1. Status of ITER Cryo-distribution and Cryoline project
Oral Id - 9-O-4B-IT-16
Status of ITER Cryo-distribution and Cryoline project
B Sarkar1, H Vaghela1, N Shah1, R Bhattacharya1, K Choukekar1, P Patel1, H Kapoor1, M Srinivasa1, H S Chang2, S Badgujar2 and E Monneret2
1ITER-India, Institute for Plasma Research, Bhat, Gandhinagar , India
2ITER Organization, Route de Vinon-sur-Verdon, CS , St. Paul Lez Durance Cedex, France
B. Sarkar
ITER-India, Institute for Plasma Research, Gandhinagar
India

2. Organization
Introduction to ITER and Cryo-distribution & Cryoline system
Scope
Project Requirements
Risk analysis, Mitigation and Interface Management
- Roadmap
- Present Status
Conclusions

3. Key word- ITER project (D-T Fusion)
D + T = He + n + energy
Q = 10
50 MW MW
Frencch Nuclear authority
Fulfillment of Regulatory Obligation
Stringent Requirements
Establishment of Reliability
ITER Project – Nuclear Establishment

4. Layout at ITER site – Specific to Cryogenic System

5. 3-D Layout – Cryogenic System
Cryolines and warmlines located in
Building 11, 52, 53
Area 53
Plant bridge

6. ITER Cryogenic System - Overview

7. Process Flow Diagram of ITER Cryoline and Cryo-distribution
11 CTBs of PF & CC coils
9 CTBs of TF coils
6 CTBs of CS coils
14 CVBs of Cryopumps (NB & Torus)
3 CVBs of magnet structures
1 CVBs of Thermal Shield
CCB
ACB-ST
ACB-PF
ACB-TF
ACB-CS
ACB-CP
LHe Plant (3 Units)
CTCB
80K He 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 (4.5K LHe, 80K GHe 80K GN2, 300K GN2, 80K Quench Tank)
LN2 Plant (2 Units)
Process Flow Diagram of ITER Cryogenic System
Indian Scope of Supply (Red Dotted line in the Figure)

8. ITER-Cryoline System
Group X (Process Pipe: > 3)
Group Y (Process Pipe: 1,2 or max. 3)
Total length is ~ 5 km
Sizes: DN 100 to DN1000
37 types of VJ lines
Spread in Tokamak building, plant bridge, and cryoplant area
Tight positional tolerances for installation
ITER
Cryolines

9. ITER-Cryo-distribution system
11/30/2011
5 ACBs,
1 CTCB, and 1 TCVBs
Dynamic heat load
Steady state heat load
State of the art system
ITER CD system =
Nuclear heat load
A Critical Component
In Radiation Environment
ITER (First of a kind development)
JT-60SA
Auxiliary Cold box
CS model coil
Existing m/c
ATLAS
SST-1
Internal Piping

10. Specific Layout of Cryoline inside Tokamak Building
[With only B1 and B2 level ]
[With only B2 level ]
Level L3 L3
Radiation Environment

11. Scope and Deliverables

12. Scope Functional scope
To distribute cold power to the clients (namely, magnets and cryo-pump) through supply of cryogens at proper temperature, pressure and flow
To perform the safety functions in case of failure
Project Life Cycle

13. Scope Preliminary Engineering Design Final Engineering Design
Manufacturing
Factory Acceptance test
Site installation
Conducting site acceptance test and
Integrated cold test

14. Scope (Physical Deliverables)
Sl. No.
System
Supplies
Details 1.
Cryo-distribution System
(i) Auxiliary Cold Box (ACB)
(ii) Thermal shield cooling system
(iii) Cryo Terminal cold box
(i) Five numbers
ACB TF
ACB PF & CC
ACB CS
ACB Structure
ACB Cryopump
(ii) One number
(iii) One number 2.
System of Cryolines
(i) Helium at 4 K level – approximately 2 km
(ii) Helium at 80 K level – approximately 2.5 km
(iii) Nitrogen at 80 K level – approximately 0.6 km
(i) cryolines from Helium plant to CTCB
(ii) Cryolines (magnet and ryopump) from CTCB to ACBs
(iii) TF, PF, CC, CS, STR cryolines from respective ACBs to CTBs
(iv) CP Cryoline from ACB to CVB
(v) Quench and relief line
(vi) liquid nitrogen lines 3.
Warm line
Approximately 6 km
All warm lines

