iter cryogenic system
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ITER Cryogenic System
Manel Sanmartí, CIEMAT-F4EPlants DIvision, ITER Department
ITER CODAC Colloquium 27th-28th October, 2008
Barcelona, SPAIN
M. Sanmarti, Ciemat-F4E, ITER CODAC Colloquium, Barcelona, October 2008 2
Outline
• ITER cryogenic requirements
• ITER CRYO project frame
• ITER cryogenic system
• Cryo controls and instrumentation
• Conclusions
M. Sanmarti, Ciemat-F4E, ITER CODAC Colloquium, Barcelona, October 2008 3
Main duties
• Basic:• Cool-down of the cryostat and torus cryopumps
• Gradual cool-down and filling of the magnet system and the 80 K thermal shield in about one month
• Cool-down of the NB cryopumps, pellet units and gyrotrons
• Maintain magnets and cryopumps at nominal temperatures over a wide range of operating modes with pulsed heat loads due to nuclear heating and magnetic field variations
• Accommodate periodic regeneration of cryopumps
• Accommodate resistive transitions and fast discharges of the magnets and recover from them in few days
• Additional• Ensure high flexibility and reliability
• Low maintenance
M. Sanmarti, Ciemat-F4E, ITER CODAC Colloquium, Barcelona, October 2008 4
Cryogenic capacity & loads
• LHe cryoplant: 65 kW equivalent @ 4.5 K
• Cooling of the superconducting magnet system: • 39 kW @ 4.2 K
• Cooling of HTS current leads:• 150 g/s GHe at 50 K
• Cooling of cryo-pumps with high regeneration frequency:• 6.5 kW @ 4.5 K and 70 g/s of LHe liquefaction
• Small users:• 1 kW @ 4.5 K (Gyrotron)
• LN2 cryoplant: 1300 kW @ 80 K
• Thermal shielding:• up to 800 kW @ 80 K during chamber baking
• LHe cryoplant pre-cooling:• up to 280 kW @ 80 K during normal operation
• HTS 50 K extra cooling power:• up to 180 kW @ 80 K during normal operation
• Helium inventory: 24 t
M. Sanmarti, Ciemat-F4E, ITER CODAC Colloquium, Barcelona, October 2008 5
Magnets Pulsed Head Load
Loads on Magnet plant during POS and dwell periods
25 000
27 000
29 000
31 000
33 000
35 000
37 000
39 000
41 000
43 000
45 000
0 1800 3600 5400 7200
time (s)
Po
we
r (W
)
Dynamics: 30W/s Amplitude: 12kW
Repetition rate: 1800 sec
M. Sanmarti, Ciemat-F4E, ITER CODAC Colloquium, Barcelona, October 2008 6
Operation scenarios
• Uninterrupted operation in order to maximize machine availability• The tokamak will be operated during two 8-hour shifts• The third shift will be used to recover nominal cryogenic conditions,
for short interventions and to regenerate the cryopumps up to 470 K
• The large dynamic loads prevent full redundancy but allow continuous and uninterrupted operation without plasma
• Short maintenance periods of few days every two weeks
• Major shutdowns every 16 months
• RAMI analysis to improve the design and requirements for spares
M. Sanmarti, Ciemat-F4E, ITER CODAC Colloquium, Barcelona, October 2008 7
Technical variants
• Analysis of technical variants compatible with the requirements and basic design principles are presently under study
• Simplification of the layout and improvement of performances, reliability and availability or reduction of investment and operation costs
• Review and update of heat loads
• Large dynamic loads handling Pulse mitigation by temporary by-pass of the structure load Use of liquid helium storage buffering and complex process control
• Helium management and cold quench tank temperature level
• Optimal size, number of cold boxes and parallel operation (flow sharing)
