# Presentation: 286998

## NOvA APD Cooling Water Update

**William Gilbert  **
**University of Minnesota**

## Cooling System Zones & Dimensions

***4 cooling zones along the length of the detector supplied by chilled water at 48 ******o******F  supplied by FESS.***
***⇒ ******3 zones of 8 sections + 1 zone of 7 sections.***

***12 rows ***
***of detectors***
***each face***

***1 cooling loop per row, ***
***per zone,***
***(water from heat exch to APDs)***
***12 row x 3 face  x 4 zones***
***      ******= 144 secondary loops ***

## Pump Unit & Instrumentation

**HEAT**
**EXCH**

**PUMP**

**Reservoir**

**Primary**
**Chill**
**Water**

**Level**
**Switch**

**Flow Switch**

**Temp**
**Probes**

**Auxiliary contact on pump starter relay gives pump status**

- Pump Unit & Instrumentation

**Remote I/O System**

**RS 485, E-NET**

**Motor**
**Starter**

**Secondary**
**Water **
**to APDs**

**24VDC**
**PWR**

**120 VAC**

**Optional valve for **
**control of secondary**
**water temperature**

**Pump Confirm**

**Pump Control**

**Notes:**
More detail on pump unit, showing instrumentation.

## NOVA Cooling Manifold Section

**2 versions needed**
**32 hoses detector top**
**16 hoses on sides**
**Serving 64 planes**

**~1” ID pipe**
**, ~12 ft long**

**Ball Valve**

**Union or other flush coupling**

**1/4”  hoses with valved **
**disconnect**

**Notes:**
Modular manifolds keep length in easy to ship range, which is important, since we want to have these contract manufactured.
Exact number of hoses(planes) needed is in flux. Since quick disconnect fittings are valved, unused hoses really aren’t a problem, we just need to make sure there are enough. A hose plus or minus doesn’t affect cost much.
Two versions of manifolds needed, 1 for detector top with about 30 hose taps, 1 for detector sides with about half that number. 
Before downsizing this was 32/16. and we received estimates from two different suppliers with different construction materials & methods. 
Both close to same cost. For the 32 tap manifolds about $780, 16 tap $580, including insulation.
Descriptions:
 1) Georg Fischer, big industrial process piping supplier, using HD polyethylene pipe with hose fittings welded(ultrasonically?) in to manifold, using true union ball valves between  coupling on ends. Good idea, since manifold can be disconnected on either side of valve, only one valve is needed between each section.
2) Tiger Tech, smaller hose product distributor and custom manufacturer. They would build from PVC pipe, drilled & tapped for 1/8” NPT metal hose barbs, with crimped hose attachments. they propose standard PVC ball valves on ends, with rubber sleeve & clamp couplings used to join sections. 
Both suppliers have said anything smaller than 1 inch pipe would make these difficult to manufacture. 

## Single Loop Heat Calculations

** ****5w  per APD module x 217units                 = 1085w**
**Assume (guess) heat pickup in pipes, etc = 1085w**
**Total = 2170w**
**Loop delta T = Q(watts) / [263 x Flow(GPM)]**
**= 2170w / [263 x 6.87GPM]**
**= 1.2 degC**
** **
**ITD = initial temp difference of fluids entering heat exchanger**
**= (APD water + del T) - FESS chilled water**
**= (15 degC + 1.2deg C) - 8.9 degC = 7.3 deg C**
**Q / ITD for this flow & load = 2170w / 7.3 degC = 297**
** ****Compare to high limit value from Lytron chart for this flow rate, 800**
**297 is much lower, so this is well within capacity of LL520!**

**Notes:**
I this slide we perform a heat load calculation and check to see if it is in the range of the selected heat exchanger.
Formula for loop delta T is modified version of specific heat formula, Q = cm(dT). 
Time units in top and bottom cancel out, units converted for input of watts and water GPM.
It appears that our total heat load could increase substantially and still be OK. 
Since delta T, and thus bottom term ITD, increases along with heat load, Q/ITD rises slower. 

## Use Macroflow?

**Innovative Research, Inc.****3025 Harbor Lane N, Suite 300****Plymouth, MN 55447, USA****Tel:(763) 519-0105**

**Notes:**
Macroflow is a CAD tool that is written by Innovative Research in Plymouth, MN. 
Company founded by a retired UMN ME professor, Suhas Patankar. 
We have made preliminary contact with them last fall. Might be well worth our while to let them model our loop design before we prototype it, and alternate designs if necessary. Full license $5k, but lower cost short term license or fee based consulting also possible.

