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Ben Hansen PIP-II Machine Advisory Committee Meeting 25-27 March 2019

This document provides an outline of the PIP-II Cryoplant, including the scope of work, capacity and building requirements, and progress to date. It also discusses the collaboration between Indian institutions and Fermilab and the cryogenic controls scheme.

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Ben Hansen PIP-II Machine Advisory Committee Meeting 25-27 March 2019

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  1. Ben Hansen PIP-II Machine Advisory Committee Meeting 25-27 March 2019 PIP-II Cryoplant

  2. Outline • Scope of Work • Cryoplant Capacity Requirements • Cryoplant Building Requirements • Progress to Date • Summary Hansen | Cryoplant P2MAC meeting

  3. Scope and Deliverables – In-Kind • DAE India • Helium Cryogenic Plant Purchased from Industry • Coldbox • Warm Compressor System • Jointly developed Cryoplant specification between DAE/India and Fermilab Cryogenic Systems SPMs during long-term visit • Joint Technical Evaluation of proposals. Commercial evaluation in progress by DAE/India ESS Compressor Room ESS Coldbox Hansen | Cryoplant P2MAC meeting

  4. Indian Institutions and Fermilab Collaboration (IIFC) • Communication is Key, weekly meetings with DAE/India Cryogenics SPC counterpart, maintain detailed action item list and meeting minutes • Face-to-face visits throughout the contract • 1-2 long-term visitors (engineers) from DAE/India will be collaborating with Fermilab locally on the PIP-II Cryoplant Hansen | Cryoplant P2MAC meeting

  5. Scope and Deliverables - Fermilab Services: • Cryoplant equipment rigging • Cryoplant Installation New Equipment: • Liquid Helium (LHe) Dewar • Helium Purifier • Helium Transferline from CP to Dewar • LN2Transferline from Dewar to Purifier • Controls and Instrumentation for Fermilab scope Existing/Repurposed Equipment: • Recovery/Purification Compressor • 7x Gas Helium (GHe) Storage Tanks • Liquid Nitrogen (LN2) Dewar Hansen | Cryoplant

  6. Cryoplant - Block Diagram • Interfaces are tabulated and tracked in: ED0007569 – PIP-II Interface Control Document – Cryogenic Plant Vendor* FNAL CryoP FNAL CF FNAL CDS * Cryoplant Vendor work managed by IIFC with Fermilab Involvement Hansen | Cryoplant

  7. Cryogenic Controls Scheme Hansen | Cryoplant P2MAC meeting

  8. Cryomodule Heat Loads • All sources were tabulated and based on experimental results or analysis • The primary heat load sources include: • Cavity dynamic heat loads • Current Leads • RF Couplers • Conduction heat leak • Radiation from thermal shield • All heat load information is documented in ED0008200 Q0 650MHz Hansen | Cryoplant P2MAC meeting

  9. Cryomodule Heat Loads • The Cryoplant design is dominated by the 2K heat load • The 2K heat load is dominated by cavity performance • Cavity heat loads are based on the expected CM installed Q0 factors and operating gradient *See ED0008200 for detailed individual cavity parameters Hansen | Cryoplant P2MAC meeting

  10. Capacity Safety Factors • Safety factors, representing the heat load uncertainty are explicitly defined to avoid mis-sizing • Under-sizing leads to expensive upgrades or lower operating energy • Over-sizing can lead to operational issues of capacity control, inefficiencies and unnecessary higher costs 𝐹𝑆 = 1.3, static heat load safety factor 𝐹𝐷 = 1.15, dynamic heat load safety factor 𝐹𝑂 = 1.1, operational safety factor Heat Load Summary: Hansen | Cryoplant P2MAC meeting

  11. Cryoplant – Process Requirements • A combined thermodynamic and hydraulic analysis of the CDS and CM system was used to refine the Cryoplant requirements • 2K heat load is a combination of isothermal and non-isothermal • The CDS heat load to 4.5 K supply and the JT Heat Exchanger effectiveness, impacts the cavity supply temperature and therefore the LHe quality (2K flow rate) Cryoplant Requirements: Hansen | Cryoplant

