1 BWEC Cooling shell designPANDA 17/2 Collaboration Meeting BWEC Cooling shell design S. Ahmed, L. Capozza, A. Dbeyssi, P. Grasemann, J. Jorge Rico, F. Maas, O. Noll, D. Rodríguez Piñeiro, S. Wolf BWEC Cooling shell design

2 Contents Overview Calculations (thermal and fluid mechanics) 3D designSimulations (thermal and fluid mechanics) Summary and future tasks BWEC Cooling shell design 2

3 Overview 1 What is our aim? BWEC Cooling shell design 3

4 Vacuum insulation panel (VIP)Overview Overview Cooling requirements Work at -25°C Maximum 500 mbar pressure drop (leakless-mode) Limited space Low temperature gradient Inserts Outer shell Mounting plate Cover Front cooling Boards Vacuum insulation panel (VIP) Crystals Coolant Inner shell Methanol 60% Water 40% Property Value Units Density 930 kg/m3 Dynamic viscosity 0.0077 kg/s/m Cp 3151 J/kg/K BWEC Cooling shell design 4

5 THE PROCESS IS THIS Calculate & Design Simulate TestBWEC Cooling shell design 5

6 Thermal and fluid mechanics calculations of the cooling shells2 Thermal and fluid mechanics calculations of the cooling shells BWEC Cooling shell design 6

7 Thermal calculations Electronics Heat flow through the wallsHeat sources Electronics Heat flow through the walls Power to cool down P +70C APFEL 1.5 BWEC Cooling shell design 7

8 Thermal calculations 150 mW/crystal * 524 crystals =78.60 WElectronics 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 8

9 Thermal calculations Worst case at 70°C surrounding temperatureOuter face Heat flow through walls Front face Back face Worst case at 70°C surrounding temperature Inner face 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 9

10 Thermal calculations Constant cooling flow Initial temperature 30°CPower to cool down Constant cooling flow Initial temperature 30°C Final temperature -25°C Time 24 h 𝑷= 𝑚∙ 𝐶 𝑝 ∙∆𝑇 𝑡 = 0,06 𝑚 3 ∙ 8280 𝑘𝑔 𝑚 3 ∙ 262 𝐽 𝑘𝑔 ∙(55°𝐶) 24 ℎ∙3600 𝑠 =𝟖𝟑.𝟎𝟎 𝑾 BWEC Cooling shell design 10

11 Summary of heat sourcesStationary Transient Source Value [W] Outer face 40.23 Inner face 17.25 Front face 16.63 Back face 18.59 Radiation 27.92 Electronics 78.60 Cooling down 83.00 Total 199.30 203.70 Total*1.5 298.95 305.98 Safety factor 1.5 BWEC Cooling shell design 11

12 Thermal calculations Mass flow calculation Distance between pipes0.3 °C between inlet and outlet (homogeneity) 𝑚 = 𝑃 𝐶 𝑝 ∙∆𝑇 = 𝑘𝑔 𝑠 → 20.88𝑙 𝑚𝑖𝑛 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 𝑃 𝐿 2 8∙𝑘∙𝑡 =∆𝑇→𝐿= 8∆𝑇𝑘𝑡 𝑃 L BWEC Cooling shell design 12

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 13

14 Fluid mechanics calculationsPipe with d = 10 mm ∆𝑝= 8 𝑄 2 𝜋 2 𝑓 𝐿 𝐷 5 𝜌=11.37𝑚𝑏𝑎𝑟 Elbow of d = 10 mm ∆𝑝= 8 𝑄 2 𝜋 2 𝑓 𝐿+ 𝐿 𝑒𝑞 𝐷 5 𝜌=21.05 𝑚𝑏𝑎𝑟 Pipe with d = 13 mm ∆𝑝= 8 𝑄 2 𝜋 2 𝑓 𝐿 𝐷 5 𝜌=3.99 𝑚𝑏𝑎𝑟 Square connector (estimation) ∆𝑝= 8 𝑄 2 𝜋 2 𝑓 𝐿+ 𝐿 𝑒𝑞 𝐷 5 𝜌=27.60 𝑚𝑏𝑎𝑟 BWEC Cooling shell design 14

15 Fluid mechanics calculations summaryPart 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 84.20 Square connectors 27.60 5 138.00 Total mbar 𝟐𝟗𝟏.𝟔𝟐𝒎𝒃𝒂𝒓<𝟓𝟎𝟎𝒎𝒃𝒂𝒓 BWEC Cooling shell design 15

16 An overview of the outer shell 3D design🎨 3D design 3 An overview of the outer shell 3D design BWEC Cooling shell design 16

