design S. Ahmed, L. Capozza, A. Dbeyssi, P. Grasemann, J. Jorge - - PowerPoint PPT Presentation

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design S. Ahmed, L. Capozza, A. Dbeyssi, P. Grasemann, J. Jorge - - PowerPoint PPT Presentation

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PANDA 17/2 Collaboration Meeting 08.06.2017 BWEC Cooling shell design S. Ahmed, L. Capozza, A. Dbeyssi, P. Grasemann, J. Jorge Rico, F. Maas, O. Noll, D. Rodrguez Pi eiro, S. Wolf BWEC Cooling shell design 08.06.2017 Contents 1.

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SLIDE 1

BWEC Cooling shell design

  • S. Ahmed, L. Capozza, A. Dbeyssi, P. Grasemann, J. Jorge Rico, F. Maas,
  • O. Noll, D. Rodríguez Piñeiro, S. Wolf

PANDA 17/2 Collaboration Meeting 08.06.2017 08.06.2017 BWEC Cooling shell design

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SLIDE 2

Contents

1. Overview 2. Calculations (thermal and fluid mechanics) 3. 3D design 4. Simulations (thermal and fluid mechanics) 5. Summary and future tasks

BWEC Cooling shell design 08.06.2017 2

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SLIDE 3

Overview

What is our aim?

BWEC Cooling shell design 08.06.2017 3

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SLIDE 4

Overview

Overview Cooling requirements

  • Work at -25°C
  • Maximum 500 mbar pressure drop (leakless-mode)
  • Limited space
  • Low temperature gradient

BWEC Cooling shell design

Cover Front cooling Outer shell Inserts Mounting plate Boards Crystals Vacuum insulation panel (VIP) Inner shell

08.06.2017 4

Coolant

Methanol 60% Water 40% Property Value Units Density 930 kg/m3 Dynamic viscosity 0.0077 kg/s/m Cp 3151 J/kg/K
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SLIDE 5

THE PROCESS IS THIS

BWEC Cooling shell design 08.06.2017 5

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SLIDE 6

Calculations

Thermal and fluid mechanics calculations of the cooling shells

BWEC Cooling shell design 08.06.2017 6

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SLIDE 7

Heat sources

◉ Electronics ◉ Heat flow through the walls ◉ Power to cool down

APFEL 1.5

Thermal calculations

+70C BWEC Cooling shell design 08.06.2017 7 ° ° P

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SLIDE 8

Electronics

Thermal calculations

◉ 150 mW/crystal * 524 crystals =78.60 W ◉ Applied in back side of crystals ◉ Cables out of the detector are not taken into account

BWEC Cooling shell design 08.06.2017 8

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SLIDE 9

Heat flow through walls

Thermal calculations

Worst case at 70°C surrounding temperature

Source Value [W] Outer face 40.23 Inner face 17.25 Front face 16.63 Back face 18.59 Radiation 27.92 BWEC Cooling shell design 08.06.2017 9

Outer face Front face Back face Inner face
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SLIDE 10

Power to cool down

Thermal calculations

◉ Constant cooling flow ◉ Initial temperature 30°C ◉ Final temperature -25°C ◉ Time 24 h

𝑸 = 𝑛 ∙ 𝐷𝑞 ∙ ∆𝑈 𝑢 = 0,06 𝑛3 ∙ 8280 𝑙𝑕 𝑛3 ∙ 262 𝐾 𝑙𝑕 ∙ (55°𝐷) 24 ℎ ∙ 3600 𝑡 = 𝟗𝟒. 𝟏𝟏 𝑿 BWEC Cooling shell design 08.06.2017 10

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SLIDE 11

Summary of heat sources

Stationary Transient Source Value [W] Source Value [W] Outer face 40.23 Outer face 40.23 Inner face 17.25 Inner face 17.25 Front face 16.63 Front face 16.63 Back face 18.59 Back face 18.59 Radiation 27.92 Radiation 27.92 Electronics 78.60 Cooling down 83.00 Total 199.30 Total 203.70 Total*1.5 298.95 Total*1.5 305.98

Safety factor 1.5

BWEC Cooling shell design 08.06.2017 11

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SLIDE 12

Thermal calculations

Mass flow calculation

  • 0.3 °C between inlet and outlet (homogeneity)

𝑛 = 𝑄 𝐷𝑞 ∙ ∆𝑈 = 0.3237𝑙𝑕 𝑡 → 20.88𝑚 𝑛𝑗𝑜

  • 2 outer shells and 2 inner shells
  • Outer shell 7.34 l/min
  • Inner shell 3.10 l/min

Distance between pipes

  • 0.25 °C max temperature difference (homogeneity)
  • 15 mm thickness
  • L= 150 mm

