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Overview
First part: Some theory Second part: More practical aspects (cryomodule design considerations)
Too much items.. and still incomplete.. But lets see how far we can proceed
My sources:
LINDEKRYOTECHNIK AG Switzerland, H.Herzog AERZEN Compressors Germany AIR LIQUIDE France WEKA Valves Switzerland VDI-Seminars Germany AD-Pressure-Vessel-Code ASME Code My colleagues from INFN, FNAL, Cornell-University, JLAB, KEK, BESSY, DESY and Steve van Sciver others
Cryogenic Fundamentals
Why is Cryogenic separated from usual cooling engineering ? Use of conventional superconductors like Nb requires cooling at liquid helium temperatures Due to basic thermodynamic laws, the efficiency of refrigerators is quite low at these temperatures (Carnot cycle) the cooling is very expensive ! -> excellent thermal insulation is required -> refrigerators should work very efficient to come closer to the Carnot cycle -> we have to deal with quantum properties of matter at these temperatures: decrease of specific heat, heat transfer, superconductivity, superfluidity -> helium is the only coolant ( low heat of vaporization, leak tightness, purification techniques.) -> careful engineering is needed: choice of materials, welding procedures, quality control, pressure vessel code requirements..
Definition: CRYOGENIC
Traditional (you can find in textbooks) : T < 120 K
Physicist view : temperatures were characteristic quantum states of matter dominate ( Cp -> 0, Helium II, conventional superconductivity..)
HERE: The engineering, which is required to specify, design, construct and operate cooling systems and cryostats for superconducting RF cavities at liquid Helium temperatures.
T2 W IN T1
3 W = W IN W OUT 4
2 1
Q LOW S1
Entropy
S2 S
Q LOW = T 1 ( S 2 S 1 )
Carnot =
Q LOW
=
T1 T2T1
Q HIGH - Q LOW
Sources of Irreversibility
(B.Ziegler, LINDE) Carnot Cycle
% Carnot
2K 5K 40 K
149 79 7
870 220 20
17 36 33
Coefficient of Performance
COP vs T 1200 1000 800 600 400 200 0 0 10 20 30 40
1200 1000 800 600 400 200 0 1.5
COPreal=1/( K * CARNOT)
CARNOT = T/(300 -T) K= 0.176 ( from latest LHC measurements at 1.8 K)
COP at Low T
COP
Temperature [K]
COP
JLab
TMR
2.1
Temperature [K]
HEX
load
H = const cooling
= 40 K for HELIUM
JT
load
JT
load
HEX HEX
HEX
JT
Cryogenic Turboexpander
Source: LINDEKRYOTECHNIK AG
Screw-Compressors
Source: AERZEN
HERA-Screw Compressors
LP + MP
HP
3.00E+10
2.50E+10
Qo
Qo
2.00E+10
1.50E+10
1.00E+10 0 5 10
Eacc[MV/m]
(Courtesy of R.Lange et al. DESY MKS)
15 20 Eacc [MV/m]
25
30
35
Qo versus Eacc measurement for a complete TTF-cryomodule type III (similar to XFEL-prototype)
HEX
subcooler JT
The 20-year old HERA cryogenic plant will be up-graded to the 2 K- XFEL-cryogenic plant
2K Box incl. Cold compressors added
A
Only the heat of evaporation of the helium is utilized.
D
The precompression is realized by several stages of cold compression.
The low pressure stream The cold low pressure is warmed up in a heat stream is precompressed exchanger inside the by a coldcompressor. refrigerator cold box.
