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Review of the CLIC Two-Beam Module Program Thermo-Mechanical Tests

Review of the CLIC Two-Beam Module Program Thermo-Mechanical Tests . L. Kortelainen, I. Kossyvakis, R. Mondello, F. Rossi. CONTENT. Introduction, aim and strategy Test stand Experimental results. Introduction. CLIC Test Modules . 2009-2013.

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Review of the CLIC Two-Beam Module Program Thermo-Mechanical Tests

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  1. Review of the CLIC Two-Beam Module Program Thermo-Mechanical Tests L. Kortelainen, I. Kossyvakis, R. Mondello, F. Rossi

  2. CONTENT • Introduction, aim and strategy • Test stand • Experimental results

  3. Introduction

  4. CLIC Test Modules 2009-2013 Two-beam test stand (PETS and ac. structures) Demonstration of the two-beam acceleration with one PETS and one accelerating structure at nominal parameters in CLEX 2011-2015 • Demonstration of the two-beam module design • 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 • validation of the thermal and mechanical module behavior TBM Lab Demonstration of the two-beam acceleration with two-beam modules in CLEX Address other feasibility issues in an integrated approach TBM CLEX

  5. CLIC Test Modules TM0#1 TM1 TM0#2 TM4 1) Under test 2) Under assembly and installation 3) Components under procurement and assembly 4) Last module – few components under procurements

  6. Aim • Temperature • Map in the module • Variations with operating modes and environmental conditions • Simulation of the real tunnel environment (e.g. air flow, ambient temperature) • Time constants • Functionality of the cooling system

  7. Thermal test steps • Temperature and alignment measurements to debug the system and to investigate the thermo-mechanical behaviour: • Heating of single components • Heating of all systems • Simulation of CLIC duty cycles • Comparison with FEA model • Parameters which can be varied: • Ambient temperature • Air speed • Heat power

  8. Thermal test program 1. STEPS (alignment and temperature measurements) infrared camera • Step 0 - WPS MEASURING SYSTEM TEST • Air speed: from 0.3 to 0.8 m/s • Step 1 - ENVIRONMENTAL HEATING • Ambient temperature: 20, 30 and 40 °C • Step 2 - heating accelerating structures AND LOADS • Ambient temperature: 20 and 40 °C • Air speed: 0.4 and 0.8 m/s • Heat power variation • Step 3 - heating PETS, RF NETWORK and DBQ • Ambient temperature: 20 and 40 °C • Air speed: 0.4 and 0.8 m/s • Heat powervariation • Step 4 - heating all module • Ambient temperature: 20 and 40 °C • Air speed: 0.4 and 0.8 m/s • Heat powervariation 2. CLIC duty cycle simulation • CLIC nominal operation mode scenarios • Failure scenarios (ex. accelerating structures breakdown)

  9. Test Stand

  10. 1. TEST STAND: heating system • The heat power dissipation is reproduced by using electric heaters Load heating jackets AS straight tubular heater DBQ cartridge heaters

  11. 1. TEST STAND: cooling system • PETS are cooled in series with the RF network waveguides and the hybrid loads. • Each super accelerating structure is cooled in series with the corresponding loads; the 4 super accelerating structures are cooled in parallel. • The cooling system for DBQ is not present in this first test. Possibility to integrate it in the future. CL = Compact Load CV = Control Valve FT = Flow Transducer HV = Hand Valve PRV = Pressure Regulating Valve SAS = Super Accelerating Structure WG = RF network waveguide

  12. 1. TEST STAND: temperature sensors • Accelerating Structure and compact loads TS29.D TS29.C TS29.E • RTD sensor • PT 100 (4-wire resistance) • Accuracy = ± 0.1 °C TS1 TS7 TS2 TS3 TS4 TS5 TS6 TS29.B TS29.A

  13. 1. TEST STAND: temperature sensors • PETS and RF network TS23 TS24 TS21 TS33 TS33.E TS20 TS25 TS34 TS22 TS26 TS19 TS35 TS18 TS36 TS17

  14. 1. TEST STAND: temperature sensors • AIR TEMPERATURE MEASUREMENT AROUND THE MODULE • 3 cross sections • 5 thermocouples for each cross section TS49 TS48 TS50 1222 979 650 275 245 TS39 TS44 TS43 TS45 979 TS40 TS38 TS42 1339 TS39 TS38 TS40 770 189 TS41 200

  15. 1. TEST STAND: layout ELECTRIC NETWORK SUPPORTING FRAME FOR COOLING SYSTEM COMPONENTS POWER SOCKET Max. 64 A POWER SOCKET Max. 64 A PETS heater AS heater Temperature sensors POWER SOCKET Max. 32 A AUL SYSTEM WATER CHILLER POWER SOCKET Max. 32 A ELECTRONICS FOR HEATING AND COOLING SYSTEM

  16. 1. TEST STAND: HVAC • Range for air temperature and speed: • Tair = 20 - 40 °C • vair = 0.2 - 0.8 m/s Heating coils • Air speed sensors installed in the middle of the room • The ceiling is movable for the transport test AIR FLOW AIR CIRCULATION transport test Air speed sensors Cooling coils

  17. Experimental results

  18. 2. EXPERIMENTAL RESULTS • Temperature measurements by varying: • heat power • ambient temperature • air speed In total about 30 measurements (analysis still under way)