𝑄𝑀2 8 ∙ 𝑙 ∙ 𝑢 = ∆𝑈 → 𝑀 = 8∆𝑈𝑙𝑢 𝑄

BWEC Cooling shell design 08.06.2017 12 L

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SLIDE 13

Fluid mechanics calculations

(Half outer shell) Outer shell parts

  • 6 pipes  d = 13 mm
  • 4 pipes  d = 10 mm
  • 5 front square connectors
  • 4 back elbow connectors

BWEC Cooling shell design 08.06.2017 13

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SLIDE 14

Fluid mechanics calculations

Pipe with d = 10 mm

∆𝑞 = 8𝑅2 𝜌2 𝑔 𝑀 𝐸5 𝜍 = 11.37𝑛𝑐𝑏𝑠

Pipe with d = 13 mm

∆𝑞 = 8𝑅2 𝜌2 𝑔 𝑀 𝐸5 𝜍 = 3.99 𝑛𝑐𝑏𝑠

Elbow of d = 10 mm

∆𝑞 = 8𝑅2 𝜌2 𝑔 𝑀 + 𝑀𝑓𝑟 𝐸5 𝜍 = 21.05 𝑛𝑐𝑏𝑠

Square connector (estimation)

∆𝑞 = 8𝑅2 𝜌2 𝑔 𝑀 + 𝑀𝑓𝑟 𝐸5 𝜍 = 27.60 𝑛𝑐𝑏𝑠 BWEC Cooling shell design 08.06.2017 14

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SLIDE 15

Fluid mechanics calculations summary

Part Pressure drop (mbar) Amount Total Pd (mbar) Straight d =13 mm 3.99 6 23.94 Straight d = 10 mm 11.37 4 45.48 Elbow d = 10 mm 21.05 4 84.20 Square connectors 27.60 5 138.00

Total 291.62 mbar

𝟑𝟘𝟐. 𝟕𝟑𝒏𝒄𝒃𝒔 < 𝟔𝟏𝟏𝒏𝒄𝒃𝒔 BWEC Cooling shell design 08.06.2017 15

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SLIDE 16

3D design

An overview of the outer shell 3D design

BWEC Cooling shell design 08.06.2017 16

🎩

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SLIDE 17

3D design

BWEC Cooling shell design 08.06.2017 17

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SLIDE 18

3D design

BWEC Cooling shell design 08.06.2017 18 Front square connectors Back elbows

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SLIDE 19

Simulations

Thermal and fluid mechanics simulations Autodesk Simulation Mechanical & Autodesk CFD 2016

BWEC Cooling shell design 08.06.2017 19

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SLIDE 20

Thermal simulations

1 quarter dummy for simulations

Inserts

(Aluminum)

Crystals

(PbWO4)

Outer shell

(Aluminum)

Inner shell

(Aluminum)

Front shell

(HDPE)

Gap

(air 4mm)

BWEC Cooling shell design 08.06.2017 20

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SLIDE 21

Only outer and inner shells

  • 25.08 °C
  • 23.14 °C

Thermal simulations

◉ Not front shielding ◉ 2°C gradient

BWEC Cooling shell design 08.06.2017 21

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SLIDE 22

Back pipe with both inner and outer shells

  • 25.10 °C
  • 23.16 °C

Thermal simulations

◉ Back homogeneity ◉ Not front shielding ◉ 2°C gradient

BWEC Cooling shell design 08.06.2017 22

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SLIDE 23

Out of scale -5°C

Front shell, back pipe and both inner and outer shells

  • 25.00 °C
  • 24.00 °C

Thermal simulations

◉ Front shielding ◉ Less than 0.5°C gradient ◉ Solid angle loss (further for the IP)

BWEC Cooling shell design 08.06.2017 23

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SLIDE 24

Possible 140W (STT worst elect. case) front without front cooling

  • 25,06 °C
  • 17.87°C

Thermal simulations

◉ Huge temperature gradient (7.13°C)

BWEC Cooling shell design 08.06.2017 24

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SLIDE 25

Possible 140W (STT worst elect. case) front with front cooling

  • 25.00 °C
  • 24.00°C

Thermal simulations

Out of scale 57°C

◉ Good front protection ◉ Less than 0.5°C gradient

BWEC Cooling shell design 08.06.2017 25

◉ Solid angle loss (further from the IP)

