beds
Process cycle design verification
Final Design Review 7-8th Sept





~90% of 92 required documents delivered
3-D modeling of internal piping completed
Missing Piping Stress & Seismic Design
Hold on top plate (upper cold box) and both
cold box vacuum shells until analysis of piping
stress and seismic analysis is complete (Note:
Internal piping/vessel structure attached to
vacuum shell)
Missing analysis scheduled to be delivered
~28th November
LCLS-II 4.5K Cold Box Director’s Review, November 16, 2016
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Schedule Recovery Action Items Implemented
• Notification of unsatisfactory schedule performance to vendor
senior management
• Vendor schedule optimization study of remaining work to recover
schedule implemented
• Continuation of weekly AL/Jlab/SLAC engineering coordination
meetings
• Invitation by AL to JLab to attend weekly AL/Subcontractor
coordination meeting for direct stakeholder communication
• PHPK
• Hopper
LCLS-II 4.5K Cold Box Director’s Review, November 16, 2016
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Summary
• Heat exchanger analysis was longer than expected in
completing PDR per contractual date and heat exchanger
ordering
• Heat exchanger delay affected 3-D piping, piping stress and
seismic analysis completion dates for FDR
• Lacking stress/seismic analysis, formal approval for cold box
shell ordering (needed for CB fabrication) was delayed
• FDR Seismic analysis completion is scheduled for Nov 28th
• Schedule study implemented to recovery schedule slip
• Expanded JLab interaction with vendor subcontractors
LCLS-II 4.5K Cold Box Director’s Review, November 16, 2016
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MAY I ANSWER ANY QUESTIONS?
LCLS-II 4.5K Cold Box Director’s Review, November 16, 2016
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LCLS-II 4.5K Cold Box Director’s Review, November 16, 2016
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Cryoplant Modes of Operation (1)
*Tables from 4.5K Cold Box Procurement Specification 79220-S001
Table 3.4(A) – Mode 1, Max. Capacity
Load
Warm Shield
Cold Intercept
4-K Refrigeration
4-K Liquefaction
Sub-Atmospheric
w
[g/s]
146
37
15
200
Supply
p
T
[atm]
[K]
Note 1
35
3.25
5.5
3.2
3.2
4.5
4.5
Return
p
T
[atm]
[K]
2.5
55
1.29
7.50
1.10
1.20
q
[kW]
15.2
1.3
Warm Shield
Cold Intercept
4-K Refrigeration
4-K Liquefaction
Sub-Atmospheric
w
[g/s]
96.7
27
157
Supply
p
T
[atm]
[K]
Note 1
35
3.2
5.5
3.2
4.5
Return
p
T
[atm]
[K]
2.5
55
1.29
7.50
1.20
Load
Warm Shield
Cold Intercept
4-K Refrigeration
4-K Liquefaction
Sub-Atmospheric
300.0
30.0
Table 3.4(B) – Mode 2, Nominal turn down
Load
Table 3.4(C) – Mode 3, Max. Liquefaction
q
[kW]
10.10
0.9
30.0
w
[g/s]
155
20
40
Supply
p
T
[atm] [K]
Note 1 44
3.2
5.8
3.2
4.5
Return
p
T
[atm] [K]
2.3
56.5
1.23
10.8
1.10
q
[kW]
10.1
0.9
300.0
Table 3.4(D) – Mode 4, Max. Refrigeration
Load
Warm Shield
Cold Intercept
4-K Refrigeration
4-K Liquefaction
Sub-Atmospheric
w
[g/s]
146
31
481
Supply
p
T
[atm] [K]
Note 1 35
3.2
5.3
3.2
4.5
Return
p
T
[atm] [K]
2.5
55
1.23
9.0
1.23
4.45
q
[kW]
15.2
1.3
9.0
The specification requires the cryoplant to support a wide operational variable domain
while maintaining plant efficiency.
LCLS-II 4.5K Cold Box Director’s Review, November 16, 2016
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Cryoplant Modes of Operation (2)
Table 3.4(E) – Mode 5, Max. Fill
Load
Warm Shield
Cold Intercept
4-K Refrigeration
4-K Liquefaction
Sub-Atmospheric
w
[g/s]
146
35
45
157
Supply
p
T
[atm]
[K]
Note 1
35
3.2
5.3
3.2
3.2
4.5
4.5
Return
p
T
[atm]
[K]
2.7
55
1.23
7.8
1.10
1.20
Table 3.4(F) – Mode 6, Standby
q
[kW]
15.2
1.3
300.0
30.0
Load
Warm Shield
Cold Intercept
4-K
Refrigeration
w
[g/s]
96.7
25
27
Supply
p
T
[atm]
[K]
Note 1
35
3.2
5.3
3.2
4.5
Return
p
T
q
[atm] [K] [kW]
2.7
55 10.1
1.23
7.5
0.9
1.23
4.5
0.5
Mode 7, 50% Turn Down
Load
w
[g/s]
Warm Shield
Cold Intercept
4-K Liq.
Sub-Atm.
7.5
100
Supply
p
T
[atm]
[K]
[Note
35.0
2]
[±5]
5.0
3.2
[±0.5]
3.2
4.5
3.2
4.5
Return
p
[atm]
2.5
1.29
1.1
1.2
T
[K]
55
[±5]
8.0
[±0.5]
300
30
q
[kW]
7.5
0.7
1.9
A seventh operating point was
checked and validated by the vendor
for operation at 50% of maximum
single plant operation mode as an
additional operating point within the
domain
*Tables from 4.5K Cold Box Procurement Specification 79220-S001
LCLS-II 4.5K Cold Box Director’s Review, November 16, 2016
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Process Model Validation- JLAB/SLAC Calculation
(Example: Mode 1- Max Capacity), All 7 Modes completed
LCLS-II 4.5K Cold Box Director’s Review, November 16, 2016
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Validation of Heat Exchanger UAs
Heat Exchanger Cooling Curve
 For the heat exchanger sizing, the mode yielding the maximum UA value is
considered (highlighted in yellow).
 Integrated UAs were calculated and compared with the vendor calculated
values.
 Good agreement in the UA and the NTU values
LCLS-II 4.5K Cold Box Director’s Review, November 16, 2016
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Safety Margin on UAs
“A uniformly applied UA safety
margin of 15% is required for all
heat exchangers for the operating
mode requiring the highest UA”.
The UA provided by the Vendor is
in compliance with the
requirement for the Heat
Exchangers
LCLS-II 4.5K Cold Box Director’s Review, November 16, 2016
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4.5K CB Pressure Drop in Heat Exchangers-Vendor Data
Pressure Drops in HXs for Mode 1: Max Capacity (Example for each Mode)
 “The ratio of the core
pressure drop to the
distributor pressure drop > 3.”
 “The ratio of the sum of the
core and distributor pressure
drops to the sum of the
header and nozzle pressure
drop > 3.”
 The pressure drop values
provided by the vendor
satisfy the above
requirements
LCLS-II 4.5K Cold Box Director’s Review, November 16, 2016
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