fabrizio.rossi@cern.ch
Updates on thermal tests
F. Rossi
September 5, 2012
1
Updates on thermal tests
EXPERIMENTAL PROGRAM FOR THERMAL TESTS
fabrizio.rossi@cern.ch
STEP 0 – Alignment tests
ALL THE TESTS ARE PERFORMED WITH NO VACUUM
ENVIRONMENT
Tamb = 20 & 40 °C
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 1 – Heating environment
STEP 2 – Heating only PETS
ENVIRONMENT
ENVIRONMENT
in steady-state conditions and by steps of 5 °C
HEATING
No active heating in RF structures
COOLING
Tamb = 20 °C
MEASUREMENTS
Tamb = 20 - 40 °C
in steady-state conditions
1. Temperature
HEATING
2. Alignment
• Laser tracker
• Romer arm
• WPS
• Micro-Triangulation
system
PETS
by steps up to 110 W/unit
COOLING
PETS
No active cooling in RF structures
Tamb = 20 °C
in steady-state conditions
HEATING
AS
by steps up to 400 W/unit
COOLING
AS
1. Temperature
2. Volumetric flow rate
3. Alignment
• Laser tracker
• Romer arm
• WPS
• Micro-Triangulation
system
< max calculated T
STEP 3 – Heating only AS
ENVIRONMENT
MEASUREMENTS
STEP 4 – Heating all module
ENVIRONMENT
MEASUREMENTS
Tamb = 20 - 40 °C
1. Temperature
in steady-state conditions and by steps of 5 °C
2. Volumetric flow rate
HEATING
3. Alignment
• Laser tracker
• Romer arm
• WPS
• Micro-Triangulation
system
AS + PETS + DBQ
by steps up to max power/unit
COOLING
AS + PETS + DBQ
< max calculated T
MEASUREMENTS
1. Temperature
2. Volumetric flow rate
3. Alignment
• Laser tracker
• Romer arm
• WPS
• Micro-Triangulation
system
< max calculated T
2
Updates on thermal tests
fabrizio.rossi@cern.ch
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. Numerical simulations
3
Updates on thermal tests
1. CLIC prototype module type 0
fabrizio.rossi@cern.ch
• First module type 0 ready by the end of
September (RF network, vacuum
network, compact load, cooling system
inside module, etc. )
4
Updates on thermal tests
2. LABORATORY ENVIRONMENT: air conditioning and ventilation system
fabrizio.rossi@cern.ch
T = 20 - 40 °C
v = 0.2 - 0.8 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
AIR
CIRCULATION
(v = 4 m/s)
AIR
COOLING
5
Updates on thermal tests
3. HEATING SYSTEM: heaters
fabrizio.rossi@cern.ch
•
G. Riddone, A. Samoshkin, CLIC
Test Module meeting 25.07.2011
Experimental conditions to be reproduced:
DBQ heaters
AS + PETS heaters
GROUP
HEATER
Q.TY
S/N
Dimensions (mm)
8 AS
1
0680/TC31-80/6065W240V/SF
Ø8 x 2032
2 PETS unit
1
S/N 0680/TS44-80/2175W240V/SF
Ø11.17 x 2032
2 DBQ
8+8=16
CSS-303200_220v
Ø12.7 x 76
TOTAL
6
Voltage
240V
AC
Pmax (W)
Imax (A)
Operating condition
6095
25.4
50%
2175
9.1
20%
3200
13.3
9%
11470
47.8
35%
Updates on thermal tests
3. HEATING SYSTEM: temperature sensors
fabrizio.rossi@cern.ch
PWM signal for controlling
the heaters
Duty cycle (%)
solid state relay
T = 10 s
heaters
1 DOF for each
heating subsystem (AS, PETS
and DBQ)
temperature
sensors
max. temp. limit: 50 °C
IL
All temperature sensors are
currently stored in the lab
7
Hardware thermal
interlock (2 for AS, 1 for
each PETS and DBQ)
Updates on thermal tests
3. HEATING SYSTEM: temperature sensors
fabrizio.rossi@cern.ch
1.2 m
• 5 thermocouples for each section
o
1m
Thermocouple type T (± 0.5 °C)
• 15 thermocouples in total
• Continuous acquisition during tests
1.3 m
2m
NI 9214
16-Channel Isothermal Thermocouple
Input Module
8
Updates on thermal tests
