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AIDA-2020-NOTE-2017-008

AIDA-2020Advanced European Infrastructures for Detectors at Accelerators

Scientific/Technical Note

User manual of the station for tests onmicro-channel test devices

Hellenschmidt, D (CERN) et al

08 November 2017

The AIDA-2020 Advanced European Infrastructures for Detectors at Accelerators projecthas received funding from the European Union’s Horizon 2020 Research and Innovation

programme under Grant Agreement no. 654168.

This work is part of AIDA-2020 Work Package 9: New support structures andmicro-channel cooling.

The electronic version of this AIDA-2020 Publication is available via the AIDA-2020 web site<http://aida2020.web.cern.ch> or on the CERN Document Server at the following URL:

<http://cds.cern.ch/search?p=AIDA-2020-NOTE-2017-008>

Copyright c© CERN for the benefit of the AIDA-2020 Consortium

http://aida2020.web.cern.ch

http://cds.cern.ch/search?p=AIDA-2020-NOTE-2017-008

Grant Agreement 654168 PUBLIC 1 / 19

Grant Agreement No: 654168

AIDA-2020 Advanced European Infrastructures for Detectors at Accelerators

Horizon 2020 Research In f rast ructures p ro ject A IDA -2020

TECHNICAL NOTE

USER MANUAL OF THE STATION FOR

TESTS ON MICRO-CHANNEL TEST

DEVICES

Date: 08/11/2017

Work package: WP9.1

Authors: D. Hellenschmidt, P. Petagna

Abstract:

Compact user manual of the new test station designed specifically to execute precision measurements

on complex micro-channel devices and on simple mini- and micro-pipes with boiling CO2 flows.

Date: 08/11/2017


AIDA-2020 Consortium, 2017

For more information on AIDA-2020, its partners and contributors please see www.cern.ch/AIDA2020

The Advanced European Infrastructures for Detectors at Accelerators (AIDA-2020) project has received funding from

the European Union’s Horizon 2020 Research and Innovation programme under Grant Agreement no. 654168. AIDA-

2020 began in May 2015 and will run for 4 years.

http://aida2020.web.cern.ch/

Date: 08/11/2017


TABLE OF CONTENTS

1. INTRODUCTION ......................................................................................................................................... 4

1.1. OBJECTIVE ......................................................................................................................................................... 4 1.2. GENERAL INFORMATION .................................................................................................................................... 4

2. EXPERIMENTAL TESTS ........................................................................................................................... 5

2.1. PREPARATION .................................................................................................................................................... 5 2.1.1. Installation of test sections ....................................................................................................................... 5 2.1.2. Filling the experimental circuit with CO2................................................................................................. 6 2.1.3. Switching on the vacuum pump ................................................................................................................ 8

2.2. RUNNING EXPERIMENTS ................................................................................................................................... 10 2.2.1. Start-up of the cooling plant ................................................................................................................... 10 2.2.2. Cooling plant: parameter control ........................................................................................................... 11 2.2.3. Labview user interface: parameter control ............................................................................................ 13

2.3. DATA READOUT ............................................................................................................................................... 16 2.4. DATA SAVING .................................................................................................................................................. 17

REFERENCES .................................................................................................................................................... 19

ANNEX: GLOSSARY ......................................................................................................................................... 19

Date: 08/11/2017


1. INTRODUCTION

1.1. OBJECTIVE

The general objective for the new test station is to extend experimental research on evaporative flow

of CO2 in mini- and micro-channels, namely at CERN. To give any user a short overview of the

operational mode of the system the following, compact user manual describes the main interfaces of

interaction with the setup.

1.2. GENERAL INFORMATION

The system consists of a cooling plant and an experimental setup. Both are depicted in Figure 1 with

the main components involved. For a more detailed description of the setup please refer to [1,2].

Fig. 1 Global test station layout.

a: refrigeration and circulation unit; b: transfer line; c: Local box; d: metal flexible lines; e: experimental unit

The interfaces the user has to interact with are on one hand a personal computer where all the read

out is shown on-line and all gathered data are saved - this is done with National Instruments hardware

and software (Labview) - and on the other hand the touch panel on the cooling plant which allows the

user to control the output parameters of the plant. Each interface will be described in the following

paragraphs along with the corresponding hardware control steps (e.g. open/close valves).

In addition to this user manual it is highly recommended to also refer to the user manual of the

cooling plant [3].

It is assumed that the cooling plant is already filled with CO2 and set for operation. For all remaining

issues concerning the cooling plant, such as the filling procedure of the cooling plant with CO2 please

refer to [3].

