1. T EVATRON LCW COOLING R ECONFIGURATION A NALYSIS T EVATRON D ECOMMISSIONING A CTIVITY Abhishek Deshpande 09/29/2011 1

2. O VERVIEW Motivation Future heat loads Future flow demand Possible scenarios Method of approach Results Scenario 1(F1 pump running) Scenario 2 (F1 and E4 pumps running) Scenario 3 (F0 pumps running) Scenario 4 (F1, F2, and E4 pumps running) Conclusions Time, Labor, and Material Estimate (simplified) Acknowledgements 2

3. M OTIVATION After September 30 th 2011, when the Tevatron shuts down, it will not be necessary to pump water through all 24 service buildings However, the Main Ring remnant (F+ Sector) has to be operational to support rest of the accelerator complex Running all 24 pond pumps to keep the water in the ponds flowing just to cool the Main Ring remnant would be costly It would be prudent to use an alternate, smaller pond, situated close to F0, F1 service buildings, to provide cooling to the Main Ring remnant Thus, a flow analysis was undertaken to determine if one or more service buildings in the F-sector could provide cooling to the entire Main Ring remnant 3

4. M OTIVATION Diagrammatic illustration: 4

5. M OTIVATION 5 http://www.fnal.gov/pub/visiting/map/site.html

6. F UTURE HEAT LOADS The future worst case heat load was determined by Dan Wolff et.al, and it is summarized in the table below: Worst case is when all the magnets, with an exception of 3Q120s, are operated at an RMS current of 700 Amps Since P150 line is being cooled by MI52, the actual heat load is approximately 1800 kW Total Heat Load Information LinesService BuildingsComponentsTotal Heat Load, kW P1 or P150MI52 Magnets, bus (1), and power supplies 1700 P2E4R, F1 Magnets, bus (1), and power supplies 382 P3F23, F27,F2, F3, F4 Magnets, bus (1), and power supplies 1400 A0A1Laser lab loads?? 6 Notes: 1.Bus heat load assumed to be 12 W/Ft

7. F UTURE FLOW DEMAND The design flow requirements for the Main Ring remnant can be summarized in the following tables: 7

8. F UTURE FLOW DEMAND 8 The actual calculated flow requirements, when the magnets are operated at 700 Amps of RMS current, for the Main Ring remnant can be summarized in the following tables: Actual F1 Flow Requirement Type of Magnet I rms, Amps Resistance, mOhmsP rms, kW Max. dT cooling, 0 F Min. Flow, Gal/minQuantity Total flow, Gal/min IDA700.000.820.4017.000.1600.00 IDB700.000.820.4017.000.1600.00 B1700.007.403.6317.001.4600.00 B2700.007.403.6317.001.463043.95 ILA Lambertsons700.0020.5010.0517.004.06416.23 3Q84700.004.502.2117.000.8987.13 3Q120378.00161.0023.0017.009.291 Total flow, Gal/min (Including 20 GPM for power supply and 6 GPM for MR choke)102.6 Actual F2 Flow Requirement Type of Magnet I rms, Amps Resistance, mOhmsP rms, kW Max. dT cooling, 0 F Min. Flow, Gal/minQuantity Total flow, Gal/min IDA700.000.820.4017.000.1600.00 IDB700.000.820.4017.000.1600.00 B1700.007.403.6317.001.461521.97 B2700.007.403.6317.001.461623.44 ILA Lambertsons700.0020.5010.0517.004.0600.00 3Q84700.004.502.2117.000.8998.02 3Q120378.00161.0023.0017.009.2900.00 Total flow, Gal/min (No power supplies, no MR chokes)53.43 Continued…

9. F UTURE FLOW DEMAND 9 Actual F3 Flow Requirement Type of Magnet I rms, Amps Resistance, mOhmsP rms, kW Max. dT cooling, 0 F Min. Flow, Gal/minQuantity Total flow, Gal/min IDA700.000.820.4017.000.1600.00 IDB700.000.820.4017.000.1600.00 B1700.007.403.6317.001.461623.44 B2700.007.403.6317.001.461623.44 ILA Lambertsons700.0020.5010.0517.004.0600.00 3Q84700.004.502.2117.000.8987.13 3Q120378.00161.0023.0017.009.2900.00 Total flow, Gal/min, (Includes 1 power supply (20 GPM) and 1 MR choke (6 GPM))80 Actual F4 Flow Requirement Type of Magnet I rms, Amps Resistance, mOhmsP rms, kW Max. dT cooling, 0 F Min. Flow, Gal/minQuantity Total flow, Gal/min IDA700.000.820.4017.000.1600.00 IDB700.000.820.4017.000.1600.00 B1700.007.403.6317.001.461623.44 B2700.007.403.6317.001.461623.44 ILA Lambertsons700.0020.5010.0517.004.0600.00 3Q84700.004.502.2117.000.89119.80 3Q120378.00161.0023.0017.009.2900.00 Total flow, Gal/min, (Includes 2 power supplies (40 GPM) and 2 MR chokes (12 GPM))108.68

