cern slides
TRANSCRIPT
Atlas Inner B-Layer
CO2 cooling system
CMS Tracker Week, 17 July 2012
Bart Verlaat
Jan Godlewski
1
Atlas Inner B-Layer (IBL)
2 New detector with smaller beam
pipe in space of current beam pipe
IBL detector:
• Ø80mm x 800mm
• 1.5 kW @ -40°C
• 14 staves with 1 cooling pipe
Carbon foam structure
1.5mm ID titanium cooling pipe
Pixel detector chips
(71 watt/stave)
[email protected] IBL cooling
requirements
3
• 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
[email protected] Atlas IBL Thermal
runnaway
4
-40 -30 -20 -10 0 10 20 30-40
-30
-20
-10
0
10
20
30
TCO2
(ºC)
Sensor
Tem
pera
ture
(ºC
)
Atlas IBL
TFoM
=5
TFoM
=10
TFoM
=15
TFoM
=20
TFoM
=25
TFoM
=30
TFoM
=35
TFoM
=40
Vbias=1000V & I0=0.675 mA @ T0=-15 ºC
Qsensor=0.19989 W/m2, Qchip=0.38202 W/m2
Asensor=3.3768 cm2, Int.lum=550fb-1
-40 -30 -20 -10 0 10 200
1
2
3
4
5
6
Sensor Temperature (ºC)
Heatf
lux (
W/c
m2)
Atlas IBL
Vbias=1000 V
Int.lum=550 fb-1
Qsensor
(W/cm2)
Qmodule
(W/cm2)
A TFoM of 20°C*cm2/W and a cooling of -35°C gives a silicon temperature
of -25°C. Thermal runaway starts to be visible at a cooling temperature of
-25°C (-10°C sensor temperature)
Significant leakage
current effect on
sensor power
IBL cooling layout in Atlas
5
Tracking
LAR
Tile Calorie
Accessible manifolds
Capillaries
in IDep
Vacuum
insulated
capillaries
14 IBL staves
LA
R
LA
R
Tracking
LAR
Tile Calorie
Vacuum insulated
concentric transfer tube
IBL Cooling pipes layout (C-Side view)
6
Vacuum insulated straight concentric
transfer tube
In- and outlet
Manifolds
Inlet capillaries
and outlet lines
Foam insulated junction piping (With condensation channels)
Vacuum insulated
Concentric tubes LAR station
Foam insulated transfer tubing
(Concentric TBV)
To USA-15 cavern
In- and outlet
Manifolds
Inlet capillaries and
outlet lines
Foam insulated junction piping
(With condensation channels)
Vacuum insulated
Concentric tubes
[email protected] Cooling system P&I
7
FL018
⅜”
AV016
18
20
36 38
FL016
BD016PT116 / PT316TT116 / TT316
26 32
28 30
34
Tracking detectors
Tile calorie meter
LAR calorie meter
MV018
MV036
14 IBL staves (a-g),(7 flow pairs) (7x A-›C flow / 7x C-›A flow)
Vacuum insulated concentric tube (~13 m)
Detector boundary
Junction box @ Muon Sector 5 (Accessible)
Vacuum insulation
Dry volume
Transfer tubes (~72m)
LAR Cryo area
VP591
USA-15
HX014
HX036
½”⅜”
¾”x5/16”
⅜”
Du
mm
y lo
ad
(tes
tin
g o
nly
)
IBL CO2 Cooling layout
½”
¾”x5/16”
VP592
14
16mm vacuum line
16mm vacuum
10
12
16
40
10
Freon chiller A
200
Freon chiller B
400
CO2
plant A 100
CO2
plant B 300
22
HX012
BD018PT118 / PT318TT118 / TT318
BD020PT120 / PT320TT120 / TT320TTz20 (DCS)
24DCS: TTa24 – TTn24
DCS: TTa28 – TTn28
EH122TS122
DCS: TTa30 – TTn30
BD036PT136 / PT336TT136 / TT336TTz36 (DCS)
MV034
MV017MV035
EH117TT117TS117
MV016
PT138 / PT338TT138 / TT338
PT114/ PT314TT114 / TT314
HX
03
8
PR591PT191 / PT391
91
PT193 / PT393
93
PT192/ PT392 92
MV593
MV592
MV591
26
2830
32
[email protected] Cooling system
redundancy approach • Two cooling plants (A&B) sharing a common transfer piping and
accumulator
• Dedicated chiller (A2A & B2B) with air and water cooled condenser
• Controls and sensors are completely redundant. – Control items on common hardware like accumulator or transfer line are
doubled.
