phase 1 fpix cooling loop design
DESCRIPTION
Phase 1 FPix Cooling Loop Design. Kirk Arndt February 1, 2012 ( on behalf of CM Lei, Erik Voirin , Simon Kwan , Joe Howell). Tubing within Rings. Coupler bonded 2 tubing together permanently, further development and proof of feasibility needed. - PowerPoint PPT PresentationTRANSCRIPT
Phase 1 FPix Cooling Loop Design
Kirk ArndtFebruary 1, 2012
(on behalf of CM Lei, Erik Voirin, Simon Kwan, Joe Howell)
CMS Phase 1 FPix Cooling Loop Design 2
Typical bending R for tubing beyond ring = 1/8” = 6.35mm
1-Feb-12
Coupler bonded 2 tubing together permanently, further
development and proof of feasibility needed
HD Tubing AssemblyLength = 3,209 mm
Couplers bond tubing between half-rings permanently,
further development and proof of feasibility needed
Tubing within Rings
CMS Phase 1 FPix Cooling Loop Design 31-Feb-12
Tubing Length Info
Outer-Outer Outer-Inner Inner-Inner Inner-Outer
L (mm) 1134 739 501 835
Outer Outer Outer Inner Inner Inner Inner Outer
CMS Phase 1 FPix Cooling Loop Design 41-Feb-12
1.435mm ID/1.638mm OD SS tubing connects all rings in a Half-Disk in series
To optimize:– examine the ∆T reduction vs. material increase if changing to 1.63mm
ID tubing.– examine the ∆T reduction vs. material increase if changing to parallel
flow to Outer Assembly and Inner Assembly.– conduct a 4-blade thermal test to verify the ∆T from coolant to pixel
modules.– conduct a single tube mock-up CO2 cooling test to verify the ∆T along
the tube with simulated detector heat load.
Baseline Design of HD Cooling Tube
CMS Phase 1 FPix Cooling Loop Design 5
Cooling Calculations for HD1<< Courtesy from Joao Noite >>
1
2 3 4 5
6
7
8
9
10
11
ID 1.435 mm ST Supply DC-DC ST PC ST O-O O-I I-I I-O ST ReturnFlow Path 1->2 2->3 3->4 4->5 5->6 6->7 7->8 8->9 9->10 10->11Qt [W] 0 30.00 0 15 0 61.20 40.8 26.4 39.6 0d [m] 0.002 0.002 0.002 0.002 0.002 0.001435 0.001435 0.001435 0.001435 0.0028lt[m] 1.1 0.9 0.35 0.9 0.95 1.134 0.739 0.501 0.835 2.345t [m] 0.0001 0.0001 0.0001 0.0001 0.0001 0.00005 0.00005 0.00005 0.00005 0.0001kw [W/m.°C] 16 16 16 16 16 16 16 16 16 16
1-Feb-12
ID 1.63 mm ST Supply DC-DC ST PC ST O-O O-I I-I I-O ST ReturnFlow Path 1->2 2->3 3->4 4->5 5->6 6->7 7->8 8->9 9->10 10->11Qt [W] 0 30.00 0 15 0 61.20 40.8 26.4 39.6 0d [m] 0.002 0.002 0.002 0.002 0.002 0.00163 0.00163 0.00163 0.00163 0.0028lt[m] 1.1 0.9 0.35 0.9 0.95 1.134 0.739 0.501 0.835 2.345t [m] 0.0001 0.0001 0.0001 0.0001 0.0001 0.00005 0.00005 0.00005 0.00005 0.0001kw [W/m.°C] 16 16 16 16 16 16 16 16 16 16
Tubing diameters and lengths are the same from point 1 to point 6 before coolant entering O-O,and on the return line from point 10 to point 11.
