1. BWEC Cooling shell design
PANDA 17/2 Collaboration Meeting
BWEC Cooling shell design
S. Ahmed, L. Capozza, A. Dbeyssi, P. Grasemann, J. Jorge Rico, F. Maas,
O. Noll, D. Rodríguez Piñeiro, S. Wolf
BWEC Cooling shell design

2. Contents Overview Calculations (thermal and fluid mechanics) 3D design
Simulations (thermal and fluid mechanics)
Summary and future tasks
BWEC Cooling shell design 2

3. Overview 1
What is our aim?
BWEC Cooling shell design 3

4. Vacuum insulation panel (VIP)
Overview
Overview
Cooling requirements
Work at -25°C
Maximum 500 mbar pressure drop (leakless-mode)
Limited space
Low temperature gradient
Inserts
Outer shell
Mounting plate
Cover
Front cooling
Boards
Vacuum insulation panel (VIP)
Crystals
Coolant
Inner shell
Methanol 60% Water 40%
Property
Value
Units
Density
930
kg/m3
Dynamic viscosity
0.0077
kg/s/m Cp
3151
J/kg/K
BWEC Cooling shell design 4

5. THE PROCESS IS THIS Calculate & Design Simulate Test
BWEC Cooling shell design 5

6. Thermal and fluid mechanics calculations of the cooling shells2
Thermal and fluid mechanics calculations of the cooling shells
BWEC Cooling shell design 6

7. Thermal calculations Electronics Heat flow through the walls
Heat sources
Electronics
Heat flow through the walls
Power to cool down P
+70C
APFEL 1.5
BWEC Cooling shell design 7

8. Thermal calculations 150 mW/crystal * 524 crystals =78.60 W
Electronics
150 mW/crystal * 524 crystals =78.60 W
Applied in back side of crystals
Cables out of the detector are not taken into account
BWEC Cooling shell design 8

9. Thermal calculations Worst case at 70°C surrounding temperature
Outer face
Heat flow through walls
Front face
Back face
Worst case at 70°C
surrounding temperature
Inner face
Source
Value [W]
Outer face
40.23
Inner face
17.25
Front face
16.63
Back face
18.59
Radiation
27.92
BWEC Cooling shell design 9

10. Thermal calculations Constant cooling flow Initial temperature 30°C
Power to cool down
Constant cooling flow
Initial temperature 30°C
Final temperature -25°C
Time 24 h
𝑷= 𝑚∙ 𝐶 𝑝 ∙∆𝑇 𝑡 = 0,06 𝑚 3 ∙ 8280 𝑘𝑔 𝑚 3 ∙ 262 𝐽 𝑘𝑔 ∙(55°𝐶) 24 ℎ∙3600 𝑠 =𝟖𝟑.𝟎𝟎 𝑾
BWEC Cooling shell design 10

11. Summary of heat sources
Stationary
Transient
Source
Value [W]
Outer face
40.23
Inner face
17.25
Front face
16.63
Back face
18.59
Radiation
27.92
Electronics
78.60
Cooling down
83.00
Total
199.30
203.70
Total*1.5
298.95
305.98
Safety factor 1.5
BWEC Cooling shell design 11

12. Thermal calculations Mass flow calculation Distance between pipes
0.3 °C between inlet and outlet (homogeneity)
𝑚 = 𝑃 𝐶 𝑝 ∙∆𝑇 = 𝑘𝑔 𝑠 → 20.88𝑙 𝑚𝑖𝑛
2 outer shells and 2 inner shells
Outer shell 7.34 l/min
Inner shell 3.10 l/min
Distance between pipes
0.25 °C max temperature difference (homogeneity)
15 mm thickness
L= 150 mm
𝑃 𝐿 2 8∙𝑘∙𝑡 =∆𝑇→𝐿= 8∆𝑇𝑘𝑡 𝑃 L
BWEC Cooling shell design 12

13. Fluid mechanics calculations (Half outer shell)
Outer shell parts
6 pipes  d = 13 mm
4 pipes  d = 10 mm
5 front square connectors
4 back elbow connectors
BWEC Cooling shell design 13

14. Fluid mechanics calculations
Pipe with d = 10 mm
∆𝑝= 8 𝑄 2 𝜋 2 𝑓 𝐿 𝐷 5 𝜌=11.37𝑚𝑏𝑎𝑟
Elbow of d = 10 mm
∆𝑝= 8 𝑄 2 𝜋 2 𝑓 𝐿+ 𝐿 𝑒𝑞 𝐷 5 𝜌=21.05 𝑚𝑏𝑎𝑟
Pipe with d = 13 mm
∆𝑝= 8 𝑄 2 𝜋 2 𝑓 𝐿 𝐷 5 𝜌=3.99 𝑚𝑏𝑎𝑟
Square connector (estimation)
∆𝑝= 8 𝑄 2 𝜋 2 𝑓 𝐿+ 𝐿 𝑒𝑞 𝐷 5 𝜌=27.60 𝑚𝑏𝑎𝑟
BWEC Cooling shell design 14

