Vacuum flex lines design, production, qualification and ...€¦ · •Common interconnection piping for maintenance operations •Integrated internal by pass and small evaporator

Claudio Bortolin 1Forum on Tracking Detector Mechanics 2015

Vacuum flex lines design, production, qualification and tests for theATLAS IBL CO2 cooling system

C. Bortolin, C. Arregui, J. Ballansat, O. Crespo-Lopez, M. Gil Costa, P. Delebecque, C. Deluca Silberberg, T. Eisel, N. Geffroy, A. Gerardin, G. Glonti, J. Godlewski, M. Gutt-Mostowy, S. Jézéquel, W. Kosmale, A. Laassiri, D. Laporte, M. Lippert, N. Massol, S.

Nichilo, A. M. Piguiet, A. Porret, T. Rambure, T. Todorov, M. v. Overbeek, A. Vacca, B. Verlaat, E. Vigeolas-Choury, S. Vogt, M. Wehrsmeister, L. Zwalinski

Hey Houston, the flex lines are

too short!

Is Claudio there?


Outline• ATLAS IBL cooling system

• Concentric flex lines design and prototype

• Final design of the IBL flex lines and production process

• Final qualification test and final installation

IBL detector CO2 2PACL concept Cooling system components and layout

Concept motivations First prototype Thermal and stress tests

Flex lines and Rotatable connectors: parts manufacturing Welding campaign and qualification procedure Leak and pressure tests

Liquid CO2 flow test Final connection and integration in Muon sector 5 of ATLAS


ATLAS IBL detector IBL installation 05/2014

Detector characteristics:• 14 staves (r≈3.3 cm)• 1.9% X/X0 radiation length

beam pipe included• Pixel size (f; z) 50, 250 um• 12Mpx • Cooling T min= - 400C• Max Power dissipation: 1500W

IBL stave layout


2-Phase Accumulator Controlled Loop

Pump

1 4

5

32

6

7

Gas

Pre

ssu

re

Liquid

Isothermal line

Enthalpy

2-phase(Evaporation)

3

4 56

2

17

4-5 Det. stave2 phase cooling

DETECTOR POWER

Plant

Detector

Heat exchanging transfer line

Why CO2 cooling?

• Large latent heat of evaporation• Low liquid viscosity• High heat transfer coefficient • High thermal stability due to the high

pressure• Operating Temperature: -40 to 25 C• Environmentally friendly


IBL cooling system

•2 cooling plants (redundancy)

•2 two stage chillers (redundancy)

•1 accumulator with redundant control

•Common interconnection piping for

maintenance operations

•Integrated internal by pass and small

evaporator for stand-by operation

El. CabinetChiller A CO2 Plant A

Accumulator

Chiller B CO2 Plant B


No heat exchange + good insulation

Detector

Tliquid

T2phase

Plant

Vapor return

Pipe length

Gas

Pre

ssure Liquid

Isothermal line

Enthalpy

2-phase(Evaporation)

Transfer line

Concentric Flex lines

• Inlet flow is “insulated” from ambient heating effects.

• Enhanced thermal heat exchange contact

Tliquid

T2phase

Vapor return

Concentric transfer tube

Pipe length

Plant

Detector

Transfer line

Ambient heat

With concentric transfer lines thanks to the heat exchanged between inlet and outletthe inlet flow is provided with optimal thermodynamic conditions at the inlet of thedetector.


Flex lines design

From inside:

• CO2 inlet ss capillary (Ø 1.6 mm OD)

• CO2 return ss pipe (Ø 4 mm OD)

• Multi Layer Insulation (MLI): used to avoid heat transfer by radiation

• Glass fibre sleeve: to limit conduction btw the inner pipe and the outer hose

• Vacuum flex hose: to reduce the heat picked up from environment by convection

Design layout based on cryogenics insulation technics


Prototype test layout in PH-DT

C6F14 was circulated at low temperature through the line prototype at different flow rates

Fluid and surface temperatures monitored in different points between inlet and outlet

Vacuum level monitored at the outlet of the flex line with a vacuum gauge, while the vacuum pump was connected at the inlet of the lines.