Ring I-O of the 4 rings is cooled last
CMS Phase 1 FPix Cooling Loop Design 6
0 1 2 3 4 5 6 7 8 9 10-25
-20
-15
-10
Loop Length [m]
Tem
pera
ture
[°C
]
m = 1.87g/s | Qtotal = 213.00W | Pin = 22.10Bar | Tin = -20.00°C | dP = 2.44Bar | dT = 5.52°C
0 1 2 3 4 5 6 7 8 9 1018
20
22
24
Pre
ssur
e [B
ar]
Theory Wall TemperatureTheory CO2 Temperature
Theory CO2 Pressure
ST S
uppl
y
DC-D
C
ST PC ST O-O
O-I
I-I I-OST Return
0 1 2 3 4 5 6 7 8 9 10-25
-20
-15
-10
Loop Length [m]
Tem
pera
ture
[°C
]
m = 1.87g/s | Qtotal = 213.00W | Pin = 21.20Bar | Tin = -20.00°C | dP = 1.58Bar | dT = 4.22°C
0 1 2 3 4 5 6 7 8 9 1019
20
21
22
Pre
ssur
e [B
ar]
Theory Wall TemperatureTheory CO2 Temperature
Theory CO2 Pressure
ST S
uppl
y
DC-D
C
ST PC ST O-O
O-I
I-I I-O
ST Return
HD1 (1.63mm ID)HD1 (1.435mm ID)
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 = 1.87g/s | Qtotal = 213.00W | Pin = 22.10Bar | Tin = -20.00°C | dP = 2.44Bar | xout = 0.40
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 = 1.87g/s | Qtotal = 213.00W | Pin = 21.20Bar | Tin = -20.00°C | dP = 1.58Bar | xout = 0.40
liquid starts boiling at ~-17°C corresponding to saturation pressure of 22.1 bar
liquid starts boiling at ~-18°C corresponding to saturation pressure of 21.2 bar
1-Feb-12
CMS Phase 1 FPix Cooling Loop Design 7
HD1 (1.63mm ID)HD1 (1.435mm ID)
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
1200
1400
1600
Vapor Quality
Mas
s V
eloc
ity [k
g/m
2 .s]
G = 1156kg/m2.s | q = 11.97kW/m2 | Psat = 21.61Bar | xout = 0.18 | xdryout = 0.57
A D
M
I
SLGS SW
B
O-O
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
1200
1400
1600
Vapor Quality
Mas
s V
eloc
ity [k
g/m
2 .s]
G = 1156kg/m2.s | q = 12.25kW/m2 | Psat = 21.16Bar | xout = 0.27 | xdryout = 0.57
A D
M
I
SLGS SW
B
O-I
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
1200
Vapor Quality
Mas
s V
eloc
ity [k
g/m
2 .s]
G = 896kg/m2.s | q = 10.54kW/m2 | Psat = 20.83Bar | xout = 0.19 | xdryout = 0.63
A D
M
I
SLGS SW
B
O-O
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
1200
Vapor Quality
Mas
s V
eloc
ity [k
g/m
2 .s]
G = 896kg/m2.s | q = 10.78kW/m2 | Psat = 20.56Bar | xout = 0.27 | xdryout = 0.63
A D
M
I
SLGS SW
B
O-I
1-Feb-12
CMS Phase 1 FPix Cooling Loop Design 8
HD1 (1.63mm ID)HD1 (1.435mm ID)
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
1200
1400
1600
Vapor Quality
Mas
s V
eloc
ity [k
g/m
2 .s]
G = 1156kg/m2.s | q = 11.69kW/m2 | Psat = 20.75Bar | xout = 0.32 | xdryout = 0.57
A D
M
I
SLGS SW
B
I-I
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
1200
1400
1600
Vapor Quality
Mas
s V
eloc
ity [k
g/m
2 .s]
G = 1156kg/m2.s | q = 10.52kW/m2 | Psat = 19.82Bar | xout = 0.40 | xdryout = 0.58
A D
M
I
SLGS SW
B
I-O
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
1200
Vapor Quality
Mas
s V
eloc
ity [k
g/m
2 .s]
G = 896kg/m2.s | q = 10.29kW/m2 | Psat = 20.32Bar | xout = 0.32 | xdryout = 0.63
A D
M
I
SLGS SW
B
I-I
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
1200
Vapor Quality
Mas
s V
