ASSEMBLY INSTALLATION STUDIES FOR THE ITER CRYOLINE SYSTEM

Transcription

1 ASSEMBLY INSTALLATION STUDIES FOR THE ITER CRYOLINE SYSTEM S Badgujar 1, N Shah 2, A Forgeas 1, N Navion-Maillot 1, E Monneret 1, D Grillot 1, L. Benkheira 1 and B Sarkar 2 1 ITER Organization, Route de Vinon-sur-Verdon, CS , St. Paul Lez Durance Cedex, France 2 ITER-India, Institute for Plasma Research, Bhat, Gandhinagar , India The views and opinions expressed herein do not necessarily reflect those of the ITER Organization Page 1

2 OUTLINE INTRODUCTION THE CRYOLINE SYSTEM BRIEF SPECIFICATION INSTALLTION PLAN CONFIGURATION, TRANSPORTATION SEQUENCE, ASSEMBLY SITE WORK STATISTICS SCHEDULE INSTALLTION CHALLENGES AND RISKS CONCLUSION Page 2

3 Magnets: PF Magnets: CS ITER CRYOGENIC SYSTEM Magnets: TF Magnets: STR Magnets: C Leads Cryo Pumps Thermal Shields K 3 Plants Avg K 300K to 80K: LN2 PLANTS (1,2) LHe 1 LHe 2 LHe 3 80K: Ghe Loops (1,2) EU-DA IO IN-DA IN-DA Cryoplants 4K: LHe Distribution 80K: GHe Distribution Cryodistribution 8 boxes CryoLines ~ 5 km 4K USERS 80K USERS Page 3

4 LAYOUT ITER CRYOGENIC SYSTEM Page 4

5 THE CRYOLINE SYSTEM IN TOKAMAK BUILDING South West Shaft L3 level From Plant bridge North West Shaft Y B1 level B2M level X X Y+W B2 level W TOKAMAK BUILDING Page 5

6 TECHNICAL SPECIFICATION OF CLs and WLs Specifications Cryolines (CLs) Warm lines (WLs) No. of process pipes (PP) 1 to 7 1 Length ~ 5000 m ~ 6000 m No, Type of lines 21 multi, 16 single PP 55 single process Outer jacket (OVJ) Size DN 100 to DN 1000 DN 50 to DN 1600 Segments Straight, Tee, Elbow, Z Straight, Tee, Elbow, Z Temperature levels 4.5 K (3.8 K), 50 K, 80 K, 300 K 300 K, 423 K, 473 K Fluids Helium(He), Nitrogen(N2) Helium, Nitrogen, He+N2+Oil Pressure of process fluid Maximum 21 bar Maximum 42 bar Materials of PP/OVJ ,14435 (304L,316L) 304/304L (or eq. EN) Quality Classes (QC) QC 1, QC 2 QC 2, QC 3, QC 4 Seismic Classes (SC) SC1 (SF), SC1 (S), SC2, NSC SC2, NSC Safety Classes SIC-II, SR, Non-SIC SR, Non-SIC DN 500 OVJ most common among complex cryolines (X) Biggest DN of the process pipe DN300 C/s of 342CM0 Page 6

7 INSTALLATION PLAN 3 different buildings B50x, Plant bridge, Tokamak building Area by area installation in building [Parallel installation] Given area Construction work package [1-2-3 CLs] Modular approach for installation of the CLs Straight Tee Elbow [90 ] Elbow [>90 ] Step Max. dimensions as per site constraints ~ 10 m Max weight of spool ~ 10 ton C1 C2 (Cryolines Group-X) Design, Mgf, Supply Installation* (Cryolines Group-Y) Design, Mgf, Supply, installation (Warmlines Group- W) Design, Mgf, Supply, installation Installation contractor - 1 Installation contractor -2 Page 7

