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RFQ Cooling Schemes and Instrumentation PXIE RFQ Fabrication Readiness Review LBNL – June 26, 2013 Andrew Lambert - Engineering Division Lawrence Berkeley.

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Presentation on theme: "RFQ Cooling Schemes and Instrumentation PXIE RFQ Fabrication Readiness Review LBNL – June 26, 2013 Andrew Lambert - Engineering Division Lawrence Berkeley."— Presentation transcript:

1 RFQ Cooling Schemes and Instrumentation PXIE RFQ Fabrication Readiness Review LBNL – June 26, 2013 Andrew Lambert - Engineering Division Lawrence Berkeley National Laboratory

2 A. Lambert: RFQ Cooling Schemes and Instrumentation PXIE RFQ Fabrication Readiness Review LBNL – June 26-27, 2013 Outline Cooling Channel Layout and Heat Loads Required Chiller Heat Loads P&IDs for Cooling Channels and Pi-mode Rods Axial Frequency Drop Channel to Channel Heat Transfer Instrumentation Manifolding Conclusions

3 A. Lambert: RFQ Cooling Schemes and Instrumentation PXIE RFQ Fabrication Readiness Review LBNL – June 26-27, 2013 RFQ Cooling Channels PXIE RFQ is cooled via wall, corner and vane water channels – Can be used for dynamic tuning of the RFQ – Wall and Corner channels on same cooling loop – Vane channels on separate cooling loop – Allow for different channel temperatures PXIE Frequency ShiftAverage Overall (kHz/ o C)-2.8 Vane (kHz/ o C)-16.7 Wall (kHz/ o C)13.9 Sum of Vane and Wall (kHz/ o C)-2.8 Theoretical Shift (kHz/ o C)-2.9 % Error3.8%

4 A. Lambert: RFQ Cooling Schemes and Instrumentation PXIE RFQ Fabrication Readiness Review LBNL – June 26-27, 2013 RFQ Cooling Channels Heat Load Calculate the head load to each RFQ cooling channel – Wall heating, cutback heating, slug tuner heating – Pi-rods not included as they are on separate cooling circuit RFQ cooling supplied by two chillers – One chiller for the Corner and Wall channels – One chiller for the Vane channels Module 2 Heat Load per Channel [kW] Heat Load for all Channels [kW] Water ΔT [K] Corner1.305.191.20 Vane1.797.171.66 Wall1.445.781.34 Total18.14 Module 1 Heat Load per Channel [kW] Heat Load for all Channels [kW] Water ΔT [K] Corner1.244.971.15 Vane1.807.191.66 Wall1.365.431.26 Total17.60 Module 3 Heat Load per Channel [kW] Heat Load for all Channels [kW] Water ΔT [K] Corner1.305.191.20 Vane1.797.171.66 Wall1.445.781.34 Total18.14 Module 4 Heat Load per Channel [kW] Heat Load for all Channels [kW] Water ΔT [K] Corner1.254.991.15 Vane1.837.341.70 Wall1.375.481.27 Total17.81

5 A. Lambert: RFQ Cooling Schemes and Instrumentation PXIE RFQ Fabrication Readiness Review LBNL – June 26-27, 2013 Chiller Heat Loads Flow velocity = 7.5 ft/s Water temperature = 30 o C Resulting temperature range of 32.8-36.6 o C – CW temperature rise of 1.7 o C in vane channels and 1.3 o C in wall/corner channels – Higher heat load into the vane channels Max CW ΔT [K]Required Cooling [kW] Required Flow [GPM] Vane Chiller 1.7 29 (38)65 (78) Wall/Pi-Rod Chiller 1.3 50 (65)136 (163)

6 A. Lambert: RFQ Cooling Schemes and Instrumentation PXIE RFQ Fabrication Readiness Review LBNL – June 26-27, 2013 Wall/Corner Cooling 8 wall/corner channels per module – Cool the RFQ body and absorb slug tuner heat – 12.0 mm diameter – Nominal flow rate of 4.1 GPM – Each module must be supplied with ~32.5 GPM – Total supply is ~130 GPM