eloc
ity [k
g/m
2 .s]
G = 896kg/m2.s | q = 9.26kW/m2 | Psat = 19.78Bar | xout = 0.40 | xdryout = 0.64
A D
M
I
SLGS SW
B
I-O
1-Feb-12
CMS Phase 1 FPix Cooling Loop Design 9
HD1 (2.0-1.63-2.8mm ID)HD1 (2.0-1.43-2.8mm ID)
HD1 2.0-1.43-2.8mm 2.0-1.63-2.8mm
Pin 22.1 21.2
dP 2.44 1.58
Wall Tin for ring OO -15 -16.2
Wall Tin for ring OI -15.9 -17.1
Wall Tin for ring II -16.8 -17.8
Wall Tin for ring IO -17.5 -18.2
Wall Tout for ring IO -19.1 -19.1
Wall ∆T for 4 rings 4.2 2.9
Last Ring I-O Vapor Quality at Dryout 0.58 0.64
1-Feb-12 Conclusion: Larger tubing performs better with extra 6% margin from dryout.
CMS Phase 1 FPix Cooling Loop Design 10
3 removable couplings; each weighs 0.7 g2 permanent couplings btw outer & inner rings1 supply + 1 return tube per HD
4 removable couplings2 permanent couplings btw outer & inner rings2 supply + 2 return tubes per HD
Possible Parallel Flow Layout
1-Feb-12
Baseline Serial Flow Layout
CMS Phase 1 FPix Cooling Loop Design 111-Feb-12
Possible Parallel Flow LayoutWant to calculate ∆P & ∆T of parallel flow to Outer and Inner Assemblies with 1.435mm ID tubing in rings
CMS Phase 1 FPix Cooling Loop Design 12
-17.6oC-18.2oC
New I-I start if cooling last
-16.9oC
-19.2oC
IO start IO end II start II endexisting wall temp, IO last -17.6 -19.2 -16.9 -17.6proposed wall temp, II last -16.9 -18.2 -18.2 -19.2∆ T 0.7 1 -1.3 -1.6
HD1 (2.0-1.43-2.8mm ID)
These temperatures were used as the heat sink temperatures
for the blade FEA
These temperatures were used as the heat sink temperatures
for the blade FEA(see next slides)
Study on whether the Inner-Inner ring should be cooling last<< The total ∆T across the 4 rings is the same >>
Existing I-I start if cooling second-to-last
1-Feb-12
CMS Phase 1 FPix Cooling Loop Design 13
Alternative, Inner Inner Ring cooled last:Inner Outer ring temp = -16.9oCInner Inner ring temp = -18.2oCMax Temp on Module = -11.3oC∆T = 6.9 C across the whole model
Comparing results with different heat sink temps TIM conductivity at blade ends = 1 W/m-K
Baseline, Inner Outer Ring cooled last:Inner Outer ring temp = -17.6oCInner Inner ring temp = -16.9oCMax Temp on Module = -11.1oC∆T = 6.5 C across the whole model
1-Feb-12
CMS Phase 1 FPix Cooling Loop Design 14
Alternative, Inner Inner Ring cooling last:Inner Outer ring temp = -16.9oCInner Inner ring temp = -18.2oCMax Temp on Module = -15.1oC∆T = 3.1 C across the whole model
Comparing results with different heat sink temps TIM conductivity at blade ends = 34 W/m-K
Baseline, Inner Outer Ring cooled last:Inner Outer ring temp = -17.6oCInner Inner ring temp = -16.9oCMax Temp on Module = -14.9oC∆T = 2.7 C across the whole model
Module inner radius end temp =
-15.5oC
Module inner radius end temp =
-16.5oC
1-Feb-12
CMS Phase 1 FPix Cooling Loop Design 15
Ring Cooled Last Inner-Outer Ring Inner-Inner RingTemperatures I-O -17.6oC -16.9oC
Temperatures I-I -16.9oC -18.2oC
If TIM at blade ends is 1 W/m-K
Max Temp on Module -11.1oC -11.3oC
