wp 11: detector cooling outline of the talk

DT Steering Board Meeting - April 30th 2010

WP 11: Detector Cooling - Paolo Petagna 1/19

PH-DT

WP 11: DETECTOR COOLING Outline of the Talk

• WP mandate• Human resources implicated• 2009 investment• Status and plans of projects (2010 – 2011)• Ideal “White Paper” budget 2010 – 2011 • Mid- & long-term perspectives



PH-DT

WP 11 Mandate (June 2009)

1.Future (CO2) Cooling Plants1.1 Construction of a functional CO2 “Proto-0” at Cryolab1.2 Two-Phase flow in CO2: models and correlations1.3 Design and construction of a standardized complete “portable” 2kW (?) unit1.4 Process modeling and dynamic simulation

2.“On Detector” Thermal Management2.1 Materials for thermal contact2.2 Structural materials with high thermal conductivity2.3 Local cooling through Micro-channels

3.Leak Search and in-situ Repair3.1 From “leak rates” to “fluid loss”3.2 Leak repair methods

4.New Instrumentation 4.1 Optical fibre-based Relative Humidity sensors (FOS)

+ Support to ATLAS and CMS cooling systems both on M&O and on specific R&D and refurbishment programmes

Agreed with PH management and experiments + endorsed by DCP

NOT COVERED IN THIS TALK



PH-DT

Human Resources for General R&D (2009-10)

NAME POS START TIME END ACTIVITIES

Daguin FELL Sep 09 70% Aug 11 m-channel cooling / Thermal materials / Engineering support

Dumps STAF Jul 09 20% - FOS / Thermal materials / Technical support

Godlewski STAF Oct 09 30% - CO2 / Leak search & repair

Mapelli USER Jul 09 90% …? m-channel cooling / Thermal materials

Moraux DOCT Nov 09 100% Oct 12 Process modeling / CO2 / Control support

Noel STAF Oct 09 60% - m-channel cooling / Technical support

Noite UPAS Jan 09 90% …? CO2

Nuessle USER Jul 09 100% … m-channel cooling

Petagna STAF Jan 09 85% - Coordination / FOS / m-channel cooling / Thermal materials

Tropea STAF Oct 09 40% - CO2 / Leaks search & repair

Zwalinski FELL Oct 09 50% Sep 11 CO2 / Control support

Effective total: 2.35 + 1.2 + 1 + 2.8 = 7.35

+ External Post-docs and “stagiaires” (~ 3 / year)1 Summer student (from June 2010)Jobs descriptions for trainees posted (2)Punctual use of technicians from ATLAS and CMS



PH-DT

July 2009: Start of Activity

23%

31%

6%

17%

11% 12%

New PH-DT cooling lab4 – 5 experimental areasTemporary office space

Small meeting spaceInstrumentation, test stand, DAQ

White Paper expenditure 2009 - TOT: 109 kCHF

(Material + subs. CERN personnel excluded)



PH-DT

Equipment Available

• Flexible and complete NI-based DAQ system• Miniaturized RTD and capacitive sensors for temperature and relative humidity measurement• General lab equipment (precision scale, RH calibration salts, magnifying glass, etc…)• A small portable dew point meter (Xentaur LTDP)• A -70 C dew point dry air source• Custom made temperature controlled environmental chamber connected to a gas mixer• One ad hoc light attenuation interrogation/DAQ system for tip-coated optical fibre sensors (planned for

substitution with a new wavelength interrogation/DAQ system for multiple FBG or LPG sensors in 2010).• Two small water-glycol cooling units, each capable of few hundred Watts cooling power at -20 C.• A large C6F14 cooling unit with cooling power in excess of 3kW @ -25 C and 6 bar head loss capacity,

pressure-boosted up to 15 bars for reduced flow rates.• Owned set of tools and components for piping, circuitry preparation and small electro-mechanical works.• Programmable RTD and signal simulators for the commissioning of new PLC-based control loops.• A high precision capacitive absolute manometer MKS “Baratron”• An EdgeTech “Dewmaster DM-C1” hygrometer with a 3 stage Peltier-cooled chilled mirror head for

precise absolute humidity reference down to dew points of the order of -75 ˚C• Two Krohne Optimass Coriolis flow meters• …



PH-DT

Status of 4.1 (RH FOS)

• Test set-up complete• Measurement principle proven• One morphology of tip-coated SnO2 sensor

validated• Static and dynamic behaviour analysed

between +20 and -20 °C

0.4 FTEExpenditure 2009: 18.5 kCHFBudget 2010: 48 kCHFCollaborations: TE/VSC, Napoli,

Sannio (possibly Wuppertal to join?)



