cryoops2014petersenday211112014

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Full cryogenic
operation of AMTF
– the first year
6th International
Workshop on Cryogenic
Operations
Bernd Petersen DESY MKS
presenting the work of many
colleagues:
IFJ-PAN (Poland)
WUT(Poland),BINP(Russia),
Linde/Cofely and several DESY
groups
6th International Workshop on Cryogenics Operations
Bernd Petersen DESY
XFEL WP10 Accelerator Module Test Facility
Outline

AMTF - purpose & objectives (TDR)
 AMTF – layout
 AMTF- main cryogenic components
 Refrigerator availability
 Main cryo operation problems
 General safety requirements
 Cryogenic safety
 Safety of work organisation
 Some preliminary test results for XFEL cavities & modules
 (Preliminary) conclusions
6th International Workshop on Cryogenics Operations
Bernd Petersen DESY
2
XFEL WP10 Accelerator Module Test Facility
AMTF: purpose & objectives (TDR)
3
- Complete cold performance test of all XFEL cryomodules before
tunnel installation (RF, vacuum,cryo-losses)
103 cryomodules, rate: 1/week
- Cold RF test of all XFEL superconducting cavities before
cryomodule assembly
824 cavities, rate 6/week
- Cold test of all superconducting magnet packages before
cryomodule assembly
103 magnets, 1/week
- ( Assembly and tests of RF Waveguides (WP1)
at Waveguide Assembly and Test Facility WATF)
6th International Workshop on Cryogenics Operations
Bernd Petersen DESY
XFEL WP10 Accelerator Module Test Facility
AMTF layout (TDR)
84m x 48m
 Three test benches (XATB1, XATB2 and XATB3) for testing assembled modules and
for high power tests of assembled cavities
 Two test cryostats (XATC1 and XATC2) for RF performance tests of the cavities
 (One magnet test stand XMTS (located in the Magnet Test Hall Building 55) for testing
magnets)
6th International Workshop on Cryogenics Operations
Bernd Petersen DESY
4
XFEL WP10 Accelerator Module Test Facility
AMTF Hall - Cavity
Vertical Cryostat
Cavity storage area
 Radiation protection shielding
Cavity incoming check area
6th International Workshop on Cryogenics Operations
Bernd Petersen DESY
5
Cavity preparation area
 Clean room
XFEL WP10 Accelerator Module Test Facility
AMTF Hall - Cryomodule
Unloading of the cryomodule
after transport
6
Cryomodule preparation area
Cryomodule test stand – module
inside
6th International Workshop on Cryogenics Operations
Bernd Petersen DESY
Cryomodule test stand
Cryomodule test stand – front
view
XFEL WP10 Accelerator Module Test Facility
XMTS: Test stand for sc XFEL Quadrupoles
Formal part of AMTF but installed
and in operation since July 2008
Status November 2014:
96 (of 103) Quadrupols tested
For the development and series tests
of superconducting magnet packages
& current leads (in MTH-bldg 55)
6th International Workshop on Cryogenics Operations
Bernd Petersen DESY
7
XFEL WP10 Accelerator Module Test Facility
Cryogenic operation of AMTF
8
AMTF is supplied by the FLASH-Helium-Refrigerator (former refrigerator 42 of the HERA plant)
For the operation of the AMTF 3 KW at 40/80K, 0.5 KW at 4.5K and a peak liquifaction rate of 33 g/s
have to be delivered. The peak liquifaction is buffered by means of a 1oooo ltr liquid helium
storage dewar (XAST.)
Capacity limit:
return gas peak
screw compressor
capacity during cool
down/warm-up
2 dynamic procedures in
parallel
6th International Workshop on Cryogenics Operations
Bernd Petersen DESY
XFEL WP10 Accelerator Module Test Facility
