EN-CV: LHCb SciFi Common chiller. Martin Doubek September 25, 2017

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1 EN-CV: LHCb SciFi Common chiller Martin Doubek September 25, 2017

2 Common chiller Novec plant (pumps) 8 kw SciFi 9.4 kw ~ 30 kw UT + Velo CO 2 plant 7+4 kw Evaporation ~ -48 C Evaporation ~ -65 C

3 UT+Velo cooled by direct expansion Evaporation temperature ~ -48 C (1 bar) Liquid pipe: copper ID 12 mm Vapor pipe: copper ID 38.8 mm 13 bar a Saturation: 26 C 15 bar a These lines will be installed in YETS 2017/

4 Our Strategy We select the technoglogy (refrigerants, compressors) I have done preliminary sizing and component selection in order to get an idea about the size of the chiller. We will define the arrangement of the chiller, external dimensions and position of input/outputs. Due to the space constrains and size of the transport lift and available space we have to split the chiller into several modules that can be transported separately. The company selected in the tender process will carry out the final design, sizing and component selection based on our specifications. 10/26/2017 LHCb common chiller study 4

5 Refrigerant selection The flammable refrigerants can be ruled out even though they can be used for very low temperatures. The CO 2 solidifies at -56 C. There are only two options: R404a with Two-Stage compression R23-R404a or R23-R134a cascade 10/26/2017 LHCb common chiller study 5

6 Common chiller - Options R404a two stage Two stage compression is needed to achieve low evaporation temperatures. Relatively simple technology Evaporation pressure well below atmosphere Low temperature and power margin see following slides Cascade system R404a R23 Possibly with screw compressors Larger system and more complex system Generous temperature and power margin

7 Future of refrigerants Regulation (EU) No 517/2014 of The European Parliament and of The Council of (16 April 2014) From 2020 onwards: Stationary refrigeration equipment, that contains HFCs with GWP of 2500 or more will not be permitted except equipment intended for application designed to cool products to temperatures below -50 C HFC of very high GWP (>2500) will not be permitted in hermetically sealed equipment This regulation does not concern us directly, but it will impact price and availability of the R404a refrigerant in the future. In fact, the price is already increasing.

8 Bitzer 2-stage R404a compressors Evaporation at -65 C Condensation limit 40 C 18 bar a

9 Evaporator duty [kw] Bitzer 2-stage compressors S6F - The most powerful single 2-stage Bitzer compressor Hz 60 Hz (70 Hz) S6F Bitzer compressor performance Subcooler, Condensation 32 C, 5 C superheat Evaporation temperature [ C]

10 Pressure [bar] R404a R404a saturation curve Evaporation temperature [ C]

11 Note: ATLAS IBL Marco chillers The two-stage Bitzer R404a compressor are used in small chillers for ATLAS IBL C The compressors will be used also in ATLAS and LHCB baby demos. We have some experience with this technology The Marco chillers have proven reliable, however, they operate the higher suction pressures than we need 10/26/2017 LHCb common chiller study 11

12 Condensation temp. Alternatives to R404a Several low GWP alternatives for R404a are available: Bitzer compressor are compatibile with the alternative low-gwp blends However, the low temperature operation envelope is limited probably due to higher discharge temperatures Evaporation temperature 10/26/2017 LHCb common chiller study 12

13 Cooling capacity [kw] Alternatives to R404a The alternative refrigerants have significantly lower density which causes decrease of mass flow and cooling capacity: R448a R404a Compressor cooling capacity Full subcooling compressor: S6F-30-2Y 60Hz Condensing: 35 C Superheat: 5K Reference temp: Dew point Evaporation temperature [ C] 10/26/2017 LHCb common chiller study 13

14 Chiller concept: Two modules each with 3 compressors (R404a Bitzer S6F) Third module contains the condenser, receiver and SciFi evaporator Module 1 3 x compressor Bitzer SF6 Module 2 3 x compressor Bitzer SF6 Module 3 Condenser Oil separators Liquid receiver SciFi Evaporator (Novec) 10/26/2017 Thermosiphon commissioning 14

15 Concept: The modules with compressors can work together with the same suction pressure Each module can be switch between the UT+Velo or SciFi Only one module can cool all the system (UT+Velo and SciFi) 10/26/2017 Thermosiphon commissioning 15

16 Concept: UT+Velo SciFi 10/26/2017 Thermosiphon commissioning 16

17 Valves Valves Concept: UT+Velo SciFi Module 1 Module 2 10/26/2017 Thermosiphon commissioning 17

18 Concept: UT+Velo Module 1 is cooling the UT+Velo Module 2 is cooling the SciFi SciFi 1 compressor -50 C UT+Velo 3 compressors -65 C SciFi 10/26/2017 Thermosiphon commissioning 18

