1 denis grondin – sept.23 th, 2010 cooling & mechanics status calice collaboration meeting @...
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1Denis Grondin – Sept.23 TH, 2010
Cooling & mechanics
statusCALICE Collaboration Meeting @ Casablanca
at LPSC
ECAL
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Mechanics & Cooling – Sept 23th, 2010 CALICE Collaboration Meeting @ Casablanca
Si-W ECAL – Current baseline
D=3686 int
4056 ext
12 modules-3 distinct types Compactness, no dead zone if…
W/Si – ECAL weight: ~ 112 T (80 barrel+32 End-Cap)
1562
940
1
85
Module Barrel
Poids / module :
~ 2 T
No dead zone, compactness 40 identical trapezoidal modules
Module End-Cap n°2
Multi-module End-Cap
~ 4600 cells to join
186,8 × 7,3 mm186,8 × 9,4 mm
Thickness : 1 mm
Composite Partwith metallic inserts (15 mm thick) + rails
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Mechanics & Cooling – Sept 23th, 2010 CALICE Collaboration Meeting @ Casablanca
Construction of 2.5 m long composite alveoli :
demonstrate whether or not the main process steps (similar to barrel ones) can be adapted
Design n°2: width of alveoli:186,8
Today, with the barrel’s demonstrator and EUDET, the process for composite structure is going to be validated, with a built layer module width based on 182.1 mm for EUDET, and 1,50 m long…
Long. 2.5 m
R2=2093
End-Caps structure: baseline
From Design of EUDET module CALICE End-caps modules
550 mm
1495 mm
Composite Partwith metallic inserts
(15 mm thick)
182,1 × mm
182,1 × mm
Thickness : 1 mm
7,3
9,4
End-cap structure : study and validation of most of technological solutions which could be used for the final detector taking into account industrialization aspect of process:
• Moulding process for long alveoli,
• Cooling system,
• Thick composite plates and stronger rails
• sizes of structures,…
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Mechanics & Cooling – Sept 23th, 2010 CALICE Collaboration Meeting @ Casablanca
2.5 m alveoli molding
End-Caps : long alveoli molding test
Single alveoli mould
3 alveoli assembling mould
CORE
• The end-cap layer test consisted of • 1 long alveolar cell
(representative of the end-cap module longest layers)
• Width of cell : 186.8 mm (Design2 - to fit LOI parameters (R~2090))
• Thickness of cells : 6.5 mm - wall: 0.5 mm
• Length : 2.492 m 4
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Mechanics & Cooling – Sept 23th, 2010 CALICE Collaboration Meeting @ Casablanca
Alveoli 2,50m: extraction of core
Pliers for extraction with good adhesion on carbon plies
Extraction : >> 6000 N !
Þ To riskyAdaptation on alveoli
New alveoli to mould with aluminium core:
Fall 10
5m
Gauge
First test: negative
Friction core/ 2,5 m carbon plies
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Mechanics & Cooling – Sept 23th, 2010 CALICE Collaboration Meeting @ Casablanca
Fastening ECAL/HCAL
Mould for HexMC & SMC Carbon rails on a 80T heating press
From metallic rails… to… composite structural system • validation of technological solution• industrialization aspect of process• Alternative for fastening and positioning system: larger and
thinner rails:
1 stave of 5 modules
Fastening in a structure “wheel”: bending constraints
Carbon structure (thick plates and support…) Cooling pipes & cables (DAQ + HV + GND )
integration
ConstraintsConstraints
A column (cooling pipe), (25 mm wide minimum) to ensure quick thermal system’s connection
EUDET thick plate
Carbon rails
Barrel fastening End-cap fastening
Rails
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Mechanics & Cooling – Sept 23th, 2010 CALICE Collaboration Meeting @ Casablanca
Module section thermal simulation
Temperature
Thermal flux / layer
SLAB / Cooling connection
Test on demonstrator: correlation with simulation
Contact thermal resistance
Water circulation on module3D pipe modeling
Global cooling Leakless mode restriction
(leakless zone is at the top of the loop)
INTEGRATION COOLING ECAL
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22
23
24
25
26
27
28
29
30
31
S 15-16 S 13-14 S 11-12 S 9-10 S 7-8 T 17-48
Tem
pér
atu
re °
c
Essais
Simulation h
Temperature along the SLAB
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Mechanics & Cooling – Sept 23th, 2010 CALICE Collaboration Meeting @ Casablanca 8
First step : Correlate test with simulation
Thermal test with the first alveolar structure
Integrate W break
EF model of the section
Integrate thermal contact resistance (air gap)
SLAB : thermal simulation
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Many thermal tests were done on heat pipe system and water system.
Goal => learn more about contact thermal resistance with the different configuration.
