FPIX Upgrade – Status of CO 2 Cooling S tudies
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FPIX Upgrade – Status of CO2 Cooling Studies
S.Grünendahl, FNAL
for the FPIX Upgrade Mechanical GroupH. Cheung, G. Derylo, S.G., S. Kwan, C.M. Lei, E.
Voirin (Fermilab) K. Arndt, Q. Liu (Purdue)
S.Grünendahl – CMS Pixel CO2 Meeting March 19, 2013
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FPIX CO2 Cooling Areas of Progress
March 19, 2013 S.Grünendahl – CMS Pixel CO2 Meeting
Tests since previous meeting::2/12 1.4mm ID outer half-disk loop2/14 1.4mm ID inner half-disk loop2/21 1.6mm ID full length loop2/27 Multi-blade disk w/TC 5022 pocket slots for blade-ring jointFEA study of through slot joint
3 Half Disks
Port Cards and POH
End Flange
DC-DC converters
Pipes and Cables
CO2 cooling tubes and flex cables
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Loop Tests UpdateFull length stainless steel tubing assemblies with dummy heat loads• Measure temperatures vs. flow &
pressure drop• Initial finding: pressure drop larger
than in simulation• Adding concentric heat exchanger,
to guarantee subcooled liquid, and fine-grained RTD placement to confirm transition to two-phase flow
• New studies:• variations in tube
diameter• inner/outer half
lengths configurations
March 19, 2013 S.Grünendahl – CMS Pixel CO2 Meeting
Supply Line
Return Line
Optional Concentric Tube Heat Exchanger
DC-DC & POH Evaporator
FPix Detector Evaporator
Supply & Return Manifolds
Existing Copper Lines
Manifold PP1 PP1 PP0 Near SC Endflange Inside FPix SC Inside FPix
Supply Line
Return Line
1st Half-Disk
3rd Half-Disk 2nd Half-Disk
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Loop Setup
March 19, 2013 S.Grünendahl – CMS Pixel CO2 Meeting
subcooler
Fine grained RTD placement to locate onset of two-phase flow
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1.6mm ID Full Loop Test
March 19, 2013 S.Grünendahl – CMS Pixel CO2 Meeting
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Loop Tests: Combined Results
March 19, 2013 S.Grünendahl – CMS Pixel CO2 Meeting
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Loop Tests: Combined Results II
March 19, 2013 S.Grünendahl – CMS Pixel CO2 Meeting
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Joao’s CalculationsOuter loop, full heat load, lowest stable experimental mass flow (0.65 g/s) and 1.5 times l.s.e.m.f. (1.07 g/s)
March 19, 2013 S.Grünendahl – CMS Pixel CO2 Meeting
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Joao’s Calculation I
March 19, 2013 S.Grünendahl – CMS Pixel CO2 Meeting
0 1 2 3 4 5 6 7 8 9-25
-20
-15
-10
Length [m]
Tem
pera
ture
[°C
]
FPix HD Series RDT | m = 0.65g/s | Qtotal = 157.00W | dP = 0.99Bar | dT = 3.47°C
0 1 2 3 4 5 6 7 8 919.5
20
20.5
21
Pre
ssur
e [B
ar]
Theory Wall TemperatureTheory CO2 Temperature
Theory CO2 Pressure
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 = 0.65g/s | Qtotal = 157.0W | Pin = 20.69Bar | Tin = -20.00°C | dP = 0.99Bar | xout = 0.86
0 0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 0.9 10
100
200
300
400
500
600
Vapor Quality
Mas
s V
eloc
ity [k
g/m
2 .s]
G = 194kg/m2.s | q = 2.22kW/m2 | Psat = 20.68Bar | xout = 0.29 | xdryout = 0.88
0 0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 0.9 10
100
200
300
400
500
600
700
800
900
Vapor Quality
Mas
s V
eloc
ity [k
g/m
2 .s]
G = 412kg/m2.s | q = 12.26kW/m2 | Psat = 20.59Bar | xout = 0.86 | xdryout = 0.75
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Joao’s Calculation II
March 19, 2013 S.Grünendahl – CMS Pixel CO2 Meeting
0 1 2 3 4 5 6 7 8 9-21
-20
-19
-18
-17
-16
-15
-14
Length [m]
Tem
pera
ture
[°C
]
FPix HD Series RDT | m = 1.07g/s | Qtotal = 157.00W | dP = 1.16Bar | dT = 3.10°C
0 1 2 3 4 5 6 7 8 919.6
19.8
20
20.2
20.4
20.6
20.8
21
Pre
ssur
e [B
ar]
Theory Wall TemperatureTheory CO2 Temperature
Theory CO2 Pressure
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 = 1.07g/s | Qtotal = 157.0W | Pin = 20.85Bar | Tin = -20.00°C | dP = 1.16Bar | xout = 0.52
