«BE-RF-PM» CLIC prototype two-beam modules Thermal test planning G. Riddone, F. Rossi Introduction Thermal tests 1.Environment 2.Heating and cooling system 3.Measurements 4.Numerical simulations Schedule

«BE-RF-PM» Prototype two-beam modules LAB version 4 modules, 2 sequences foreseen Type 0, Type 0, Type 1, Type 4 Type 0, Type 1. Type 0, Type 4 CLEX version 3 modules Type 0, Type 0, Type 1 Demonstration of the two-beam module design (from single technical system to complete modules) 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 Demonstration of the two-beam acceleration with beam and RF with real modules Address other feasibility issues in an integrated approach

«BE-RF-PM» Thermal tests planning for CLIC prototype module type 0 Prototype modules – LAB version 1) Currently under assembly and installation 2) Main components under procurement 3) Last module TM1TM0 TM4

«BE-RF-PM» Prototype modules – CLEX version TM0 TM1 Design finalization, Supporting/alignment system under fabrication beam 21

«BE-RF-PM» Prototype modules - Status TM0#1 Lab: First 2-m accelerating structure stack completed (EBW last week) RF network under final installation During assembly, validation of girder and supporting system Several alignment/positioning tests successfully performed Next main step: Thermal tests TM0#1 CLEX First double length from CIEMAT fully assembled Integrated supporting system (including girder, positioning system and Rf structure supports)under fabrication (ZTS-Boostec) Superstructures under machining at VDL

«BE-RF-PM» Thermal tests Program Presented and validated at CTC in July 2012 Main actors for tests and analysis F. Rossi L. Kortelainen I. Kossyvakis R. Mondello A. Xydou

«BE-RF-PM» Thermal tests planning for CLIC prototype module type 0 CLIC prototype modules - LAB Assembly and integration of all technical systems (dummy RF structures and quadrupoles can be used – real dead weight and interfaces to other systems) Validation of different types of girders and movers Full metrology of the module components Pre-alignment of girders and RF structures on girders in the module environment, including fiducialisation Validation of interconnections and vacuum system Stabilization of main beam quad in the module environment Vibration study of all systems and identification of vibration sources Measurement of resonant frequencies (both in lab and in the tunnel/underground area) Simulation of several thermal cycles: measurements of thermal transients (e.g. how long it takes to achieve a new equilibrium state), fiducialisation verification Transport of the module and verification of alignment Recall of main objectives

