fpix upgrade – status of co 2 cooling s tudies
DESCRIPTION
FPIX Upgrade – Status of CO 2 Cooling S tudies. S.Grünendahl, FNAL for the FPIX Upgrade Mechanical Group H. Cheung, G. Derylo, S.G., S. Kwan, C.M. Lei, E. Voirin (Fermilab) K. Arndt, Q. Liu (Purdue). FPIX CO 2 Cooling Areas of Progress. T ests since previous meeting:: - PowerPoint PPT PresentationTRANSCRIPT
1
FPIX Upgrade – Status of CO2 Cooling Studies
S.Grünendahl, FNAL
for the FPIX Upgrade Mechanical GroupH. Cheung, G. Derylo, S.G., S. Kwan, C.M. Lei, E.
Voirin (Fermilab) K. Arndt, Q. Liu (Purdue)
S.Grünendahl – CMS Pixel CO2 Meeting March 19, 2013
2
FPIX CO2 Cooling Areas of Progress
March 19, 2013 S.Grünendahl – CMS Pixel CO2 Meeting
Tests since previous meeting::2/12 1.4mm ID outer half-disk loop2/14 1.4mm ID inner half-disk loop2/21 1.6mm ID full length loop2/27 Multi-blade disk w/TC 5022 pocket slots for blade-ring jointFEA study of through slot joint
3 Half Disks
Port Cards and POH
End Flange
DC-DC converters
Pipes and Cables
CO2 cooling tubes and flex cables
3
Loop Tests UpdateFull length stainless steel tubing assemblies with dummy heat loads• Measure temperatures vs. flow &
pressure drop• Initial finding: pressure drop larger
than in simulation• Adding concentric heat exchanger,
to guarantee subcooled liquid, and fine-grained RTD placement to confirm transition to two-phase flow
• New studies:• variations in tube
diameter• inner/outer half
lengths configurations
March 19, 2013 S.Grünendahl – CMS Pixel CO2 Meeting
Supply Line
Return Line
Optional Concentric Tube Heat Exchanger
DC-DC & POH Evaporator
FPix Detector Evaporator
Supply & Return Manifolds
Existing Copper Lines
Manifold PP1 PP1 PP0 Near SC Endflange Inside FPix SC Inside FPix
Supply Line
Return Line
1st Half-Disk
3rd Half-Disk 2nd Half-Disk
4
Loop Setup
March 19, 2013 S.Grünendahl – CMS Pixel CO2 Meeting
subcooler
Fine grained RTD placement to locate onset of two-phase flow
5
1.6mm ID Full Loop Test
March 19, 2013 S.Grünendahl – CMS Pixel CO2 Meeting
6
Loop Tests: Combined Results
March 19, 2013 S.Grünendahl – CMS Pixel CO2 Meeting
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Loop Tests: Combined Results II
March 19, 2013 S.Grünendahl – CMS Pixel CO2 Meeting
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Joao’s CalculationsOuter loop, full heat load, lowest stable experimental mass flow (0.65 g/s) and 1.5 times l.s.e.m.f. (1.07 g/s)
March 19, 2013 S.Grünendahl – CMS Pixel CO2 Meeting
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Joao’s Calculation I
March 19, 2013 S.Grünendahl – CMS Pixel CO2 Meeting
0 1 2 3 4 5 6 7 8 9-25
-20
-15
-10
Length [m]
Tem
pera
ture
[°C
]
FPix HD Series RDT | m = 0.65g/s | Qtotal = 157.00W | dP = 0.99Bar | dT = 3.47°C
0 1 2 3 4 5 6 7 8 919.5
20
20.5
21
Pre
ssur
e [B
ar]
Theory Wall TemperatureTheory CO2 Temperature
Theory CO2 Pressure
100 150 200 250 300 350
10
20
30
40
