1. Mechanical calculations of the CDS key elements
Janusz Skrzypacz
Jarosław Poliński
Maciej Chorowski
Preliminary Design Review Meeting, 20 May 2015, ESS, Lund, Sweden

2. CDS Aim of the project CTL CDL (75 m) 21 High Beta Linac – 174 m
9 Medium Beta Linac – 75 m

3. Codes and standards
EN 13480

4. Thermal properties were taken from CryoComp software
Materials
Process pipes and their elements: (EN :2004 );
Vacuum jacket and their elements: (EN :2004 );
Thermal shield: aluminum T4 (EN 755-2);
Sliding supports of the process pipes: G10
Thermal properties were taken from CryoComp software

5. Pipe parameters EN 10220 EN 13480 e/Do Type of process line
Pipe description
Size
PS [bar]
Tn [K]
Do [mm]
emin [mm]
e [mm]
e/Do
Main cold process lines
MC - He supply line
DN65 6
4,5
76,1
0,159
2.6
0.03
MB - VLP line CDS
DN200 3
219,1
0,458
2,9
0.013
MB - VLP line CTL
DN250
273
0,570
0.011
ME - TS supply line
DN50 25 40
60,3
0,521
2.3
0.033
MF - TS return line 50
Branch cold process lines
BC - He supply branch line
DN10
17,1
0,036 2
0.117
BB - VLP branch line
0,126
BE - TS supply branch line
DN8
13,7
0,118
0.146
BF - TS return branch line
Side cold process lines
SC1 - He supply side line 1
SC 2- He supply side line 2
SB - VLP side line
SE - TS supply side line
SF1 - TS return side line1
SF2 - TS return side line 2
Vacuum Shield
DN550
1.5
293
559
0.292
EN 13480

6. Assumptions of Process Pipe Model
Calculations in accordance with EN 13480;
Each process pipe was analysed separately;  
The pipe model encompasses only three CDL modules and all CTL line;
The jumper connection was created only in one CDL module;.  

7. Parameters of calculations
Flexible elements - Bellows
Support distances for process pipes and vacuum shield
Order
Pipe DN
PS [bar]
L1max [mm]
L2max
[mm]
Lgmax [mm] 1
DN 8 25 32
112
1100 2
DN 10 6 40
140
2100 3
DN 50
200
700
6800 4
3300 5
DN 65
260
910
8000
DN 200
800
2800
18000 7
DN 250
1000
3500
19000 8
DN600
1.5
2200
7700
>20000
Metal bellows parameters – WITZENMANN catalog DN PN
Type
2dn
[mm] W
[kg] A
[mm2] ca
[N/mm]
[Nm/deg] cl 50 25
ARN 32 2
4500
216
2.8
159 65 6
ARN 72
3,5
6820
111
2.2 39
125
ARN 63
3.6
18600 81
4.2
349
200
ARN 90
9.1
43000
151 18
529
250
ARN 96
12.2
66300
161 30
995
600
2.5
ARN 76 23
319200
205
182
11569

8. Parameters of calculations
Flexible elements – Metal Hoses
Applied parameters of metal hoses – WITZENMANN calaog DN PN
Type
W [kg]
rN [mm] ca
[N/mm]
[Nm/deg]  cl
[N/mm]  50 25
RS331S12
1.67
320
1e5/500 9
145 65 6
2.88
460
6.6
540
200
RS430S12
520 60
2200
250
620 90
2500

9. Geometry of the process pipe model
Interface to SPOKE modules
Node of the interface

10. Geometry of the process pipe model
Interface to Cryomodule
Node of the interface

11. Geometry of the process pipe model
Interface to ColdBox
Node of the interface

12. Process Pipes - results of calculations
Criteria
of stress acceptance
LC1 - The summary of the calculations (operating conditions) No
Parameter
VLP
He supply
TS supply
TS return 1
DN [mm]
200/250 65 50 2
Design pressure PS [bar] 6 25 3
Temperature [K]
4.5 40 4
Fluid density [kg/m3]
135
Max. sustained stress s1 [MPa]
15.51
10.21
43.3
43.27 7
Max. expansion stress s3 [MPa]
128
86.69
67.84
67.03 8
Max. s4 (s1+s3) [MPa]
134.4
89.32
76.48
75.67 9
Max bellows movement [mm]
24.7
24.2
24.5
fh = min (fc; f) = [MPa]
fa = U(1.25fc fh)Eh/Ec
= [MPa]
fh+a = fh+fa = 341 [MPa]
LC2 - The summary of the calculation (pressure test conditions) No
Parameter
VLP
He supply
TS supply
TS return 1
DN [mm]
200/250 65 50 2
Test pressure PT [bar]
8.58
35.75 3
Temperature [K]
300.5 4
Fluid density [kg/m3]
1.25 6
Max. sustained stress s1 [MPa]
24.19
15.92
61.97
61.66 7
Max. expansion stress s3 [MPa] 8
Max. s4 (s1+s3) [MPa]
fh = 0.95Rp1.0 = [MPa]

13. Process Pipes - results of calculations
Maximal loads acting on the fixed support of the process pipes
LC 1 operating conditions
Node
Fx [N]
Fy [N]
Fz [N]
Mx [Nm]
My [Nm]
Mz [Nm]
2153
VLP
-1796
37498
-505
-194
817
He supp.
-251
2025
-108
-42
116
TS supp.
-206
6980
-96 97
TS return
-203
7028 95
LC 2 pressure test conditions
Node
Fx [N]
Fy [N]
Fz [N]
Mx [Nm]
My [Nm]
Mz [Nm]
2153
VLP
56896
-1367
-565
He supp.
5825
-173
-72
TS supp.
15981
-134
-60
TS return
15893