AMTF – cryogenics contributions
Red = WUT
Blue = DESY MKS
Wroclaw University of
Technology
-> Kriosystem
Acting for XFEL company
(no in-kind !) -> DEMACO
6th International Workshop on Cryogenics Operations
Bernd Petersen DESY
9
Green= BINP
Budker Institute
Novosibirsk
XFEL WP10 Accelerator Module Test Facility
AMTF components (utilities etc./DESY in-kind)
Test hall
Compressor station
Control building
Piping bridge
HERA Kälteanlage Halle
Pump station
Water towers
0
10m
 Pump station – completed in September 2010
 Compressor station – completed in August 2010
 Control building – completed in October 2010
 Test Hall – erected in May 2010
 Piping bridge – completed in October 2010
6th International Workshop on Cryogenics Operations
Bernd Petersen DESY
10
XFEL WP10 Accelerator Module Test Facility
Transfer line XATL1
The ~170m long DN400 transfer line XATL1 supplies
the test stands with cryogenic power from HERA
refrigerator. WUT/Poland in-kind.
Spec DESY:
 Short specification in August 2008
 Full specification in August 2009
 Commissioning August 2012
– in continuous operation since December 2012
6th International Workshop on Cryogenics Operations
Bernd Petersen DESY
11
DESY (in-kind):
Valve box for XATL1 at
refrigerator
XFEL WP10 Accelerator Module Test Facility
Helium compressors (DESY in-kind)
2 sets of compressors for 2K operation at AMTF ( 2 x 20 g/s helium at 20 mbar)
1 set = 13 x parallel (WS 2001 RUVAC roots blower + SOGEVAC SV750B )
– simple, (robust), modular, redundant
RUVAC
SOGEVAC
Manifacturer: Oerlikon Leybold
SOGEVAC:
4 unscheduled repairs,
complete replacement of bearings &
packing rings (all SOGEVAC)
RUVAC: 4 repairs,
complete exchange of bearings
ongoing (all RUVAC)
No impact for AMTF
operation
Very reliable service &
support from manufacturer
In average: about 5000 h operation (status November 2014)
6th International Workshop on Cryogenics Operations
Bernd Petersen DESY
12
XFEL WP10 Accelerator Module Test Facility
AMTF Vertical Cryostats
13
SPEC DESY
April 2009
Cavity Frame
Design:
Design & Construction
DESY FLA
WUT&Kriosystem
6 inserts for
AMTF
Poland in-kind
Delivery & installation:
July 2012 – April 2013
Ø
~Ø
~Ø
Vacuum flange
Stainless steel ring 30mm thick
~
A-A
Vacuum lid
Concrete floor
min.
3xM20
Concrete cylinder
140mm thick
The lowest
radiation shield
Vacuum vessel
Cold magnetic
shield (MHF-sl)
Cold magnetic
shield (MKS1)
Thermal shield
Warm magnetic
shields
LHe vessel
Space for heaters
PVC pipe DN200
Ø
max.Ø
Ø
Support
~
Soil
Concrete
6th International Workshop on Cryogenics Operations
Bernd Petersen DESY
Water drain pipe DN100
(PVC or stainless steel)
XFEL WP10 Accelerator Module Test Facility
AMTF: 3 cryomodule test stands & cryostat adapters
Spec DESY (February 2010)
Design, Construction, Installation: BINP in-kind
First test stand delivered & installed May 2013 (cold commissioning July 2013)
Cold commissioning of 3rd test stand December 2013
2 cryostat adapters for the test of single dressed cavities at AMTF
6th International Workshop on Cryogenics Operations
Bernd Petersen DESY
14
XFEL WP10 Accelerator Module Test Facility
XAST,XAVB, XAVB
15
DESY is acting for the XFEL company
Manufacturer: DEMACO NL
Wessington
Cryogenics
Ltd UK
L Helium Dewar XAST
Sub Cooler Box XASB
6th International Workshop on Cryogenics Operations
Bernd Petersen DESY
Valve Box XAVB
XFEL WP10 Accelerator Module Test Facility
Cool down and Warm up
16
XATC1, XATC2
XATB1, XATB2, XATB3


