Pixel upgrade CO2 cooling plants – 3D modelling Nick Lumb, IPN-Lyon CERN, 01 Feb. 2012

People Main contributors: Robert Becker (CERN) Jean-Christophe Ianigro (IPN-Lyon) Alexis Eynard (IPN-Lyon) With input from the rest of the CO2 team at CERN Nick Lumb

Overall system P. Tropea / B. Verlaat Nick Lumb

Plant core From manifold / To manifold to accumulator PM101 1006 1078 1092 1090 1082 PR1002 PT1002 TT1002 1002 PR1072 PT1072 TT1072 1072 PR1006 PT1006 TT1006 Filter LEWA LDE1 SWEP B17 From manifold / to accumulator To manifold Temp. / pressure / rupture disk cluster Bypass Damper Heat exchanger Pump Sampling points To / from existing C2F14 system Storage bottle Nick Lumb

Insulation Global layout is driven by insulation policy Options: Each individual pipe and component separately insulated For pipe insulation 80~100mm, this means we need to lay out the design on a 3-D grid with 100mm spacing → large volume system Tricky to do well – very labour intensive Place everything in an insulated box Whole system subject to icing if box opened to replace / repair single component Feed-throughs Main components (pump / HEX) in a box; valves and sensor clusters in a 2-D foam ‘sandwich’ In all scenarios, it must be possible to warm up one of the plants for major interventions while keeping the other one cold Nick Lumb

Example of foam sandwich (Nikhef) Nick Lumb

Definition of cold box and sandwich regions This zone goes in sandwich Accumulator can be at some distance, insulated separately These components in cold box R. Becker Nick Lumb

3-D model (CATIA R5v19) A. Eynard Valves + actuators arranged in plane to allow insulation using foam sandwich Quickly gets very long, and not all sensor clusters can be included in plane A. Eynard 1500 Nick Lumb 900

3-D model (2) A. Eynard Damper Pump motor Connections panel (C6F14 system, etc.) HEX Remote pump head Nick Lumb

3-D model (3) A. Eynard 1” pipes on 2-phase return lines ½” pipes on sub-cooled liquid side A. Eynard Nick Lumb

Proposed location in USC We have to fit in two plants here! Even worse if we have to place in UXC Nick Lumb

New proposal (rough layout) Include majority of components in the cold box R. Becker Overall volume will be greatly reduced Nick Lumb

As it might look in the USC… Nick Lumb

Conclusions / Outlook Good collaboration between Lyon and CERN has been established in order to deliver the 3D design of the cooling plants (+ 2D drawings for construction) Agreed design protocols and good information exchange Regular meetings at CERN or via Skype ‘Sandwich’ idea was investigated but will probably be abandoned due to space limitations Baseline is now to include most components in the cold box volume; exceptions being Pump motor Valve actuators (not designed for low temp.) Connections between the two plants (must remain cold even during long room temp. maintenance of one of the plants) – insulate separately outside the box For detailed planning see Paola’s talk from this morning Nick Lumb