14. Process Pipes - results of calculations
Loads acting on process pipes interfaces – operating conditions
Node
Fx [N]
Fy [N]
Fz [N]
3120
VLP
2990
He supp.
3058
TS supp.
3081
TS return
3043
Interface to ColdBox
Node
Fx [N]
Fy [N]
Fz [N]
265
VLP
153 45
He supp. 55 15
TS supp. 30 8
TS return 29 7
Interface to CM
Node
Fx [N]
Fy [N]
Fz [N] 40
VLP
25731 54
He supp.
1694 34
TS supp.
6535
-30
TS return
Interface to spoke module

15. Process Pipes - results of calculations
Loads acting on process pipes interfaces – pressure test conditions
Node
Fx [N]
Fy [N]
Fz [N]
3120
VLP
-333
He supp.
-41
TS supp.
-33
TS return
Interface to ColdBox
Node
Fx [N]
Fy [N]
Fz [N] 40
VLP
36894
-365
He supp.
5833
-35
TS supp.
15873
-16
TS return
Interface to spoke module

16. Process Pipes - results of calculations
Sustained stress s1 [MPa] for VLP – operating conditions

17. Process Pipes - results of calculations
Expansion stress s3 [MPa] for VLP – operating conditions

18. New concept of the vacuum jacket model

19. Vacuum Jacket - results of calculations
LC 1 - The summary of the calculation – operating conditions
Criteria
of stress acceptance No
Parameter
Outer Jacket 1
DN [mm]
300/550 2
Design pressure PS [bar] -1 3
Temperature [K]
300.5 4
Continuous load [kg/m] 30 6
Max. sustained stress s1 [MPa]
14.34 7
Max. expansion stress s3 [MPa] 8
Max. s4 (s1+s3) [MPa] 9
Max bellows movement [mm]
0.5
fh = min (fc; f) = [MPa]
LC 2 - The summary of the calculation – failure conditions No
Parameter
Outer Jacket 1
DN [mm]
300/550 2
Design pressure PS [bar]
1.5 3
Temperature [K]
173 4
Continuous load kg/m 30 6
Max. sustained stress s1 [MPa]
11.96 7
Max. expansion stress s3 [MPa]
100.2 8
Max. s4 (s1+s3) [MPa]
104.1 9
Max bellows movement [mm]
19.2
fh = min (fc; f) = [MPa]
fa = U(1.25fc fh)Eh/Ec
= [MPa]
fh+a = fh+fa = [MPa]

20. Vacuum Jacket - results of calculations
Loads acting on process pipes interfaces – operating conditions
Node
Fx [N]
Fy [N]
Fz [N] 10
31826
1010
161
1426
206
3120
1553
Maximal loads acting on the fixed support of the vacuum jacket

21. Vacuum Jacket - results of calculations
Sustained stress s1 [MPa] for vacuum jacket – operating conditions

22. Vacuum Jacket - results of calculations
Loads acting on process pipes interfaces – failure conditions
Node
Fx [N]
Fy [N]
Fz [N] 10
46477
1022
161
20940
1007
3120
7131
Maximal loads acting on the fixed support of the vacuum jacket

23. Vacuum Jacket - results of calculations
Stress distrybution for vacuum jacket – failure conditions
Sustained stress s1 [MPa]
Expansion stress s3 [MPa]

24. Vacuum Jacket model verification

25. Vacuum Jacket model verification

26. Internal Fixed Support Calculations

27. Internal Fixed Support Calculations

28. Internal Fixed Support Calculations

29. Internal Fixed Support Calculations
LC1 – thermal calculations;
LC2 – normal operating conditions; the forces and the moments values were taken for the most loaded supports: CTL – node 2153, CDL – node 410 (Table 10) and thermal load.
LC3 – normal operating conditions with pure mechanical loads; the forces and the moments values were taken for the most loaded supports: CTL – node 2153, CDL – node 410 (Table 10).
LC4 – pressure test conditions; the values of the forces and the moments were taken for the most loaded supports – CTL – node 2153, CDL – node 410 (Table 13).

30. Internal Fixed Support Calculations
LC 1 – thermal calculations
 CTL
VLP
He supply
TS supply
TS return
Heat [W]
1.22
0.3
0.1
22.5
 CDL
VLP
He supply
TS supply
TS return
Heat [W]
0.77
0.36
0.13
22.2

31. Internal Fixed Support Calculations
LC 2 – operating conditions

32. Internal Fixed Support Calculations
LC 3 – Mechanical loads only

33. Internal Fixed Support Calculations
LC 4 – Pressure Test Conditions

34. Valve Box Vacuum Barrier Calculations

35. Valve Box Vacuum Barrier Calculations

36. Valve Box Vacuum Barrier Calculations
LC 1 – thermal calculations
VLP
He supply
TS supply
TS return
Heat [W]
0.1546
0.045
0.0383
0.136

37. Valve Box Vacuum Barrier Calculations
LC 2 – operating conditions

38. Valve Box Vacuum Barrier Calculations
LC 3 – Mechanical loads only

39. Valve Box Vacuum Barrier Calculations
LC 4 – failure conditions

40. Valve Box Vacuum Barrier Calculations
LC 4 – failure conditions

41. Valve Box Vacuum Barrier Calculations
LC 4 – failure conditions

42. Sliding support calculations

43. Sliding support calculations

44. Sliding support calculations

45. Sliding support calculations
LC 1 – thermal calculations

46. Sliding support calculations
LC 2 – only mechanical loads

47. Sliding support calculations
LC 3 – operating conditions

48. Sliding support calculations
LC 3 – operating conditions