• Thermodynamic cycle optimization for the refrigerators
• Developments of technology and engineering solutions for key components
• Example: SHe circulating pumps and heat exchangers
M. Sanmarti, Ciemat-F4E, ITER CODAC Colloquium, Barcelona, October 2008 8
Outline
• ITER cryogenic requirements
• ITER CRYO project frame
• ITER cryogenic system
• Few thoughts on control and instrumentation
• Conclusions
M. Sanmarti, Ciemat-F4E, ITER CODAC Colloquium, Barcelona, October 2008 9
The ITER CRYO project frame
•Cryoplants system: helium refrigerators, LN2 and 80K loop system, ancillary equipment (warm/cold/liquid tanks, recovery & purification systems)
•Cryodistribution system: main distribution boxes with cold circulating pumps and cold compressors, cryolines from cryoplant building and inside tokamak complex
•Cryoplant procurement packages are based on functional specs and include manufacturing, delivery, installation & on-site individual sub-package acceptance test
ITER CRYO Team System
Integration
IN PTCryodistribution & Cryolines (100%)
EU PT – F4ECryoplants (50%)
ITER Cryo Team Cryoplants (50%)
M. Sanmarti, Ciemat-F4E, ITER CODAC Colloquium, Barcelona, October 2008 10
Cryogenics Schedule
1 2 3 4 1 2 3 4 1 2 3 4 1 2 3 4 1 2 3 4 1 2 3 4 1 2 3 4 1 2 3 4 1 2 3 4FIRST PLASMADesign review
Prototyping, tests
CRYODISTRIBUTION
Manufacturing
Installation
CRYOLINES
Manufacturing
Installation
CRYOPLANTS
Manufacturing
Installation
COMMISSIONING
OPERATION
20182014 2015 2016 20172010 2011 2012 2013
M. Sanmarti, Ciemat-F4E, ITER CODAC Colloquium, Barcelona, October 2008 11
Outline
• ITER cryogenic requirements
• ITER CRYO project frame
• ITER cryogenic system
• Few thoughts on control and instrumentation
• Conclusions
M. Sanmarti, Ciemat-F4E, ITER CODAC Colloquium, Barcelona, October 2008 12
ITER Cryoplant System
Cryodistribution
M. Sanmarti, Ciemat-F4E, ITER CODAC Colloquium, Barcelona, October 2008 13
Cryoplant architecture
He Compressor stationHe
Compressors
N2 CompressorStation
1 1 1
9 10
6
8
5
7
2 2
3 3
4
1 – Cold process boxes of LHe Plant
LHe Plant 80 K He loopOutdoor storage
LN2 PlantQuench line
2 – Cold process boxes of LN2 Plant
3 – Cold boxes of 80 K He loop
4 – Auxiliary LN2 box of 80 K He loop
5 – helium gas purifier and recovery compressors
6 – LN2 Tank
7 – Warm 1.8 MPa He tanks
8 – 80 K He Quench tanks
9 – Cryoplant termination box
10 – LHe tank
50 KLHe
4.6 – 4.8 K
80 – 100 K
80 – 100 K
4.6 – 4.8 KLHe
M. Sanmarti, Ciemat-F4E, ITER CODAC Colloquium, Barcelona, October 2008 14
Cryoplant architecture
He Compressor stationHe
Compressors
N2 CompressorStation
1 1 1
9 10
6
8
5
7
2 2
3 3
4
1 – Cold process boxes of LHe Plant
LHe Plant 80 K He loopOutdoor storage
LN2 PlantQuench line
2 – Cold process boxes of LN2 Plant
3 – Cold boxes of 80 K He loop
4 – Auxiliary LN2 box of 80 K He loop
5 – helium gas purifier and recovery compressors
6 – LN2 Tank
7 – Warm 1.8 MPa He tanks
8 – 80 K He Quench tanks
9 – Cryoplant termination box
10 – LHe tank
50 KLHe
4.6 – 4.8 K
80 – 100 K
80 – 100 K
4.6 – 4.8 KLHe
Pictures courtesy of CERN
M. Sanmarti, Ciemat-F4E, ITER CODAC Colloquium, Barcelona, October 2008 15
Cryoplant layout option 1
Option 1 – LN2 plant and boxes of 80 K helium loop are located at outdoor area
Room for power supply
Instrumentation (control) room
Unloading area
LN2 plant
80 K He loop
Power supply
Unloading area
