wp3 mr system target moderator cryoplant fzj/ess kick-off meeting john jurns lead engineer tmcp 20...

WP3 MR SystemTarget Moderator Cryoplant

FZJ/ESS Kick-off Meeting

John JurnsLead Engineer TMCP

www.europeanspallationsource.se20 August 2015

http://www.europeanspallationsource.se/

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Moderator-Reflector Systems

• Overview• Requirements• Design/functionality• Project execution• Procurement

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Target Cryogenic Cooling System Overview

A key feature of ESS is a tungsten target wheel, which uses high-energy protons to create fast neutrons via the spallation process. A moderator-reflector system then transforms these fast neutrons into slow neutrons.

A key feature of the moderator-reflector system are the H2 moderators, which use supercritical H2 at 17 K and 1.5 MPa to reduce the energy of the neutrons before they reach the instrument lines.

Neutronic heat is removed from the H2 by a Cryogenic Moderator System (CMS). The CMS circulates circulates supercritical hydrogen to the moderators, and removes heat through a heat exchanger to a cold helium circuit, maintaining its nominal operating temperature of 17 K.

The Target Moderator Cryoplant (TMCP) will provide the cooling for the CMS. The heat deposited into the H2 is removed via a heat exchanger in the CMS cold box that transfers the heat from the H2 circuit to a cold gas He circuit operating at approximately 15 K and 1.9 MPa, which is connected to the TMCP cold box.

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M-R Cryogenic Systems Overview

Overall simplified schematic

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Requirements

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TMCP System RequirementsPrimary Functions• To remove heat from CMS hydrogen circuitOperational Functions• Circulate cold helium through Cryogenic Transfer Line (CTL)• Operate between maximum and minimum heat loads• Function efficiently under defined operational modes• Manage TMCP helium inventorySafety & Reliability Functions• Meet Target lifetime and availability goals• Meet safety goals for pressurized cryogenic systems

Requirements

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General Requirements forTarget Station

General Requirements related to TMCP

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Specific System Requirements for TMCP

CMS process requirement on TMCPHeat Input• Heat load (Neutronics) maximum – 24.0 kW• Heat load (static) maximum – 4.9 kW• Total Heat load maximum – 30.3 kWHeat exchanger• Media – He/H2

• Capacity minimum – 33 kW Operational parametersHydrogen Pressure• Design maximum – 17 bar• Operation minimum – 13 barTemperature• Operation maximum 21.0 K• Operation minimum 15.0 K • Allowable ΔT maximum 3.5KMass flow • Total mass flow nominal 1000g/sOperational modes• Cool down maximum – 24 hr• Heat up maximum – 24 hr

CMS other requirement on TMCP

Availability• 24/7 365 days per year (not counting

scheduled down times)Location• H2 room, D02 level 150• Ambient 285-303 K, 20-80% RH

References:

ESS-0036931, TMCP heat load summary

ESS-0033354, CMS SDD-Req

ESS-0034424, Neutronic report for the PDR

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TMCP capacity range – Expected operating scenarios once TMCP is fully commissioned

• Steady-state operation modes– Nominal design mode – 100% capacity– Nominal low power mode – 25-70% capacity– Nominal turndown mode – 16% capacity

• Short term• Long term

• Transient operation modes– Cool down/warm up

• Cool/warm up of TMCP alone• Cool down/warm up of TMCP and CTL

– Switching modes• Short term switch from nominal power to turn down power and back• Long term switch from Nominal to Turn Down • Long term switch from Turn Down to Nominal

– Beam trip

Requirements – TMCP capacity

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Design & Functionality

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Target Moderator Cryoplant

Cryogenic Moderator System

M-R Cryogenic Systems Design Overview

Overall schematic

Hydrogen Moderators

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TMCP Process Parameters Overview

Safety factor & operational margin development

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TMCP Process Parameters Overview

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TMCP Operating Capacity Range

Start of operations (2019) to nominal capacity (2025) with & without margins

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TCMP Schematic

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TMCP Process Design Description

