Cryogenic Refrigeration System Revamp at the Paul Scherrer

Cryogenic Refrigeration System Revamp at the Paul Scherrer Institute. A Split Scope Project. Andreas Rüegge Christian Geiselhart Beijing, 2018 June 7 th

Contents. 1. Company profile 2. Customer services 3. History 4. Revamp Project at Paul Scherrer Institute Collaborate. Innovate. Deliver. 5. Summary 11/25/2020 2

Linde Kryotechnik. Company Profile. Brief introduction — Independent company and center of excellence within The Linde Group for low temperature cryogenic equipment (helium and hydrogen liquefaction & refrigeration plants with auxiliaries) — Established in 1992 to combine the activities of Sulzer and Linde in the field of cryogenics — Linde Kryotechnik AG is a member of the Engineering Division of the Linde Group situated in Munich — Approx. 90 specialized employees — 20 min from Airport Zürich 11/25/2020 3

Linde Kryotechnik. Customer Service Organisation. Customer Services After Sales Field Services Spare parts Technical support Maintenance contracts & Revamps Commissioning & Start-Up Plant Operation China India USA ROW 11/25/2020 4

Linde Kryotechnik. Customer Services Scope. Maintenance and remote support Customer trainings Operations → Maintenance contract → Operator training in Pfungen → Preventive maintenance → On-site training Operation of your entire cryogenic infrastructure → Inspection → Remote support Modifications , revamps and engineering → Inspection, Installation and Maintenance Spare parts and components → Spare parts (availability for ten years guaranteed) → Multi component detector (MCD) → Compressor replacements → Cryogenic adsorber → Turbine modifications → Remote monitoring and control system (RMCS) → Process fine-tuning for performance gains → Control system retrofits → RMCS and PC upgrades → Helium recovery retrofits → Efficiency and performance upgrades → Process design → Software optimisation → Design of components 11/25/2020 → Plant operation according to customer requirements → Advice for spare parts management and optimising plant operation → Recruitment and training of on-site personnel Studies → De-Bottlenecking → Performance increase → Engineering studies Troubleshooting and start-up → Repairs → (Re-) Commissioning 5

Linde Kryotechnik. Customer Services Scope for PSI. Maintenance and remote support Customer trainings Operations → Maintenance contract → Operator training in Pfungen → Preventive maintenance → On-site training Operation of your entire cryogenic infrastructure → Inspection → Remote support Modifications, revamps and engineering → Inspection, Installation and Maintenance Spare parts and components → Spare parts (availability for ten years guaranteed) → Multi component detector (MCD) → Compressor replacements → Cryogenic adsorber → Turbine modifications → Remote monitoring and control system (RMCS) → Process fine-tuning for performance gains → Control system retrofits → RMCS and PC upgrades → Helium recovery retrofits → Efficiency and performance upgrades → Process design → Software optimisation → Design of components 11/25/2020 → Plant operation according to customer requirements → Advice for spare parts management and optimising plant operation → Recruitment and training of on-site personnel Studies → De-Bottlenecking → Performance increase → Engineering studies Troubleshooting and start-up → Repairs → (Re-) Commissioning 6

Revamp Project. History. Project Procedure 2011 First study and proposal, but not realized at this time 2015 Due to federal funding of the Swiss government (Prokilowatt), PSI issued an RFI on basis of the 2011 study 2016 Issue of specification and clarification of scope of supply 2017 April conclusion of contract December 2018 11/25/2020 January delivery of equipment Start of construction and piping work May Commissioning, Start-up June Performance tests (pending) 7

Revamp Project. Motivators and Goals. Motivators - Components ageing - Laborious and costly compressor maintenance - High energy consumption - Compressor vibrations propagation - End of product life-cycle of the local HMI solution Main goals — Lifetime extension — Improved overall energy balance — Reduced maintenance cost , time, complexity Other requirements - Cooling water tower to be removed; air cooled machines shall be used instead 11/25/2020 8

Revamp Project. The Challenge. The Paul Scherrer Institut (PSI) launched a revamp project for compressor stations belonging to the cryogenic refrigeration plants: — KA 1 3000 W@20 K Sulzer TCF 50 — KA 4 990 W@4. 5 K Sulzer TCF 200 Each plant is equipped with a dry piston compressor — KA 1 Sulzer K 160 - A 2 — KA 4 Sulzer K 4 K 165 -3 C Piston compressor Each plant is controlled by a Siemens S 7 PLC with a local HMI with interface to EPICS (this upgrade was done in 2005 at KA 1 and in 2006 at KA 4) Control unit 11/25/2020 9

Revamp Project. The Scope Split. Project management Paul Scherrer Institut Linde Kryotechnik AG Overall Project Management Contractor project management P&ID drafting HAZOP Basic engineering System Integration Component specification Engineering lists Re-drafting of wiring diagrams in ELCAD Detail engineering 3 D plant design Design Oil removal / Gas management skids Procurement and Manufacturing Rebuild of control cabinets Procurement of equipment and assemblies Modification of EPICS DB and GUI Modification of PLC software Implementation Site activities As-built documentation 11/25/2020 Programming of the local HMI in TIA portal Construction and piping Construction supervision Commissioning each party for its scope 10

