3.

11 Water-cooling System

3.11 Water-cooling system and corrosion 3.11.1 Design philosophy

Thermal waste is removed by de-ionized water and forced air flow. Figure 3.11.1 depicts the thermal propagation. The chilled water undergoes a secondary heat exchange. All thermal waste eventually purge into the air via the cooling towers. In the accelerator facility, the cooling-water system, including de-ionized water, chilled water, cooling-tower water and hot water are supplied in closed-loop systems. The return water must flow into heat exchangers and water treatment systems, before being pumped bach into heat load devices. The total system consists of high stable quality and stable cooling devices and air conditioners.

De-ionized Water Chilled Water Cooling-Tower Water

Facility

Air Conditioning

Fig. 3.11.1.1 Diagram to show thermal propagation In the accelerator field, water is the main cooling medium. De-ionized water is the primary heat-exchange refrigerant, providing a stable cooling capacity. The cooling-water system is divided into four subsystems, such as de-ionized water of Cu piping system for magnets and power devices, de-ionized water of Al piping system for vacuum chambers, de-ionized water for the RF stations, de-ionized water for booster devices and beam line optical instruments. The separate water subsystems can prevent corrosion induced by voltage difference and each has its own working pressure, flow rate and temperature controls during operation. The Cu, Al, RF, and booster de-ionized water is regulated at pressure of 7.50.1 kg/cm2 and a temperature of 250.1 to satisfy the requirements of the TPS accelerators. Some diagnostic facilities including XBPMs and I0 monitors have a stricter criterion for temperature control, which is targeted within 250.01. In Fig. 3.11.1.2 and 3.11.2.1, the green line represents the de-ionized water loop in the water processing system. The return water from the heat-loaded device flows first into a separator, which separates air from water. The air is purged via an expansion tank and about 5 % of return water flows into the loop for de-ionization water treatment. Finally, the water is pumped forward to all heat-loaded devices. Between heat-loaded devices and pumps, two heat exchangers are required: one exchanges heat with chilled water (7.0) to extract thermal waste, shown as a blue line, and another exchanges heat with hot water (50) to stabilize the supply water temperature, shown as a red line. The whole process forms a closed-loop water cooling system. If there is water leakage, the level sensor can trigger a process to add water from a RO reservoir. The electric heater and buffer tank are employed to minimize the variation in temperature if the high precision temperature control, e.g. of 0.01, is needed.

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Fig. 3.11.1.2 System for de-ionized water The chilled water, hot water and cooling-tower water are the second and the third heat-exchange processes. Chilled water at 7.00.2, hot water at 320.5 and cooling tower water at 320.5 are required to ensure the stability of the temperature of the water.

3.11.2 Facility and Piping Design

The cooling-water system has numerous components and piping that are distributed over the location of heat-loaded devices and air conditioners, as shown in Fig. 3.11.2.1. The central water facility is located in a utility building with isolation to diminish effects of vibration or high-power electric noise caused by compressors, fans, pumps and other equipments. The utility building has a trench in which effective anti-vibration piping links the tunnel and the experimental area located on the storage ring. Each lattice cell has two underground trenches providing stable de-ionized water.

Fig. 3.11.2.1 A 3-D layout of the cooling water system extracting the thermal waste

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3.11 Water-cooling System

Fig. 3.11.2.2 Piping and trench design near the storage ring The water system includes some primary facilities, such as pumps, inverters, heat exchangers, chillers, cooling towers and boilers, which are described below.

3.11.2.1 Pump
Pumps of three types centrifugal, rotary and reciprocating are available. According to a pump curve, we can adopt an adequate flow and suction (??) head to meet our requirements. The accurate calculation of NPSH (Net Positive Suction Head) to prevent cavitation damage and an effective anti-vibration-support design must be noted.

3.11.2.2 Inverter
As the flow throughout the subsystem is variable, the inverter is introduced to shift the pump characteristic curve, as shown in Fig. 3.11.2.3. The pump can provide stable pressure within 0.1 kg/cm2 and enough flow for all subsystems. Using two synchronous inverters, that provide the possibility to perform pump exchange or maintenance without affecting the operation. Dual inverters also extend the lifespan with a low loading. The electric circuit of the inverter typically generates electric harmonics and therefore an isolation transformer and filters must be installed to reduce the harmonics interference to other devices.

