bverlaat@nikhef.

nl

Atlas Inner B-Layer CO2 cooling system

CMS Tracker Week, 17 July 2012

Bart Verlaat Jan Godlewski

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Atlas Inner B-Layer (IBL)

IBL detector: 80mm x 800mm 1.5 kW @ -40C 14 staves with 1 cooling pipe

Pixel detector chips (71 watt/stave)

New detector with smaller beam pipe in space of current beam pipe

Carbon foam structure 1.5mm ID titanium cooling pipe

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IBL cooling requirements

Conclusion:
A CO2 system with an evaporator capacity of 1.5kW, operational from +20C to -40C Accessible manifolds Redundant cooling plant Fail safe operational during back-out (blow system) 3

https://edms.cern.ch/document/1204776/1

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Atlas IBL Thermal runnaway

Atlas IBL Atlas IBL 6 Vbias=1000 V
oM =5

30

20
oM TF =40 oM TF =35 oM = TF 30 oM = TF 25 oM =2 0 TF oM =1 5 TF oM =1 0

Int.lum=550 fb-1

Sensor Temperature (C)

10

TF

Heatflux (W/cm 2)

4 Qsensor (W/cm2) Qmodule (W/cm2)

TF

-10

2 -20 Vbias=1000V & I0=0.675 mA @ T0=-15 C -30 Qsensor=0.19989 W/m 2, Qchip=0.38202 W/m 2 Asensor=3.3768 cm , Int.lum=550fb -40 -40 -30 -20 -10 0 TCO2 (C) 10 20
2 -1

Significant leakage current effect on sensor power

30

0 -40

-30

-20 -10 0 Sensor Temperature (C)

10

20

A TFoM of 20C*cm2/W and a cooling of -35C gives a silicon temperature of -25C. Thermal runaway starts to be visible at a cooling temperature of -25C (-10C sensor temperature)
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IBL cooling layout in Atlas

Accessible manifolds

Vacuum insulated concentric transfer tube

Vacuum insulated capillaries

Tile Calorie

LAR

LAR

Capillaries in IDep

Tracking

14 IBL staves

LAR

IBL Cooling pipes layout

bverlaat@nikhef.nl

(C-Side view)
Foam insulated junction piping Foam insulated junction piping (With condensation condensation channels) channels) (With

In- and outlet Inand outlet Manifolds Manifolds

Vacuum insulated straight concentric transfer tube Vacuum insulated Vacuum insulated Concentric tubes Concentric tubes

LAR station

To USA-15 cavern
Foam insulated transfer tubing (Concentric TBV)

Inlet capillaries and Inlet capillaries outlet lines and outlet lines

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Cooling system P&I

Detector boundary LAR Cryo area
PT114/ PT314 TT114 / TT314 HX014
14

Junction box @ Muon Sector 5 (Accessible)

BD016 PT116 / PT316 TT116 / TT316
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PT192/ PT392 MV016

92

x5/16

HX036 MV036
36

x5/16
HX038

FL016

Vacuum insulated concentric tube (~13 m)

MV592
VP592

PT138 / PT338 TT138 / TT338

38

Transfer tubes (~72m)

AV016 BD018 PT118 / PT318 TT118 / TT318

EH117 TT117 TS117

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Dummy load (testing only)

MV017

BD036 PT136 / PT336 TT136 / TT336 TTz36 (DCS)

VP591

MV593

MV591
91 PR591

HX012

16mm vacuum line

MV035

PT191 / PT391

MV018

FL018 MV034

12

93

BD020 PT120 / PT320 TT120 / TT320 TTz20 (DCS)

16mm vacuum
20

PT193 / PT393
22

40 10 10

EH122 TS122

DCS: TTa24 TTn24

24 34

Vacuum insulation
CO2 plant A 100
32 26

Tile calorie meter

26 32 28 30

Freon chiller A 200

Freon chiller B 400

CO2 plant B 300

LAR calorie meter Tracking detectors

DCS: TTa28 TTn28 DCS: TTa30 TTn30
30 28

14 IBL staves (a-g),(7 flow pairs) Dry volume (7x A-C flow / 7x C-A flow)

USA-15

IBL CO2 Cooling layout

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Cooling system redundancy approach

Two cooling plants (A&B) sharing a common transfer piping and accumulator Dedicated chiller (A2A & B2B) with air and water cooled condenser Controls and sensors are completely redundant.
Control items on common hardware like accumulator or transfer line are doubled.