8 SITE WORK FLOW Upstream ACB Downstream ACB WITH TEST END CAPS Page 8

9 ARRIVAL ON SITE AND TRANSPORTATION ROAD FOR DELIVERY STORAGE ROADS FOR PRE-ASSEMBLY WORKSHOPS ROADS FOR INSTALLATION NORTH Spools inside container on truck Delivery Packaging: Closed containers (~ISO 40 feet) Approximate estimation based on present schedule and scope 300 nos [X,Y,W] ITER incoming inspection Documentation, Pressure gauge, Accelerometer Page 9

10 NORTH ENTRY TO TOKAMAK BUILDING B2 B11 Tokamak Bldg. B14 Tritium Bldg. Mobile crane near the platform in seismic pit 5.3 m H x 6.6 m L 5.3 m H x 6.6 m L 12 m L x 9 W x 3.3 high Page 10

11 MOVEMENT IN TOKAMAK BUILDING Opening at B2 L3 B2 SOUTH-WEST Opening at L3 ALL BUILDING OPENINGS, CONSTRAINTS AND LIMITATIONS HAVE BEEN STUDIED POSSIBLE TO MANOEUVRE IN B11- AT ALL THE LEVELS: B2,B2M,B1 and L3 Page 11

12 SEQUENCE IN TOKAMAK BUILDING From farthest point from the entrance of spools to nearest point From top (close to ceiling) to bottom (floor) From inner wall (centre of Tokamak) to outer wall (external wall of tokamak building) From bigger to smaller line NORTH Material movement Installation progress B D Point of entry at B2 E WEST EAST Section S-S A S S SOUTH C Area in the level Seque nce No. Prefered installation sequence among the lines [CLs-WLs] Building Level Tokamak B2 South 1 342CTS - TF cryoline 2 342CPL - PF cryoline 3 342SQL - Quench line 4 342WP0 - Purge line WCL - Current lead line 6 342WDH - He distribution line 7 342SR0 - Relief line Page 12

13 Outer Wall Inner Wall SEQUENCE IN TOKAMAK BUILDING Installation starts once the building are ready for equipment (RFE) CLs first equipment to be installed in most of the areas in B11 Other systems will follow the installation after 4 weeks General principal Specific situations! Ceiling B D Slab A C B2M QUADRANT B2 Page 13

14 SPOOL INTERCONNECTIONS Internal pipe welds TEST Shield Outer jacket welds Global TEST B2M AMONG CRYOLINE SPOOLS A Tests on PP Install MLI on PP Shield assembly and MLI WITH INTERFACE EQUIPMENTS B CVB B1 TYPE I WITH BELLOW TYPE II - WITHOUT Page 14

15 ASSEMBLY OF THE LINE Finish Joining of spools one by one to form the complete cryoline Start INSTALLATION TIME FOR ONE INTER-CONNECTION ~24 hrs DN 500 lines ~36 hrs for DN lines ~48 hrs DN 1000 line Page 15

16 Process pipes WELDS MAJOR IN PROCESS INSEPCTION Radiography All weld joints on PP during assembly and installation Visual test All weld joints on PP during assembly and installation VT RT Visual QC VT RT LT LN % 100% 100% * 2 100% 20% 20% * 3 100% 10% 10% NA LT Radiography LN2 Helium leak tightness test Liquid nitrogen thermal shock test - *SAMPLE Helium leak testing All weld joints assembly and installation at room temperature Overall leak testing at warm and cold (for complete line) Thermal Shock test Sample welds during assembly and installation Pressure test All independent sub-assemblies (e.g. one complete cryoline) at room temperature Cold test (for cryolines only) Overall performance at cold temperature (thermal performance measurement, leak test, checking for cold spot on OVJ) Page 16