0 0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 0.9 10
100
200
300
400
500
600
700
800
Vapor Quality
Mas
s V
eloc
ity [k
g/m2 .s
]
G = 319kg/m2.s | q = 2.22kW/m2 | Psat = 20.84Bar | xout = 0.17 | xdryout = 0.85
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
Vapor Quality
Mas
s V
eloc
ity [k
g/m2 .s
]
G = 679kg/m2.s | q = 12.26kW/m2 | Psat = 20.73Bar | xout = 0.52 | xdryout = 0.67
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Calculation vs. ExperimentLots of discussion and progress on understanding of difference simulation vs. experimentMany calculations by Joao (Thanks!)My conclusion:• all except Delta P seem to
agree• difference maybe not all that
surprising: Even (easier) single phase flow depends a lot on parameters like e.g. tube roughness that are hard to control
March 19, 2013 S.Grünendahl – CMS Pixel CO2 Meeting
(From Eric & Joao)
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Loop Test ConclusionBoth parallel (with 1.4mm ID) and serial (with 1.6mm ID) are viableDecision will have to take into account complexity, material accounting and redundancy/failure tolerance considerations
March 19, 2013 S.Grünendahl – CMS Pixel CO2 Meeting
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Multi-blade Tests: TC 5022 in Pocket Joints
Improved joint geometry control (dry fit to equalize radial play for all blades before assembly)
March 19, 2013 S.Grünendahl – CMS Pixel CO2 Meeting
A1 silicon 1 ctr -12.35A2 silicon 2 ctr -12.61A3 silicon 3 ctr -12.82A4 Blade 1 ctr -12.49A5 Blade 2 ctr -12.85A6 Blade 3 ctr -13.40A7 silicon 1 i -13.07A8 silicon 2 i -13.39A9 silicon 3 i -13.15
A10 silicon 1 o -13.34A11 silicon 2 o -13.94A12 silicon 3 o -13.67A13 Blade 1 i -13.29A14 Blade 2 i -13.70A15 Blade 3 i -13.53A16 Blade 1 o -14.42A17 Blade 2 o -14.90A18 Blade 3 o -14.68B1 Ring i 1 -15.72B2 Ring i 2 -15.16B3 Ring i 3 -15.64B4 Ring o 1 -16.35B5 Ring o 2 -15.85B6 Ring o 3 -16.39B7 silicon 4 ctr -11.70B8 Blade 4 ctr -12.00B9 silicon 4 i -13.05
B10 Blade 4i -13.27B11 Ring i 4 -15.22B12 silicon 4 o -13.16B13 Blade 4o -13.82B14 Ring o 4 -16.29B18 tubing mid -18.45B19 tubing in -18.84B20 tubing out -19.67
-12.6-12.8 -11.7
-12.9-13.4 -12.0
-13.1-13.4
-13.2
-13.9
-13.7
-13.2
-13.3-13.7
-13.5
-14.9
-14.7
-13.8
-15.7-15.2
-15.6
-15.9
-16.4
-16.3
∆T=0.3
∆T=0.6
∆T=-0.3
∆T=1.0
∆T=1.0
∆T=0.6
∆T=1.0
∆T=1.7
∆T=2.5
∆T=0.2
∆T=0.3
∆T=0.3
∆T=2.4
∆T=1.5
∆T=2.1
∆T from CO2 to inner ring = 3.5 4.1 3.6 4.0
-13.1-13.3-15.2
∆T=0.2∆T=1.9
-12.4-12.5
∆T=0.1
-13.3
-14.4
-16.4
∆T=1.1
∆T=2.0
∆T from CO2 to outer ring = 2.9 3.4 2.9 3.0
∆T from CO2 to silicon center = 6.9 6.7 6.4 7.6
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Ansys vs. Experiment
March 19, 2013 S.Grünendahl – CMS Pixel CO2 Meeting
Good match using data sheet material properties and nominal dimensions (i.e. no fudge factors)
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ConclusionTC 5022 pocket joint fully qualified• Necessary joint QC depends on blade manufacturing tolerances; in any
case doable, even if a bit labor intensive
March 19, 2013 S.Grünendahl – CMS Pixel CO2 Meeting
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Blade-Ring Joint FEA Studies
Motivation: Through slot might have practical advantages for half-disk assembly
March 19, 2013 S.Grünendahl – CMS Pixel CO2 Meeting
Maximum Silicon Temperature
Radial Thermal Conductance (W/m^2/K)
2 5 10 25 50
Axial Conductance
2 0.91 -2.50 -5.13 -8.30 -10.65
5 -6.90 -7.70 -8.40 -10.14 -11.30
10 -10.03 -10.35 -10.59 -11.30 -11.83
25 -12.00 -12.08 -12.30 -12.34 -12.50
50 -12.73 -12.76 -12.78 -12.86 -12.94
Maximum Silicon Temperature
Radial Thermal Resistance (cm^2*K/W)
5 2 1 0.4 0.2
Axial Resista
nce
5 0.91 -2.50 -5.13 -8.30 -10.65
2 -6.90 -7.70 -8.40 -10.14 -11.30
1 -10.03 -10.35 -10.59 -11.30 -11.83
0.4 -12.00 -12.08 -12.30 -12.34 -12.50
0.2 -12.73 -12.76 -12.78 -12.86 -12.94
Nominal joint parameters (material & thicknesses)
Conclusion: radial heat transfer less important => might want to look at through slot again