Revamp Project. The Scope Split. Project management Paul Scherrer Institut Linde Kryotechnik AG Overall Project Management Contractor project management P&ID drafting HAZOP Basic engineering System Integration Component specification Engineering lists Re-drafting of wiring diagrams in ELCAD Detail engineering 3 D plant design Design Oil removal / Gas management skids Procurement and Manufacturing Rebuild of control cabinets Procurement of equipment and assemblies Modification of EPICS DB and GUI Modification of PLC software Implementation Site activities As-built documentation 11/25/2020 Programming of the local HMI in TIA portal Construction and piping Construction supervision Commissioning each party for its scope 11

Revamp Project. The Challenge. Original Compressor System. Cooling tower Gas cooler Gas Management System 2 nd stage Gas cooler HP to Coldbox 1 st stage He Buffer Tank LP from Coldbox 11/25/2020 12

Revamp Project. The Solution. New compressor system. Gas cooler Fine Oil Removal System Bulk Oil Separator Heat Recovery HP to Coldbox Oil cooler He Buffer Tank Gas Management System LP from Coldbox Oil Injected Screw Compressor Package 11/25/2020 Oil Removal and Gas Management Skid 13

Revamp Project. The Scope Split. Project management Paul Scherrer Institut Linde Kryotechnik AG Overall Project Management Contractor project management P&ID drafting HAZOP Basic engineering System Integration Component specification Engineering lists Re-drafting of wiring diagrams in ELCAD Detail engineering 3 D plant design Design Oil removal / Gas management skids Procurement and Manufacturing Rebuild of control cabinets Procurement of equipment and assemblies Modification of EPICS DB and GUI Modification of PLC software Implementation Site activities As-built documentation 11/25/2020 Programming of the local HMI in TIA portal Construction and piping Construction supervision Commissioning each party for its scope 14

Chosen Equipment. Recycle Compressors. Chosen compressor model : KA 1 1 x Kaeser ESD 442 KA 4 2 x Kaeser ESD 442 Lube: Breox B 35 (used in all of PSI’s compressors) Features of the ESD 442 - Proven: Used in multiple Helium applications worldwide - IE 4 motor (highest efficiency class) - Air cooled - Heat recovery - Fully automatic machine control - Common maintenance scheme for all compressors 11/25/2020 15

Chosen Equipment. ORS and GMP. Fine oil removal and gas management system. Although every conversion project is very specific, standard components are preferred. As a result, costs are low at the purchase and in the subsequent maintenance For KA 1 the design of a standard HAD 30 skid from the current L-series was adapted to the specifics of this project. 500 mm diam. adsorber vessel. For KA 4 the design of a standard HAD 60 skid from the current L-series was adapted to the specifics of this project 700 mm diam. adsorber vessel. 11/25/2020 16

Revamp Project. The Scope Split. Project management Paul Scherrer Institut Linde Kryotechnik AG Overall Project Management Contractor project management P&ID drafting HAZOP Basic engineering System Integration Component specification Engineering lists Re-drafting of wiring diagrams in ELCAD Detail engineering 3 D plant design Design Oil removal / Gas management skids Procurement and Manufacturing Rebuild of control cabinets Procurement of equipment and assemblies Modification of EPICS DB and GUI Modification of PLC software Implementation Site activities As-built documentation 11/25/2020 Programming of the local HMI in TIA portal Construction and piping Construction supervision Commissioning each party for its scope 17

Revamp Project. The Scope Split. PSI decided for Siemens Comfort-Panels model TP 1500 — 15’’ TFT display — Touchscreen — Programmed with Siemens TIA Portal — All controls available by finger-tip 11/25/2020 18

Revamp Project. Scope Split. Project management Paul Scherrer Institut Linde Kryotechnik AG Overall Project Management Contractor project management P&ID drafting HAZOP Basic engineering System Integration Component specification Engineering lists Re-drafting of wiring diagrams in ELCAD Detail engineering 3 D plant design Design Oil removal / Gas management skids Procurement and Manufacturing Rebuild of control cabinets Procurement of equipment and assemblies Modification of EPICS DB and GUI Modification of PLC software Implementation Site activities As-built documentation 11/25/2020 Programming of the local HMI in TIA portal Construction and piping Construction supervision Commissioning each party for its scope 19

Revamp Project. Paul Scherrer: Site engineering. 11/25/2020 20

Summary. Targets of customer — Lifetime extension — Improved overall energy balance — Reduced maintenance cost , time, complexity Achieved by — Understanding of the general surrounding effects e. g. limited financial resources given by the funding system — Through close cooperation, the project was realized cost-effectively with the help of a scope split agreement — Linde Kryotechnik supplied the cryogenic technology, equipment and expertise Partnering with our customer lead to a state of the art compression system for the Paul Scherrer Institute. 11/25/2020 21

Thank you for your attention. Author Co-Author Linde Kryotechnik AG Andreas Rüegge andreas. rueegge@linde-kryotechnik. ch Paul Scherrer Institut Herr Christian Geiselhart christian. geiselhart@psi. ch