V Thermo-siphon Workshop Test protocol

1. V Thermo-siphon WorkshopTest protocol Jan Godlewski PH/DT-PO On behalf of thermo-siphon working group https://espace.cern.ch/thermosiphon/default.aspx

2. Context • Basic components of Thermo-siphon installation • Installation schedule • Components oriented tests • Chiller • Brine circuit • Primary water • Thermo-siphon piping • Thermo-siphon commissioning • Commissioning with dummy load • Detector oriented tests • Back-up system and swap between TS and compressors • Merge of control systems • Automatic change from TS → compressors and backwards • Thermo-siphon integration with ATLAS DCS Jan Godlewski PH/DT-PO

3. Basic components Brine Circuit Thermo-siphon Chillers Primary Water Jan Godlewski PH/DT-PO

4. Installation of thermo-siphon components will be spread in time by around 6 month’s. Each of the subsystems will have to be checked and tested before the final connection to overall system. • One of the first components installed in point one will be the chiller No 1 manufactured by J&E Hall. It should happen in January 2012 • In the first half of 2012; brine/C3F8 circuit; primary water circuit and thermo-siphon piping with instrumentation will be installed. • All of these items will undergo exhausting tests as single components to shorten the commissioning time of full thermo-siphon. • For each test there should be written protocol with information concerning: • Scope of the test • Responsible person • Date • Result • Conclusions • Protocol will be registered in EDMS and will be the part of final Thermo-siphon documentation Jan Godlewski PH/DT-PO

5. Chiller (1) • Chiller • Two chiller with 100% efficiency will be installed • First chiller in January 2012 • Second???? • Each chiller will have the possibility to: • Work in warm regime only with high temperature stage • Work with air cooled condenser in case of primary water circuit failure • First chiller will be installed in January 2012 • Chiller tests • At J&E Hall Basing on Functional Analysis prepared by J&E Hall CERN will write the control code and program the PLC. All the necessary hardware will be installed at J&E Hall premises and necessary functional tests of the chiller control system will be performed before sending it to CERN. It is vital step as after installing Chiller at CERN infrastructure will not be ready before June 2012 Jan Godlewski PH/DT-PO

6. Chiller (2) • Technical Specification for the Design, Construction, Installation and Commissioning of a Low Temperature Chiller https://edms.cern.ch/document/1078475/2 • Tests at J&E Hall • Welding inspection • 100% visual inspection • 10% X-rays for each welder • Pressure test (PED standard 97/23/EC) • Leak test • Electrical connections – mapping • Tests at CERN • Performance test • This test can be done only when full infrastructure of Thermo-siphon will be ready Water and brine/C6F14 circuits Electrical and pneumatic services Integrated control system Jan Godlewski PH/DT-PO

7. Brine and primary water circuits These circuits will undergo all standard for EN/CV tests and inspections • Visual inspections • Agreement between labels on the components and P&ID naming • Hydraulic scheme verification • Electrical mapping • Connections (hydraulic, electrical, pneumatic) • Mechanical tests • Pressure tests • Leak tightness • Electrical tests • Power supply (cabinets, switches, etc) • Motors, heaters (coupling, rotation, etc) • Instrumentation tests • Crosscheck all the sensor, mapping • Safety instrumentation • Tests of each item with calibration (regulation valves, etc) • Functional tests • According to the functional analysis all the different sequences will be checked Jan Godlewski PH/DT-PO

8. Thermo-siphon piping C3F8 piping is bringing to the surface fluorocarbon that is passing through high radiation zone of the Inner Detector and then is going through USA15 and access building SDX1. Therefore this piping has to be very reliable and risk of leaks should be minimized as people safety is involved • C3F8 piping • Support calculation and installation • Mechanical and thermal-stresses • Seismic analysis • Piping will start end of January/February 2012 • Pipes cleaned by EN/MME • 100 % x-ray • Pressure tests • Insulation by Ouvaroff Jan Godlewski PH/DT-PO

9. Thermo-siphon commissioning – dummy load • After completion of all the components tests the commissioning of single staying thermo-siphon will take place. To allow it dummy load with capacity of ~100 kW will be installed on the platform in USA15 level 2. With this dummy load the following tests will be performed: • Start up tests from ambient temperature • Cool down to the normal working conditions • Regulation tests • Abnormal conditions • Warm operation • Swap between water and air cooled condensers of the chiller • Power cut simulation • Running tests at different temperature set points and cooling capacities • Thermo siphon should be able to work correctly and smoothly with the range from 10% to 100% • Check of alarms and safety interlocks Jan Godlewski PH/DT-PO

10. Thermo-siphon commissioning – together with Inner Detector After finishing the stand alone tests of thermo-siphon, during the long shut-down 2013-2014 new installation will be connected with existing C3F8 piping in piping in USA15 CV room. Connection should allow for changing from TS to compressors without switching off Pixel and SCT detectors. All the tests with dummy load will be repeated and after: • Switching of between TS and compressors in: • Run conditions with full load • Run conditions with partial load • Warm operation • Power cut in any conditions • During these tests there will be final proof of the control systems and necessary changes will be applied • Tests of the connection between TS control system and ATLAS DCS and DSS Jan Godlewski PH/DT-PO

11. Summary • Very challenging Thermo-siphon project requires careful and detailed planning of all tests and checks • Templates • Results • Conclusions • These tests have to be done during time slots available for different TS components • All the tests have to be well documented • Test protocols will be registered in TS EDMS folder • Protocols will be part of official TS documentation • Thermo-siphon is the very challenging project and as such requires very careful, exhaustive and well prepared tests Jan Godlewski PH/DT-PO