15. Project Requirements

16. Acceptable heat load
System of cryolines is 2.6 kW at 4.5 K, 6.2 kW at 80 K
Cryo-distribution: 3 kW at 4.5 K and 3.9 kW at 80 K.
Codes and standards ASME and EN/ISO
- Project imposed system classifications
Safety Importance Classification (SIC): Non Safety important, Safety relevant, SIC-2
Quality Classification (QC): QC 1, QC 2, QC 3 and QC 4
Seismic Classification (SC): Non-Seismic, SC2, SC1 (SF)
Vacuum Quality Classification (VQC): VQC 4A/B
Two events of seismic level (SL) spectrum: Cadarache site specific, SL1 and SL2.

17. - Site specific requirements:
(i) French Decree dated December 13, 199, amendments and
(ii) French order of December 21, 1999
(iii) INB order of February 07, 2012 [3].
These regulatory requirements ensure proper classification, identification of category and evaluation of conformity of the pressure equipment in a nuclear establishment.
SC1(SF): damage limit ‘normal’ as per code for Seismic Level-2,
SC1(S) and SC(2): damage limit ‘faulted’ as per code for Seismic Level-2,
SIC-II: Safety Important Class component which is part of secondary confinement boundary for nuclear establishment – stringent quality control and inspection by nuclear authority,
QC1: 100% volumetric inspection,
QC2: typically 20% volumetric inspection

18. Major codes and standards
Sl. No.
Purpose
Code 1.
Construction
EN 13480 2.
Pipes
ISO 1127 3.
Welding
ISO 5817, ISO 14731, ISO 14343, ISO 14344 4.
Safety Devices
EN 764, ISO 4126, EN 13648 5.
Cryogenic valves
EN 1626, EN , AD 2000, PED 97/23/EC 6.
Non Destructive Testing
ISO 17636, EN 12517, EN 473, ISO 17636

19. Loads & constraints considered for design of ITER cryolines
Cryoline Design
Pressure (internal, external)
Temperature (minimum, maximum)
Seismic load
Loads due to transportation and material handling
Layout constraints (routing, location of supports, interfaces)
External fields (magnetic, nuclear radiation)
Flow induced vibrations, vibrations from interface equipment
Self weight, supported weight
Loss of Insulation Vacuum
Snow load, wind load

20. Risk analysis and Mitigation

21. Risk Management Process
The risk management process followed the specific path
Identification,
Assessment,
Impact Determination,
Monitoring
Reporting and
Risk Closure

22. Reliability (Risk Assessment)
Likelihood of Occurrence (O)
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 (9)
Medium (25)
Correlation 𝑹= 𝑰 𝟐  𝑶 with four rank zones as low, medium, high and very high.

23. Risk Drivers
First of its kind Design
Management of establishing too many interfaces,
Interface Load,
Compatibility of material,
Compliance with French nuclear safety,
Space constraints and layout,
Stringent Quality Requirements
Regulatory requirement.

24. Prototyping – Mitigation by Design & Test
Two Prototype test
Two Designs
Design-2
OVJ: DN600
Q 0.98 W/m
Q 3.73 W/m
Process pipes CC, CD, C, CR ~ 4.5 K
Process Pipe E, F ~ 80K
Cold Circulator -2
Cold Circulator -1
PTCL-1
Design-1
OVJ: DN600
Q 0.88 W/m
Q 4.33 W/m
PTCL-2
Process pipes CC, CD, C, CR ~ 4.5 K
Process Pipe E, F ~ 80K
Design-1
OVJ: DN600
Q 0.88 W/m
Q 4.33 W/m
Design-2
Q 0.98 W/m
Q 3.73 W/m

25. Result of risk assessment
CL – Cryoline
CD – Cryo-distribution
Risk Category – Technology, Interface, Safety, Site, Quality, Regulatory, Contamination

