1 21-09-2012 «BE-RF-PM» CLIC prototype two-beam modules Thermal test planning G. Riddone, F. Rossi Introduction Thermal tests 1.Environment 2.Heating and

121-09-2012 «BE-RF-PM»

CLIC prototype two-beam modulesThermal test planning

G. Riddone, F. Rossi

• Introduction• Thermal tests

1. Environment2. Heating and cooling system 3. Measurements4. Numerical simulations

• Schedule

221-09-2012 «BE-RF-PM»

Prototype two-beam modules

• LAB version• 4 modules, 2 sequences foreseen

• Type 0, Type 0, Type 1, Type 4• Type 0, Type 1. Type 0, Type 4

• CLEX version• 3 modules

• Type 0, Type 0, Type 1

Demonstration of the two-beam module design (from single technical system to complete modules)This implies the assembly and integration of all components and technical systems, such as RF, magnet, vacuum, alignment and stabilization, in the very compact 2-m long two-beam module

Demonstration of the two-beam acceleration with beam and RF with real modulesAddress other feasibility issues in an integrated approach

2010-2014+

321-09-2012 «BE-RF-PM»Thermal tests planning for CLIC prototype module type 0

Prototype modules – LAB version

1) Currently under assembly and installation

2) Main components under procurement

3) Last module

TM1 TM0 TM0 TM4

421-09-2012 «BE-RF-PM»

Prototype modules – CLEX version

TM0 TM0TM1

Design finalization, Supporting/alignment system under fabrication

beam

2 1

521-09-2012 «BE-RF-PM»

Prototype modules - Status

• TM0#1 Lab: • First 2-m accelerating structure stack completed (EBW last week) • RF network under final installation• During assembly, validation of girder and supporting system

• Several alignment/positioning tests successfully performed • Next main step: Thermal tests

• TM0#1 CLEX• First double length from CIEMAT fully assembled• Integrated supporting system (including girder, positioning system and Rf

structure supports)under fabrication (ZTS-Boostec) • Superstructures under machining at VDL

621-09-2012 «BE-RF-PM»

Thermal tests

• Program• Presented and validated at CTC in July 2012

• Main actors for tests and analysis• F. Rossi • L. Kortelainen• I. Kossyvakis• R. Mondello• A. Xydou


CLIC prototype modules - LAB

• Assembly and integration of all technical systems (dummy RF structures and quadrupoles can be used – real dead weight and interfaces to other systems)

• Validation of different types of girders and movers• Full metrology of the module components• Pre-alignment of girders and RF structures on girders in the module environment,

including fiducialisation• Validation of interconnections and vacuum system • Stabilization of main beam quad in the module environment• Vibration study of all systems and identification of vibration sources• Measurement of resonant frequencies (both in lab and in the tunnel/underground

area)• Simulation of several thermal cycles: measurements of thermal transients (e.g. how

long it takes to achieve a new equilibrium state), fiducialisation verification• Transport of the module and verification of alignment

Recall of main objectives


Experimental program for thermal tests

HEATING

No active heating in RF structures

COOLING

No active cooling in RF structures

MEASUREMENTS

1. Temperature

2. Alignment• Laser tracker• Romer arm• WPS• Micro-Triangulation

system

STEP 1 – Heating environment

ENVIRONMENT

Tamb = 20 - 40 °Cin steady-state conditions and by steps of 5 °C

HEATING

PETSby steps up to 110 W/unit

COOLING

PETS< max calculated T

MEASUREMENTS

1. Temperature

2. Volumetric flow rate


system

STEP 2 – Heating only PETS

ENVIRONMENT

Tamb = 20 °Cin steady-state conditions

HEATING

ASby steps up to 400 W/unit

COOLING

AS< max calculated T

MEASUREMENTS

1. Temperature



system

STEP 3 – Heating only AS

ENVIRONMENT

Tamb = 20 °Cin steady-state conditions

HEATING

AS + PETS + DBQby steps up to max power/unit

COOLING

AS + PETS + DBQ< max calculated T

MEASUREMENTS

1. Temperature



system

STEP 4 – Heating all module

ENVIRONMENT

Tamb = 20 - 40 °Cin steady-state conditions and by steps of 5 °C

G. Riddone, A. Samoshkin, CLIC Test Module meeting 25.07.2011

MEASUREMENTS

a. Comparison between laser tracker and WPS measurements (no movements of girders)

b. Alignment tests by moving girders via actuators and comparison between laser tracker and WPS measurements

STEP 0 – Alignment tests

ENVIRONMENT

Tamb = 20 & 40 °C

ALL THE TESTS ARE PERFORMED WITH NO VACUUM


TOPICS

Topics and updates concerning the status of:

