Download - 14 May 2009Hans Postema - CERN CMS Upgrade Workshop Tracker Phase I upgrades 14 May 2009 1
14 May 2009 Hans Postema - CERN
CMS Upgrade Workshop
Tracker Phase I upgrades
14 May 2009
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CO2 cooling
• Distributed effort in many different places
• Lot of progress everywhere
• Study and engineering are advancing
• Some installations are built
• Some installations are running
• Some preliminary results
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Participating places (1)
• Aachen – Lutz Feld, Michael Wlochal
• Lyon – Nick Lumb, Didier Contardo
• Karlsruhe – Wim de Boer et al.
• Fermilab – Simon Kwan, Richard Schmitt, Terry Tope, Kirk Arndt
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Participating places (2)
• CERN Cryolab – Friedrich Haug, Jihao Wu, Torsten Koettig, Christopher Franke
• University Esslingen – Walter Czarnetzki, Stefan Roesler
• CERN DT group – Joao Noite, Antti Onnela, Paolo Petagna
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Participating places (3)
• PSI – Roland Horisberger, Stefan Koenig
• CERN CMS –Duccio Abbaneo, Paola Tropea, Hans Postema
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System overview
• Thin and light pipe inside the detector
• Pipe connecting techniques
• Existing pipe-work inside CMS detector
• Cooling station– Pump, heat exchangers, components
• Interface to cooling plant in USC
• Control system
• Other items
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Lyon test setup
• System operated from CO2 bottle
• 5.5 m tube ID=1.4 mm
• Simulates Pixel barrel tube
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Set-up in Lyon
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5.5 m tube in the freezer
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Last results Lyon
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CERN Cryolab setup
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CERN Cryolab setup
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CERN-DT setup
• System operated from CO2 bottle
• 5.5 m tube ID=1.4 mm
• Simulates Pixel barrel tube
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Detector Cooling Tube Requests
• The preferred cooling liquid temperature during operation is around -12°C, which corresponds to a pressure of 25 Bar.
• The Pixel Barrel cooling tube is specified as ID=1.5 mm, wall thickness 50 microns.
• Layer 1 of the Pixel detector dissipates 144 W over a cooling pipe length of 5.5 m.
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CO2 Cooling Test Setup
DataAcquisitionSystem
Test Zone
CO2 Test Rack
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Temperature Sensors Placement
PT100 TemperatureSensors
Detector Tube ID = 1.4 mm
Insulation
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Test Zone
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Data Aquisition System
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Temperature vs Lenght
• Power = 144 W• Mass Flow = 1 g/s• ΔT ≈ 3.7°C• ΔP ≈ 2.5 Bar
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CO2 Cooling Test Next Steps
Tube testing using diferent conditions of:
• Mass Flow
• Power
• Pressure
• Tube Geometry
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dT at - 9 C
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Power=145WMass Flow=1g/sPressure=27 BarΔT=2.6°CΔP=1.9 Bar
dT at – 21 C
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Power=144WMass Flow= 1g/sPressure= 19 BarΔT=5.4°CΔP=2.9 Bar
Existing cooling pipes
• The currently installed cooling pipes are virtually impossible to replace
• People ask: “Is this really the case”
• Please have a look at the following slides
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YB0 – fully cabled
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YB0 - numbers
• Tracker cooling pipes below all the cables• HB: 180 cables, 180 optical fiber cables• EB: 1600 cables, 180 optical fiber cables• Tracker: 3000 cables, 640 Optical fiber
cables• 9 month plus, installation time• Removing and reinstalling ~10 year old EB
cables is inviting trouble
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Re-use of installed pipes
• The currently installed pipes are OD=14 and OD=16 mm copper pipes with a wall of 1 mm
• Cannot be used for 2 phase CO2 cooling without special precaution
• But can be used when the system design takes care that pressures remain below a limit
• Avoiding 100+ bar pressures is also advantageous for detector design
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Storage tank
• The system contains a cooled storage tank • When system is inoperative, all liquid is
condensed in the tank, all warm components are filled with gas (Standard for cryogenic systems)
• A very similar system is used for the CDF COT flange cooling, same concept, different fluid, different temperature. See next slide
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CDF – COT endplate cooling
Courtesy Richard Schmitt FNAL
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Operation modes
• Normal operation, system cooled by commercial chiller, CO2 temperatures between 0 and -20 C, pressures 35 to 20 bar
• Strong request for detector operation with coolant at +15 C (50 bar). This to avoid condensation during the installation and testing phase.
• For this a safety valve setting at 57 bar, corresponding to +20 C seems acceptable.
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Meeting with CERN safety
• Meeting with Benoit Delille on 5/12/2008
• Using French safety code CODAP-2000
• Stress limit during operation: UTS/4
• Stress limit during test: UTS/2.6
• Thus pressure test at 1.43x max. operating pressure
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Questions from safety
• Questions by CERN-safety concerning safety factors during operation and during test, certificates of installed materials and quality control of the brazed connection have been answered and documented.
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Summary
• With this system design, max coolant temp at 15 degrees C and safety valve at 57 bar, the currently installed copper tubes can be approved by CERN safety
• We shall build one equivalent circuit for destructive testing by CERN safety
• We will pressure test the installed copper tubes with gas at 1.25x57=71 bar
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System aspects 1
• Aachen is building a re-circulating system. Experience with pump, heat exchanger and other components will be useful for all CO2 systems
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heat removal
design considerationso load: 500 W maximumo CO2 temperature at detector:
-45°C … +20°Co precise temperature controlo precise flow measuremento continuous operationo safe operation (100 bar max.)
chiller temperature vapour pressure evaporation temperature
Re-Circulating CO2 Cooling Test System
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Chiller 2
Chiller 1
flow meter
Implementation of Re-Circulating CO2 Cooling Test System
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Components
Chiller 1: Huber Unistat 815 (1.2 kW@-60C)
Chiller 2: Huber CC-505
Expansion Vessel: Swagelok 304LHDF4-1Gal
Levelmeter: Rechner SensorsKFS-1-500-365-PEEK-VA-3/4“
Heat Exchangers: SWEP B16DWx8/1P-SC-U
Pump: GATHER 1MX-X/12-11/X-SS/S/Q/K200/HDT/DS2D50
Flow Meter: Rheonik RHM015-T2-P1-SM0-M0-G1-N
Piping, fittings etc.: Swagelok
Frame: ITEM
Temperature Probes: various
System aspects 2
• Fermilab is looking into system aspects, investigating into pump and heat exchangers.
• Calulations by Terry Tope determining pressure drops due to sharp bends in detector pipes.
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COCO22 System
• We would like to build a prototype COCO22 cooling
system at Fermilab• Goals: for testing the completely assembled pixel
half-cylinder (3 half-disks) and gaining operation experience of a COCO22 cooling system; design and
experience may be expandable and valuable to the final system at P5 or useful for Track/trigger layer R&D at Fermilab
• Design spec: be able to operate detector at ~18C to -10C; total heat load ~ 1 kW; chiller can cool down to -40C (design with safety margin)
System aspects 3
• Karlsruhe is providing TEC cooling plant for system test purposes, acquired LEWA pump and a HEX.
• Planning on building a large scale test setup in a joint effort together with DT and Cryolab
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Conclusions
• Distributed effort over many different places.
• All critical aspects receive attention.
• Maintaining the excellent and open communication that we have today, is the most crucial ingredient for success.
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