«BE-RF-PM» Thermal tests planning for CLIC prototype module type 0 Experimental program for thermal tests HEATING No active heating in RF structures HEATING No active heating in RF structures COOLING No active cooling in RF structures COOLING No active cooling in RF structures MEASUREMENTS 1.Temperature 2.Alignment Laser tracker Romer arm WPS Micro-Triangulation system MEASUREMENTS 1.Temperature 2.Alignment Laser tracker Romer arm WPS Micro-Triangulation system STEP 1 – Heating environment ENVIRONMENT T amb = °C in steady-state conditions and by steps of 5 °C ENVIRONMENT T amb = °C in steady-state conditions and by steps of 5 °C HEATING PETS by steps up to 110 W/unit HEATING PETS by steps up to 110 W/unit COOLING PETS < max calculated T COOLING PETS < max calculated T MEASUREMENTS 1.Temperature 2.Volumetric flow rate 3.Alignment Laser tracker Romer arm WPS Micro-Triangulation system MEASUREMENTS 1.Temperature 2.Volumetric flow rate 3.Alignment Laser tracker Romer arm WPS Micro-Triangulation system STEP 2 – Heating only PETS ENVIRONMENT T amb = 20 °C in steady-state conditions ENVIRONMENT T amb = 20 °C in steady-state conditions HEATING AS by steps up to 400 W/unit HEATING AS by steps up to 400 W/unit COOLING AS < max calculated T COOLING AS < max calculated T MEASUREMENTS 1.Temperature 2.Volumetric flow rate 3.Alignment Laser tracker Romer arm WPS Micro-Triangulation system MEASUREMENTS 1.Temperature 2.Volumetric flow rate 3.Alignment Laser tracker Romer arm WPS Micro-Triangulation system STEP 3 – Heating only AS ENVIRONMENT T amb = 20 °C in steady-state conditions ENVIRONMENT T amb = 20 °C in steady-state conditions HEATING AS + PETS + DBQ by steps up to max power/unit HEATING AS + PETS + DBQ by steps up to max power/unit COOLING AS + PETS + DBQ < max calculated T COOLING AS + PETS + DBQ < max calculated T MEASUREMENTS 1.Temperature 2.Volumetric flow rate 3.Alignment Laser tracker Romer arm WPS Micro-Triangulation system MEASUREMENTS 1.Temperature 2.Volumetric flow rate 3.Alignment Laser tracker Romer arm WPS Micro-Triangulation system STEP 4 – Heating all module ENVIRONMENT T amb = °C in steady-state conditions and by steps of 5 °C ENVIRONMENT T amb = °C in steady-state conditions and by steps of 5 °C G. Riddone, A. Samoshkin, CLIC Test Module meeting MEASUREMENTS a.Comparison between laser tracker and WPS measurements (no movements of girders) b.Alignment tests by moving girders via actuators and comparison between laser tracker and WPS measurements MEASUREMENTS a.Comparison between laser tracker and WPS measurements (no movements of girders) b.Alignment tests by moving girders via actuators and comparison between laser tracker and WPS measurements STEP 0 – Alignment tests ENVIRONMENT T amb = 20 & 40 °C ENVIRONMENT T amb = 20 & 40 °C ALL THE TESTS ARE PERFORMED WITH NO VACUUM

«BE-RF-PM» Thermal tests planning for CLIC prototype module type 0 TOPICS Topics and updates concerning the status of: 1.CLIC prototype module type 0 2.Laboratory environment (air conditioning, ventilation, etc. ) 3.Heating system (heaters, temperature sensors, etc.) 4.Cooling system (water supply, inlet/outlet cooling circuits, control valves, etc.) 5.Measurements 6.Numerical simulations

«BE-RF-PM» Thermal tests planning for CLIC prototype module type 0 1. CLIC MODULES CLIC module type 1 Constraints for CLIC module type 1

«BE-RF-PM» Thermal tests planning for CLIC prototype module type 0 1. CLIC PROTOTYPE MODULE TYPE 0 Cooling circuit Vacuum flange RF flange Manifold Interconnection flange RF waveguide Accelerating structure (AS) Super-accelerating structure (SAS) Test Module type 0 (TM0) D. Gudkov ToleranceMock-upReal D ext ± 4 μm± 2.5 μm Ra0.4 μm0.025 μm Flatness10 μm1 μm

«BE-RF-PM» Thermal tests planning for CLIC prototype module type 0 1. CLIC PROTOTYPE MODULE TYPE 0 First CLIC prototype module type 0 READY Assembly of RF network, vacuum network, compact load, cooling system inside module, etc. in progress EBW of 2 stacks

«BE-RF-PM» Thermal tests planning for CLIC prototype module type 0 1. CLIC PROTOTYPE MODULE TYPE 0 4. VACUUM BRAZING 7. CLEANING 9. VACUUM BRAZING 6. MACHINING 3. CLEANING 10. VACUUM BRAZING 12. VACUUM BRAZING 13. VACUUM BRAZING QC (Cooling circuit test) 5. QC (Cooling circuit test) Vacuum test 14. QUALITY CONTROL 11. MACHINING 8. VACUUM BRAZING

