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

2. 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

3. Overall system
P. Tropea / B. Verlaat
Nick Lumb

4. 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

5. 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

6. Example of foam sandwich (Nikhef)
Nick Lumb

7. 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

8. 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

9. 3-D model (2) A. Eynard Damper Pump motor Connections panel
(C6F14 system, etc.)
HEX
Remote pump head
Nick Lumb

10. 3-D model (3) A. Eynard 1” pipes on 2-phase return lines ½” pipes on
sub-cooled
liquid side
A. Eynard
Nick Lumb

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

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

13. As it might look in the USC…
Nick Lumb

14. 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