Date: 08/11/2017


It is further assumed that cooling plant and experimental setup are already interconnected safely via

the local box. However the circuits are still not coupled fluid-dynamically such that the experimental

part is not filled yet with CO2.

2. EXPERIMENTAL TESTS

2.1. PREPARATION

2.1.1. Installation of test sections

The two major types of test sections (Oct 2017) are stainless steel single mini- and micro-channels

and silicon micro-channel devices. The single channels can be installed in a straight-forward way by

using the fluidic connectors provided as default in the setup. If new tubes have to be installed the

corresponding ferrules (front and back ferrule) have to be available (1/16” and 1/8 “ OD, Swagelok)

to make a new interconnection. Figure 2 shows the fluidic connections of the single channels.

Fig. 2 Fluidic connections of the single channels

The silicon devices are also equipped with fluidic connectors (1/16” OD) and can be connected with

the given in- and outlet of the setup by means of an in-house-made fluidic link. Figure 3 shows the

fluidic connections of the silicon devices.

Fig. 3 Fluidic connections of the silicon micro-channels

All connections have to be tightened as specified by the manufacturer (Swagelok, three-quarters turn

after hand tightening the connection) to avoid leakage and damage of the connector and tubing.

Date: 08/11/2017


2.1.2. Filling the experimental circuit with CO2

Figure 4a shows the layout of the local box of the cooling plant and the different valves installed.

Note that here the insulation has been removed to make the circuit visible. Figure 4b shows the local

box in natura and the initial valve positions.

Fig. 4a Layout of local box with valves

experiment flow

control valve

experiment shut-off

valve

to experiment

from

experiment experiment vacuum

and venting

experiment shut-off

and venting valve

by-pass flow control

valve

to/ from cooling

plant

Date: 08/11/2017


Fig. 4b Local box with valves in initial position, before filling the circuit

After installation of the test sections the experimental circuit has to be vacuumed in order to remove

all the remaining moisture in the system. This can be done by connecting a small vacuum pump to

the local box. This pump has to be connected to the outlet of the local box indicated as experiment

vacuum and venting in Figure 4a and 4b. Whilst pumping the vacuum in the system for a minimum

of 15 minutes the handle of the experiment shut-off and venting valve remains pointing upwards. Any

leak in the circuit could be detected by observing the live pressure plots of the running VI interface

of the Labview program written for this experiment which is shown on the PC next to the setup. The

user interface of this program is explained in more detail in 2.2.3. If the internal circuit pressure

(pressure abs 1-4) does not stabilize around 0 bar the leak in the system has to be found by checking

and re-tightening all connections. If no major leaks can be detected after 15 minutes the experiment

shut-off and venting valve can be closed (horizontal position), as indicated in Figure 4c, left side.

The system can now be filled with CO2. The two circuits can be linked by putting the handle of the

experiment shut-off and venting valve (three-way valve) pointing downwards whilst the experiment

shut-off valve can now be opened slowly (vertical position, pointing downwards), as indicated in

Figure 4c, right side.

The experimental circuit is now also filled with CO2 at room temperature and no cooling is applied

yet. If any new connections have been made such as installing a new test section the circuit has to be

checked with a CO2 sniffer.

to/ from cooling

plant

experiment shut-off

valve

experiment flow

control valve

experiment vacuum

and venting

experiment shut-off

and venting valve

by-pass flow control

valve

UP

horizontal

Date: 08/11/2017


$

Fig. 4c Valve positions

2.1.3. Switching on the vacuum pump

In order to get an adiabatic environment for the experiments within the vessel the vessel vacuum

pump has to be switched on. This involves a series of steps until the full pumping power is available.

The following list has to be checked in sequential order:

1. close the vacuum vessel manually. No cable should catch in the vessel rim.

2. make sure both valves on vacuum sensor and connecting flange are open (see Figure 5)

Fig. 5 Valves connected to vacuum pump and vessel flanges

1. close → horizontal 2. open → pointing

downwards

3. open → pointing

downwards

OPEN

Date: 08/11/2017


3. switch on the vacuum pump

4. hold the vessel shut for a few seconds until the pump can operate

5. read pressure from the pressure gauge (see Figure 6a and 6b): The top display line which is

connected to the vessel initially reads ‘or’ (out of range) until the vacuum level reaches the

reading range of the sensor.

Fig. 6a Display of pressure gauge: out of range Fig. 6b Display of pressure gauge: 2.18∙10-2 mbar

6. wait until 10-2 mbar is reached (between 20 to 60 minutes)

7. then switch on booster pump (see Figure 7)

Fig. 7 Display of the booster pump control

= full pumping power is now available

It will take about 6 hours for the vacuum level in the vessel to go down to 10-4 mbar.

