# Presentation: 533344

## Proton Driver Cryogenics

**Jay Theilacker**
**March 15 , 2005**

- Theilacker  - Proton Driver Director's Review

- March 15-17, 2005

## Outline

**Cryogenic Design Scope**
**Heat Load and Capacity Requirements**
**Design Concept**
**Technical Feasibility**
**Cost Estimate**
**Conclusions**

- Theilacker  - Proton Driver Director's Review

- March 15-17, 2005

## Cryogenic Design Scope

**Cryogenic Plant**
**Cryogenic Distribution System**
**Ancillary Systems**

- Theilacker  - Proton Driver Director's Review

- March 15-17, 2005

## Cryogenic Plant

**Warm Compressors**
**4K Cold Box**
**2K Cold Box**
**Cold Compressors**
**Controls**
**Installation Contracts**

- Theilacker  - Proton Driver Director's Review

- March 15-17, 2005

## Spoke Option

- Theilacker  - Proton Driver Director's Review

- March 15-17, 2005

## Cryogenic Distribution System

**Low pressure cryogenic transfer line**
**High pressure cryogenic transfer line**
**Bayonet cans**
**Expansion boxes**
**Upstream string feed box and end caps**
**Downstream string feed box and end caps**
**Gas helium header**

- Theilacker  - Proton Driver Director's Review

- March 15-17, 2005

## Ancillary Systems

**Cooling towers**
**Helium gas storage**
**Helium and nitrogen liquid storage**
**Helium purifier**
**Recovery compressors**
**Miscellaneous ( arc cells, hydrometers, instrument air, etc)**

- Theilacker  - Proton Driver Director's Review

- March 15-17, 2005

## Cryogenic Components

**Spoke Option **
**25 warm RF section solenoids**
**30 spoke CM solenoids**
**86 spoke resonators**
**336 elliptical cavities**
**Cryogenic distribution system**
**Temperature levels – 2K, 4K, 5-8K and 40-80K**

- Theilacker  - Proton Driver Director's Review

- March 15-17, 2005

## Heat Load

**Estimated total heat load:****	****	**
- 0.2 kW (static) + 0.5 kW (dynamic) =   0.7 kW @  2K
- 1.1 kW (static) + 0.1 kW (dynamic) =   1.1 kW @  4K
- 0.6 kW (static) + 0.3 kW (dynamic) =   0.9 kW @  5-8K
- 4.3 kW (static) + 6.1 kW (dynamic) = 10.4 kW @  40-80K
**Static to the total heat load at 2K is 26%**
**Heat load uncertainty factor is 30%**
**Over capacity is  50%**

- Theilacker  - Proton Driver Director's Review

- March 15-17, 2005

## Plant Performance Requirements

**Plant installed capacity:**
-   1.5 kW @ 2K
-   2.5 kW @ 4K
-   2.1 kW @ 5-8K
- 25.1 kW @ 40-80K
**Plant installed power  - 2.1 MW**
**COP’s **
- 588 W/W @ 2K
- 240 W/W @ 4.5K
- 168 W/W @ 5-8K
-  17 W/W  @ 40-80K
**Good partial load efficiency **

- Theilacker  - Proton Driver Director's Review

- March 15-17, 2005

## Design Concept

**Cryogenic Plant**
- Hybrid plant
**Cryogenic Distribution System**
- Cryogenic Unit
- Up to 9 cryo modules
- Two strings
- Upstream String at 4K – One cryo unit
- Downstream String at 2K – Five cryo units
**Ancillary Systems**
- Industrially available components

- Theilacker  - Proton Driver Director's Review

- March 15-17, 2005

## Technical Feasibility

**Cryogenic Plant**
- All major components of the Proton Driver helium refrigerators have been used successfully in similar systems before – LHC, SNS, CEBAF, etc.
**Cryogenic Distribution System**
- Design of cryogenic distribution system components has low technical risk
**Ancillary System**
- All elements are commercially available

