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