17 SITE WORK STATISTICS Summary of the spools for all ITER CLs and WLs Building/Area Area/level in building CLs WLs Total L NW Shaft (L2, L1) Tokamak SW Shaft (L2, L1) Building (B11) B B2 / B2M Plant Bridge Cryoplant building/area 51 (Compressor building) (Cryoplant building) Area Total WELDS >11000 ~7000 CLs ~1300 WLs ~3000 Supports Summary estimated welding length (meter) CLs + WLs + Building/Area Total supports supports Tokamak Building Plant Bridge Cryoplant building/area Total Summary of estimated test length (meter) Building/Area CLs WLs Total PP OVJ Tokamak Building Plant Bridge Cryoplant building/area 900 Total Page 17

18 SITE WORK STATISTICS - TIME Level No. of No. of interfa element ce to s to be be connect connec ed ted Total Total intercon nections 1 working day per intercon nection 1 shift installati on [1 working day=3 shifts=3d ays] 10 days overlap, 10 days test 22 working days in 1 month Factor used for single and multi normalizat ion Days Days Days Months Months Years Tokamak Building L NW Shaft SW 0 15 Shaft B B2M B ~3/4 teams working in parallel in Tokamak building to meet the schedule Night shift for RT Second shift (if needed) to accelerate the installation Page 18

19 1 Typical Assembly & Installation Team Welder(s) (manual welds) stainless steel/carbon steel 2 Welders / Operator(s) (orbital welding machine) 3 Fitter(s) Rigger(s)/ Helper(s) transport of pipe 4 spools/supports, Material handling 5 Technician - MLI 6 Technician NDT [RT, LT, VT, LN2 shock] 7 Engineer(s) technical/construction 8 Inspector(s)/Controller(s) - Inspections agencies 9 QA Officer 10 Safety Officer 11 Site in-charge 12 Office Support Staff RESOURCES 3-4 team ~6-8 person per team per location >30 people on site during the peak installation period To be adapted: Based on the site requirements/constraints Contractor execution plan Page 19

20 TOOLS Portable small crane Forklift-stacker Arrangement from EP Mini spider crane A type cranes Platform + specific forklift Use of Embedded plates for fixation of Lifting equipment + Chain pulley block Page 20