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NSRRC - TPS Design Handbook - June 2008

120 100

Load Curve

% Pressure

80 2 60 40 20

3 1

Characteristic Curve of Pump

20 40 60 80 100 120 140 160

% Flow

Fig. 3.11.2.3 Characteristic curve of a pump operating with an inverter

3.11.2.3 Heat exchanger

The heat exchanger is made from thin metal with a rough and uneven surface. Each metal surface separating cool and hot water channels enables the heat of the water to be exchanged. The thickness of the plate varies with the material used, such as stainless steel, titanium, copper and nickel of thickness about 0.6~1 mm. The plates are commonly made with a wave shape to enhance thermal conduction and structural stress. The heat-exchanger plate of de-ionized water is made from stainless steel. In addition to flow capacity, the pressure drop of the plates within 0.5 kg/cm2 is important to decrease load of the pump and to reduce operating cost. The inner piping in the heat exchange, also should prevent blocking from associated particles or rust.

3.11.2.4 Chiller
Chillers are core components of a water-cooling system. A chiller has a compressor to control the refrigerant with adequate pressure and to exchange the thermal waste into the cooling-tower water. The temperature of chilled water is specified to be 7.00.2. The chiller should be interlocked with pumps, valves and cooling towers to perform optimal operation. Because of high-power consumption, the chiller with an inverter should also be considered in order to achieve the goal of energy savings. Besides, the selected refrigerant must meet the regulation of environmental protection.

3.11.2.5 Cooling tower

Cooling towers use the convection of air to exchange the thermal waste from the water in the chiller condenser. There are three types of cooling tower designs using natural flow, jet flow and forced flow. Due to poor performance, the natural-flow and jet-flow cooling tower are no longer used. The forced-flow cooling towers perform satisfactorily and meet our temperature requirement of 320.5. The wet bulb temperature and the approach of cooling towers must be considered carefully and a perfect design can perform variable-speed fan control. Also a cooling tower may induce vibration and must therefore have a good support design with anti-vibration devices.

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3.11 Water-cooling System

3.11.2.6 Boiler
Hot water is required to ensure that the moisture content in air conditioners is small and that the temperature of the cooling-water system can be precisely controlled. A boiler with a silicon-controlled rectifier (SCR) is introduced to ensure the stability of the temperature within 500.3. The SCR has two mechanisms zero-voltage control and phase-voltage control that rectify the voltage and current to balance the thermal load output. A heat pump serving as a primary heater is employed for energy saving, because of its high Coefficient Of Performance (COP).

3.11.3 Evaluating capacity and saving energy 3.11.3.1 Evaluating capacity

Adequate cooling capacity and water flow should be evaluated carefully. These evaluations involve the temperature stabilization and energy-saving issues. For instance, a parallel-piping loop replaces a serial loop to maintain smaller temperature variations between inlet and outlet water. A smaller increment of temperature corresponds to a greater flow capacity. The constraints in variation of temperature also affect total thermal load. Table 3.11.3.1 presents the requirements of temperature and flow capacity. Table 3.11.3.1 Requirements of the cooling-water system Temperature 250.1 250.1 250.1 250.1 320.5 7.00.2 500.3 Pressure 7.50.1 kg/cm2 7.50.1 kg/cm2 7.50.1 kg/cm 7.50.1 kg/cm 3.00.2 kg/cm 3.50.2 kg/cm
2 2 2 2

Cu De-ionized Water AL De-ionized Water RF De-ionized Water Booster De-ionized Water Cooling Tower Water Chilled Water Hot Water

Capacity 1600 GPM 380 GPM 1200 GPM 700 GPM 9000 RT 7000 RT 1600 kW

2.50.2 kg/cm2

3.11.3.2 Saving energy

In an accelerator facility, most power is consumed by the air-conditioning and cooling-water systems. Chillers with a satisfactory Energy-Efficient Ratio (EER) and Coefficient Of Performance (COP) must be chosen carefully to save the long-term operation cost. Additionally, the chiller is an important subsystem for secondary heat exchange, which supplies chilled water to the air conditioner and de-ionized water. Figure 3.11.3.1 plots the relationship between the chiller efficiency and the load. Control logic is also employed to evaluate an optimal operating condition above 50 % thermal load and to yield acceptable efficiency. The alternative is to use inverters, which apply adaptive control logic to decrease the rotor speed so as to minimize power consumption, as shown in Figure 3.11.3.1. The starting mechanism is improved and sonic noise is also suppressed. The balance of flows among the pipelines is important. Pumps with inverters and accurate balance valves can serve the purpose of optimizing the water flow. Furthermore, piping with isolation from air can prevent thermal conduction, especially in chilled water at 7 and hot water at 50.