- Theilacker  - Proton Driver Director's Review

- March 15-17, 2005

## Design Issues

**Refine Heat Load Requirements**
**Efficient Partial Load Operation**
**Long Strings Of Cryogenic Modules**
**Schedule and Resources**

- Theilacker  - Proton Driver Director's Review

- March 15-17, 2005

## Cost Estimate

**Cost model based on the LHC methodology**
**Model was verified against SNS actual cost**
**Ancillary systems - based on the actual costs**

- Theilacker  - Proton Driver Director's Review

- March 15-17, 2005

## Conclusions

**PD cryogenic system is technically feasible**
**PD cryogenic system is financially predicable. Cost estimate is consistent with SNS actual cost, LHC project methodology, TESLA TDR, and US LCSG cost estimate approach**
**Technical and cost risks are deemed to be either low or medium/low **
**Design of new cryogenic distribution components has low technical risk**
**Proton Driver R&D at SMTF will assist to improve heat load requirements and optimize cost**

- Theilacker  - Proton Driver Director's Review

- March 15-17, 2005

## Reference Material Follows

## Cryogenic Unit

- Theilacker  - Proton Driver Director's Review

- March 15-17, 2005

## Heat Load – Spoke Option

- Theilacker  - Proton Driver Director's Review

- March 15-17, 2005

## Refrigerator Capacity

- Theilacker  - Proton Driver Director's Review

- March 15-17, 2005

## Refrigeration Technology

- Theilacker  - Proton Driver Director's Review

- March 15-17, 2005

## Cryogenic Cost Estimate

| Identifier | Item description |   |   | Material | Labor |  |  |
| --- | --- | --- | --- | --- | --- | --- | --- |
|   |   |   |   | Total | Engineer | Technician | Designer |
|   |   | basis | Unit | M&S $k | [month] | [month] | [month] |
|   | Location Summary |   |   |  $       22,917  | 164 | 226 | 217 |
| 1 | 4.5 Refrigeration system | 1 | each |  $         9,314  | 12 | 24 | 12 |
| 2 | Cold Box, 2K | 1 | each |  $         2,334  | 12 | 12 | 9 |
| 3 | Cold Compressor | 1 | each |  $         1,872  | 6 | 9 | 6 |
| 4 | Ancillary Equipment | 2 | each |  $         2,287  | 10 | 15 | 30 |
| 5 | Refrigerator Controls | 1 | each |  $         1,417  | 48 | 48 | - |
| 6 | Warm Header, 6"IPS | 3 | ft |  $            198  | 12 | 12 | 12 |
| 7 | Feed box, feed caps and vac. support | 4 | each |  $         2,000  | 12 | 12 | 40 |
| 8 | Low Pressure Transfer Line  ( plant/FB) | 2,5 | ft |  $            105  | 12 | 12 | 40 |
| 9 | High Pressure Transfer Line | 2.5 | ft |  $             99  | 4 | 10 | 4 |
| 10 | Bayonet, anchor and expansion cans | 5 | each |  $            500  | 12 | 12 | 40 |
| 11 | System installation contracts | 1 | each |  $         1,352  | - | - | - |
| 12 | Misc. ( ODH sys, instrument air, etc) | 1,4,5 | each |  $            439  | 12 | 24 | 12 |
| 13 | LN2 cooldown system | 6 | each |  $         1,000  | 12 | 36 | 12 |

- Theilacker  - Proton Driver Director's Review

- March 15-17, 2005

## Cryogenic Cost Estimate Notes

**Notes**
- Ancillary equipment
- No G&A is included
- No contingency is included
- € to $ Exchange rate is 1.3
- Cost of the Linac Instrumentation and Controls is not included
**Costs Basis**
- CERN - LHC
- SNS
- Vendor quote
- DESY – TTF
- AD/Cryogenic Department
- Engineering judgment

- Theilacker  - Proton Driver Director's Review

- March 15-17, 2005