15 kw two-phase co2 cooling system status march 20, 2012 input: all of the pixel co2 cooling team !...
TRANSCRIPT
15 KW two-phase CO2 cooling system statusMarch 20, 2012
Input: All of the Pixel CO2 cooling team!
Slides: R.Becker
B-Pix Plant core(US)
1094
1096
1080
PR1080aPR1080bPT1080LT1080
F-pix Plant core(US)
CO2Storage
B-Pix Accumulator(US)
F-Pix Accumulator(US)
1094
1096
1080
PR1080aPR1080bPT1080LT1080
CMS Pixel CO2 Cooling System
PM10
1
1006
1078
1092
10901082
PR1002PT1002TT1002
1002
PR1072PT1072TT1072
1072
1004
PR1006PT1006TT1006Filter
PM101
1006
1078
1092
10901082
PR1002PT1002TT1002
1002
PR1072PT1072TT1072
1072
1004
PR1006PT1006TT1006
BPix
FPi
x
ManifoldBox (UX)
PR10xxPT10xxTT10xx
10xxPR10xxPT10xxTT10xx
10xxPR10xxPT10xxTT10xx
10xxPR10xxPT10xxTT10xx
10xx
IN/O
UT Cu pipes bundled together
Filter
Filter Filter
IN/O
UT
Cu p
ipes
bun
dled
toge
ther
(Input: P. Tropea & B.Verlaat)
PM10
1
1006
1078
1092
10901082
PR1002PT1002TT1002
1002
PR1072PT1072TT1072
1072
1002
PR1006PT1006TT1006
LEWA Filter ?
Filter (swagelok)
Selfa 1”
Selfa ½”Selfa ½ ”Selfa 9008
metering
Selfa 1” ???
Swagelok U8, ¼”
LEWA LDE1
SWEP B17
Swagelok ½”
Part IndicationsCAD input for Alexis, Jean-Christophe, & Nick
(Lyon)
For TIF plant: fittings here
Swagelok U8, ¼”
Swagelok U8, ¼”
Swagelok U8, ¼”
Fpix / Bpix 15 KW Plant Core
“Brine” plumbing & valve to be defined
Damper Calculation sheet received (13/03/2012)
SWEP max inlet size: 16mm.. Two sided possible!
Metering & Shut-off valve available! CV-??
(Selfa)(19/03/2012)
Missing and/or Unsized components:
Plant Core:1) Damper2) Heat exchanger (swep B17: port size? Multiple exchangers?)
3) “Brine” Valve4) 1” Filter5) Cold box (dimensions & feed-throughs needed)
6) Fittings: 1” VCR bulkhead connector
1” 3-dimensional elbow1” Tee1” cross 1”-12mm automatic buttweld reduction 1”-1/2”-1” union T -VCR fittings?¾ NPT -VCR adapter (or ISO G 3/4" to 1”) -pump connection-1-1/2-1” VCR T fitting, 1” VCR Tee fitting
Manifolds:7) Flow meter (3 leads)
8) Cold box (dimensions & feed-throughs needed)
We came… (US)
Service Cavern location for 15KW cooling stations
460
400
225
300
50
60
125x27
Cabinet to
be moved
We measured…(US)
And now we design..
(US)
Tube Routing
To UX
Rough Plant Core Proposal V2
Lyon CAD Status:
Real CAD files requested (the viewer does not allow adequate rotating or viewing)
Example of a cold Remote-head LEWA Pump
LEWA Visit key pointsFrom LEWA: Marc Geiselhart, [email protected], +41 61 717 9400, Fax: +41 61 717 9401, Mobile: +41 79 825 39 69 Stephan Dueblin, [email protected], +41 61 717 9400, Fax: +41 61 717 9401. Mobile: +41 79 126 8040
Attendees CERN: Jerome, Paola, Bart, Hans, Joao, Robert, (remote: Nick)
LEWA LDE1/MR510S/44 mm pump LEWA quotation: LL1-6329 rev1 (247598) was reviewed in detail going through the offer point-by-point.