26. ZONE
NO. OF RISKS 1 10 2 9 3 5
Xfmea®, ReliaSoft
INITIAL SYSTEM CRITICALITY
ZONE
NO. OF RISKS 1 4 2 11 3 9
COLD Circulating Pumps
(i) step-1: component level test (ii) step-2: prototype test of CCP in operating conditions, considering the overall cost factors.
ZONE
NO. OF RISKS 1 - 2 15 3 9

27. Roadmap
Cryodistribution system: Highly process oriented (Industrial cold box approach)
Cryolines & Warmlines: Mechanical integrity (Supply Chain
management)

28. Include feedback in respective design Two Prototype test
Roadmap (Cryoline)
Include feedback in respective design
Two Prototype test
Pre-Qualification
Manufacturing of Prototype cryolines
Award of contract
Issue of tender to successful bidders
Design of prototype cryolines (Two) by pre-qualified bidders and acceptance
Warmlines – Public Tender
Process pipes CC, CD, C, CR ~ 4.5 K
Process Pipe E, F ~ 80K
Design-1
OVJ: DN600
Q 0.88 W/m
Q 4.33 W/m
Design-2
Q 0.98 W/m
Q 3.73 W/m

29. Roadmap (Cryo-distribution)
Include feedback in respective design
Two Prototype test
Award of contract
Pre-Qualification
Two Prototype design
Issue of tender to successful bidders
Award of contract to two industries
Issue of tender to internationally well known bidders
Cold Circulators
Process pipes CC, CD, C, CR ~ 4.5 K
Process Pipe E, F ~ 80K
Design-1
OVJ: DN600
Q 0.88 W/m
Q 4.33 W/m
Design-2
Q 0.98 W/m
Q 3.73 W/m

30. Present Status

31. Cryolines

32. Prototype Cryoline (Consortium of INOX India Limited & A S Scientific)
“Straight” section
“T” section
“Z” section
Elbow section

33. Three sections of PTCL

34. Vacuum 4 X 10-7 without active pumping
Prototype cryolines made by M/s INOX India Limited & A S Scientific has been cold tested at 4.5 K /7-8 K
The thermal stresses are with in limits
The PTCL withstood the Break of Insulation Vacuum (No damage occurred – Safety test)
Vacuum maintained within specified limit (order of 10-7 mbar) without active pumping
The Plan
Experimental Results
Vacuum 4 X 10-7 without active pumping
Vacuum 4 X 10-7 without active pumping
Measurement
of steady state heat load
Time

35. Prototype Cryoline (ALAT)
Manufacturing is near completion

36. Cryo-distribution

37. CTCB – Preliminary design completed
Magnet and Cryo-pump Cryoline
CL 1, 2, 3
Total Weight is approximately 20 Tons

38. Cold Circulating Pumps: Test ACB Highlights
TACB as manufactured
3D Model

39. Installation at JAEA

40. Qualification and Performance test for TWO cold circulators completed
Simulation of ITER magnet (TF, PF & CC, CS) and Cryo-pump scenarios
9-O-4B-4
- All operating parameters of ITER are satisfied
- The performance test has been conclusive
- The qualified circulator will be used for the cryo-distribution system

41. Cumulative Progress – Cryodistribution system
February

42. Cumulative progress – Group X Cryoline

43. Cumulative Progress- Group Y

44. Conclusions

45. The ITER Cryodistribution and Cryoline project of INDA is dynamically progressing to satisfy the overall ITER project objectives.
After overcoming the initial teething problems both at technical and project management, the project took off, on the pathway of the strategy decided after the risk analysis.
Interfaces remain as an issue for specific cases; however, it is being addressed on case to case basis, when the need arises.
The project has completed an overall cumulative progress of approximately
29 % for Y-group of cryolines,
22 % for X-group of cryolines
14 % for Cryodistribution system in February 2016
as per INDA contractual schedule

46. Acknowledgements
ITER-India, especially colleagues from the procurement and finance departments with specific gratitude to the Project Director, ITER-India and Director, IPR.
Industrial partners,
Consortium of M/s INOX India Limited & A. S. Scientific,
M/s Air Liquide Advanced Technologies,
M/s Linde Kryotechnik,
M/s DeMaCo,
M/s Barber Nichols Inc.,
M/s IHI,
M/s Taiyo Nippon Sanso
and JAEA

47. Welcome to the world of Fusion
Thanks
&
Welcome to the world of Fusion