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
DT Steering Board Meeting - April 30th 2010
WP 11: Detector Cooling - Paolo Petagna 2/19
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
DT Steering Board Meeting - April 30th 2010
WP 11: Detector Cooling - Paolo Petagna 3/19
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
DT Steering Board Meeting - April 30th 2010
WP 11: Detector Cooling - Paolo Petagna 4/19
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)
DT Steering Board Meeting - April 30th 2010
WP 11: Detector Cooling - Paolo Petagna 5/19
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• …
DT Steering Board Meeting - April 30th 2010
WP 11: Detector Cooling - Paolo Petagna 6/19
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?)
DT Steering Board Meeting - April 30th 2010
WP 11: Detector Cooling - Paolo Petagna 7/19
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
DT Steering Board Meeting - April 30th 2010
WP 11: Detector Cooling - Paolo Petagna 8/19
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
DT Steering Board Meeting - April 30th 2010
WP 11: Detector Cooling - Paolo Petagna 9/19
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
DT Steering Board Meeting - April 30th 2010
WP 11: Detector Cooling - Paolo Petagna 10/19
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
DT Steering Board Meeting - April 30th 2010
WP 11: Detector Cooling - Paolo Petagna 11/19
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
DT Steering Board Meeting - April 30th 2010
WP 11: Detector Cooling - Paolo Petagna 12/19
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
DT Steering Board Meeting - April 30th 2010
WP 11: Detector Cooling - Paolo Petagna 13/19
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
DT Steering Board Meeting - April 30th 2010
WP 11: Detector Cooling - Paolo Petagna 14/19
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
DT Steering Board Meeting - April 30th 2010
WP 11: Detector Cooling - Paolo Petagna 15/19
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…
DT Steering Board Meeting - April 30th 2010
WP 11: Detector Cooling - Paolo Petagna 16/19
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
DT Steering Board Meeting - April 30th 2010
WP 11: Detector Cooling - Paolo Petagna 17/19
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
DT Steering Board Meeting - April 30th 2010
WP 11: Detector Cooling - Paolo Petagna 18/19
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
DT Steering Board Meeting - April 30th 2010
WP 11: Detector Cooling - Paolo Petagna 19/19
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