Spallation Neutron Source Drift Tube Linac Water Cooling and

Transcription

(SNS-104020500-DE0001-R01)
Spallation Neutron Source
Drift Tube Linac
Water Cooling and Resonance Control System
Final Design Report
(SNS-104020500-DE0001-R01)
by:
J. D. Bernardin, R. Brown, S. Brown, G. Bustos, M. Crow, J. Gioia, W. Gregory,
M. Hood, J. Jurney, D. Katonak, Z. Konecni, P. Marroquin,
I. Medalen, A. Owen, L. Parietti, and R. Weiss
Mechanical Engineering Group
Spallation Neutron Source Division
Los Alamos National Laboratory
April 4, 2001
TABLE OF CONTENTS
1. Introduction ------------------------------------------------------------------------------------------5
1.1 Project Scope, Deliverables, and Design Criteria -----------------------------------5
1.2 Drift Tube Linac (DTL) Water Cooled Environment ------------------------------7
1.3 DTL Resonance Control--------------------------------------------------------------- 19
1.3.1 Basic Philosophy ---------------------------------------------------------- 19
1.3.2 Water Cooling Resonance Control Technique ----------------------- 22
1.4 DTL Cooling Requirements ---------------------------------------------------------- 25
1.5 Mechanical and Electrical Interfaces ------------------------------------------------ 32
1.6 Comments and Action Items from Preliminary Design Review --------------- 33
2. DTL Water Cooling and Resonance Control System Design Summary---------------- 40
2.1 Water System Layout ------------------------------------------------------------------- 40
2.1.1 Manifolding on the RF Structure --------------------------------------- 41
2.1.2 Water Skid ------------------------------------------------------------------ 43
2.1.3 Transfer Lines -------------------------------------------------------------- 47
2.1.4 Facility Chilled Water Source ------------------------------------------- 50
2.2 Instrumentation and Controls---------------------------------------------------------- 50
3. Water Cooling Analyses ------------------------------------------------------------------------- 51
3.1 DTL Water Cooling Loops - Lumped-Parameter Flow Network Modeling-- 51
3.1.1 DTL RF Structure Cooling Loop --------------------------------------- 51
3.1.1.1 Design Goals ------------------------------------------------------ 51
3.1.1.2 Design Specifications-------------------------------------------- 55
3.1.1.3 Tank 3 Global Model Description----------------------------- 56
3.1.1.3.1 Drift Tube Sub-model Description-------------- 60
3.1.1.3.2 Drift Tube Sub-model Results ------------------- 65
3.1.1.3.3 Slug Tuner Sub-model Description ------------- 70
3.1.1.3.4 Slug Tuner Sub-model Results ------------------ 75
3.1.1.3.5 Post Coupler Sub-model Description----------- 78
3.1.1.3.6 Post Coupler Sub-model Results ---------------- 83
3.1.1.3.7 Dipole Magnet Sub-model Description -------- 87
3.1.1.3.8 Dipole Magnet Sub-model Results ------------- 91
3.1.1.3.9 Tank Wall Sub-model Description-------------- 94
3.1.1.3.10 Tank Wall Sub-model Results ------------------- 97
3.1.1.3.11 End Wall Sub-model Description --------------- 99
3.1.1.3.12 End Wall Sub-model Results -------------------103
3.1.1.3.13 Drive Iris Sub-model Description --------------105
3.1.1.3.14 Drive Iris Sub-model Results -------------------108
3.1.1.4 Tank 3 Global Model Design Studies/Results -------------110
3.1.1.5 Summary----------------------------------------------------------114
3.1.2 DTL Water Skid ----------------------------------------------------------115
3.1.2.1 Design Goals -----------------------------------------------------115
3.1.2.2 Design Specifications-------------------------------------------116
3.1.2.3 Model Description ----------------------------------------------116
3.1.2.4 Design Studies/Results -----------------------------------------128
3.1.2.5 Summary----------------------------------------------------------136
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3.1.3 SINDA/FLUINT Uncertainty Analysis-------------------------------137
3.2 DTL Water Cooling Loops – Stability and Response Modeling---------------142
3.2.1 Design Goals --------------------------------------------------------------142
3.2.2 Model Description--------------------------------------------------------143
3.2.3 Design Studies/Results --------------------------------------------------148
3.2.4 Summary -------------------------------------------------------------------158
4. Mechanical Design-------------------------------------------------------------------------------160
4.1 Introduction------------------------------------------------------------------------------160
4.2 Engineering Codes and Drawing Standards ---------------------------------------160
4.3 Plumbing Materials---------------------------------------------------------------------162
4.3.1 Radiation Damage Assessment ----------------------------------------162
4.3.2 Material Selection for Design ------------------------------------------165
4.3.3 General Manuracturing and Assembly Techniques ----------------167
4.4 DTL RF Structure Water Manifolds and Lines -----------------------------------169
4.4.1 Piping and Instrumentation Diagrams --------------------------------169
4.4.2 Major Components -------------------------------------------------------175
4.4.3 Assemblies -----------------------------------------------------------------177
4.5 Water Skid -------------------------------------------------------------------------------179
4.5.1 Piping and Instrumentation Diagrams --------------------------------180
4.5.2 Performance Specifications---------------------------------------------182
4.5.2.1 Vibration Isolation ----------------------------------------------182
