02.06.2014lukasz zwalinskiatlas ibl co 2 cooling 1 co 2 cooling system for insertable b layer...

02.06.2014 Lukasz Zwalinski ATLAS IBL CO2 cooling 1

CO2 cooling system forInsertable B Layer detector into the ATLAS experiment

L. Zwalinski, C. Bortolin, T. Blaszczyk, S. Berry,F. Corbaz, G. Glonti, O. Crespo-Lopez,

J. Godlewski, M. Lippert, S. Nichilo, M. Ostrega,M. van Overbeek, P. Petagna, E. Roeland,

B. Verlaat, S.Vogt, M. Zimny

ATLAS experiment


Diameter: 25m Length: 46m

Barrel Toroid Length: 26m Overall weight: 7000 tonnes

~100 million electronic channels 3000 km of cables

IBL detector


ATLAS IBL Info:• Number of staves: 14• Number of modules per stave

(single/double FE-I4) 32 /16• Pixel size (f; z) 50, 250 um• Required cooling power: 1500W• Tevap min at 1.5kW = - 400C• Tevap max at 1.5kW = + 200C

Where do we come from?


2PACL concept Previous experience Preparation study ATLAS IBL

AMS 2

LHCb Velo

MARCO

CORA

20142011201020092008 2012

CO2 cooling plants


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

PV108

PV144

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

no

nc

MV050

MV054MV052 MV056BD054

PT054

EV148 EV348

nc nc

50

PT350/ TT350/ SC350

SV040 MV040

SV041 BD01210

MV058

NV110

MV110 MV310nc

CV142

nc

CV342

ncnc

ncnc

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

Main system elements:• 2 independent, redundant cooling plant cores • 2 independent, redundant two stage chillers• 1 common accumulator with redundant control • Common interconnection piping for

maintenance operations including vacuum pump

• Integrated internal by pass and small evaporator for stand-by operation

Designed cooling power at -400C = 3kW

Front side with foam box

CO2 pipes

Pump foam box

Flow meter

3kW heater

Valve

CO2 cooling primary chiller


Main system elements:

• R404a 2 stage compressor

• Air cooled and water cooled condenser

• Hot gas bypass & liquid injection

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)

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

Commercial standard refrigeration chiller

capable to work from zero to full IBL load!

Front side with c. cabinet and air condenser

Electronic cabinet Frequency inverter

Air cooled condenser

Back side with piping

2-stage compressor

Water cooling

Freon connections

Cooling system inside the service cavern


CO2 distribution from plant into detector


~100m concentric transfer line from manifolds to plant in service cavern

3424

DCS:TTa24 - TTn24(FTa24 - FTn24)

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 Cryoarea

HX036

½”

¾”x5/16”

⅜”

Dummy load (testing only)

BD020PT120 / PT320TT120 / TT320TTz20 (DCS)

DCS: TTa28 – TTn28 DCS: TTa30 – TTn30

BD036PT136 / PT336TT136 / TT336TTz36 (DCS)

MV035

EH117TT117TS117

26

2830

32

HX012

FL017

MV017

Manifold boxes (S5)

02

08

USA-15

USX-15

DN40 vacuum Vacuum system(LAR Cryo area)

DN40¼” ⅜”

¼”

½”

TTa02-TTn02

Transfer tubes (~92m)CO2: 10x1mm inside 21.3x2.11mm outside

16

A200 A100 B400 B300 C042

D012

UX15

Transfer lines


UX15Experimental cavern

Transfer line installed in October ‘13

USA15Service cavern

Service gallery

Fluid distribution inside toroid area


3kW dummy load heater

Manual valves

Sensors and inst.connection

Juncti

on box

Manifold box

Rotatable connector

Vacuum flexible to vac. manifold

Detector interconnections


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

• 14 staves of 70W each connected via concentric 29m long loops to manifolds in the muon area