Cold spots were checked using a thermal IR camera


Test setup

Inlet and

Transition from rigid to flex pipe

PFEIFFER Dual GaugeTM TPG 262 PFEIFFER Compact FullRangeKROHNE mass flow meter

Flex line prototype

Cold spot 1 Cold spot 2


Test results: Delta T inlet-outlet

Temperature difference between inlet and outlet of the transfer line depending on the mass flow rate in straight configuration with temperature of the coolant measured at the inlet = -40°C.


Delta T btw ambient and surface temperature measured on the rigid and flexible part of the transfer line in straight configuration with different mass flow rates with the coolant temperature measured at the inlet = -40°C.

Test results: surface temperatures


Cold spots

The temperatures of the flex hose surface were always well above 20 degrees. The measurements were taken during summer nights.

Different flows Different Coolant T


Vacuum quality effect

1) The transfer line can easily operate without significant loss of performance only with a backing pump. 2) In case of failure of the turbo-molecular pump no special actions are required to prevent the coolant condensation on the outer hose of the transfer line.


Stress tests and cold spots

Flex line coiled (Ø≈ 20cm)

T sensors installed


Routing of the transfer lines at side A of Inner Detector (ID) Endplate. Lines length about 11 m, the lines flexibility is fundamental to snake to the ID Endplate.

Tracking

LAR

Tile Calorie

Flex lines From S5 to IDEP

Side A Side C

Manifold box (Muon sector 5)


A-A ( 1 : 1 )

B-B ( 10 : 1 )

A

A

1.4301 X5CrNi18-10112-040101.iptEnd of the Flex Line Part 111

Fa.Witzenmann RS341S00-UA22S DA12 RS341S00-UA22S-DN12.iamFextube12

novotek 1522-3SO1.4301 X5CrNi18-101522-3SO.iptKF M. ROHRANS.304 KZ,

NW16 L=30 D=17,2 / D =14

13

1.4301 X5CrNi18-10112-040102.iptEnd of the Flex Line Part 214

1.4301 X5CrNi18-10112-040103.iptpipe elbow 315

Inner tubes.iamInnertubes17

1.4301 X5CrNi18-10VA-Rohr DA 1.6-DI 1.iptpipe 1.617.1

1.4541 X6CrNiTi18-10VA-Rohr DA 4-DI 3.iptpipe 317.2

super insulst ionsuper insulat ion.iptsuper insulst ion17.3

St cklisteBemerkungNormAbmessungenWerkstoffZeichn. Nr.BenennungSt .Teil

B

B

DIN EN 20 216 - A2 (420 x 594)

Hauptprojekt ion Gewicht .........: -

mmDimensionen :

Ma e ohne Toleranzangabe nach

DIN ISO 2768 m K

Werkstoff

Zeichnungsnummer / EDV Nr.:

Software......: Inventor 2011

Blat t : Gesamtzahl: 1 V12.b1

Teil:

Flex Line

Flex Line

Flex Line

CO2-ATLAS-BELLEProjekt

Max-Planck-Institut f r Physik(Werner-Heisenberg-Institut)

gezeichnet

geprueft

geplot tet

Tag Name

31.01.2014 S.Vogt

M nchen

+0,1 -0,1

Ma stab

112-040100.idw

1:1

11000mm

51 42

7.1

3

st itch up the 10 layers Super- insulat ion

144,8 mm + 105mm = ca.250

144,9

orbital welding 3

orbital welding 3orbital welding 3

orbital welding 17,2 orbital welding 17,2 orbital welding 6

35

28

6

R10

19

44

59

KF16

17,2

10

55

12,5

16,5 14 17,2

30

96

10

orbital welding 4

1.6mm braze joint

Presure seal welded for:

test pressure: 160bart ightness with 100 bar over 48h: nomodificat ions to the pressure gauge Welde cleanliness: inside with

protect ive gas / outside brushed orbital welding TIG where possible

7.2

7.3

16 Flex concentric transfer lines

Design by S. Vogt (MPI)

Many mechanical parts and customized fittings machined at MPI in Munich


C-C ( 1 : 1 )

D-D ( 1 : 1 )

E-E ( 1 : 1 )

C CD D

Fa. Swagelok 6LV-2-VCR-3S-2TB7316L (1.4404)112-021001.iptVCR Gland, 1/ 8 in. modifyed11

