M. Battistin 1

Detector Cooling ProjectThermosiphon Project Status Report

Michele BattistinEN/CV/Detector Cooling

14/12/2011

M. Battistin

• Basic schematics

• Review process

• Integration

• Main Components

• Risk Analysis

• Project Management

• Cost tracking

• Planning

• Resources

2

Agenda

14/12/2011

3

Basics schematics

liquidtank

USA15cavern

Surface

ATLAS IDDetector

UX15cavern

Normal operation evap.

R404aCascade condenser

Watercondenser

R23

Warm operation evap. Air condenser

C6F14 brine circuit

Normal operation -65°C to -70°C

Warm operation -15°C to -20°C

C3F8 H2O

14/12/2011 M. Battistin

Real P&I

EDMS 1101188

4

• Pre-design and general lines of the project.• Indico agenda and documents here.

1st Thermosiphon review: 6th July 2009

• Detailed design for the 2 kW Thermosiphon, mini-thermosiphon and blends.• Indico agenda and documents here.

2nd Thermosiphon review: 1st October 2009

• Advancement status of Thermosiphon project, oil free centrifugal compressors and sonar sensor. • Indico agenda and documents here.

3rd Thermosiphon review: 28th May 2010

• Project Readiness Review.• Indico agenda and documents here.

4th Thermosiphon review: 19th of November 2010

• Project advancement.• Indico agenda and documents here.

5th Thermosiphon review: 20th of October 2011

Reviews process

14/12/2011 M. Battistin

M. Battistin 5

Integration: Point 1 overview

CondenserLocation

SH1

SUX1

SX1

PX15

SDX1

USA15

Chiller and Brine Station Location

14/12/2011

M. Battistin 6

Thermosyphon Piping and By-pass components

14/12/2011

SDX1

Piping connection to condenser

SDX1

PX15

Pipe route to PX15 pit 72m vertical pipe line

USA15 - Thermosyphon by- pass components

USA15 Components locationThermosyphon by-pass

<1,2 m

>3 m

By-pass integration on platform

M. Battistin 7

Water and Brine Circuits

14/12/2011

Primary water HX(inside the underground gallery)

Underground gallery(dashed line)

Service Hole

Water pumps location(inside SH1)

M. Battistin 8

Integration documentation status

14/12/2011

Document Approval Status

Condenser integration EDMS 1141928 v1 Under Approval

C3F8 pipe integration EDMS 1155062 v1 Approved

Chiller & Brine Pumps Integration EDMS 1157706 v1 Approved

Electrical Requirements EDMS 1159012 v1 Under Approval

Electrical Cabinet Integration EDMS 1166645 v1 Under Approval

USA15 Integration EDMS 1164037 v1 Under Approval

Water Circuit Integration EDMS 1162726 v1 Under Approval

Brine Piping Integration EDMS 1166643 v1 Under Approval

Brine piping calculation specifications EDMS 1164132 v1 Under Approval

M. Battistin 9

Chiller: 170kW @ -70°C

14/12/2011

Technical Specifications (Done)

Market Survey (Done)

Invitation to Tender (Done)

Purchase Order (Done)

Chiller Construction (On going)

• Contract started: 10% Completed (September 2011)

• Design phase completed 20% Completed (October 2011)

• Construction of the Chiller 30% On going (December 2011)

• Delivery and Installation at CERN 30% Planned to January 2012

• Commissioning at CERN 10% Planned to June 2012

Chiller Construction Schedule

M. Battistin 10

Thermosyphon Condenser

14/12/2011

Technical Specifications (Done)

Request for Quotation (Done)

Purchase Order (Done)

Condenser Construction (On going)

Condenser Construction Schedule• Contract start: October 2011• Detailed design: November 2011• Purchasing of material: January 2012• Condenser construction: March 2012• Final pressure tests: May 2012• Insulation of the condenser: May 2012• Delivery at CERN: June 2012

Thermosyphon C3F8 Liquid outlet

Thermosyphon C3F8 Vapour inlet

Brine Condenser IN

Brine Condenser OUT

Brine Sub-cooler IN

Brine Sub-cooler OUT

De-superheating & Condensing tubes (240x)

Sub-cooling tubes (28x)

M. Battistin 11

Hydraulic Components Selection

14/12/2011

• Fluids: Fluorocarbons C2F6, C3F8, C6F14• Pressure: PN16, PN40, DESP 97/23EC approval• Temperature: 20°C to -70°C. Cryo extension• Material: Stainless steel, flat metallic gasket, no fluorinated plastic• Leak tightness: General 10-7 mbar.l/s

• Cleaning: every part degreased, driers, 1µm filter• Safety: Twin relief valves with 3 ways valve, Deported sensors, Double switches on valves

All project working documents on SharePoint

Components Selection Criteria

Part list (reference #, order status, cost, specs, etc)

EDMS

M. Battistin 12

Electrical Installed Power

14/12/2011

New switchboard in SX1 New switchboard in SX1

Chill

erI 2

30 k

WCh

iller

II 23

0 kW

Wat

er p

ump

10 k

WW

ater

pum

p 10

kW

Brin

e he

ateI

40 k

W

Chill

erI 2

37 k

WCh

iller

II 23

7 kW

Brin

e pu

mp

30 k

W

Brin

e pu

mp

30 k

W

Diesel power(source not yet known)

New drawers in UIAC115/1UX

EOD2/1DX

New switchboard in SX1

Normal distribution Diesel distribution UPS distribution

Cont

rol C

hille

rICo

ntro

l Chi

llerI

I Co

ntro

l TS

New switchboard in USA15 New switchboard in USA15

Hea

ter I

15.