15. Fluid mechanics calculations summary
Part
Pressure drop (mbar)
Amount
Total Pd (mbar)
Straight d =13 mm
3.99 6
23.94
Straight d = 10 mm
11.37 4
45.48
Elbow d = 10 mm
21.05
84.20
Square connectors
27.60 5
138.00
Total
mbar
𝟐𝟗𝟏.𝟔𝟐𝒎𝒃𝒂𝒓<𝟓𝟎𝟎𝒎𝒃𝒂𝒓
BWEC Cooling shell design 15

16. An overview of the outer shell 3D design🎨
3D design 3
An overview of the outer shell 3D design
BWEC Cooling shell design 16

17. 3D design
BWEC Cooling shell design 17

18. 3D design Front square connectors Back elbows
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19. 4 Simulations Thermal and fluid mechanics simulations
Autodesk Simulation Mechanical & Autodesk CFD 2016
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20. Thermal simulations 1 quarter dummy for simulations
Outer shell (Aluminum)
Front shell (HDPE)
Inserts (Aluminum)
Gap (air 4mm)
Crystals (PbWO4)
Inner shell (Aluminum)
1 quarter dummy for simulations
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21. Only outer and inner shells
Thermal simulations
Only outer and inner shells
Not front shielding
2°C gradient °C °C
BWEC Cooling shell design 21

22. Back pipe with both inner and outer shells
Thermal simulations
Back pipe with both inner and outer shells
Back homogeneity °C
Not front shielding
2°C gradient °C
BWEC Cooling shell design 22

23. Front shell, back pipe and both inner and outer shells
Thermal simulations
Front shell, back pipe and both inner and outer shells
Out of scale -5°C
Front shielding
Less than 0.5°C gradient °C °C
Solid angle loss (further for the IP)
BWEC Cooling shell design 23

24. Possible 140W (STT worst elect. case) front without front cooling
Thermal simulations
Possible 140W (STT worst elect. case) front without front cooling
-25,06 °C
Huge temperature
gradient (7.13°C)
-17.87°C
BWEC Cooling shell design 24

25. Possible 140W (STT worst elect. case) front with front cooling
Thermal simulations
Possible 140W (STT worst elect. case) front with front cooling
Out of scale 57°C
Good front protection
Less than 0.5°C gradient °C
-24.00°C
Solid angle loss (further from the IP)
BWEC Cooling shell design 25

26. Straight pipes and elbow
Fluid mechanics simulations
Straight pipes and elbow
4.00 mbar
23.82 mbar
11.63 mbar
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27. Front square connectors
Fluid mechanics simulations
Front square connectors
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28. Front square connectors
Fluid mechanics simulations
Front square connectors
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29. Front square connectors
Fluid mechanics simulations
Front square connectors
BWEC Cooling shell design 29

30. Front square connectors
Fluid mechanics simulations
Front square connectors
35.44 mbar
31.21 mbar
30.28 mbar
BWEC Cooling shell design 30

31. Fluid mechanics simulations
Summary
Part
Pressure drop/part(mbar)
Amount
Total Pd (mbar)
Straight d = 10 mm
11.63 4
46.52
Straight d = 13 mm
4.00 6
24.00
Elbow d = 10 mm
23.82
95.28
Square conn 1
35.44 2
70.88
Square conn 2
31.21
62.42
Square conn 3
30.28 1
Total
mbar
BWEC Cooling shell design 31

32. Fluid mechanics calculations vs. simulations
Part
Pressure drop (mbar)
Amount
Total Pd (mbar)
Straight
d =10 mm
11.37 4
45.48
d = 13 mm
3.99 6
23.94
Elbow
d = 10 mm
21.05
84.20
Square conn 1
27.60 2
55.20
Square conn 2
Square conn 3 1
Total
mbar
Part
Pressure
drop
(mbar)
Amount
Total Pd (mbar)
Straight
d = 10 mm
11.63 4
46.52
d = 13 mm
4.0 6
24.00
Elbow
23.82
95.28
Square conn 1
35.44 2
70.88
Square conn 2
31.21
62.42
Square conn 3
30.28 1
Total
mbar
BWEC Cooling shell design 32

33. Summary and future works5
What is next?
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34. Summary Less than 0.3oC of gradient in the coolant temperature
Good homogeneity with front cooling
Low pressure drop:
Different pressure drop values because of the square parts (simplifications in calculations for complex geometry)
Calculations
Simulation
mbar
mbar
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35. Future works Building an outer shell prototype (on process)
Make measurements for validating calculations and simulations
Tests for front cooling with existing prototype (on process)
Design inner shell with the same procedure
BWEC Cooling shell design 35

36. Any questions? You can write me jjorgeri@uni-mainz.de
THANKS!
Any questions?
You can write me
BWEC Cooling shell design 36

37. Back Up slides
BWEC Cooling shell design

38. Front cooling Connectors MP Hole Preparation in Outer shell and MP
BWEC Cooling shell design B1

39. Front cooling Parallel circuits (low pressure drop)
Preliminary design
Parallel circuits (low pressure drop)
Different diameter each branch (homogeneity)
3D printed (HDPE)
BWEC Cooling shell design B2