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SLIDE 26

Straight pipes and elbow

Fluid mechanics simulations

BWEC Cooling shell design 08.06.2017 26 4.00 mbar 23.82 mbar 11.63 mbar

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SLIDE 27

Front square connectors

Fluid mechanics simulations

BWEC Cooling shell design 08.06.2017 27

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SLIDE 28

Front square connectors

Fluid mechanics simulations

BWEC Cooling shell design 28 08.06.2017

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SLIDE 29

Front square connectors

Fluid mechanics simulations

BWEC Cooling shell design 08.06.2017 29

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SLIDE 30

Front square connectors

Fluid mechanics simulations

BWEC Cooling shell design 08.06.2017 30 35.44 mbar 30.28 mbar 31.21 mbar

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SLIDE 31

Summary

Fluid mechanics simulations

Part Pressure drop/part(mbar) Amount Total Pd (mbar) Straight d = 10 mm 11.63 4 46.52 Straight d = 13 mm 4.00 6 24.00 Elbow d = 10 mm 23.82 4 95.28 Square conn 1 35.44 2 70.88 Square conn 2 31.21 2 62.42 Square conn 3 30.28 1 30.28

Total 329.38 mbar

BWEC Cooling shell design 08.06.2017 31

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SLIDE 32

Fluid mechanics calculations vs. simulations

Part Pressure drop (mbar) Amount Total Pd (mbar) Straight d = 10 mm 11.63 4 46.52 Straight d = 13 mm 4.0 6 24.00 Elbow d = 10 mm 23.82 4 95.28 Square conn 1 35.44 2 70.88 Square conn 2 31.21 2 62.42 Square conn 3 30.28 1 30.28

Total 329.38 mbar

BWEC Cooling shell design 08.06.2017 32 Part Pressure drop (mbar) Amount Total Pd (mbar) Straight d =10 mm 11.37 4 45.48 Straight d = 13 mm 3.99 6 23.94 Elbow d = 10 mm 21.05 4 84.20 Square conn 1 27.60 2 55.20 Square conn 2 27.60 2 55.20 Square conn 3 27.60 1 27.60

Total 291.62 mbar

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SLIDE 33

Summary and future works

What is next?

BWEC Cooling shell design 08.06.2017 33

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SLIDE 34

Summary

◉ Less than 0.3oC of gradient in the coolant temperature ◉ Good homogeneity with front cooling ◉ Low pressure drop:

◉ Different pressure drop values because of the square parts

(simplifications in calculations for complex geometry)

BWEC Cooling shell design 08.06.2017 34 Calculations Simulation 291.62 mbar 329.38 mbar

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SLIDE 35

Future works

◉ Building an outer shell prototype (on process) ◉ Make measurements for validating calculations and simulations ◉ Tests for front cooling with existing prototype (on process) ◉ Design inner shell with the same procedure

BWEC Cooling shell design 08.06.2017 35

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SLIDE 36

THANKS!

Any questions?

You can write me jjorgeri@uni-mainz.de

BWEC Cooling shell design 08.06.2017 36

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SLIDE 37

Back Up slides

08.06.2017 BWEC Cooling shell design

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SLIDE 38

Preparation in Outer shell and MP

Front cooling

BWEC Cooling shell design 08.06.2017 B1

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SLIDE 39

Preliminary design

Front cooling

BWEC Cooling shell design 08.06.2017 B2

◉Parallel circuits (low pressure drop) ◉Different diameter each branch (homogeneity) ◉3D printed (HDPE)

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SLIDE 40

Velocity examples

Simulations

BWEC Cooling shell design 08.06.2017 B3

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SLIDE 41

General inputs

Thermal calculations

BWEC Cooling shell design 08.06.2017 B4

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SLIDE 42

Example

Thermal calculations

BWEC Cooling shell design 08.06.2017 B5

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SLIDE 43

Output summary

Thermal calculations

BWEC Cooling shell design 08.06.2017 B6

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SLIDE 44

Serial Pressure drop calculator

Fluid mechanic calculations

BWEC Cooling shell design 08.06.2017 B7

◉ Inputs:

  • Coolant
  • Section´s geometry
  • Length
  • Local elements
  • Flow
  • Valve
  • Height
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SLIDE 45

Serial Pressure drop calculator

Fluid mechanic calculations

BWEC Cooling shell design 08.06.2017 B8

◉ Outputs:

  • Reynolds
  • Laminar/ Turbulent
  • Friction factor
  • Pressure drop
  • Pressure difference
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SLIDE 46

Parallel calculator

Fluid mechanic calculations

BWEC Cooling shell design 08.06.2017 B9

◉ Aim:

  • Constant flow through

all branches.

◉ Procedure:

  • Change diameter of branches.

Flow Flow Flow/4 Flow/4 Flow/4 Flow/4

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SLIDE 47

Parallel calculator

Fluid mechanic calculations

BWEC Cooling shell design 08.06.2017 B10

◉ Inputs:

  • Coolant
  • Different geometry for sections
  • Lengths
  • Local elements
  • Number of branches
  • Height

.

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SLIDE 48

Parallel calculator

Fluid mechanic calculations

BWEC Cooling shell design 08.06.2017 B11

◉ Outputs:

  • Total pressure drop
  • Pressure drop in manifold
  • Different diameters

.