«BE-RF-PM» Thermal tests planning for CLIC prototype module type 0 1. CLIC PROTOTYPE MODULE TYPE VACUUM BRAZING 17. VACUUM BRAZING 19. EBW 20. TIG WELDING 1.Vacuum test 2.Cooling circuit test 3.Fiducialisation 1.Vacuum test 2.Cooling circuit test 3.Fiducialisation 18. QUALITY CONTROL TYPE 2 TYPE 1 TYPE 3 TYPE 1 1.Vacuum test 2.Cooling circuit test 3.Fiducialisation 1.Vacuum test 2.Cooling circuit test 3.Fiducialisation 21. QUALITY CONTROL Vacuum test STACK 1 STACK QUALITY CONTROL Vacuum test

«BE-RF-PM» Thermal tests planning for CLIC prototype module type 0 1. CLIC PROTOTYPE MODULE TYPE 1 Real super-AS for CLEX CLIC prototype module type 1 will be also used to test real RF structures: o 1 super-AS having real RF geometry o PETS on-off mechanism These tests are necessary to validate current assembly procedures developed for mock-ups as well as to check current alignment requirements Real RF structures used for TM1 can be also used for RF tests in CLEX PETS on-off mechanism

«BE-RF-PM» Thermal tests planning for CLIC prototype module type 0 TOPICS Topics and updates concerning the status of: 1.CLIC prototype module type 0 2.Laboratory environment (air conditioning, ventilation, etc. ) 3.Heating system (heaters, temperature sensors, etc.) 4.Cooling system (water supply, inlet/outlet cooling circuits, control valves, etc.) 5.Measurements 6.Numerical simulations

«BE-RF-PM» Thermal tests planning for CLIC prototype module type 0 2. LABORATORY ENVIRONMENT: air conditioning and ventilation system AIR COOLING T = °C v = m/s AIR CIRCULATION (v = 4 m/s) Air conditioning and ventilation system to reproduce thermal conditions inside CLIC tunnel Installation: end of October 2012 Cupboards inside and outside experimental area are being moved to bld. 162 Transport test

«BE-RF-PM» Thermal tests planning for CLIC prototype module type 0 TOPICS Topics and updates concerning the status of: 1.CLIC prototype module type 0 2.Laboratory environment (air conditioning, ventilation, etc. ) 3.Heating system (heaters, temperature sensors, etc.) 4.Cooling system (water supply, inlet/outlet cooling circuits, control valves, etc.) 5.Measurements 6.Numerical simulations

«BE-RF-PM» Thermal tests planning for CLIC prototype module type 0 3. HEATING SYSTEM: heaters Experimental conditions to be reproduced: G. Riddone, A. Samoshkin, CLIC Test Module meeting GROUP HEATER Q.TYS/NDimensions (mm)VoltageP max (W)I max (A)Operating condition 8 AS10680/TC31-80/6065W240V/SFØ8 x V AC % 2 PETS unit1S/N 0680/TS44-80/2175W240V/SFØ11.17 x % 2 DBQ8+8=16CSS _220vØ12.7 x % TOTAL % DBQ heaters AS + PETS heaters

«BE-RF-PM» Thermal tests planning for CLIC prototype module type 0 3. HEATING SYSTEM: temperature sensors solid state relay heaters IL Hardware thermal interlock (2 for AS, 1 for each PETS and DBQ) max. temp. limit: 50 °C All temperature sensors are currently stored in the lab 1 DOF for each heating sub- system (AS, PETS and DBQ) temperature sensors PWM signal for controlling the heaters T = 10 s Duty cycle (%)

«BE-RF-PM» Thermal tests planning for CLIC prototype module type 0 3. HEATING SYSTEM: temperature sensors 2 m 1.2 m 1 m 1.3 m 5 thermocouples for each section o Thermocouple type T (± 0.5 °C) 15 thermocouples in total Continuous acquisition during tests NI Channel Isothermal Thermocouple Input Module

«BE-RF-PM» Thermal tests planning for CLIC prototype module type 0 3. HEATING SYSTEM: electronics Data acquisition and control cards 24 V power supplies Digital control electronics for proportional valves Computer for data acquisition and control Installation of electronics for thermal tests in progress

