1. CMS CO 2 Cooling System Design Elements Erik Voirin Mark Adamowski Erik VoirinCMS Pixel Mechanical Upgrade1

2. Topics Design Parameters System Overview Specific Equipment Info Control System Info Safety Commissioning Procedure Erik VoirinCMS Pixel Mechanical Upgrade2

3. Design Parameters Deliver Saturated or slightly sub cooled CO 2 to the detector Ability to handle 15-60 psi detector pressure drops Ability to handle any vapor quality at the detector outlet Capacity to handle up to 5 kW heat load Ability to provide liquid CO 2 at -30 °C to +15 °C CO 2 quality at detector outlet of 25%, maximum CO 2 side, design pressure of 1200 psig Erik VoirinCMS Pixel Mechanical Upgrade3

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5. Cooling System Overview Erik VoirinCMS Pixel Mechanical Upgrade5

6. 1400W 2400W 4800W Erik VoirinCMS Pixel Mechanical Upgrade6

7. Commercial Refrigeration Units Three Mechanical refrigeration chillers will be used to cool the CO 2 reservoir. These are commercial, off the shelf units, capable of providing refrigerant to the CO 2 condenser at -40 °C. Use of commercial packages provides proven refrigeration technology at reasonable cost using R404A. Erik VoirinCMS Pixel Mechanical Upgrade7

8. Cooling System Overview Erik VoirinCMS Pixel Mechanical Upgrade8 Versatile System Control: – Seven steps of cooling capacity, with trim heater to trim final cooling capacity from 0 to up to 20,000 Watts from -40C to 20C

9. System Cooling Capacity Erik VoirinCMS Pixel Mechanical Upgrade9

10. Design Elements Closed CO 2 Cooling Loop Design pressure of 1200 psig – At 30 °C the CO2 equilibrium pressure is 1031.6 psig. Vessels are ASME rated at 1200 psi, tested at 1560 psi Flanges are class 600, rated at 1480 psi Pump housing tested at 1827 psi Valves/Unions/Fittings rated minimum of 1480 psi ½” to 1-½” Sch 10 stainless steel rated minimum of 1916 psi Erik VoirinCMS Pixel Mechanical Upgrade10

11. Storage tank Condensers Trim Heater Variable Speed Pump -------> to detector Erik VoirinCMS Pixel Mechanical Upgrade11

12. Storage Tank Erik VoirinCMS Pixel Mechanical Upgrade12 ASME Vessel - 12” schedule 80s stainless seamless pipe Will be filled with up to 300 lbs CO 2 Three condensers mounted on flanged ends

13. CO2 Condenser Heat will be removed from the CO2 tank by CO2 condensers. The CO2 wetted components will be stainless steel for corrosion resistance. Corrosion would produce exchanger fouling and reduce condenser capacity. The cooling fluid to the CO2 condenser will be refrigerant R-404A. Erik VoirinCMS Pixel Mechanical Upgrade13

14. Design Elements Electric CO2 Trim Heater An electric heater will be used as a trim control in holding a particular CO2 coolant temperature. – 0-6000 Watt capacity electric resistance heater. – Bayonet style. Housed in ASME vessel – Coaxial 2” in 4” pipe – Heater housed inside 2” pipe – Heat Flux from 0 – 18500 W/m 2 Erik VoirinCMS Pixel Mechanical Upgrade14

15. Pump Warrender High Pressure WMDAT6-2S – Alloy Dual Stage Regenerative Turbine Mag-Drive Pump – Flow up to 32 gpm (2250 grams/sec ) – Duty Point is 11.2 gpm @ 64 psi (788 grams/sec at 440kPa) – Variable speed – 3 HP motor (2240 Watts) – Hydrostatically Pressure Tested at 1827 psi (12.6MPa) Erik VoirinCMS Pixel Mechanical Upgrade15

16. Control Valve CO2 Drier Phase Separator Flowmeter Erik VoirinCMS Pixel Mechanical Upgrade16

17. Phase Separator Quality into the phase separator would be at a maximum of 5% Passive liquid full design with control valve on mixture outlet ASME vessel rated to 1200 psi Mixture outlet flow controlled by manual V-ball valve Erik VoirinCMS Pixel Mechanical Upgrade17

18. CO 2 Drier Ice and/or carbonic acid will form if the water concentration reaches a level above the solubility limit in liquid CO 2. Ice can plug small channels and carbonic acid is corrosive. Controlling the water content in the CO 2 is critical. Original plan was to use a desiccant filter, however 1200 psi rated filter housing are unavailable. – Desiccant granule bed with granules held in class 600 strainer Erik VoirinCMS Pixel Mechanical Upgrade18

19. Additional Experiment Flanged connections Pressure Differential Transmitter Test Heater Erik VoirinCMS Pixel Mechanical Upgrade19

20. Detector Test Stand Detector Test Stand – Identical to Trim Heater An electric heater will be used as a detector test stand for simulating detector heat load. – 0-6000 Watt capacity electric resistance heater. – Bayonet style. – Controllable manually from PLC Housed in ASME vessel – Coaxial 2” in 4” pipe – Heater housed inside 2” pipe – Heat Flux from 0 – 18500 W/m 2 Erik VoirinCMS Pixel Mechanical Upgrade20

21. Detector Test Stand Erik VoirinCMS Pixel Mechanical Upgrade21 Flow estimates through actual detector tubes at a set pressure drop 0.15 MPa have been calculated. Test stand will have an orifice placed at the opening to replicate the pressure drop of 0.15 MPa (21.75 psi) at the calculated total detector flow rate of 138 grams/sec.