17 3D design BWEC Cooling shell design 17

18 3D design Front square connectors Back elbowsBWEC Cooling shell design 18

19 4 Simulations Thermal and fluid mechanics simulationsAutodesk Simulation Mechanical & Autodesk CFD 2016 BWEC Cooling shell design 19

20 Thermal simulations 1 quarter dummy for simulationsOuter shell (Aluminum) Front shell (HDPE) Inserts (Aluminum) Gap (air 4mm) Crystals (PbWO4) Inner shell (Aluminum) 1 quarter dummy for simulations BWEC Cooling shell design 20

21 Only outer and inner shellsThermal simulations Only outer and inner shells Not front shielding 2°C gradient °C °C BWEC Cooling shell design 21

22 Back pipe with both inner and outer shellsThermal simulations Back pipe with both inner and outer shells Back homogeneity °C Not front shielding 2°C gradient °C BWEC Cooling shell design 22

23 Front shell, back pipe and both inner and outer shellsThermal simulations Front shell, back pipe and both inner and outer shells Out of scale -5°C Front shielding Less than 0.5°C gradient °C °C Solid angle loss (further for the IP) BWEC Cooling shell design 23

24 Possible 140W (STT worst elect. case) front without front coolingThermal simulations Possible 140W (STT worst elect. case) front without front cooling -25,06 °C Huge temperature gradient (7.13°C) -17.87°C BWEC Cooling shell design 24

25 Possible 140W (STT worst elect. case) front with front coolingThermal simulations Possible 140W (STT worst elect. case) front with front cooling Out of scale 57°C Good front protection Less than 0.5°C gradient °C -24.00°C Solid angle loss (further from the IP) BWEC Cooling shell design 25

26 Straight pipes and elbowFluid mechanics simulations Straight pipes and elbow 4.00 mbar 23.82 mbar 11.63 mbar BWEC Cooling shell design 26

27 Front square connectorsFluid mechanics simulations Front square connectors BWEC Cooling shell design 27

28 Front square connectorsFluid mechanics simulations Front square connectors BWEC Cooling shell design 28

29 Front square connectorsFluid mechanics simulations Front square connectors BWEC Cooling shell design 29

30 Front square connectorsFluid mechanics simulations Front square connectors 35.44 mbar 31.21 mbar 30.28 mbar BWEC Cooling shell design 30

31 Fluid mechanics simulationsSummary 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 95.28 Square conn 1 35.44 2 70.88 Square conn 2 31.21 62.42 Square conn 3 30.28 1 Total mbar BWEC Cooling shell design 31

32 Fluid mechanics calculations vs. simulationsPart Pressure drop (mbar) Amount Total Pd (mbar) Straight d =10 mm 11.37 4 45.48 d = 13 mm 3.99 6 23.94 Elbow d = 10 mm 21.05 84.20 Square conn 1 27.60 2 55.20 Square conn 2 Square conn 3 1 Total mbar Part Pressure drop (mbar) Amount Total Pd (mbar) Straight d = 10 mm 11.63 4 46.52 d = 13 mm 4.0 6 24.00 Elbow 23.82 95.28 Square conn 1 35.44 2 70.88 Square conn 2 31.21 62.42 Square conn 3 30.28 1 Total mbar BWEC Cooling shell design 32

33 Summary and future works5 What is next? BWEC Cooling shell design 33

34 Summary Less than 0.3oC of gradient in the coolant temperatureGood homogeneity with front cooling Low pressure drop: Different pressure drop values because of the square parts (simplifications in calculations for complex geometry) Calculations Simulation mbar mbar BWEC Cooling shell design 34

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 35

36 Any questions? You can write me [email protected]THANKS! Any questions? You can write me BWEC Cooling shell design 36

37 Back Up slides BWEC Cooling shell design

38 Front cooling Connectors MP Hole Preparation in Outer shell and MPBWEC Cooling shell design B1

39 Front cooling Parallel circuits (low pressure drop)Preliminary design Parallel circuits (low pressure drop) Different diameter each branch (homogeneity) 3D printed (HDPE) BWEC Cooling shell design B2

40 Simulations Velocity examples BWEC Cooling shell design B3

41 Thermal calculations General inputs BWEC Cooling shell design B4

42 Thermal calculations Example BWEC Cooling shell design B5

43 Thermal calculations Output summary BWEC Cooling shell design B6

44 Fluid mechanic calculationsSerial Pressure drop calculator Inputs: Coolant Section´s geometry Length Local elements Flow Valve Height BWEC Cooling shell design B7

