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

1

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

14 May 2009 2Hans Postema - CERN

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



• 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



• PSI – Roland Horisberger, Stefan Koenig

• CERN CMS –Duccio Abbaneo, Paola Tropea, Hans Postema


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

Hans Postema - CERN14 May 2009 6

Lyon test setup

• System operated from CO2 bottle

• 5.5 m tube ID=1.4 mm

• Simulates Pixel barrel tube


Set-up in Lyon


5.5 m tube in the freezer


Last results Lyon


CERN Cryolab setup


CERN Cryolab setup


CERN-DT setup

• System operated from CO2 bottle

• 5.5 m tube ID=1.4 mm

• Simulates Pixel barrel tube


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.


CO2 Cooling Test Setup

DataAcquisitionSystem

Test Zone

CO2 Test Rack


Temperature Sensors Placement

PT100 TemperatureSensors

Detector Tube ID = 1.4 mm

Insulation


Test Zone


Data Aquisition System


Temperature vs Lenght

• Power = 144 W• Mass Flow = 1 g/s• ΔT ≈ 3.7°C• ΔP ≈ 2.5 Bar


CO2 Cooling Test Next Steps

Tube testing using diferent conditions of:

• Mass Flow

• Power

• Pressure

• Tube Geometry


dT at - 9 C


Power=145WMass Flow=1g/sPressure=27 BarΔT=2.6°CΔP=1.9 Bar

dT at – 21 C


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


YB0 – fully cabled

24Hans Postema - CERN14 May 2009

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


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


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


CDF – COT endplate cooling

Courtesy Richard Schmitt FNAL


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.


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


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.


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


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


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

14 May 2009 Hans Postema - CERN 34

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Implementation of Re-Circulating CO2 Cooling Test System


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.



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


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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14 May 2009Hans Postema - CERN CMS Upgrade Workshop Tracker Phase I upgrades 14 May 2009 1.

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