1. CLIC prototype module type 0

2. Laboratory environment (air conditioning, ventilation, etc. )

3. Heating system (heaters, temperature sensors, etc.)

4. Cooling system (water supply, inlet/outlet cooling circuits, control valves, etc.)

5. Measurements

6. Numerical simulations


1. CLIC MODULESCLIC module type 1

Constraints for CLIC module type 1


1. CLIC PROTOTYPE MODULE TYPE 0

Cooling circuit

Vacuum flange

RF flange

Manifold

Interconnection flange

RF waveguide

Accelerating structure (AS)Super-accelerating

structure (SAS)

Test Module type 0 (TM0)

D. Gudkov

Tolerance Mock-up Real

Dext ± 4 μm ± 2.5 μm

Ra 0.4 μm 0.025 μm

Flatness 10 μm 1 μm



• First CLIC prototype module type 0 READY

• Assembly of RF network, vacuum network, compact load, cooling system inside module, etc. in progress

EBW of 2 stacks



4. VACUUM BRAZING

7. CLEANING

9. VACUUM BRAZING

6. MACHINING

3. CLEANING

10. VACUUM BRAZING

12. VACUUM BRAZING

13. VACUUM BRAZING

4 4 4 44

4

4

5. QC(Cooling

circuit test)

Vacuum test14. QUALITY CONTROL

11. MACHINING

8. VACUUM BRAZING



32 32 8

15. VACUUM BRAZING

17. VACUUM BRAZING

19. EBW

20. TIG WELDING

1. Vacuum test2. Cooling circuit test3. Fiducialisation

18. QUALITY CONTROL

TYPE 2 TYPE 1 TYPE 1 TYPE 1 TYPE 3 TYPE 1 TYPE 1 TYPE 1

1. Vacuum test2. Cooling circuit test3. Fiducialisation

21. QUALITY CONTROL Vacuum test

STACK 1 STACK 2

16. QUALITY CONTROL Vacuum test Vacuum test



Real super-AS for CLEX

• CLIC prototype module type 1 will be also used to test real RF structures:

o 1 super-AS having real RF geometry

o PETS on-off mechanism

• These tests are necessary to validate current assembly procedures developed for mock-ups as well as to check current alignment requirements

• Real RF structures used for TM1 can be also used for RF tests in CLEX

PETS on-off mechanism


TOPICS






5. Measurements



2. LABORATORY ENVIRONMENT: air conditioning and ventilation system

AIR COOLING

T = 20 - 40 °Cv = 0.2 - 0.8 m/s AIR

CIRCULATION (v = 4 m/s)

• Air conditioning and ventilation system to reproduce thermal conditions inside CLIC tunnel

• Installation: end of October 2012

• Cupboards inside and outside experimental area are being moved to bld. 162

Transport test


TOPICS






5. Measurements



3. HEATING SYSTEM: heaters• Experimental conditions to be reproduced:

G. Riddone, A. Samoshkin, CLIC Test Module meeting 25.07.2011

GROUPHEATER

Q.TY S/N Dimensions (mm) Voltage Pmax (W) Imax (A) Operating condition

8 AS 1 0680/TC31-80/6065W240V/SF Ø8 x 2032240V

AC

6095 25.4 50%

2 PETS unit 1 S/N 0680/TS44-80/2175W240V/SF Ø11.17 x 2032 2175 9.1 20%

2 DBQ 8+8=16 CSS-303200_220v Ø12.7 x 76 3200 13.3 9%

TOTAL 11470 47.8 35%

DBQ heaters

AS + PETS heaters


3. HEATING SYSTEM: temperature sensors

solid state relay

heaters

ILHardware thermal

interlock (2 for AS, 1 for each PETS and DBQ)

max. temp. limit: 50 °C

All temperature sensors are currently stored in the lab

1 DOF for each heating sub-

system (AS, PETS and DBQ)

temperature sensors

PWM signal for controlling the heaters

T = 10 s

Duty cycle (%)


3. HEATING SYSTEM: temperature sensors

2 m

1.2 m

1 m

1.3 m

• 5 thermocouples for each section

o Thermocouple type T (± 0.5 °C)

• 15 thermocouples in total

• Continuous acquisition during tests

NI 921416-Channel Isothermal Thermocouple Input Module


3. HEATING SYSTEM: electronics

Data acquisition and control cards

24 V power supplies

Digital control electronics for proportional valves

Computer for data acquisition

and control

• Installation of electronics for thermal tests in progress


3. HEATING SYSTEM: software

Software interface

Panel for control valves

• Modifications to the previous configuration are being integrated in the software