21 Bldg 51.1 C&W lines B51 upper Trench W C&W lines B52 Fire Wall Bldg 51.2 CRYOPLANT INSTALLATION SUMMARY Area 53: Building 51: Bldg 51.1 Building 51: Bldg 51.2 Building 51: Bldg 51.3 Building 52: Name PBS Date Name PBS Date Name PBS Date Name PBS Name PBS Date Name PBS Date Name PBS Date Name PBS Date 1 C&W lines Area 53 Part Apr-17 9 Test heater 34.1W.E k CB L.B1 25 LHe tanks valve box 34.1S.HB 1 He CS (CPs) 34.4H.C2 21-Apr He CS 1 (CPs) 34.4H.C1 21-Apr C&W lines B51 Fire Wall Apr-17 1 C&W lines B52 Fire Wall Apr-17 2 GHe Storage 34.1S.HG 10 GAN Purifier 34.1G.B k CB L.B K heaters 34.1W.E 2 He CS (CPs) 34.4H.C3 22 Cryolines 80K Junction 34.2S.L0 32 Gasbag Storage 34.1S.B0 2 He Cold box H.B1 3 GN2 Storage 34.1S.NG 11 Air Compressor 34.1G.C0 19 He Purifaction 34.1P.B0 27 C&W lines Area 53 Final Cnt He CS 2 (ORS) 34.4H.C1 23 He CS 1 (ORS) 34.4H.C1 33 He CS 1 (FORS) 34.4H.C1 3 He Cold box H.B2 4 N2 CB N.B1 12 Liquid disposal Atmo. He Heater 34.1W.AH 4 He CS 3 (ORS) 34.4H.C k CS L.C2 34 He CS 2 (FORS) 34.4H.C2 4 He Cold box H.B3 5 C&W lines Area 53 Part LN2 Storage Warm Skid 34.1S.NL 21 C&W lines Area 53 Part IN-DA 5 N2 CS N.C k CS L.C1 35 Dryers 34.1P.D1 5 Test Cryostat 34.4H.T0 6 N2 CB N.B2 14 LN2 Storage Vaporizer 34.1W.AN 22 Quench Tank 34.1S.Q0 IN-DA 6 N2 CS N.C2 26 Helium Recovery System 34.1P.R0 36 He CS 3 (FORS) 34.4H.C3 6 CTCB Y 7 LN2 Storage 34.1S.NL 15 Casing Pump 34.1S.NL 23 LHe storage 34.1S.HL F4E 7 C&W lines B51 upper Trench W Leak treatment 34.1P.T0 37 C&W lines B51 upper Trench N/S C&W lines B52 Final Cnt Air Separation Column 34.1G.D0 16 C&W lines Area 53 Part Quench tanks cold box 34.1S.QB IO 28 C&W lines B51 upper Trench N C&W lines B52 CTCB Area C&W lines Area Part C&W lines Area 53 Part 1 5 C&W lines Area 53 Part 2 16 C&W lines Area 53 Part C&W lines Area CRYOLINES AND WARM LINES IN B50s X Y+W C&W lines B51 Fire Wall Bldg 51.3 Bldg 52 Area 53: Name PBS Date Name PBS Date Name PBS Date Name PBS Date 1 C&W lines Area 53 Part Building 1 51: Bldg Apr-17 9 Test heater Building 51: 34.1W.E0 Bldg k CB 1 Building 34.1L.B1 51: Bldg LHe tanks valve box Building 34.1S.HB 52: 2 GHe Storage Name 34.1S.HG PBS Date 10 GAN Purifier Name 34.1G.B0 PBS Date18 80k CB 2 Name 34.1L.B2 PBS Date K heaters Name34.1W.E0 PBS 3 GN2 Storage 1 He CS 2 (CPs) 34.1S.NG 34.4H.C2 21-Apr Air Compressor 21 He CS 1 (CPs) 34.1G.C0 34.4H.C1 21-Apr He Purifaction 31 C&W lines B51 Fire Wall 34.1P.B Apr C&W lines 1Area C&W 53 lines Final B52 CntFire Wall N2 CB 12 He CS 3 (CPs) 34.1N.B1 34.4H.C3 12 Liquid 22 disposal Cryolines 80K Junction S.L0 20 Atmo. He 32Heater Gasbag Storage 34.1W.AH 34.1S.B0 2 He Cold box H.B1 5 C&W lines 3 He Area CS 253 (ORS) Part H.C1 13 LN2 Storage 23 He Warm CS 1 (ORS) Skid 34.1S.NL 34.4H.C1 21 C&W lines 33 Area He CS 531 Part (FORS) H.C1 IN-DA 3 He Cold box H.B2 6 N2 CB 24 He CS 3 (ORS) 34.1N.B2 34.4H.C1 14 LN2 Storage 24 80k Vaporizer CS W.AN 34.1L.C2 22 Quench 34 Tank He CS 2 (FORS) 34.1S.Q0 34.4H.C2 IN-DA 4 He Cold box H.B3 7 LN2 Storage 5 N2 CS S.NL 34.1N.C1 15 Casing 25 Pump 80k CS S.NL 34.1L.C1 23 LHe storage 35 Dryers 34.1S.HL 34.1P.D1 F4E 5 Test Cryostat 34.4H.T0 8 Air Separation 6 N2 CS Column G.D0 34.1N.C2 16 C&W lines 26 Helium Area 53 Recovery Part 3 System P.R0 24 Quench 36 tanks He cold CS 3 box (FORS) 34.1S.QB 34.4H.C3 IO 6 CTCB Y 7 C&W lines B51 upper Trench W Leak treatment 34.1P.T0 37 C&W lines B51 upper Trench N/S C&W lines B52 Final Cnt C&W lines B51 upper Trench N C&W lines B52 CTCB Page 21

