SPS High Energy Dump @ LSS5 Thermal contact & cooling aspects P. Ríos-Rodríguez (EN-STI). 06/04/2016 Contributions from several colleagues from EN/STI, EN/MME.

Thermal contact and cooling aspects Cooling systems (270KW) First shielding’s cooling water pipes Core’s cooling water pipes almost all amount of 10 cooling plates (20KW/plate) energy deposition 06/04/2016 High Energy Dump LSS5 - Design review

Thermal contact and cooling aspects TCC depends on: Temperature, pressure, roughness, micro hardness…Some tests are needed to better define TCC: TCC Test bench 06/04/2016 High Energy Dump LSS5 – Design review

Thermal contact and cooling aspects TCC Test bench Upper column insulator Cooling tubes Load cell meter Refrigerated/heating circulator Heat flux meter (Cu) Spring box RTD (32) Vacuum chamber assembly Column sample Column assembly Heat flux meter (Cu) Vacuum pump Cartridge heaters (~125W) Lower column insulator 06/04/2016 High Energy Dump LSS5 – Design review

Thermal contact and cooling aspects TCC Test bench Tests to be done during 2016. 06/04/2016 High Energy Dump LSS5 – Design review

Thermal contact and cooling aspects First shielding’s cooling system Cast iron SS pipes. Implemented already in TIDVG & TED. Prototype: ultrasound tests. 06/04/2016 High Energy Dump LSS5 – Design review

Thermal contact and cooling aspects Core’s cooling 2 cooling circuits needed from CV v=0,5m/s Cooling Channels (2 inlets and 2 outlets) Copper core Springs (18/plate) 06/04/2016 High Energy Dump LSS5 - Design review

Thermal contact and cooling aspects Core’s cooling Large radius (30mm) in the hole of water circulation to avoid erosion- corrosion OFE-Cu. To be tested with the prototype. 06/04/2016 High Energy Dump LSS5 - Design review

Thermal contact and cooling aspects Cooling plates Material: plate of Glidcop, pipes of Cu30Ni. Erosion-corrosion rate Cu30Ni: 0,02mm/yr. Concept already implemented in the collimators. Supplier: still to be defined- research on going. Square external section to improve thermal contact. Use of the main magnet circuit (deionized water) as the primary of this exchanger Bending Brazing 20KW v=1,5m/s 28°C 50°C 06/04/2016 High Energy Dump LSS5 - Design review

Thermal contact and cooling aspects Cooling plates 06/04/2016 High Energy Dump LSS5 – Design review

Thermal contact and cooling aspects Block assembly 1/2 We call nominal position, the position of the cooling plate when the blocks are installed and in contact with the upper part of the core. HB = Height of the block. Step 1 Lowering of the cooling plate: 2mm lower than the nominal position Initially Step 2 Insertion of 2mm thick wedges Inflatable seal HB-1 HB+2 HB+2 Support of the inflatable seal 3mm Wedges Gap: 0mm Gap: 3mm Gap: 1mm Higher stresses 06/04/2016 High Energy Dump LSS5 - Design review

Thermal contact and cooling aspects Cooling plates Structural analysis: plate thickness 10 mm and pressure applied by the springs 0,7MPa (450kg per spring, 18 springs). New calculation has to be done when the final bending shape of the pipes is defined. 06/04/2016 High Energy Dump LSS5 - Design review

Thermal contact and cooling aspects Cooling plates - equivalent stresses 06/04/2016 High Energy Dump LSS5 - Design review

Thermal contact and cooling aspects Cooling plates - plate deformation 06/04/2016 High Energy Dump LSS5 - Design review

Thermal contact and cooling aspects Brazing of the cooling plates Brazing with silver/copper based filling materials (~800°C). Joint strength: ~200MPa. Good flatness expected (~0.02mm). No problems foreseen but: Brazing of Glidcop: A layer of Cu & Ni by electroplating on the surface has to be applied. 06/04/2016 High Energy Dump LSS5 - Design review

Thermal contact and cooling aspects Conclusions: The cooling system plays an important role for the lifetime of the dump. The TCC test bench is on-going. Tests will be made during 2016. The cooling circuits for the first shielding and the copper core are feasible and no problems are foreseen. The cooling plates that cool the blocks have to evacuate high amount of energy (20KW/plate). They are a critical point in the design. The research of suppliers for CuNi pipes and of alternative solutions is still on-going. 06/04/2016 High Energy Dump LSS5 - Design review

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Thermal contact and cooling aspects Cooling flow data: Copper core: Q=1,46m3/s; v=0,5m/s; T1=28C, T2=50C Cooling plates: Q=0,218m3/s; v=1,5m/s; T1=28C, T2=50C 06/04/2016 High Energy Dump LSS5 - Design review

Thermal contact and cooling aspects Solution: HIPed Glidcop plates Out of budget 06/04/2016 High Energy Dump LSS5 - Design review

Copper Core design details - Proposed design Block assembly 2/2 Step 3 Removing of the seal and Insertion of the blocks Step 4 Lowering of the block and the cooling plate and removing of the wedges Step 5 Removing of the seal Gap: 1mm Gap: 0mm Gap: 2mm HB+1 HB+2 HB Gap: 0mm Gap: 1mm Gap: 1mm 06/04/2016 High Energy Dump LSS5 - Design review

TCC and cooling aspects Dump Cooling specifications Activities started and still on going First mechanical simulations: first results validate the choice of materials for the cooling plate and the maximal pressure of the springs A concept for the cooling plates is under study. Pre-design done. This concept has been presented to: (see minutes in https://indico.cern.ch/category/7648/) Manufacturing experts (A.Dallochio, G.Favre , JM.Geisser, D.Grenier). Vacuum experts (C.Garion, C.Pasquino, A.Harisson). Welding control expert (JM.Dalin). Electron beam welding expert (T.Tardy). Brazing expert (F. Motschmann). Material experts ( S. Sgobba, F. Leaux, G. Arnau Izquierdo, JM. Dalin). The conclusion of these meetings is that the concept seems realistic and feasible. Some points need to be validated but nothing appears to be a show-stopper for this design. One of the weak points is the cooling plates on finding a supplier for the Cu30Ni cooling pipes (square section) and the low thermal conductivity: 29W/mk Prototyping seems to be necessary to validate the concept and the uncertain points. The prototype would be a short sector of 500mm of the coper core with a cooling plate. With the prototype, we will define: the best solution for the brazing of the flange the shape of the pipe on the cooling plate 06/04/2016 High Energy Dump LSS5 - Design review

Final heat exchanger location SURFACE ECA5 ECX5 Heat exchanger, pump and filtration. Control and power racks for CV: flow meters, pressure detectors, humidity, temperature and leaks detectors. 06/04/2016 High Energy Dump LSS5 - Design review