3. HEATING SYSTEM: status

• Heaters: DELIVERED

• RTD sensors: DELIVERED

• NI hardware: DELIVERED

• Thermocouples + DAQ card: DELIVERED

• Electric scheme (IL, SSR, etc.): COMPLETED


TOPICS






5. Measurements



4. COOLING SYSTEM

•Demineralized water

•Nominal volumetric flow rate: 0.36 m3/h

•Water inlet temperature: 25 °C

•Water outlet temperature: ~45 °C

•Max. pressure allowed: 5 bar


4. COOLING SYSTEM: AS

TS7

TS1 TS2

TS6

TS4


4. COOLING SYSTEM: PETS

TS17

TS22

TS23

TS24

TS25

TS26


4. COOLING SYSTEM: hydraulic circuit

Water pump

Heat exchanger

Temperature regulator

Inlet/outlet port

Water tank

POWER SOCKETMax. 16 A


air cooling

safety valves

control valves

flow (+temperature) transducer

PRV

pressure transducer

inlet/outlet hydraulic circuit


4. COOLING SYSTEM: status

• Water supply: DELIVERED

• Hydraulic parts (pipes, elbows, etc. ): DELIVERED

• Control valves: DELIVERED

• Measuring devices (pressure transducer, flow rate transducer, etc. ): DELIVERED

• PRV: DELIVERED

• Safety valves: DELIVERED

• Supporting frames (beams, ladders, etc. ): end of September

• Electric scheme: COMPLETED


FINAL LAYOUT

AS heaterPETS heaterDBQ heaters

Temperature sensors (q.ty 29)



• Upgrade of current electric network of Lab completed



Supporting system for:• Control valves (q.ty 7)• Flow transducer (q.ty 1)• Pressure sensor (q.ty 1)

• Electric scheme for control valves, heaters, temperature sensors, etc. (J. Blanc)

CUPBOARD for:• NI cDAQ-9178 8 slots (q.ty 1)• NI cDAQ-9174 4 slots (q.ty 1)• 24 V supply• Digital control electronics for proportional valves (q.ty 7)

SSR


TOPICS






5. Measurements



5. MEASUREMENTSMeasuring arm Romer Multi Gage• With a length of 60 cm, this kind

of portable CMM allows to measure fiducials by probing or by one point. According to Romer, the maximum permissible error is less than 18 µm.

Laser tracker Leica AT401• According to simulation calculations, the

expected accuracy of AT401 measurements on a girder and its components is about 5 µm rms (up to 40 °C).

• Fiducials are measured with respect to a fixed reference system.

• Measurements taken from different stations can be elaborated and combined together.

• The measuring device must be at the same temperature of the parts to be measured.

Micro-Triangulation system• The principle of Micro-

Triangulation is to use the full potential of a theodolite by substituting a CCD camera instead of the eye of an operator.

• This method has clearly demonstrated its high precision capability on the 2 m long mock-up where a precision about 10 µm along each axis has been obtained in the determination of the illuminated fiducials locations.

Fiducials dedicated to Micro-triangulationThe aluminium main part of this fiducial (made in CERN) is equipped with a breakthrough ceramic ball with a diameter of 8 mm, a removable drawer which contain a LED allows to illuminate the accurate ball.

S. Griffet et al.

WPS system


TOPICS






5. Measurements



6. NUMERICAL SIMULATIONS: thermo-mechanical modelling

Deformed shape of prototype module type 0 due to applied thermal RF loads (values in

µm)

Displacements [m]

(location and load type)Prototype type

0

MB (RF load) 183

DB (RF load) 47

MB (vacuum load) 30

DB (vacuum load) 131

MB (gravity load) 27

DB (gravity load) 40

Resulting displacements on the DB and MB lines due to thermal, vacuum and

gravity loads

Temperature [°C]Prototype type

0

Max temp. of module 43

Water output temp. MB 35

Water output temp. DB 30

Resulting temperatures inside the modules

R. Raatikainen

(SAS = 820 W, PETS unit = 78 W, Tamb = 25 °C)


6. NUMERICAL SIMULATIONS: hydraulic circuit modelling

SAS CLs

SAS CLs

SAS CLs

SAS CLs

PETS unit PETS unit WG1 WG2 WG3 WG4

PUMPPRV

CV2

CV7

CV3

CV4

CV5

Q1

Q2

Q3

Q4

Q5

Q

Q = total flow rate [m3/h]

Q1 ~ Q4 = flow rate for SAS [m3/h]

Q5 = flow rate for PETS unit and wave guides [m3/h]

PPRV = set pressure for PRV [Pa]

CV = control valve

PUMP = water pump

fi = pipe distributed energy loss (Li = pipe length)

Ki = Pipe fitting coefficient (ni = Number of fittings)