50
60
70
80
-40°C -30°C -20°C -10°C 0°C 10°C 20°C 30°C
Enthalpy [kJ/kg]
Pre
ssur
e [B
ar]
m = 0.65g/s | Qtotal = 157.0W | Pin = 20.69Bar | Tin = -20.00°C | dP = 0.99Bar | xout = 0.86
0 0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 0.9 10
100
200
300
400
500
600
Vapor Quality
Mas
s V
eloc
ity [k
g/m
2 .s]
G = 194kg/m2.s | q = 2.22kW/m2 | Psat = 20.68Bar | xout = 0.29 | xdryout = 0.88
0 0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 0.9 10
100
200
300
400
500
600
700
800
900
Vapor Quality
Mas
s V
eloc
ity [k
g/m
2 .s]
G = 412kg/m2.s | q = 12.26kW/m2 | Psat = 20.59Bar | xout = 0.86 | xdryout = 0.75
10
Joao’s Calculation II
March 19, 2013 S.Grünendahl – CMS Pixel CO2 Meeting
0 1 2 3 4 5 6 7 8 9-21
-20
-19
-18
-17
-16
-15
-14
Length [m]
Tem
pera
ture
[°C
]
FPix HD Series RDT | m = 1.07g/s | Qtotal = 157.00W | dP = 1.16Bar | dT = 3.10°C
0 1 2 3 4 5 6 7 8 919.6
19.8
20
20.2
20.4
20.6
20.8
21
Pre
ssur
e [B
ar]
Theory Wall TemperatureTheory CO2 Temperature
Theory CO2 Pressure
100 150 200 250 300 350
10
20
30
40
50
60
70
80
-40°C -30°C -20°C -10°C 0°C 10°C 20°C 30°C
Enthalpy [kJ/kg]
Pre
ssur
e [B
ar]
m = 1.07g/s | Qtotal = 157.0W | Pin = 20.85Bar | Tin = -20.00°C | dP = 1.16Bar | xout = 0.52
0 0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 0.9 10
100
200
300
400
500
600
700
800
Vapor Quality
Mas
s V
eloc
ity [k
g/m2 .s
]
G = 319kg/m2.s | q = 2.22kW/m2 | Psat = 20.84Bar | xout = 0.17 | xdryout = 0.85
0 0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 0.9 10
200
400
600
800
1000
Vapor Quality
Mas
s V
eloc
ity [k
g/m2 .s
]
G = 679kg/m2.s | q = 12.26kW/m2 | Psat = 20.73Bar | xout = 0.52 | xdryout = 0.67
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Calculation vs. ExperimentLots of discussion and progress on understanding of difference simulation vs. experimentMany calculations by Joao (Thanks!)My conclusion:• all except Delta P seem to
agree• difference maybe not all that
surprising: Even (easier) single phase flow depends a lot on parameters like e.g. tube roughness that are hard to control
March 19, 2013 S.Grünendahl – CMS Pixel CO2 Meeting
(From Eric & Joao)
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Loop Test ConclusionBoth parallel (with 1.4mm ID) and serial (with 1.6mm ID) are viableDecision will have to take into account complexity, material accounting and redundancy/failure tolerance considerations
March 19, 2013 S.Grünendahl – CMS Pixel CO2 Meeting
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Multi-blade Tests: TC 5022 in Pocket Joints
Improved joint geometry control (dry fit to equalize radial play for all blades before assembly)
March 19, 2013 S.Grünendahl – CMS Pixel CO2 Meeting
A1 silicon 1 ctr -12.35A2 silicon 2 ctr -12.61A3 silicon 3 ctr -12.82A4 Blade 1 ctr -12.49A5 Blade 2 ctr -12.85A6 Blade 3 ctr -13.40A7 silicon 1 i -13.07A8 silicon 2 i -13.39A9 silicon 3 i -13.15