  12. Cryoplant Building Requirements - Risk Mitigation • We have a high degree of confidence that the PIP-II Cryoplant Building requirements can support a cryoplant with a capacity up to 3 kW at 2K [1] • Confidence is based on the vendor proposed equipment and what we know about the ESS specified cryoplant and building ESS Cryoplant Requirements: J. Weisend et. al. Hansen | Cryoplant P2MAC meeting

  13. Cryoplant Building Requirements • Vendors submitted detailed equipment requirements with proposals • Worst case vendor requirements used to define the Cryoplant Building Requirements (ED0006719-TRS-Cryoplant Building) • An independent review of the TRS was carried out and action items addressed (ED0008588) • The ESS Cryoplant vendor specified ~identical equipment, providing a level of confidence in our building requirements … Hansen | Cryoplant P2MAC meeting

  14. Cryoplant Building – Coldbox Size and Layout Vendor 1 • Equipment Weight: • 56000 kg (Coldbox) • Crane Capacity: • 22,679 kg • Crane Hook Clearance: • 26 ft Hansen | Cryoplant P2MAC meeting

  15. Cryoplant Building – Compressor Size and Layout Vendor 1 • Equipment Weights: • 12,000 kg (SP Compressor) • 12,000 kg (LP Compressor) • 12,000 kg (HP Compressor) • 12,000 kg (HP oil and gas unit) • 18,000 kg (SP&LP Oil and Gas Unit) • 2,500 kg (Coalescer Skid) • 3,700 kg (Oil Adsorber) • 1,700 kg (GMP) • 900 kg (Dryer) • Crane Capacity: • 22,679 kg • Crane Hook Clearance: • 26 ft Hansen | Cryoplant P2MAC meeting

  16. Cryoplant Building – Coldbox Layout Vendor 2 • Equipment Weight: • 75000 kg (Coldbox) • Crane Capacity: • 22,679 kg • Crane Hook Clearance: • 26 ft LastName | Your System Name P2MAC meeting

  17. Cryoplant Building – Compressor Size and Layout Vendor 2 Equipment Weights: • 35,000 kg (SP Compressor) • 35,000 kg (LP Compressor) • 35,000 kg (HP Compressor) • 15,000 kg (HP oil and gas unit) • 15,000 kg (LP Oil and Gas Unit) • 15,000 kg (SP Oil and Gas Unit) • 13500 kg (ORS, Dryer and GMP) Crane Capacity: • 22,679 kg Crane Hook Clearance: • 26 ft Hansen | Cryoplant P2MAC meeting

  18. Requirements - Layout • Building layouts were generated based on the two vendor proposals. • The largest of the two vendor equipment sizes drove the overall Cryoplant Building size • Provisions made for a spare compressor and a 4.5 K Coldbox Coldbox Station 4.5K Coldbox (space) Compressor Station Mech Room LHe Dewar CDS Distribution Box Control Room Purification System Hansen | Cryoplant P2MAC meeting

  19. Requirements - Layout 111’ 151’ Coldbox Oil Unit (spare) LP/SP Oil Unit HP Oil Unit 55’ Vendor 1 157’ 111’ Coldbox 55’ • Primary difference is Vendor 2 did not combine the SP and LP oil and gas skid Vendor 2 Hansen | Cryoplant

  20. Requirements – Layout • Actively working with building contractor to incorporate their model and verify space requirements • Modeled in primary pipe headers to verify space requirements, keep away zones and column support requirements Hansen | Cryoplant P2MAC meeting

  21. Summary • Cryoplant requirements defined and joint specification written • Proposals were received, technical evaluation complete and bid evaluations in progress by DAE/India • Cryoplant Building Requirements are defined, independently reviewed and action items addressed • Preliminary building layout defined • On track for CD-2/3a and look forward to your feedback Hansen | Cryoplant P2MAC meeting

  22. End Hansen | Cryoplant P2MAC meeting

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