1. Cooling systems for HL-LHC (WP17.3)
Alexandre Broche
CERN
Engineering Department
Cooling and Ventilation Group
Cooling and Ventilation Review – 14th March 2017

2. Cooling infrastructure Point 1 and 5 User Requirements Design Criteria
Content
Cooling infrastructure Point 1 and 5
User Requirements
Design Criteria
Cooling overview schematic
SFx7 Primary water station
SUx7 Chiller water station
UWx7 Underground cooling station
Central heating Point 1
Cooling infrastructure Point 1 and 5
User Requirements
Design Criteria
Cooling overview schematic
SFx7 Primary water station
SUx7 Chiller water station
UWx7 Underground cooling station
Central heating Point 1
HL-LHC CV Tech Review, CERN, 14 March '17

3. Cooling infrastructure Point 1
Chiller water station SU17
Underground cooling station UW17
Primary water station SF17
HL-LHC CV Tech Review, CERN, 14 March '17

4. Cooling infrastructure Point 5
Chiller water station SU57
Primary water station SF57
Underground cooling station UW57
HL-LHC CV Tech Review, CERN, 14 March '17

5. Cooling infrastructure Point 1 and 5 User Requirements Design Criteria
Content
Cooling infrastructure Point 1 and 5
User Requirements
Design Criteria
Cooling overview schematic
SFx7 Primary water station
SUx7 Chiller water station
UWx7 Underground cooling station
Central heating Point 1
HL-LHC CV Tech Review, CERN, 14 March '17

6. Primary water for surface buildings
User requirements (1/4)
Primary water for surface buildings
Location
Name
Heat load (kW)
Supply
temperature
(°C) ∆T ∆P
(bar)
Pmax
SHMx7
Helium compressor
5000 25 8 3 10
SDx7
Cold box
200
TOTAL
5200
Secondary raw-water for underground
Location
Name
Heat load
(kW)
Supply
temperature
(°C) ∆T ∆P
(bar)
Pmax
USx7
Cold box 70 27 10 3
HL-LHC CV Tech Review, CERN, 14 March '17

7. Secondary demineralised water for underground
User requirements (2/4)
Secondary demineralised water for underground
Location
Name
Heat load
(kW)
Supply
temperature
(°C) ∆T ∆P
(bar)
Pmax
URx5
Power converters
272 27 10 3 16
WCC
420 2
Energy extraction 78 NC
UAx3
RF amplifier
332 (664) 5
HV PS
92 (184)
UAx7
TOTAL
1618 (2466)
½ CC
(Full CC)
HL-LHC CV Tech Review, CERN, 14 March '17

8. Cooling power on chilled water Cooling power on mixed water
User requirements (3/4)
Surface Air Handling Units
Location
Name
Heating power
50°C – 40°C
(kW)
Heat recovery
power
30°C – 25°C
Cooling power on chilled water
5°C – 10°C
Cooling power on mixed water
14°C – 20°C
SUx7
Pressurisation shaft
120 - 80
Primary air 60 50
250
SU building 35
SD building 30
SHMx7
SHM building
SFx7
SF building 20
SEx7
SE – LV 15
SE – HV
TOTAL
325
265
HL-LHC CV Tech Review, CERN, 14 March '17

9. Underground Air Handling Units
User requirements (4/4)
Underground Air Handling Units
Location
Name
Heat load
(kW)
Supply
temperature
(°C) ∆T ∆P
(bar)
UAx3
RF – HV PS
80 (160) 14 6
0.3
UAx7
URx5
PC – WCC –EE – Racks
240
Faraday cage
11 (20)
USx7
Safe room 10
UWx7
Safe room back-up
US cavern 55
Station UW 12
TOTAL
499 (677)
Mixed water
½ CC
(Full CC)
HL-LHC CV Tech Review, CERN, 14 March '17

10. Cooling infrastructure Point 1 and 5 User Requirements Design Criteria
Content
Cooling infrastructure Point 1 and 5
User Requirements
Design Criteria
Cooling overview schematic
SFx7 Primary water station
SUx7 Chiller water station
UWx7 Underground cooling station
Central heating Point 1
HL-LHC CV Tech Review, CERN, 14 March '17