PH-DT

Plans for 4.1 (RH FOS)

Complete the characterization of SnO2 refractometric (tip-coated) sensor with particular emphasis on reproducibility and T/RH calibration

• Launch the study of LPG-based multi sensors;• Material investigated: SnO2, TiO2, Al2O3 and

SW-CNT;• Deposition techniques: Sol-gel (Sannio),

Evaporation (CERN), Sputtering (CERN);• K-contract in preparation

Objective: full characterization of the sensor (including radiation hardness, reproducibility and production yield) by END 2010

Objective: Definition of the best suited coating, proof of feasibility of the deposition techniques by END 2011



PH-DT

Status of 2.3 (m-channel cooling)2.2 FTEExpenditure 2009: 12 kCHFBudget 2010: 5 kCHFCollaborations: Louvain, EPFL-

LMIS4, EPFL-LTCM, (Several potential partners discussing)

• Test set-up complete

• Silicon-Pyrex prototypes produced

• Pressure burst tests ongoing

• Fluid dynamic calculations for geometry

optimization

• Structural calculations for manifold

dimension and wall thickness optimization



PH-DT

Plans for 2.3 (m-channel cooling)

• Consolidation of the manifolds and m-channel design methods• Optimization of the manufacturing technique (e.g. Pyrex thinning…)• Feasibility of Silicon-on-Silicon fusion bonding techniqueObjectives: 1) Well mastered design & production technique: END 2010

2) Sound and validated proposal for NA62 GTK: END 2010

• Integration of cooling chip into GTK module• Minimization of material in sensitive area• Feasibility of evaporative CO2 heat transfer Objectives: 1) m-cooling / GTK module integration: MID 2011

2) Reliable assessment on minimal material and CO2: END 2011

• Preliminary engineering of configurations of potential SLHC interest (e.g. trigger layers, phase-2 PIX upgrades, etc): 2011

• Partnership with CMOSAIC (EPFL, ETH, IBM & others: http://esl.epfl.ch/page78902-en.html) to study integration in 3D architectures: 2011



PH-DT

Status of 1.3 (CO2 models and correlations)0.5 FTEExpenditure 2009: 0 kCHFBudget 2010: 0 kCHFCollaborations: TE/CRG (CryoLab),

Esslingen, EPFL-LTCM, + many institutes from experiments

• Application-driven tests ongoing in DT on

pressure/temperature drop in long mini-

pipes (straight and multi-bent geometry)

• Highly accurate base measurements

ongoing at Cryolab on HTC and flow

regimes in mini-pipes

• HTC and flow parameter test ongoing at

Esslingen on long Ø12 mm pipes

• Data provided to EPFL-LTCM for model

enhancement for CO2 applications



PH-DT

Plans for 1.3 (CO2 models and correlations)

• Continue the activity throughout 2011

• Act as a link between HEP laboratories and external institutes

• Create a database / repository of the produced information

• Disseminate good practice for test and design

• Interact with EPFL-LTCM towards optimized models for CO2 designers



PH-DT

Status of 1.1 / 1.2 (CO2 plants)1.1 FTEExpenditure 2009: 13 kCHFBudget 2010: 36 kCHFCollaborations: NIKHEF, EPFL-

LTCM, TE/CRG (CryoLab) + many institutes from experiments

• The prototype of a new CO2 2PACL cooling

unit (based on the LHCb VeLo system) is

complete and tested for leaks

• All controls and monitors are cabled and

commissioned

• Waiting for SC agreement for the final high-

pressure (~100 bar) safety test in order to

start warm operation

• Accumulator (needed for cold operation) in

fabrication / qualification at NIKHEF

(expected in few weeks)

• Constant analysis of the market for new

components to appear, allowing for possible

new solution



PH-DT

Plans for 1.1 / 1.2 (CO2 plants)

• Launch full operation of the CO2 prototype• Provide a test facility available for the experiments (piping, staves, etc)• Test new components, verify / modify controls• Make experience of use and train engineers and techniciansObjectives: 1) Test station available: SUMMER 2010

