1. 14 May 2009Hans Postema - CERN CMS Upgrade Workshop Tracker Phase I upgrades 14 May 2009 1

2. CO2 cooling Distributed effort in many different places Lot of progress everywhere Study and engineering are advancing Some installations are built Some installations are running Some preliminary results 14 May 20092Hans Postema - CERN

3. Participating places (1) Aachen – Lutz Feld, Michael Wlochal Lyon – Nick Lumb, Didier Contardo Karlsruhe – Wim de Boer et al. Fermilab – Simon Kwan, Richard Schmitt, Terry Tope, Kirk Arndt 14 May 20093Hans Postema - CERN

4. Participating places (2) CERN Cryolab – Friedrich Haug, Jihao Wu, Torsten Koettig, Christopher Franke University Esslingen – Walter Czarnetzki, Stefan Roesler CERN DT group – Joao Noite, Antti Onnela, Paolo Petagna 14 May 20094Hans Postema - CERN

5. Participating places (3) PSI – Roland Horisberger, Stefan Koenig CERN CMS – Duccio Abbaneo, Paola Tropea, Hans Postema 14 May 20095Hans Postema - CERN

6. System overview Thin and light pipe inside the detector Pipe connecting techniques Existing pipe-work inside CMS detector Cooling station –Pump, heat exchangers, components Interface to cooling plant in USC Control system Other items Hans Postema - CERN14 May 20096

7. Lyon test setup System operated from CO2 bottle 5.5 m tube ID=1.4 mm Simulates Pixel barrel tube Hans Postema - CERN14 May 20097

8. Set-up in Lyon Hans Postema - CERN14 May 20098

9. 5.5 m tube in the freezer Hans Postema - CERN14 May 20099

10. Last results Lyon Hans Postema - CERN14 May 200910

11. CERN Cryolab setup Hans Postema - CERN14 May 200911

12. CERN Cryolab setup Hans Postema - CERN14 May 200912

13. CERN-DT setup System operated from CO2 bottle 5.5 m tube ID=1.4 mm Simulates Pixel barrel tube Hans Postema - CERN14 May 200913

14. Detector Cooling Tube Requests The preferred cooling liquid temperature during operation is around -12°C, which corresponds to a pressure of 25 Bar. The Pixel Barrel cooling tube is specified as ID=1.5 mm, wall thickness 50 microns. Layer 1 of the Pixel detector dissipates 144 W over a cooling pipe length of 5.5 m. 14 May 200914Hans Postema - CERN

15. CO 2 Cooling Test Setup Data Acquisition System Test Zone CO2 Test Rack 14 May 200915Hans Postema - CERN

16. Temperature Sensors Placement PT100 Temperature Sensors Detector Tube ID = 1.4 mm Insulation 14 May 200916Hans Postema - CERN

17. Test Zone 14 May 200917Hans Postema - CERN

18. Data Aquisition System 14 May 200918Hans Postema - CERN

19. Temperature vs Lenght Power = 144 W Mass Flow = 1 g/s ΔT ≈ 3.7°C ΔP ≈ 2.5 Bar 14 May 200919Hans Postema - CERN

20. CO 2 Cooling Test Next Steps Tube testing using diferent conditions of: Mass Flow Power Pressure Tube Geometry 14 May 200920Hans Postema - CERN

21. dT at - 9 C Hans Postema - CERN14 May 200921 Power=145W Mass Flow=1g/s Pressure=27 Bar ΔT=2.6°C ΔP=1.9 Bar

22. dT at – 21 C Hans Postema - CERN14 May 200922 Power=144W Mass Flow= 1g/s Pressure= 19 Bar ΔT=5.4°C ΔP=2.9 Bar

23. Existing cooling pipes The currently installed cooling pipes are virtually impossible to replace People ask: “Is this really the case” Please have a look at the following slides 2314 May 2009Hans Postema - CERN

24. YB0 – fully cabled 24Hans Postema - CERN14 May 2009

25. YB0 - numbers Tracker cooling pipes below all the cables HB: 180 cables, 180 optical fiber cables EB: 1600 cables, 180 optical fiber cables Tracker: 3000 cables, 640 Optical fiber cables 9 month plus, installation time Removing and reinstalling ~10 year old EB cables is inviting trouble 2514 May 2009Hans Postema - CERN

26. Re-use of installed pipes The currently installed pipes are OD=14 and OD=16 mm copper pipes with a wall of 1 mm Cannot be used for 2 phase CO2 cooling without special precaution But can be used when the system design takes care that pressures remain below a limit Avoiding 100+ bar pressures is also advantageous for detector design 2614 May 2009Hans Postema - CERN