M. Sanmarti, Ciemat-F4E, ITER CODAC Colloquium, Barcelona, October 2008 16
ITER Cryodistribution System
Cryodistribution
M. Sanmarti, Ciemat-F4E, ITER CODAC Colloquium, Barcelona, October 2008 17
Cryodistribution architecture
3 CVBs of magnet
Structure
9 CTBs of TF Coils
6 CTBs of CS Coils
11 CTBs of PF&CS Coils
14 CVBs of Cryopumps for Cryostat, Torus&PIS,
NB
LHe bath
System of long cryogenic lines for cryogenic users inside the Tokamak building
LHe bath LHe bath LHe bath
Str-ACB PF-ACB TF-ACB CS-ACB CP-ACB
SHe pump
Cold Compressor
Bypass valve for mitigation of pulsed heat loads on Lhe Plant
Heat exchanger
4.6 K SHe Supply
4.8 K GHe Return
4.5 K LHe Supply
50 K GHe Supply
LHe bath
Cryolines from cryoplant building
80 – 100 KThermal shields not shown
M. Sanmarti, Ciemat-F4E, ITER CODAC Colloquium, Barcelona, October 2008 18
ComingFrom cryoplant
25000LHe tank
ACBTF
ACBSTR
ACBCS
ACBCryopumps
ACBPF
4 CVBs NB
2 CVBs Cryostat
8 CVBsTorus
>50 Cold Boxes, 3 km of cryolines, 4500 componentsCTCB
ITER Cryodistribution system
Differentlevels
M. Sanmarti, Ciemat-F4E, ITER CODAC Colloquium, Barcelona, October 2008 19
Cryodistribution system: P&ID
LOCATI ON TO BECONFI RM ED
M. Sanmarti, Ciemat-F4E, ITER CODAC Colloquium, Barcelona, October 2008 20
ACB structure P&ID
TO/FROM SCVB outlet
HP WARM CONNECTIONS
FTC : Fluid tends to close
LP WARM CONNECTIONS
TO/FROM SCVB inlet
HELIUM GUARD HEADER
CALIBRATION HEADER
PURGE-FILLING HEADER
RECOVERY HEADER
M. Sanmarti, Ciemat-F4E, ITER CODAC Colloquium, Barcelona, October 2008 21
ACB Structure Detail Design
M. Sanmarti, Ciemat-F4E, ITER CODAC Colloquium, Barcelona, October 2008 22
Outline
• ITER cryogenic requirements
• ITER CRYO project frame
• ITER cryogenic system
• Controls and instrumentation for cryogenics• As personal views this presentation does not necessarily
reflect those from other involved parties (IO and IN DA)
• Conclusions
M. Sanmarti, Ciemat-F4E, ITER CODAC Colloquium, Barcelona, October 2008 23
Instrumentation requirements
• Cryogenic instrumentation (industrial process/plants)• Pressure (1-200b, mbar, vacuum), Temperature (300-3.7K), Flow
(warm/cold; 2-2000 g/s), • Gas quality & impurities (N2/H20/CxHy-ppm)• Actuators: Control & Pneumatic Valves, Quench valves (mech/PV), Heaters,
Motors (On/Off, speed control)• Switches (safety interlocks)
• Cryoplants• Installed redundancy for “inner” instrumentation Cold Boxes• Specific components like turbines (speed sensor, gas impurities)
• Cryoditribution• Sub-atmospheric circuits (helium guard)• Speed/Freq. controllers for circulators/cold comp.• High magnetic fields and radiation environment• Accessibility constrains (operation scenarios)• Installed redundancy for “inner” instrumentation ACB
M. Sanmarti, Ciemat-F4E, ITER CODAC Colloquium, Barcelona, October 2008 24
Estimated I/O (tbc)
System I/O Units Sub-total
LHe module 1500 3 3000
LN2 module 1000 2 2000
80K loop 300 2 600
Ancillary equip.
800 - 800
ACB (CCB) 400 5 2000
TOTAL (tbc) 8400
M. Sanmarti, Ciemat-F4E, ITER CODAC Colloquium, Barcelona, October 2008 25
Control requirements
• Cryoplants• Modular individual control sub-systems
• Commissioning (staged, acceptance)• Operation scenarios
• Dedicated PLC for critical components by suppliers: turbines• Cryoditribution
• High magnetic fields and radiation environment• Accessibility constrains (operation scenarios)• Dedicated PLC for critical components by suppliers: cold circulators, cold comp.