• Able to run 2nd CO2 system in stand-by using the running chiller – CO2 system A to chiller B and visa versa.
– Local circulation in 2nd plant; cooling power limited for internal circulation only
– Stand by mode gives the possibility for a quick switchover
• Able to shut-off and empty 2nd system to do maintenance
8
Cooling Plant P&I
9
AC042
LP101
vent evacuate
6
8
FT106
FL104
NV104
⅜”
FL106
EH106TT106TS106
Fill port
EH101 / EH102 / EH103TT101 / TT102 / TT103TS101 / TS102 / TS103PT101 / PT102 / PT103
HX150
CO2 system A100 labels
PT142LT142
FT306
FL304
NV304
⅜”
FL306
VP
05
6
50
4
40
12
4444
46
48
PV110
BD150/ PT150/ TT150
¼”
BD104PT104TT104
BD108PT108TT108
CO2 from experiment
CO2 to experiment
42
PT342LT342
EH142TT142TS142
EH342TT342TS342
PV108
PV144
MV106
HX148
TT148
SV042 SV043
MV042
FL144
MV041
TT146
AV108
Freon chiller A
200
Freon chiller B
400
CO2 system B300 labels
10
LP101EH301 / EH302 / EH303TT301 / TT302 / TT303TS301 / TS302 / TS303PT301 / PT302 / PT303
4
FL344
BD304PT304TT304
MV3066
8
EH306TT306TS306
BD308PT308TT308
AV308
PV308
PV310
PV344
46 TT346
48 TT348
HX350
HX348
LP301
Fill portnc
nc
nc
nc
nc
nc
MV050
MV054MV052MV056
BD050
EV148 EV348
nc nc
50
BD350/ PT350/ TT350
SV040
MV040
SV041 BD108 10
MV058
NV110
MV110
NV310
MV310
nc
CV142
nc
CV342
[email protected] Documents in
preparation:
10
1. P&I document
2. Functional analyses
3. DCS interface
[email protected] CoBra Model (CO2 BRAnch Model)
11
R1x
R2x
R3x
R5x R2y+1
R3y+1
R4x R4y+1
R1y+1
R1 X+1 R2 X+1
R3 X+!
R5 X+1 R2 y
R3 y
R4 X+1 R4 y
R1 y
Px+1,Hx+1,Tx+1
Px,HxTx
Py+1,Hy+1,Ty+1
Py,Hy,,Ty
T 2
3
4
1
Px+1=dPx+1+Px
Hx+1=dHx+1+Hx
dH=Q1/MF
Q1 is calculated in the
thermal network
2
3
4
The thermal node network calculates the heat influx in the cooling pipe based on: •Applied power Q3 on node 3
•Environmental heating from fixed temperature T4 on node 4
•Heat exchange with another pipe section via R5 between nodes 2 and 2 of the connected
sections
Node network for IBL
12
Tenvironement
R4≈ HTCair
R2 +R3 ≈ TFoM
R1 ≈ HTCCO2
TCO2
Tenvironement
TCO2 TCO2
R4 +R3 ≈ Insulation+HTCair
R5≈ Heat exchange
R1≈ HTCCO2
R2 ≈ Tube wall
Q3 ≈ Applied power
Tenvironement
TCO2
R4 +R3 ≈ HTCair R1≈ HTCCO2
R2 ≈ Tube wall
Tenvironement
TCO2
R1≈ HTCCO2
