bart verlaat
DESCRIPTION
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 - PowerPoint PPT PresentationTRANSCRIPT
Overview of recent CO2 cooling developments
As an example for LHCb-Velo and UT cooling?Kick-off meeting 28 may 14
Bart Verlaat
1
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
2
Cooling method used in detector cooling:The 2-Phase Accumulator Controlled Loop (2PACL)
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 operational temperature range (+20’C to -
40’C)
Con
dens
er
Pump Transfer line (Heat exchanger)
Evaporator inside detector (4-5)
2-Phase Accumulator
Heat in
Detector heat
1
2 3
4
5
6
P7
P4-5
Long distance (50-100m)
HFC Chiller
Shielding wall
Capillaries (3-4) for flow distribution
Liquid Vapor
2-phase
Enthalpy
Pressure
1
2 3
4 56
P7
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 lines4
Junction box
Connectiontube bundle14x 3x0.5mm
Tracking
LAR
Tile Calorie
Manifold boxes
Vacuum insulated concentric tubes(7x1.6x0.3mm inlet inside 4x0.5mm outlet)
ID end plate dry volume
Vacuum terminal and concentricsplit
Vacuum insulated transfer line Vacuum line
34DCS: TTa24 - TTn24
EH122TS122
22
MVa24 - MVn2404
06
FL018
⅜”
AV017
20
36
BD016PT116 / PT316TT116 / TT316
26 32
28 30
Tracking detectors
Tile calorie meter
LAR calorie meter
MV018MV036
14 IBL staves (a-g),(7 flow pairs) (7x A-›C flow / 7x C-›A flow)
Detector boundaryJunction box @ Muon Sector 5 (Accessible)
Dry volume
LAR Cryo area
HX036
½”
¾”x5/16”
⅜”
Dummy load (testing only)
BD020PT120 / PT320TT120 / TT320
DCS: TTa28 – TTn28 DCS: TTa30 – TTn30
BD036PT136 / PT336TT136 / TT336
MV035
EH117TT117TS117
26
2830
32
HX012
FL017
MV017
Manifold box (S5)
08
USA-15
USX-15
DN40 vacuum Vacuum system(LAR Cryo area)
DN40
⅜”
¼”
½”
BV,28-01-2014
Transfer tubes (~92m)CO2: 10x1mm inside 21.3x2.11mm outside
16
A200 A100 B400 B300 C042
D012
Flow
dir
Stav
e #
Flow
dir
a 12 C-A
b 13 A-C
c 14 C-A
d 1 A-C
e 2 C-A
f 3 A-C
g 4 C-A
h 5 A-C
i 6 C-A
j 7 A-C
k 8 C-A
l 9 A-C
m 10 C-A
n 11 A-C
TTz20 (DCS)
24
TTz36 (DCS)
AC042
LP101
ventevacuate
6
8
FT106
⅜”
EH106TT106TS106
EH101 / EH102 / EH103TT101 / TT102 / TT103TS101 / TS102 / TS103PT101 / PT102 / PT103
HX150
CO2 system A100 labels
LT142LT342
FT306
FL304
⅜”
FL306
VP05
6
50
40
12
4444
46
48
PV110
PT150/ TT150/ SC150
¼”
BD108PT108TT108
CO2 from experiment
CO2 to experiment
42
PT142
PV108PV144
HX148
TT148BD148
SV042 SV043MV042
FL144
MV041
TT146
AV108
Freon chiller A
200
CO2 system B300 labels
10
LP101EH301 / EH302 / EH303TT301 / TT302 / TT303TS301 / TS302 / TS303PT301 / PT302 / PT303
4
FL344
PT304TT304
MV306
6
8
EH306TT306TS306
BD308PT308TT308
AV308
PV308
PV310
PV344
46 TT346
HX350
HX348
LP301
Fill port
nc
nc
no
nc
nonc
MV050
MV054MV052 MV056BD054
PT054
EV148 EV348
nc nc
50
PT350/ TT350/ SC350
SV040 MV040
SV041 BD01210
MV058
NV110
MV110 MV310nc
CV142
nc
CV342
ncnc
nc nc
nc
nc
Cold CO2 lineCold R404a lineWarm service line(Cold lines require 32mm insulation)
no
NV310
no
¼” ¼”
½”½”
½”
½” ½”
48 TT348BD348
Freon chiller B
400
MV043
PT342
BV, 28-01-2014
PT040
PT042
PT056
PRC142 controlling CV142, EH142/143(PT142 & SC150)
PRC342 controlling CV342, EH342/143(PT342 & SC350)
PT050 PT058
no
FL104
4 PT104TT104
nc
FL106
Fill port
MV106
EH142/143TT142/143TS142/143
FL042
EH342/343TT342/343TS342/343
MV012
MV039
AV012
cooling water
R404A 2-stage compressor GP250
AC042
CV205
48GP246 GP248
PS250
MV202 SG202
TT248PT248
SR248
HX208
HX205
Air cooled condenser
AC210
2
HX201
HX216
HX212
MV222
MV224
MV246
MV228
MV230
4
BR234PRC234 (PT234)
12
16
38
22
26
28
30
34 36
TT202AC202
NV202
AC244HX220 /HX244CV222
SHC224(SH224)
CV238PRC244 (PT244)
TX212
PT224TT224SH224
PT244 & PT250TT244SH244
24
TT2066
8TT210 10
TT220
TT21818
20
44
14
TT24242
TT228
TT246
46
MV248
MV210
SG216
FL216
HX142 / HX230
HX226
HX348
HX150
7/8”
28
½”
⅜”
½”¼”
⅜”
½”
⅜”
½”
⅜” ½”
¼”
½”½”
28
nc
nc
nc
