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
721-09-2012 «BE-RF-PM»Thermal tests planning for CLIC prototype module type 0
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
821-09-2012 «BE-RF-PM»Thermal tests planning for CLIC prototype module type 0
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
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
921-09-2012 «BE-RF-PM»Thermal tests planning for CLIC prototype module type 0
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
1021-09-2012 «BE-RF-PM»Thermal tests planning for CLIC prototype module type 0
1. CLIC MODULESCLIC module type 1
Constraints for CLIC module type 1
1121-09-2012 «BE-RF-PM»Thermal tests planning for CLIC prototype module type 0
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
1221-09-2012 «BE-RF-PM»Thermal tests planning for CLIC prototype module type 0
1. CLIC PROTOTYPE MODULE TYPE 0
• 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
1321-09-2012 «BE-RF-PM»Thermal tests planning for CLIC prototype module type 0
1. CLIC PROTOTYPE MODULE TYPE 0
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
1421-09-2012 «BE-RF-PM»Thermal tests planning for CLIC prototype module type 0
1. CLIC PROTOTYPE MODULE TYPE 0
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
1521-09-2012 «BE-RF-PM»Thermal tests planning for CLIC prototype module type 0
1. CLIC PROTOTYPE MODULE TYPE 1
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
1621-09-2012 «BE-RF-PM»Thermal tests planning for CLIC prototype module type 0
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
1721-09-2012 «BE-RF-PM»Thermal tests planning for CLIC prototype module type 0
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
1821-09-2012 «BE-RF-PM»Thermal tests planning for CLIC prototype module type 0
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
1921-09-2012 «BE-RF-PM»Thermal tests planning for CLIC prototype module type 0
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
2021-09-2012 «BE-RF-PM»Thermal tests planning for CLIC prototype module type 0
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 (%)
2121-09-2012 «BE-RF-PM»Thermal tests planning for CLIC prototype module type 0
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
2221-09-2012 «BE-RF-PM»Thermal tests planning for CLIC prototype module type 0
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
2321-09-2012 «BE-RF-PM»Thermal tests planning for CLIC prototype module type 0
3. HEATING SYSTEM: software
Software interface
Panel for control valves
• Modifications to the previous configuration are being integrated in the software
2421-09-2012 «BE-RF-PM»Thermal tests planning for CLIC prototype module type 0
3. HEATING SYSTEM: status
• Heaters: DELIVERED
• RTD sensors: DELIVERED
• NI hardware: DELIVERED
• Thermocouples + DAQ card: DELIVERED
• Electric scheme (IL, SSR, etc.): COMPLETED
2521-09-2012 «BE-RF-PM»Thermal tests planning for CLIC prototype module type 0
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
2621-09-2012 «BE-RF-PM»Thermal tests planning for CLIC prototype module type 0
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
2721-09-2012 «BE-RF-PM»Thermal tests planning for CLIC prototype module type 0
4. COOLING SYSTEM: AS
TS7
TS1 TS2
TS6
TS4
2821-09-2012 «BE-RF-PM»Thermal tests planning for CLIC prototype module type 0
4. COOLING SYSTEM: PETS
TS17
TS22
TS23
TS24
TS25
TS26
2921-09-2012 «BE-RF-PM»Thermal tests planning for CLIC prototype module type 0
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
3021-09-2012 «BE-RF-PM»Thermal tests planning for CLIC prototype module type 0
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
3121-09-2012 «BE-RF-PM»Thermal tests planning for CLIC prototype module type 0
FINAL LAYOUT
AS heaterPETS heaterDBQ heaters
Temperature sensors (q.ty 29)
POWER SOCKETMax. 63 A
POWER SOCKETMax. 63 A
• Upgrade 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
3221-09-2012 «BE-RF-PM»Thermal tests planning for CLIC prototype module type 0
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
3321-09-2012 «BE-RF-PM»Thermal tests planning for CLIC prototype module type 0
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
3421-09-2012 «BE-RF-PM»Thermal tests planning for CLIC prototype module type 0
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
3521-09-2012 «BE-RF-PM»Thermal tests planning for CLIC prototype module type 0
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)
3621-09-2012 «BE-RF-PM»Thermal tests planning for CLIC prototype module type 0
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
3721-09-2012 «BE-RF-PM»Thermal tests planning for CLIC prototype module type 0
6. 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 = 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]
3821-09-2012 «BE-RF-PM»Thermal tests planning for CLIC prototype module type 0
6. NUMERICAL SIMULATIONS: hydraulic circuit modelling
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
3921-09-2012 «BE-RF-PM»Thermal tests planning for CLIC prototype module type 0
6. NUMERICAL SIMULATIONS: hydraulic circuit modelling
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
4021-09-2012 «BE-RF-PM»Thermal tests planning for CLIC prototype module type 0
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
4121-09-2012 «BE-RF-PM»Thermal tests planning for CLIC prototype module type 0
6. 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
Wall(no penetration condition)
vx = 0.5 m/s
Wall(no penetration condition)
yz
x
• Initial temperature = 25 °C• Time period = 300 s
4221-09-2012 «BE-RF-PM»Thermal tests planning for CLIC prototype module type 0
6. 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
4321-09-2012 «BE-RF-PM»Thermal tests planning for CLIC prototype module type 0
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
4421-09-2012 «BE-RF-PM»Thermal tests planning for CLIC prototype module type 0
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
4521-09-2012 «BE-RF-PM»Thermal tests planning for CLIC prototype module type 0
SCHEDULE