R2 ≈ Tube wall
TCO2
R1b≈ HTCCO2
R1a≈ HTCCO2
R4 +R3 ≈
Insulation+HTCair
1. Concentric line
3. Bare tube
2. Bundled lines
4. Stave
Model configuration
13
ID (mm) Length
(m)
HX with
node
Power (W) Tambient
(ºC)
Node
network
1-2 1 6.3 7-8 20 1
2-3 1 2.6 6-7 20 2
3-4 1.5 3 -25 3
4-5 1.5 0.7 0,64,108 -25 4
5-6 2 3 -25 3
6-7 2.4 2.6 2-3 20 2
7-8 3 / 1.5 concentric 6.3 1-2 20 1
2
3
1
4
56
8
7For simplicity the model inlet
is cooled with its own outlet
Environment temperature inside
IST is taken to be -25⁰C (~stave
surface temperature)
14
0 5 10 15 20 25-45
-40
-35
-30
-25
-20
IBL temperature and pressure profile. MF=1g/s, Tsp=-40ºC, Q=108W, xend
=0.35
Branch length (m)
Tem
pera
ture
(ºC
)
1 2 3 4 5 6 7 8
10
11
12
13
14
15
Pre
ssure
(Bar)
T Structure (ºC)
T Tube wall (ºC)
T Fluid (ºC)
P Fluid (Bar)
-40 ⁰C cooling +15 ⁰C cooling (Commissioning)
Simulation results:
0 5 10 15 20 2510
15
20
25
IBL temperature and pressure profile. MF=1g/s, Tsp=15ºC, Q=64W, xend
=0.36
Branch length (m)
Tem
pera
ture
(ºC
)
1 2 3 4 5 6 7 8
50
53
56
59
Pre
ssure
(Bar)
T Structure (ºC)
T Tube wall (ºC)
T Fluid (ºC)
P Fluid (Bar)
[email protected] Flow balancing with
inlet capillary
15
0 0.5 1 1.5 2 2.50
2
4
6
8
10
12
14
Massflow (g/s)
Pre
ssure
Dro
p (
Bar)
Liquid
0 Watt
65 Watt
108 Watt
0 0.5 1 1.5 2 2.50
5
10
15
20
25
30
Massflow (g/s)P
ressure
Dro
p (
Bar)
Liquid
0 Watt
65 Watt
108 Watt
1mmID inlet tube. 0.8mmID inlet tube.
1.1 g/s
(15.4 g/s)
4 bar dP
1 g/s
(14 g/s)
6 bar dP
As detector performance does not depends too much on the
mass flow a 1mm inlet seems sufficient with some extra flow.
This flow gives extra margin for environmental heat pick-up.
9 bar dP
2 g/s
(28 g/s)
Design flow regime
Evaporator heat pick-up
• Due to long in and outlet lines a significant amount of parasitic heat is absorbed. The cooling system must be designed accordingly
• Shown absorbed heat is based on the environmental conditions shown in the table of page 18
• About 80 watt of parasitic heat load can be expected (Same order as IBL power)
• Total evaporator design heat load: 180Wx14=2.5 kW
16
0 0.5 1 1.5 2 2.5-50
0
50
100
150
200
Massflow (g/s)
Absorb
ed h
eat
(Watt
)
Liquid
0 Watt
65 Watt
108 Watt
Total absorbed heat including stave power.
