STRIP BARREL – PP1 & SM

Jason Tarrant 18/10/18

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• LOCATION• SERVICES / SERVICES TYPES• SERVICE MODULE POSITIONS & SEGMENTATION• CONSTRAINTS REQUIREMENTS

• ENVELOPES• INTERFACES• G&S & SEALING• THERMAL• OTHER

• DESIGN• GENERAL• ENVELOPES• INTERFACES• G&S & SEALING• THERMAL• OTHER

• CONCLUSION & FUTURE WORK

Patch Panel 1 (PP1) & Barrel Service Module (SM)

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Location

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Barrel Staves

Bu

lkh

ead

Services Gap

Service Module Tray RegionPP1 Region

Location

Staves on Barrels

ServiceModules

Patch Pipes& Routed

Services in Services Gap

PP1

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Services Types

ELECTRICAL - POWER

OPTICAL FIBRE ELECTRICAL – DETECTOR CONTROL SYSTEM(DCS)

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ALL AT PP1

Services Types

ELECTRICAL - POWER

OPTICAL FIBRE ELECTRICAL – DETECTOR CONTROL SYSTEM(DCS)

Type II Cable side

OPTICAL FIBRE

Individual wires(respecting minimum bend radii)

Shield termination& hermetic seal(to cable tray)

Type II cable

Shielded cables

Filtered D-typeconnector(Glenair)

Crimp contactHooded D-type

connector

Connector (MTP)

Array of singleconnector mounts

Sheathedribbons

Ribbons split to 3s, 2s or single fibres within

SM - TBD

Twisted pairs

Shieldedcable (?)

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ALL AT PP1

Filter

PP1 Type I Cable side

Glenair Connector

Services TypesFLUID SERVICES – CO2 INLET

FLUID SERVICES – CO2 EXHAUST

Electrical break(added after pit installfor safe connection &ease of replacement)

Vacuum insulation

Brazed inmanifold

Pipes to capillariesor just capillaries TBD

Welded jointswith fittings

3.175 mm (1/8”)OD pipes

9.525 mm (3/8”)OD pipe

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To Stave

From Stave

SM Positions & Segmentation

C Side – Looking towards Z = 0 A Side – Looking towards Z = 0

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Layout of SM positions and particular Staves serviced + quadrant rotational symmetry as shown below aims to minimise the number of different types of

Services, e.g. cable harness types

Common positions SM to Stave also minimise routing and different

services types

SM Positions & Segmentation

C Side – Looking towards Z = 0 A Side – Looking towards Z = 0

Inner 2 Layers = Short Strip (SS) Staves

Outer 2 Layers = Long Strip (LS) Staves

Most SMs service 8x Staves, The orange highlighted SM services = 9x Staves

(best way to manage 49 staves in a quadrant, was 48 previously)

SMs can service more than 1 layer BUT no mixing of SS & LS services in SMs

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SM Positions & Segmentation

C Side – Looking towards Z = 0 A Side – Looking towards Z = 0

Most SMs service 8x Staves, The orange highlighted SM services = 9x Staves

(best way to manage 49 staves in a quadrant, was 48 previously)

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8 way SM = 4 electrical connectors with 4x Type II cable to 8x Type I cable to 8x Staves

9 way SM = 5 electrical connectors with 5x Type II cable to 9x Type I cable to 9x Staves

In 9 way SM ½ of a Type II cable not used = only an extra 2 cables per end. Saves awkward routing, increases common routing & avoids 10 way cooling in a SM (9 way cooling max on higher power SS staves)

SM Positions & Segmentation

C Side – Looking towards Z = 0 A Side – Looking towards Z = 0

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SM positions should not change re. 9/8 way … but specific Staves serviced by particular SMs may change when final service optimisation takes place

Services Module Constraints / Requirements - Envelope

• Envelope ITk_Envelope_1.x (2D)• Fit with neighbour’s services & bulkhead (3D)

9 Way SM Envelope

Mid-section of ITk Cylinder(end section missing to see SM envelopes)

Bulkhead

8 Way SM Envelope

Strip Endcap Services(below and around Barrel SMs)

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PP1 region requires 3D space considerations

Services Module Constraints / Requirements - Interfaces

• Structural Interfaces• At low Z fit to ITk cylinder flange• PP1 end fixed (& sealed) to in-fill

section of Bulkhead plate• PP1 Services Interfaces

• Electrical via Glenair filtered connector

• Optical fibre via 4 or 5 single MTP connectors in a block

• DCS via D-type (filtered Glenair & hooded pair)

• CO2 cooling via flex line (1/4” HVCR 3/8” equivalent + vacuum DN25 KF)

• Stave Interfaces• Electrical via Glenair or Axon

connector• Optical fibre via MTP• DCS individual sensors• CO2 cooling via patch pipes (pre-bent

but fine tuned for point-point connection) and weld fittings

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As per Slide 5/6

Services Module Constraints / Requirements – Sealing & G&S

• Structure• Seal = SM into In-Fill Plate then In-Fill Plate sealed

to Bulkhead plate / Strip Endcap services• G&S = Ground connections as necessary

• PP1 Services Interfaces• Glenair connector

• Sealed box on entry to ITk around Bulkhead• G&S via filter, grounding of cable shield &

Faraday cage effect of enclosed box• Optical fibre

• Sealed box on entry to ITk around Bulkhead• G&S N/A

• D-type• Sealed box on entry to ITk around Bulkhead• G&S via filter, grounding of cable shield &