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Fig. 3.11.3.1 Relationship between chiller loading and efficiency [kW in figure]

3.11.4 Requirements of the control system and stability 3.11.4.1 Control system
The cooling-water system with a set of hybrid Supervisory Control and Data Acquisition (SCADA) systems includes extensive control logic. For example, pumps with inverters can be controlled using programmable logical controls (PLC); boilers are controlled via SCR driving; chillers have their own control panels and system sensors including pressure, flow, temperature, pH and conductivity are monitored via a Direct Digital Controller (DDC) or a Distributed Control System (DCS). These highly complicated hybrid-control systems ensure precise control and optimization. No single SCADA can manage the entire system. Finally, overall utility system will be integrated with the Experimental-Physics and Industrial-Control System (EPICS) of the accelerator. To achieve a purpose of integration, the overall control device must provide an open database connectivity or protocol. Such a device may be RS232, RS485 and GPIB hardware or DDE, OPC, Modbus, BACNet, PSP, TXT and ODBC software. Figure 3.11.4.1 shows the data flow that is finally integrated into the EPIC system. Furthermore, the optical-fiber network and database are installed to provide real-time data archiving. The trend-logger and data-analysis software as shown in Figure 3.11.4.2 are also developed to view, to compare, to analyze and to diagnose relations between devices at any time and anywhere.

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3.11 Water-cooling System

Fig. 3.11.4.1 Data flow of the control system

Fig. 3.11.4.2 Data analysis and user interface of archive viewer

3.11.4.2 Stability requirements

Thermal effects must be minimized to meet the requirements of high precision in the accelerator field. Table 3.11.1 presents the requirement of temperature stability for all subsystems.
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NSRRC - TPS Design Handbook - June 2008

The design guidelines of cooling water control are as follows. The de-ionized water system must include two heat exchangers for heating and cooling to avoid valve-closing problems and to support a mechanism for finely tuning the temperature within 0.1 . The nonlinear flow rate of heat exchanger and valves limit the control precision. Introducing a mixing buffer tank and periodic variation of temperature control via a heater enabling temperature variation better than 0.1 requirement is the long-term target in precision measurement system. The differences between the flows in the heat-loaded devices are likely to cause a problem of piping balance. Using a traditional bypass valve to balance the water flow still leaves a problem of unstable flow. Introducing an inverter can minimize all deficiency and stabilize the pressure control within 0.1 kg/cm2. Each valve for flow balance must be examined frequently and optimized appropriately, whenever the heat-loaded device is installed or removed. The shut-off status and the nonlinear flow of the control valve must be considered. As commercial large size control valves are normally not obtainable, using two control valves of smaller size with the same flow as a single large valve helps to optimize control.

3.11.5 Suppressing and preventing corrosion

As the cooling water circulates in the closed-loop water system year after year, acidic and alkaline ions might produce corrosion and deposition inside the piping; water treatment is thus important. Types of impurities in water include suspension, electrolyte, particles, microorganisms, organic substances and gases, which can be removed by individual physical or chemical methods, presented in Table 3.11.5.1. For example, a leakage of electric power from the dipole magnet may damage some devices via the cooling water and the water resistivity needs therefore to be controlled carefully. In the accelerator facility, the water is de-ionized. About 5 % of return water flows into the water-treatment system, which comprises 5-m filters, resin basins, 1-m filters, 0.1-m filters, membranes for dissolved oxygen and ultraviolet lamps. The added water is processed with a Reverse Osmotic (RO) system. The total system requirement must have a resistivity over 10 M-cm and dissolved oxygen less than 10 ppb as shown in Fig 3.11.5.1.

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3.11 Water-cooling System

Table

3.11.5.1

Foreign particles and removal techniques Gas

Suspensi Electrolyte Particles MicroOrganic on Organisms compounds Flocculation and precipitation filtering device Sand Filter Active Carbon Filter Ion-Exchange Device Carbon Dioxide Removal Tower Vacuum Degassing Tower Reverse Osmotic Device Ultra-filtration Device Micro filter Ultraviolet Sterilizer Dissolved-oxygen Membrane

Fig. 3.11.5.1 A 3-D layout of water treatment system

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