22. Control System Beckhoff PLC Touch Screen Controller Control and data retrieval via network Erik VoirinCMS Pixel Mechanical Upgrade22

23. CO 2 Flow Control The flow of CO 2 to the detector will be measured after the phase separator. A differential pressure transmitter will be in place across the detector test stand. The CO 2 pump will be controlled by motor on a speed controller (variable frequency drive) controlled by either: – Flow rate of CO 2 after phase separator – Differential pressure across detector test stand Erik VoirinCMS Pixel Mechanical Upgrade23

24. CO 2 Temperature Control The pressure of the CO 2 supply tank can be used as an indication of CO 2 temperature through the saturation pressure / temperature relationship for CO 2. The CO 2 tank pressure can then be used as the control to turn the refrigeration ON/OFF to maintain the CO 2 temperature (pressure). – The storage tank is equipped with a temperature element as well for comparing the pressure measurement. Any value down to -40C may be input through the touch screen. – The PLC will cycle the chilling units and Trim heater to achieve desired temperature Response time = roughly 5 minutes for 0C to -20C change Response time = roughly 17 minutes for -20C to 0C change Erik VoirinCMS Pixel Mechanical Upgrade24

25. Safety Pressure Vessel notes for four ASME vessels are out for review CO 2 Hazard Analysis out for review – Per FESHM 5064 procedures Piping Notes being prepared will comply with: – Warning signs / tags per FESHM5051 – Per FESHM 5051 and ASME 31.3 Code for process piping – Welder qualified under ASME Section IX Erik VoirinCMS Pixel Mechanical Upgrade25

26. Safety - Piping Piping Notes being prepared – solid models of each pipe section is constructed and analyzed in Ansys under conditions: – 1200 psi internal pressure + weight of pipe – Drop in temperature from 71.6F to -110F + weight of pipe – Minimum -40C operating temperature and internal saturation pressure of 131psi Erik VoirinCMS Pixel Mechanical Upgrade26

27. Safety – CO 2 Hazard CO 2 Hazard – Occurs before ODH 5000 ppm/0.5% - TWA (Time Weighted Average, 10 hr) 30,000 ppm/3.0% - STEL (Short Term Exposure Limit) 40,000 ppm/4.0% - IDLH (Immediately Dangerous to Life and Health) 100,000 ppm/10%, produces unconsciousness in a matter of minutes. Erik VoirinCMS Pixel Mechanical Upgrade27

28. Safety – CO 2 Hazard CMS Document 2966 by Erik Voirin covers CO 2 hazard – 32 pages Ventilation Fans CO 2 Monitors and Warning Systems - (In both lab C and clean room) Air flow Monitors – (On ventilation fans of both rooms) Actuated Isolation Valve Erik VoirinCMS Pixel Mechanical Upgrade28

29. Safety – CO 2 Hazard Proactive Steps aimed at personnel safety: Regarding the Clean Room – Trouble alarm at 0.3% CO 2 – Trouble alarm if the fresh air makeup is off – Close isolation valve and stop pump at 0.5% CO 2 – Evacuate at 2% CO 2 concentration Regarding the Lab C hallway – Trouble alarm at 0.3% CO 2 – Trouble alarm if local exhaust fan fails regular test – Start exhaust fan at 0.5% CO 2 – Evacuate at 2% CO 2 concentration Erik VoirinCMS Pixel Mechanical Upgrade29

30. Commissioning Plan Pressure Transmitters – Check each instrument is wired to correct input by directly applying pressure read by gauge to specific transmitters, watch touch screen for proper location Temperature Elements – Direct immersion into water baths of know temperatures, check for correct wiring and readout. Air Flow Monitors – Check for proper operation by removing from air flow path, make sure correct alarms signals are sent. Erik VoirinCMS Pixel Mechanical Upgrade30

31. Commissioning Plan CO 2 Monitors – Test with known CO 2 composition air mixtures – Check trouble signals sent through FIRUS – Check evacuation horns and light activate as set – Check activation of Lab C exhaust fan Actuated Valve – Check for manual activated closure – Test automated closure by tripping CO 2 monitor Erik VoirinCMS Pixel Mechanical Upgrade31

32. Commissioning Plan Chillers – Performance Test: activate each chiller with closed storage tank and observe dT/dt and dP/dt. Trim Heater – Equipped with power monitor. Measure units output vs. input. Compare to claimed 6000 Watt output rating. Pump – Equipped with pressure differential transmitter. Piping has flow meter. Test output of pump at various flow rates and differential pressures. Compare to claimed capabilities. Erik VoirinCMS Pixel Mechanical Upgrade32

33. Commissioning Plan Test Heater – Equipped with power monitor. Measure units output vs. input. Compare to claimed 6000 Watt output rating. Performance Tests Using Test Heater – Check systems cooling capacity of system up to 6000 Watts from -40C to 15C. – Record all data from instruments Erik VoirinCMS Pixel Mechanical Upgrade33

34. Design Parameters Met Deliver Saturated or slightly sub cooled CO 2 to the detector Ability to handle 15-60 psi detector pressure drops Ability to handle any vapor quality at the detector outlet Capacity to handle up to 5 kW heat load Ability to provide liquid CO 2 at -30 °C to +15 °C CO 2 quality at detector outlet of 25%, maximum CO 2 side, design pressure of 1200 psig Erik VoirinCMS Pixel Mechanical Upgrade34

35. Questions? Erik VoirinCMS Pixel Mechanical Upgrade35

36. Additional slides Erik VoirinCMS Pixel Mechanical Upgrade36

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