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Bart Verlaat

Overview of recent CO 2 cooling developments As an example for LHCb -Velo and UT cooling? Kick-off meeting 28 may 14. Bart Verlaat . CO2 cooling overview. At CERN 2 on-detector cooling systems are under development. Atlas IBL CO2 cooling system. 3kW@-40’C Constructed, under commissioning

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Bart Verlaat

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  1. Overview of recent CO2 cooling developmentsAs an example for LHCb-Velo and UT cooling?Kick-off meeting 28 may 14 Bart Verlaat

  2. CO2 cooling overview • At CERN 2 on-detector cooling systems are under development. • Atlas IBL CO2 cooling system. • 3kW@-40’C • Constructed, under commissioning • CMS pixel CO2 cooling system. • 15kW@-20’C • Under construction, working prototype build • Both systems are based on the LHCb-Velo1 2PACL principle • But many new lessons were learned in the development of both Atlas and CMS. • The upgrade cooling of LHCb gets the best out of both. • New technologies used: • PVSS/Unicos PLC control (CERN standard for control of cooling systems) • 2-stage chiller • Remote head pumps • Vacuum insulation • Off the shelve high pressure components • In the LHCb-Velo1 era many high pressure components had to be custom designed. • More connection with industry

  3. Cooling method used in detector cooling: The 2-Phase Accumulator Controlled Loop (2PACL) 2-Phase Accumulator Shielding wall P7 Evaporator inside detector (4-5) Heat in Long distance (50-100m) P4-5 HFC Chiller 5 Condenser 6 Detector heat 2 3 Capillaries (3-4) for flow distribution 1 Transfer line (Heat exchanger) Pump 4 2PACL principle ideal for detector cooling: • Liquid overflow => no mass flow control and good heat transfer • No local evaporator control, evaporator is passive in detector. • System not sensitive for heat load changes • Very stable evaporator temperature control at a distance (P4-5 ≈ P7) • Large operationaltemperaturerange (+20’C to -40’C)

  4. Atlas IBL cooling • 14 staves of 70W each connected via concentric 29m long loops to manifolds in the muon area. • 100m concentric transfer line from manifolds to plant in service cavern. • 2 redundant cooling plants • 1 Accumulator with redundant control. • Vacuum insulated lines

  5. Detector boundary LAR Cryo area Junction box @ Muon Sector 5 (Accessible) Transfer tubes (~92m) CO2: 10x1mm inside 21.3x2.11mm outside BD016 PT116 / PT316 TT116 / TT316 ⅜” HX036 Dummy load (testing only) ¾”x5/16” MV036 MV018 MV017 ½” EH117 TT117 TS117 BD036 PT136 / PT336 TT136 / TT336 FL018 FL017 36 26 34 30 30 28 26 20 22 28 24 32 32 16 06 08 04 BD020 PT120 / PT320 TT120 / TT320 ¼” AV017 ⅜” MV035 ½” TTz36 (DCS) TTz20 (DCS) ⅜” Manifold box (S5) HX012 DN40 vacuum Vacuum system (LAR Cryo area) EH122 TS122 DN40 USX-15 DCS: TTa24 - TTn24 MVa24 - MVn24 D012 USA-15 Tile calorie meter LAR calorie meter Tracking detectors DCS: TTa28 – TTn28 DCS: TTa30 – TTn30 14 IBL staves (a-g),(7 flow pairs) (7x A-›C flow / 7x C-›A flow) Dry volume A200 A100 B400 B300 C042 BV,28-01-2014

  6. MV012 CO2 to experiment AV012 PT142 PT342 Cold CO2 line Cold R404a line Warm service line (Cold lines require 32mm insulation) MV040 MV042 SV040 SV041 SV043 SV042 LT142 LT342 MV039 BD012 MV043 VP056 CO2 from experiment AC042 ½” NV310 NV110 CV342 PRC142 controlling CV142, EH142/143 (PT142 & SC150) ¼” CV142 PRC342 controlling CV342, EH342/143 (PT342 & SC350) ¼” PT040 PV310 PV110 no no nc nc nc nc MV310 MV110 50 50 6 8 6 4 8 4 40 46 48 44 44 42 48 46 12 10 10 CO2 system B 300 labels MV041 CO2 system A 100 labels no no AV108 AV308 ⅜” EH142/143 TT142/143 TS142/143 ⅜” PV308 PV108 EH342/343 TT342/343 TS342/343 BD108 PT108 TT108 BD308 PT308 TT308 PV144 PV344 no FL144 FL344 FL042 nc nc PT042 EH106 TT106 TS106 evacuate EH306 TT306 TS306 vent MV054 Fill port PT056 nc PT050 PT058 MV052 nc BD054 PT054 Fill port ½” MV056 MV050 nc ½” nc FL106 nc ¼” FL306 MV058 TT146 TT346 nc FT106 FT306 EV148 EV348 MV106 MV306 HX148 HX348 nc FL104 nc nc FL304 PT104 TT104 TT148 BD148 TT348 BD348 PT304 TT304 HX150 HX350 Freon chiller A 200 Freon chiller B 400 LP301 LP101 LP101 EH301 / EH302 / EH303 TT301 / TT302 / TT303 TS301 / TS302 / TS303 PT301 / PT302 / PT303 EH101 / EH102 / EH103 TT101 / TT102 / TT103 TS101 / TS102 / TS103 PT101 / PT102 / PT103 ½” ½” BV, 28-01-2014 PT150/ TT150/ SC150 PT350/ TT350/ SC350

