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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
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
Grant Agreement 654168 PUBLIC 2 / 19
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.
Date: 08/11/2017
Grant Agreement 654168 PUBLIC 3 / 19
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
Grant Agreement 654168 PUBLIC 4 / 19
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
Grant Agreement 654168 PUBLIC 5 / 19
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
Grant Agreement 654168 PUBLIC 6 / 19
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
Grant Agreement 654168 PUBLIC 7 / 19
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
Grant Agreement 654168 PUBLIC 8 / 19
$
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
Grant Agreement 654168 PUBLIC 9 / 19
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
Grant Agreement 654168 PUBLIC 10 / 19
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
Grant Agreement 654168 PUBLIC 11 / 19
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
Grant Agreement 654168 PUBLIC 12 / 19
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
Grant Agreement 654168 PUBLIC 13 / 19
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
Grant Agreement 654168 PUBLIC 14 / 19
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
Grant Agreement 654168 PUBLIC 15 / 19
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
Grant Agreement 654168 PUBLIC 16 / 19
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
Grant Agreement 654168 PUBLIC 17 / 19
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
Grant Agreement 654168 PUBLIC 18 / 19
Fig. 20 Write Rate control on the user interface
Date:Error! AutoText
entry not defined.
Grant Agreement 654168 PUBLIC 19 / 19
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
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