11. Design criteria Outdoor wet bulb temperature : 21.7°C
Piping
ISO 1127
ISO 4200
ISO 5252
EN & EN EN EN
EN /6
Welding
ISO 9712
ISO 15609
EN-ISO
EN-ISO 14732
EN-ISO 15614
Pumps
EN-ISO 2858
EN-ISO 5199
EN 733
Valves
EN 588
Outdoor wet bulb temperature : 21.7°C
Point 1 and 5 : same design with different layout
ISO and EN standards
Redundancy and durability
Level N+1 for the pumps, chillers, cooling towers
Pipes made of stainless steel
Concrete cooling tower
Half Crab Cavities vs Full Crab Cavities:
Full CC: Pipes, chillers, heat exchangers and cooling tower
½ CC: Pumps
Redundancy on Safe Room, Faraday Cage, primary air
SIA 2028
Avoid a component failure to cause a system wide failure
1 hour of cooling stop for cryo equipment is 10 hours of cryo stop
HL-LHC CV Tech Review, CERN, 14 March '17

12. Design criteria Margin Energy saving Heat recovery Variable flow rate
Water cooled chillers
Good COP, low noise, high life expectancy, low cost, compact
Standardised equipment for reliability and management of spare parts
Primary water
Secondary raw & demineralised water
Chilled/Mixed water for AHUs
+15%
No margin
System
Pumps and chillers are matching ventilation needs
HL-LHC CV Tech Review, CERN, 14 March '17

13. Cooling infrastructure Point 1 and 5 User Requirements Design Criteria
Content
Cooling infrastructure Point 1 and 5
User Requirements
Design Criteria
Cooling overview schematic
SFx7 Primary water station
SUx7 Chiller water station
UWx7 Underground cooling station
Central heating Point 1
HL-LHC CV Tech Review, CERN, 14 March '17

14. Cooling overview schematic Point 1&5SF SU
SHM SD UW
Internal C&S review of WP17, CERN, September '16

15. Cooling overview schematic Point 1&5SF
9 MW
(10.2)
1.04 MW
(1.33) SU
Chiller
5-10°C
250 kW
Ventilation
Primary air
Primary network 3 UW
Chiller
14-19°C
579 (757) kW
Ventilation
Pressurisation
80 kW
Ventilation 13 AHUs
UA, UR, FC, SR, US, UW
500 (677) kW
Primary network 2
1.94 MW
(2.92) UW
Power Converters
WCC, EE
RF-IOTs, HV-PS
1618 (2466) kW
Cryo
Cold box
70 kW US
UR+UA
6.0 MW SD
Cryo
Cold box
200 kW
SHM
Compressor
5000 kW
Primary network 1
½ CC
(Full CC)
Surface
Underground
HL-LHC CV Tech Review, CERN, 14 March '17

16. Cooling overview schematic Point 1
SFx7
SHMx7
SUx7
SDx7
25ºC
DN300
DN200
DN200
PMx7
35ºC
30ºC
33ºC
Technical galleries
Primary network 2
UWx7
Raw water→70kW
Demineralised water→ 1618 (2466) kW
Primary network 1
SHMx7→ 5MW
SDx7→200kW
Primary network 3
SUx7 → 1040 (1325) kW
UWx7
USx7
HL-LHC CV Tech Review, CERN, 14 March '17

17. Cooling infrastructure Point 1 and 5 User Requirements Design Criteria
Content
Cooling infrastructure Point 1 and 5
User Requirements
Design Criteria
Cooling overview schematic
SFx7 Primary water station
SUx7 Chiller water station
UWx7 Underground cooling station
Central heating Point 1
HL-LHC CV Tech Review, CERN, 14 March '17

18. SFx7 Primary water station
Make – up water
3 cells (N+1)
Filtration
Heating
Blowdown
Distribution
Sump
HL-LHC CV Tech Review, CERN, 14 March '17

19. SFx7 Primary water station
Evaporation Twb=21.7°C
17 m3/h
32.8 °C
25°C
5.1 MW
CF=3
Biocides, Biodispersant, Corrosion inhibitor UW
1941 kW
(2916 kW)
SHM
5750 kW SD
230 kW SU
1040 kW
(1325 kW)
167 m3/h
(251 m3/h)
644 m3/h
179 m3/h
(228 m3/h)
400 µm
Make-up water
25.5 m3/h
Heating circuit
60 m3/h
150 kW
Filtration circuit
50 to 100 m3/h
< 100 µm
Blowdown
8.5 m3/h
Sump circuit
60 m3/h
Constant flow
VSD to start pumps and save energy
HL-LHC CV Tech Review, CERN, 14 March '17

20. Cooling infrastructure Point 1 and 5 User Requirements Design Criteria
Content
Cooling infrastructure Point 1 and 5
User Requirements
Design Criteria
Cooling overview schematic
SFx7 Primary water station
SUx7 Chiller water station
UWx7 Underground cooling station
Central heating Point 1
HL-LHC CV Tech Review, CERN, 14 March '17

