CO 2 Cooling Seminar Desy Hamburg

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1 CO 2 Cooling Seminar Desy Hamburg Bart Verlaat (Nikhef/CERN) 18 February 211 1

2 CO 2 Cooling Seminar The benefits of using CO 2 cooling. History of CO 2 cooling. Introduction to the 2PACL CO 2 circulation method. CO 2 cooling in the AMS-Experiment. CO 2 cooling in the LHCb Velo Detector Future applications. Conclusions 2

3 (KJ/kg) Better Better (Pa*s) Better Large latent heat & Why is evaporative CO 2 cooling good for HEP detectors? CO 2 allows small tubing Why? Low viscosity & High pressure Allow low flow Low pressure drop Allow high pressure drop Low pressure drop Latent Heat of Evaporation CO CO 2 2 C 3 F 8 C 3 F Temperature (ºC ) Lower pressure drop 5e-4 4e-4 3e-4 2e-4 1e-4 Liquid Viscosity C 3 F 8 CO Temperature (ºC ) Allow very small tubing 3

Heating a flow from liquid to gas Liquid Gas Isotherm 2-phase 9 6 3-3 Liquid

4 Temperature ( C) Pressure (Bar) bverlaat@nikhef.nl What happens inside a cooling tube? Heating a flow from liquid to gas Liquid Gas Isotherm 2-phase Liquid Superheating Enthalpy (J/kg) Low ΔT Increasing ΔT (Dry-out) Sub cooled liquid Target flow condition 2-phase liquid / vapor Dry-out zone 4 Super heated vapor

5 Temperature (ºC) Pressure (Bar) Radiation Length (%X ) bverlaat@nikhef.nl CO 2 Calculation Example Atlas IBL stave CO 2 C 3 F 8 Inner Diameter (D i [mm]) Max. Design Pressure (MDP [bar]) CO 2 ID=1.4mm OD=1.6mm C 3 F 8 ID=3.8mm OD=4.mm Tube wall thickness (T w [mm]) Relative tube mass (m rt [g/m]) Fluid density ( f [kg/m 3 ]) Relative fluid mass (m rf [g/m]) Total relative mass (m rtot [g/m]) Relative stored Energy (Q rst [J/m]) Position (mm) 15 Watt -3-4 dp according to Friedel dp CO2 dt CO2 dp C3F8 dt C3F x 1-3 D CO2 1.4 mm Tube inner diameter (mm) D C3F8 3.6 mm -25ºC 5

Stored Energy = Pressure x Volume CO 2 is environmental friendly, non-toxic and cheap.

6 CO 2 safety issues CO 2 has a high pressure but this does not have to be an increased safety issue. Pressure Equipment Directive (PED): Stored energy determines the safety class. Stored Energy = Pressure x Volume CO 2 is environmental friendly, non-toxic and cheap. CO 2 in large concentrations is asphyxiating, be careful with venting CO 2 in unventilated small spaces. CO 2 does not exist as liquid in atmospheric conditions. It is released as -78ºC solid. Cold burn risk. ID Design Pressure Stored energy CO 2 1.4mm 1 bar 15.4 J/m C 3 F 8 3.6mm 15 bar 15.3 J/m 6

7 Is CO 2 cooling new? NO! it was used in the late 19th and early 2th century, and is one of the first used refrigerants. The high pressure of CO 2 (13 bar) was a problem for materials those days. Development of low pressure synthetic refrigerants (CFC s), causing CO 2 to disappear as refrigerant. 7

8 CO 2 cycle simulation software anno

9 CO 2 cycle simulation software anno

10 Japanese ecocute for tap water heating The last 12 years CO 2 is reintroduced as green refrigerant. Now CO 2 is getting standard again. Soon your beer at home will be cooled with CO 2 too CO 2 cooled ice creams Super market CO 2 cooling plant CO 2 Car air-conditioning CO 2 cooled ice skating rink in Haarlem 1