19 One module is cooling all the UT+Velo and SciFi SciFi is temperature is somewhat elevated UT+Velo SciFi Maintenance 3 compressor -55 C SciFi and UT+Velo 10/26/2017 Thermosiphon commissioning 19

20 See: G:\Departments\EN\Groups\CV\Detcool\Projects\04.LHCb\283.0_Scifi\02.Design_Chiller\PID The detailed P&ID will be prepared by the company selected in the tender. We will specify the concept and requirements for certain valves and filters. P&ID

21 First concept was to split the chiller into tow modules Lift size Unfortunately, the module does not fit the lift and I really don t think the module can be made any smaller. 10/26/2017 LHCb common chiller study 21

22 First draft of the modules: Module with one compressor module Suction connection Liquid and Hot gas connections 10/26/2017 LHCb common chiller study 22

23 Third module: Module with condenser and receiver Condenser SciFi evaporator Receiver 10/26/2017 LHCb common chiller study 23

24 Possibility of future upgrade New module with additional compressor Manifolds can be easily extended 10/26/2017 LHCb common chiller study 24

25 All modules on the platform 10/26/2017 LHCb common chiller study 25

26 Chiller price estimate Material price estimate EUR Component Quantity Description Supplier Manufacturer Type Unit Price Total price Price estimate note Compressor 6 Compressors needed for -60 (one redundant) Bitzer S6F-30.2F-40P Offer Compressor accessories EUR per accessories for one compressor 6 12 kw (estimated) three phase inverter 400V Rockwell Powerflex Estimated price based on 1.5kW and 30kW inverters 6 Unloading valves Danfoss Solenoid valve Check valves Danfoss Solenoid valve Suction pressure sensor Discharge pressure sensor Muffler OEM Interstage cooling expansion valve Danfoss Solenoid valve Liquid subcooler Bitzer Compressor assembly Not assembled 6 Compressor flexible dampener - Suction 35mm OEM ID 35 mm Compressor flexible dampener - Discharge 20 mm OEM ID 20 mm Compressor flexible dampener - Cooling 15mm OEM ID 15 mm Oil charge Bitzer Discharge gas temperature sensor Bitzer Condenser 1 Water condenser, horizontal, ap to 80 kw Bitzer K373H-4/ Offer Evaporators 2 Swep 15 kw Swep F120TH Offer Suction accumulator 1 Verticle Suction Accumulator 2-1/8", -40 Henry S Oil separator 1 Oil separator R404a -50 Alco OST Liquid reciver 1 Bitzer, slightly smaller variant 73 dm3 Bitzer FS Level measurement 1 Bitzer optional opto electric level monitoring Bitzer Hot gas bypass expansion valve 1 Electronic expansion valve Alco Hot gas bypass vapor mixing valve 1 Electronic mixing valve 500 Water regulation valve 1 Electronic regulation valve Alco Water TA valve 1 Manual TAV valve for balancing 1" 130 Shut off valves 2 Nickel plated brass plug valve CERN store Filter 1 Y strainer 1" CERN store Differential pressure sensor 2 Condenser water side differential pressure ENDRESS+HAUSER 1500 Thermosiphon Expansion valves 2 Electronic expansion valve Alco Electric expansion valves Solenoid shut off valves 8 Solder or Rolalock connection Danfoss Solenoid plunger valves Manual shut off valves 17 Solder connection Castel Manual valves - solder Pressure sensors 14 EN/CV typical TRIMATIC SR1 Mono Temperature sensors 20 EN/CV typical BACHOFEN SR1 Mono Sight glass 7 Sight glass with moisture indicator Henry MI-30-1/2S Large FILTERdrier 1 Filter drier 7/8", replacable core, 70kW Sporlan RSF487-T Small filter screens 3 Liquid filter with compression fitting connections OEM OEM Suction filter 1 Suction line filter 54 mm, solder connecion Sporlan SF6417-T Fittings and small parts 3500 Mechanical material fasteners etc 2500 Insulation 2000 Fluid 60kg R404a 950 Controls GRAND TOTAL EUR 10/26/2017 LHCb common chiller study 26

27 Schedule Q chiller tender documentation Q start of the tendering process Q Installation of the chiller Following course of action leading to the installation of the chiller is foreseen: Dismounting of the top platform Upgrade of the RICH OT (lower platform) Installation of the SciFi cooling plant (lower platform) Reinstallation of the top platform Installation of the chiller 10/26/2017 LHCb common chiller study 27