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1 Updates on thermal tests
Updates on thermal testsF. Rossi
September 5, 2012
2 Updates on thermal tests
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
3. Alignment• Laser tracker• Romer arm• WPS• Micro-Triangulation
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
2. Volumetric flow rate
3. Alignment• Laser tracker• Romer arm• WPS• Micro-Triangulation
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
2. Volumetric flow rate
3. Alignment• Laser tracker• Romer arm• WPS• Micro-Triangulation
system
STEP 4 – Heating all module
ENVIRONMENT
Tamb = 20 - 40 °Cin steady-state conditions and by steps of 5 °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 0 – Alignment tests
ENVIRONMENT
Tamb = 20 & 40 °C
ALL THE TESTS ARE PERFORMED WITH NO VACUUM
3 Updates on thermal tests
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
4 Updates on thermal tests
1. CLIC prototype module type 0
• First module type 0 ready by the end of September (RF network, vacuum network, compact load, cooling system inside module, etc. )
5 Updates on thermal tests
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
6 Updates on thermal tests
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
7 Updates on thermal tests
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 (%)
8 Updates on thermal tests
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
9 Updates on thermal tests
3. HEATING SYSTEM: software
Software interface
Panel for control valves
• Modifications to the previous configuration are being integrated in the software
10 Updates on thermal tests
3. HEATING SYSTEM: status
• Heaters: DELIVERED
• RTD sensors: DELIVERED
• NI hardware: DELIVERED
• Thermocouples + DAQ card: mid of September
• Electric scheme (IL, SSR, etc.): end of September
11 Updates on thermal tests
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
14 Updates on thermal tests
4. COOLING SYSTEM: hydraulic circuit
Water pump
Heat exchanger
Temperature regulator
Inlet/outlet port
Water tank
POWER SOCKETMax. 16 A
POWER SOCKETMax. 32 A
air cooling
safety valves
control valves
flow (+temperature) transducer
PRV
pressure transducer
inlet/outlet hydraulic circuit
15 Updates on thermal tests
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: end of September
• Supporting frames (beams, ladders, etc. ): end of September
• Electric scheme: end of September
16 Updates on thermal tests
FINAL LAYOUT
AS heaterPETS heaterDBQ heaters
Temperature sensors (q.ty 29)
POWER SOCKETMax. 63 A
POWER SOCKETMax. 63 A
• Improvement of current electric network of Lab completed
POWER SOCKETMax. 16 A
POWER SOCKETMax. 32 A
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
17 Updates on thermal tests
SCHEDULE
• End of September:o 1st TM0 ready
• End of October:o Installation of air conditioning and ventilation systemo Preliminary tests for heaters, cooling system and data acquisition process
• Beginning of November:o Preliminary thermal tests
18 Updates on thermal tests
5. 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)
19 Updates on thermal tests
5. NUMERICAL SIMULATIONS: hydraulic circuit modelling
SAS CLs
SAS CLs
SAS CLs
SAS CLs
PETS unit PETS unit WG1 WG2 WG3 WG4
CV1
PUMPPRV
CV2
CV7
CV3
CV4
CV5
Q11
Q12
Q13
Q14
Q2
Q
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
PUMP = water pump
Ji = pipe distributed energy loss (Li = pipe length)
PPRV
SAS = super accelerating structure
CL = compact load
WG = waveguide
L11, J11
L12, J12
L13, J13
L14, J14
L2, J2
EDMS 1233096
20 Updates on thermal tests
5. NUMERICAL SIMULATIONS: hydraulic circuit modelling
# 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=𝑘𝑉𝑠10∙V
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]
21 Updates on thermal tests
5. NUMERICAL SIMULATIONS: hydraulic circuit modelling
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
Independent variables Dependent variables (calculated)
22 Updates on thermal tests
5. 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: 20 % (800 W)
23 Updates on thermal tests
5. NUMERICAL SIMULATIONS: CFD model of air conditioning and ventilation system
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
vy = 0(no-penetration condition)
vx = 0.5 m/s
vz = 0(no-penetration condition)
yz
x
• Initial temperature = 25 °C• Time period = 300 s
24 Updates on thermal tests
5. NUMERICAL SIMULATIONS: CFD model of air conditioning and ventilation system
T = 23 °C
T = 20 °C
Ti = 20 °Cvx = 0.5 m/sQ = 800 W
25 Updates on thermal tests
5. NUMERICAL SIMULATIONS: CFD model of air conditioning and ventilation system
Ti = 30 °Cvx = 0.7 m/sQ = 1600 W
T = 35 °C
T = 30 °C
26 Updates on thermal tests
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
27 Updates on thermal tests
THERMAL TESTS: people
Roberto Mondello• Experimental tests
Ioannis Kossyvakis• Software and data
acquisition
Shoaib Azhar• Design and modelling
of cooling system
Lauri Kortelainen• FEA analysis of
thermo-mechanical behaviour of CLIC modules
• CFD analysis
Anastasia Xydou• Theoretical and
experimental investigation on the bonding/brazing process
Jeremy Blanc• Electric design of
data acquisition and control system
28 Updates on thermal tests
NEXT CLIC TEST MODULE MEETINGS
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)