TMCP

CTL

CMS

ESS

HP LP

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Compressors

Turbo-expanders

Ambient heater

Warm gas buffers

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Operating modes Checkout mode• TMCP only (jumper at cold box)


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Operating modes Checkout mode• TMCP and CTL (jumper at CMS)


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Operating modes Steady state mode• Nominal design


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Operating modes Steady state mode• Nominal low power


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Operating modes Steady state mode• Nominal turndown (short term)Switching mode• Beam trip


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Operating modes Switching mode• Long term turndown (unload CTL

to high pressure buffer tanks, CTL decrease from ~ 20 bar to ~ 6 bar)


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to low pressure buffer tanks, CTL decrease from ~6 bar to ~1 bar )


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to high pressure buffer tanks, emergency shutdown, loss of power)


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Operating modes Steady state mode• Nominal design (100%)


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Operating modes Steady state mode• Nominal low power (<50%)


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TMCP Compressor building piping

CryoplantSupplier

ESS

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TMCP Cold box room piping

CryoplantSupplier ESS

TMCP

ESS

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TMCP Utilities – cooling water

CryoplantSupplier ESS

Compressor building

He cold box building

Cryo transfer line tunnel

Connection to H2 cold box in

Target building

Cryogenic systems location overview

TMCP System Layout

Duct for cryo transfer line to Target building

He cold box building

~ 335 m between TMCP and CMS

H2 cold box

Compressorbuilding

ACCP

TiCP

TMCP

TMCP System Layout

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CTL

Duct to Target building

Duct to G04

• Integrated TMCP & CTL design description overview – layoutG02 cold box

building ACCPCold box

TiCPCold box

TMCPCold box

TMCP System Layout

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CMS cryostat interface

CTL Design Layout

TMCP interface

CTL

• Vacuum insulated supply and return lines• DN100 process pipe, DN150 vacuum jacket• ~ 335 meter length from TMCP to CMS• Total He inventory ~ 336 kg• Estimated total heat leak 1.3 kW• Estimated total pressure drop (CTL only, not including CMS HEX) – 0. 15 bar• CTL size minimized by TMCP process design (expansion turbines on return line

of helium loop to CMS)

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Add picture of interface between CMS and CTL in

D02 hydrogen room

1. Cryostat2. He transfer lines3. H2 supply and return line4. Pumps5. Removable stair6. Vent line to stack7. Cryostat assembly frame8. Folding doors open to atmosphere9. Jalousie for wind and weather protection

Interface to CMS - Physical

CTL helium line to/from TMCP

CMS hydrogen room in building

D02 level 150

TMCP/CMS Physical Interface

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ESS Site

Outdoor conditions

Ambient temperature: 250 K to 310 K

Relative Humidity: 10%-100%

Compressor room



Cold box room



Cooling water

supply pressure of 4-9 bar (3-8 bar gauge).

design pressure of 11 bar (10 bar gauge).

maximum allowed pressure drop in circuits is 2 bar.

supply temperature 303±1 K for acceptance test, may vary between 288 and 305 K in operation.

Electricity

power for main compressor motor at 6.6 kV, 50 Hz

Low voltage switchgear at 400 V, LV UPS power and

cables up to the terminals of the contractor’s LV power distribution and control system;

24 V DC with battery backup for measuring instruments and logic control circuits where necessary;

Instrument air

ISO 8573-1: dust content class 2, oil content class 2 and moisture class 2. supply pressure will be 7 bar (6 bar gauge).

Helium

purity of 99.996% (Helium grade 4.6).

Magnetic field/Radiation levels

Magnetic fields and radiation levels in the TMCP compressor building and cold box building will be negligible. The equipment will be accessible during accelerator operation as well.