  7. nc ⅜” CO2 Accumulator rack Air cooled condenser PT142 nc TT232 HX206 / HX207 EV206 PT234 ½” HX212 MV232 no HX201 ½” HX142 / HX230 AC042 nc no ⅜” HX216 SG212 MV230 EV208 CV142 PRC142 (PT142&SC150) TT206 nc FL212 SR206 ½” TT218 HX208 ½” TT228 28 ⅜” ½” SG216 CV205 MV228 PT208 TT208 FL216 HX226 SV210 ½” TT210 MV208 MV226 HX348 nc HX205 MV210 ½” NV202 cooling water ¼” TT242 SG210 AC210 TX226 EV348 CO2 B rack PT244 & PT250 TT244 SH244 PT202 ⅜” PT224 TT224 SH224 MV202 SG202 GP250 PRC250 (PT250) ¼” HX222 28 AC202 BR234 PRC234 (PT234) TT202 TT248 PT248 7/8” MV224 FL244 TT246 MV248 TT220 nc HX150 GP246 GP248 ⅜” ½” MV246 EV212 CV238 PRC244 (PT244) TX212 CV222 SHC224 (SH224) EH250 CV240 SHC244 (SH244) ½” HX220 / HX244 SR248 MV222 CO2 A rack AC244 R404A 2-stage compressor GP250 PS250 8 2 4 6 42 34 44 28 16 38 22 20 30 18 36 24 14 12 26 40 32 48 46 10 chiller A (200 series) BV, 19-11-2013

  8. Junction box in sector 5, Installed IBL CO2 coolingHardware status Transfer line in detector, Installed Transfer line USA-UX, Installed Manifold box Installed Vacuum system, Installed Plant & control @ USA-15 Installed Needed for system commissioning via dummy load Under installation Needed after IBL installation

  9. Plants @ USA15 L3

  10. Plant B and accu rack Accumulator unit CO2 unit R404a 2-stage chiller

  11. IBL R404a 2-stage chiller unit Front side with control cabinet and air condenser Back side with piping Freon connections Frequency inverter Electronic cabinet Water cooling Air condenser 2-stage compressor

  12. CO2 unit Front side with foam box Back side components Back-up cooling 3kW heater CO2 pipes Valve Flow meter Valve Main cooling Pump foam box Pump pallet CO2 pump

  13. Accumulator unit Back side with accumulator and piping Front side maintenance control box Level probes Cooling Maintenance box Service valves Vacuum pump Accumulator vessel Heaters

  14. Vacuum transfer line status Plant Side UX15

  15. Junction installation 3kW dummy load heater Manual valves

  16. Flexible vacuum insulated lines=> cooling loop routing is like cabling • 11 m long concentric lines 1.6x0.3 inside 4x0.5mm tube. • Vacuum shield 17mm flex hose • Bending radius >10cm • Up to 300 Watt tested Concentric pipes

  17. Commissioning results – cooling starts Cooldown In current configuration is 3kW to much for -40’C operation, unable to hold set-point (green line) Pressurization of the system -40’C set-point reached -35’C setpoint 3kW 2kW 1kW

  18. Commissioning results SP = -35’C operation Compressor at full speed, temperature of liquid increases 2000W 1500W 1000W 2500W 500W 0W Junction box temperature 0W Margin of sub cooling must be maintained. >10’C for safe operation Capable of maintaining set point from 0 to 3kW Chiller temperature and CO2 liquid

  19. CMS pixel cooling • New Pixel detector for CMS to arrive in 2016 • 15 kW total cooling power @ -20°C • One full scale mock up of the system ready in 2013 @ TIF • Full cooling system at P5 end of 2014 • 125 M silicon pixels (x2 compared to present detector) • 4 Barrel layers • 3 Forward discs on each side

  20. -20 degCsetpoint Pump Stopped because of too low subcooling BPR Manually opened to 100% 13 kW 12.5 kW 12 kW 10 kW 8 kW 6 kW 4 kW 2 kW Manifold Inlet Temp Dummy load Heater2 Temp Manifold Return Temp Pump Subcooling AccuTsat Return Temp before HEX Dummy load Heater1 Temp Pump Suction Temp

  21. Possible development path for LHCb(IBL model) Velo UT Requirements Requirements Conceptual design suitable for both detectors Cooling loop design feedback / define interfaces Cooling loop design feedback / define interfaces Functional Analyses / DCS interface P&ID Each blue box will be represented by a live document, constantly updated until commissioning is finished. Each green arrow is typically a review Electronics design System design Plant / transfer lines / On detector hardware Full system commissioning Electronics construction System construction Pre-commissioning

  22. IBL cooling requirements • Conclusion: • A CO2 system with an evaporator capacity of 1.5kW, operational from +20°C to -40°C • Accessible manifolds • Redundant cooling plant • Fail safe operational during back-out (blow system) https://edms.cern.ch/document/1204776/1

  23. Typical IBL documents P&I document https://edms.cern.ch/file/1233482/2/PID_document28jan14_EDMS1233482v3.pdf Functional analyses https://edms.cern.ch/file/1233462/1/Functional_Analysis_IBL_CCS_v1.3.pdf DCS interface https://edms.cern.ch/file/1233464/4/Control_interface_between_CCS_and_DCS.pdf Electrical schematics https://edms.cern.ch/file/1352063/1/IBL_A_04.pdf

  24. Next steps • Hopefully after todays kick-off meeting a picture can be shaped what would be the best approach for a common development of the Velo and UT cooling systems • It is important that both the Veloabnd UT are writing down their requirements. • Close interaction is needed between the groups (Velo/ UT / Cooling) is needed such that the on detector cooling loops are designed according to typical cooling system behavior.

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