3. HEATING SYSTEM: software
fabrizio.rossi@cern.ch
• Modifications
to
the
previous
configuration are being integrated in the
software
Software interface
Panel for control valves
9
Updates on thermal tests
3. HEATING SYSTEM: status
fabrizio.rossi@cern.ch
• Heaters: DELIVERED
• RTD sensors: DELIVERED
• NI hardware: DELIVERED
• Thermocouples + DAQ card: mid of September
• Electric scheme (IL, SSR, etc.): end of September
10
Updates on thermal tests
4. COOLING SYSTEM
fabrizio.rossi@cern.ch
• 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
11
Updates on thermal tests
4. COOLING SYSTEM: AS
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TS7
TS6
TS4
TS1
TS2
12
Updates on thermal tests
4. COOLING SYSTEM: PETS
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TS23
TS24
TS22
TS25
TS26
TS17
13
Updates on thermal tests
4. COOLING SYSTEM: hydraulic circuit
fabrizio.rossi@cern.ch
safety valves
control valves
pressure
transducer
flow (+temperature)
transducer
PRV
Temperature
regulator
POWER SOCKET
Max. 32 A
Heat
exchanger
Inlet/outlet port
POWER SOCKET
Max. 16 A
Water tank
inlet/outlet hydraulic circuit
Water
pump
air cooling
14
Updates on thermal tests
4. COOLING SYSTEM: status
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• 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: end of September
• Supporting frames (beams, ladders, etc. ): end of September
• Electric scheme: end of September
15
Updates on thermal tests
FINAL LAYOUT
fabrizio.rossi@cern.ch
Supporting system for:
• Control valves (q.ty 7)
• Flow transducer (q.ty 1)
• Pressure sensor (q.ty 1)
• Improvement of
current electric
network of Lab
completed
SSR
POWER SOCKET
Max. 63 A
POWER SOCKET
Max. 63 A
DBQ heaters
PETS heater
AS heater
Temperature sensors (q.ty 29)
• Electric scheme for
control valves,
heaters, temperature
sensors, etc. (J. Blanc)
POWER SOCKET
Max. 32 A
POWER SOCKET
Max. 16 A
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)
16
Updates on thermal tests
SCHEDULE
fabrizio.rossi@cern.ch
• End of September:
o 1st TM0 ready
• End of October:
o Installation of air conditioning and ventilation system
o Preliminary tests for heaters, cooling system and data acquisition process
• Beginning of November:
o Preliminary thermal tests
17
Updates on thermal tests
5. NUMERICAL SIMULATIONS: thermo-mechanical modelling
fabrizio.rossi@cern.ch
Resulting temperatures inside the modules
Temperature [°C]
Max temp. of module
Water output temp. MB
Water output temp. DB
Prototype type 0
Deformed shape of prototype module type 0 due
to applied thermal RF loads (values in µm)
43
35
30
Resulting displacements on the DB and MB
lines due to thermal, vacuum and gravity loads
Displacements [m]
(location and load type)
MB (RF load)
DB (RF load)
MB (vacuum load)
DB (vacuum load)
MB (gravity load)
DB (gravity load)
Prototype type 0
183
47
30
131
27
40
(SAS = 820 W, PETS unit = 78 W, Tamb = 25 °C)
R. Raatikainen
18
Updates on thermal tests
5. NUMERICAL SIMULATIONS: hydraulic circuit modelling
fabrizio.rossi@cern.ch
CV1
CV2
CV3
CV4
PUMP
Q PRV
PPRV
CV5
EDMS 1233096
Q11
Q12
Q13
Q14
Q2
SAS
CLs
SAS
CLs
SAS
CLs
SAS
CLs
PETS unit PETS unit
L11, J11
L12, J12
L13, J13
L14, J14
CV7
WG1 WG2 WG3 WG4
L2, J2
Q = total flow rate [m3/h]
Q1i = flow rate for SAS [m3/h]
Q2 = flow rate for PETS unit [m3/h]