Pump Cold-head:1) Older 500 series head chosen in our case due to long experience, and larger teflon membrane, allowing for better flexing under cold
conditions2) Positive pressure is needed for CO2 before starting the pump
3) Double membrane with lubrication and mesh separator allows membrane leak detection. LEWA requires a lubricant to “stick” the membranes together. LEWA will send us a list of lubricants for the membrane4) Check valve selected is the largest stainless steel ball and seat available (hard-hard valve). Other valve types are inferior in terms of back-leakage. The ball requires a preload/spring to achieve frequencies of above 180 strokes/min (the ball/mass’s natural frequency)5) 15mm dia check valve inlet (our pump)
6) Standard DIN flange connections. We send LEWA our VCR fitting @ they can weld (-or we do this)7) Orifice / pressure reduction needed with pulsation damper. LEWA may have a leaflet entailing calculations to size damper and reduction
Crank-case8) Weak point of pump: -the small end bearing of the piston rod wears out first!9) Adjusting flow: a) Stroke adjustment level range from 1-7, b) frequency adjustment regulation from 1-7. Rule of thumb: adjust stroke to 50% then adjust frequency to what is required10) Oil compressibility in hydraulic system: 0.4%11) The Pump in the offer is sized for all cases meeting our requirements (90 Bar, -40 degC etc) and can be run full time all year-round in any condition.12) For LEWA pumps in general: pistons larger than 25mm dia have piston rings
Motor & General13) Our pump is sized with 5.7 KW Nominal operation14) Lead time is 18 months due to custom manufactured cold head units + Connecting tube
15) After order tender 3-4weeks delay for a CAD model16) Prices in general for LEWA pumps: 1/3 Drive unit, 2/3 Pump head price -changes with multiple pump heads! 17) Tentative pricing for us: 1 pump + design work at full price. Multiple orders get a reduction, so ordering the remaining 2 units there will be slight savings as design is complete and manufacturing of 2 simultaneously will be more efficient 18) LEWA supplies filters for their pumps: We need a typical 0.3mm strainer mesh size –inquiring now for our 1” return line filter/strainer
To be resolved before ordering: Understanding all flows..1) Cryo lab test results2) Understand flow distribution behavior: Capillary sizing & overflow sizing optimization (Joao & Paola? Willi) By when?3) Main bypass flow (with overflow regulation this is adjustable –so if large range is known this shouldn’t be a big issue)
1.3m
Liquid membrane pump
200-300
??
Critical Dimensions Needed:
Dia: ~250
300-400 mm
Damper sizing paper available
15/03/2012 update
Additional LEWA info 15/03/2012:
Pressure drop of spring design valves? Spring design valves are available with pressure drops of 0.1 to 1.6bar.Usually we use this types for liquids with high viscosity. Possible Diaphragm liquids:For the space between the two layers of the sandwich diaphragm there several possible liquids.Depending on the temperature range and the reactivity/contamination requirements of the fluid the lubricant will be selected. MineraloilPolyglycoloilSiliconoilDemi waterVegetable oilChlorine fluor carbon Possible pump connections :Flange according to DIN /EN or ANSI (Size according to the valve size)Threat connections ISO G 1/2" or G 3/4" Thread connections ANSI ½ NPT or ¾ NPT
For our pump this part is on the pump chassis and not on the remote head
2) Rotarex Valve HP9008-N PP285NF I/PE MV1/4
Valve Leak-through testing
1) Swagelok SS-4UW-VCR-TF-6C valve
Using the PHOENIXL 300 He Sniffer: Lowest detectable leak rate for helium < 5 x 10-12 mbar l /s
Test Conducted:1) Leak rate checked “out of
the box”2) 50 cycles (no pressure)3) 20 Cycles (20 Bar Ar)4) Leak rate checked
0,20,50,100,150,190 Bar
PHe=20 bar 1.47 x10-8 mbar l /s. PHe=50 bar 1.79 x10-8 mbar l /s. PHe=100 bar 2.55 x10-8 mbar l /s. PHe=150 bar 3.82 x10-8mbar l /s. PHe=200 bar 6.3 x10-8 mbar l /s.After 3hours 190 Bar: 1.45 x 10-6 mbar l /s.(Diffusion through Peek seal + outside-in leak rate)
Mr Piel reclaimed test valve to insert metal-metal seals
. . . . PHe=200 bar 5 x 10-12 mbar l /s
Limit of sniffer!