22 SCHEDULE Line PBS Connections O N D J F M A MY J JL A S O N D J F M A MY J JL A S O N D T&C North 342CHN 11 T&C South 342CHS 10 TF South 342CTS 17 T&C South 342CHS 1 T&C North 342CHN 1 TF North 342CTN 21 Quench Lower 342CQL 47 PF Lower 342CPL 16 Structure Lower 342CSL 3 CS Lower 342CCL 12 Relief Line 342WR0 42 T&C North 342CHN 4 T&C South 342CHS 4 Top down approach to meet sub-system commissioning Installation RFE - Building is ready to receive the equipment Reasonable duration for each activity detailed schedule for one CL Used mainly to assign the duration for installation of certain length of CL with certain number of interconnections Detailed sequence with co-activities INSTALLATION TIME (ONE INTER-CONNECTION) ~24 hrs DN 500 TF,PF,T&C ~18 hrs DAY STR ~12 hrs QL, RELIEF ~ 12 hrs for spool transfer, position, alignment Constant Avg. Time Vicinity dependent! Major Assumption: Availability of installation window without any major interruptions Site authorizations are given within reasonable time 10% rework Not considered - Complete failure of CL during testing phase that follows the site installation Page 22

23 SUMMARY SCHEDULE PA, CDR Preliminary Design 1 st PTCL (prototype cryoline) test completed 2 nd PTCL test completion (planned) Final Design Fabrication Delivery Installation and connection to clients Connection to feeders at L3 Preliminary acceptance, COLD tests with end caps Cryoline ready to be connected to clients, sub-system commissioning Final acceptance after final connection to clients Final integrated pressure and leak test B2 L3 All Cryolines ready for integrated commissioning 1 st Cryo-plant ready SAT ACB CP ready Page 23

24 CHALLENGES AND RISKS Difficult installation and maintenance due to space limitation Sequencing among lines and with other systems in buildings More than one industrial partner for installation of CLs Co-activity, Starts Stops during installation Very limited in-service inspection and repair during operation - Detailed sequence and priority definition Stringent quality and testing requirements to avoid intervention in situ RISKS Non-availability or delayed availability of storage area / pre-assembly Non-availability of allotted timeslot for material movement/installation or radiography Slow installation at start due to learning curve and site adaptation Failure of welding during testing (non-destructive test or pressure test) Under estimation of installation process, complicacies and duration Civil work and equipment position tolerance more than considered in design Priority change due to the project decisions Page 24

25 CONCLUSION Conceptual assembly and installation plan respecting ITER CMS has been developed with detailed sequence Modular approach has been foreseen with sequential deliveries and continuous supply chain management to minimize on site inventory Site to suit interconnections with interface equipment planned Parallel installation foreseen with multiple teams at different areas Further detailed installation plan will be worked out with industrial partners Skilled teams from industries will execute the work as per work instruction, strict inspection-control and oversight of technical teams form IO-CT/IN DA Overall success for installation will depend on efficient co-ordination among all the concerned actors at ITER site Page 25

26 FEB 2016 THANK YOU FOR YOUR ATTENTION TOKAMAK BUILDING B2 B2M B52 CRYOPLANT BUILDING B51 Authors would like to thank the colleagues from ITER Organization in Cadarache, ITER-India in Gandhinagar as well as industrial partners for their contribution to ITER cryolines project Page 26

27 Extra slides Page 27

28 Two main lines - Magnets - Cryopumps COLD TEST Q Pipe = m(h 2 -H 1 ) Q Loop = m(h 4 -H 1 ) Lines from ACBs to the clients - Magnets (TF, PF, CS, STR) - Cryopumps WITH DEDICATED TEST CAPS Q Pipe = m(h 6 -H 1 ) Q Loop = m(h 8 -H 1 ) Page 28