## Macroflow example

**Electronic cooling system via manifold distribution**
**30 elements X 4 rows, reverse return**

## Macroflow example part 2

**Looks very similar**

## Loop Volume

**Using 1” dia manifolds, pipes, and 25k ton dimensions,**
**Single loop water volume = 2960 cu in     **
**= 12.8 gal        **
**= 107 lb          **
**Weight of water system, guess at 2x this, ~200lbs**
**Total length of system is ~100 feet, so 2lbs/ft, 24lbs/span**
**But, it’s just plastic, so we will need several supports along the span, ****probably every 3-4ft.**
**Total water volume, 144 loops, = 1843 gal     **
**= 15400 lb    **

**Notes:**
Left out hoses and APD modules, but this gives us a ballpark figure.

## Old Loop Cost Estimate

- SWAG cost estimate for loops on detector top, side loops a bit lower:
- 1	Pump 1/25hp bronze cast			$ 150	$    150
- 1	Heat Exchanger (~LytronLL520)		$ 200	$     200
- 16	Top manifold assembly			$ 830	$ 13280
- 1	Fluid Reservoir				$   50	$      50
- 1	Fluid level switch(float, capacitive, other)	$    80	$      80
- 2	Temp probes, RTD in welded SS fitting		$    50	$    100
- 1	Flow switch (~Omega FST-211-SPST )		$  160	$    160
- 1	enclosure			 		$  200	$    200
- 6	Remote I/O channels(2 temp, 1flow,
- 		1 level, 1 pump status, 1 pump control)	$  200	$   1200
- x	Misc pipe, wire, cable			$  100	$    100
- 24	man-hours assembly:
- 	mount 8 manifold sections
- 	make 512 quick connects
- 	mount & connect pump & other components
- 	install wire duct, field wiring, fill, test etc.	$    50	$   1200
- 					Total		$ 16720

**Notes:**
Previous estimate with truly WAG manifold cost, 30k ton dimensions

## New Loop Cost Estimate

- SWAG cost estimate for loops on detector top, side loops a bit lower:
- 1	Pump 1/6 hp bronze cast			$ 300	$    300
- 1	Heat Exchanger (~LytronLL520)		$ 200	$     200
- 14	Top manifold assembly			$ 780	$ 10920
- 1	Fluid Reservoir				$   50	$      50
- 1	Fluid level switch(float, capacitive, other)	$    80	$      80
- 2	Temp probes, RTD in welded SS fitting		$    50	$    100
- 1	Flow switch (~Omega FST-211-SPST )		$  160	$    160
- 1	enclosure		 			$  200	$    200
- 6	Remote I/O channels(2 temp, 1flow,
- 		1 level, 1 pump status, 1 pump control)	$  200	$   1200
- x	Misc pipe, wire, cable			$  100	$    100
- 24	man-hours assembly:
- 	mount 8 manifold sections
- 	make 512 quick connects
- 	mount & connect pump & other components
- 	install wire duct, field wiring, fill, test etc.	$    50	$   1200
- 					Total		$ 14510

**Notes:**
Revised estimate using manifold estimate from G Fischer, higher power pump, and 25k ton dimensions.
Loop cost for detector sides is $11,710.
Illustrates the significant role of manifold cost. 

## Utilities Version A

## Distribution Box

- Caution – High Voltage

-  Completed Distribution Box
-  Card Cage not shown
- Power Dist Boxes
- $362k

## Power Backplane

-  Backplane with Cu bus bars

## Top Power/Data

- High Voltage
- Low Voltage
- Local redistribution
- (1.7m avg. cable length)
- Each Power Distribution Box powers 64 boxes
- DAQ services along same route from neighbor box
- ~2”x6” Cable Tray along Detector

- 2 Blocks — 62 Planes — 409cm

- 12 modules  – 1570cm

- Power Distribution Box

- APD readout box

## Side Power/Data

- High Voltage
- Low Voltage
- Local redistribution
- (2.3m avg. cable length)
- Each Power Distribution Box powers 60 boxes
- DAQ services along same route

- Power Distribution Box

- APD readout box

- 2 Blocks — 62 Planes — 409cm

- 12 modules high – 1570cm

## IPND Top Power

- Distribution to 202 modules
- 202/64=4?
- Can we drop 10 planes?
- Better Distribution with 50/50/50/52
- Special channel map for DAQ

- 2 modules  – 260cm

- 10 Planes — 66cm

## IPND Side Power

- Distribution to 303 modules
- 303/64=5?
- 60/60/60/63

- 3 modules  – 390cm

**40 Planes — 264cm**

**40 Planes — 264cm**

**40 Planes — 264cm**

**41 Planes — 271?cm**

## Cable loading weights

- Largest weight of cables
- DAQ 0.8lb/ft
- Power 1.5lb/ft
- TOTAL 2.3lbs/ft
- Cable tray weight
- 1.4lb/ft (for 2x12 wire mesh)
- Tray capacity 8.3lbs/ft
- Hang H20 from cable trays?

## Comments/Questions

- Nothing here about readout box mounting
- Will be working with Tom Chase to define mounts, box and mounting procedures
- PLAN for box to fit within the plane of the module, avoiding interference issues
- How much space between detector and steel
- How much space around IPND/ND in ALL dimensions, top, side, front, back