7 A. Lambert: RFQ Cooling Schemes and Instrumentation PXIE RFQ Fabrication Readiness Review LBNL – June 26-27, 2013 Wall/Corner Channel P&ID

8 A. Lambert: RFQ Cooling Schemes and Instrumentation PXIE RFQ Fabrication Readiness Review LBNL – June 26-27, 2013 Pi-mode Rod Cooling 8 pi-mode rods per RFQ module – Remove RF heat – 5.0 mm diameter – Nominal flow rate of 0.7 GPM – Only 4 pi-rods connected in series – Each module must be supplied with ~1.4 GPM – Total supply is ~5.6 GPM

9 A. Lambert: RFQ Cooling Schemes and Instrumentation PXIE RFQ Fabrication Readiness Review LBNL – June 26-27, 2013 Pi-rod Channel P&ID

10 A. Lambert: RFQ Cooling Schemes and Instrumentation PXIE RFQ Fabrication Readiness Review LBNL – June 26-27, 2013 Vane Cooling 4 wall/corner channels per module – Cool the RFQ vanetips and provide dynamic tuning – 12.0 mm diameter – Nominal flow rate of 4.1 GPM – Each module must be supplied with ~16.25 GPM – Total supply is ~65 GPM

11 A. Lambert: RFQ Cooling Schemes and Instrumentation PXIE RFQ Fabrication Readiness Review LBNL – June 26-27, 2013 Vane Channel P&ID

12 A. Lambert: RFQ Cooling Schemes and Instrumentation PXIE RFQ Fabrication Readiness Review LBNL – June 26-27, 2013 Axial Frequency Shift As heat is removed from the RFQ, the cooling water warms up, which cause axial temperature gradients in the RFQ -> Not a problem with current flow rate – Very small effect as temperature rise is only ~1.5 o C Flow Speed (ft/s)Entrance Frequency (MHz)Exit Frequency (MHz)% Change (kHz) 5164.270164.255-0.009% 7.5164.275164.264-0.007% 10164.278164.270-0.005%

13 A. Lambert: RFQ Cooling Schemes and Instrumentation PXIE RFQ Fabrication Readiness Review LBNL – June 26-27, 2013 Channel to Channel Heat Transfer Because cooling channels are at different temperatures, there is some heat transfer from channel to channel – This has been investigated using ANSYS and the effect is estimated to be ~120 W/ o C – This effect is not significant for small temperature differentials, but can be more pronounced for large channel ΔT Effect does equalize/lessen along the length of RFQ as channel temperatures approach each other For a ΔT of +10 o C from wall to vane, the added heat transfer can be 40-50% of the vane CW load Increases required vane chiller cooling to 46 kW > 38 kW (spec.) – Establish an expected maximum temperature differential for the two chillers and size accordingly

14 A. Lambert: RFQ Cooling Schemes and Instrumentation PXIE RFQ Fabrication Readiness Review LBNL – June 26-27, 2013 Instrumentation Summary Sensor TypeVane CircuitsWall CircuitsPi-mode CircuitsTotals Pressure88-16 Temperature2012436 Flow Rate168428 Pressure and temperature monitored at supply manifolds Pressure, temperature, and flow rate monitored at exit manifolds Instrumentation should be tied into a monitoring system Less instrumentation on the wall circuits due to the parallel design of the piping

15 A. Lambert: RFQ Cooling Schemes and Instrumentation PXIE RFQ Fabrication Readiness Review LBNL – June 26-27, 2013 Manifolding Custom manifolding to tie appropriate cooling channels together – Color coding of supply and return lines for each chiller loop – Instrumentation installed on the manifolds – Manifold layout keeps instrumentation panels in 2 locations Between module 1 &2 and module 3 & 4 Easy access for monitoring

16 A. Lambert: RFQ Cooling Schemes and Instrumentation PXIE RFQ Fabrication Readiness Review LBNL – June 26-27, 2013 Conclusion PXIE RFQ cooling requirements: – Chiller 1: 38 kW @ 78 GPM – Chiller 2: 65 kW @ 163 GPM Instrumentation – Pressure: 16 – Temperature: 36 – Flow Rate: 28

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