Faraday cage effect of enclosed box• Cooling

• Sealed box on entry to ITk around Bulkhead• G&S via grounding + electrical break at PP1

on both CO2 line and Vacuum Jacket14

Services Module Constraints / Requirements – Thermal

• Isolate significant heat transfer from cables & connectors to inlet cooling

• Possibly connect cables to exhaust cooling• Perforations to allow dry gas purge of region

Services Module Constraints / Requirements – Other

• Easy connection of services (access)• Modular construction preferable (testing, maintenance & spares)• Services management (e.g. loss of excess)• Services support (secure but safe clips & fixings)• Bend radii of services (25 mm bare electrical cable under Glenair connector, 50

mm shielded cable, 15 mm min Optical fibres)• Ease of installation (simple, secure, safe)• Low mass material• Simple design / minimal parts / common items (economies of scale) / good value• Etc…

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Design – General

Glenair connectorswith filter and top

connector removed(rear mounted)

Cable tray and mainSM support

Enclosed box

Shielded cables strippedBack, grounded &

sealed here inside box

Angled sidesto save space

Pins for fixing to ITkcylinder flange go this end

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Box depth allows wires to comply with bend radii

requirements

Bulkhead in-line with this region

Inside ITk cylinder

Outside Bulkhead

Design – General

Glenair connectorswith filter and top

connector

Enclosed box

Angled sidesto save space

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Box depth allows wires to comply with bend radii

requirements

Design – General

Underside of previous assembly

Optical fibres in enclosed box / tray

DCS in enclosed box / tray

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Design – General

Back to top of assembly

Inlet pipe assembly

Exhaust pipe assembly

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Pipe supports fixed to support frame (see

next slide)

Design – General

Bulkhead support interface frame

Smooth closure in-line with Bulkhead (all

services sealed inside)

Sealing takes place here(this is inside bulkhead in-fill)

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Design – Envelope

This nut drops downInsertion envelope line(Glenair connector & filter

removed)

Space required herefor seal to bulkhead

With Type II services

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Power cable

Glenair filter & top connector

Fits the envelope

Design – Envelope

Envelopes are cylindrical the SM is relatively straight…

Various cross sections through the PP1 & SM, some close but within the envelope

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Design – Envelope

Fit with the Bulkhead Plate

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These are actually all 9-way PP1/SMs copied round

Design – Interfaces (Structural)

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Design – Sealing & G&S

• Structural Seal• Seal = SM into Bulkhead In-Fill Plate• G&S = Ground connections as necessary

• PP1 Services Interfaces• Glenair connector

• Sealed box on entry to ITk around Bulkhead• G&S via filter, grounding of cable shield &

Faraday cage effect of enclosed box• Optical fibre

• Sealed box on entry to ITk around Bulkhead• G&S N/A

• D-type• Sealed box on entry to ITk around Bulkhead• G&S via filter, grounding of cable shield &

Faraday cage effect of enclosed box• Cooling

• Sealed box on entry to ITk around Bulkhead• G&S via grounding + electrical break at PP1

on both CO2 line and Vacuum Jacket

✔✔

✔

✔25

Services Module Constraints / Requirements – Thermal

• Isolate significant heat transfer from cables & connectors to inlet cooling

• Possibly connect cables to exhaust cooling

• Perforations to allow dry gas purge of region

As cables alreadyshielded perforate trays

for purge gas flow

Distance cables in trayfrom inlets & insulateto create ‘cold side’

Connect exhaust returnthermally to

‘hot side’ of tray

Possibility of GFRP(insulating) tray

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Services Module Constraints / Requirements – Other

• Easy connection of services (access)• All services at top / back of PP1 = free access even when neighbouring structures

added• Modular construction preferable (testing, maintenance & spares)

• Separate electrical, optical fibre & DCS units + 2 x individual cooling• Services management (e.g. loss of excess)

• Space to lose service length in SM for optical fibre & DCS, electrical will be lost in services gap as will capillary, other pipes pre-bent and tweaked to fit

• Services support (secure but safe clips & fixings)• Mostly in trays, simple clips to be designed for cooling

• Bend radii of services• Guides to restrict min bends and/or space in structure for loose bends in services

• Ease of installation (simple, secure, safe)• Prongs, clips & simple fastenings to secure into ITk Cylinder / Bulkhead In-Fill

• Low mass material• Aluminium, GFRP, Ti

• Simple design / minimal parts / common items (economies of scale) / good value• 9 way metalwork differs from 8 way but possibility of using ‘blanked’ 9 way structure

for all 8 way PP1/SMs). Overall design relatively simple with minimum number of parts for function

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Conclusion & Future Work• Conclusion:

• Known requirements met

• Further Design work• Thermal modelling to check for any unwanted heat load on inlets pipes• Design needs detail adding

• Sealing PP1 frame to In-Fill• Minor fastening detail for services• Tray closure fastening (probably PEM inserts & screws with keyhole slots & locks)• G&S connection review / OK (advice to be sought from G&S expert)• Probably capillary from manifold to Stave on inlet side

• Bulkhead seal to be designed (Marco Oriunno overseeing this)

• Future work• Prototype to fit on RAL mock-up

• Services routing checks• Services support design• Welding in-situ• Maintenance / rework trials• Etc…

• QA/QC & Reception Testing• Installation Instruction• Production & Transport Planning

First prototype SM in ITk cylinder mock-up28