ITER Cryogenic System

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


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


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


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


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


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


Outline




• Few thoughts on control and instrumentation

• Conclusions


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%)


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


Outline




• Few thoughts on control and instrumentation

• Conclusions


ITER Cryoplant System

Cryodistribution


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


Cryoplant architecture


Compressors


1 1 1

9 10

6

8

5

7

2 2

3 3

4








6 – LN2 Tank




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


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


ITER Cryodistribution System

Cryodistribution


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


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


Cryodistribution system: P&ID

LOCATI ON TO BECONFI RM ED


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


ACB Structure Detail Design


Outline




• Controls and instrumentation for cryogenics• As personal views this presentation does not necessarily

reflect those from other involved parties (IO and IN DA)

• Conclusions


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


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


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


Cryoplant control architecture?


Compressors


1 1 1

9 10

6

8

5

7

2 2

3 3

4








6 – LN2 Tank




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


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


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]


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


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


THANK YOU!!

[email protected]

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ITER Cryogenic System

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