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SLIDE 49

Different materials

Front cooling test

BWEC Cooling shell design 08.06.2017 B12

◉ Aim:

  • See the effect of different materials

in the front cooling

  • Effect of different VIP´s configuration

20mm 2x10mm

  • Validate thermal and fluid mechanic

calculation system. .

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SLIDE 50

Different materials

Front cooling test

BWEC Cooling shell design 08.06.2017 B13

◉ Layout

.

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SLIDE 51

Cool down the nitrogen

Cold nitrogen test

BWEC Cooling shell design 08.06.2017 B14

◉ Layout

.

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SLIDE 52

Calculations

Dew point at 20°C

BWEC Cooling shell design 08.06.2017 B14

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SLIDE 53

Psychrometric chart

Dew point at 20°C

BWEC Cooling shell design 08.06.2017 B14

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SLIDE 54

Kapton heating

Dew point at 20°C

BWEC Cooling shell design 08.06.2017 B14

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SLIDE 55

Distance between pipes

BWEC Cooling shell design 08.06.2017 B14

◉ All the heat received for the plate is transported by conduction

Q x t w dx 𝑒 𝑒𝑦 𝑅𝐷 = 𝑄 ∙ 𝑥 ∙ 𝑒𝑦 𝑄 −𝑙 ∙ 𝑢 ∙ 𝑥 ∙ 𝑒2𝑈 𝑒𝑦2 𝑒𝑦 = 𝑄 ∙ 𝑥 ∙ 𝑒𝑦 (𝑟𝑑+∆𝑦 −𝑟𝑑) ∙ 𝑢 ∙ 𝑥 = 𝑄 ∙ 𝑥 ∙ 𝑒𝑦 𝑟𝑑 𝑟𝑑+∆𝑦 𝑟𝑑+∆𝑦 = 𝑟𝑑 +

𝜖𝑟 𝜖𝑦 𝑒𝑦 + ⋯

𝑟𝑑+∆𝑦 − 𝑟𝑑 =

𝜖𝑟 𝜖𝑦 𝑒𝑦 + ⋯

𝑟𝑑+∆𝑦 − 𝑟𝑑 =

𝜖 𝜖𝑦 − 𝑙 𝜖𝑈 𝜖𝑦 𝑒𝑦 + ⋯

𝑒2𝑈 𝑒𝑦2 = − 𝑄 𝑙 ∙ 𝑢

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SLIDE 56

◉ Boundary conditions

◉ Symmetry: Q(L/2)=0 ◉ T(0)=Te 𝑈 𝑦 = − 𝑄 2 ∙ 𝑙 ∙ 𝑢 ∙ 𝑦2 + 𝐵 ∙ 𝑦 + 𝐶 𝑈 0 = − 𝑄 2 ∙ 𝑙 ∙ 𝑢 ∙ 02 + 𝐵 ∙ 0 + 𝐶 → 𝐶 = 𝑈𝑓 𝜖𝑈 𝜖𝑦 𝑀/2 = − 2𝑄 2 ∙ 𝑙 ∙ 𝑢 ∙ 𝑀 2 + 𝐵 = 0 → 𝐵 = 𝑄𝑀 2𝑙𝑢

Distance between pipes

BWEC Cooling shell design 08.06.2017 B14 𝑒2𝑈 𝑒𝑦2 = − 𝑄 𝑙 ∙ 𝑢 L/2 Te x

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SLIDE 57

Distance between pipes

BWEC Cooling shell design 08.06.2017 B14 L/2 Te x 𝑈 𝑀/2 = − 𝑄𝑀2 8 ∙ 𝑙 ∙ 𝑢 + 𝑄𝑀2 4 ∙ 𝑙 ∙ 𝑢 + 𝑈𝑓 = 𝑈𝑓 + 0,5 𝑈 𝑦 = − 𝑄 2 ∙ 𝑙 ∙ 𝑢 ∙ 𝑦2 + 𝑄𝑀 2 ∙ 𝑙 ∙ 𝑢 ∙ 𝑦 + 𝑈𝑓 We want T(L/2) ≤ Te+0,5 𝑄𝑀2 8 ∙ 𝑙 ∙ 𝑢 + 𝑈𝑓 = 𝑈𝑓 + 0,5 𝑄𝑀2 8 ∙ 𝑙 ∙ 𝑢 = ∆𝑈 → 𝑀 = 8𝑙𝑢∆𝑈 𝑄

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SLIDE 58

Thermal simulations Out of scale

BWEC Cooling shell design 08.06.2017 B14

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SLIDE 59

Thermal simulations Out of scale

BWEC Cooling shell design 08.06.2017 B14

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SLIDE 60

Leakless mode

Calorimeter

Pressure Height Total static energy Losses