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Value Engineering in System of Cryoline and Cryodistribution for ITER: In-kind Contribution from INDIA INTRODUCTION B. Sarkar 1 , N. Shah 1 , H. Vaghela 1 , R. Bhattacharya 1 , K. Choukekar 1 , P. Patel 1 , H. Chang 2 , S. Badgujar 2 , M. Chalifour 2 1 ITER-India, Institute for Plasma Research, Bhat, Gandhinagar 382428, India; 2 ITER Organization, Route de Vinon-sur-Verdon, CS 90 046, 13067 St. Paul Lez Durance Cedex, France Presented at the Cryogenic Engineering Conference and International Cryogenic Materials Conference, 2015 June 28-July 2, Tucson, Arizona; Program I.D. number: C1PoD-08 [C30] The ITER cryogenic system consists of three main subsystems; the Cryoplant, the Cryo-distribution (CD), as well as the system of Cryoline (CL) and Warmlines (WL) systems. The CD and CL systems are part of the in-kind supply from India. The cryoplants provide the required cooling power for the clients, namely, the superconducting magnet system, Cryo-pumps and thermal shield for the main cryostat. The CD system controls and manipulates the different operational scenario of ITER and the CL system establishes the two way communication of the required flow of cryogen as per the ITER cryogenic process with the structured network of multi (two to eight) and single process pipe cryolines. Basis of Risk, Analysis and its Mitigation Likelihood of Occurrence Impact or Consequence Negligible (1) Marginal (2) Significant (3) Critical (4) Crisis (5) Very Likely (5) Low (5) Medium (20) High (45) Very High (80) Very High (125) Likely (4) Low (4) Medium (16) High (36) High (64) Very High (100) Unlikely (3) Low (3) Medium (12) Medium (27) High (48) High (75) Very Unlikely (2) Low (2) Low (8) Medium (18) Medium (32) High (50) Not Credible (1) Low (1) Low (4) Low (9) Medium (16) Medium (25) ITER Cryodistribution System ITER Cryolines System Specifications ITER Cryolines PTCL OVJ Size DN 100 to DN 1000 DN 600 Number of process pipes 1 to 7 6 Length ~ 5000 m 27 m Segments Straight, Tee, Elbow, Z Straight, Tee, Elbow, Z Quality Classes QC 1*, QC 2 QC 1 Seismic Classes SC1 (SF)*, SC1 (S), SC2, NSC SC1 (S) Safety Classes SIC-II*, SR, Non-SIC Non-SIC Fluids Helium, Nitrogen Helium Temperature levels 4.5K, 50K, 80K, 300K 4.5K, 80K, 300K Pressure of process fluid Maximum 21 bar 21 bar (design), max. 6.5 bar (cold test) Major Technical specifications of ITER Cryolines and PTCL Planning and Synchronization – Development of Prototype Cryoline (PTCL) with ITER Cryolines The high risk zone due to the availability of ‘limited resources of industrial partners’ and their understanding on the technical specifications was found to have both direct and indirect cascading impact on the technical performance of the system of CLs for ITER. A four-step process was implemented starting from global expression of interest with pre-qualification, PTCL design followed by fabrication and test The technical uncertainty of the overall CL system was mitigated by selecting particular segments in the PTCL such as ‘T,’ C-sections with different angles, straight section and a specific out of plane ‘Z’ sections. System optimization – Individual cold compressors over Common cold compressor F LHe Bath E E F C D D C E F E F D C F E LHe Bath D C H F E D C H LHe Bath F E D C H LHe Bath LHe Bath F E D C A F D C E A H C F D E GN2 LN2 11 CTBs of PF & CC coils 6 CTBs of CS coils 9 CTBs of TF coils 12 CVBs of Cryopumps for Cryostat, NB & Torus 3 CVBs of magnet structures 2 CVBs of Thermal Shield CCB ACB-ST ACB-PF ACB-CS ACB-TF ACB-CP LHe Plant (3 Units) CTCB 80K Loop (2 Units) Legends A: LHe Header C: SHe Supply Header D: 4.8 K Return Header E: 80 K Supply Header F: 100 K Return Header H: 50 K Supply Header Storage (4.5 K LHe, 300 K GHe, 80 K LN2, 300 K GN2, 80 K Quench Tank, Gas Bag) LN2 Plant (2 Units) *most stringent Conclusion Common cold compressor configuration, requires one cold compressor of capacity ~2.1 kg/s, which calls industrial up scaling or development. Individual cold compressors provide flexibility to operate each ACB at different temperature level as well as reduces the maximum mass flow rate for compressor. Maximum mass flow rate requirement is now restricted to 0.6 kg/s, 0.8 kg/s and 1.3 kg/s for ACB-TF, CS and ST respectively. ‘Very high’ and ‘high’ risks brought down to ‘medium’ and ‘low’ level with implementation of prototyping both in CD and CL The PTCL design, the development of two CCPs by two industrial collaborations - a blessing towards the further development Above planning and actual implementation as well as value engineering has enabled ITER-India to enter in to the industrial level of development for CL and CD system of ITER. Acknowledgements Authors would like