«BE-RF-PM» Thermal tests planning for CLIC prototype module type 0 3. HEATING SYSTEM: software Software interface Panel for control valves Modifications to the previous configuration are being integrated in the software

«BE-RF-PM» Thermal tests planning for CLIC prototype module type 0 3. HEATING SYSTEM: status Heaters: DELIVERED RTD sensors: DELIVERED NI hardware: DELIVERED Thermocouples + DAQ card: DELIVERED Electric scheme (IL, SSR, etc.): COMPLETED

«BE-RF-PM» Thermal tests planning for CLIC prototype module type 0 TOPICS Topics and updates concerning the status of: 1.CLIC prototype module type 0 2.Laboratory environment (air conditioning, ventilation, etc. ) 3.Heating system (heaters, temperature sensors, etc.) 4.Cooling system (water supply, inlet/outlet cooling circuits, control valves, etc.) 5.Measurements 6.Numerical simulations

«BE-RF-PM» Thermal tests planning for CLIC prototype module type 0 4. COOLING SYSTEM Demineralized water Nominal volumetric flow rate: 0.36 m 3 /h Water inlet temperature: 25 °C Water outlet temperature: ~45 °C Max. pressure allowed: 5 bar

«BE-RF-PM» Thermal tests planning for CLIC prototype module type 0 4. COOLING SYSTEM: AS TS7 TS1 TS2 TS6 TS4

«BE-RF-PM» Thermal tests planning for CLIC prototype module type 0 4. COOLING SYSTEM: PETS TS17 TS22 TS23 TS24 TS25 TS26

«BE-RF-PM» Thermal tests planning for CLIC prototype module type 0 4. COOLING SYSTEM: hydraulic circuit Water pump Heat exchanger Temperature regulator Inlet/outlet port Water tank POWER SOCKET Max. 16 A POWER SOCKET Max. 32 A air cooling safety valves control valves flow (+temperature) transducer PRV pressure transducer inlet/outlet hydraulic circuit

«BE-RF-PM» Thermal tests planning for CLIC prototype module type 0 4. COOLING SYSTEM: status Water supply: DELIVERED Hydraulic parts (pipes, elbows, etc. ): DELIVERED Control valves: DELIVERED Measuring devices (pressure transducer, flow rate transducer, etc. ): DELIVERED PRV: DELIVERED Safety valves: DELIVERED Supporting frames (beams, ladders, etc. ): end of September Electric scheme: COMPLETED

«BE-RF-PM» Thermal tests planning for CLIC prototype module type 0 FINAL LAYOUT AS heater PETS heater DBQ heaters Temperature sensors (q.ty 29) POWER SOCKET Max. 63 A POWER SOCKET Max. 63 A Upgrade of current electric network of Lab completed POWER SOCKET Max. 16 A POWER SOCKET Max. 32 A Supporting system for: Control valves (q.ty 7) Flow transducer (q.ty 1) Pressure sensor (q.ty 1) Electric scheme for control valves, heaters, temperature sensors, etc. (J. Blanc) CUPBOARD for: NI cDAQ slots (q.ty 1) NI cDAQ slots (q.ty 1) 24 V supply Digital control electronics for proportional valves (q.ty 7) SSR

«BE-RF-PM» Thermal tests planning for CLIC prototype module type 0 TOPICS Topics and updates concerning the status of: 1.CLIC prototype module type 0 2.Laboratory environment (air conditioning, ventilation, etc. ) 3.Heating system (heaters, temperature sensors, etc.) 4.Cooling system (water supply, inlet/outlet cooling circuits, control valves, etc.) 5.Measurements 6.Numerical simulations

