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Inner detector upgrade / IBL Activities on cooling circuits @ LAPP. Specifications Current R&D goals and program Fittings R&D Stainless steel cooling loop EB welding and brazing Bending Pipes order Qualification and quality assurance. LAPP team - PowerPoint PPT Presentation
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Theodore TodorovPixel mechanics november 8th 2010 1
Inner detector upgrade / IBL Activities on cooling circuits @ LAPP
LAPP team Jacky Ballansat, Patrick Baudin,Pierre-Yves David, Pierre Delebecque, Nicolas Massol,Thibaut
Rambure, Theodore Todorov,Tamer Yildizkaya
1. Specifications2. Current R&D goals and program3. Fittings R&D 4. Stainless steel cooling loop5. EB welding and brazing6. Bending7. Pipes order8. Qualification and quality assurance
Theodore TodorovPixel mechanics november 8th 2010
Cooling services for IBL
2
Inlet connectors
Outlet connectors
Theodore TodorovPixel mechanics november 8th 2010 3
Specifications (mainly for IBL)
Functionnal:Maximum leak flow (He) : 10-5 mbar.l.s-1 @1 barPresure (bar):
Xo (minimise) Radiation level : up to 1000 Mrad Temperature : mean = -35 °C (maxi +40 °C ; mini -60 °C)Pipes inner diameters : 0.8 to 3 mmPipe material : Titanium grade 2Pipe thickness : 0.1 to 0.3 mm depending on IDAvailable space for the fittings : less than F10 mm
Test Max design
service ultimate
service normal
CO2 150 100 70 20C3F8 25 ?? 15 10
1 - Specifications
Theodore TodorovPixel mechanics november 8th 2010
Connector positions for ID Upgrade
4
At end of stavesBoth SCT and Pixel
At PP1Both SCT and Pixel No manifolding in ID volumeManifold at PP1
Alternative for Pixel:• Patch panel with manifold at
end of pixel package• Small connectors between
staves and PPP• Larger connectors & pipes
between PPP and PP1
Theodore TodorovPixel mechanics november 8th 2010 5
EB welding tests Bending tests
2 - Current R&D goals and program
Ti Pipe/fitting linkage
Dismountable connexion of 2 pipes Bending of Ti pipes
Ti Electron beam welding
Custom fittingIndustrial fitting
STÄUBLI ?
Brazing
Brazing tests
R&D program @ LAPP
Fitting tests
Theodore TodorovPixel mechanics november 8th 2010 6
Until recently, we were focused on development of the Fitting, optimizing the geometry and the properties of the different surfaces.We performed test in order to validate the different designs, focusing on the minimal torque needed to achieve leak tightness.
Main developments
The last few months we have also worked on the "commissioning" of the fittings for routine use by other labs, for the cooling loop tests (stainless steel) and for the next stave prototypes (Ti).This involved studying the usable torque range, in order to deduce a recommended torque and the tooling.
2 - Current R&D goals and program
Theodore TodorovPixel mechanics november 8th 2010 7
Base line design
Test @cold• 4 combinations 1 MaleTA6V /1 femaleTA6V tested -
OK • 1 MaleTA6V /1 female Stainless steel tested - OK
3 –Fittings R&D
Test @room temperature• 21 combinations 1 MaleTA6V /1 femaleTA6V tested -
OK • 6 MaleTA6V /1 female Stainless steel tested – OK• 2 tests to find ultimate torque : 8 N.m• Many more combinations tested in variations of the
design
Tightness optimisation• Define the optimal parameters (friction on the surfaces and
the threads• Tooling needed to control the torque
Theodore TodorovPixel mechanics november 8th 2010 8
Spherical designToroid design
Misalignment influence (5°)
3 –Fittings R&D
Theodore TodorovPixel mechanics november 8th 2010 9
Tests @ cold3 –Fittings R&D – tests @cold
Theodore TodorovPixel mechanics november 8th 2010 10
1. Hydraulic pressure test @ 150 bars @ room temp2. He Leak test @20 bars @ room temp3. Cooling from 20°C to -50°C4. He Leak test @20 bars @ -50°C5. Pressure test @ 150 bars @ -50°C6. He Leak test @20 bars @ -50°C7. Heating from -50°C to 20°C
General tests procedure @ cold
P
T20
-50
20
150
2 3 4 5 6 71
H20 He
3 –Fittings R&D – tests @cold
Theodore TodorovPixel mechanics november 8th 2010 11
Next steps The base line solution for PP1 is defined
Increase the number of tested combinations with the base line designKeep on performing cold testsThermal cycling (100 cycles)Simple tests with liquid CO2 (bottle)Determine the limits of use for pressureStudy the tooling needed to control the torqueStudy the integration aspects
3 –Fittings R&D – next steps
Optimized design will be studied
OD reduced to 8mm (maybe 7 mm)Reduction of the amount of material
Theodore TodorovPixel mechanics november 8th 2010 12
Cooling loop production and tests3 –Stainless steel cooling loops
Goal Cooling loop made of stainless steel will be tests @ Nikhef
Production Pipes from NikhefFitting and bushings made @LAPPBrazing made by Bodycote -> new surface treatment made of graphiteProduction samples made of same components and brazed at the same time as the cooling lines tested @LAPP (QA procedure)Should be delivered on Week 46
Fitting tests Design developed for Ti -> need to be check for stainless steel
Theodore TodorovPixel mechanics november 8th 2010 13
Stainless steel fitting
Test @cold• To be done
3 –Stainless steel cooling loops
Test @room temperature• 13 combinations 1 MaleTA6V /1 femaleTA6V tested - OK • 2 tests to find ultimate torque : 8 N.m ->no leak• Dismounting/mounting torque 4 N.m –No leak• Dismounting/mounting torque 2 N.m –leak flow few 10-7
Kept under 20 Bar He 2 hours : leak flow -> few 10-9 to few 10-8
Kept under 20 Bar He 17 hours : leak flow -> same evolution (He diffusion around the leak detector ?)
• 20 mounting/dismounting : OK
Theodore TodorovPixel mechanics november 8th 2010 14
4 –EB welding and brazing
Status 30 samples brazed and 30 EB welded, changing the material and the cleaning
FinishedBrazed an EB samples were tested @RT ->OKCold tests on part of the brazed samples ->OK
In progressFinish the cold tests (mostly finished, OK) Perform thermal cyclingMetallographic analysis to be performed @CERN
Theodore TodorovPixel mechanics november 8th 2010 15
Stainless steel cooling loops brazing• Temperature : > 1000 °C
• Material 60%cupper / 40% Gold
Issue : capillaries may be filled upID 0.8 mm
ID 2 mm
4 –EB welding and brazing
Theodore TodorovPixel mechanics november 8th 2010 16
4 –EB welding and brazing-in situ brasing machine
GoalBrazing the pipes during integration
DeviceVacuum chamber + heater (induction, infra red ?)Experts from Bodycote + ….
LimitationsEffects on the environment ?Control of the brazing ?
!! Brainstorming !!
Vacuum chamber
Heaters