layout by TU-Dresden advice from CERN discussion with industry component number and size, flow rates, power consumption flow scheme 8 screw compressors 9 turbines 3 cold compressors
40 - 80 K Shield
5-8K Shield
2 K Load
Example of a cold compressor with active magnetic bearings used at Tore Supra, CEBAF and Oak Ridge
1st stage
Temperature (T)
P2
2 2'
70 60 50 40 30 20 10 0
Entropy (s)
H 2' H1 is = H 2 H1
For T -> 0 condensation in the ground state E = binding energy -> condensation of matter , liquifaction of gases E = h phonons in solids -> specific heat, thermal conductivity E = superconducting energy gap -> superconductivity E = band gap of semiconductors -> electrical resistance Other effects are not disturbed by thermal energy at low T like: Helium II phenomena (Bose condensation), Kapitza-Effect,
Thermal conductivity
L/L
77K
Quantum Properties of Matter at low T Latent Heat and Entropy of liquid HELIUM
20 15 JT-Quality % 10
0.03 0.02
5 0
Vapor pressure
0.01 0.00
1.2 1.3 1.4 1.5 1.6 1.7 1.8 1.9 Temperature [K]
2.1 2.2
T2 q max * L** 1/3 = [ f(T) dT ]**1/3 T1 T1 = F ( P1 ) Temperature function of vapour pressure T2 = F ( P1 + P ) P = *L*g = density of liquid g=9.81 m/s2 L= depth in bath T1, P1 at liquid surface L T2, P2 at depth L in the bath T2 must not be exceeded to avoid bubbles !
14000 12000 10000 8000 6000 4000 2000 0 1 1.2 1.4 1.6 1.8 2 2.2 'Diffusivity' = Lambda/(RHO*Cp) [m/s] Cp of liquid
Design
0.04 0.02 0
Temperature [K]
Diffusivity [m/s]
For Niobium
Hk=0.043*T**3.18
W/K*cm2
0.2
HERA Accelerator Lumi-up-Grade SC Magnets + = no excess liquid -= large mass flows extra pump
liquid
T bath = f ( P bath )
Film-boiling 1 W / cm2
Over-Heating
Layout of XFEL-linac cryogenic: Helium II bath cooling About 1000 1.3 GHz sc cavities will be cooled in a 2K Helium II bath
support
GRT
8 K return cool down/ warmup 2 K 2-phase
cavity coupler
Strings 5 - 11
Vapor flow large Gas return tube Two phase tube
JT Vapour Liquid
0.35 0.30 0.25
Beam tube
Module 1
0.20 0.15 0.10 0.05 0.00 -2.00 0.00 -0.05 -0.10 -0.15 2.00 4.00 6.00 8.00 10.00 12.00 14.00
Module 2 Module 3 Module 4 Module 5 Module 6 Module 7 Module 8 Module 9 Module 10 Module 11 Module 12
BC
JT
BC
JT
JT
8 Modules
Length [m]
66 141 String 11
978
1561
5 String 4
1660 String 1
Beam direction
17,7
0,04
26,3
36,3
Two phase Helium II flow: for the XFEL-linac we want stratified-smooth flow
Design operation of XFEL: 2 K, 20 GeV, 23.6 MV/m 15 W/cryomodule K = [ (l * g * VGS2 * VLS ) / ( (l g) * g * * cos () )]1/2
Flow Pattern String 10
String 11
10.00
Flow PatternString 11
10.00
String 10
K
1.00 0.00 0.10
K-Parameter
3.9 GHz
0.20 0.30 0.40 0.50
smooth
0.60 0.70 0.80 0.90 1.00 He II level / Tube diameter
K-Parameter 1.00 0.00 0.20 0.40 0.60 He II level / Tube diameter 0.80 1.00
wavy
String 5
String 1
K-Param eter
Flow PatternString 1
K-Param eter
1.00 0.00 0.20 0.40 0.60 0.80 1.00 He II level / Tube diameter
1.00 0.00 0.20 0.40 0.60 He II level / Tube diameter 0.80 1.00
heat conductivity
Knudsen
vacuum pumping may be enhanced by small holes in foil space between foils required to limit heat conduction: use of wrinkled foils or spacer layers spacer materials: glas-paper, glas fiber net, paper,
80K shield
0.6
0.5
20
30
40
Note: All helium process areas inside the cryostat should be covered with about 5-10 layers of MLI to limit the impact of insulation vacuum loss !
