1. Tracker Outer Barrel
COOLING
Antti Onnela, CERN

2. Cooling: Main features
TK standard coolant: C6F14 at -20 ºC ºC
Pipes in Copper and Copper-nickel
Soldered pipe connections inside TK
688 TOB Rods divided into 44 cooling segments.

3. Coolant distribution

4. Coolant distribution
22 cooling segments at each end of the TOB.

5. Coolant distribution

6. One cooling segment

7. Single & double module tests (2001) M. Mermoud, W. Glessing
Tested in –20 °C.
Tmax = 10 °C between silicon and coolant.

8. Cooling tests on rods
Single-sided rod frame with dummy modules (2002) / A. Onnela et al.
Complete single-sided rod with real modules, optohybrids, cables, etc. (2002) / S. Koestner et al.
Tested in room-temperature.
Confirmed results from calculations and earlier tests.
Complete double-sided rod with real modules, optohybrids, cables, etc. (2003) / R. Chierici et al.
First in building 598, room-temperature.
Presently in building 186, TOB lab
Next in 186 cold room (or in Lyon?), –20 °C.

9. Double-sided rod with dummy modules (2002) A. Onnela et al.
Tested in –20 °C.
Tmax = 10 °C between silicon and coolant.
Equal cooling in all module positions along the rod.

10. Complete rod

11. Cooling segment tests
TOB cooling segment with 19 rod pipes ( ) / A. Onnela et al.
Cooling segment manufacture and assembly tested ok (bent connection pipes, solderings, etc.).
Room temperature tests with water:
Filling/draining ok with all orientations of the segment (horizontally, vertically, feed pipes low/middle/top).
Feeding+Manifolds work ok: uniform flow in rods.
Cold tests (–20 °C) with C6F14 and with full CMS pipework distances in building 186.
TK Scale 1 Alu-tube mock-up in building 186 (2004)
Services arrangement, including cooling pipes and their connections (in-situ assembly work and connection soldering inside the TK tube)

12. Cooling segment test with 19 “rods”

13. Cooling pipe life-cycle (1)
Pipe manufacture [High Tech Tubes, Ireland]
Material: Copper-Nickel (70% Cu, 30% Ni)
Specification: EN.12449:1999:CW354H
Temper: Half Hard
Ultimate Tensile Strength: MPa
Tolerance on wall thickness: 10%
Manufactured by drawing from seamless pipe
Each rod pipe pressure tested to 35 bar (Manifold and distribution pipes need to be tested by us)
Pipes cleaned at factory with high-temperature steam
All ‘raw’ pipes made and delivered to CERN.

14. Cooling pipe life-cycle (2)
Manufacture of Rod Pipes [CERN]
Mineral “sand” filler
Custom-made bending tools to keep the pipe circular
Removal of the sand
Cutting in final length
Preparation of pipe and end pieces for soldering:
Removal of oxide layer with emery cloth
Degreasing with isopropyl alcohol
Soldering of the end piece to the pipe
ERSIN multicore solder; Alloy: Sn 62% - Pb 36 % - Ag 2 %; Flux type: ERSIN 362; Melting temperature 179 °C; Tension strength 90 MPa; Corresponds to CERN SCEM: F
Pressure test with air (20 bar) in warm water (60 ºC).
Flushing with isopropyl alcohol
Flushing with air
Packing and shipping to Helsinki
Status 18 March 2004:
250 pipes (of 760) made.
15 (6%) failed in leak test: tiny leaks in the pipe wall; solderings ok.

15. Cooling pipe connections
A test-set of soldered connections. Leak-tightness tested to 15 bar pressure, and thermal cycling down to -196C.

16. Cooling pipe manufacture: soldering of end pieces

17. Cooling pipe manufacture: pressure testing

18. Cooling pipe life-cycle (3)
Gluing of Pipe to Rod Frame [Helsinki]
Mold-release coating to leave the pipe “slide” in the module inserts
Capillary Araldite 2020 to glue the pipe + closing “hat” in the module inserts
Completed rod frame dipped into –30 °C freezer for a “thermal shock” test
Cooling performance of each module support of all rods measured with clamp+heater+temp.sensor and with water coolant running in the pipe (room temp.)
Status 18 March 2004:
112 rod frames (of 760) produced and ready
In 3 rods found bad thermal contacts, due lack of filling glue. Corrected.

19. Cooling QC in Helsinki

20. Cooling pipe life-cycle (5)
Completed rods tested in USA (burn-in, thermal cycling):
- 20 °C
C6F14
After transport completed rods tested at CERN (XY-table and Cosmic Rack)
Room-temperature, Cosmic Rack also in - 20 °C
Additional cleaning, checking of the rod pipe before insertion to TOB?
Details not decided yet. Use Fluorocarbon, Alcohol? (Acetone must not be used)
Flushing with N2 and measurement of the exhaust?

21. Cooling pipe life-cycle (6)
Preparation of the manifold pipes
Same CuNi material as in the rods
Same preparations: Bending, Pressure testing, Cleaning, …
Insertion of rods to the TOB
Connection soldering of the cooling pipes. THIS IS CRITICAL! Have exercised with the TOB sector mock-up, but needs still preparation work:
Protection around the soldering spot
As reasonable as possible working position and support
Pressure testing; Cleaning; Flushing and measuring exhaust

22. Cooling pipe life-cycle (7)
Final connections inside CMS
Flushing with dry N2 and measuring the exhaust (Content of water; other impurities?)
Pressure test (20 bar?) with N2 for the leak tightness of the system
Filling with final fluid
Pressure test with final fluid?
Operation…