40. Simulations
Velocity examples
BWEC Cooling shell design B3

41. Thermal calculations General inputs BWEC Cooling shell design B4

42. Thermal calculations
Example
BWEC Cooling shell design B5

43. Thermal calculations Output summary BWEC Cooling shell design B6

44. Fluid mechanic calculations
Serial Pressure drop calculator
Inputs:
Coolant
Section´s geometry
Length
Local elements
Flow
Valve
Height
BWEC Cooling shell design B7

45. Fluid mechanic calculations
Serial Pressure drop calculator
Outputs:
Reynolds
Laminar/ Turbulent
Friction factor
Pressure drop
Pressure difference
BWEC Cooling shell design B8

46. Fluid mechanic calculations
Parallel calculator
Flow
Aim:
Constant flow through
all branches.
Procedure:
Change diameter of branches.
Flow/4
Flow/4
Flow/4
Flow/4
Flow
BWEC Cooling shell design B9

47. Fluid mechanic calculations
Parallel calculator
Inputs:
Coolant
Different geometry for sections
Lengths
Local elements
Number of branches
Height .
BWEC Cooling shell design
B10

48. Fluid mechanic calculations
Parallel calculator
Outputs:
Total pressure drop
Pressure drop in manifold
Different diameters .
BWEC Cooling shell design
B11

49. Front cooling test Aim: See the effect of different materials
in the front cooling
Effect of different VIP´s configuration
20mm
2x10mm
Validate thermal and fluid mechanic
calculation system. .
BWEC Cooling shell design
B12

50. Front cooling test Layout . Different materials
BWEC Cooling shell design
B13

51. Cold nitrogen test Layout . Cool down the nitrogen
BWEC Cooling shell design
B14

52. Dew point at 20°C Calculations BWEC Cooling shell design 08.06.2017

53. Dew point at 20°C Psychrometric chart BWEC Cooling shell design
B14

54. Dew point at 20°C Kapton heating BWEC Cooling shell design 08.06.2017

55. Distance between pipes
All the heat received for the plate is transported by conduction 𝑃
𝑞𝑐 +∆𝑥 = 𝑞𝑐+ 𝜕𝑞 𝜕𝑥 𝑑𝑥+… Q w
𝑞𝑐 +∆𝑥 − 𝑞𝑐= 𝜕𝑞 𝜕𝑥 𝑑𝑥+… 𝑞𝑐
𝑞𝑐 +∆𝑥 t
𝑞𝑐 +∆𝑥 − 𝑞𝑐= 𝜕 𝜕𝑥 −𝑘 𝜕𝑇 𝜕𝑥 𝑑𝑥+… dx x
𝑑 𝑑𝑥 𝑄 𝐶 =𝑃∙𝑤∙𝑑𝑥
(𝑞𝑐 +∆𝑥 −𝑞𝑐)∙𝑡∙𝑤=𝑃∙𝑤∙𝑑𝑥
−𝑘∙𝑡∙𝑤∙ 𝑑 2 𝑇 𝑑 𝑥 2 𝑑𝑥=𝑃∙𝑤∙𝑑𝑥
𝑑 2 𝑇 𝑑 𝑥 2 =− 𝑃 𝑘∙𝑡
BWEC Cooling shell design
B14

56. Distance between pipes
Boundary conditions
Symmetry: Q(L/2)=0
T(0)=Te
𝑇 𝑥 =− 𝑃 2∙𝑘∙𝑡 ∙ 𝑥 2 +𝐴∙𝑥+𝐵
𝑇 0 =− 𝑃 2∙𝑘∙𝑡 ∙ 0 2 +𝐴∙0+𝐵→𝐵=𝑇𝑒
𝜕𝑇 𝜕𝑥 𝐿/2 =− 2𝑃 2∙𝑘∙𝑡 ∙ 𝐿 2 +𝐴=0→𝐴= 𝑃𝐿 2𝑘𝑡
𝑑 2 𝑇 𝑑 𝑥 2 =− 𝑃 𝑘∙𝑡 Te x
L/2
BWEC Cooling shell design
B14

57. Distance between pipesTe
𝑇 𝑥 =− 𝑃 2∙𝑘∙𝑡 ∙ 𝑥 2 + 𝑃𝐿 2∙𝑘∙𝑡 ∙𝑥+𝑇𝑒 x
L/2
We want T(L/2) ≤ Te+0,5
𝑇 𝐿/2 =− 𝑃 𝐿 2 8∙𝑘∙𝑡 + 𝑃 𝐿 2 4∙𝑘∙𝑡 +𝑇𝑒=𝑇𝑒+0,5
𝑃 𝐿 2 8∙𝑘∙𝑡 +𝑇𝑒= 𝑇𝑒+0,5
𝑃 𝐿 2 8∙𝑘∙𝑡 =∆𝑇→𝐿= 8𝑘𝑡∆𝑇 𝑃
BWEC Cooling shell design
B14

58. Thermal simulations Out of scale
BWEC Cooling shell design
B14

59. Thermal simulations Out of scale
BWEC Cooling shell design
B14

60. Leakless mode
Calorimeter
Pressure
Height
Total static energy
Losses