Concept idea for the modular 2PACL
system for the Atlas ITK
3 June 2015
Bart Verlaat
1
CO2 cooling: the current status
• The last year lots of progress in CO2 cooling development is achieved.– 2 new systems for detector operation have been developed:
• IBL cooling system (3kW @ -35°C) => In operation• CMS pixel CO2 cooling system (15 kW@ -30°C) => under commissioning
– Many laboratory test units have been build:• 2x Traci V1, 3x Traci V2, 4x Traci V3 up to 400W• Marco 1kW• CMS-TIF prototype plant 15 kW
– New development lessons learned:• Operation at cold temperatures < -30°C • Scaling from 1kW (LHCb-Velo) to 3kW (IBL) and 15 kW (CMS)
– Scaling did not give surprises.
• Positive experience with vacuum shielded concentric lines.• Standard approach for control.• Redundancy policy
• From the current experience and the availability of standard components a scaling towards 40kW 2PACL units should be feasible
2
Atlas IBL CO2 cooling system 2-Phase Accumulator Controlled Loop
(2PACL)
Chiller CO2 Transfer line, Ca 100m
Pump
Compressor
Cooling plant
Junction box
Accumulator with integrated heating and cooling
dummy load
A
C
B
DE
Flex lines to IBL
USA15 UX15
Manifold box
-35’C cooling
20’C cooling
Accumulator pressure lowering for cool down
Pressure increase for liquefying prior to start-up
Sub cooled pumped liquid
Saturation temperature
Sub cooled liquid margin for pump operation (>10 ‘C)
Liquid cooling
2-phase cooling
Gas
Pre
ssur
e Liquid
Isothermal line
Enthalpy
C
E D
B
A
Liquid
7
2-phase(Evaporation)
Accu
AC042
LP101
ventevacuate
6
8
FT106
⅜”
EH106TT106TS106
EH101 / EH102 / EH103TT101 / TT102 / TT103TS101 / TS102 / TS103PT101 / PT102 / PT103
HX150
CO2 system A100 labels
LT142LT342
FT306
FL304
⅜”
FL306
VP05
6
50
40
12
4444
46
48
PV110
PT150/ TT150/ SC150
¼”
BD108PT108TT108
CO2 from experiment
CO2 to experiment
42
PT142
PV108
PV144
HX148
TT148BD148
SV042 SV043MV042
MV041
TT146
AV108
Freon chiller A
200
CO2 system B300 labels
10
LP101EH301 / EH302 / EH303TT301 / TT302 / TT303TS301 / TS302 / TS303PT301 / PT302 / PT303
4PT304TT304
MV306
6
8
EH306TT306TS306
BD308PT308TT308
AV308
PV308
PV310
PV344
46 TT346
HX350
HX348
LP301
Fill port
nc
nc
no
nc
no
nc
MV050
MV054MV052 MV056BD054
PT054
EV148 EV348
nc nc
50
PT350/ TT350/ SC350
SV040 MV040
SV041 BD01210
MV058
NV110
MV110 MV310nc
CV142
nc
CV342
ncnc
ncnc
nc
nc
Cold CO2 lineCold R404a lineWarm service line(Cold lines require 32mm insulation)
no
NV310
no
¼” ¼”
½”½”
½”
½” ½”
48 TT348BD348
Freon chiller B
400
MV043
PT342
BV, 03-09-2014
PT040
PT042
PT056
PRC142 controlling CV142, EH142/143(PT142 & SC150)
PRC342 controlling CV342, EH342/143(PT342 & SC350)
PT050 PT058
no
FL104
4 PT104TT104
nc
FL106
Fill port
MV106
EH142/143TT142/143TS142/143
FL042
EH342/343TT342/343TS342/343
MV012
MV039
AV012
Atlas IBL cooling system CO2 cooling plant layout
Chiller CO2 Transfer line, Ca 100m
Pump
Compressor
Cooling plant
Junction box
Accumulator with integrated heating and cooling
dummy load
A
C
B
DE
Flex lines to IBL
USA15 UX15
Manifold box
cooling water
R404A 2-stage compressor GP250
AC042
CV205
48GP246 GP248
PS250
MV202 SG202
TT248PT248
SR248
HX208
HX205
Air cooled condenser
AC210
2
HX201
HX216
HX212
MV222
MV224
MV246
MV228
MV230
4
BR234PRC234 (PT234)
12
16
38
22
26
28
30
34 36
TT202AC202
NV206
AC244HX220 /HX244CV222
SHC224(SH224)
CV238PRC244 (PT244)
TX212
PT224TT224SH224
PT244 & PT250TT244SH244
24
TT2066
8TT210 10
TT220
TT21818
20
44
14
TT24242
TT228
TT246
46
MV248
MV210
SG216
FL216
HX142/ HX230
HX226
HX348
HX150
7/8”
28
½”
⅜”
½”¼”
⅜”
½”
⅜”
½”
⅜”½”
¼”
½”½”
28
nc
nc
nc
nc
nc
no
HX206 / HX207
TX226 EV348