Valve interfaces (attachment)
AttachmentPossibilities(clamp collar or neck)
AttachmentPossibility(thread Size?_)
Heat Exchanger SWEP B17
Contact: Bjorn Felgenhauer +49 170 798 [email protected]
Max port size: 16mm IDDouble ports are possible!
(front and back!)
Port dimensions
Filters:
SAGANA:
In-line: Metric: 20mm Imperial: 3/4”
LEWA 1” ?
Swagelok:T-Filter: Metric: 12mImperial: ½”
Coming soon: LEWA 1” strainer 0.3mm mesh
Component Selection
30.2 ID
(CV to be verified, DN25 for Preshower plant and DN32 for Pixels plant), and the model is the following: Valve Type 3241 (Company? Samson..? Y/N) with long stemActuator type 3277 120 cm2Positioner type 3766
DN25 (1”) 34.5 mm IDDIN32 (1 ¼”) 43.5 mm ID
24.9 mm dia manifold tubes for C6F14 system
Clues for Brine Valve and respective tubing size:
Current heat exchanger
45.5 mm ID(valve connected)
30.5 mm ID 39.2 mm ID
Current Understanding:CO2: 1” inlet, 12mm outlet 16mm ID restriction, but connection OKBrine: 34.5? mm Inlet, 43.5? mm outlet 16mm ID restriction… enlarger or custom needed
Resolving heat exchanger port sizing:
Freon or C6F14: what are the differences wrt. port size / double porting?
To UX
Tube Routing
From 15KW Plants in US To the UX Cavern
Entry in UXTo Manifolds
15 KW Plant
15KW Plant
Service CavernExperiment Cavern
From 15KW (US) Plant to Manifold Pipework (UX)
Jerome
From UX cavern entry To the Manifold BoxOver CMS
UX entry from US
To Manifold box
CMS midsection
Balcony
Manifold Box
location:UX Balcony far Side, X4
(+Side)
Tubing bundles
Fpix / Bpix Manifold Box (UX)
Outlet
Inletoutlet inlet
BPix
FPi
x
ManifoldBox (UX)
PR10xxPT10xxTT10xx
10xxPR10xxPT10xxTT10xx
10xx
PR10xxPT10xxTT10xx
10xxPR10xxPT10xxTT10xx
10xx IN
/OU
T Cu pipes bundled together IN/O
UT
Cu p
ipes
bun
dled
toge
ther
Manifolds
Swagelok SS 8UW (1/2”) bellows actuated
Swagelok SS 8UW (1/2”) bellows actuated
Swagelok series 45 (1/2”) Manuel
Swagelok SS 31 (1/4”) Metering
Fike / Swagelok Rupture disk 88 Bar
Flowmeter
In/Out bundled
Cold Box
Single Branch Components
½” tubing
½” tubing
1” tu
bing
Possible Alternatives:Rembe (www.Rembe–safety-control.de)Schlesinger (www.cotswoldvalves.co.uk)Fike (www.Fike.com)
Multiple parallel branches 1.4mm dia Cappilaries
Two replaceable modules
Current CAD design :
Parallel VersionAccess everywhere
“Staggered” VersionAccess everywhere
“Staggered” Version
Burst Disk Choices:
Standard Swageloc VCR ½”, 90 Bar ±10%, 100 SF/pc (see offer O-37996-12)
VCR “washer”
Plug:
Offer from Fike (Swagelok)(15/03/2012 Mr. Ruby at Fike.de)
They have designed an 88Bar +/-10% disk for us (including housing):
168 SF/pc 40 pc
Samuel Ruby Projektingenieur Fike Deutschland Tel. +49 (621) 321 6715 Fax +49 (621) 321 6750 Innstrasse 34; 68199 Mannheim, Deutschland www.fike.de
André Ramseyer AGIndustriestrasse 32CH-3175 FlamattFon +41 31 744 00 20Fax +41 31 741 25 55
Flow Meter Search:Early options
Omniflo®Turbine Flowmeters
• Measures flow rates as low as 0.001 GPM (3.78 mLPM)in liquids, and 0.0015 ACFM (2.5 LPH) in gas• Accuracy of ±0.25% in liquids and ±0.60% in gaswhen paired with linearizing electronics• Repeatability better than ±0.1% of reading in liquidsand ±0.2% of reading in gas• Standard configuration withstands pressures up to400 BAR (5,800 psi) • Compact size, 3" face-to-face with NPT or MS endConnectionsMagnetic field? Cost? Durability?