11 CERDEC team earns Secretary of the Army Environmental Award CO 2 cooling is SO GREEN that the even the Hummer guys won a environmental prize because of their CO 2 air-conditioning. 11

12 Pressure Pressure Heater How to get the ideal 2-phase flow in the detector? Liquid Vapor Traditional method: (Atlas) Compressor Vapor compression system BP. Regulator Warm transfer 2-phase Enthalpy Cooling plant Detector 2PACL method: (LHCb) Pumped liquid system Liquid Vapor Compressor Pump 2-phase Chiller Liquid circulation Cold transfer Enthalpy Cooling plant Detector 12

13 CO 2 systems in HEP 2 CO 2 cooling systems have been developed for HEP detectors so far. AMS-TTCS (Tracker Thermal Control System) Q= 15 watt T=+15ºC to -2ºC LHCb-VTCS (Velo Thermal Control System) Q=15 Watt (2 parallel systems is 75 W) T= +8ºC to -3ºC Both systems are based on the 2PACL principle invented at Nikhef 13

AMS-TTCS 2PACL also implemented in LHCb-VELO Liquid P 1 2 3 2-phase 4 6 5

14 Radiator Pressure 2-Phase Accumulator Controlled Loop (2PACL) 2PACL was developed for the AMS-TTCS 2PACL also implemented in LHCb-VELO Liquid P phase Vapor In 2-phase area T=Constant Enthalpy 6 5 Pump Deep space = Cold Q= 15 watt T= +15ºC to -2ºC AMS-Tracker 14

15 Pressure 2-Phase Accumulator Controlled Loop (2PACL) 2PACL was developed for the AMS-TTCS 2PACL also implemented in LHCb-VELO Liquid P phase Vapor In 2-phase area T=Constant Enthalpy Pump 6 5 Chiller = Also cold Q= 2 x 75 =15 Watt T= +8ºC to -3ºC (2 parallel systems) LHCb-Velo 15

16 Temperature ( C) Pressure (Bar) P [bar] Pressure bverlaat@nikhef.nl 2x Accumulator Cooling = Pressure decrease 1 1 5x1 5 5 D PACL Operation VTCS start-up and ope rating cycle s From start-up to cold operation C 5 8 9,1, C E VTCS start-up and ope rating cycle s h [kj/kg] 3,5 B 8 1, D Path of 5 4 9, C B -2 C A -4 C.6 C 2 C A -2 C C 2 C.8 4 C Set-point range Enthalpy A B C D Pump head pressure (Bar) 45 - Accumulator pressure (Bar) Clock time (hour) Evaporator temperature ( C) 1 Pumped liquid temperature ( C) 16

17 Alpha Magnetic Spectrometer

18 AMS-Detector Ready for flight STS-134 (19 April 211) 18

Keeping the detector temperature stable <3ºC over orbit.

19 Tracker Thermal Control system (TTCS) TTCS: Bringing the 15 Watt from the insulated detector center to the external radiator panels. Keeping the detector temperature stable <3ºC over orbit. Evaporator set-point between -2ºC and +15ºC (Depending on seasonal temperature. 15 Watt Set point temperature Radiator temperature

20 MAGNETE Tracker Thermal Control system (TTCS) RADIATORE condensatori 144 WATT TRD TOF TRACKER TOF RICH ECAL 15 Watt detector with evaporator rings Cooling system component boxes (1 redundant) 2

21 AMS-Tracker with CO 2 cooling rings. Tracker connections Inner plane thermal bars and hybrids Inner plane evaporator rings Inner plane silicon ladders 21

22 TTCS Evaporator system Top evaporator loops Inner plane thermal bars Outer plane thermal bars Bottom evaporator loops Tracker plane with evaporator loop Welding of the evaporators Thermal conductors 22

23 TTCS Schematics

24 TTCS Components Component box Evaporator section Condenser and radiators Heat exchanger Centrifugal pump Accumulator 24 24

TTCS Engineering Model Test Results The TTCS installed in AMS can only be tested in vacuum. All the functional tests have been done with an engineering model.