• Cross flow of the CO2

• Required min. vacuum level 10-3 mbar• Standard vacuum components capable to work

in the vicinity of the magnetic filed.• Required constant pumping

Control system


CERN Technical Network

CERN GPN

OWS OWS OWS

EN/CV Terminal server

Detector Control System

DIP

CERN Control Room

Critical data tunnel from PLC to DCS

IBL plant ALocal MODBUS TCP/IP

Pneumatic lines

FESTO

WAGO I/Os

Local Touch Screen

Premium CPU Premium CPU

IBL plant BLocal MODBUS TCP/IP

Pneumatic lines

FESTO

WAGO I/Os

Local Touch Screen

Vacuum PLC

M340M CPU

Privet network Privet network

Controls:

• Schneider PLCs: 2x Premium + 1x 340 M all in technical network

• SCADA based on Siemens WinCC OA 3.11

• PLC and SCADA software based on UNified Industrial COntrol

System (UNICOS) Continuous Process Control CPC6 of CERN

• WAGO Ethernet IP distributed I/Os in privet network

• Access control via e-groups

• Long term data storage in LHC logging data base

• Grouped alarms send via LASER to CERN Control Centre (CCC)

• Communication to the Detector Control System (DCS) uses Data

Interchange Protocol (DIP)

• Additional direct MODBUS communication to DCS for critical data

• Hard wired signals connected to Detector Safety System (DSS)

• Siemens local touch screens used for the redundancy and safety

needs

Electricity and power distribution:

• Standard industrial components (ABB, Siemens, etc.)

• 24V DC hot swappable redundant power supplies

Few numbers for ATLAS IBL CO2 cooling software:

• ~230k lines of PLC code• 366 alarms and interlocks• 81 user interface panels

PH-DT standard

common for ATLAS and CMS CO2 cooling systems

(including TIF and P5 of CMS)

AnaDO 5Analog 13

Analog Alarm 43

Analog Digital 12

Analog Input 90

Analog Input Real 51

Analog Output 16

Analog Output Real 10

Analog Parameter 100

Analog Status 10

Controller 16

Digital Alarm 319

Digital Input 149

Digital Output 68

Digital Parameter 20

Local 20

OnOff 32

ProcessControlObject 4

Word Status 12

IBL A UNICOS object list

Fully commissioned!

User interfaces


• Click to edit Master text styles– Second level

• Third level– Fourth level

» Fifth level

Typical cold operation


Pressurization of the system

Cool down

-40’C set-point reached

1kW 2kW 3kW

-35’C set point

In current configuration 3kW is to much for -40’C operation, unable to hold set-point (green line)

Typical cold operation


Capable of maintaining set point from 0 to 3kW

0W 500W1000W 1500W 2000W

2500W

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

SP = -35’C

Typical reaction on load changes


Junction box saturation

Accumulator saturation

CO2 liquid temperature

Turbo-mode bit

Junction box heat load (1.5 kW)Chiller super heating (Control input)

Freon injection valve

Aggressive control in turbo-mode

turbo-mode needed to remain sub cooling

Temporarily accumulator cooling stops to give priority to CO2 liquid cooling

Summary


• All cooling units are running relatively smooth.

• All electrical and control verification and checks are completed.

• Commissioning continues via junction box until final connection with the detector

is completed.

• First observations shows:

• -40’C operation is more critical than expected

• -35’C operation is okay up to 3kW

• More heat load in liquid pump, meaning a higher needed minimum sub cooling.

• Direct effect on the lowest possible temperature.


Thank You.

ATLAS IBL CO2 cooling team:L. Zwalinski, C. Bortolin, T. Blaszczyk, S. Berry,

F. Corbaz, G. Glonti, O. Crespo-Lopez, J. Godlewski, M. Lippert, S. Nichilo, M. Ostrega,

M. van Overbeek, P. Petagna, E. Roeland, B. Verlaat, S.Vogt, M. Zimny

02.06.2014lukasz zwalinskiatlas ibl co 2 cooling 1 co 2 cooling system for insertable b layer...

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