MV226
CV142PRC142
(PT142&SC150)
no
MV208
⅜”
SR206
½”
½”
PT234
EV208
PT142
GP250PRC250(PT250)
32
TT232
MV232
CO2 A rack
CO2 B rack
CO2 Accumulator rack
PT208TT208CV240
SHC244(SH244)
40
HX222
nc
EV206
FL212
SG212
SG210
SV210
PT202
EH250
FL244
EV212
EV207
no
Gas
Pre
ssur
e Liquid
Isothermal line
Enthalpy
C
E D
B
A
Liquid
7
2-phase(Evaporation)
Accu
Cooling plants in USA-15
5
Transfer line
CO2 cooling hardware in UX
Junction box
Vacuum system
Flex lines Manifold box
CMS Pixel Cooling System 2x 15kW @ -30 C⁰
7
FPix Plant core(USC55)
BPix Plant core(USC55)
CO2Storage
FPix Accumulator(USC55)
BPix Accumulator(USC55)
FPix
BPix
ManifoldBoxes
(UXC55)
Concentric SS pipes –insulated (vacuum
)Co
ncen
tric
SS
pipe
s –
insu
late
d (v
acuu
m)
PT PT
CMS Pixel Cooling System
8
2 Plants with accu’s
Plant interior
Transfer lines
Cooling systems for the ITK
• The ITK tracker has a total power of 180 kW (TBUpdated)• The largest CO2 2PACL plant build for CMS is 15kW • When looking to the “standard” components (Pumps, heat exchanger,
valves etc.) a system scaling up to 40kW seems possible.• The current approach to the ITK cooling is a modular approach of
several stand alone operating systems.• Redundancy is obtained by swapping a failing plant for a spare plant• Segmentation to be decided based on best segmentation logic in the
detector – 10x 20kW or 5x 40 kW??
• Roughly 2 possibilities for segmentation– Cool per sector (Take a pie of the combined detector (End-cap + barrel, but
split strip and pixel)– Cool per sub detector
• Is preferred as it makes it possible to operate each sub detector at different temperatures, eg a colder pixel detector. 9
Cooling segmentation
10
19/55
31/55
12/215/11 5/11
7/202/3 2/3
Pixel, short strop barrel, long strip barrel, end cap, services, thermal enclosure
x/y => x: power at begin without safety factor.y: Power after irradiation with safety factor
Detector segmentation or pie segmentation
PP2 segmentation2x5 locations
PP2 is the most likely space for the junction box and manifold
ITK cooling history• In the past the large upgrade cooling plant is discussed several times. Below an overview of
some relevant talks given in upgrade meetings with links.– Thermal management working group meeting - phase II system design 30 September 2009 @ CERN
• https://indico.cern.ch/conferenceDisplay.py?confId=68949• Topics: alternative concept solutions
– Atlas Upgrade week April 2011 @ Oxford• https://indico.cern.ch/contributionDisplay.py?contribId=207&sessionId=23&confId=116547• CO2 cooling activities at CERN
– Atlas Upgrade week November 2011 @ CERN• https://indico.cern.ch/materialDisplay.py?contribId=79&sessionId=35&materialId=slides&confId=108365• Cooling plant segmentation• Cavern fit check
– Atlas Upgrade week March 2012 @ SLAC• https://indico.cern.ch/contributionDisplay.py?contribId=62&sessionId=53&confId=158038• Topics: Cooling pipe sizing• Component availability
– ECFA High Luminosity LHC Experiments Workshop, 2 October @ Aix Les Bains• http://indico.cern.ch/materialDisplay.py?contribId=27&sessionId=9&materialId=slides&confId=252045• Topics: Future look on common cooling plant development
– ITK kick-off 23 January 2014 @ CERN• https://indico.cern.ch/event/288081/session/3/contribution/29/material/slides/• Topics: Wrap up of status
– ITK Cooling kick-off 11 December 2014 @ Cracow• https://indico.cern.ch/event/353053/• Topics: Kick-off of the cooling group
• Due to IBL – CO2 cooling development, the discussion of the Atlas upgrade system was stalled for a while, however most presented topics in the past are still relevant.