«BE-RF-PM» Thermal tests planning for CLIC prototype module type 0 5. MEASUREMENTS Measuring arm Romer Multi Gage With a length of 60 cm, this kind of portable CMM allows to measure fiducials by probing or by one point. According to Romer, the maximum permissible error is less than 18 µm. Laser tracker Leica AT401 According to simulation calculations, the expected accuracy of AT401 measurements on a girder and its components is about 5 µm rms (up to 40 °C). Fiducials are measured with respect to a fixed reference system. Measurements taken from different stations can be elaborated and combined together. The measuring device must be at the same temperature of the parts to be measured. Micro-Triangulation system The principle of Micro- Triangulation is to use the full potential of a theodolite by substituting a CCD camera instead of the eye of an operator. This method has clearly demonstrated its high precision capability on the 2 m long mock-up where a precision about 10 µm along each axis has been obtained in the determination of the illuminated fiducials locations. Fiducials dedicated to Micro-triangulation The aluminium main part of this fiducial (made in CERN) is equipped with a breakthrough ceramic ball with a diameter of 8 mm, a removable drawer which contain a LED allows to illuminate the accurate ball. S. Griffet et al. WPS system

«BE-RF-PM» Thermal tests planning for CLIC prototype module type 0 TOPICS Topics and updates concerning the status of: 1.CLIC prototype module type 0 2.Laboratory environment (air conditioning, ventilation, etc. ) 3.Heating system (heaters, temperature sensors, etc.) 4.Cooling system (water supply, inlet/outlet cooling circuits, control valves, etc.) 5.Measurements 6.Numerical simulations

«BE-RF-PM» Thermal tests planning for CLIC prototype module type 0 6. NUMERICAL SIMULATIONS: thermo-mechanical modelling Deformed shape of prototype module type 0 due to applied thermal RF loads (values in µm) Displacements [  m] (location and load type) Prototype type 0 MB (RF load)183 DB (RF load)47 MB (vacuum load)30 DB (vacuum load)131 MB (gravity load)27 DB (gravity load)40 Resulting displacements on the DB and MB lines due to thermal, vacuum and gravity loads Temperature [°C]Prototype type 0 Max temp. of module43 Water output temp. MB35 Water output temp. DB30 Resulting temperatures inside the modules R. Raatikainen (SAS = 820 W, PETS unit = 78 W, T amb = 25 °C)

«BE-RF-PM» Thermal tests planning for CLIC prototype module type 0 6. NUMERICAL SIMULATIONS: hydraulic circuit modelling SAS CLs SAS CLs SAS CLs SAS CLs PETS unit WG1 WG2WG3 WG4 PUMP PRV CV2 CV7 CV3 CV4 CV5 Q1Q1 Q2Q2 Q3Q3 Q4Q4 Q5Q5 Q Q = total flow rate [m 3 /h] Q 1 ~ Q 4 = flow rate for SAS [m 3 /h] Q 5 = flow rate for PETS unit and wave guides [m 3 /h] P PRV = set pressure for PRV [Pa] CV = control valve PUMP = water pump f i = pipe distributed energy loss (L i = pipe length) K i = Pipe fitting coefficient (n i = Number of fittings) P PRV SAS = super accelerating structure CL = compact load WG = waveguide L 1, f 1 L 2, f 2 L 3, f 3 L 4, f 4 L 5, f 5 CV1 n 1, K 1 n 2, K 2 n 3, K 3 n 4, K 4 n 5, K 5

«BE-RF-PM» Thermal tests planning for CLIC prototype module type 0 6. NUMERICAL SIMULATIONS: hydraulic circuit modelling #BURKERT REFERENCEk Vs [m 3 /h]DN [mm] CV1 Type 1 (2835, n ) CV2 CV3 CV4 CV5 Type 2 (2833, n ) CV7 Type 4 (2835, n ) k Vs value: Flow rate value for water, measured at +20 °C and 1 bar pressure differential over a fully opened valve CHARACTERISTICS OF PROPORTIONAL VALVES k V = flow coefficient for a certain opening position of control valve V = input voltage signal for control valve [ volt] Δp = pressure drop across control valve for a certain opening position [bar] ρ = water density [kg/dm 3 ]