A10 silicon 1 o -13.34A11 silicon 2 o -13.94A12 silicon 3 o -13.67A13 Blade 1 i -13.29A14 Blade 2 i -13.70A15 Blade 3 i -13.53A16 Blade 1 o -14.42A17 Blade 2 o -14.90A18 Blade 3 o -14.68B1 Ring i 1 -15.72B2 Ring i 2 -15.16B3 Ring i 3 -15.64B4 Ring o 1 -16.35B5 Ring o 2 -15.85B6 Ring o 3 -16.39B7 silicon 4 ctr -11.70B8 Blade 4 ctr -12.00B9 silicon 4 i -13.05
B10 Blade 4i -13.27B11 Ring i 4 -15.22B12 silicon 4 o -13.16B13 Blade 4o -13.82B14 Ring o 4 -16.29B18 tubing mid -18.45B19 tubing in -18.84B20 tubing out -19.67
-12.6-12.8 -11.7
-12.9-13.4 -12.0
-13.1-13.4
-13.2
-13.9
-13.7
-13.2
-13.3-13.7
-13.5
-14.9
-14.7
-13.8
-15.7-15.2
-15.6
-15.9
-16.4
-16.3
∆T=0.3
∆T=0.6
∆T=-0.3
∆T=1.0
∆T=1.0
∆T=0.6
∆T=1.0
∆T=1.7
∆T=2.5
∆T=0.2
∆T=0.3
∆T=0.3
∆T=2.4
∆T=1.5
∆T=2.1
∆T from CO2 to inner ring = 3.5 4.1 3.6 4.0
-13.1-13.3-15.2
∆T=0.2∆T=1.9
-12.4-12.5
∆T=0.1
-13.3
-14.4
-16.4
∆T=1.1
∆T=2.0
∆T from CO2 to outer ring = 2.9 3.4 2.9 3.0
∆T from CO2 to silicon center = 6.9 6.7 6.4 7.6
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Ansys vs. Experiment
March 19, 2013 S.Grünendahl – CMS Pixel CO2 Meeting
Good match using data sheet material properties and nominal dimensions (i.e. no fudge factors)
15
ConclusionTC 5022 pocket joint fully qualified• Necessary joint QC depends on blade manufacturing tolerances; in any
case doable, even if a bit labor intensive
March 19, 2013 S.Grünendahl – CMS Pixel CO2 Meeting
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Blade-Ring Joint FEA Studies
Motivation: Through slot might have practical advantages for half-disk assembly
March 19, 2013 S.Grünendahl – CMS Pixel CO2 Meeting
Maximum Silicon Temperature
Radial Thermal Conductance (W/m^2/K)
2 5 10 25 50
Axial Conductance
2 0.91 -2.50 -5.13 -8.30 -10.65
5 -6.90 -7.70 -8.40 -10.14 -11.30
10 -10.03 -10.35 -10.59 -11.30 -11.83
25 -12.00 -12.08 -12.30 -12.34 -12.50
50 -12.73 -12.76 -12.78 -12.86 -12.94
Maximum Silicon Temperature
Radial Thermal Resistance (cm^2*K/W)
5 2 1 0.4 0.2
Axial Resista
nce
5 0.91 -2.50 -5.13 -8.30 -10.65
2 -6.90 -7.70 -8.40 -10.14 -11.30
1 -10.03 -10.35 -10.59 -11.30 -11.83
0.4 -12.00 -12.08 -12.30 -12.34 -12.50
0.2 -12.73 -12.76 -12.78 -12.86 -12.94
Nominal joint parameters (material & thicknesses)
Conclusion: radial heat transfer less important => might want to look at through slot again
(Caveat: Studies without CF in joint area – repeat with CF)
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Blade-Ring Joint FEA Studies II
Better structural strength if carbon fiber cladding continues into joint pocket/slot
Simulation looks ok
March 19, 2013 S.Grünendahl – CMS Pixel CO2 Meeting
S.Grünendahl – CMS Pixel CO2 Meeting 18
FPIX Cooling Layout ‘Decision Tree’ (from Kirk)
March 19, 2013
Left vs. Right HCs Symmetric (3 main
lines)or
Asymmetric (2+2 main lines)
HD Inner + Outer in
Series (1.6mm ID HD
tubing)
HD Inner + Outer inParallel
(1.4mm or 1.6mm ID HD tubing)
2 + 4 3 + 3