nc
nc
no
HX206 / HX207
chiller A (200 series) BV, 19-11-2013
TX226 EV348
MV226
CV142PRC142
(PT142&SC150)
no
MV208
⅜”
SR206
½”
½” PT234
EV208
PT142
GP250PRC250(PT250)
32
TT232
MV232
CO2 A rack
CO2 B rack
CO2 Accumulator rack
PT208TT208CV240
SHC244(SH244)
40
HX222
nc
EV206
FL212SG212
SG210
SV210
PT202
EH250
FL244
EV212
IBL CO2 coolingHardware status
8Needed for system commissioning via dummy load
Needed after IBL installation
Plant & control @ USA-15Installed
Transfer line USA-UX, Installed
Transfer line in detector, Installed
Junction box in sector 5, Installed
Vacuum system, Installed
Manifold box Installed
Under installation
Plants @ USA15 L3
9
Plant B and accu rack
10
R404a 2-stage chillerCO2 unit Accumulator
unit
IBL R404a 2-stage chiller unit
11
Front side with control cabinet and air condenser Back side with piping
Electronic cabinet Frequency inverter
Air condenser 2-stage compressor
Water cooling
Freon connections
CO2 unit
12
Front side with foam box Back side components
CO2 pipes
Pump foam box Pump pallet CO2 pump
Flow meter
3kW heater
Valve
Valve
Back-up cooling
Main cooling
Accumulator unit
13
Back side with accumulator and pipingFront side maintenance control box
Maintenance box
Accumulator vesselVacuum pump Service valves
Cooling
Heaters
Level probes
Vacuum transfer line status
14
Plant Side
UX15
Junction installation
15
3kW dummy load heater
Manual valves
Flexible vacuum insulated lines=> cooling loop routing is like cabling
Tracking
LAR
Tile Calorie
Concentric pipes
• 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
Pressurization of the system
Cooldown
-40’C set-point reached
1kW 2kW 3kW
-35’C setpoint
In current configuration is 3kW to much for -40’C operation, unable to hold set-point (green line)
Commissioning results – cooling starts
Capable of maintaining set point from 0 to 3kW
0W 500W1000W 1500W 2000W
2500W
0W
Compressor at full speed, temperature of liquid increases
Margin of sub cooling must be maintained. >10’C for safe operation
Chiller temperature and CO2 liquid
Junction box temperature
Commissioning resultsSP = -35’C operation
• 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
CMS pixel cooling
125 M silicon pixels (x2 compared to present detector)
4 Barrel layers3 Forward discs on
each side
20
2 kW
12.5 kW12 kW
10 kW
8 kW
6 kW
4 kW
13 kW
-20 degC setpoint
BPR Manually opened to 100%
Pump Stopped because of too low
subcooling
Manifold Inlet Temp
Manifold Return Temp
Accu Tsat
Dummy load Heater1 Temp
Dummy load Heater2 Temp
Pump Subcooling
Pump Suction Temp
Return Temp before HEX
[email protected] development
path for LHCb (IBL model)
21
Velo UT
Conceptual design suitable for both
detectors
Requirements Requirements
Cooling loop design
feedback / define
interfaces Cooling loop design
feedback / define
interfaces
P&IDFunctional Analyses /
DCS interface
System designPlant / transfer lines / On detector hardware
Electronics design
System construction
Electronics construction
Pre-commissioning
Full system commissioning
1. Each blue box will be represented by a live document, constantly updated until commissioning is finished.
2. Each green arrow is typically a review
[email protected] IBL cooling requirements
22
• 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
Typical IBL documents
23
1. P&I document https://edms.cern.ch/file/1233482/2/PID_document28jan14_EDMS1233482v3.pdf2. Functional analyses https://edms.cern.ch/file/1233462/1/Functional_Analysis_IBL_CCS_v1.3.pdf 3. DCS interface https://edms.cern.ch/file/1233464/4/Control_interface_between_CCS_and_DCS.pdf4. Electrical schematics https://edms.cern.ch/file/1352063/1/IBL_A_04.pdf
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 Velo abnd 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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