10. F UTURE FLOW DEMAND 10 Actual E4R Flow Requirement (Magnets only) Type of Magnet I rms, Amps Resistance, mOhmsP rms, kW Max. dT cooling, 0 F Min. Flow, Gal/minQuantity Total flow, Gal/min IDA700.000.820.4017.000.1640.65 IDB700.000.820.4017.000.1640.65 B1700.007.403.6317.001.4600.00 B2700.007.403.6317.001.4600.00 ILA Lambertsons700.0020.5010.0517.004.0600.00 3Q84700.004.502.2117.000.8900.00 3Q120378.00161.0023.0017.009.2900.00 Total flow, Gal/min (Includes a total of 140 GPM to 3 power supplies)141.3 Measured A0 Flow Requirement Type of load Measured Flow rate, Gal/minMeasured dT, 0 FPower, kWQuantity Total flow, Gal/min A0 L188.90Almost noneNo Load??188.9 A0 L219.00Almost noneNo Load??119 A0 L31.10Almost noneNo Load??11.1 A0 L41.10Almost noneNo Load??11.1 A0 L56.30Almost noneNo Load??16.3 A0 L69.70Almost noneNo Load??19.7 A0 L722.80Almost noneNo Load??122.8 Total flow, Gal/min148.9 Actual F 23 Flow Requirement Type of load Measured Flow rate, Gal/minMeasured dT, 0 FPower, kWQuantity Total flow, Gal/min Dyna Power2.00N/A 1326 P=EI5.00N/A 315 Misc.2.00N/A 24 Total flow, Gal/min45

11. P OSSIBLE SCENARIOS The following flow scenarios were modeled to find out if the actual flow demand presented in the previous slides would be met: 1. Scenario 1: Pumps at F1 service building were turned on, while rest of the main ring pumps were turned off 2. Scenario 2: Only the pumps at E4 and F1 service buildings were turned on 3. Scenario 3: F0 pumps were piped into the main ring, and were turned on, while E4, F1, F2, F3, and F4 were turned off 4. Scenario 4: E4, F1, F2 pumps turned on 11

12. M ETHOD OF APPROACH An incompressible fluid modeling tool; AFT Fathom 7.0 was used to model all the loads connected to E4, E4R, F1,F23, F2,F3,F4, A0 and A1 cooling systems Drawings from MDS’s drafting database were used to determine the pipe, bus routing Individual bus lengths and diameters were determined Flow resistance curves for all the components; magnets, chokes, power supplies, etc. were generated Pump curves, HX curves were taken from the manufacturer’s manuals All of the above data and more were fed into the model, and was simulated… 12

13. M ETHOD OF APPROACH 13 E4 Enclosure F1 Enclosure F2 Enclosure F3 Enclosure F4 Enclosure F0 Pump room F23 A0 Loads E4R

14. R ESULTS A summary of flows through the magnets, chokes, and the power supplies of all the service buildings for all scenarios will be presented Also, the operation points on the pump curves for all the scenarios will be presented 14

15. S CENARIO 1 (F1 P UMP RUNNING ) 15 F1 Flow summary Total magnet flow (gal/min)187.94 (50.54) 1 Total power supply flow (gal/min)30.73 (20) 1 Total choke flow (gal/min)17.06 (6) 1 Total flow (gal/min)235.72 (102.6) 1 F2 Flow summary Total magnet flow (gal/min)136.10 (53.43) 1 Total power supply flow (gal/min)0.00 Total choke flow (gal/min)0.00 Total flow (gal/min)136.10 (53.43) 1 F3 Flow summary Total magnet flow (gal/min)112.35 (54.01) 1 Total power supply flow (gal/min)16.77 (20) 1 Total choke flow (gal/min)4.61 (6) 1 Total flow (gal/min)133.72 (80) 1 F4 Flow summary Total magnet flow (gal/min)49.85 (56.68) 1 Total power supply flow (gal/min)22.31 (40) 1 Total choke flow (gal/min)2.54 (12) 1 CUB flow (gal/min)41.27 (130) 1 Total flow (gal/min)115.97 (238) 2 Notes: 1.Actual required flow in parenthesis 2.Addition of actual required flow and 130 GPM to CUB in parenthesis 3.Flow measured on 09/26/2011 in parenthesis