Heat absorption calculated with an IST air temperature of -25⁰C (20 ⁰ C outside IST)
[email protected] Stave test results (1)
• Measured TFoM is excluding gradient caused by pressure drop due to absence of the long outlet line
17
0
5
10
15
20
25
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
TFo
M (⁰
C*
cm2)/
W
Silicon sensor ID#
TFoM of 1.5mm cooling tube stave (Flow unknown due to absence of flow meter)
187 (Watt), TCO2=-23.7ºC
69 (Watt), TCO2=-21.9ºC
29 (Watt), TCO2=-23.9ºC
87 (Watt), TCO2=-24.6ºC
118 (Watt), TCO2=-24.6ºC
149 (Watt), TCO2=-24.3ºC
68 (Watt), TCO2=-26.15ºC
68 (Watt), TCO2=-29.05ºC, flow reduced close to dry-out
10
11
12
13
14
15
16
17
18
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
TFo
M (⁰
C*
cm2 )
/W
Silicon sensor ID#
TFoM of IBL staves(ca. 90 Watt)
ID=2mm ID=1.5mm
Oct ‘11 Mar ‘12
Stave test results (2)
18
-30
-20
-10
0
10
20
30
40
0 2 4 6 8 10 12 14 16 18
Tem
pe
ratu
re (⁰
C)
Silicon heater ID#
Reversed flow stave temperatures of a 1.5mm cooling tube stave (Flow unknown due to absence of flow meter)
70 (Watt), TCO2=-24.7ºC, Reversed flow
186 (Watt), TCO2=-24.3ºC, Reversed flow
29 (Watt), TCO2=-24.6ºC,Reversed flow
345 (Watt), TCO2=-16.05ºC, Reversed flow flow increase
Inlet CO2 temperatureOutlet CO2 temperature (Reference of TFoM)
0 5 10 15 20 25 30 35 40 45 50-40
-30
-20
-10
0
10
20
TFoM (ºC*cm2/W)
Sensor
Tem
pera
ture
(ºC
)
T CO2=-40ºC
T CO2=-35ºC
T CO2=-30ºC
T CO2=-25ºC
T CO2=-20ºC
T CO2=-15ºCT CO2
=-10ºCT CO2=-5ºCT CO2
=0ºC
Nominal stave power Measurement IBL nominal condition
Thermal runaway
Maximum stave power in test set-up
345 Watt, Tsilicon<30 ⁰ C (-16⁰C CO2)
=> 4.8 kW! No problems during back-out!
MARCO project (The IBL prototype)
19
An IBL plant look-a-like (Similar specs) build together with
MPI Munich (prototype for their Belle-2 development)
A CO2 2PACL build in MPI
Controls build
at CERN-DT
2-stage chiller for IBL
temperatures from
ECR-Nederland
MARCO 2-stage chiller
• Frequency controlled 2-stage chiller concept is new for us and crucial for IBL low temperatures, MARCO commissioning is crucial for IBL.
• Challenge is the narrow temperature band as CO2 freezes at -56⁰C while IBL condenser temperature is -45 ⁰C and pump need some sub cooling (~5 ⁰C SC = -50 ⁰C liquid)
• MARCO 2-stage chiller fulfils IBL requirement of an estimated 3.5kW @ -50 ⁰C 20
0
0.5
1
1.5
2
2.5
3
3.5
4
4.5
5
-80 -70 -60 -50 -40 -30 -20
Co
oli
ng
Po
we
r (k
W)
R404a evaporation temperature ('C)
Bitzer 2-stage compressor S4T-5.2Y performance
60 Hz
30 Hz
Minimum load
(Hot gas by pass)
Marco max heat loadB
ack-p
ressu
re
reg
ula
tor
Long branch vacuum
shield
21
Super
insulation?
7x 1.5mmOD /
1.0mmID concentric
inlet tube
7x 4mmOD /
3mmID outlet
tube
Or a spacer only?
7x ??mmOD vacuum
tube
Tracking
LAR
Tile Calorie
We have to grasp the bundle from under-
neath the muons and bend it in place
50mm PVC tube mock-up
[email protected] Vacuum shielding
prototyping
22
At SLAC a prototype with a flexible
CO2 bellow is developed:
-> Very flexible but larger diameter
At Cryolab a prototype with a the
4mm tube is developed:
-> Stiff but bendable, has a reduced
diameter
Outcome of the tests will determine which one to use, maybe both are needed
depending on needed flexibility vs space available
[email protected] Conclusions and
outlook
23
• IBL Cooling system development status:
– Conceptual design of piping and control is
finalized.
– Detailed design will start after summer
• Ongoing prototyping of vacuum insulated
transfer lines
• Concept studies using MARCO
– 2-Stage chiller for low temperature