25 TTCS Engineering Model Test Results The TTCS installed in AMS can only be tested in vacuum. All the functional tests have been done with an engineering model. Pre-heaters Cold orbit heater APS Accu Start-up radiator and with pumps DPS HX with pre-heaters Figure Error! No text of specified style in document.-1: TTCB Engineering Model lay-out Thermal stable operation with varying heat loads & varying orbital conditions

AMS Thermal Vacuum Tests @ ESA-Estec in the LSS In April 21 the TTCS was tested in AMS in the Large Space Simulator (LSS) at ESA- Estec.

26 AMS Thermal Vacuum ESA-Estec in the LSS In April 21 the TTCS was tested in AMS in the Large Space Simulator (LSS) at ESA- Estec. TTCS radiators The LSS is a large vacuum chamber with nitrogen cooled walls to simulate the cold of space. The TTCS was tested under different wall temperatures. Orbital variations were simulated with IR heaters facing the radiator panels. IR lamps 26

27 Temperature( C) Temperature( C) Pump Speed (rpm) TTCS Test results from the LSS vacuum : Transient performance Evaporator( C) Silicon plane( C) Evaporator saturation( C) Pump liquid( C) Ram Radiator( C) W Evaporator saturation( C) Pump liquid( C) Ram Radiator( C) Wake Radiator( C) Primary pu ation( C) Pump 1 liquid( C) Ram Radiator( C) Wake Radiator( C) Primary pump speed (rpm) Secondary pump speed (rpm) Accumulator Single phase evaporator Pump speed Two- phase evaporator Redundant pump speed Detector Evaporator Wake Radiator Pumped liquid Ram Radiator : 21: : 3: 7-Apr-21 Time (hh:mm) 27

28 LHCb Detector 28

29 VTCS Evaporator 29

30 VTCS Evaporator 3

31 TLR_PM11 TL_VL19 TL_VL11 TR_VL11 TR_VL19 TL_AC11 TR_AC11 TL transfer line TR transfer line VTCS Schematics TL CO2 bridge VELO TR CO2 bridge TL_TT46 TL_VL2 TR_TT46 Liquid Pump TL_VL7 TR_VL7 TL_TT48 Velo vacuum tank with silicon modules, module base and CO 2 evaporator. TL_TT48 Electronic 3-way valve Electronic 2-way valve TL_PT12 Cooling plant at UXAC3 TR_PT12 Manual restriction valve PLC and electronics rack No return valve Electric heater TL_VL112 TR_VL112 Damper with heater TL_VL111 TL_HT14 TL_TT125 TL_HT15 TR_HT15 TR_TT125 TR_VL111 TR_HT14 Heat exchanger Pressure transmitter TL_PT14 TL_HT13 TL_HX12 Air-cooled SB chiller TR_HX12 TR_PT14 TR_HT13 Temperature transmitter TL_TT112 TL_HX11 TR_HX11 TR_TT112 TL_VL13 TL_PT11 Water-cooled SA chiller TLR_VL11 TR_VL13 TR_PT11 TL_TT112 TR_TT112 TL_TT122 TL_HT12 TL_PM11 TLR_TT112 TLR_TT122 TR_HX15 TR_PM11 TR_TT122 TR_HT12 TLR_HT12 TL CO2 system TLR system TLR_VL19 TR_VL18 TR CO2 system 31

32 Evaporator Passive tubing only VTCS Locations Transfer tube Concentric assembly Cooling Plant All active hardware LHCb experimental cavern 32

33 Accumulators VTCS Cooling plant Condensers Liquid pumps 33

34 VTCS Accumulator Cooling spiral for pressure decrease (Condensation) Thermo siphon heater for pressure increase (Evaporation) 34

