1. CMS FPIX Cooling System Studies Joe Howell, Fermilab for the FPIX Upgrade Mechanical Working Group CMS Upgrade Workshop April 27, 2010 1

2. 2 Outline FPIX C02 Cooling2 CMS Upgrade Workshop April 27, 2010 CO2 system System Design System Elements Status Half-cylinder cooling loops design and testing

3. FPIX C02 Cooling CMS Upgrade Workshop April 27, 2010 3 C02 System Design Parameters Deliver saturated or slightly sub-cooled CO2 to detector Ability to handle 1-4 bar detector pressure drops Capacity to handle up to 5 kW heat load Ability to provide liquid CO2 at -30 °C to +15 °C CO2 quality at detector outlet of 25%, maximum CO2 side, design pressure of 82 bar (closed loop system will retain all CO2 at room temperature)

4. FPIX C02 CoolingCMS Upgrade Workshop April 27, 20104 C02 System Heat and Mass Balance Model 353 g/s 4.1 bar A heat and mass balance EXCEL model was built based on C02 properties and the vendor supplied pump characteristics for the Warrender turbine pump. 18.7 bar 0.44 L/s 452 g/s 98 g/s.09 L/s.34 L/s

5. FPIX C02 CoolingCMS Upgrade Workshop April 27, 20105 System Elements CO2 Pump Passive Phase Separator ( returns a portion of liquid) C02 Filter Dryer (absorb water to prevent ice and carbonic acid) CO2 Flow Control (pump speed control with flow instrumentation) Pressure (Temperature) Controlled CO2 Condenser Electric CO2 Tank Heater Three Commercial Refrigeration Units Pressure, Temperature and Flow Instrumentation

6. FPIX C02 CoolingCMS Upgrade Workshop April 27, 20106 C02 System Piping & Instrumentation Diagram Refrigeration Units Pump Storage tank with condenser coils and heaters Phase Separator

7. FPIX C02 CoolingCMS Upgrade Workshop April 27, 20107 Some Major System Elements Warrender WMDAT6-2SM with a 3 Hp motor 610 mm 1524 mm Storage Tank Commercial R404A Refrigeration Unit

8. FPIX C02 CoolingCMS Upgrade Workshop April 27, 20108 Refrigeration Control 3 Commercial refrigeration units (on/off style) Sized and operated in combination to provide 0 to 8 kW of cooling Electric heater used to trim to the final cooling requirement

9. FPIX C02 CoolingCMS Upgrade Workshop April 27, 20109 Preliminary What-if ? Analysis for Major Components Sample

10. FPIX C02 CoolingCMS Upgrade Workshop April 27, 201010 C02 System Design and Construction Status System ElementStatus PumpIdentified, procurement process started CO2 Condenser Vendor quotes received, procurement to start soon Electric Heaters Working with vendors for cost effective option to meet high pressure requirement Storage Tank Vessel In design, fine tuning to match details of condenser and heater Refrigeration unitsSpecified, awaiting vendor quote Filter Adapting a commercial C02 filter for use in a custom high pressure housing Expected date for operational system, Fall 2010

11. HD2 I-O FPIX C02 CoolingCMS Upgrade Workshop April 27, 201011 Cooling Loops in Half-cylinder FPIX Cooling Loop Heat Load from modules (t=0) [W]* Heat Load from DC-DC converters & port-cards [W] Total Heat Load on Cooling Loop [W] Length of cooling loop on half-ring OD 1.6 mm ID 1.4 mm [mm] Length of radial legs of cooling loop OD= 1.6 mm ID= 1.4 mm [mm] Length of 1st longitudinal legs of cooling loop OD = 1.6 mm ID = 1.4 mm [mm] Length of 2nd longitudinal legs of cooling loop OD = 2.0 mm ID = 1.8 mm [mm] Fluid mass flow [g/s] Fluid exit quality HD1 O-O56.51066.510520340+3501784+1774 HD1 O-I37.61047.658487+87373+3831784+1774 HD1 I-O & I-I60.91070.9962137+78+59342+3521784+1774 HD2 O-O56.51066.510520296+3061784+1774 HD2 O-I37.61047.658487+87265+2751784+1774 HD2 I-O & I-I60.91070.9962137+78+59265+2751784+1774 HD3 O-O56.51066.510520168+1781784+1774 HD3 O-I37.61047.658487+87201+2111784+1774 HD3 I-O & I-I60.91070.91052137+78+59170+1801784+1774 Heat Load and Tube Lengths for 9 Cooling Loops of an FPix Half-cylinder (typical for each of 4 half-cylinders)

12. FPIX C02 CoolingCMS Upgrade Workshop April 27, 201012 Cooling Loop Design Considerations Minimize the number of loops within a reasonable pressure drop limit Allow the inner half-disk portions to be removed separate from the outer half-disk portions Use the C02 flow exiting the half-disks to cool the DC-DC converters and Opto-isolators The slightly larger tube on the return feed lines should minimize the pressure drop from the additional heat load The alternative is a separate loop but the loop must reach the port-cards which need to be within the 600 mm cable reach of the half-disks Use the 4 available copper lines to PP1 to provide 2 segments that could be isolated in case of a coolant leak

13. FPIX C02 CoolingCMS Upgrade Workshop April 27, 201013 Outer Loop Flow Test Model of a stainless steel tube embedded in a half-disk cooling ring stainless steel tube prototype Prototype cooling loop of half-disk outer ring sent to CERN for testing Cooling loop instrumented and connected for testing inside a freezer with C02 system First round of results received last week and in process of comparing to calculations

14. FPIX C02 CoolingCMS Upgrade Workshop April 27, 201014 Summary Design of a 5 kW C02 cooling system is in the final details phase The procurement of major items has started The expected first operation of the system is in Fall 2010 Preliminary arrangement has been developed for the cooling tubes within the half-cylinder Pressure drop calculations are underway Details of tube routing and connections are in process Initial results of the flow tests of a prototype cooling tube have been received and are being compared to predictions.