5 kW

Dum

my

load

100

kW

Hea

ter I

I 56

kWD

umm

y lo

ad 2

5 kW

Diesel power(source not yet known)

New drawers in EWD1/15A

EOD2/15A

New switchboard in USA15

Normal distribution Diesel distribution UPS distribution

Cont

rol T

S

115kW 81kW5kW

PLC & 24v. power supply

(UPS)

15.5kWheater100kWD.load

(Standard)

56kWheater25kW D.load

(Diesel)

Surface – SX1 Underground – USA15

60kW5kW 60kW 5kW468kW

Chiller High T.237kW(Diesel)

PLC & 24v. power supply

(UPS)

Chiller Low T.231kW

(Standard)

2x10kW (pumps)

40kW (heater)

(Standard)

2x30kWBrine

pumps

(Diesel)

PLC & 24v. power supply

(UPS)

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Risk Analysis

14/12/2011

Determination of thesystem limits

Hazard identification – identifying the hazards and environmental aspects occurring in normal and

exceptional conditions

Risk estimation

Risk evaluation

1. Usage limits

Operating phases and procedures (2kW Thermosiphon)

Control system (overall architecture)

System users (accesses control)

2. Time limits (continues operation)

3. Space limits (Point 1, USA15, B3184 roof)

4. Other limits (properties of cooling fluids)

Brine circuit C6F14

Brine circuit / main cooling loop

Vertical liquid line, PX15 and roof of B3184

By-pass dummy load, USA15

By-pass, USA15

Detector vapor return line,

Detector liquid supply line, USA15

M. Battistin 14

Risk Analyses

14/12/2011

Considered: 240 hazards 202 hazardous events 76 individual components in 7 groups 98 risk reduction proposals mechanical, electrical and control failures included EDMS 1165951 document under approval

A116%

A226%

B140%

B212%

C15% C2

1%

FST risk evaluation after risk reduction

A17%

A225%B1

10%

B29%

C14%

C21%

D144%

FST risk evaluation before risk reduction

Medium [A3, A4, B2, B3, C1, C2, D1] Unacceptable risk: actions are necessary to reduce the risk.

EDMS 1165951(New version with updated P&ID in work)

M. Battistin 15

Cost and Planning – Earned Value Management

14/12/2011

•Conceptual design reportDefinition

•Project breakdown structure

•Equipment coding convention

PBS

•Work breakdown structure •List of working unitsWBS & WU’s

•Resource responsibility matrixRRM

•Work units dictionaryWU

•PlanningProject

coordination schedule

Proje

ct Br

eakd

own S

tructu

re

Resp

onsib

ility a

nd Re

sour

ces M

atrix

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Cost Tracking

14/12/2011

• Cost rise from 2010.

• Last budget presented to ATLAS management on 08/2011.

• Chiller N2 is not accounted.

• Cost are constantly tracked on EVM.

• The project has negative cost variance

• The project has negative schedule variance

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Planning

14/12/2011

Time Autumn 2011 Winter 2011/2012 Spring 2012 Summer 2012 Autumn 2012 Winter

2012/2013

Design and integration

Complete detailed design and integration

Chiller system Manufacture

Supply and installation

Brine circuit Integration Tendering Installation connection

Tank/condenser

Contract signature Manufacture Supply and

installation

C3F8 piping Design and Supports

installationInstallation of the pipes

By-pass Detailed design

Purchase of material Construction

USA15 installati

on

Instrumentation and control

Functional analysis

Purchase of

hardwareProgramming Program tuning

Electricity and

Pneumatic installations

Study the requirements

Cupboards construction and installation

Commissioning

Tests with by-pass

Tests with detector

Exte

nded T

ech

nic

al Sto

p inte

rfere

nce

M. Battistin

• The TS detailed design is well advanced

• The equipment integration is still an important open issue.

• We shall start and operate the 2 kW to obtain insight for the functional analysis.

• Chiller construction is under-control.

• Condenser order has been sent.

• Support Piping installation is going to start

• In general the project is late and needs extra-resources to get the target date (Dec 2012):

– one Catia draftsman for 2 week to finalize 3D integration.

– one member of ATLAS ID collaboration will be welcome to join the team.

– a polish technician team for the assembly of the hydraulic part.

– resource to develop the PVSS/UNICOS control system shall be guaranteed.

• A workshop shall still be identified to give space and tools or the assembly!

18

Conclusions

14/12/2011