35 Condenser Restriction Temperature( C), Level(%) Temperature( C), Level(%) Temperature( C), Level(%) Heatload (W) Start up of the VTCS during October 8 29 commissioning: 8:4 - Start-up with set-point -5 C 11:1 - Detector switched on 6 12:5 Set point to -15 C 15:3 - Set point to -25 C 5 17:1 - Set point to -3 C 18:2 - Set point to -35 C (System Limit) 19:1 - Set point to -34 C 4 19:3 - Set point to -25 C 2: - Detector Switched off Accumulator Set-point temperature Silicon temperature ( C) ( C) Pump liquid Accumulator temperature Set-point ( C) temperature Evaporator ( C) saturation Pump liquid temperature ( C) 7 3 VTCS Commissioning results: Start-up and operation ator Set-point temperature ( C) Pump liquid temperature ( C) Evaporator saturation temperature ( C) Accumulator liquid level (%) Detector heat load (W) Accu liquid level 1-Accumulator set-point Detector power A-Silicon temperature 9-Pumped liquid gas 1 Accumulator 2-6 9: 12: 15: 18: 21: 1-Oct-29 Time (hh:mm) Silicon temperature ( C) Accumulator Set-point temperature ( C) Pump liquid temperature ( C) Evaporator saturation temperature ( C) Accumulator liquid phase Cooling plant area Transfer lines (Ca. 1 5m) VELO area Evaporator / Modules C SP R57a chiller C SP gas 2-phase 9 Pump Concentric tube A C SP 35

sequence 1. Increase pressure to make liquid. SP=-5 C Freezing (Solid/Liquid) SP=-15 C T= C T=-2 C 2.

36 Pressure (Bar) T=-4 C bverlaat@nikhef.nl VTCS Commissioning results: Start-up and operation in the PH-diagram SP=21 C (Start-up) 9-Pump inlet Liquid T=2 C Start-up sequence 1. Increase pressure to make liquid. SP=-5 C Freezing (Solid/Liquid) SP=-15 C T= C T=-2 C 2. Pump at high pressure and cool down in liquid mode 3. Lower pressure to desired set-point 4. Power-up detector SP=-25 C SP=-3 C SP=-35 C 2-Phase (Liquid/Vapor) T=-4 C Switch-off detector Lowest possible set-point (liquid approaches saturation line) Enthalpy (kj/kg) 36

37 Temperature( C) Temperature( C) Condenser Restriction gas 2-phase Accumulator 1 Accumulator Cooling plant area VTCS Commissioning results: Steady State Performance Transfer lines (Ca. 5m) VELO area Evaporator / Modules R57a chiller Return Fluid Evaporator 7 gas 2-phase 9 Pump 8 6 A Silicon 1 2 Concentric tube Evaporator outlet( C) 8. Condenser Inlet ( C) 9. Pump inlet liquid ( C) 7. Evaporator 1. Accumulator outlet( C) Saturation 8. Condenser ( C) Inlet ( C) 9. Pump inlet liquid ( C) 1 2 A. Module tip (Silicon)( C) 7. Evaporator outlet( C) 8. Condenser Inlet ( C) 9. Pump inlet liquid ( C) 1. Accumulator Saturation ( C) Detector Switched-off Detector Powered-Up Detector Switched-off 2 Detector Switched Off Detector Switched On C Liquid -3-4 Liquid Accumulator Set-Point ( C) Accumulator Set-Point ( C) 37

38 Temperature( C) Temperature( C) VTCS Commissioning results: Heat loads : Evaporator Heat Load (Detector On) 6-7: Evaporator Heat Load (Detector Off) 7-8: Transfer Tube Heat Pick-up (Detecto 6 6-7: 7-8: Transfer Tube Heat Pick-up (Detector On) 7-8: Transfer Tube Heat Pick-up(Detector Off) 7-8: Transfer Tube Internal Exchang tor Off) 7-8: Transfer Tube Internal Exchange (Detector On) 7-8: Transfer Tube Internal Exchange (Detector Off) ube Environemantal Heat (Detector On) 7-8: Transfer Tube Environemantal Heat (Detector Off) 7-8: Transfer Tube Internal Ex Detector Power 4 2 Environmental heat pickup in transfer line same order as detector power. (all heat pick-up only in the return line) Accumulator Set-Point ( C) 38-4

