1. 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.

2. 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

3. 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

4. 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

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

6. 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

7. 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

8. 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

9. 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

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

11. 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

12. 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

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

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

15. 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

16. 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

17. Thank you! Do you have any questions?

18. 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

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

20. 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

21. 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
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

22. 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