ON

Date: 08/11/2017


2.2. RUNNING EXPERIMENTS

2.2.1. Start-up of the cooling plant

The start-up procedure of the cooling plant is described in [3]. The cooling plant is controlled by

means of a touch control panel on the front of the plant. Figure 8 shows the front of the cooling plant

and Figure 9 the touch control panel in detail. The control panel displays all important parameters

along the circuit within the cooling plant. Table 1 lists the key parameters that one may be interested

in as a user whilst the cooling plant is operating and experiments are run.

Fig. 8 Front side of the cooling plant

Fig. 9 Control panel of the cooling plant (I)

Date: 08/11/2017


Measured and calculated signals of cooling plant

TT103 Accumulator outlet temperature

TT106 Accumulator saturation temperature

TT110 Heater temperature

PT101 Pump inlet pressure

PT103 Pressure after accumulator

PT110 Accumulator pressure

FT103 Flow

DP101 Delta pressure over pump

SC103 Sub-cooling before flowmeter

Table 1 Measured and calculated signals of the cooling plant

The cooling plant can be started by pressing the START icon on the panel (left bottom corner). In

general during start-up the delta pressure over the pump (DP101) has to be monitored to avoid the

plant to stop automatically. Due to a pump protection interlock in the cooling plant software, DP101

has to rise over 1 bar within 30 seconds and its behaviour depends on the pressure drop across the

experiment which can be regulated further (see below). The pressure drop DP101 should fall between

1 and 8 bar to guarantee a good start-up behaviour. Otherwise if no further errors occur CO2 is now

flowing in the experiment.

2.2.2. Cooling plant: parameter control

The main parameters which can be controlled with the cooling plant are saturation temperature and

pressure of the flowing CO2. Either one can be set on the touch panel and the second one follows

according to thermodynamics. This can be achieved by pressing on the corresponding number below

the set point indicator, shown in Figure 10. A numeric input field opens and the set point can be

changed.

Fig. 10 Control panel of the cooling plant (II)

Date: 08/11/2017


The experimental flow rate (and the mentioned pressure drop across the experiment related to DP101)

can be changed by means of the experiment flow control valve on the local box (refer to Figures 4a

and b). However, the experimental flow through the actual micro-channel sample can be further

controlled with the experimental by-pass valve mentioned in [1,2]. Figures 11 and 12 show the

position of the valve within the setup. Opening and closing it regulates the flow rate through the

channels. The rotational speed of the cooling plant pump can also be adjusted to change the flow rate

delivered by the cooling plant. This can be achieved by pressing the Speed feedback indicator in the

bottom left corner of the display. However, it is preferred to set the pump at a constant rpm level

(2000 – 2500 rpm) and regulate the flow with the valves mentioned before.

Two different flow meters are used to measure the flow rate within the experiment. This is done to

split the desired flow range between two Coriolis flowmeters: There is the flow meter within the

cooling plant with a measuring range of 0.13 to 10 g/s and a flow meter installed just after the

experiment with a measuring range of 0.003 to 0.16 g/s. According to which flow rate is wanted in

the experiment the corresponding flow meter can be used by operating two valves mounted on the

out-line of the experiment. This leads to by-passing the flow meter which is out of range for this

specific measurement. The location of the by-pass valves is shown in Figure 11 and 12.

Fig. 11 Schematic of the experimental unit

Fig. 12 Valve location within experimental unit

experimental

by-pass valve

flow meter by-

pass valves

experimental

by-pass valve

(hidden)

flow meter by-

pass valves

(hidden)

Date: 08/11/2017


2.2.3. Labview user interface: parameter control

The second major user interface is the Labview control panel open on the PC next to the station.

Figure 13 gives a screenshot of the Labview program scripted for this setup. All important read out

parameters can be evaluated online such as the temperature on the four measurement points and along

the sample tube, the pressures in the experiment, the flow rate and the heat loads. The parameters

can be controlled and saved with this interface. The controlling and saving process will be explained

in the following. It is assumed that the user is acquainted with the basics of the Labview software.

Fig. 13 Labview program of the new CO2 setup

2.2.3.1. Definition of input dimensions

In order to obtain the correct data from the experiments some dimensions and properties have to be

given as input parameters by the operator. For the case of single channel experiments the inner and

outer diameter of the tested tube has to be defined along with the tube length and the length of the

Joule heater. The input field and its location in the VI interface are shown in Figure 14.

Fig. 14 Input parameters

Date: 08/11/2017


2.2.3.2. Applying heat load

The power output of all heaters can be controlled with the same Labview program.