Fa. Swagelok d 1/ 8"x150mm1.4404 X2CrNiMo17-12-2112-021002.ipttube 1/ 8 12

1.4404 X2CrNiMo17-12-2112-021003.iptpuller13

Fa. Swagelok SS-4-VCR-P316L (1.4404)112-021004.iptSS-4-VCR-P-112-02 modified14

Fa. Swagelok SS-4-VCR-2316L (1.4404)112-021005.iptSS-4-VCR-2-112-02 modified15

Fa. Swagelok 6LV-4-HVCR-3- .60SR316L (1.4404)112-021006.iptTube But t Weld modified16

Fa. Swagelok SS-8-VCR-3-BL316 (1.4401)112-021007.iptBlind (Undrilled) Gland 1 modified17

Fa. Swagelok SS-8-VCR-2316L (1.4404)112-021008.iptVCR Face Seal Fit t ing, 1/ 2 in Gasket modified18

Fa. Swagelok SS-8-VCR-T316L (1.4404)112-021009.iptUnion Tee up drilling19

112-021010-000.iamsplit nut 1/ 8" VCR110

Fa. Swagelok SS-8-VCR-3-BL316 (1.4401)112-021014.iptBlind (Undrilled) Gland 2 modified114

DIN 934 1.4301 X5CrNi18-10112-021015.iptpuller-nut -M6.5x0,5115

Fa. Swagelok SS-8-VCR-2316L (1.4404)SS-8-VCR-2.iptVCR Face Seal Fit t ing, 1/ 2 in Gasket220

Fa. Swagelok SS-100-R-2BTA2SS-100-R-2BT.iptBored-Through Reducer, 1/ 16 in. x 1/ 8 in121

Fa. Swagelok SS-8-VCR-1316 (1.4401)SS-8-VCR-1.ipt1/ 2 in. Female Nut222

novotek 1571-71.4301 X5CrNi18-101571-7.iptKF mit Rohransatz lg VA 1.4301 NW 10 L=70 / D=14 / d=10130

novotek 1212E1.4301 X5CrNi18-101212E.iptZentrierring VA 1.4301/ EPDM NW 16 a=16 / b=17231

novotek 13411.4301 X5CrNi18-101341.iptSpannring FL Massiv, VA NW 10/ 16 a=22 / b=55 / c=47332

novotek 11221.4301 X5CrNi18-101122.iptT-St ck VA 1.4301 NW 16 a=40 / d=15 / s=1,5133

novotek 1241E1.4301 X5CrNi18-101241E-novotek.iptberg.Zentrier. VA/ EPDM NW 10/ 16 a=10 / b=17 / b1=12134

Fa.Ket terer

CO2 line from the Detector

AD4WD0,51.4404 X2CrNiMo17-12-24mm-0-5 copy.ipttube da 4mm Dummy140

Fa.Ket terer

CO2 line to the Detector

AD1,6WD0,31.4404 X2CrNiMo17-12-21-6mm-0-3 copy.ipttube da 1,6mm Dummy141

Fa. Swagelok SS-2-VCR-2316L (1.4404)SS-2-VCR-2.iptVCR Face Seal Fit t ing, 1/ 8 in. Gasket171

St cklisteBemerkungNormAbmessungenWerkstoffZeichn. Nr.BenennungSt.Teil

E

E

Hauptprojekt ion Gewicht .........: -

mmDimensionen :

Ma e ohne Toleranzangabe nach

DIN ISO 2768 m K

Werkstoff

Zeichnungsnummer / EDV Nr.:

Software......: Inventor 2011

Blatt : Gesamtzahl: 1 V12.b1

Teil:

Dismoutable & rotable concentricjoint

CO2 Manifold

Dismoutable & rotableconcentric joint

CO2-ATLAS-BELLEProjekt

Max-Planck-Institut f r Physik(Werner-Heisenberg-Institut)

gezeichnet

geprueft

geplot t et

Tag Name

17.01.2014 S.Vogt

M nchen

+0,1 -0,1

Ma stab

112-021000.idw

1:1

DIN EN 20 216 - A1 (594 x 841)