  19. 2. EXPERIMENTAL RESULTS: power variation at 20 °C Tamb= 20 °C, vair= 0.4 m/s, VSAS= 0.0686 m3/h 28.2 27.6 28.3 28.5 25.5 24.8 25.0 25.5 Heat power: 50% 28.4 27.2 28.1 26.6 27.7 28.6 27.1 27.3 • Surface temperature • Average: 28.0 °C • Max: 28.6 °C • Average water temperature increase per SAS: +3 °C Heat power: 100% 31.4 30.7 32.0 32.1 25.5 24.8 25.0 25.5 31.8 29.7 31.7 28.5 32.1 32.0 • Surface temperature • Average: 31.4 °C • Max: 32.1 °C • Average water temperature increase per SAS : +6.3 °C • Transient time from 50% to 100%: ~20' 29.5 30.5

  20. 2. EXPERIMENTAL RESULTS: power variation at 20 °C Tamb= 20 °C, vair= 0.4 m/s, VPETS= 0.0374 m3/h 27.2 27.0 Heat power: 50% • Surface temperature • Average: 26.4 °C • Max: 27.2 °C • Water temperature increase after PETS: +2.2 °C 25.8 25.4 27.5 30.7 25.3 30.7 Heat power: 100% • Surface temperature • Average: 29.0 °C • Max: 30.7 °C • Water temperature increase after PETS: +5.8 °C • Transient time from 50% to 100%: ~40' 27.4 27.3 31.1 25.3

  21. 2. EXPERIMENTAL RESULTS: power variation at 20 °C • For the SAS: • The thermal response is linear with the heat power • The transient time to reach the steady-state conditions is about 20' • At full power the temperature gradient along the SAS is about 3 °C • The temperature is increasing from the first SAS to the last one • Part of the heat power generated inside the module is dissipated into the air • For the PETS: • The transient time to reach steady-state conditions is about 40' • The temperature is increasing from the first PETS unit to the second one • Part of the heat power generated inside the module is dissipated into the air

  22. 2. EXPERIMENTAL RESULTS: power variation at 40 °C Tamb= 40 °C, vair= 0.4 m/s, VSAS= 0.0686 m3/h 30.2 28.7 29.5 29.0 24.2 24.9 25.1 24.2 Heat power: 50% 29.2 28.1 29.6 29.9 29.0 28.5 • Surface temperature • Average: 29.0 °C • Max: 29.9 °C • Average water temperature increase per SAS: +4.8 °C 28.3 29.7 Heat power: 100% 34.0 31.4 32.7 33.0 24.2 24.9 25.1 24.2 32.6 29.2 32.0 32.7 31.2 32.2 • Surface temperature • Average: 32.0 °C • Max: 32.7 °C • Average water temperature increase per SAS: +8.2 °C 29.4 32.6

  23. 2. EXPERIMENTAL RESULTS: power variation at 40 °C Tamb= 40 °C, vair= 0.4 m/s, VPETS= 0.0374 m3/h 32.2 34.0 Heat power: 50% • Surface temperature • Average: 32.2 °C • Max: 34.0 °C • Water temperature increase after PETS: +5.4 °C 29.9 32.5 30.2 35.2 24.8 37.1 Heat power: 100% • Surface temperature • Average: 34.7 °C • Max: 37.1 °C • Water temperature increase after PETS : +8.4 °C 31.7 34.7 33.2 24.8

  24. 2. EXPERIMENTAL RESULTS: power variation at 40 °C • At Tamb = 40 °C the heat is flowing from the ambient to the structures. • The measured temperatures at Tamb = 40 °C are higher than at Tamb = 20 °C • SAS surface temperature (at full power): + 0.6 °C • PETS surface temperature (at full power): + 5.7 °C

  25. 2. EXPERIMENTAL RESULTS: validation of the numerical modelling • Finite elements modelling of CLIC prototype module type 0 Bellow (spring elements) SAS (solid elements) Central vacuum tank (shell elements) • The thermo-mechanical modelling takes into account: • Heat loads • Cooling system • Heat transfer to air • Gravity • Vacuum Cooling channel (linear element)

  26. 2. EXPERIMENTAL RESULTS: validation of the numerical modelling INPUT OUTPUT FEA Inlet temperature of water Water flow rate Ambient temperature Air speed Heat power for SAS, PETS, CL and DBQ Discrete temperature Beams axis misalignments (comparison with SU measurements) water temperature surface temperature beam axis misalignments

  27. CONCLUSIONS • The module has been successfully tested at 100% of the total heat power. The experimental results show that: • The influence of the air speed on the resulting temperatures is less than 1 °C for the two air speeds considered. • Part of the heat power generated inside the module is dissipated into the air (detailed analysis under way). • At Tamb = 20 °C the heat power is flowing from the structure into the air, it is the opposite at Tamb = 40 °C. • The validation of the numerical modelling is currently in progress. The preliminary comparison with the experimental results shows a slight overall discrepancy of ~2 °C between the predicted and measured temperatures. • Next step: simulation of CLIC duty cycles, as defined at the CMWG on Sept. 18, 2013. From nominal operation mode to failure scenarios: • Accelerating structure breakdown • PETS breakdown

  28. LINKS • List of documents available in EDMS (CLIC Technical design -> Thermal Test program): • An analytical model to describe the experimental results (https://edms.cern.ch/document/1320625/1) • Temperature measurements for MB and DB (https://edms.cern.ch/document/1304241/1, https://edms.cern.ch/document/1304242/1) • Simulation of CLIC Duty Cycles (Nick Gazis, CLIC Test Module Meeting on Sept. 18, 2013)

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