TRACI-XLDemonstrator under Development

Jorge Sánchez Rosado

CRISP: 2nd Annual Meeting, PSI, Villigen, Switzerland

Work package 13 – CO2 Cooling CRISP: 2nd Annual Meeting, PSI, Villigen, Switzerland

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TABLE OF CONTENTS

1.STS-CBM thermodynamical requirements

2.I-2PACL principle (Under patent)

3.Introduction to TRACI-XL

4.System diagram (State points + Ph diagram)

5.CO2 Line

a) Remote head pump

b) Pulsation Dampener

c) Accumulator

6.Condensing Unit + Interface (Heat exchanger)

7.P&ID

8.Control system

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1.STS-CBM thermodynamical requirementsThe requirements for the STS cooling are twofold:

• The innermost sensors with high radiation load have to be kept at or below -5 ⁰C Cooling based in gaseous, convective cooling of the (innermost) silicon sensors and other heat generating components, like power cables.

• Complete removal of the heat dissipated by the front-end electronics boards. This a prerequisite of the first requirement.

System based in an evaporative CO2 cooling of the front-end electronics, which is located in the FEE blocks. This kind of evaporative cooling based on CO2, is also under consideration and thus under intense technical development for upgrades of the silicon trackers of LHC experiments.

The total heat power dissipated by the STS components is estimated as:212 FEE blocks at 200 W (10 FEBs with 20 W each), resulting in a power dissipation of 42.4 kW.

The innermost sensors around the beam pipe with the highest radiation load will dissipate in operation around 6 mW on (2 x 3) cm2 after the accumulation of a certain radiation dose.

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2. I-2PACL principle (Under patent)

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3. Introduction to TRACI-XL

• Upgrade of TRACI up to 1kW unit.

• Accumulator MARCO’s Adaption

• LEWA remote head Pump

• PLC Siemens Simatic S1200 controlled

P = 1kW @ -30 C ⁰

Liquid piping: O.D. 1/4 “ = 6.35 mm th = 0.889

Liquid+gas piping: O.D. 3/8 “ = 9.525 mm th = 0.889

2000

1000

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4. System diagram (State points + Ph diagram)

65

32

1

CO2 Line

Condensing Unit

47

8

TRACI-XL

Accumulator Control

Capacity Control

12

34

5

Fill

Experiment venting

Flow regulation

FL

Q

Thermal Box1 kW

FT

VL

VLVL

VL

Ac

PM

HT

VL

PR

TEV

Vessel

Heat Exchanger

Compressor

VL

Concentric Hose

Accu

mul

ato

r

Condenser

FL

R404a

Set Point

Control Box

ø3/8”x0.035 Gas lineø1/4”x0.035 Liquid line

�̇�=15𝑔 /𝑠

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-45

⁰C

-40

⁰C

-30 ⁰C

4. System diagram (State points + Ph diagram)

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1-2 Pumping: Psuctionline = 15 bar Pdischargeline = 27 bar ΔPpump = 12 barh1(-45) = 102.57 kJ/kgQpump?? = mco2(h2-h1) = = 0.015(108.88-102.57) = 0.09 kWincrement of 3 ⁰C h1 = 102.57 kJ/kg h2 = 108.88 kJ/kg 2-3 Coil heating: Qcoil = mco2 (h3 – h2) =0.165 kW h3 = 119.88 kJ/kg 3-4 Inner hose: Qtransferline = mco2 (h4 – h3) = 0.3 kW h4 = 139.88kJ/kg(Hose calculation required)

4-5 Restriction valve: ΔP = -12 bar h5 = h4 = 139.88 kJ/kg

5-6 DETECTOR: Qdetector = mco2 (h6 – h5) = 1kW h6 = 206.55 kJ/kg 6-7 Outer hose: Qtransferline = mco2 (h7 – h6) = 0.3 kW h7=186.55 kJ/kg(Hose calculation required) 7-1 Heat Exchanger: Qhex = mco2 (h1 – h7) = -1.26 kW interpolating we should set up the compressor working at:30 hz provides 0.5kW 87 hz provides 1.6 kW Therefore 1.26kW are providing fixing a frequency of 69.38hz

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5a. CO2 Line: Remote Head Pump

At least 30° inclination &Less than 1m

QTRACIXL = 48.30 l/h

oil transfer line redesigned @ GSIAeroShell Fluid 4

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5b. CO2 Line: Pulsation Dampener

Discharge pressures LEWA pump: Pd,min=22 bar Pd,max=79 bar Pmin=P1=20.9 bar Pmax=P2=82.95 bar Dampener should be able to work in this range.Pt ≈ theoretical or work pressure. Residual pressure admitted ±5% (by now)P1 = Pt1 - ( 5/100 ) Pt∙ 2 = 20.9 bar (1)P2 = Pt2 + ( 5/100 ) Pt∙ 1 = 82.95 barPlunger: ø=25mm L=15 mm dv=7363.11 mm3 If V1 = V0 – v, and v = 0.1 V∙ 0 We have V1 = 0.9 V∙ 0 (2) And also V2 =V1- dv (3)From (1) and (2) we obtain P0=0.9xP1 = 18.81 bar (4)Finally from (1) (2) (3) and (4) we will obtain:P0 V∙ 0=P2 V∙ 2 ; 0.9P1 V∙ 0=P2 (V1-dv) =P2 (0.9V0-dv) From the underlined equalities we have the final formula

This will change the charging gas value at 20 ⁰C (take note that for a 10 ⁰C of temperature variation the gas pressure will change approx. a 3%)This volume has to be equal to ”V2” from the formula P2/P0 = V0/V2 then:( V0 / 13.67 ) = ( 82.95/ 18.81 ) and V0 = 60.28 cm3

Necessity of a pulsation dampener to prevent pulsations which produce negative effects in the stability of the temperatures and therefore in the heat extraction by the biphasic system.