Heat pipe exchanger
Waterexchanger
Connection Copper drain / exchanger
Test bench
“SLAB” copper extremity
Front SLAB : thermal connection
Heater
Temp sensor
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Heat-pipe optimizations
Heating System
Sensors
Tests on Heat-pipe
Sensors
CondenserEvaporator
Temperature decrease / 29%
Independent cooling /columnTemperature decrease / 28%
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Cooling: heat pipe evolution
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Mechanics & Cooling – Sept 23th, 2010 CALICE Collaboration Meeting @ Casablanca
S = 24 cm²S = 20 cm²
S = 24 cm²
S = 10 cm²
S = 6 cm²
S = 4 cm²
S = 10 cm²
ECAL Cooling : 3D pipe modeling
Water circulation on module
Leakless mode restriction
(leakless zone is at the top of the loop)
3D pipe modeling
Global design- Water cooling system
- Leakless zone over the entire height of the detector.
- One line / module.
- Inlet water temp: 18°c / Outlet water temp : 23°c
- Maximum power / column : 100 W.
- Pipe diameter : 13 mm.Pathways of pipes through HCAL barrel
leak less Zone
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Mechanics & Cooling – Sept 23th, 2010 CALICE Collaboration Meeting @ Casablanca
Pathways of pipes on ECAL barrel
50mm
Smax = 44 cm²
Air pipe :
Water pipe :
Dimensions of connecting zones
3 modules : S = 58 cm²
110 mm93mm
62mm
2 modules : S = 20 cm²
Narrow passage: connecting area too small ! (study on going)
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Integration Cooling on ECAL
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Barrel solution 1(1 line per column)
Barrel solution 2(1 line per module)
Barrel solution 3(1 line per module with valves)
Heat pipe or water
Total amount of pipes <->Pipe diameter
4006mm
8015mm
80 (water) + 400 (air)15mm (water), 4mm (air)
Maxi. Power 15W 150W 150W
Flow section 14 cm² 15 cm² 15,5 cm²
Advantages - Command per column from exterior of detector
- Less connexions to install- Important power range: 15/150W- Reduces volume (80 lines for barrel)
- Command per column (on front-end circuit only) - Important power range: 15/150W
Disadvantages - Power evacuated limited to15W per column- Important Congestion- Flow management=> a flowmeter /line=> important cost- Pressures management => 1 pressure gauge / line => important cost- High number of fitting may leak (400 lines for the barrel)
- Command per module - More important congestion (water & air pipes + valves) - Connexions added near valves - Zone insulated per valves: restricted / to the addition of needed equipments - Valves management (distributor, command)
Solution 2 (one line per module): best technical compromise between reliability and congestion
INTEGRATION COOLING ECAL
Insulated Zone via valves
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Mechanics & Cooling – Sept 23th, 2010 CALICE Collaboration Meeting @ Casablanca
This solution requires a 30mm gap between ECAL & HCAL Endcaps (15mm today)
Endcap solution 1
INTEGRATION COOLING ECAL
Endcap solution 2
This solution also requires a 30mm gap between ECAL & HCAL Endcaps
Pathways of pipes between HCAL & ECAL Endcaps
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Control by column
Control by module
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Mechanics & Cooling – Sept 23th, 2010 CALICE Collaboration Meeting @ Casablanca
ECAL: Global COOLINGSimplified P&I diagram of cooling plant extrapolated from a CERN's Detector.
True scale leakless cooling system test Base line : leakless system with representative systems to control
• the right components, sensors… • process, regulation• Interface and control
Study of the global cooling system for ECAL to continue:
• Design including safety systems
• Cost estimation (several solutions)
Leakless system : - Low water speed - Heat pipe termination - Temperature and power range adapted
Leakless cooling system mock-up: 2010
Power results / goal ILD Global Power : 4565 W @ 15 W / column
to dissipate
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Mechanics & Cooling – Sept 23th, 2010 CALICE Collaboration Meeting @ Casablanca
Conclusion :Cooling Cooling
End-cap design, mechanical & thermal simulations update 2011…
Fastening system ECAL/HCAL: alternatives for rails Spring 2011
Handling and positioning tools for modules Summer 2011
Barrel / End cap global section simulation June 2010
Slab / cooling system connection thermal test (transfer coeff., contacts…) End 2010
Cooling systems for EUDET(heat pipe/water-143W) + portable cooling station March 2011(final dimensions of the alveolar structure needed before November 2010)
Module mockup: implementation & test of connectors for safe cooling Spring 2011
Design & build a “true scale test Leakless loop” (<1atm) Spring 2011
Design: hydraulic safety, hardened components, cooling supervision Summer 2011
Alternative cooling studies: µ-cooling devices (with LEGI & CEA-LETI)… 2011…
Conception - SimulationConception - Simulation
End-cap: 2.5 m alveoli molding test may 2010
End-cap: 2.5 m alveoli molding optimisation (core & wrapping) fall 2010
Characterisation, tests & optimisation: composite elements and rails Spring 2011
Fabrication – Long alveoli molding tests - characterizationFabrication – Long alveoli molding tests - characterization
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Mechanics & Cooling – Sept 23th, 2010 CALICE Collaboration Meeting @ Casablanca 17
Mechanical R&D on ECAL
Thank you for your attention
Cooling system & test
Water cooling block
THERMAL tests
Destructive tests
15mm thick plate with it’s rails; ready to be assembled with EUDET’s layers
Fastening system integration
End-cap design
Connection Copper drain / exchanger
EUDET thick plate
Carbon rails