to thank the colleagues from ITER-India, ITER Organization in St. Paul Lez Durance France as well as industrial partners namely M/s INOX India Limited (India) and their consortium partner, M/s Air Liquide Advanced Technologies (France), M/s Linde Kryotechnik (Switzerland), M/s Barber Nichols Inc. (USA), M/s IHI (Japan), M/s Tayyo Nippon Sanso (Japan) Group X (Process Pipe: > 3) Group Y (Process Pipe: 1,2 or max. 3) Total length is ~ 5 km Sizes: DN 100 to DN1000 Complex Routing with large number of bends at odd angles, branches 37 types of VJ lines Spread in Tokamak building, plant bridge, and cryoplant area Tight positional tolerances for installation ~ 70m ITER Cryolines CL inside tokamak building CL inside Cryoplant area ~ 130 m The CD system of ITER is specifically configured for a fusion machine, meaning thereby managing of steady state heat load, dynamic heat load arising from the magnets system as well as nuclear heating and supporting the operational scenarios. In parallel to the conceptual design, market survey to identify the cryogenic industries that can strongly support to accomplish the CD project was started through the pre- qualification process Process pipes CC, CD, C, CR ~ 4.5 K Process Pipe E, F ~ 80K Design-1 OVJ: DN600 Q (@4.5K): 0.88 W/m Q (@80K): 4.33 W/m No. of segments: 4 Avg. weight: 376 kg/m Major Requirements OVJ < DN600 Q (@4.5K) < 1.2 W/m Q (@80K) < 4.5 W/m No. of segments: shall be minimized Avg. weight: shall be minimized Design-2 OVJ: DN600 Q (@4.5K): 0.98 W/m Q (@80K): 3.73 W/m No. of segments: 5 Avg. Weight: 254 kg/m Two designs of PTCL PTCL (mock up) Test Box A LHe Dewar Test Box C Test Box B 80K Cold Box View of ITER-India cryogenic facility (ready for PTCL test) C1PoD-08 [C30] Developed taking in to account the technical requirements of the major components such as CCPs, valves, heat exchangers, filters, instrumentation, etc. Technical risk mitigation and Value engineering: Cold Circulating Pumps and its test Cold Circulating Pumps (CCP) Test ACB (TACB) First of a kind technical specification in terms of mass flow, pressure head and variation in input conditions (i.e. P & T). In all modes of operation inclusive of 110 % of mass flow, more than 70 % efficiency required. By optimization of the position of thermal intercept with respect to the flange, it has been possible to increase the temperature from 289 K to 298 K satisfying the requirement. TACB : Manufacturing Near completion CS TF ST ACB-CS ACB-TF ACB-ST CCB LHe Bath Heat Exch- anger C D Y X E Y B A Separation of External supports & EPs C D Y X X E Y B A A, B, C, D, E are EPs; X and Y are CLs Shared Supports and EPs Individual Supports and EPs Detailed study PTCL in Manufacturing phase ‘T’ section ‘Z’ section Straight section References 1. Serio L et al., The Cryogenic System For ITER, Fusion Science and Technology, Volume 56, p. 672-75 2. Chang H.-S., Serio L., Henry D., Chalifour M. and Forgeas A., Operation Mode Studies Of The ITER Cryodistribution System, Advances in Cryogenic Engineering, 2012, p. 1691-98 3. Klein J. H. and Cork R. B., An Approach to Technical Risk Assessment, International Journal of Project Management, Volume 16, No. 6, p. 345-51 4. Shah N, Bhattacharya R, Sarkar B, Badgujar S, Vaghela H and Patel P, Preliminary system design and analysis of an optimized infrastructure for ITER prototype cryoline test, Advances in Cryogenic Engineering, Volume 57, p. 1935-42 5. Shah N, Sarkar B, Choukekar K, Bhattacharya R and Kumar Uday, Investigation of Various Methods for Heat Load Measurement of ITER Prototype Cryoline, Advances in Cryogenic Engineering, Volume 58, p. 856-63 6. Vaghela H., Sarkar B., Bhattacharya R., Kapoor H., Chalifour M., Chang H.-S. and Serio L., Performance evaluation approach for the supercritical helium cold circulators of ITER, Advances in Cryogenic Engineering, 2014, p. 872-79 7. P. C. Rista, J. Shull, B. Sarkar, R. Bhattacharya and H. Vaghela, Engineering, Manufacture and Preliminary Testing of the ITER Toroidal Field (TF) Magnet Helium Cold Circulator, CEC/ICMC 2015, (C1OrC-05) Replacing CCB with individual cold compressor TACB: 3D Model ACB-TF CS Cold Comp ressor TF ST ACB-ST ACB-CS LHe Bath EPs for one group of line EPs for another group of line ITER Specifications Design of PTCL Manufacturing of PTCL Cold Test of PTCL Preliminary Design of ITER Cryolines Final Design of ITER Cryolines Manufacturing of ITER Cryolines Low Technical and Low EN and PED harmonized standards for design, fabrication and materials for the ITER CLs were followed to satisfy the requirement of CE marking as the final use of the components will be in France The views and opinions expressed herein do not necessarily reflect those of the ITER-India or ITER Organization