Able to run 2nd CO2 system in stand-by using the running chiller

CO2 system A to chiller B and visa versa. Local circulation in 2nd plant; cooling power limited for internal circulation only Stand by mode gives the possibility for a quick switchover

Able to shut-off and empty 2nd system to do maintenance

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Cooling Plant P&I

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MV042 BD108
10

MV040 SV043 PT142 LT142 PT342 LT342 AC042 SV040 SV041

10

CO2 to experiment

SV042

40

CO2 from experiment CV142 PV110 nc NV110 CV342 nc NV310 PV310 nc MV110
42

nc

CO2 system A 100 labels

BD108 PT108 TT108 Fill port EH106 TT106 TS106

8

MV310 MV041 AV308 PV308 PV344 nc

VP056

CO2 system B 300 labels

AV108 PV108

nc
PV144 nc
44

FL144

EH142 TT142 TS142

EH342 TT342 TS342

FL344

nc

BD308 PT308 TT308 EH306 TT306 TS306

44

Fill port

vent MV052 MV054 BD050

6

evacuate MV056 MV058

6 46

FL106

FL306

MV106 FT106 NV104 FL104 BD104 PT104 TT104

4

TT146

46

MV050 EV148

EV348 nc
48

TT346 FT306

MV306

HX148 TT148
48

nc

HX348 TT348 BD304 PT304 TT304

4

NV304

FL304

HX150

LP101

Freon chiller A 200

Freon chiller B 400

HX350

LP301 LP101

EH101 / EH102 / EH103 TT101 / TT102 / TT103 TS101 / TS102 / TS103 PT101 / PT102 / PT103

50

50

EH301 / EH302 / EH303 TT301 / TT302 / TT303 TS301 / TS302 / TS303 PT301 / PT302 / PT303

BD150/ PT150/ TT150

BD350/ PT350/ TT350

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Documents in preparation:

1. P&I document 2. Functional analyses 3. DCS interface

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CoBra Model
(CO2 BRAnch Model)
Px+1,Hx+1,Tx+1
R3X+! R1X+1 R2X+1 4 R5X+1 4 R4X+1 R4y R3y R2y

Px+1=dPx+1+Px Hx+1=dHx+1+Hx dH=Q1/MF Q1 is calculated in the thermal network

Py,Hy,,Ty
R1y

Px,HxTx
1 2

R4x

R4y+1

R3x R1x R2x R5x

2

R3y+1 R2y+1

T
R1y+1

Py+1,Hy+1,Ty+1

The thermal node network calculates the heat influx in the cooling pipe based on:
Applied power Q3 on node 3 Environmental heating from fixed temperature T4 on node 4 Heat exchange with another pipe section via R5 between nodes 2 and 2 of the connected sections

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Node network for IBL

R1b HTCCO2 Tenvironement R4 +R3 Insulation+HTCair TCO2 TCO2 R2 Tube wall Tenvironement R4 +R3 Insulation+HTCair R1 HTCCO2

R1 HTCCO2

R2 Tube wall

TCO2

TCO2

R1a HTCCO2

R5 Heat exchange

2. Bundled lines
Q3 Applied power Tenvironement R4 HTCair R2 +R3 TFoM R1 HTCCO2 TCO2

1. Concentric line
R2 Tube wall R1 HTCCO2 Tenvironement R4 +R3 HTCair

TCO2

3. Bare tube

4. Stave

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Model configuration
8 1

Environment temperature inside IST is taken to be -25C (~stave surface temperature)

For simplicity the model inlet is cooled with its own outlet
5

6 3

ID (mm) 1-2 2-3 3-4 4-5 5-6 6-7 1 1 1.5 1.5 2 2.4

Length (m) 6.3 2.6 3 0.7 3 2.6

HX with node 7-8 6-7

Power (W)

Tambient (C) 20 20 -25

Node network 1 2 3 4 3 2

0,64,108 2-3

-25 -25 20

7-8

3 / 1.5 concentric

6.3

1-2

20

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Simulation results:
IBL temperature and pressure profile. MF=1g/s, Tsp=15C, Q=64W, x end=0.36 25 59 T Structure (C) T Tube wall (C) T Fluid (C) P Fluid (Bar) 20 56
Pressure(Bar)

IBL temperature and pressure profile. MF=1g/s, Tsp=-40C, Q=108W, x end=0.35 -20 T Structure (C) T Tube wall (C) T Fluid (C) P Fluid (Bar) 15

-25

14

Temperature (C)

-30

13

-35

12

Temperature (C)

Pressure(Bar)

15 1 -40 1 2 3 45 6 7 8 11 2 3 45 6 7 8

53

-45

10 15 Branch length (m)

20

10 25

10

10 15 Branch length (m)

20

50 25

-40 C cooling

+15 C cooling (Commissioning)

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Flow balancing with inlet capillary

1mmID inlet tube. 0.8mmID inlet tube.
30 25 Liquid 0 Watt 65 Watt 108 Watt

14 Liquid 0 Watt 65 Watt 108 Watt

12

2 g/s (28 g/s)

Pressure Drop (Bar)

10
Pressure Drop (Bar)

9 bar dP 1.1 g/s (15.4 g/s) 4 bar dP

Design flow regime
0.5 1 1.5 Massflow (g/s) 2 2.5

20

1 g/s (14 g/s)

15

10

6 bar dP
5

0 0

0.5

1 1.5 Massflow (g/s)

2.5

As detector performance does not depends too much on the mass flow a 1mm inlet seems sufficient with some extra flow. This flow gives extra margin for environmental heat pick-up.

