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Inner detector upgrade / IBL Activities on cooling circuits @ LAPP. LAPP team Jacky Ballansat , Patrick Baudin, Pierre-Yves David, Pierre Delebecque , Sabine Elles , Mohamed El Kacimi , Nicolas Massol , Thibaut Rambure , Jean Tassan , Theodore Todorov , Tamer Yildizkaya. - PowerPoint PPT Presentation
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Pierre DelebecqueCooling – upgrade 2012 May 31 st1
Inner detector upgrade / IBL Activities on cooling circuits @ LAPP
LAPP team Jacky Ballansat, Patrick Baudin, Pierre-Yves David, Pierre Delebecque, Sabine Elles, Mohamed El Kacimi,
Nicolas Massol, Thibaut Rambure, Jean Tassan, Theodore Todorov, Tamer Yildizkaya
Pierre DelebecqueCooling – upgrade 2012 May 31 st2
Beam Pipe
Manifold connexion
Ceramic
PP0 brazed sleeve
OUTLET
SS ID 1.5-OD2.5
IST
INLET
Stave
LAPP Fitting 1.7mm
Ti ID 1.5-OD1.7 Ti ID 2.0-OD2.2
LAPP Fitting 2.2mm
SS ID 2.0-OD3.0
1 – IBL Cooling lines Layout pp1-pp0
Pierre DelebecqueCooling – upgrade 2012 May 31 st 3
Specifications2 –Fittings
• Small fitting, less than 10 mm :– To minimize budget material– To fit inside a limited volume
• Maximum leak rate (He) : 10-8 mbar.l.s-1 @ 20bar• Pressure (bar):
• Radiation level : up to 1000 Mrad • Working temperature : mini -40 °C maxi +20 °C• Pipes dimensions :
– Typical type I tubes : 1.5 and 2 mm ID, 0.1mm wall thickness• Pipe material : Titanium T40
Pierre DelebecqueCooling – upgrade 2012 May 31 st 4
Context2 –Fittings
• Current developments based on IBL context (but upgrade is the next step)• Fittings will be used @ PP1 (end of IST)• Developments for Upgrade …and other experiments
Pierre DelebecqueCooling – upgrade 2012 May 31 st 5
3 –Fittings Fittings evolution summary
Pierre DelebecqueCooling – upgrade 2012 May 31 st 6
Fittings evolution summary(Baseline)
3 –Fittings
Material• Titanium grade 2 and 4 : hardness to low• Titanium grade 5 (TA6V) : same hardness as Stainless steel use for commercial fittings
Shape• Cone/cone : “random” results • Cone/toroid : good results but design sensitive to misalignment• Cone/sphere
Gliding surface treatment• PVD carbon tungsten : good to prevent “metal chips” (good hard wearing)• Graphite : should be as good as MOS2 but same results as “no treatment” ???• MOS2 ( special attention to prevent treatment migration on cone and sphere)
Leak tightness surfaces• Cone raw from machining / sphere polished
Pierre DelebecqueCooling – upgrade 2012 May 31 st 7
Tests - prototypes2 –Fittings
Prototypes “base line type” manufactured and tested• 16 prototypes made @ LAPP• 50 prototypes made in the industry
Tests motivations• Comparison between LAPP and industrial production (similar results)• Influence of the polishing• Comparison MOS2, graphite, PVD (tests on fittings + specific tests)• Influence of the heating on material characteristics ( conclusion= decreasing of the
hardness !! -> no brazing !!! (for Titanium and stainless steel)
Prototypes on other devices• Stainless steel on cooling loop prototypes • TA6V on first IBL stave 0
Other developments• Special tooling to prevent rotation and to apply the required torque : first prototypes
Pierre DelebecqueCooling – upgrade 2012 May 31 st 8
2 –Fittings
Issue• Connection between samples and test device seemed not as good as the fitting itself• Difficulties to validate the samples if there were other leaks• No problems @ room temperature but leaks appeared @ -40 °C (He 20 bars)
Actions• He test of the vacuum seals (room temperature and cold) : seemed OK• Different type of materials for seals and flanges and shapes (and glues) have been
tested• Take into account the expansion coefficients of the materials• Performed simulations
Conclusion• Leaks appear on elastomer vaccum seals @ a precise (cold) temperature.• Elastomer seal replaced by an helicoflex (aluminium + spring)• Hoped the problem would have been solved sooner• Better sample/flange connexion • New titanium seal developed• Needs “high torque level (30 N.m)
Leak tightness studies
Pierre DelebecqueCooling – upgrade 2012 May 31 st 9
2 –Fittings Leak tightness studiesNew Sample flange assembly
Pierre DelebecqueCooling – upgrade 2012 May 31 st 10
2 –Fittings
• Tests of proto stave have been performed @ LAPP• Up to 50 temperature (-40 to +50 °C) and pressure cycles
(5 to 60 bars)• LAPP fittings (10 mm) + swagelok mounted on the
stave• 150 bars hydraulic pressure test
CO2 cooling tests
Pierre DelebecqueCooling – upgrade 2012 May 31 st 11
2 –Fittings
New tests• Last tests to be done on 18 10mm fittings • Leak tests on new 8mm fitting (1st standard test
OK (1.510-8 mbar.l.s-1 @ 20bar @ -50 °C)
Developments• Tightening tool :
Next steps
8mm design
Pierre DelebecqueCooling – upgrade 2012 May 31 st12
3 –EB welding
4x10 samples weldedGood general results, no leak @ 1bar He (Techmeta)Small amount of material inside the pipeMore metallographic analysis results from CERN in the futureLeak test :1st standard test OK (1.810-8 mbar.l.s-1 @ 20bar @ -50 °C)
Metallographic analysis from Techmeta ( 1.5mm and 2 mm ID pipes)
Pierre DelebecqueCooling – upgrade 2012 May 31 st 13
4 –Electrical break
Baseline solution : electrical break independent from the fittingPlaced on the “dismountable” sideStainless steel pipe EB welded on a “kovar” coverTitanium pipe EB welded on a titanium coverCeramic brazed on the 2 coversMaterial used for brazing can contain silverCovers have to be machined to produce prototypes
Alternative solution : electrical break included in the fittingOne part of the fitting is made of ceramic (male or female) or bothThe ceramic is placed on the dismountable sideMore compact than the baseline solutionFirst tests : no good results -> elements back to the manufacturer for polishingImprovement: titanium coating on the contact surfaces.
Stainless steel pipe
Titanium pipekovar cover
Titanium cover
Ceramic
Pierre DelebecqueCooling – upgrade 2012 May 31 st 14
5 –Quality
Goals Made by leak tightness and industrial developments experts Survey of the design, the tests and prototypes, the methodology, the QA Last step before production
First main recommendations Improve the qualification of the test devices Be more rigorous to analyse the “untypical” results Check if a fitting machined at the limit of the tolerances fit the specifications Perform geometrical and dimensional measurements Better define the risks of pollution and damage Better define the backup solutions in the case of trouble (risk analysis) Work on the production procedure and be sure the sensible parameters are
recordedNext action
Production quality management : need a new contract and €€
CETIM audit
Pierre DelebecqueCooling – upgrade 2012 May 31 st 15
Summary
• 10mm Fittings seem OK • 8mm Fittings have to be validated• EB welding : last tests to perform but we are confident• Electrical break : Base line solution to be tested – integrated
solution seems more tricky • Cooling lines production : preparation in work / help of CETIM to
manage the quality