27. Storage tank The system contains a cooled storage tank When system is inoperative, all liquid is condensed in the tank, all warm components are filled with gas (Standard for cryogenic systems) A very similar system is used for the CDF COT flange cooling, same concept, different fluid, different temperature. See next slide 2714 May 2009Hans Postema - CERN

28. CDF – COT endplate cooling Courtesy Richard Schmitt FNAL 2814 May 2009Hans Postema - CERN

29. Operation modes Normal operation, system cooled by commercial chiller, CO2 temperatures between 0 and -20 C, pressures 35 to 20 bar Strong request for detector operation with coolant at +15 C (50 bar). This to avoid condensation during the installation and testing phase. For this a safety valve setting at 57 bar, corresponding to +20 C seems acceptable. 2914 May 2009Hans Postema - CERN

30. Meeting with CERN safety Meeting with Benoit Delille on 5/12/2008 Using French safety code CODAP-2000 Stress limit during operation: UTS/4 Stress limit during test: UTS/2.6 Thus pressure test at 1.43x max. operating pressure 3014 May 2009Hans Postema - CERN

31. Questions from safety Questions by CERN-safety concerning safety factors during operation and during test, certificates of installed materials and quality control of the brazed connection have been answered and documented. 3114 May 2009Hans Postema - CERN

32. Summary With this system design, max coolant temp at 15 degrees C and safety valve at 57 bar, the currently installed copper tubes can be approved by CERN safety We shall build one equivalent circuit for destructive testing by CERN safety We will pressure test the installed copper tubes with gas at 1.25x57=71 bar 3214 May 2009Hans Postema - CERN

33. System aspects 1 Aachen is building a re-circulating system. Experience with pump, heat exchanger and other components will be useful for all CO2 systems Hans Postema - CERN14 May 200933

34. heat removal design considerations o load: 500 W maximum o CO 2 temperature at detector: -45°C … +20°C o precise temperature control o precise flow measurement o continuous operation o safe operation (100 bar max.) chiller temperature  vapour pressure  evaporation temperature Re-Circulating CO 2 Cooling Test System 14 May 2009Hans Postema - CERN34 1 1 2 2 3 3 5 5 6 6 4 4 1 1 2 2 4 4 5 5 6 6 pump sub-cooled liquid 4 -> 5: detector load QQ 3 3 Pressure Enthalpy QQ Chiller 2 Chiller 1 flow meter

35. Implementation of Re-Circulating CO 2 Cooling Test System 14 May 2009Hans Postema - CERN35 Components Chiller 1: Huber Unistat 815 (1.2 kW@-60C) Chiller 2: Huber CC-505 Expansion Vessel: Swagelok 304LHDF4-1Gal Levelmeter: Rechner Sensors KFS-1-500-365-PEEK-VA-3/4“ Heat Exchangers: SWEP B16DWx8/1P-SC-U Pump: GATHER 1MX-X/12-11/X-SS/S/Q/K200/HDT/DS2D50 Flow Meter: Rheonik RHM015-T2-P1-SM0-M0-G1-N Piping, fittings etc.: Swagelok Frame: ITEM Temperature Probes: various

36. System aspects 2 Fermilab is looking into system aspects, investigating into pump and heat exchangers. Calulations by Terry Tope determining pressure drops due to sharp bends in detector pipes. Hans Postema - CERN14 May 200936

37. 14 May 2009Hans Postema - CERN 37 CO 2 CO 2 System CO 2We would like to build a prototype CO 2 cooling system at Fermilab CO 2Goals: for testing the completely assembled pixel half-cylinder (3 half-disks) and gaining operation experience of a CO 2 cooling system; design and experience may be expandable and valuable to the final system at P5 or useful for Track/trigger layer R&D at Fermilab Design spec: be able to operate detector at ~18C to -10C; total heat load ~ 1 kW; chiller can cool down to -40C (design with safety margin)

38. System aspects 3 Karlsruhe is providing TEC cooling plant for system test purposes, acquired LEWA pump and a HEX. Planning on building a large scale test setup in a joint effort together with DT and Cryolab Hans Postema - CERN14 May 200938

39. Conclusions Distributed effort over many different places. All critical aspects receive attention. Maintaining the excellent and open communication that we have today, is the most crucial ingredient for success. Hans Postema - CERN14 May 200939