Forum on Tracking Detector Mechanics - Bonn, May 2016 The CMS PIXEL Phase 1 CO2 cooling system: Commissioning and operation of a large scale CO2 system J. Daguin, P. Tropea, H. Postema, M. Ostrega, L. Zwalinski, B. Verlaat, P. Petagna 25.05.16 Forum on Tracking Detector Mechanics - Bonn, May 2016

Forum on Tracking Detector Mechanics - Bonn, May 2016 Summary System specifications System description System performances Conclusions 25.05.16 Forum on Tracking Detector Mechanics - Bonn, May 2016

System specifications 2-PACL based system Operating temperature: -20 °C to +15 °C (original request) -23 °C to +15 °C (modified request) Cooling power: 2 x 7.5 kW CO2 quantities: 2 x 100 kg 2 independent cooling plants with capability of full system coverage in case of need Service pressure (safety valves setting): 110 bar Test pressure: 157 bar Operating pressures: 10 bar (-40 °C) – 57 bar (+20 °C) Max 75 bar in supply line when running warm with high DP (20 bar) Vacuum jacketed concentric transfer lines to ensure CO2 transport up to detector connection area 25.05.16 Forum on Tracking Detector Mechanics - Bonn, May 2016

The CMS Pixel Phase 1 Upgrade CO2 cooling system UXC55 2 manifolds (X4 near balcony) Manifold to YB0 edge transfer lines YB0 edge to PP1 transfer lines PP1 to PP0 piping PIXEL detector USC55 2 cooling plants 2 accumulators 3 control racks Services (power, dry air, network) USC to UXC transfer lines Services between USC and UXC 25.05.16 Forum on Tracking Detector Mechanics - Bonn, May 2016

Forum on Tracking Detector Mechanics - Bonn, May 2016 System safety Construction following HSE (CERN safety unit) recommendations and safety standards (PED) 100% visual inspection + 10% X-Rays Standard for one PED class higher Safety file on EDMS: https://edms.cern.ch/ui/#!master/navigator/document?P:1996242359:1020213357:subDocs CO2 detection in USC close to storage vessels 4 detection heads in USC connected to fire brigade CO2 exhaust close to equipment Connected to the N2 exhaust of the magnet cryo in USC Routed to the air extraction in UXC 25.05.16 Forum on Tracking Detector Mechanics - Bonn, May 2016

Forum on Tracking Detector Mechanics - Bonn, May 2016 Cooling plants 2 identical cooling plants Designed, built and tested at CERN (EP-DT-FS workshop) Remote head LEWA LDE pump Up to 160 g/s of CO2 Cold head away from the engine Heat exchanger connected to R507 TK chiller circuit Condenses two-phase return and subcools liquid Two filters: 500 µm strainer at the pump suction 40 µm filter at the pump discharge 25.05.16 Forum on Tracking Detector Mechanics - Bonn, May 2016

Forum on Tracking Detector Mechanics - Bonn, May 2016 Accumulators 2 identical accumulators Designed, built and tested at HOEFNAGEL&MEIJN (NL) Delivered with the CE certification 140l capacity Heat exchanger on top of the vessel to condense CO2 vapor Lower the pressure in the system 5 x 1 kW heaters at the bottom of the vessel to vaporize liquid CO2 Rise the pressure in the system Back-up chiller installed to lower system pressure in case of need 25.05.16 Forum on Tracking Detector Mechanics - Bonn, May 2016

Forum on Tracking Detector Mechanics - Bonn, May 2016 Manifolds 2 identical manifolds Designed, built and tested at CERN (EP-DT-FS workshop) 8 loops with individual mass flowmeter, filter (140 µm) and regulation valve 15 kW dummy load 2 safety valves per loop 25.05.16 Forum on Tracking Detector Mechanics - Bonn, May 2016

Timeline 2014 2015 2016 Manifolds construction Manifolds installation in UXC Plants construction Accumulators at CERN Plants ans accumulators installation in USC First CO2 circulation Full perf tests First maintenance 24/7 operation 2014 2015 2016 25.05.16 Forum on Tracking Detector Mechanics - Bonn, May 2016

Forum on Tracking Detector Mechanics - Bonn, May 2016 Manifolds in UXC 25.05.16 Forum on Tracking Detector Mechanics - Bonn, May 2016

Plants and Accumulators in USC 25.05.16 Forum on Tracking Detector Mechanics - Bonn, May 2016

Forum on Tracking Detector Mechanics - Bonn, May 2016 System at CMS 25.05.16 Forum on Tracking Detector Mechanics - Bonn, May 2016

Forum on Tracking Detector Mechanics - Bonn, May 2016 Transfer lines Section 1: USC to UXC (2 x vacuum insulated concentric lines) Installed by CRIOTEC in Fall 2014 Section 2: Manifold to top and bottom of YB0 periphery (4 x 1 common vacuum jacket for 4 concentric lines) Installed by DEMACO in August/September 2014 Section 3: YB0 periphery to PP1 (4 x 4 vacuum jackets for 4 concentric lines) Installed by DEMACO in February/March 2014 1 2 3 1 1 2 3 25.05.16 Forum on Tracking Detector Mechanics - Bonn, May 2016

Forum on Tracking Detector Mechanics - Bonn, May 2016 CMS system P&I (BPix) 25.05.16 Forum on Tracking Detector Mechanics - Bonn, May 2016