Dampener effect

Values for a possible version applied in TRACI-XL: • Bladder: NBR Low Temperature -40/85 ⁰C• With 150 ml of oil for low temperatures inside

the bladder• Pre-charged at 18 bar

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- Resizing of the diameter of the coil to ¼”

- Inlet and outlet coming from the top of the vessel instead like from the bottom as in MARCO

5c. CO2 Line: AccumulatorData sheet: 1x Accumulator, according to drawing 1-10.456-01Design code : R.T.o.D. / PEDDesign conditions : 110 Barg @ -55/40°C (vessel).Design conditions : 110 Barg @ -55/40°C (coil).Medium : Harmless, gas.Category / Module : II / A1.Material : 1.4404/316L.Corrosion allowance : 0mm.Shell : ø168.3x10.97mm, LG.400mm.Heads : 2x pipecap, 6”sch.80s.Coil : ø6.35x1.24mm.Connections : See drawing.

resizing

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6. Condensing Unit +Interface (Heat exchanger)

- Compressor with crankcase heater, discharge and suction service valve, frequency inverter, HP/LP safety switch.- Discharge line with vibration damper.- Condenser with condenser fan 1x230V.- Hot gas bypass valve including service valve.- Alfa Laval heat exchanger AXP10-10H-F- Swagelok connections on CO2 side.- Suction line mounted with vibration dampener and suction accumulator both insulated with Armaflex.- Gauge panel with two service valve, LP and HP pressure transmitter.

System performance:at 30 Hz aprox. ; Qo = 0,50 kW, To = -45 ⁰C, Tsuction = -30 ⁰C, Tc = +35 ⁰C, Tsc = 3 K, Tsh = 5 K? R404a.at 87 Hz aprox. ; Qo = 1,60 kW, To = -45 ⁰C, Tsuction = -30 ⁰C, Tc = +35 ⁰C, Tsc = 3 K, Tsh = 5 K? R404a.

All parts functionally mounted on the compressor base plate.

Recent provider

change

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6. Condensing Unit +Interface (Heat exchanger)

• Reliable brazed heat exchanger used @CERN with enough capacity for a maximum 1.6 kW provided by the chiller.

• In terms of pressure is more than enough for CO2 applications.

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7. P&ID

Based in EN81346-1, EN81346-2, EN 61175 will be translated to CERN nomenclature

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• For TRACI-XL PLC Siemens S1200 replaces rail transmitters used in TRACI• Distributed Inputs/Outputs modules• PROFINET protocol• HMI touch panel to have total automation control from TRACI-XL

Siemens TIA V11 (2 licenses @ CBM)

PROFINET protocol

Data logging

In contact with Siemens to clarify

544 800

847

Control cabinet 544x800x847 enough?

7. TRACI-XL Control System

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Analog inputs

•RTD signal (Pt 100)(1) BT01 (Temperature transmitter - pump inlet/heat exchanger output)(2) BT02 (Temperature transmitter - pomp outlet)(3) BT03 (Temperature transmitter – Accumulator gas)(4) BT04 (Temperature transmitter – Accumulator coil outlet)(5) BT05 (Temperature transmitter – supply line,before lexible trans. line)(6) BT06 (Temperature transmitter – experiment input)(7) BT07 (Temperature transmitter – experiment output)(8) BT08 (Temperature transmitter – Heat exchanger input)

•Other sensors• (1) BT09 (Termocouple type K on EB01)• (2) Experiment heater protection• (3) BP01 (Pressure transmitter – accumulator pressure)• (4) BP02 (Pressure transmitter - supply line,before flexible trans.

line)• (5) Pressure transmitter – R404A chiller suction line• (6) BF01(Mass flow meter)

Digital output

• Compressor frequency, • Chiller condenser fan• Service valve(HB chiller)• Pump Frequency?

Power supply Input 120/230 V AC, output 24 V DC/2.5 A

S7-1200 CPU 1215C14 Digital input2 Analog input (0-10V)10 Digital output2 Analog output (0-20mA)

SM 1231 RTD Module8 Analog input RTD signal

SM 1231 TC Module4 Analog input - termocouple

SM 1231 AI Module4 Analog input (±10V, ±5V, ±2.5V, ±1.25V 0-20mA, 4-20mA)

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- Temperature sensors PT100 OD4mm (NiCrNi) by RODAX. (8UNITS)

- Pressure sensors Unik 5000 PTX5072-TC-A2-CA-H0-PE 0-100bar abs by General Electric (2 UNITS, PROBABLY 3)

- Coriolis Mass flow meter Rehonik RHM03 TA P1 PMO MO N1 AT without terminal box with Mass flow transmitter RHE14 T1 D1 I2 N by General Electric (1 UNIT)

- Pump LEWA: Manometer pressure gage ? + Frequency.

- Heater with thermocouple type k (NiCr-Ni) 1000W 80mm TC 'k' 3000mm by Türk Hillinger (1UNIT)

- Condensing unit R404 1.57kW evaporating system -45⁰C :LP and HP pressure transmitterMain switchJohnson control (fan speed regulator)Lodan compressor/condenser regulator with displayPotential contacts for running and alarm.

Inputs / Outputs

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FOR YOUR ATENTION