1/ 4" Pipes

Color Code for Pipes

3/ 8" Pipes

1/ 2" Pipes

3/ 4" Pipes

1/ 8" Pipes

KF NW16/ 10

Dummy

parts to be processed

3432 3033314140 14 2220 9 21 8 63 10 17 5 4 15 2

orbital welding 4

orbital welding 14

orbital welding 9,652





split nutM6,5x0,5

SW4SW4

4S

W

16 Rotatable connectors

Design by S. Vogt (MPI)

Many mechanical parts and customized fittings machined at MPI in Munich


Flex lines welding strategy• The sequence of the orbital welding was carefully checked and defined

o Welding started from inside towards the outside

• Orbital Welding heads procurement according to the flex design layout (access space requirement and interference with other components to be avoided)

o Agreed with EN-MME and PH-DT to check the welds with X-rays at the Crystal Palace during nights

Welding head

Clamping ring

o We used two different orbital welding machines

• Reparation of a “non-conform” weld wasn’t always possible, to cut a weld could jeopardize the whole assembly process

o Welding parameters optimization well tested and X-Rays checked systematically

o Once we determined the right welding parameters we tried to weld the samples using neighborhoods parameters (NASA-AMS strategy) in order to reduce any risk of failure

Carried out about 200 orbital welding qualified them with Non-Destructive and Destructive testing, pressure and leak tested within 6 weeks (“maybe less if you can” Bart said). We did it in 4 weeks

• Capillary brazing optimization was a long process that was carried out in parallel in order to qualify the process and be ready for the production


Welding quality verifiedWelding parameters optimized by Abdel L., Sylvain N., Martijn van O. and checked with ND or D tests for diameters: 3 mm, 4 mm, ¼”, 14 mm and 17.2 mm

The welding program parameters are available on EDMS for possible future productionshttps://edms5.cern.ch/document/1421558/1

Capillary brazing: Pressure and leak tested


Capillaries productionCapillaries brazing parameters optimized and checked with a destructive test

Metallography check result: “No lack of brazing could be observed. No overflown filler could be observed in the pipe.” Alexandre Gerardin (EN-MME)

Brazing made by: Agostino Vacca (EN-MME)


The reverse VCR connector: to make it “standard”

NutGasket

Sealing glands

45°≅25 Nm

45° VCR ≅ 360° reverse VCR

VCR ¼” thread pitch= 1.5mm

Reverse VCR thread pitch= 0.5mm

Profilometer measurements made by G. Romagnoli(PH-DT) at the EPFL (Lausanne)

Pressure tests at 160 bars and Helium leak test were successful


17.2mm orbital welding


Capillaries insertion and ¼” Orbital welding


Each line may affect 14% of IBL

Acceptance criteria: EN1435 (Class B EN 25817)

X-rays applied to:

1) welding test samples

2) all pressurized pipes connections

Results: 16 lines with 100% welding conformities


Pressure test

Helium Pressure test: we pressurized the liquid and gas pipes and looked for any leak with vacuum hoses connected to a leak detector

Caps

Helium leak detector

Helium Bottle

Leak rates measured:8x10-9 to 2x10-8 mbar l/s


Flow test results

Very good correlations between Flow and Dp

Nominal flow region


Tightening and pressure test

5) No leaks!

3) Pressurizing with helium

4) Leak search with a sniffer

2) Tightening of the rotatable conn.1) Pre-positioning of the lines


14 Flex lines installed in Muon sector 5


Conclusions

Great collaboration with many colleagues was the key to this achievement, especially with the welders (Abdel, Martijn and Sylvain) who worked with perfect synchronism, efficiency and always smiling.

I would like to particularly thank the PH-DT gas group, lead by Roberto Guida, for theirsupport and effort during the production phase

Concentric transfer lines was developed starting from cryogenic applications to detector cooling to optimize the inlet fluid conditions and be insulated by heat environmental effects.

The final design was optimized according to a prototype thermal qualification and the layout of the final installation

Thanks to teamwork, good planning and QA we built, qualified and tested 16 flex lines in about 6 weeks.

I would also like to mention George and Piotr who were always ready to help to face the difficulties we met during the production, particularly Piotr that setup a new practical mechanical test to check the robustness of the flex hoses.

Documents

Vacuum flex lines design, production, qualification and ...€¦ · •Common interconnection piping for maintenance operations •Integrated internal by pass and small evaporator