PPRV = set pressure for PRV [bar]
CV = control valve
SAS = super accelerating structure
PUMP = water pump
CL = compact load
Ji = pipe distributed energy loss (Li = pipe length)
WG = waveguide
19
Updates on thermal tests
5. NUMERICAL SIMULATIONS: hydraulic circuit modelling
fabrizio.rossi@cern.ch
CHARACTERISTICS OF PROPORTIONAL VALVES
#
BURKERT REFERENCE
kVs
[m3/h]
DN [mm]
CV1
CV2
CV3
Type 1
(2835, n. 175996)
0.12
2
Type 2
(2833, n. 175869)
0.04
1.2
Type 4
(2835, n. 176006)
0.45
CV4
CV5
CV7
𝑘𝑉 =
4
𝑘𝑉𝑠
∙V
10
kVs value: Flow rate value for water, measured at +20 °C
and 1 bar pressure differential over a fully opened valve
𝑄
0 − 10 𝑣𝑜𝑙𝑡 → 𝑘𝑉 → ∆𝑝 = ρ ∙
𝑘𝑉
kV = flow coefficient for a certain opening position of control valve
2
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]
20
Updates on thermal tests
5. NUMERICAL SIMULATIONS: hydraulic circuit modelling
fabrizio.rossi@cern.ch
Dependent variables (calculated)
Independent variables
CV1,..7 (% open)
pPRV [bar]*
Q [m3/h]
Q1i [m3/h]
ΔpCV1i [bar]
Q2 [m3/h]
ΔpCV2 [bar]
ΔpCV7 [bar]
50%
3.25
0.31
0.071
1.39
0.024
1.39
1.85
75%
1.45
0.31
0.071
0.62
0.024
0.62
0.82
100%
0.82
0.31
0.071
0.35
0.024
0.35
0.46
*all pressure values are relative to the atmospheric pressure
21
Updates on thermal tests
5. NUMERICAL SIMULATIONS: CFD model of air conditioning and ventilation system
fabrizio.rossi@cern.ch
• 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: 20 % (800 W)
22
Updates on thermal tests
5. NUMERICAL SIMULATIONS: CFD model of air conditioning and ventilation system
fabrizio.rossi@cern.ch
TM0
(2 x 1 x 1 m)
2m
14.6 m
4.6 m
Lab volume
Vertical cutview
2.3 m
vz = 0
(no-penetration condition)
vx = 0.5 m/s
Ti = 20 °C
•
•
Initial temperature = 25 °C
Time period = 300 s
vy = 0
(no-penetration condition)
y
vx = 0.5 m/s
x
z
23
Updates on thermal tests
5. NUMERICAL SIMULATIONS: CFD model of air conditioning and ventilation system
fabrizio.rossi@cern.ch
Ti = 20 °C
vx = 0.5 m/s
Q = 800 W
T = 20 °C
T = 23 °C
24
Updates on thermal tests
5. NUMERICAL SIMULATIONS: CFD model of air conditioning and ventilation system
fabrizio.rossi@cern.ch
Ti = 30 °C
vx = 0.7 m/s
Q = 1600 W
T = 30 °C
T = 35 °C
25
Updates on thermal tests
CONCLUSIONS: THERMAL TESTS STRATEGY
fabrizio.rossi@cern.ch
NAME
LAB CONFIGURATION
TT1
PARAMETERS
Heating
Cooling
Vacuum
TM0
V
V
X
TT2
TM0 + TM0
V
V
X
TT3
TM1 + TM0
V
V
V
TT3
TT2
26
Updates on thermal tests
THERMAL TESTS: people
fabrizio.rossi@cern.ch
Roberto Mondello
• Experimental tests
Shoaib Azhar
• Design and modelling
of cooling system
Ioannis Kossyvakis
• Software and data
acquisition
Lauri Kortelainen
• FEA analysis of
thermo-mechanical
behaviour of CLIC
modules
• CFD analysis
Jeremy Blanc
• Electric design of
data acquisition and
control system
Anastasia Xydou
• Theoretical and
experimental
investigation on the
bonding/brazing process
27
Updates on thermal tests
NEXT CLIC TEST MODULE MEETINGS
fabrizio.rossi@cern.ch
1. CLIC Test Module Meeting (19.09.2012)
• A. Schoaib: "Modelling of hydraulic system of CLIC prototype type 0"
2. CLIC Test Module Meeting (03.10.2012)
3. CLIC Test Module Meeting (17.10.2012)
4. CLIC Test Module Meeting (31.10.2012)
5. CLIC Test Module Meeting (14.11.2012)
6. CLIC Test Module Meeting (28.11.2012)
7. CLIC Test Module Meeting (12.12.2012)
28
Updates on thermal tests