2) Operational life: EXTEND BEYOND 2011

• Compact and simplify the design of the prototype into a standard “rackable” unit with 1-2 kW power @ -40 °C

• Procure components and assemble a first unitObjectives: 1) Design of compact unit: END OF SUMMER 2010

2) First compact unit assembled: END 2010 (cost and delay time for accumulator to be verified)

• Procure or design and assemble a small (~ 100 W) unit, not necessarily “oil-free”

• Commission the unit and propose for wide distribution for small-scale testsObjective: Unit available for distribution: MID 2011



PH-DT

Status of 3.1 / 3.2 (Leaks)0.4 FTEExpenditure 2009: 0 kCHFBudget 2010: 40 kCHFCollaborations: TE/VSC,

Krakow (Discussion ongoing with other potential partners for 3.2)

• Leak investigation: new enhanced rack for

leak search including high precision

absolute manometer and reference volume

in assembly phase

• Leak quantification: old set-up previously

used for work on translation of He leaks into

liquid CnF2n+2 loss being refurbished

• Remote leak repair: Test section to

investigate the “fluid” proposed in

assembly



PH-DT

Plans for 3.1 / 3.2 (Leaks)

?

• Several “unconventional” methods of remote leak detection investigated at Krakow (k-contract in preparation). In particular the use of acoustic detectors

Objective: Detailed report on methods for remote leak detection and analysis suited for HEP detectors: MID 2011

• Extensive tests (fluid dynamics, chemistry, physics, geometrical compatibility, etc) on the proposed sealant agent (“Seal-Up”) both for water and for CnF2n+2 circuits

Objective: Detailed report of possibility of use of the sealant agent: END 2011

• Investigation to find a partner to study more exotic (active) devices for remote leak repair ongoing…



PH-DT

Status and Plans for 1.4 (Process Modeling)

• Move from Cryo experience (EN/ICE) and

apply the technique to cooling systems

• Check validity of existing objects

• Modification of some components

• Integrate CO2 data from REFPROP and

from LATEST ENHANCED MODELS

• Investigate new components– Condenser– Evaporator

Mi,jEi,j

ρi,j

Mi-1,jEi-1,jρi-1,j

Ei+1,jρi+1,j

0.8 FTEExpenditure 2009: 0 kCHFBudget 2010: 5 kCHFCollaborations: Grenoble, EN/ICE,

EPFL-LTCM (possibly Krakow)

Objective: Develop a dynamic simulator modeling the full process of the CO2 prototype END 2011



PH-DT

Status and Plans for 2.1 (Thermal Materials)1.0 FTEExpenditure 2009: 0 kCHFBudget 2010: 45 kCHFCollaborations: EN/MME, EPFL-

LPMC, CNR-Napoli, experiments

• Launch activity on definition of new generation

thermal adhesives

• Assumed benchmark: Al Technology ME7159

diamond-filled epoxy (~ 11 W/mK)

• Investigate SU-8 doping with diamond and with

CNT’s (EPFL)

• Investigate doping of Araldite 2011 epoxy and of

an RTV silicon with metal nano-wires, diamond

nano-particles and CNT’s (CNR Napoli)

Objective: Detailed reports on doping methodologies and obtained results with different adhesives: END 2011



PH-DT

Allocation of “White Paper” Financial Resources

2009 : effective expenditure2010 – 11 : “optimal” projection for

fixed objectives

Included:• Equipment• Material• Consumables• External collaborations• SubsistenceCERN Manpower not accounted for

4 x (projects 2009) +40% Equipment 2009 +Travel / Training



PH-DT

Mid- & Long-Term Perspectives

Relative Humidity FOS: Follow-up the engineering and industrialization of

the selected sensor(s)

Micro-channel cooling: Ensure full integration in the NA62 GTK module

Engineer solutions of interest for SLHC (and ILC)

CO2 cooling: Develop (and maintain?) laboratory cooling units (2

scales)

Collaborate to future CO2 cooling plants for experiments

Remote leak search and repair: long-term activity to be continued

Process modeling: Develop a standardized tool for use in all experiment for

commissioning, enhanced operation and training

Thermal materials: Follow-up the engineering and industrialization of the

selected solutions

wp 11: detector cooling outline of the talk

Documents

local cooling

detector cooling outline

channel cooling petagnastafjan

watts cooling power

cms cooling systems

future co2 cooling plants1

new phdt cooling lab4

large c6f14 cooling