21. SUx7 Chiller water station
Primary water
Chilled water
Mixed water production
Heat recovery
Mixed water
distribution
Make-up
HL-LHC CV Tech Review, CERN, 14 March '17

22. SUx7 Chiller water station
250 kW
Ventilation
Primary air
250 kW
42 m3/h
53 m3/h
250 kW
10°C
5°C
7 m3
7 m3
422 kW
88 m3/h
73 m3/h
19°C
14°C
12 m3
20°C
14°C
13 AHUs
499 kW
(677 kW)
Pressu.
80 kW
Primary water
25°C - 30°C
Small chillers, 1 screw, 25 to 100%
Large chillers, Double screw, 12.5 to 100%
R134A then HFO Hydrofluoroléfine classé A2L (lslightly inflammable)
Heat recovery circuit . delta P constant. 2 ways valve
summer Primary air, mid season lower load, winter up to max
SHMx7
30 kW
SDx7
Primary air
50 kW
Pressurisation
120 kW
SUx7
35 kW
46 m3/h
30°C
25°C
27°C °C
265 kW
31°C
1040 kW
(1325 kW)
HL-LHC CV Tech Review, CERN, 14 March '17

23. Cooling infrastructure Point 1 and 5 User Requirements Design Criteria
Content
Cooling infrastructure Point 1 and 5
User Requirements
Design Criteria
Cooling overview schematic
SFx7 Primary water station
SUx7 Chiller water station
UWx7 Underground cooling station
Central heating Point 1
HL-LHC CV Tech Review, CERN, 14 March '17

24. UWx7 Underground cooling station
Secondary
Demineralised water
Primary
water
Secondary
Raw-water
HL-LHC CV Tech Review, CERN, 14 March '17

25. UWx7 Underground cooling station
PMx7
UAx3
ULx3
ULx7
UAx7
½ CC
(Full CC)
HV PS
92 kW
(184 kW)
HV PS
92 kW
(184 kW)
35°C °C
RF Amplifier
332 kW
(664 kW)
RF Amplifier
332 kW
(664 kW)
UWx7
81 kW
QURCG
70 kW
7 m3/h
27°C
37°C
URx5
USx7
WCC
210 kW
160 m3/h
(244 m3/h)
Energy
extraction
39 kW
Power converters
272 kW
Energy
extraction
39 kW
WCC
210 kW
27°C
37°C
1861 kW
(2836 kW)
HL-LHC CV Tech Review, CERN, 14 March '17

26. UWx7 Underground cooling station
Demineralised water
Conductivity <0.5μS/cm
HL-LHC CV Tech Review, CERN, 14 March '17

27. Cooling infrastructure Point 1 and 5 User Requirements Design Criteria
Content
Cooling infrastructure Point 1 and 5
User Requirements
Design Criteria
Cooling overview schematic
SFx7 Primary water station
SUx7 Chiller water station
UWx7 Underground cooling station
Central heating Point 1
HL-LHC CV Tech Review, CERN, 14 March '17

28. Central heating Point 1 Heating sub-station in SU17
Meyrin central heating is available from October to May
SHM17
30 kW
SU17
35 kW
Primary air
50 kW
Pressurisation
120 kW
SD17
41 m3/h
50°C
40°C
475 kW
80°C
60°C
SE17
SF17 - AHU
20 kW
SF17 - Heater
150 kW
3 ways valve but delta pressure constant because of the basin heater SF17 is 2 ways
HL-LHC CV Tech Review, CERN, 14 March '17

29. Existing central heating network
Central heating Point 1
SF17
SHM17
SU17
SE17
Technical galleries
Existing central heating network
80/60ºC
SD17
New pipeline
HL-LHC CV Tech Review, CERN, 14 March '17

30. …any questions? Thanks to:
M. Battistin, Y. Body, F. Borralho, A. Mejica, M. Nonis, P. Pepinster.
HL-LHC CV Tech Review, CERN, 14 March '17

31. BACK-UP SLIDES

32. Payback study energy savings

33. SFx7 Primary water plant
Cooling cell
HL-LHC CV Tech Review, CERN, 14 March '17

34. SFx7 Primary water plant A distribution circuit
HL-LHC CV Tech Review, CERN, 14 March '17

35. SFx7 Primary water plant
Filtration
Running cycle
Internal C&S review of WP17, CERN, September '16

36. SFx7 Primary water plant
Filtration
Water and air
Internal C&S review of WP17, CERN, September '16

37. SFx7 Primary water plant
Filtration
Cleaning
Internal C&S review of WP17, CERN, September '16

38. SFx7 Primary water plant
Filtration
Rinsing
Internal C&S review of WP17, CERN, September '16