45 Fluid mechanic calculationsSerial Pressure drop calculator Outputs: Reynolds Laminar/ Turbulent Friction factor Pressure drop Pressure difference BWEC Cooling shell design B8

46 Fluid mechanic calculationsParallel calculator Flow Aim: Constant flow through all branches. Procedure: Change diameter of branches. Flow/4 Flow/4 Flow/4 Flow/4 Flow BWEC Cooling shell design B9

47 Fluid mechanic calculationsParallel calculator Inputs: Coolant Different geometry for sections Lengths Local elements Number of branches Height . BWEC Cooling shell design B10

48 Fluid mechanic calculationsParallel calculator Outputs: Total pressure drop Pressure drop in manifold Different diameters . BWEC Cooling shell design B11

49 Front cooling test Aim: See the effect of different materialsin the front cooling Effect of different VIP´s configuration 20mm 2x10mm Validate thermal and fluid mechanic calculation system. . BWEC Cooling shell design B12

50 Front cooling test Layout . Different materialsBWEC Cooling shell design B13

51 Cold nitrogen test Layout . Cool down the nitrogenBWEC Cooling shell design B14

52 Dew point at 20°C Calculations BWEC Cooling shell design 08.06.2017

53 Dew point at 20°C Psychrometric chart BWEC Cooling shell design B14

54 Dew point at 20°C Kapton heating BWEC Cooling shell design 08.06.2017

55 Distance between pipesAll the heat received for the plate is transported by conduction 𝑃 𝑞𝑐 +∆𝑥 = 𝑞𝑐+ 𝜕𝑞 𝜕𝑥 𝑑𝑥+… Q w 𝑞𝑐 +∆𝑥 − 𝑞𝑐= 𝜕𝑞 𝜕𝑥 𝑑𝑥+… 𝑞𝑐 𝑞𝑐 +∆𝑥 t 𝑞𝑐 +∆𝑥 − 𝑞𝑐= 𝜕 𝜕𝑥 −𝑘 𝜕𝑇 𝜕𝑥 𝑑𝑥+… dx x 𝑑 𝑑𝑥 𝑄 𝐶 =𝑃∙𝑤∙𝑑𝑥 (𝑞𝑐 +∆𝑥 −𝑞𝑐)∙𝑡∙𝑤=𝑃∙𝑤∙𝑑𝑥 −𝑘∙𝑡∙𝑤∙ 𝑑 2 𝑇 𝑑 𝑥 2 𝑑𝑥=𝑃∙𝑤∙𝑑𝑥 𝑑 2 𝑇 𝑑 𝑥 2 =− 𝑃 𝑘∙𝑡 BWEC Cooling shell design B14

56 Distance between pipesBoundary conditions Symmetry: Q(L/2)=0 T(0)=Te 𝑇 𝑥 =− 𝑃 2∙𝑘∙𝑡 ∙ 𝑥 2 +𝐴∙𝑥+𝐵 𝑇 0 =− 𝑃 2∙𝑘∙𝑡 ∙ 0 2 +𝐴∙0+𝐵→𝐵=𝑇𝑒 𝜕𝑇 𝜕𝑥 𝐿/2 =− 2𝑃 2∙𝑘∙𝑡 ∙ 𝐿 2 +𝐴=0→𝐴= 𝑃𝐿 2𝑘𝑡 𝑑 2 𝑇 𝑑 𝑥 2 =− 𝑃 𝑘∙𝑡 Te x L/2 BWEC Cooling shell design B14

57 Distance between pipesTe 𝑇 𝑥 =− 𝑃 2∙𝑘∙𝑡 ∙ 𝑥 2 + 𝑃𝐿 2∙𝑘∙𝑡 ∙𝑥+𝑇𝑒 x L/2 We want T(L/2) ≤ Te+0,5 𝑇 𝐿/2 =− 𝑃 𝐿 2 8∙𝑘∙𝑡 + 𝑃 𝐿 2 4∙𝑘∙𝑡 +𝑇𝑒=𝑇𝑒+0,5 𝑃 𝐿 2 8∙𝑘∙𝑡 +𝑇𝑒= 𝑇𝑒+0,5 𝑃 𝐿 2 8∙𝑘∙𝑡 =∆𝑇→𝐿= 8𝑘𝑡∆𝑇 𝑃 BWEC Cooling shell design B14

58 Thermal simulations Out of scaleBWEC Cooling shell design B14

59 Thermal simulations Out of scaleBWEC Cooling shell design B14

60 Leakless mode Calorimeter Pressure Height Total static energy Losses