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Evaporator heat pick-up

Due to long in and outlet lines a significant amount of parasitic heat is absorbed. The cooling system must be designed accordingly Shown absorbed heat is based on the environmental conditions shown in the table of page 18 About 80 watt of parasitic heat load can be expected (Same order as IBL power) Total evaporator design heat load: 180Wx14=2.5 kW

Total absorbed heat including stave power.

Heat absorption calculated with an IST air temperature of -25C (20 C outside IST)
200

150

Absorbed heat (Watt)

100

50

Liquid 0 Watt 65 Watt 108 Watt 0 0.5 1 1.5 Massflow (g/s) 2 2.5

-50

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Stave test results (1)

187 (Watt), TCO2=-23.7C 69 (Watt), TCO2=-21.9C 29 (Watt), TCO2=-23.9C 87 (Watt), TCO2=-24.6C 118 (Watt), TCO2=-24.6C

TFoM of 1.5mm cooling tube stave

(Flow unknown due to absence of flow meter)
25

20

15

TFoM (C*cm2)/W

149 (Watt), TCO2=-24.3C 68 (Watt), TCO2=-26.15C

10

68 (Watt), TCO2=-29.05C, flow reduced close to dry-out

0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16

TFoM of IBL staves

(ca. 90 Watt)
18 17 16

Silicon sensor ID#

ID=2mm Oct 11

ID=1.5mm Mar 12

Measured TFoM is excluding gradient caused by pressure drop due to absence of the long outlet line

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TFoM (C*cm2)/W

14 13 12 11 10 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16

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Silicon sensor ID#

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Stave test results (2)

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Reversed flow stave temperatures of a 1.5mm cooling tube stave

(Flow unknown due to absence of flow meter)
40 30 70 (Watt), TCO2=24.7C, Reversed flow 186 (Watt), TCO2=24.3C, Reversed flow 29 (Watt), TCO2=24.6C,Reversed flow 345 (Watt), TCO2=16.05C, Reversed flow flow increase
2 T CO

C =0 C =-5
2

10

Thermal runaway
C -10
2 T CO

2 T CO

Sensor Temperature (C)

T CO

Temperature (C)

20

5C =-1

2 T CO

0C =-2

10 0 -10

2 T CO

5C =-2

-10

2 T CO

0C =-3

2 T CO

5C =-3 T CO

0C =-4

-20

-30

-20

Inlet CO2 temperature

-30

Outlet CO2 temperature (Reference of TFoM)

-40

10

12

14

16

18

10

15

20

25

30

35

40

45

50

Silicon heater ID#

TFoM (C*cm2/W)

Nominal stave power

Measurement

IBL nominal condition

Maximum stave power in test set-up 345 Watt, Tsilicon<30 C (-16C CO2) => 4.8 kW! No problems during back-out!

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MARCO project
bverlaat@nikhef.nl

(The IBL prototype)

An IBL plant look-a-like (Similar specs) build together with MPI Munich (prototype for their Belle-2 development)

Controls build at CERN-DT

2-stage chiller for IBL temperatures from ECR-Nederland

A CO2 2PACL build in MPI

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MARCO 2-stage chiller

Bitzer 2-stage compressor S4T-5.2Y performance

5
4.5 4
Cooling Power (kW)

60 Hz 30 Hz
Marco max heat load

3.5 3 2.5

2
1.5 1 0.5 0 -80 -70
Minimum load (Hot gas by pass)

-60 -50 -40 R404a evaporation temperature ('C)

Back-pressure regulator

-30

-20

Frequency controlled 2-stage chiller concept is new for us and crucial for IBL low temperatures, MARCO commissioning is crucial for IBL. Challenge is the narrow temperature band as CO2 freezes at -56C while IBL condenser temperature is -45 C and pump need some sub cooling (~5 C SC = -50 C liquid) MARCO 2-stage chiller fulfils IBL requirement of an estimated 3.5kW @ -50 C
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Long branch vacuum shield

We have to grasp the bundle from underneath the muons and bend it in place

Or a spacer only? Super insulation?

Tile Calorie
LAR

Tracking

50mm PVC tube mock-up

7x 4mmOD / 3mmID outlet tube 7x 1.5mmOD / 1.0mmID concentric inlet tube

7x ??mmOD vacuum tube

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Vacuum shielding prototyping

At SLAC a prototype with a flexible CO2 bellow is developed: -> Very flexible but larger diameter At Cryolab a prototype with a the 4mm tube is developed: -> Stiff but bendable, has a reduced diameter

Outcome of the tests will determine which one to use, maybe both are needed depending on needed flexibility vs space available

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Conclusions and outlook

IBL Cooling system development status:

Conceptual design of piping and control is finalized. Detailed design will start after summer

Ongoing prototyping of vacuum insulated transfer lines Concept studies using MARCO
2-Stage chiller for low temperature
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Questions?

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