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Project Execution

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TMCP Project Execution

ESS expects this project to be generally executed as follows:TMCP – Commercial procurement for:

• Cryoplant & controls• Installation• Checkout & commissioning

CTL – Commercial procurement for:• Cryogenic Transfer Line• Installation & testing

ESS will provide:• Facility piping & cabling (as part of overall cryoplants installation)• Buildings & civil work, power, cooling water, instrument air• Overall project coordination

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TMCP Scope

12.3.4.2 Scope ESS Scope

Warm compressor station Warm gas buffer tanks

Gas management panel CMS H2 cryostat

Oil removal system Warm helium distribution piping

Warm interconnecting piping & cabling Cooling water system

Ambient heater Power, medium & low voltage switchgear

Cold box UPS for control system

Gas analysis Ethernet

Control system EPICS framework

Spare parts Civil & structural work & buildings

He/H2 heat exchanger for CMS

CTL jumper spool

He cryogenic transfer line (CTL)

Hardware Scope

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TMCP Scope

Engineering Services Scope12.3.4.2 Scope ESS Scope

Project management, scheduling, interface and quality control Overall project management and scheduling

Basic and detail design, and specification of equipment, piping, cabling & controls

Basic and detail design, and specification of ESS provided equipment, cabling & controls

Project meetings and fabrication checks Project meetings and fabrication checks

Pressure and leak checks, signal checks and function checks Overall layout and civil engineering

Planning of shipping, testing, installation, commissioning and acceptance testing

Organizing third party approvals from Swedish authorities for TMCP operating permit

Packing and shipping TMCP equipment Assistance & training for contractor w.r.t. connecting to ESS EPICS

Packing and shipping of H2/He heat exchanger Integration and implementation into broader ESS control system

Project management, scheduling, interface and Quality documentation, inspection and test protocols, material certificates etc. Health, safety and environmental analyses

All software and tools to commission, acceptance test, operate and maintain the TMCP including communication between EPICS IOC(s) and PLC(s)Naming of all devices and signals according to the ESS naming convention

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TMCP Scope

Site Services Scope12.3.4.2 Scope

Unloading and placing TMCP components Set up of the two EPICS based local touch panels;

Arranging for lifting and transport to place heavy plant components

Signal checks of contractor provided equipment and skids;

Removing of package material etc. Function checks of contractor provided equipment;

Interconnection and installation of process and utility piping between contractor provided components

Adjustment of contractor provided equipment and skids;

Interconnection and installation of process and utility piping between contractor provided equipment and ESS interfaces

Calibration of transmitters on contractor provided equipment and skids;

Cleaning, purging, evacuating and filling with helium of all equipment and interconnecting piping;

Commissioning of the TMCP

Pressure and leak checks of contractor provided equipment and skids;

Acceptance testing of the TMCP

Activation of all adsorbers; Training of ESS personnel

Supply, installation and termination of cables from CC/MCCs, TBs to Contractor supplied equipment

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TMCP

Site Services ScopeESS Scope

Access to ESS site

Site safety training

Limited storage for contractor provided equipment

Access to sanitary facilities including fresh water;

Start-up utilities (helium, nitrogen, instrument air, cooling water and electricity)

Receipt and inspection and appropriate storage;

Interconnection and installation of ESS scope piping between contractor provided equipment

Interconnection and installation of piping in scope of ESS between ESS provided equipment and contractor provided skids and equipment;Support for operating and trouble-shooting during start-up

Measurement of electric power usage during acceptance tests

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TMCP Installation & Commissioning

Installation & CommissioningTests at manufacturer site

• Welds (radiograph)• Pressure tests • Leak tests • Warm compressors – test at maximum nominal condition• Turbines – equivalent steady state operation mode test at warm conditions

Mechanical tests at ESS (installation)• Welds (radiograph) • Pressure tests • Leak tests

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Installation & CommissioningAcceptance tests at ESS• Warm compressor• Performance (capacity, noise, oil removal, control)• Utilities (power, water)

• TMCP only • Functional test – mechanical, controls, adsorber regeneration• Capacity tests – steady state (maximum, low power, turndown)• Transient performance tests – Emergency shutdown, failures, restart, turbo-

expander replacement

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Installation & CommissioningAcceptance tests at ESS•Integrated TMCP/CTL tests• Additional performance tests• Transition 100% turndown (ramp down)• Transition turndown 100% (ramp up)• Transition 100% beam trip (instantaneous)• Transition turndown 100% (instantaneous)• Transition 100% 70% (ramp down)• Transition 70% 50% (shut down one compressor)• Transition 50% 100% (restart one compressor)• Isolate TMCP from CTL, shutdown, unload He to buffer tanks• Full cool down of TMCP & CTL 300 K 15 K (load He from buffer tanks)• Full warm up of TMCP & CTL 15 K 300 K (unload He from CTL)

