J. Direito - M. Battistin – 28th May 2010 EN/CV/DC

J. Direito, M. Battistin (EN/CV/DC)

28th May 2010

Detector Cooling ProjectIII Thermosiphon Workshop

-Thermosiphon solution

for Alice SPD cooling system

J. Direito - M. Battistin – 28th May 2010 EN/CV/DC

Why we are talking about modifications

• The actual Cooling Plant could need to be refurbished:– Increasing leak rates could not be compatible with the volume of the present condenser.– It has been the first evaporative plant built in EN/CV/DC… we have learnt since…– The original plant has been modified several times (Sub Cooling HX, Filters, Redundant

Pumps and Compressors).• This lead to a higher probability of occurrence of leaks.• Access to some components is very difficult.• The plant became less reliable.

• Low reliability of the Pumps:– Some Cavitation problems while restarting the plant and when switching between the

pumps.– The graphite impellers can pollute the system once they break (filters have been

installed to avoid the pollution of the circuit).

• Maintenance of the compressors:– MTBF = 125days– Long time of the intervention:

• RP of the fluid, locking the the manifold, Draining the Manifold, replacing the membranes, leak test the manifold (more than 1 day).

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This system is not critical now, but it could become it…

J. Direito - M. Battistin – 28th May 2010 EN/CV/DC

Overview of the present plant and Thermodynamic Cycle (P-h diagram)

Chilled Water

PT

Return Manifold (Gas)

PTSupply Manifold (Liq)

Return Gas pressure set point of 1.6 to 1.8 bar

H=~8m

C4F10

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Supply Liquid pressure set point of 3.5 to 5.5bar

J. Direito - M. Battistin – 28th May 2010 EN/CV/DC

PT

Return Manifold (Gas)

PT

Supply Manifold (Liq)

Return Gas pressure set point of 1.6 to 1.8 bar

Supply Liquid pressure set point of 3.5 to 5.5bar

SPD Thermosiphon solution

Chiller

DUMMY LOAD(By – Pass)

Height

C4F10

Pre

ssure

[bar]

Enthalpy [kJ/kg]

AB

C

D

EF

G H

A-B: Condensation and sub-coolingB-C: Hydrostatic Pressure differenceC-D: Pressure regulationD-E: Detector heightE-F: Sub-CoolingF-G: Capillary/ExpansionG-H: Evaporation and superheatingH-A: Return pressure drop

H=~8m

Supply and Return Manifolds would not be modified!

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A

B

H

E

A

D C

DN25DN32

J. Direito - M. Battistin – 28th May 2010 EN/CV/DC

SPD Thermosyphon Parameters

• Condensation Pressure:– Dependent on the evaporation temperature and return pressure drop:

• PCond = Pevap – DPReturn

• PCond = 1.73 bar (Evap. Temp. 12°C) – 0.015 bar (DN32, 45m) = 1.715 bar (Saturation Temperature of 11.8°C).

• The TSP un stability requires 5K of difference between condensing gas and sub-cooled liquid (to be verified for C4F10 on mini thermosiphon)

– Condenser Liquid Temperature = 11.8 °C – 5 K = 6.8°C– Chilled water could even be enough to run the system

• Required Height:– The liquid distribution set point id 5.5 bara today. – The pressure regulator will tune it: we have to assure 6 bar before it

• Pset point SetPoint = PHydrostatic + Pcondenser – DPsupply pipes

• Phydrostat = Pset point – Pcondenser + DPsupply pipes

• Phydrostatic = 6 bar - 1.715 bar + 0.01 bar (DN25, 45m)

• Phydrostatic required = 4.3 bar (density is 1560 kg/m3 between 5 and 10°C)• Minimum Height = 28 m

– We have 30.5 m available!

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J. Direito - M. Battistin – 28th May 2010 EN/CV/DC

ALICE SPD Thermosyphon main Parameters

• Total required flow:– Cooling of the Detector 36g/s + 15g/s (by-pass) = 51g/s– Return pipe (45 m) gas pressure drop on DN35 = 15 mbar– Supply pipe (45 m) liquid pressure drop on DC25 = 10 mbar

• Chiller required power:– 5.1 kW at 5°C.– Standard industrial chiller

• Dummy Load required Power:– 1.5 kW: standard construction for EN/CV/DC

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J. Direito - M. Battistin – 28th May 2010 EN/CV/DC

Operation Set Points

• Chiller PID – Sets the Temperature reading the Saturation Temperature (from the pressure transmitter).

• Pressure regulator – Sets the supply pressure.

• Three Way Valve on the Chiller Circuit – Sets a minimum ΔT between the Saturation temperature and the liquid temperature (This set point is fixed at 5K).

• Dummy Load PID – Sets the gas return temperature (Fixed Value of 20°C).

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J. Direito - M. Battistin – 28th May 2010 EN/CV/DC

Civil Engineering Integration

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J. Direito - M. Battistin – 28th May 2010 EN/CV/DC

Cost Estimation

Thermosyphon Hypothetic Refurbishment

Component Price estimation [kCHF]

Condenser/Tank 10

Chiller (7kW @ 0°C)

3.5

Dummy Load 2

Pressure Regulator

1.5

Piping 25

Manpower 8

TOTAL 50

Component Price estimation [kCHF]

Condenser/Tank 10

New Rack 5

Piping 10

Manpower 10

TOTAL 35

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J. Direito - M. Battistin – 28th May 2010 EN/CV/DC

Conclusions

• The Thermosyphon solution is perfect for the ALICE SPD

– All physical parameters fits

– A drastic reduction of maintenance activity

– An increased reliability for the future years

• It can be tested by connecting it to the supply and return manifolds.– The present plant could remain as back up during the commissioning

phase.

• We can test the C4F10 solution on the mini thermosiphon installation.

• The implementation could be compatible with the 2011 technical shutdown.

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