Coolant Systems & Process Control Section (CSPCS)

The Indus accelerator machine houses two synchrotron light sources. The accelerator subsystems like Magnets, Power supplies, Photon Absorbers, RF cavities etc. get heated during operation either due to joules heating effect or because of radiation. Thermal consistency of accelerator systems is very imperative for maintaining beam energy and position stability which are remarkably helpful by providing proper cooling arrangement with precise temperature stability. As the Low Conductivity Water (LCW) flows through the machine cooling circuits which are subjected to radiation environment. The water chemistry is also an important factor to mitigate the possibility of having activation products. Deionized (DI) water is used as LCW coolant for cooling the accelerator subsystems due to following reasons:

• To avoid leakage of electrical current from the machine component’s metal surface :
  Since, coolant water flows through the electrical power carrying metal core surfaces, a part of electrical current can be carried away by the coolant water, if the coolant is conducting.
  
  
• To avoid the electrical short-circuiting between system components :
  Since various accelerator components are operated at different electrical potential, conductive water can cause short-circuiting and creating unsafe working condition which can damage the system components.
  
  
• To avoid corrosion / scaling effect on wetted surfaces :
  Dissolved salts and impurities can increase coolant carrying surface corrosion (damaging the component being cooled) or scaling (hampering effective heat transfer during cooling). DI water has minimal salt content & provide clean working environment.
  
  

More detailed information about CSPCS is as below:

• Mandate
• Specifications
• Development Activities
• Publications
• Team members
 

List of Installed & Operating LCW Plants:

Sl No	Location	Capacity of Plant
1	Indus – 1 LCW Plant	600 kW
2	Indus – 2 LCW Plant	4000 kW
3	IMA Building LCW Plant	300 KW
4	Magnet Testing Lab Plant	200 KW
5	ADL Building Cooling System	20 kW
6	ARPF Site LCW Plant	300 kW

List of Installed & Operating Precision Cooling Systems (PCS) & Chiller Plants:

Sl No	Details	No of Units	Max Cooling Capacity
1	Indus-1 PCS units	3	10 kW
2	Indus-2 PCS units	8	500 kW
3	Indus-2 Chiller Plants	2	2000 kW

Specification for LCW Plant for Accelerator Machine:

Plant Details	Indus-1	Indus-2 SRS	Indus-2 RF,PS,TL3
Plant Cooling Capacity	600 KW	1000 KW	2000
Electrical Power	120 kVA	850 kVA
Primary Circuit
Flow Rate	60 m3/hr	110 m3/hr	170 m3/hr
Supply Pressure	10 kg/cm2	10 kg/cm2	10 kg/cm2
Inlet Temperature	30 ° C ± 1 °C	26 ° C ± 0.5 °C	26 ° C ± 1 °C
Electrical Conductivity	< 1 µS/cm	< 1 µS/cm	< 1 µS/cm
Surge Tank Volume	2 x 5.0 m3	7.5 m3	7.5 m3
Secondary Circuit
Flow Rate (Max)	120 m3/hr	160 m3/hr	300 m3/hr
Supply Pressure	5 kg/cm2	5 kg/cm2	5 kg/cm2
Hardness	< 5 ppm	< 5 ppm	< 5 ppm
DI Circuit
Flow Rate	0.5 m3/h (1m3/h max)		1 m3/h (3 m3/h max)
Output Between Regenerations (OBR)	~ 20 m3		~ 40 m3

LCW Plant Layout Photographs / Figures:


Figure1: Schematic view of the LCW Plant with the general layout of Primary & Secondary systems with CT


Figure 2: LCW Plant Service block Area view with Primary & Secondary Pumping Systems.


Figure 3: LCW Plant Indus-2 SRS cooling System view with PHE.


Figure 4: LCW Plant Primary Cooling System view.


Figure 5: LCW Plant Heat Exchanger view with control valves arrangement


Figure 6: Refrigeration Cooling Chiller Units view in Indus-2 LCW Plant.


Figure 7: LCW Plant Cooling Tower view located on the terrace with makeup Tank


Figure 8: LCW Water Treatment Plant view

Refrigeration based Precision Cooling Systems (PCS):

Indus-1 Accelerator Machine related Chiller units
Table-1

S.No.	Chiller Unit Details	Qty	Cooling Capacity (Each)
1	Chiller Units for  Microtron RFC	2	1 kW
2	Ring Chiller for  Booster RFC	1	3  kW
3	Chiller-1 for  SRS Ring RFC	1	3  kW
4	Chiller-2 for  SRS Ring RFC (standby)	1	10  kW

Indus-2 Accelerator Machine related Chiller units
Table-2

S. No.	Chiller Unit Details	Qty	Cooling Capacity (Each)
PCS for RF Cavity (RFC) cooling
	Chiller unit Type -1 for LS-8 RFC	3	65 kW
	Chiller unit Type-2 for	2	90 kW
	Chiller unit type-3	2	210  kW
Chiller Plant for SRS Cooling System
	Air Cooled Chiller units	2	1000 kW

Specification of Precision Cooling Units installed in Indus:
Table-3

Parameters	Microtron	Booster	Indus-1SRS	Indus-2 SRS
Pump Flow Rate	5 LPM	30 LPM	40 LPM	12 m3/h
Temperature Range	20 ~ 30 ºC	20 ~ 30 ºC	20 ~ 31 ºC	25 – 79 ºC
Temperature Stability	± 0.5 ºC	± 0.5 ºC	± 0.5 ºC	± 0.1 ºC
Refrigerant in Use	R-22	R-22	R-22	R-22
Condenser	Air Cooled	Air Cooled	Air Cooled	Air Cooled
Evaporator	Dipped Tube	Dipped Tube	Brazed PHE	Brazed PHE
Heater Bank	NIL	NIL	2 KW	32 kW, Insertion Type
Temperature Control	ON/OFF Ctrl	ON/OFF Ctrl	PID Control	PID Control

Precision Cooling Systems photographs and performance graphs:


Figure 9: Precision Cooling Systems (PCS) for Indus-2 RF Cavity conditioning


Figure 10: Precision Cooling Systems operation mimic view


Figure 11: PCS supply temperature stability within ±0.1 ºC during Indus-2 operation at 2.5 GeV.

• Development of water analysis Lab as shown in Fig-12 & Fig. 13 for the coolant quality control, analysis of deposits and efficiency measurement of treatment media.
  
  
• Development of Flow Calibration Rig as shown in Fig. 14 to calibrate Flow Meters & Flow Switches
  
  
• Development of Thermal Lab as shown in Fig. 15 for checking the PCS operating parameters and development activities.
  
  
• Development of machine shop and fabrication area as shown in Fig. 16 to carryout CSPCS related maintenance works.
  
  
• Development of Hydraulic Lab as shown in Fig, 17 for hydraulic cum pneumatic testing of Plant related valves & pipeline fittings.
  
  
• Development of Instrumentation Lab for Calibration of Temperature sensor, transmitter & Controllers.
  
  
• Development for Utilization of TESS (Thermal Energy Storage System) in LCW Plant.
  
  
• Development of PHE plates conditioning setup for improving the heat transfer efficiency.
  
  

Figure 12: LCW Plant Water Analysis Laboratory.


Figure13: LCW Plant Instrumental Analysis Laboratory.


Figure 14: Flow Calibration Lab Test Setup


Figure 15: Thermal Lab Test Facility in CSPCS


Figure 16: CSPCS Workshop & Maintenance Facility


Figure 17: Hydraulic cum Pneumatic Valve Test Bench facility in CSPCS