39 Temperature( C), Level(%) Temperature( C), Level(%) Temperature( C), Level(%) Heatload (W) Temperature( C) VTCS Commissioning results: Thermal Stability The 2PACL is a very high precision temperature control method. The Velo evaporator is controlled from 6m distance. The stability <.1 C; reaction time immediate (pressure control) (Note: Chiller is fluctuating ~8 C, Temperature archiving.1 C) TLPT3.Tsat TLPT12.Tsat TLTT16.temp TLTT17.temp TLHX12.watt : 1: 11: 12: 13: 1 1-Oct-29 Time (hh:mm) Silicon temperature ( C) Accumulator Set-point temperature ( C) Pump liquid temperature ( C) Evaporator saturation temperature ( C) Accumulator liquid level (%) Detector heat load (W) 8 temperature Silicon temperature ( C) ( C) Pump liquid Accumulator temperature Set-point ( C) temperature Evaporator ( C) saturation Pump liquid temperature ( C) Ev 8 A Accumulator Set-point Pumped liquid : 12: 15: 18: 21: 1-Oct-29 Time (hh:mm) Accu liquid level Detector power A-Silicon temperature Accumulator set-point

40 Temperature ( C), Power (Watt), Level (vol %) Temperature ('C), Liquid level (vol %), Power (%kw or Watt) bverlaat@nikhef.nl Accumulator response (powering up and down and a temperature change) Total C detector load (% kw) Evaporator Temperature ('C) Accumulator Liquid Level (vol %) Acumulator heating/cooling (% kw) Module VL11-C power (Watt) Module VL11-C cookie temperature ('C) Module VL11-C NTC temperature ('C) Module VL11-C NTC1 temperature ('C) Accu Heating/Cooling Detector half heat load (x1) Module Heat load Accu level -7 C -2-2 Silicon temperature Evaporator SP=-5 C SP=-25 C temperature -4 :3 1: 1:3 2: Clock time (Hour) Time (Hour) 4 4

41 Temperature( C), Stroke (mm) Temperature( C), Stroke (mm) Temperature( C), Stroke (mm) Temperature( C), Stroke (mm) Pressure Heatload (W) VTCS Commissioning results: Superheating An interesting phenomenon is observed, which needs attention for future systems. Sometimes the liquid is slightly sub cooled and boiling does not always start immediately => Superheating! troke (mm) Evaporator saturation 1 ( C) Evaporator 12 begin ( C) Evaporator 12 end ( C) Evaporator 27 begin ( C) Evaporator 27 end ( C) C D C ,1, E 9 1 9, C -8-2 HX12 heat Enthalpy 4 1 h [kj/kg] -4 3,5 B 8 1,13 C -2 C -4 C -2 C A C 2 C C HX12 inlet HX12 outlet HX27 heat Pump stroke HX27 in & outlet Evaporator temperature Pump stroke (mm) Evaporator saturation ( C) Evaporato Pump stroke (mm) Evaporator saturation ( C) Evaporator 1 12 begin ( C) Evaporator 12 end ( C) Evaporat Pump stroke (mm) Evaporator saturation ( C) Evaporator 1 12 begin ( C) Evaporator 12 end ( C) Evaporator 27 begin ( C) Evaporator 27 end ( C) Evapora Evaporator saturation ( C) Evaporator 12 begin ( C) Evaporator 12 end ( C) Evaporator 27 begin ( C) Evaporator 27 end ( C) Evaporator 12 heatload (watt) Evaporator 27 heatload (watt) 8 1 VTCS start-up and operating cycle s : 18:3 19: 19:3 2: 2:3 21: 2-Oct-29 Time (hh:mm)