•
•

Pump and purge manual
Cool-down to 4K, liquid helium transfer
and warm-up process automatized by
use
of SNL scripts
Pump-down to 2K manual
Pump and purge manual
Complete cool-down and warm-up
process performed manually by cryooperators
Pump and purge
Pump and purge
Cooldown to
100K
Liquid
helium
transfer to
the cryostat
Pumpdown to 2K
Cooldown to
70K
Measurement at
2K
Warmup to
300K
Liquid
helium
transfer
from the
cryostat
Pressure
rise to 1 Bar
Cryogenics operation sequence for vertical
cryostat
6th International Workshop on Cryogenics Operations
Bernd Petersen DESY
Cool-down
to 4K, helium
liquefaction
Pumpdown to 2K
Measurement at 2K
Warmup to
300K
Liquid
helium
evaporation
Pressure
rise to 1
Bar
Cryogenics operation sequence for cryomodule test
stand
XFEL WP10 Accelerator Module Test Facility
Vertical Cryostats Operation Cycles
17
Example: July 2014 -> September 2014
About 180 cycles since start of AMTF operation in 2013
Courtesy of
J.Zajac Linde/Cofely
6th International Workshop on Cryogenics Operations
Bernd Petersen DESY
XFEL WP10 Accelerator Module Test Facility
XFEL Cryomodule tests operation Cycles
18
About 20 cycles since September 2013 (now 13th XFEL cryomodule under test)
Courtesy of
J.Zajac Linde/Cofely
6th International Workshop on Cryogenics Operations
Bernd Petersen DESY
XFEL WP10 Accelerator Module Test Facility
Refrigerator Avialability 2013
19
Availability 2013 = 98,80%
CRYOGENIC PLANT OPERATION 2013
100
40
Voltage drop - cryoplant
shutdown
CBX
Maintenance
50
Cooling water failure - cryoplant
shutdown
60
Maintenance
70
Maintenance
80
Maintenance
[ Availability per week in % ]
90
30
20
10
Courtesy of
J.Zajac Linde/Cofely
0
1 2 3 4 5 6 7 8 9 10111213141516171819202122232425262728293031323334353637383940414243444546474849505152
[ Week ]
6th International Workshop on Cryogenics Operations
Bernd Petersen DESY
XFEL WP10 Accelerator Module Test Facility
Refrigerator Avialability 2014
20
Availability 2014 = 98,4%
CRYOGENIC PLANT OPERATION 2014
100
50
40
CBX
Maintenance
60
IOC
Maintenance
70
IOC
Maintenance
80
12K2 Frequency converter failure - cryoplant
52CVC310 Valve positioner
shutdown
malfunction
IOC Maintenance
[ Availability per week in % ]
90
30
20
02.11.2014
10
0
1 2 3 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 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52
[ Week ]
6th International Workshop on Cryogenics Operations
Bernd Petersen DESY
Courtesy of
J.Zajac Linde/Cofely
XFEL WP10 Accelerator Module Test Facility
Main Cryo Operation Problems in AMTF
 Mixing of serial tests with installation work and commissioning
 Problems with warm 2K helium compressors (see transparency)
 Mixing of warm&cold gas for controlled cool-down/warm up
LHe level measurements affected by electrical heaters
 2K supply JT-valve in module test stand 3 (XATB3) out of shape
 Misalignment of process tube flanges (feed-caps) -> adapters
‚Digital‘ operation of valve positioners -> change type of positioners
 Thermal contact of electrical heaters -> use of ‚CMTB-type‘ heaters
 Liquid level measurements -> increase current
 Mix-up of thermometers (calibration) -> try to sort, some recalibration
-> Several problems with well known and ‚mature‘ components !
6th International Workshop on Cryogenics Operations
Bernd Petersen DESY
21
XFEL WP10 Accelerator Module Test Facility
Cryogenic safety
22
no general risk of oxygen deficiency within the AMTF hall (about 50 000 m3 volume)
 oxygen deficiency monitors in each module test stand radiation protection cave
 design of helium safety valves and venting systems according to our cryomodule
‚crash-tests‘ on CMTB
 or – on default- according to ‚Lehmann-Zahn‘ values
 5K and 40/80K helium release systems separated from 2K release systems (20 bar
vs. 4 bar)
 all safety valves vent into helium volumes – venting to atmosphere outside the hall
Oxygen monitor
6th International Workshop on Cryogenics Operations
Bernd Petersen DESY
XFEL WP10 Accelerator Module Test Facility
AMTF: general design & safety requirements