16. 16 S CENARIO 1 (F1 P UMP RUNNING ) E4R Summary Total magnet flow (gal/min)89.96 (1.69) 1 Total power supply flow (gal/min)110.34 Total flow (gal/min)200.30 A0 Summary Total flow (gal/min)45.02 (148.9) 3 F 23 Summary Total flow (gal/min)45.17 (45) 3 Notes: 1.Actual required flow in parenthesis 2.Addition of actual required flow and 130 GPM to CUB in parenthesis 3.Flow measured on 09/26/2011 in parenthesis

17. S CENARIO 1 (F1 P UMP RUNNING ) F1’s pump, 727 GPM @ 309 Ft of TDH (at pump’s run-off!!!) 17 Aurora Pump Curve (2.5 X 3 X 9)

18. S CENARIO 2 (F1 AND E4 PUMPS RUNNING ) 18 F1 Flow summary Total magnet flow (gal/min)213.38 (50.54) 1 Total power supply flow (gal/min)34.73 (20) 1 Total choke flow (gal/min)18.99 (6) 1 Total flow (gal/min)267.10 (102.6) 1 F2 Flow summary Total magnet flow (gal/min)154.29 (53.43) 1 Total power supply flow (gal/min)0.00 Total choke flow (gal/min)0.00 Total flow (gal/min)154.29 (53.43) 1 F3 Flow summary Total magnet flow (gal/min)127.45 (54.01) 1 Total power supply flow (gal/min)25.53 (20) 1 Total choke flow (gal/min)5.22 (6) 1 Total flow (gal/min)158.20 (80) 1 F4 Flow summary Total magnet flow (gal/min)58.75 (56.68) 1 Total power supply flow (gal/min)25.45 (40) 1 Total choke flow (gal/min)5.53 (12) 1 CUB flow (gal/min)46.59 (130) 1 Total flow (gal/min)136.32 (238) 2 Notes: 1.Actual required flow in parenthesis 2.Addition of actual required flow and 130 GPM to CUB in parenthesis 3.Flow measured on 09/26/2011 in parenthesis

19. S CENARIO 2 (F1 AND E4 PUMPS RUNNING ) 19 E4R Summary Total magnet flow (gal/min)131.51 (1.69) 1 Total power supply flow (gal/min)161.31 Total flow (gal/min)292.82 A0 Summary Total flow (gal/min)50.83 (148.9) 3 F 23 Summary Total flow (gal/min)47.12 (45) 3 Notes: 1.Actual required flow in parenthesis 2.Addition of actual required flow and 130 GPM to CUB in parenthesis 3.Flow measured on 09/26/2011 in parenthesis

20. S CENARIO 2 (F1 AND E4 PUMPS RUNNING ) F1’s Pump, 504 GPM @ 351 Ft. E4’s Pump, 425 GPM @ 361 Ft. 20 BEP at 520 GPM @ 350 Ft. (76%) Aurora Pump Curve (2.5 X 3 X 9)

21. S CENARIO 3 (F0 PUMPS RUNNING ) 21 F1 Flow summary Total magnet flow (gal/min)133.80 (50.54) 1 Total power supply flow (gal/min)26.52 (20) 1 Total choke flow (gal/min)13.95 (6) 1 Total flow (gal/min)174.27(102.6) 1 F2 Flow summary Total magnet flow (gal/min)117.85 (53.43) 1 Total power supply flow (gal/min)0.00 Total choke flow (gal/min)0.00 Total flow (gal/min)117.85 (53.43) 1 F3 Flow summary Total magnet flow (gal/min)99.94 (54.01) 1 Total power supply flow (gal/min)20.34 (20) 1 Total choke flow (gal/min)4.16 (6) 1 Total flow (gal/min)124.44 (80) 1 F4 Flow summary Total magnet flow (gal/min)38.60 (56.68) 1 Total power supply flow (gal/min)20.76 (40) 1 Total choke flow (gal/min)4.54 (12) 1 CUB flow (gal/min)36.85 (130) 1 Total flow (gal/min)100.74 (238) 2 Notes: 1.Actual required flow in parenthesis 2.Addition of actual required flow and 130 GPM to CUB in parenthesis 3.Flow measured on 09/26/2011 in parenthesis

22. S CENARIO 3 (F0 PUMPS RUNNING ) 22 E4R Summary Total magnet flow (gal/min)112.70 (1.69) 1 Total power supply flow (gal/min)138.23 Total flow (gal/min)250.93 A0 Summary Total flow (gal/min)42.03 (148.9) 3 F 23 Summary Total flow (gal/min)43.19 (45) 3 Notes: 1.Actual required flow in parenthesis 2.Addition of actual required flow and 130 GPM to CUB in parenthesis 3.Flow measured on 09/26/2011 in parenthesis

23. S CENARIO 3 (F0 PUMPS RUNNING ) F0’s Pump1, 402 GPM @ 329 Ft. (point does not lie on pump curve)!! F0’s Pump2, 366 GPM @ 330Ft. (point does not lie on pump curve)!! 23 Ingersoll Rand Pump Curve (4 X 9AS)