Forum on Tracking Detector Mechanics - Bonn, May 2016 CMS Control system Standard CERN UNICOS control system Control layer: 1 PLC Schneider Premium located in USC SCADA Layer: 1 SIEMENS WinCC-OA project located in CCC External communications Interlocks sent to DSS (hardwire) Process data and cooling system status sent to CMS DCS (MODBUS) Publication of high level informations for CMS DCS (DIP) 25.05.16 Forum on Tracking Detector Mechanics - Bonn, May 2016

CMS Control system architecture Direct MODBUS to DSS LHC Logging 25.05.16 Forum on Tracking Detector Mechanics - Bonn, May 2016

Cooling plant controls Manifold Accumulator Manifold CO2 Plant 25.05.16 Forum on Tracking Detector Mechanics - Bonn, May 2016

Manifold controls Bpix detector (in future) Supply line pneumatic valves (NO) Bypass line + dummy load Return line pneumatic valves (NO) 25.05.16 Forum on Tracking Detector Mechanics - Bonn, May 2016

Cooling plant regulation loops Accumulator pressure split range controller Back-pressure controller Superheating controller Pump speed controller Damper temperature controller 25.05.16 Forum on Tracking Detector Mechanics - Bonn, May 2016

Cooling plant operation 25.05.16 Forum on Tracking Detector Mechanics - Bonn, May 2016

Forum on Tracking Detector Mechanics - Bonn, May 2016 CMS System overview UXC55 cavern R507 BPIX PLANT FPIX PLANT FPIX ACCUMULATOR BPIX ACCUMULATOR Transfer lines FPIX MANIFOLD BPIX MANIFOLD 8 return 8 supply Sector +5 and -6 PP1 Sector +14 and -15 PP1 USC55 cavern 25.05.16 Forum on Tracking Detector Mechanics - Bonn, May 2016

Start-up procedure Start-up temperature depends on detector T (hardwired DSS signal) and user setpoint Start-up from room temperature to +15 °C circulation takes ≈ ½ h Another 40 min are needed to go down to -23 °C Pressurisation of the system 25 min 25.05.16 Forum on Tracking Detector Mechanics - Bonn, May 2016

Re-start times estimate after a stop Operation mode Cooling plant Detector Time estimate Observation Normal Warm 1/2h Need to liquify CO2 before the pump Cold 1h – 2h Need to rise pressure in accumulator up to detector temperature Few minutes CO2 conditions already fulfilled Back-up 25.05.16 Forum on Tracking Detector Mechanics - Bonn, May 2016

Performances in normal operation System in normal operation: Each plant serving its own manifold Two different temperature set points possible Minimum temperature down to -32 °C with 7 kW Cooling power up to 2 x 11 kW at -23 °C FPIX system 11 kW 7 kW -23 °C setpoint -28 °C setpoint -32 °C setpoint Manifold inlet temp Accumulator saturation temp Pump discharge temp Manifold outlet temp Manifold DL heater2 power Manifold DL heater1 power Pump suction temp Mass flow 25.05.16 Forum on Tracking Detector Mechanics - Bonn, May 2016

Performances in back-up operation System in Back-up operation: One plant serving both manifolds Only one common temperature set points possible In case of failure: Both system have to be switched OFF Restart in back-up is similar to restart in normal operation Switch-over takes several minutes Minimum temperature down to -27 °C with 2 x 7 kW Cooling power up to 2 x 9 kw at -23 °C Stop from normal operation BPIX system Re-start in back-up 9 kW Manifold inlet temp Accumulator saturation temp Pump discharge temp Manifold outlet temp Manifold DL heater1 power Pump suction temp Mass flow Manifold DL heater2 power FPIX system 9 kW -23 °C setpoint Manifold inlet temp Accumulator saturation temp Manifold outlet temp Pump discharge temp Manifold DL heater2 power Manifold DL heater1 power Pump suction temp Mass flow 25.05.16 Forum on Tracking Detector Mechanics - Bonn, May 2016

Go to warm interlock -23 °C +15 °C Cooling plant temperatures PP1 bypasses temperatures -23 °C 50 min +15 °C 4 hours 25.05.16 Forum on Tracking Detector Mechanics - Bonn, May 2016

Cooling plant performances - Summary Normal operation: Minimum -32 °C reached with 7 kW on each plant Maximum load of 11 kW on each plant reached at -23 °C Maximum load of 6.5 kW on each plant reached at +15 °C Back-up operation: Minimum -27 °C reached with 2 x 7.5 kW Maximum load of 2 x 9 kW reached at -23 °C 25.05.16 Forum on Tracking Detector Mechanics - Bonn, May 2016

Forum on Tracking Detector Mechanics - Bonn, May 2016 Conclusions System installed since almost one year System fully operational and tested Cooling plant performances fully satisfactory and above expectations Cooling power above specifications But system can also work with very low load !!! -23 °C reachable in all conditions Back-up operation functional 25.05.16 Forum on Tracking Detector Mechanics - Bonn, May 2016

Thank you for your attention… and to all the people involved! abdel l, andrea d’a, bart V, cedric l, Hans p, jerome n, lukasz z, maciej o, norbert F, paola T, paolo P, philippe l, robert b, steven p, and many others… 25.05.16 Forum on Tracking Detector Mechanics - Bonn, May 2016