EU/German law ‚Betriebssicherheitsverordnung‘
DESY safety rules
Rules&procedures for buildings & utilities
General safety & radiation safety rules
Pressure vessels: PED (AD2000,EU harmonized code)
This means in advance of technical commissioning:
 Third party interlock approvals
 PVI(=appoval before operation) by third party
(the complete procedure took several months for AMTF)
 … (list is not complete)
6th International Workshop on Cryogenics Operations
Bernd Petersen DESY
23
XFEL WP10 Accelerator Module Test Facility
AMTF safety at work - organisation
 Safety
officers for different working areas
 Electronic access control for AMTF (‚DACHS‘)
 Safety instructions checked by electronic access control (general safety, cryogenic safety, radiation safety)
‚DACHS‘
electronic access control
6th International Workshop on Cryogenics Operations
Bernd Petersen DESY
24
XFEL WP10 Accelerator Module Test Facility
Vertical acceptance tests

25
Analysis of vertical acceptance tests includes
 Series Cavities + “ILC HiGrade”-Cavities
 NO infrastructure commissioning tests


So far delivered:
Total RF tested:
488 cavities (status November 2014)
450 cavities
Manufacturer 1
Manufacturer 2
Average:
> 9 tests per week
since Oct 2013
(full operation of AMTF)
Status of plot: July 2014
Courtesy of
J.Swierblewski IFJ-PAN details see LINAC 2014
6th International Workshop on Cryogenics Operations
Bernd Petersen DESY
XFEL WP10 Accelerator Module Test Facility
Yield of gradients: “As received”

26
Yield of usable and maximum gradient of 339 cavities “as received”
M1
M1
M2
M2
Average maximum gradient:
(30.4 ± 7.6) MV/m
Average usable gradient:
(26.6 ± 7.6) MV/m
M1: (28.4 ± 7.1) MV/m
M2: (32.4 ± 7.6) MV/m
M1: (24.8 ± 7.0) MV/m
M2: (28.6 ± 7.9) MV/m
given errors are
standard deviation
Courtesy of
J.Swierblewski IFJ-PAN details see LINAC 2014
6th International Workshop on Cryogenics Operations
Bernd Petersen DESY
XFEL WP10 Accelerator Module Test Facility
Summary of preliminary module results
27
Status November 2014: XM13 is under test, 18 modules at DESY
average
max. gradient
module
[MV/m]
average
max. gradient
vertical
[MV/m]
Average
operational
gradient
module
[MV/m]
Average
usable gradient
vertical
[MV/m]
XM-2
27.2
28.1
24.5
26.5
XM-1
28.2
30.8
25.1
29.4
XM1
30.3
32.5
27.6
29
XM2
27.7
32.7
25.5
28.6
XM3
30.4
32.0
28.8
29.3
XM4
28.6
33.3
23.8
30.5
XM5
27.8
28.9
24.9
26.9
All results above XFEL specs. 23.6 MV/m
6th International Workshop on Cryogenics Operations
Bernd Petersen DESY
Courtesy of
J.Swierblewski IFJ-PAN details see LINAC 2014
XFEL WP10 Accelerator Module Test Facility
Some (preliminary) conclusions








Deliveries & installation of XATCs,XATB,XAVB,XATL
were ‚just-in-time‘ for start-up of cavity production
Deliveries & installation of XATBs
were ‚just-in-time‘ for start-up of cryomodule production
No dedicated de-bugging of cryo-supply (and other systems)
XATCs design capacities demonstrated
Complexity of XATBs commissioning underestimated
General effort for installation & commissioning underestimated
To be demonstrated: 1 cryomodule test/week
So far: in budget and almost ‚in time‘ (not ‚on schedule‘)
Thank you for your attention !
6th International Workshop on Cryogenics Operations
Bernd Petersen DESY
28
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