∆T of the whole model 6.5oC 6.9o C
∆T across the TIM 3.9oC on IO & 4.1oC on II 3.5oC on IO & 4.9oC on II
Reaction Heat Load to IO 3.85 W (64.2%) 3.42 W (57.0%)
Reaction Heat Load to II 2.15 W (35.8%) 2.58 W (43.0%)
If TIM at blade ends is 34 W/m-K
Max Temp on Module -14.9oC -15.1oC
∆T of the whole model 2.7oC 3.1oC
∆T across the TIM 0.2oC on IO & 0.2oC on II 0.1oC on IO & 0.3oC on II
Reaction Heat Load to IO 3.81 W (63.5%) 2.77 W (46.1%)
Reaction Heat Load to II 2.19 W (36.5%) 3.23 W (53.9%)
Summary on FEA Results on Which Ring is Cooled Last
Inner-Outer Ring cooled last (existing design) in the 4-tubing series connection scheme has a smaller ∆T, but at a slightly warmer module temperature.
1-Feb-12
CMS Phase 1 FPix Cooling Loop Design 161-Feb-12
Backup slides
CMS Phase 1 FPix Cooling Loop Design 171-Feb-12
• 2 blades will be bonded to C-C ring segments with indium and the other 2 with thermally conductive epoxy
• Coating process on parts is being prepared
• Tooling for bonding blades was machined (this was designed for epoxy joints, some adjustments are needed for bonding with indium due to thermal changes)
• Some dummy 2x8 modules with module holders and flex heater were made
• Considering indium as the thermal filler between the tubing and the ring groove
4-Blade Thermal Testing Assembly
CMS Phase 1 FPix Cooling Loop Design 18
These FEA results appear overly optimistic…considering indium as the thermal filler between tubing and ring groove to promote heat transfer into the tube
Study on Heat Transfer of Different Tubing Sizes in C-C Ring Groove
Temp Plot on
Epoxy OnlyTubing OD 1.63 1.82
Groove ID 1.75 1.93
CC Thickness 2.00 2.25
Radial epoxy thickness 0.058 0.056
∆T across 10 mm model 1.66 1.66
∆T across epoxy layer 1.05 1.06
1-Feb-12
CMS Phase 1 FPix Cooling Loop Design 19
A New Plastic Prototype for the HD Outer Assembly - will be used to check fit of tubing with bends and coupling fittings
1-Feb-12
CMS Phase 1 FPix Cooling Loop Design 20
Male nut with M3.5 threads and welded with tubing
Gland welded with tubing
Replaceable aluminum gasket
Female nut with M3.5 threads
CO2 Cooling Coupling Design
1-Feb-12
Front face with knife-edge Front face with knife-edge
CMS Phase 1 FPix Cooling Loop Design 21
CO2 Cooling Coupling Status
Two sets of assemblies were laser-welded• Direct welding was done on gland • Welding rod 312 SS was used for male
thread nut because of larger part tolerance (0.005” vs. 0.002”)
Vacuum leak check was made on both assemblies• No leak on aluminum washer sealing• No leak on gland weld• Leak on the male thread nut weld
Quick conclusion: Design and fabrication method OK, but requires tighter fitting tolerance
Plan: leak on the weldment will be fixed and a pressure test will be conducted before a new round of coupling parts is machined.Will follow Hans suggestion and try vacuum brazing or low-temp soldering (which would remove the need for threaded couplers)
Weld for gland
1-Feb-12
Weld for male threaded fitting