PPRV

SAS = super accelerating structure

CL = compact load

WG = waveguide

L1, f1

L2, f2

L3, f3

L4, f4

L5, f5

CV1n1, K1

n2, K2

n3, K3

n4, K4

n5, K5



# BURKERT REFERENCE kVs [m3/h] DN [mm]

CV1

Type 1(2835, n. 175996) 0.12 2

CV2CV3CV4

CV5 Type 2(2833, n. 175869) 0.04 1.2

CV7 Type 4(2835, n. 176006) 0.45 4

kVs value: Flow rate value for water, measured at +20 °C and 1 bar pressure differential over a fully opened valve

CHARACTERISTICS OF PROPORTIONAL VALVES

[0−10𝑣𝑜𝑙𝑡 ]→𝑘𝑉→∆𝑝= ρ∙( 𝑄𝑘𝑉)2

kV = flow coefficient for a certain opening position of control valve

V = input voltage signal for control valve [0 - 10 volt]

Δp = pressure drop across control valve for a certain opening position [bar]

ρ = water density [kg/dm3]



ΔPcv = Pressure Drop across control valve [bar]

ΔPf = Total Distributed Pressure Drop due to pipe friction

ΔPc = Total Pressure Drop in component/fittings

V = control valve set voltage

• On the basis of the operating condition of the control valves (i.e. input voltage), the pressure to be set at PRV depends on the requested flow rate inside the cooling system.

• For each control valve, a desired voltage input can be considered into the simulation. The corresponding flow rates inside each branch of the circuit are calculated consequently.

Inputs

V PPRV

(volts) [bar]

4 5.5

6 2.6

8 1.8

10 1.6

Results

Q Q1~4 ΔPCV1~4 ΔPf1~4 ΔPc1~4 Q5 ΔPCV5 ΔPf5 ΔPc5 ΔPCV7 ΔPc7

[m3/h] [m3/h] [bar] [bar] [bar] [m3/h] [bar] [bar] [bar] [bar] [bar]

0.360 0.083 2.100 0.204 0.253 0.0300 2.500 0.035 0.024 2.840 0.100

0.360 0.082 0.884 0.201 0.248 0.033 1.275 0.041 0.029 1.217 0.100

0.360 0.081 0.536 0.199 0.245 0.035 0.902 0.046 0.033 0.749 0.100

0.360 0.081 0.457 0.198 0.244 0.036 0.815 0.048 0.035 0.642 0.100



PUMPPRV

FT PT

CV

PT

FT = flow transducerPRV = pressure regulating valvePT = pressure transducerCV = control valve

• Preliminary test on a simplified version of the cooling system for:

o Testing data acquisition and control systemo Testing electronicso Measuring Kv of control valves

Characteristic curve of control valves to be measured


6. NUMERICAL SIMULATIONS: CFD model of air conditioning and ventilation system

• Total RF power per module: 4 kW

• Number of modules: 4

• Assumptions per module:

o Heat dissipation to cooling system: 80 % (3200 W)

o Heat dissipation to air: 15-20 % (600-800 W)

QRF

Qair

Qcooling Qair



2 m

4.6 m

14.6 m

2.3 mVertical cutviewLab volume

TM0(2 x 1 x 1 m)

vx = 0.5 m/sTi = 20 °C

Wall(no penetration condition)

vx = 0.5 m/s

Wall(no penetration condition)

yz

x

• Initial temperature = 25 °C• Time period = 300 s



T = 23 °C

T = 20 °C

Ti = 20 °Cvx = 0.5 m/sQ = 800 W


CONCLUSIONS: THERMAL TESTS STRATEGY

NAME LAB CONFIGURATIONPARAMETERS

Heating Cooling Vacuum

TT1 TM0 V V X

TT2 TM0 + TM0 V V X

TT3 TM1 + TM0 V V V

TT2

TT3


SCHEDULEHEATING SYSTEM• Heaters: DELIVERED• RTD sensors: DELIVERED• NI hardware: DELIVERED• Thermocouples + DAQ card: DELIVERED• Electric scheme (IL, SSR, etc.): COMPLETED

COOLING SYSTEM• Water supply: DELIVERED• Hydraulic parts (pipes, elbows, etc. ): DELIVERED• Control valves: DELIVERED• Measuring devices (pressure transducer, flow rate transducer, etc. ): DELIVERED• PRV: DELIVERED• Safety valves: DELIVERED• Supporting frames (beams, ladders, etc. ): end of September• Electric scheme: COMPLETED

LAB ENVIRONMENT• Air conditioning and ventilation system: end of October

o Main work for HVAC installation should start W42o Some smaller work should be done before with limited

impact for the lab (move the compressed air supply, remove the sink/ fridge and furniture, move some lighting fixtures)

Preliminary thermal

tests start:

November 2012


SCHEDULE

Documents

1 21-09-2012 «BE-RF-PM» CLIC prototype two-beam modules Thermal test planning G. Riddone, F. Rossi Introduction Thermal tests 1.Environment 2.Heating and