O.Büchner, FZJ/ZAM 1 Core D-Grid Infrastructure AstroGrid-D Meeting 24./25.07.2006 ARI Heidelberg.
WP3 MR System Target Moderator Cryoplant FZJ/ESS Kick-off Meeting John Jurns Lead Engineer TMCP 20...
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Transcript of 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
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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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TMCP Process Design Description
Compressors
Turbo-expanders
Ambient heater
Warm gas buffers
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Operating modes Checkout mode• TMCP only (jumper at cold box)
TMCP Process Design Description
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Operating modes Checkout mode• TMCP and CTL (jumper at CMS)
TMCP Process Design Description
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Operating modes Steady state mode• Nominal design
TMCP Process Design Description
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Operating modes Steady state mode• Nominal low power
TMCP Process Design Description
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Operating modes Steady state mode• Nominal turndown (short term)Switching mode• Beam trip
TMCP Process Design Description
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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)
TMCP Process Design Description
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Operating modes Switching mode• Long term turndown (unload CTL
to low pressure buffer tanks, CTL decrease from ~6 bar to ~1 bar )
TMCP Process Design Description
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Operating modes Switching mode• Long term turndown (unload CTL
to high pressure buffer tanks, emergency shutdown, loss of power)
TMCP Process Design Description
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Operating modes Steady state mode• Nominal design (100%)
TMCP Process Design Description
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Operating modes Steady state mode• Nominal low power (<50%)
TMCP Process Design Description
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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
Ambient temperature: 278 K to 313 K
Relative Humidity: 20%-80%
Cold box room
Ambient temperature: 283 K to 303 K
Relative Humidity: 20%-80%
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
43
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
44
TMCP Installation & Commissioning
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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TMCP Installation & Commissioning
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
48
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
49
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
50
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
51
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
52
• 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