42 Future CO 2 cooling projects CO 2 cooling is foreseen for the following experiments: Near future: Atlas Inner B-layer (IBL) detector: 213 (1.5kW@-4ºC) CMS-pixel detector: 214 (9kW@-2ºC) Belle-II pixel vertex detector: 214 (1.2 kw@-35ºc XFEL R&D: 211 (1.2kW@-15ºC) Atlas silicon detector upgrade Atlas silicon detector upgrade: 22 (18kW@-4ºC) CMS silicon detector upgrade: 22 (1kW@-25ºC) International Linear Collider TPC: 2xx (2kW@+2ºC) Any more CO 2 cooling projects that we are not aware off? Please tell me. 42

43 Near future CO 2 challenges CMS pixel detector (Extreme small diameter small dp allowed) Belle-II pixel detector (Rapid Prototyping heat sink) Atlas IBL detector (Long in and outlet tubing) 43

44 CO 2 research plants To support the research on CO 2 cooling plants are constructed all over the world. At CERN/Nikhef the following systems are operational: Nikhef 2PACL system CERN Cryolab 2PACL system Systems under development: CERN-DT / Nikhef 1kW system CERN-DT 1W system 44

Operational: Nikhef CO 2 2PACL test system

45 Operational: Nikhef CO 2 2PACL test system Capacity 1kW Evaporative temperature range: -4ºC to +25ºC Universal test box for experiments Pre set-up temperature sensors and pressure sensors. Controllable power supply Automatic scanning connected experiments 45

46 PVSS Automated scanning Easy test procedure. Steady state data recorded after each setting change. Able to change: Outlet pressure (Evaporative Temperature), Inlet enthalpy (Inlet temperature) Mass flow Power Several structures have been tested and analyzed. Tests fully protected to overheating. Power Flow Dec 29 Carbon tube scanning results, data recorded at steady state 46

47 Operational: CERN-Cryolab 2PACL test system Capacity W to 3kW 27 liter accumulator for large volume experiments. Temperature range +25ºC to -45ºC (To be verified in upcoming commissioning) Small (15 watt) and large experiment outlet. 47

48 Accumulator Under development: CERN / Nikhef 1kW Unit Schematics. Common CERN-DT / Nikhef development. User friendly system, designed for series production to distribute among labs. Project can use additional collaborators. If you want to invest money and man power in CO 2 cooling, please consider joining this collaboration and benefit from the 12 years of CO 2 cooling knowledge. Base design for future cooling plants (IBL, XFEL) 7 6 fill PR18 PT18 TT18 8 CO2 from experiment vent Experiment connection CO2 to experiment FL112 VL111 evacuate VL18 VL16 VL15 PR16 by-pass HT11.temp ¼ ⅜ ⅜ VL112 VL11 ⅜ TT15 5 ⅜ ¼ HT14.temp HT14 PM111 PR11 PT11 AC11 HT11 ⅜ PT28 TT28 ½ 7 8 ⅜ 6 ½ VL29 VL26 hot gas 1 R44A condenser 2 R44A compressor cooling water Cooling water ¼ FT13 ¼ 4 ⅜ 9 HX24 5 VL13 FL13 VL14 3 ¼ PM12 PR14 PT14 TT14 2 PM11 Condenser TT11 1 ¼ ⅜ 4 VL24 Commercial chiller 3 CU Pump option

49 1.6 m bverlaat@nikhef.nl CO 2 Cooling unit mechanical design Electronics cabinet for experiments Valves Control cabinet with touch screen Accumulator Chiller connections Condenser Experiment and fill connections Liquid pumps 49

50 Conclusions CO 2 cooling is the future for particle physics cooling. CO 2 cooling seems also very beneficial for other scientific instrument cooling. 2PACL technology is interesting as a system principle (high stability, easy to operate). If you plan to invest money and manpower in CO 2 cooling, consider to join the CERN/NIKHEF 1kW unit development. 5

CO 2 COOLING FOR THE LHCB-VELO EXPERIMENT AT CERN.

GL2008 8 th IIF/IIR Gustav Lorentzen Conference on Natural Working Fluids 7-10 September 2008 Copenhagen, Denmark Paper number: xxx CO 2 COOLING FOR THE LHCB-VELO EXPERIMENT AT CERN. B. Verlaat*, A. Van