24. S CENARIO 4 (F1, F2, AND E4 PUMPS RUNNING ) 24 F1 Flow summary Total magnet flow (gal/min)239.23 (50.54) 1 Total power supply flow (gal/min)36.48 (20) 1 Total choke flow (gal/min)19.82 (6) 1 Total flow (gal/min)295.53 (102.6) 1 F2 Flow summary Total magnet flow (gal/min)197.48(53.43) 1 Total power supply flow (gal/min)0.00 Total choke flow (gal/min)0.00 Total flow (gal/min)197.48 (53.43) 1 F3 Flow summary Total magnet flow (gal/min)169.39 (54.01) 1 Total power supply flow (gal/min)28.89 (20) 1 Total choke flow (gal/min)6.93 (6) 1 Total flow (gal/min)205.21 (80) 1 F4 Flow summary Total magnet flow (gal/min)66.04 (56.68) 1 Total power supply flow (gal/min)33.70 (40) 1 Total choke flow (gal/min)7.33 (12) 1 CUB flow (gal/min)61.17 (130) 1 Total flow (gal/min)168.24 (238) 2 Notes: 1.Actual required flow in parenthesis 2.Addition of actual required flow and 130 GPM to CUB in parenthesis 3.Flow measured on 09/26/2011 in parenthesis

25. S CENARIO 4 (F1, F2, AND E4 PUMPS RUNNING ) 25 E4R Summary Total magnet flow (gal/min)135.17 (1.69) 1 Total power supply flow (gal/min)165.80 Total flow (gal/min)300.97 A0 Summary Total flow (gal/min)67.95 (148.9) 3 F 23 Summary Total flow (gal/min)50.56 (45) 3 Notes: 1.Actual required flow in parenthesis 2.Addition of actual required flow and 130 GPM to CUB in parenthesis 3.Flow measured on 09/26/2011 in parenthesis

26. S CENARIO 4 E4’s Pump, 360 GPM @ 365 Ft. F1’s Pump, 328 GPM @ 369 Ft. 26 F2’s Pump, 356 GPM @ 367 Ft. BEP at 520 GPM @ 350 Ft. (76%) Aurora Pump Curve (2.5 X 3 X 9)

27. C ONCLUSIONS Scenario 1 (only F1 pump running) can be eliminated, for the pump would be operating at its run-off Scenario 2 (E4 and F1 pumps running) looks promising as both the pumps would be operating close to the BEP of the pump Scenario 2 can work for us if A0 is alright with 3 times the present temperature difference across its loads. However, in this scenario the power supplies at F4 would get 25 GPM of total flow--they need 40 GPM. And the MR chokes would get a predicted 5.5 GPM of total flow--they need 12 GPM This can be sorted out by performing minor piping modifications Scenario 3 (F0 pumps running) can also be eliminated as it is unrealistic Scenario 4 (F1, F2, and E4 pumps running) comes closest to meeting the actual calculated demand for all the loads However, again A0’s 148.9 GPM demand is not met If A0 is alright with 2 times the present temperature difference across its loads, this scenario can work 27

28. C ONCLUSIONS 28 Two more scenarios were simulated: Scenario 5 (E4, F1, F2, and F4 pumps running) predicted the total flow at A0 to be 150.57 GPM, current flow at A0 is 148.9 GPM Scenario 6 (E4, F1, F2, and F3 pumps running) predicted the total flow at A0 to be 83.58 GPM, current flow at A0 is 148.9 GPM If A0’s present flow demand needs to be met, Scenario 5 (E4, F1, F2, and F4 pumps running) is recommended One can also discuss the possibility of placing A0 on a separate cooling system, and choose Scenario 2 or 4 All the service buildings have heat exchangers with a maximum capacity of 2.9 MW at 600 GPM and 34 0 F ∆T of DI water. Heat dissipation is not difficult, but providing flow to the loads is a challenge

29. R OUGH T IME, L ABOR, AND M ATERIAL E STIMATE 29 Activity:Cut, drain, and welding of headers Time:2-3 weeks Labor: 2-4 water technicians and a welder, all working full-time Material:  6, Aluminum end caps,$95 each, a total of $570 for 6  Aluminum welding rod, $27.71/Pound, a total of $140 for 5 Pounds  Bottle of Argon gas, $195

30. A CKNOWLEDGEMENTS EE Support: Dan Wolff Steve Hays Bob Brooker Operations: Todd Johnson Walter Kissel Paul Allcorn Donovan Tooke Technical Division: Oliver Kiemschies ADMS: Maurice Ball Karl Williams Bob Slazyk Tim Hamerla Denny Schmitt Raul Campos Tom McLaughlin John Sobolewski 30