EN-CV: LHCb SciFi Common chiller Martin Doubek September 25, 2017
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 02.05.2017 2
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 2017/18 02.05.2017 3
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
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
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 02.05.2017 6
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.
Bitzer 2-stage R404a compressors Evaporation at -65 C Condensation limit 40 C 18 bar a 02.05.2017 8
Evaporator duty [kw] Bitzer 2-stage compressors S6F - The most powerful single 2-stage Bitzer compressor 16 14 12 50 Hz 60 Hz (70 Hz) S6F Bitzer compressor performance Subcooler, Condensation 32 C, 5 C superheat 10 8 6-66 -64-62 -60-58 -56 Evaporation temperature [ C] 02.05.2017 9
Pressure [bar] R404a R404a saturation curve 1.2 1 0.8 0.6 0.4 0.2 0-80 -70-60 -50-40 Evaporation temperature [ C] 02.05.2017 10
Note: ATLAS IBL Marco chillers The two-stage Bitzer R404a compressor are used in small chillers for ATLAS IBL 2 kw @ -50 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
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
Cooling capacity [kw] Alternatives to R404a The alternative refrigerants have significantly lower density which causes decrease of mass flow and cooling capacity: 35 30 25 20 15 10 5 0 R448a R404a Compressor cooling capacity Full subcooling compressor: S6F-30-2Y 60Hz Condensing: 35 C Superheat: 5K Reference temp: Dew point -70-60 -50-40 Evaporation temperature [ C] 10/26/2017 LHCb common chiller study 13
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
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
Concept: UT+Velo SciFi 10/26/2017 Thermosiphon commissioning 16
Valves Valves Concept: UT+Velo SciFi Module 1 Module 2 10/26/2017 Thermosiphon commissioning 17
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
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
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 02.05.2017 20
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
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
Third module: Module with condenser and receiver Condenser SciFi evaporator Receiver 10/26/2017 LHCb common chiller study 23
Possibility of future upgrade New module with additional compressor Manifolds can be easily extended 10/26/2017 LHCb common chiller study 24
All modules on the platform 10/26/2017 LHCb common chiller study 25
Chiller price estimate Material price estimate 125 000 EUR Component Quantity Description Supplier Manufacturer Type Unit Price Total price Price estimate note Compressor 6 Compressors needed for 30kW @ -60 (one redundant) Bitzer S6F-30.2F-40P 7263 43578 Offer Compressor accessories 3896 23376 EUR per accessories for one compressor 6 12 kw (estimated) three phase inverter 400V Rockwell Powerflex 1680 10080 Estimated price based on 1.5kW and 30kW inverters 6 Unloading valves Danfoss Solenoid valve 120 720 http://www.kaeltetechnik-shop.at/ 6 Check valves Danfoss Solenoid valve 130 780 http://www.kaeltetechnik-shop.at/ 6 Suction pressure sensor 300 1800 6 Discharge pressure sensor 300 1800 6 Muffler OEM 90 540 http://www.kaeltetechnik-shop.at/ 6 Interstage cooling expansion valve Danfoss Solenoid valve 120 720 http://www.kaeltetechnik-shop.at/ 6 Liquid subcooler Bitzer Compressor assembly 744 4464 Not assembled 6 Compressor flexible dampener - Suction 35mm OEM ID 35 mm 58 348 http://www.kaeltetechnik-shop.at/ 6 Compressor flexible dampener - Discharge 20 mm OEM ID 20 mm 42 252 http://www.kaeltetechnik-shop.at/ 6 Compressor flexible dampener - Cooling 15mm OEM ID 15 mm 22 132 http://www.kaeltetechnik-shop.at/ 6 Oil charge Bitzer 150 900 6 Discharge gas temperature sensor Bitzer 140 840 Condenser 1 Water condenser, horizontal, ap to 80 kw Bitzer K373H-4/2 1500 1500 Offer Evaporators 2 Swep 15 kw Swep F120TH 950 1900 Offer Suction accumulator 1 Verticle Suction Accumulator 2-1/8", 35kW @ -40 Henry S-7721 480 480 http://www.firstcaremaintenance.com/ Oil separator 1 Oil separator R404a 35kW @ -50 Alco OST-411 430 430 http://www.kaeltetechnik-shop.at/ Liquid reciver 1 Bitzer, slightly smaller variant 73 dm3 Bitzer FS732 1700 1700 http://www.kaeltetechnik-shop.at/ Level measurement 1 Bitzer optional opto electric level monitoring Bitzer 840 840 Hot gas bypass expansion valve 1 Electronic expansion valve Alco 500 500 Hot gas bypass vapor mixing valve 1 Electronic mixing valve 500 Water regulation valve 1 Electronic regulation valve Alco 500 500 Water TA valve 1 Manual TAV valve for balancing 1" 130 Shut off valves 2 Nickel plated brass plug valve CERN store 20 40 40.40.64.216.6 Filter 1 Y strainer 1" CERN store 116 116 40.15.11.240.4 Differential pressure sensor 2 Condenser water side differential pressure ENDRESS+HAUSER 1500 Thermosiphon Expansion valves 2 Electronic expansion valve Alco 500 1000 Electric expansion valves http://www.climatecenter.co.uk/ Solenoid shut off valves 8 Solder or Rolalock connection Danfoss 120 960 Solenoid plunger valves http://www.climatecenter.co.uk/ Manual shut off valves 17 Solder connection Castel 60 1020 Manual valves - solder http://www.climatecenter.co.uk/ Pressure sensors 14 EN/CV typical TRIMATIC 280 3920 SR1 Mono Temperature sensors 20 EN/CV typical BACHOFEN 295 5900 SR1 Mono Sight glass 7 Sight glass with moisture indicator Henry MI-30-1/2S 50 350 http://www.climatecenter.co.uk/ Large FILTERdrier 1 Filter drier 7/8", replacable core, 70kW Sporlan RSF487-T 300 300 http://www.climatecenter.co.uk/ Small filter screens 3 Liquid filter with compression fitting connections OEM 50 150 OEM Suction filter 1 Suction line filter 54 mm, solder connecion Sporlan SF6417-T 330 330 http://www.climatecenter.co.uk/ Fittings and small parts 3500 Mechanical material fasteners etc 2500 Insulation 2000 Fluid 60kg R404a 950 Controls 25000 GRAND TOTAL 124970 EUR 10/26/2017 LHCb common chiller study 26
Schedule Q4 2017 chiller tender documentation Q1 2018 start of the tendering process Q2 2019 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