• Master control system• Cryo Integrated control system (IN, IO, EU)• General/individual data/interlocks exchange with other WBS (magnets, TS, cryopumps)• Machine interface (CODAC)
• Standardization: hardware and software• Flexibility and “accessibility” during commissioning and first years of operation• Logging and post-mortem system for data/event analysis• Quality control (software updates, modifications)• Cryo and Central control room
M. Sanmarti, Ciemat-F4E, ITER CODAC Colloquium, Barcelona, October 2008 26
Cryoplant control architecture?
He Compressor stationHe
Compressors
N2 CompressorStation
1 1 1
9 10
6
8
5
7
2 2
3 3
4
1 – Cold process boxes of LHe Plant
LHe Plant 80 K He loopOutdoor storage
LN2 PlantQuench line
2 – Cold process boxes of LN2 Plant
3 – Cold boxes of 80 K He loop
4 – Auxiliary LN2 box of 80 K He loop
5 – helium gas purifier and recovery compressors
6 – LN2 Tank
7 – Warm 1.8 MPa He tanks
8 – 80 K He Quench tanks
9 – Cryoplant termination box
10 – LHe tank
50 KLHe
4.6 – 4.8 K
80 – 100 K
80 – 100 K
4.6 – 4.8 KLHe
OWS[1..x]
DataServers
EWS[1..x] Ethernet
M. Sanmarti, Ciemat-F4E, ITER CODAC Colloquium, Barcelona, October 2008 27
Cryoplant control architecture?
OWS[1..x]
DataServers
EWS[1..x] Ethernet
CV, PV, EH, EM
FIELD BUS networks
TT, PT, LT, FT, TS, PS, LS, FS
LHe CP1 LHe CP2
LHe CB1
LHe CP3
LHe CB2 LHe CB3
CTCB
Storage
Recup &Purif.
LN2_1 LN2_2
80K Loop1&2
M. Sanmarti, Ciemat-F4E, ITER CODAC Colloquium, Barcelona, October 2008 28
Cryodistribution architecture?
3 CVBs of magnet
Structure
9 CTBs of TF Coils
6 CTBs of CS Coils
11 CTBs of PF&CS Coils
14 CVBs of Cryopumps for Cryostat, Torus&PIS,
NB
LHe bath
System of long cryogenic lines for cryogenic users inside the Tokamak building
LHe bath LHe bath LHe bath
Str-ACB PF-ACB TF-ACB CS-ACB CP-ACB
SHe pump
Cold Compressor
Bypass valve for mitigation of pulsed heat loads on Lhe Plant
Heat exchanger
4.6 K SHe Supply
4.8 K GHe Return
4.5 K LHe Supply
50 K GHe Supply
LHe bath
Cryolines from cryoplant building
80 – 100 KThermal shields not shown
Ethernet
DataServers
EWS[1..x]
OWS[1..x]
M. Sanmarti, Ciemat-F4E, ITER CODAC Colloquium, Barcelona, October 2008 29
Cryodistribution architecture?
Ethernet
EWS[1..x]
OWS[1..x]
DataServers
Str. ACB TF ACBPF ACB CS ACB Cryopumps ACB
CV, PV, EH, EM
FIELD BUS networks
TT, PT, LT, FT, TS, PS, LS, FS
Accessibility constrainsHigh magnetic field
High radiation enviroment
M. Sanmarti, Ciemat-F4E, ITER CODAC Colloquium, Barcelona, October 2008 30
Conclusions
• Cryogenics is a large industrial plant system • Instrumentation and controls requirements are well
understood and identified• Controls architecture not yet defined• RAMI analysis and other projects experience to be used• Integration with clients (magnets, cryopumps, TS, others)
• Radiation and high magnetic fields impact on cryodistribution instrumentation and electronics has to be validated
• Standardization and integration of all cryogenics sub-systems is mandatory• Hardware (I&C) and software• To be defined before PA by involved parties
• Common strategy and standard to be defined by all involved parties (IO, IN DA & F4E) before PA
M. Sanmarti, Ciemat-F4E, ITER CODAC Colloquium, Barcelona, October 2008 31
THANK YOU!!
Manel.Sanmarti@f4e.europa.eu
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