Cryogenics Simulation with

E
EcosimPro
i P and d CRYOLIB

Empresarios Agrupados (EA)

Magallanes 3, Madrid 28015 (Spain)
Phone: 34.91.3098142
EA web : www.empre.es
EcosimPro web: www.ecosimpro.com

Cryogenics Simulation with EcosimPro and CRYOLIB -1-

 Why Cryogenics Simulation ?

• Cryogenic plants are large scale systems with non-linear behaviors

and large operating ranges
– 1.9
19K K-300
300 K & 14 mbar
mbar-20
20 bar

• These systems are unique

– The
Th are designed
d i d based
b d on steady
t d calculations
l l ti for
f the
th nominal
i l
operation. However, in order to design the control system of
these plants is necessary having information about the dynamic
of the system.

• Dynamic simulation of cryogenic plants allows control engineers to:

– Test control systems off-line in advance: control strategies,
strategies
starting/ending sequences, check supervision layers and more
– Optimize the control strategies without disturbing operation
– Train operators on regular operation of the plant
plant, dealing with
emergency situations, etc
– Analyse the dynamic of the plant working together in order to
optimize
opt e itt

Cryogenics Simulation with EcosimPro and CRYOLIB -2-

 CRYOLIB Library
CRYOLIB library is an EcosimPro library resulting of the collaboration between
CERN and EA based on the modelling and simulation works performed during
last years at CERN.

The library allows users to model and simulate dynamically small and large-scale
cryogenic plants
plants.

The library is being currently used by Nuclear Fundamental Research Labs and
C
Cryogenicsi iindustry.
d t
Aplications

CONTROL OPTIMIZATION - Allows to improve control strategies in terms of

stability, reability and robustness

VIRTUAL COMMISIONING Verification of control programs before implementation

on the real plant

REAL TIME SIMULATOR -To simulate failure scenarios and prevent human
reactions in case of failure
- Improves safety in operation

DESIGN - Design of cryogenic plants

Cryogenics Simulation with EcosimPro and CRYOLIB -3-

 Cryogenic Modelling and Simulation

CRYOLIB includes:

- CRYOLIB library: a library for cryogenic components : pipes, pumps,

volumes, tanks, compressors, heat exchangers, turbines…

- FLUID_PROP library: a specific library providing a standard

properties database for different fluids

- PLC library: a specific library providing control components

compatible with UNICOS (UNified COntrol System), methodology
developed at CERN to design and build industrial based control
systems for CERN installations

Cryogenics Simulation with EcosimPro and CRYOLIB -4-

 Characteristics of CRYOLIB

Available working fluids: helium, nitrogen,

CO2, oxygen, argon.

Main cryogenic components :

– Valves
– Heat exchangers
– Turbines
T bi
– Pipes
– Phase separators
– Tanks
– Warm Screw Compressors
– Cold compressors
– Heaters…

The fluid phase is automatically calculated in

the thermodynamic functions

Reverse flow, inertia and high speed

phenomena are considered in pipes, volumes
and junctions (the pipes incorporating a 1-D
spatial discretization into n (input data)
volumes)
ol mes)

Cryogenics Simulation with EcosimPro and CRYOLIB -5-

 CRYOLIB Palette of Components

Cryogenics Simulation with EcosimPro and CRYOLIB -6-

 PLC Library

The PLC library provides a set of components related with PLCs that are
compatible with the UNICOS (UNified Industrial Control System), such as:

• Components “ANALOG” to drive analog actuators

• Components “PIDFF” for PID control loops

• AI/DI/AO/DO components to exchange signals with an

eventual future external control systems

• Other blocks to perform control tasks.

Cryogenics Simulation with EcosimPro and CRYOLIB -7-

 Performed Industrial Application Cases_1

• The CMS cryoplant at CERN including:

– The Warm Compression Station
– The
Th Cold
C ld B
Box : 1
1.5
5 kW @ 4.5
45K
– The Coil Cryogenic System with the CMS magnet

• The 1.8K refrigeration unit for the LHC at CERN including:

– The Warm Compression Station
– The Cold Compressor Box : 2.4 kW @1.8 K
– The Cryogenic Distribution Line (Header B)

• The Warm compression

p station for the LHC at CERN

• The CERN central Helium liquefier at CERN

– Compressor + TCF50 Liquefier 60 LHe/h @ 4.5K

• Refrigerator of Bat 163 at CERN

– Compressor + TCF50 400W @ 4 4.5
5K

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Performed Industrial Application Cases_2

• ITER helium cryogenic system:

– The Warm Compression Station
– The Cold Box : 2.5 kW @ 4.5 K
– Distribution system: the transfer lines between the coldbox and
the Tokamak building
building, a cold compressor box and 4 auxiliary
coldboxes.