Pre-heater/cooler and post-heater: Peltier element 1 & 2

There is a SubVI control panel which has to be opened for the output control of the two Peltier

elements used. The user interface is depicted in Figure 15.

Fig. 15 Virtual control panel for the power output of the heaters

Peltier 1 can be used as a pre-heater or cooler whilst Peltier 2 is only used as a heater. The voltage

level of both Peltier elements can be changed by means of a virtual controller, shown in red in Figure

15. The current and the power follow according to electrodynamics and are also indicated. The

maximum power level is given on the right. To switch between heating and cooling properties of the

first Peltier element a relay is installed which is also controlled by means of a separate interface. This

is shown in Figure 16. Here it can be differentiated between COOL and HEAT by means of a control

switch.

Fig. 16 Virtual control panel for the relay

Date: 08/11/2017


Joule Heater

The control of the Joule heat which is applied to the experimental section is realised in a similar way.

The VI interface is shown in Figure 17.

Fig. 17 Virtual control panel for the power output of the Joule heater

It can be chosen between voltage and current control (big switch on the left, Fig. 17). Depending on

which is chosen the voltage or the current is then controlled by means of a virtual controller (shown

in red in Figure 16: left: voltage control, right: current control). If the wires of the Joule heater have

been disconnected to reinstall a new test section, Figure 18 shows the layout of the cabling for the

Joule heat so that the user is able to reconnect them again in the correct way.

Fig. 18 Cable layout for Joule heater

Date: 08/11/2017


2.3. DATA READOUT

The following parameters are read out or calculated by the program for further evaluation and saved

when specified as a text file.

RTD 1 -4 °C

TC 1-6 (lower tube) °C

TC 1'-6' (upper tube) °C

room temperature °C

Tsat @ 1- 4 °C

absolute pressure 1-4 bar

differential pressure 2-3 bar

differential pressure 2-4 bar

vacuum pressure mbar

�̇� (experiment flow meter) g/s

�̇� (TRACI flow meter) g/s

G (experiment flow meter) kg/m2 s

G (TRACI flow meter) kg/m2 s

Q Peltier 1 W

Q Peltier 2 W

Q Joule heat W

q Peltier 1 W/m2

q Peltier 2 W/m2

q Joule heat W/m2

h @ 1-4 kJ/kg

x @ 1-4

Table 2. Experimental readout parameters

The saturation temperature Tsat, the enthalpy h and the vapour quality x at the four measurement

points are evaluated by means of an implementation of the REFPROP software into the Labview

program. The mass flux G is calculated by the program with following formula:

𝐺 = �̇�

𝜋4 𝐷𝑖

2

where �̇� is the mass flow rate (g/s) and Di is the inner diameter of the tested tube. The power input

Q is calculated by the program with following formula: = 𝑈 ∙ 𝐼 .

Date: 08/11/2017


U is the applied voltage and I the corresponding current. This formula applies to all three

heating/cooling elements. The heat flux q is calculated by the program with following formula:

𝑞 = 𝑈 ∙ 𝐼

𝜋 ∙ 𝐿ℎ ∙ 𝐷𝑖

where Lh is the length of the heater.

2.4. DATA SAVING

As soon as the SAVE button is hit on the user interface and given that the program is running a dialog

box opens and the user is requested to specify the name and the desired location of the file where to

save the online-data. No default name and location is implemented here. Please take care not to save

on the desktop which will increase the saving time and may interfere with other timed loops in the

program. Save on C: instead. Figure 19 shows the SAVE button in saving mode and its location on

the user interface.

Fig. 19 SAVE button on the user interface

The 1 Hz acquisition frequency for all sensors is set as default. Especially for the temperatures and the pressures in the system it may be of relevance to acquire with higher frequencies. The frequency of the pressure and temperature measurements can be changed whilst the program is not in acquisition mode. This can be achieved by clicking on the dedicated control on the control panel and giving the desired value in Hz. Figure 20 shows the Write Rate control button

and its location on the user interface whilst the program is off.

Date: 08/11/2017


Fig. 20 Write Rate control on the user interface

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REFERENCES

[1] Hellenschmidt, D., “Station for tests on micro-channel test devices”, AIDA-2020-D9.1, 2017,

https://cds.cern.ch/record/2291552

[2] Hellenschmidt, D., AIDA-2020-NOTE-2017-009, 2017

[3] TRACI cooling plant user manual, see: https://edms.cern.ch/document/1579988/1

ANNEX: GLOSSARY

Acronym Definition

TRACI Transportable Refrigeration Apparatus for CO2 Investigations

https://cds.cern.ch/record/2291552

https://edms.cern.ch/document/1579988/1

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