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Procurement

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Procurement –TMCP

HistoryBudget request from ALAT, Linde Kryotechnic for 20 kW, 16.5 K cryoplant• Responses (4Q14)

– Linde 9.6 M€, including installation & CTL– ALAT 9.5 M€, including CTL, satellite box, no installation

Revised budget request from ALAT & Linde for 35 kW, 15 K cryoplant • Responses (2Q15)

– Linde 10.6 M€, including installation– ALAT 10.3 M€, including H2/H2 HEX, no installation

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Procurement –TMCP

Current statusDrafted the following documents to procure a 30 kW, 15 K cryoplant:• Technical Specification (ESS-0034501), includes:

– 30.3 kW, 15 K cryoplant complete– 33 kW H2/He heat exchanger for CMS– Vacuum jacketed CTL jumper spool for performance tests– Installation of all TMCP, including interconnecting piping & cabling– Controls– Acceptance testing, commissioning, training, documentation

• Statement of Work, outlining scope of supply for both vendor and ESS for:– Hardware deliverables– Engineering services– Installation services– Documentation– Responsibilities

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Procurement –TMCP

Current status (continued)• Open Call for Tender, including:

– Instructions to bidders– Description of supplies & services– Bid assessment criteria– Requirements for submittal– References to SOW and Technical Specification

Next steps• Final edits to Technical Specification, SOW, OCT based on review comments• Release OCT by end of August

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Procurement –CTL

Current statusDrafted a request for budgetary estimate to procure, install, and checkout two 335 m, DN100 vacuum jacketed pipe assemblies (one supply, one return):• Sent request to five VJ piping fabricators. Feedback as shown below:

• Cryo World – 732.1 k€ (1,100 €/meter)• KrioSystem – 700 k€ (1000 €/meter)• CryoTherm – 1,960 k€ (2,800 €/meter)• Cryo Diffusion – 1189.4 k€ (1,750 €/meter)• Demaco – 559 k€ (834 €/meter)

Next steps• Finalize routing of CTL in coordination with ESS SI organization• Draft Technical Specification, SOW, OCT• Release OCT by 2Q2016

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Schedule

Target Moderator CryoplantPDROCTContract awardTMCP PDRTMCP CDRInstallationCommissioningCryo Transfer lineOCTContract awardCTL PDRCTL CDRInstallation

Concept Phase Final Design Make Phase

PDR

2019Q1 Q2

2015Q1 Q2 Q3 Q4

2016Q1 Q2 Q3 Q4

2017Q1 Q2 Q3 Q4

2018Q1 Q2 Q3 Q4

PDR

PDR

PDR

PDR

SAT

PDR

Delivery CDRPDR

PDRPDR

PDR

Site Inst. & Testing

Site Work

2014Q3 Q4

PDR

PDR

Procurement

Schedule

PDR

PDR

PDR

PDR

PDR

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• TMCP configuration – The cryogenic heat load to the CMS and subsequently to the TMCP are characterized by a wide range of heat load, narrow range of operating conditions, and expected fast changes in heat load that the systems must respond to safely and efficiently.

• The proposed configuration of the TMCP and CTL effectively addresses these challenges by providing a system that can:– Operate efficiently over the entire range of operating conditions – Respond quickly to changes in heat loads – Designed to minimize helium mass

• The unique operating requirements of the CMS and TMCP will require continuing efforts to coordinate the design of hardware and development of the operating scheme

• The project is still generally on schedule, but diligence is required to maintain momentum and forward progress

Summary

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Finis

wp3 mr system target moderator cryoplant fzj/ess kick-off meeting john jurns lead engineer tmcp 20...

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