Bart Verlaat 2 nd October 2013 Development of a portable CO 2 cooling system for CO 2 R&D in HEP

Bart Verlaat 2 nd October 2013 Traci project Development of a portable CO 2 laboratory cooling unit called Traci –TRACI=Transportable Refrigeration Apparatus for Co2 Investigation. Development in AIDA framework together with interested partners. –Nikhef & CERN lead development with engineering support of the Cracow University of Technology. –Co-funding from clients –Collaboration with Sheffield, Oxford, Liverpool and Milano? Would be great to boost the project to the next level! Designed for applications like: –Test beam telescope (AIDA) –Micro channel development (LHCb) –Pixel development (CMS) –Detector thermal/mechanical support structure development (Atlas IBL, ILC-TPC) –Detector commissioning (Atlas IBL) Focus on simplicity for easy production in series Focus on simplicity for easy non expert use

Bart Verlaat 2 nd October 2013 Traci design overview The need for laboratory CO 2 cooling is in the order of several 100 watt from room temperature down to -40 º C. –Capacity is a function of temperature. –A kw version under design in collaboration with GSI (Traci-XL) Stable CO 2 temperature, heat load independent System must be easy to operate by non expert users –On/off button + temperature set point –Stand-alone operation (PC only for monitoring or sending set point commands) Simplified concept called I-2PACL. –Modified 2PACL concept developed for AMS and LHCb. Several functions are integrated for a simpler use and operation 2PACL = 2-Phase Accumulator Controlled Loop I-2PACL = Integrated 2PACL (several 2PACL functions are integrated into 1 component) I-2PACL concept is patent pending (CERN&Nikhef)

Bart Verlaat 2 nd October 2013 I-2PACL concept 2-Phase Accumulator Controlled Loop Integrated 2-Phase Accumulator Controlled Loop Patented ! (patent owners: CERN & NIKHEF) Used in LHCb-Velo, Atlas IBL & CMS-Pixel

Bart Verlaat 2 nd October 2013 Transportable Refrigeration Apparatus for CO 2 Investigation Brrrrrrr! TRACI-1a (LHCb) TRACI-1b (Atlas) T R A C I Portable laboratory cooling unit Cooling power Temperature range Turn key Very simple to operate ”fridge like” TRACI-2 (Uni GVA, CMS, KeK)

Bart Verlaat 2 nd October 2013 Typical Traci performance, stable cooling over a large temperature range Liquid CO 2 Evaporative CO 2 Experiment Sub cool protection

Bart Verlaat 2 nd October 2013 Current Traci Capacity Traci-2 Prototype Julabo FP40-ME Traci capacity is comparable with a Julabo FP40-ME thermostatic bath cooler

Bart Verlaat 2 nd October 2013 Traci 1&2 design Foam box with CO 2 piping Door panel with control interfaces Off-the shelve R404a condensing unit Conditioner and relay based control logic CO 2 liquid pump CO 2 accumulator CO 2 transfer hose Other side

Bart Verlaat 2 nd October 2013 Traci experiences Traci-1&2 LHCb, Atlas and CMS has now been running for a decent amount of time. Several lessons learned: –Operation of the systems turns out to be easy, no experts were needed for operation. –Protection against empty start up incorporated. Users are not looking at the numbers apparently (also when you tell them to do so…). –Serious pump wear problem, chosen gear pump is not suitable for long term CO 2 pumping. Traci set-up in Atlas SR1Traci set-up for IBL stave tests Traci set-up for LHCb micro channel tests

Bart Verlaat 2 nd October 2013 Pump issues CO 2 is a problematic fluid to pump –Very low viscosity (15% of water) Limited or no lubrication Low pumping efficiency –High system pressure No reliable small pump on the market found so far. –Currently using Gather gear pumps –Long duration use of current Traci’s show short and variable life times of Gather pumps. Exploring different new pump options –HNP pump –3m pump –Lewa pump (LHCb style) –Design special pump in house LHCb pump with excellent track record too big for small systems. –Being installed in KEK system, but severe performance degradation at colder temperature Problem giving gather pump 3Mpump under study (Too big for a small Traci) Lewa pump: reliable but heavy (and pulsating) Large and expensive HNP pump Too small? HNP pump

Bart Verlaat 2 nd October 2013 Gather pump behavior Atlas-SR1 1 pump, slowly wearing out CMS 3 pumps in half of the SR1 time 1 st dead 2 nd dead Still alive Why CMS dies and SR1 not? No idea..

Bart Verlaat 2 nd October 2013 Traci SR1 Elapsed time Run time without stops Zoomed in

Bart Verlaat 2 nd October 2013 Traci CMS

Bart Verlaat 2 nd October 2013 Pump requirements For a 300Watt system based on 50% VQ –Liquid density range: kg/m3 –Liquid viscosity range: cP (0.07 at start-up, nominal 0.15 to 0.2 cP) –Trange: -50'C to 20'C –Flowrate: 5 g/s => 270 ml/min –Minimum sub cooling of inlet liquid: 3'C –Pressure head: 10 bar (at 0.15 cP viscosity) –Static design pressure: 110 bar –Efficiency: >15% (dT over pump must remain 10bar*270ml/min=5watt, Qpump total (Qext+Work) is ca.30Watt at -40'C) –Backwards leak is not a problem as long as the over effeciency remains above the requested 15%, infect the efficiency is backward flow related. –Low pulsation >25Hz –Oil free –Leak tight < 0.1 g/*y CO2 –Limited liquid pollution due to wear. (Avoid rubbing concepts) –Maintenance: Pump should be able to operate full time without intervention for at least 1 year.  What are your specific needs?

Bart Verlaat 2 nd October 2013 HNP 7255 pump Requirement Current Traci

Bart Verlaat 2 nd October 2013 Future Traci developments Now working on Traci-3, with improvements on: –Control: PLC control included –Different pump Traci-3 is build with AIDA funds Traci-3 designTraci-3 assembly has started

Bart Verlaat 2 nd October 2013 Future goals of the Traci project GOAL: General purpose CO 2 laboratory cooler competitive with water / glycol / silicon oil chillers Size reduction High risk of contamination of expensive equipment by leaking Fluids CO 2 -I-2PACL is clean CO 2 -I-2PACL has a very accurate distant temperature control Small hardware in experiment

Bart Verlaat 2 nd October 2013 Traci-2 for KEK/Desy For reliability reasons Traci- KeK was supplied with a Lewa pump (LHCb - Track record) –Performance degradation expected due to too large pump. –KeK specs allow a performance degradation. –Question for us was: How much? New configuration, new surprises? Status of today: –Exploration has started and 1 st signs look positive –Further tuning needed to deliver a solid product and give us the experience for further development.

Bart Verlaat 2 nd October 2013 Traci KeK (With Lewa)

Bart Verlaat 2 nd October 2013 Traci-2 capacity estimate Loss of cooling power at low temperatures Traci-Lewa (0.16 lpm) Traci-Lewa (0.28 lpm) Traci-Gather KeK Requirement Calculated capacity based on 50% vapor quality 250W accu heater Preliminary

Bart Verlaat 2 nd October 2013 Traci collaboration If Liverpool, Oxford, Sheffield and Milano can join that would be perfect! Work packages: –Redesign Traci concept for easy production (Outsourcing, so we can order for demand) –Prototype production –Pump development With industry Test stand at CERN –Control development Under control at CERN How to continue? I look forward in a good working collaboration!