• HELIOS experimental supercritical helium loop at CEA,

CEA France
– Scaled down circuit of the CS magnet cooling loop of the JT60-
SA Tokamak.

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 Simulating CMS Cryoplant, CERN_1
The refrigerator of the CMS (Compact Muon Solenoid) particle detector
maintains the superconductor magnet of the CMS detector to 4.5K. Its
compressor station is composed by two screw compressors and the
coldbox is formed by 3 turbines, 6 heat exchangers and a Joule-
Thomson valve that perform a Claude Cycle. The compressor station
can p
provide a massflow of 200g/s
g of helium at 18 bar. The coldbox cools
the helium from 300K to 4.5K.
The EcosimPro model does not take into account the distribution system
off the
th CMS,
CMS thi
this partt is
i defined
d fi d with
ith boundaries
b d i in i the
th model.
d l

Cryogenics Simulation with EcosimPro and CRYOLIB - 10 -

Simulating CMS Cryoplant, CERN_2

Compressor
station of
CMS
cryoplant

Cryogenics Simulation with EcosimPro and CRYOLIB - 11 -

 Simulating CMS Cryoplant, CERN_3

Coldbox of
CMS cryoplant

Cryogenics Simulation with EcosimPro and CRYOLIB - 12 -

 Simulating of CMS Cryoplant, CERN_4

The simulation performs a complete cooldown of the system from 300K to

4.5K. The compression station starts to work with the activation of the
compressors and their control system. At 700s the compression station is
connected with the coldbox, firstly it is connected the low pressure line
and then the high pressure line. After that, turbines are activated and the
cooling
g process
p begins
g

Massflow in T1 and T2 Evolution of temperature at the outlet of the HX6

Activation of T3

Regulation of speed in T1 Massflow dewar

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Simulating the Refrigerator 1.8kW/4.5 K, LHC, CERN_1

The model is composed by a compressor station with two stages, the

first stage is composed by 3 screw compressors in parallel that
compress helium from 1.01 bar to 4 bar. The second stage
compresses it from 4 bar to 15 bar. The by-pass valves present
between the high pressure line (HP),
(HP) the medium pressure line (MP)
and the low pressure line (LP) allow the regulation of pressure in the
system. The dewar between HP and LP allows bleeding from HP and
also
a so injecting
ject g helium
e u in tthe
e LP line
e when
e necessary.
ecessa y

The LHC coldbox at 4.5K is composed by 10 heat exchangers

working in countercurrent.
countercurrent There are 10 turbines distributed as
follows: the first 7 work between HP line and MP line divided in three
groups, turbines 8 and 9 work between the HP line and the LP line
while the last one is connected in the HP line before the Joule
Joule-
Thomson valve.

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Simulating the Refrigerator 1.8kW/4.5 K, LHC, CERN_2

Cryogenics Simulation with EcosimPro and CRYOLIB - 15 -

Simulating the Refrigerator 1.8kW/4.5 K, LHC, CERN_3

Cryogenics Simulation with EcosimPro and CRYOLIB - 16 -

 Simulating the Refrigerator 1.8kW/4.5 K, LHC, CERN_4

The complexity of the plant

makes simulation very
important it allows engineers
important,
to have the whole picture of
the system and perform off-
line tests.
tests It diminishes stop
times and gives engineers
the possibility of analysing
transient aspects due to
perturbation, the
performance of the system
duringg starting/ending
g g
sequences, etc.

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 Building a Simulator for Operator Training_1

C++ code is automatically generated with EcosimPro. This allows the

user to connect the model with external systems.

Models can be exported as a black box (deck) or connected directly

With PLCs or SCADA systems

•Operators Supervision Layer

OPC
ocol TCPIP / O

•SCADA Servers
etwork & proto

•PLC simulators Simulated

Control layer
•Ethernet Ne

•Cryogenic Process Simulator Simulated Interface for operators

Field layer
Process
model
d l on
EcosimPro

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 Building a Simulator for Operator Training_2

Simulator Features (*):

• Run as fast as possible or in Real-Time

• Change boundary
bo ndar conditions during
d ring simulation
sim lation

• Change integration step size during simulation

• Freeze simulation

• Save current state and restore it later

• Make reports of the simulations with all simulated variables

(readable on MATLAB) for post-process analysis

* For more information see 1.3.2 PROCOS

Cryogenics Simulation with EcosimPro and CRYOLIB - 19 -