11
Modular 2PACL approach• A modular approach of multiple 2PACL stations is a novelty.• A 2PACL needs a dedicated filling to operate.
– Linking systems together mixes up the fluid quantity– CMS has 2 systems connected together
• Complex recovery procedures to equalize the fluid quantity before separation
– Atlas IBL has 2 plants, but 1 accumulator volume• Easy approach in mixing and separation• But accumulator cannot be taken out of service
– Best approach would be to separate the accu volume from the actuators and sensors which need maintenance
• Possible concept for a modular 2PACL approach– Have the accu volume be always part of the transfer system – Separate accu cooling, heating and sensing by housing them in a separate siphon– The modular plant contains all hardware and its volume is small
• Not much fluid mixing during a swap, therefore no complex equalization procedure needed.
– 1 spare plant is always running over a manifold connecting all units. – When a unit fails the spare can take over 1 system– The out of service unit can be repaired or swapped with another plant– Redundancy of a common primary cooling system
12
Cooling plant concept for a modular 2PACL
13
Modular plant unit with the following features:1. Local by pass for dP control 2. 2 condensers connected to 2 primary cooling systems.3. Remote head triple Lewa pump4. Contain most sensors and actuators5. Swappable for another unit
Accu unit with the following features:1. Heaters and sensors in a parallel siphons (1 for
redundant hardware)2. Thermosiphon condensers each connected to a
dedicate primary cooling system3. Able to access all active components in a separated
volume
PP2 manifold with heated by-pass
Transfer line
Modular 2PACL concept
14Plant 1Plant 2Plant 3
Spare plant(Without Accu)Runs cold over the spare manifold for direct kick-in
Spare plant manifold
USA-15
To UX15
Direct swapping in case of an event
15
Plant 1Plant 2Plant 3
Spare plantReplaces failed or serviced unit
Spare plant manifold
USA-15
To UX15
Accu as volume stays active (Belongs to the transfer line volume)Accu has its own redundancy for heating and cooling
Failed plant can be taken out of service or repaired
Quantity of cooling units
• Given the fact that we have 2x5 PP2 manifold locations:– 2x (5 systems +1 spare) = 12 active units (option 1)– 2 spares ready for direct replacement– A total of 14 units are needed
• Quantity optimization – Less units possible if segmentation is not following the 5 PP2 locations– Less units possible if A and C side PP2 manifold are connected to the same system
• Option 2: 6 active + 2 passive plants
• With a 150 kW Tracker the subunits will need cooling power in the order of:– Option 1: 15 kW– Option 2: 30 kW– Both options are okay with respect to the availability of technology (CMS = 15kW)
• 2 primary cooling plants are needed to cool all units (1 redundant)– This could be the current surface unit with a liquid brine bridging the surface and the
cavern– A local chiller is an option too, but might have space constraints
16
Conclusions
• A modular approach with x 2PACL stations is the baseline concept
• The concept seem feasible when a separation of the accu and plant is foreseen
• 1 running spare unit via a back-up manifold for immediate kick-in.
• Concept needs prototyping
17
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