(Caveat: Studies without CF in joint area – repeat with CF)
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Blade-Ring Joint FEA Studies II
Better structural strength if carbon fiber cladding continues into joint pocket/slot
Simulation looks ok
March 19, 2013 S.Grünendahl – CMS Pixel CO2 Meeting
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S.Grünendahl – CMS Pixel CO2 Meeting 18
FPIX Cooling Layout ‘Decision Tree’ (from Kirk)
March 19, 2013
Left vs. Right HCs Symmetric (3 main
lines)or
Asymmetric (2+2 main lines)
HD Inner + Outer in
Series (1.6mm ID HD
tubing)
HD Inner + Outer inParallel
(1.4mm or 1.6mm ID HD tubing)
2 + 4 3 + 3
3 inners+
3 outers
Outer-inner-outer+
Inner-outer-inner
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291396
η = 1.3 η = 1.6
η = 2.1
η = 2.5
2x8s 2x8s 2x8s
Z loc. TBD shown 491mm from IP
161
45
2x8s 2x8s 2x8s
Full geometry
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η = 1.6
η = 2.1
η = 2.5
2x8s
2x8s
2x8s
2x8s
η = 1.6
η = 2.1
η = 2.5
2x8s
2x8s
Segmentation alternative #0 - Baseline - 1st HD on one main line + 2nd and 3rd HDs in parallel on the other main line = two
main cooling loops per Half-Cylinder
2nd + 3rd disks
1st disks
3 hits3.5 hits
3 hits
4 hits3 hits
2 hits
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η = 1.3
η = 1.6
η = 2.1
η = 2.5
2x8s
2x8s
2x8s
η = 1.3
η = 1.6
η = 2.1
η = 2.5
2x8s
2x8s
2x8s
Outer-inner-outer
4 hits3 hits
2.5 hits
Inner-outer-inner
3 hits3.5 hits
2.5 hits
Segmentation alternative #1 – two cooling loops per Half Cylinder
(Total 4 cooling loops per end)
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η = 1.6
η = 2.1
η = 2.5
2x8s
2x8s
2x8s
η = 1.6
η = 2.1
η = 2.5
2x8s
2x8s
2x8s
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Segmentation alternative #2 - All outers in parallel + all inners in parallel
on two main cooling loops per Half Cylinder
All Outers
4 hits3.8 hits
1.5 hits
All Inners
3 hits2.5 hits
3.5 hits
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η = 1.6
η = 2.1
η = 2.5
2x8s
2x8s
2x8s
2x8s
η = 1.6
η = 2.1
η = 2.5
2x8s
2x8s
2x8s
2x8s
Segmentation alternative #3 – three cooling loops per two Half-Cylinders
(Total 3 cooling loops per end)
2nd + 3rd disks
1st + 3rd disks
3 hits3.5 hits
3 hits
4 hits3.5 hits
3 hits
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η = 1.6
η = 2.1
η = 2.5
2x8s
2x8s
2x8s
2x8s
Segmentation alternative #3 – three cooling loops per two Half-Cylinders (cont.)
(Total 3 cooling loops per end)
1st + 2nd disks
4 hits4 hits
3 hits
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Summary Loop tests show both parallel cooling loops with
1.4mm ID and serial loops with 1.6mm ID are viable solutions
Multi-blade tests: TC 5022 in pocket slot has been fully qualified for blade – ring joint
Further multi-blade assembly tests for carbonized and soldered joint are in preparation
Discussion on optimizing the FPIX cooling loop connection scheme is underway
March 19, 2013 S.Grünendahl – CMS Pixel CO2 Meeting
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Backup Slides• Progress in related areas, from Purdue• Delta p vs. flow for different diameters• Tables for loop measurements
March 19, 2013 S.Grünendahl – CMS Pixel CO2 Meeting
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• Designed custom front-end tools to pick-and-place HDI onto bare 2x8 bump-bonded modules.
• Semi-automated module assembly trials with prototype HDI will take place once these custom tools are fabricated.
• Work in progress to build a practical design and installation sequence for mounting, connecting, and cooling double-stacked port cards/POH in service (half) cylinders.
Custom tools for pick-and-placing the HDI onto the 2x8 bump-bonded
module
Progress@Purdue (from Kirk):
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Delta P vs. Flow
March 19, 2013 S.Grünendahl – CMS Pixel CO2 Meeting
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S.Grünendahl – CMS Pixel CO2 Meeting 29
Loop Measurement Tables
March 19, 2013