«BE-RF-PM» Thermal tests planning for CLIC prototype module type 0 6. NUMERICAL SIMULATIONS: hydraulic circuit modelling ΔP cv = Pressure Drop across control valve [bar] ΔP f = Total Distributed Pressure Drop due to pipe friction ΔP c = Total Pressure Drop in component/fittings V = control valve set voltage On the basis of the operating condition of the control valves (i.e. input voltage), the pressure to be set at PRV depends on the requested flow rate inside the cooling system. For each control valve, a desired voltage input can be considered into the simulation. The corresponding flow rates inside each branch of the circuit are calculated consequently. Inputs VP PRV (volts)[bar] Results QQ 1~4 ΔP CV1~4 ΔP f1~4 ΔP c1~4 Q5Q5 ΔP CV5 ΔP f5 ΔP c5 ΔP CV7 ΔP c7 [m 3 /h] [bar] [m 3 /h][bar]

«BE-RF-PM» Thermal tests planning for CLIC prototype module type 0 6. NUMERICAL SIMULATIONS: hydraulic circuit modelling PUMP PRV FTPT CV PT FT = flow transducer PRV = pressure regulating valve PT = pressure transducer CV = control valve Preliminary test on a simplified version of the cooling system for: o Testing data acquisition and control system o Testing electronics o Measuring Kv of control valves Characteristic curve of control valves to be measured

«BE-RF-PM» Thermal tests planning for CLIC prototype module type 0 6. NUMERICAL SIMULATIONS: CFD model of air conditioning and ventilation system Total RF power per module: 4 kW Number of modules: 4 Assumptions per module: o Heat dissipation to cooling system: 80 % (3200 W) o Heat dissipation to air: % ( W) Q RF Q air Q cooling Q air

«BE-RF-PM» Thermal tests planning for CLIC prototype module type 0 6. NUMERICAL SIMULATIONS: CFD model of air conditioning and ventilation system 2 m 4.6 m 14.6 m 2.3 m Vertical cutview Lab volume TM0 (2 x 1 x 1 m) v x = 0.5 m/s T i = 20 °C Wall (no penetration condition) v x = 0.5 m/s Wall (no penetration condition) y z x Initial temperature = 25 °C Time period = 300 s

«BE-RF-PM» Thermal tests planning for CLIC prototype module type 0 6. NUMERICAL SIMULATIONS: CFD model of air conditioning and ventilation system T = 23 °C T = 20 °C T i = 20 °C v x = 0.5 m/s Q = 800 W

«BE-RF-PM» Thermal tests planning for CLIC prototype module type 0 CONCLUSIONS: THERMAL TESTS STRATEGY NAMELAB CONFIGURATION PARAMETERS HeatingCoolingVacuum TT1TM0VVX TT2TM0 + TM0VVX TT3TM1 + TM0VVV TT2 TT3

«BE-RF-PM» Thermal tests planning for CLIC prototype module type 0 SCHEDULE HEATING SYSTEM Heaters: DELIVERED RTD sensors: DELIVERED NI hardware: DELIVERED Thermocouples + DAQ card: DELIVERED Electric scheme (IL, SSR, etc.): COMPLETED COOLING SYSTEM Water supply: DELIVERED Hydraulic parts (pipes, elbows, etc. ): DELIVERED Control valves: DELIVERED Measuring devices (pressure transducer, flow rate transducer, etc. ): DELIVERED PRV: DELIVERED Safety valves: DELIVERED Supporting frames (beams, ladders, etc. ): end of September Electric scheme: COMPLETED LAB ENVIRONMENT Air conditioning and ventilation system: end of October o Main work for HVAC installation should start W42 o Some smaller work should be done before with limited impact for the lab (move the compressed air supply, remove the sink/ fridge and furniture, move some lighting fixtures)

«BE-RF-PM» Thermal tests planning for CLIC prototype module type 0 SCHEDULE