Kobold 350KAL (100Bar)calorimetric principle: The end face of the sensor is heated to a few degrees above the temperature of the flow medium. When the medium flows, the heat generated in the sensor is transferred to the medium, ie, the sensor is cooled. The cooling procedure is an accurate measure of the flow velocity.
Min Temp (-20 deg C)?CO2 medium untested
Investigated:Paddle, turbine, float-type, variable area
Hopefulls: Thermal mass, coreolis?!.
Contact: [email protected] Innovative Sensor Technology IST AGIndustriestrasse 2, 9630 Wattwil, SwitzerlandPhone: +41 71 987 73 73 | Fax: +41 71 987 73 [email protected]
First promising lead for a flow-meter!100 Bar, -40 deg C, ~1-24 g/s liquid CO2 flow, 3000 G Field
Contact: [email protected] INSTRUMENT COMPANY217 STERNER MILL ROADTREVOSE, PA [email protected]
Second lead for a flow-meter!100 Bar, -40 deg C, ~1-24 g/s liquid CO2 flow, 3000 G Field
Specifications Accuracy: 0.5% of Full Scale or 2% of reading - whichever is better Repeatability: Better than 0.2% of reading Temperature Extremes: -250°F to 1100°F (-156°C to 593°C) Pressure Extremes: Up to 60,000 psi (dependent upon size) Response Time: Liquids less than 1/2 second, Gases 1 to 2 seconds typical (4 to 8 seconds worst case) Pressure Drop: Negligible - completely unobstructed straight thru flow path Flow Element: Construction meets NEMA 4, 7 & 9 explosion proof requirements Flow Wetted Parts: 316 S.S. standard, also many exotic metals and coatings available to suit requirements
Operating Principle: The Model 600-9/9500 operates using a constant temperature system that employs two RTD sensors: one for sensing temperature, and one for sensing flow. The flow sensor is heated to a precise temperature above that of the fluid passing by. The fluid conducts heat off the sensor in direct proportion to the mass flow rate. The temperature sensor is used to set the heat on the flow sensor and correct changes in the fluid temperature. Thermal Instrument's thermal mass flowmeters consist of one piece; a flow element with a bridge controller, signal conditioner with power supply, flow signal, A/D converter, linearizing network, 4-20 MA DC, flow output, operational flow display, and totalizer.
Theo Investigating this one!
Third lead for a flow-meter!100 Bar, -40 deg C, ~1-24 g/s liquid CO2 flow, 3000 G Field
Jerome Investigating this one,
(and is having more success than I did!)
Bronkhorst offers low flow rate options & perhaps they can adjust one for higher flows?
Bronkhorst (France) S.A.S.53 Rue Jacques Verniol95370 Montigny-Les-CormeillesI http://www.bronkhorst.fr
Contact: Gérald Lamarche T +33 (0)1 34508700F +33 (0)1 34508991M +33 (0)6 08066206E [email protected]
Manifold to Pixel detector TubingWith manifold in X4
Lengths and heights from manifold to PP1
µsec+5/PP1+5LTOT=38,0m+4,1m/-8m
µsec+9/PP1+14
LTOT=40,1m+8,2m/-12,9m
µsec-6/PP1-6LTOT=33,2m
+3,4m/-7,5m
µsec-10/PP1-15
LTOT=50,1m+11,5m/-15,3m
BPIX
+Z -Z
FPIX FPIX
BPIX1S, 1R2S, 2R3S, 3R4S, 4R
+1 spare pipe+ TS and Gas
Fluid IN
Fluid OUT
Fluid IN
Fluid OUT
1
3
2
4
B-Pix + B-Pix -
F-Pix + F-Pix -
BPIX5S, 5R6S, 6R7S, 7R8S, 8R
+1 spare pipe+ TS and Gas
FPIX1S, 1R2S, 2R3S, 3R4S,4R
+1 spare pipes+ TS and Gas
FPIX5S, 5R6S, 6R7S,7R8S,8R
+1 spare pipes+ TS and Gas
Jerome Daguin