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

06-November-2013 Thermo-Mechanical Tests BE-RF-PM 3 Introduction

06-November-2013 Thermo-Mechanical Tests BE-RF-PM 4 CLIC Test Modules TBM Lab 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 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 CLEX Address other feasibility issues in an integrated approach

06-November-2013 Thermo-Mechanical Tests BE-RF-PM 5 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

06-November-2013 Thermo-Mechanical Tests BE-RF-PM 6 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

06-November-2013 Thermo-Mechanical Tests BE-RF-PM 7 Thermal test steps Temperature and alignment measurements to debug the system and to investigate the thermo-mechanical behaviour: o Heating of single components o Heating of all systems Simulation of CLIC duty cycles Comparison with FEA model Parameters which can be varied: o Ambient temperature o Air speed o Heat power

06-November-2013 Thermo-Mechanical Tests BE-RF-PM 8 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

06-November-2013 Thermo-Mechanical Tests BE-RF-PM 9 Test Stand

06-November-2013 Thermo-Mechanical Tests BE-RF-PM 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] componentheat power (W) AS410 PETS110 DBQ150 CL178

06-November-2013 Thermo-Mechanical Tests BE-RF-PM TEST STAND: cooling system CL = Compact Load CV = Control Valve FT = Flow Transducer HV = Hand Valve PRV = Pressure Regulating Valve SAS = Super Accelerating Structure WG = 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.

06-November-2013 Thermo-Mechanical Tests BE-RF-PM TEST STAND: temperature sensors TS1 TS2TS3TS4TS5TS6 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

06-November-2013 Thermo-Mechanical Tests BE-RF-PM TEST STAND: temperature sensors TS23 TS17 TS18 TS19 TS20 TS21 TS22 TS24 TS25 TS26 TS36 TS35 TS34 TS33 TS33.E PETS and RF network

06-November-2013 Thermo-Mechanical Tests BE-RF-PM TEST STAND: temperature sensors TS39 TS41 TS38 TS40 TS TS43 TS45 TS44 TS38 TS40 TS39 TS48 TS50 TS49 AIR TEMPERATURE MEASUREMENT AROUND THE MODULE 3 cross sections 5 thermocouples for each cross section

06-November-2013 Thermo-Mechanical Tests BE-RF-PM 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 SOCKET Max. 32 A ELECTRIC NETWORK AUL SYSTEM

06-November-2013 Thermo-Mechanical Tests BE-RF-PM 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:  T air = °C  v air = m/s

06-November-2013 Thermo-Mechanical Tests BE-RF-PM 17 Experimental results

06-November-2013 Thermo-Mechanical Tests BE-RF-PM EXPERIMENTAL RESULTS Temperature measurements by varying: heat power ambient temperature air speed In total about 30 measurements (analysis still under way)

06-November-2013 Thermo-Mechanical Tests BE-RF-PM EXPERIMENTAL RESULTS: power variation at 20 °C Surface temperature o Average: 28.0 °C o Max: 28.6 °C Average water temperature increase per SAS: +3 °C T amb = 20 °C, v air = 0.4 m/s, V SAS = m 3 /h Heat power: 50% Heat power: 100% Surface temperature o Average: 31.4 °C o Max: 32.1 °C Average water temperature increase per SAS : +6.3 °C Transient time from 50% to 100%: ~ 20'

06-November-2013 Thermo-Mechanical Tests BE-RF-PM EXPERIMENTAL RESULTS: power variation at 20 °C T amb = 20 °C, v air = 0.4 m/s, V PETS = m 3 /h Heat power: 50% Heat power: 100% Surface temperature o Average: 26.4 °C o Max: 27.2 °C Water temperature increase after PETS: +2.2 °C Surface temperature o Average: 29.0 °C o Max: 30.7 °C Water temperature increase after PETS: +5.8 °C Transient time from 50% to 100%: ~ 40'

06-November-2013 Thermo-Mechanical Tests BE-RF-PM EXPERIMENTAL RESULTS: power variation at 20 °C 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

06-November-2013 Thermo-Mechanical Tests BE-RF-PM EXPERIMENTAL RESULTS: power variation at 40 °C Surface temperature o Average: 29.0 °C o Max: 29.9 °C Average water temperature increase per SAS: +4.8 °C Surface temperature o Average: 32.0 °C o Max: 32.7 °C Average water temperature increase per SAS: +8.2 °C T amb = 40 °C, v air = 0.4 m/s, V SAS = m 3 /h Heat power: 50% Heat power: 100%

06-November-2013 Thermo-Mechanical Tests BE-RF-PM EXPERIMENTAL RESULTS: power variation at 40 °C T amb = 40 °C, v air = 0.4 m/s, V PETS = m 3 /h Heat power: 50% Heat power: 100% Surface temperature o Average: 32.2 °C o Max: 34.0 °C Water temperature increase after PETS: +5.4 °C Surface temperature o Average: 34.7 °C o Max: 37.1 °C Water temperature increase after PETS : +8.4 °C

06-November-2013 Thermo-Mechanical Tests BE-RF-PM EXPERIMENTAL RESULTS: power variation at 40 °C At T amb = 40 °C the heat is flowing from the ambient to the structures. The measured temperatures at T amb = 40 °C are higher than at T amb = 20 °C o SAS surface temperature (at full power): °C o PETS surface temperature (at full power): °C

06-November-2013 Thermo-Mechanical Tests BE-RF-PM 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 loads o Cooling system o Heat transfer to air o Gravity o Vacuum

06-November-2013 Thermo-Mechanical Tests BE-RF-PM EXPERIMENTAL RESULTS: validation of the numerical modelling FEA INPUT 1.Inlet temperature of water 2.Water flow rate 3.Ambient temperature 4.Air speed 5.Heat power for SAS, PETS, CL and DBQ 1.Discrete temperature 2.Beams axis misalignments (comparison with SU measurements) OUTPUT surface temperaturewater temperaturebeam axis misalignments

06-November-2013 Thermo-Mechanical Tests BE-RF-PM 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 T amb = 20 °C the heat power is flowing from the structure into the air, it is the opposite at T amb = 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, From nominal operation mode to failure scenarios:  Accelerating structure breakdown  PETS breakdown

06-November-2013 Thermo-Mechanical Tests BE-RF-PM 28 LINKS List of documents available in EDMS (CLIC Technical design -> Thermal Test program): An analytical model to describe the experimental results ( Temperature measurements for MB and DB ( Simulation of CLIC Duty Cycles (Nick Gazis, CLIC Test Module Meeting on Sept. 18, 2013)