review of the clic two-beam module program thermo-mechanical tests

06-November-2013 Thermo-Mechanical Tests BE-RF-PM

Review of the CLIC Two-Beam Module Program

Thermo-Mechanical Tests L. Kortelainen, I. Kossyvakis, R. Mondello, F. Rossi

06-November-2013 Thermo-Mechanical Tests BE-RF-PM 2

CONTENT

• Introduction, aim and strategy

• Test stand

• Experimental results


Introduction


CLIC Test Modules

TBM Lab

Demonstration of the two-beam module designThis 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

Two-beam test stand (PETS and ac. structures)

TBM CLEX

Demonstration of the two-beam acceleration with one PETS and one accelerating structure at nominal parameters in CLEX

Demonstration of the two-beam acceleration with two-beam modules in CLEXAddress other feasibility issues in an integrated approach

2011-2015

2009-2013


CLIC Test Modules TM0#1

1) Under test

3) Components under procurement and

assembly 4) Last module – few components under

procurements

TM1 TM0#2 TM4

2) Under assembly and installation


Aim • Temperature

o Map in the module o Variations with operating modes and environmental

conditions o Simulation of the real tunnel environment (e.g. air flow,

ambient temperature)o Time constants

• Functionality of the cooling system


Thermal test steps• Temperature and alignment measurements to debug the

system and to investigate the thermo-mechanical behaviour:o Heating of single componentso Heating of all systems

• Simulation of CLIC duty cycles

• Comparison with FEA model

• Parameters which can be varied:o Ambient temperatureo Air speedo Heat power


Thermal test program

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 power variation

STEP 4 - HEATING ALL MODULE Ambient temperature: 20 and 40 °C Air speed: 0.4 and 0.8 m/s Heat power variation

1. STEPS (alignment and temperature measurements)

2. CLIC duty cycle simulation

• CLIC nominal operation mode scenarios

• Failure scenarios (ex. accelerating structures breakdown)

infrared camera


Test Stand


1. TEST STAND: heating system• The heat power dissipation is reproduced by using electric heaters

DBQ cartridge heaters

Load heating jackets

AS straight tubular heater

Max heat power dissipation [7.58 kW]

component heat power (W)AS 410

PETS 110DBQ 150CL 178


1. TEST STAND: cooling system

CL = Compact LoadCV = Control ValveFT = Flow TransducerHV = Hand ValvePRV = Pressure Regulating ValveSAS = Super Accelerating StructureWG = RF network waveguide

• 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.


1. TEST STAND: temperature sensors

TS1TS2 TS3 TS4 TS5 TS6

TS7

TS29.C

TS29.ATS29.B

TS29.D

TS29.E

• Accelerating Structure and compact loads

RTD sensor• PT 100 (4-wire resistance)• Accuracy = ± 0.1 °C



TS23

TS17

TS18TS19

TS20TS21

TS22

TS24

TS25

TS26

TS36

TS35

TS34

TS33TS33.E

• PETS and RF network



1222

1339

650

770

27524

5

200

TS39

TS41

TS38 TS40TS42

189

979

979

TS43 TS45TS44

TS38 TS40TS39

TS48 TS50TS49

AIR TEMPERATURE MEASUREMENT AROUND THE MODULE• 3 cross sections• 5 thermocouples for each

cross section


1. TEST STAND: layout

AS heater

PETS heater

Temperature sensors

SUPPORTING FRAME FOR COOLING SYSTEM

COMPONENTS

WATER CHILLER

ELECTRONICS FOR HEATING AND COOLING

SYSTEM

POWER SOCKET

Max. 64 A

POWER SOCKET

Max. 64 A

POWER SOCKET

Max. 32 A

POWER SOCKETMax. 32 A

ELECTRIC NETWORK

AUL SYSTEM


1. TEST STAND: HVAC

AIR FLOW

Cooling coils

Heating coils

AIR CIRCULATION

• Air speed sensors installed in the middle of the room

Air speed

sensors

transport test

• The ceiling is movable for the transport test

• Range for air temperature and speed:

Tair = 20 - 40 °C vair = 0.2 - 0.8 m/s


Experimental results


2. EXPERIMENTAL RESULTS

Temperature measurements by varying:

• heat power

• ambient temperature

• air speed

In total about 30 measurements (analysis still under way)


2. EXPERIMENTAL RESULTS: power variation at 20 °C

24.828.5

30.7

29.5

29.7

30.5

31.725.0

32.1

32.025.5

32.0

32.125.5

31.8

31.4

24.826.6

27.6

27.1

27.2

27.3

28.125.0

27.7

28.325.5

28.6

28.525.5

28.4

28.2

• Surface temperatureo Average: 28.0 °Co Max: 28.6 °C

• Average water temperature increase per SAS: +3 °C

Tamb = 20 °C, vair = 0.4 m/s, VSAS = 0.0686 m3/h

Heat power:

50%

Heat power:100% • Surface temperature

o Average: 31.4 °Co Max: 32.1 °C

• Average water temperature increase per SAS : +6.3 °C

• Transient time from 50% to 100%: ~20'



Tamb = 20 °C, vair = 0.4 m/s, VPETS = 0.0374 m3/h

Heat power:

50%

Heat power:100%

25.3

27.525.4

25.8

27.0

27.2

25.3

31.127.3

27.4

30.730.7


• Water temperature increase after PETS: +2.2 °C



• Transient time from 50% to 100%: ~40'



• For the SAS:

o The thermal response is linear with the heat power

o The transient time to reach the steady-state conditions is about 20'

o At full power the temperature gradient along the SAS is about 3 °C

o The temperature is increasing from the first SAS to the last one

o Part of the heat power generated inside the module is dissipated into the air

• For the PETS:

o The transient time to reach steady-state conditions is about 40'

o The temperature is increasing from the first PETS unit to the second one

o Part of the heat power generated inside the module is dissipated into the air



24.929.2

31.4

29.4

32.0

32.6

32.725.1

31.2

32.724.2

32.2

33.024.2

32.6

34.0

24.928.1

28.7

28.3

29.6

29.7

29.925.1

29.0

29.524.2

28.5

29.024.2

29.2

30.2


• Average water temperature increase per SAS: +4.8 °C


• Average water temperature increase per SAS: +8.2 °C

Tamb = 40 °C, vair = 0.4 m/s, VSAS = 0.0686 m3/h

Heat power:

50%

Heat power:100%



Tamb = 40 °C, vair = 0.4 m/s, VPETS = 0.0374 m3/h

Heat power:

50%

Heat power:100%

24.8

30.232.5

29.9

34.0

32.2

24.8

33.234.7

31.7

37.135.2




• Water temperature increase after PETS : +8.4 °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

o SAS surface temperature (at full power): + 0.6 °C

o PETS surface temperature (at full power): + 5.7 °C


2. EXPERIMENTAL RESULTS: validation of the numerical modelling

Central vacuum tank (shell elements)

Cooling channel (linear element)

SAS (solid elements)

Bellow (spring elements)

• Finite elements modelling of CLIC prototype module type 0

• The thermo-mechanical modelling takes into account:o Heat loadso Cooling systemo Heat transfer to airo Gravityo Vacuum


2. EXPERIMENTAL RESULTS: validation of the numerical modelling

FEAINPUT

1. Inlet temperature of water 2. Water flow rate3. Ambient temperature4. Air speed5. Heat power for SAS, PETS, CL and

DBQ

1. Discrete temperature2. Beams axis misalignments

(comparison with SU measurements)

OUTPUT

surface temperature

water temperature beam axis misalignments


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


LINKSList 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)

https://edms.cern.ch/document/1320625/1








review of the clic two-beam module program thermo-mechanical tests

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