3 inners+
3 outers
Outer-inner-outer+
Inner-outer-inner
19
291396
η = 1.3 η = 1.6
η = 2.1
η = 2.5
2x8s 2x8s 2x8s
Z loc. TBD shown 491mm from IP
161
45
2x8s 2x8s 2x8s
Full geometry
20
η = 1.6
η = 2.1
η = 2.5
2x8s
2x8s
2x8s
2x8s
η = 1.6
η = 2.1
η = 2.5
2x8s
2x8s
Segmentation alternative #0 - Baseline - 1st HD on one main line + 2nd and 3rd HDs in parallel on the other main line = two
main cooling loops per Half-Cylinder
2nd + 3rd disks
1st disks
3 hits3.5 hits
3 hits
4 hits3 hits
2 hits
21
η = 1.3
η = 1.6
η = 2.1
η = 2.5
2x8s
2x8s
2x8s
η = 1.3
η = 1.6
η = 2.1
η = 2.5
2x8s
2x8s
2x8s
Outer-inner-outer
4 hits3 hits
2.5 hits
Inner-outer-inner
3 hits3.5 hits
2.5 hits
Segmentation alternative #1 – two cooling loops per Half Cylinder
(Total 4 cooling loops per end)
η = 1.6
η = 2.1
η = 2.5
2x8s
2x8s
2x8s
η = 1.6
η = 2.1
η = 2.5
2x8s
2x8s
2x8s
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Segmentation alternative #2 - All outers in parallel + all inners in parallel
on two main cooling loops per Half Cylinder
All Outers
4 hits3.8 hits
1.5 hits
All Inners
3 hits2.5 hits
3.5 hits
23
η = 1.6
η = 2.1
η = 2.5
2x8s
2x8s
2x8s
2x8s
η = 1.6
η = 2.1
η = 2.5
2x8s
2x8s
2x8s
2x8s
Segmentation alternative #3 – three cooling loops per two Half-Cylinders
(Total 3 cooling loops per end)
2nd + 3rd disks
1st + 3rd disks
3 hits3.5 hits
3 hits
4 hits3.5 hits
3 hits
24
η = 1.6
η = 2.1
η = 2.5
2x8s
2x8s
2x8s
2x8s
Segmentation alternative #3 – three cooling loops per two Half-Cylinders (cont.)
(Total 3 cooling loops per end)
1st + 2nd disks
4 hits4 hits
3 hits
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Summary Loop tests show both parallel cooling loops with
1.4mm ID and serial loops with 1.6mm ID are viable solutions
Multi-blade tests: TC 5022 in pocket slot has been fully qualified for blade – ring joint
Further multi-blade assembly tests for carbonized and soldered joint are in preparation
Discussion on optimizing the FPIX cooling loop connection scheme is underway
March 19, 2013 S.Grünendahl – CMS Pixel CO2 Meeting
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Backup Slides• Progress in related areas, from Purdue• Delta p vs. flow for different diameters• Tables for loop measurements
March 19, 2013 S.Grünendahl – CMS Pixel CO2 Meeting
• Designed custom front-end tools to pick-and-place HDI onto bare 2x8 bump-bonded modules.
• Semi-automated module assembly trials with prototype HDI will take place once these custom tools are fabricated.
• Work in progress to build a practical design and installation sequence for mounting, connecting, and cooling double-stacked port cards/POH in service (half) cylinders.
Custom tools for pick-and-placing the HDI onto the 2x8 bump-bonded
module
Progress@Purdue (from Kirk):
28
Delta P vs. Flow
March 19, 2013 S.Grünendahl – CMS Pixel CO2 Meeting
S.Grünendahl – CMS Pixel CO2 Meeting 29
Loop Measurement Tables
March 19, 2013