Heat input caused by the break down of Insulation vacuum: 40kW / m2 without MLI 6kW/ m2 with MLI
Thermal intercept
Desy philosophy: NO metal/metal sealings !!! Use of plastic seals like Vespel SP1 (polyimid)
Definition of Kv-value: volume flow of water [m3/h] at P = 1bar and T 278 K -313 K (Cv= 1,17 Kv USA)
Availability
99.6 %
1 9 9 2 1 9 9 3 1 9 9 4 1 9 9 5 1 9 9 6 1 9 9 7 1 9 9 8 1 9 9 9 2 0 0 0 2 0 0 1 2 0 0 2 year 2 0 0 3
(utilities excluded)
N u m b e r
1 99 5
1 99 6
1 99 7
1 99 8
1 99 9
2 00 0
2 00 1
2 00 2
year
HERA Cryo Plant: Interruptions over 10 years of operation 1994 - 2003 25 20 N u m b e r 15 10 5 0
C ompressors C omputer C ontrol Main Power Water A ir
average: 6,2 interruptions /year 0,16 interruptions /week 1,04 h / week
2 00 3
kind of interruption
D o w n tim e(h )
Availability increase by redundant refrigerators? Rating Source of unavailability 1 2 External utility failures Blockage by frozen out gaseous impurities Operational problems Single component failure not leading to total plant shutdown Catastrophic component failure leading to plant shutdown
Example
Electrical power, cooling water, instrument air failure Air and/or water vapor Controls, instrumentation, operators Electrical motor burnout, compressor bearings, leaking oil pump seal, turbine bearing trouble Loss of insulation vacuum, rupture of heat exchanger, oil spill into cold process piping
Multiple refrigerators ... ? would bring no advantage provide somewhat larger tolerance would be detrimental, because of higher complexity of the system would bring no advantage over component redundancy within a single refrigerator would have a positive effect
3 4
Redundant compressors and low temperature adsorbers Easy exchange of turbines and cold compressors
coalescence filter I
oil fog
coalescence filter II
oil fog
dryer
H2O vapor
HD Coalescence Filter
Helium Dryer
Low temperature embrittlement Causes overloaded components to fracture spontaneously rather than accommodating the stress by plastic deformation Appropriate steels for low temperature use are listed in the Technical Rules for Pressure Vessels AD-Merkblatt W10 /European harmonized technical rules /ASME-code (USA) . (In general, materials with face-centered cubic (fcc) crystal structure as copper, nickel, certain copper nickel alloys, zircon and titanium are suitable for cryogenic applications.) .
European Harmonized Rules Stainless steels for the use at low temperatures
DIN EN 13445-2 B.2.2.4 Lowest material temperature for austenitic stainless steels Apply also for 2K ! (material spec corresponding to ASTM type AISI may differ ! )
Material spec
X1NiCrMoCu 31-27-4 X1CrNiMoN 25-22-2 X1CrNi 25-21 X2CrNiMoN 17-13-3 X2CrNiMoN 17-11-2 X2CrNiMoN 18-12-4 X2CrNiMo 18-15-4 X2CrNiN 18-10 X2CrNiMo 18-14-3 X2CrNi 19-11
DIN EN number
1.4563 1.4466 1.4335 1.4429 1.4406 1.4434 1.4438 1.4311 1.4435 1.4306
TM (in C)
-270
310 L 316 LN
Cryogenic safety aspects Pressure Build-up by Evaporation Large air leak into the wave guide of an insert -> Evaporation of about 2.6 kg/s mass flow through safety valve
Heat input caused by the break down of Insulation vacuum: 40kW / m2 without MLI 6kW/ m2 with MLI
Cryogenic safety aspects Preventive Measures against PressureBuild-up Release Flap + Safety Valve
Q m = v * sqrt ( dh / d v) P
T=T flow Q heat input m mass flow V specific volume H specific enthalpy
sqrt ( v )
= f(T) v * sqrt ( dh / d v) P
Calculate heat input Q Find T flow (by ASME code) Calculate mass flow at T flow (by ASME code) Calculate sv dimensions ( by AD code)
Example: