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Value Engineering in System of Cryoline and Cryodistribution for ITER: In-kind Contribution from INDIA
INTRODUCTION
B. Sarkar1, N. Shah1, H. Vaghela1, R. Bhattacharya1, K. Choukekar1, P. Patel1, H. Chang2, S. Badgujar2, M. Chalifour2 1ITER-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
EF C D D C
E
F
EF 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 CE AHCF DE
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
XX
E
Y
B
A
C
D
Y
XX
E
Y
B
A
A, B, C, D, E
are Embedded
Plates
X and Y are
cryolines
Separation of External
supports & EPs
C
D
Y
XX
E
Y
B
A
C
D
Y
XX
E
Y
B
A
A, B, C, D, E
are Embedded
Plates
X and Y are
cryolines
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-STACB-CS
LHe Bath
EPs for one
group of line
EPs for
another
group
of line
ITER SpecificationsDesign,
Manufacturing of ITER Cryolines
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
High Technical and Low Schedule Risk
Low Technical and Low Schedule Risk
ITER SpecificationsDesign, Manufacturing &
Cold Testing of PTCLLow Technical and High
Schedule Risk
Design, Manufacturing of
ITER Cryolines
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