4.5.2.2 Noise Level Requirements-------------------------------------183
4.5.3 Major Components and Specifications -------------------------------184
4.5.3.1 Structure ----------------------------------------------------------184
4.5.3.2 Plumbing----------------------------------------------------------185
4.5.3.3 Pump---------------------------------------------------------------186
4.5.3.4 Heat Exchanger --------------------------------------------------189
4.5.3.5 Control Valves ---------------------------------------------------200
4.5.3.6 Heater--------------------------------------------------------------201
4.5.3.7 Water Purification System-------------------------------------202
4.5.4 System Performance -----------------------------------------------------202
4.6 Parts Database and Naming Convention -------------------------------------------204
5. Water System Purity-----------------------------------------------------------------------------207
5.1 Introduction------------------------------------------------------------------------------207
5.2 Water Purification Techniques -------------------------------------------------------208
5.3 Particle Accelerator Specific Issues -------------------------------------------------211
5.4 Operating Parameter Specifications-------------------------------------------------213
5.5 Water Purification System Design---------------------------------------------------215
5.6 Prototype Design and Testing --------------------------------------------------------217
5.7 Facility-related Issues------------------------------------------------------------------228
6. Instrumentation and Controls ------------------------------------------------------------------231
6.1 Local Controls---------------------------------------------------------------------------231
6.1.1 Introduction and Design Requirements-------------------------------231
6.1.2 Instrumentation and Control System Architecture------------------232
6.1.3 Control Methodology and Logic ---------------------------------------240
6.1.4 Safety Interlocks and Equipment Protection-------------------------248
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6.1.5 Signal List------------------------------------------------------------------253
6.2 Global Controls -------------------------------------------------------------------------257
6.2.1 Interfaces -------------------------------------------------------------------257
6.2.2 Configuration--------------------------------------------------------------258
6.2.3 Interlocks -------------------------------------------------------------------259
6.2.4 Operator Interface --------------------------------------------------------260
6.2.5 Archiving-------------------------------------------------------------------260
6.2.6 Alarm Management ------------------------------------------------------260
7. SNS Facility Interfaces--------------------------------------------------------------------------261
7.1 Klystron Gallery -----------------------------------------------------------------------261
7.2 Linac Tunnel-----------------------------------------------------------------------------267
7.3 Chases ------------------------------------------------------------------------------------268
8. Safety-----------------------------------------------------------------------------------------------272
8.1 Hazard Analyses and Protective Measures-----------------------------------------273
8.2 Personnel Safety ------------------------------------------------------------------------274
9. Procurement---------------------------------------------------------------------------------------275
9.1 Water Skid Procurement --------------------------------------------------------------277
9.2 Water Manifold Procurement --------------------------------------------------------278
9.3 Hardware Costs -------------------------------------------------------------------------279
9.4 Delivery and Inspection ---------------------------------------------------------------279
9.5 Quality Assurance ----------------------------------------------------------------------280
10. Assembly, Installation, and Certification Plans --------------------------------------------284
11. Operation, Reliability and Maintenance -----------------------------------------------------286
11.1 Operation-------------------------------------------------------------------------------286
11.2 Reliability------------------------------------------------------------------------------289
11.3 Maintenance---------------------------------------------------------------------------292
12. Decommissioning--------------------------------------------------------------------------------294
13. Project Summary and Schedule ---------------------------------------------------------------295
13.1 Project Summary and Ongoing Work --------------------------------------------295
13.2 Cost Summary ------------------------------------------------------------------------297
13.3 Schedule--------------------------------------------------------------------------------298
14. Appendix A – ASME B31.3 Code Tables --------------------------------------------------301
15. Appendix B – Engineering Drawings -------------------------------------------------------307
16. Appendix C – Water Skid Specifications ---------------------------------------------------312
17. Appendix D – Hardware Costs ---------------------------------------------------------------336
18. Appendix E – Parts Database/Device Name List for DTL Tank 1---------------------341
19. Appendix F – DTL Drift Tube Heat Load and Cooling Requirements----------------352
20. Appendix G – Orifice Plate Spreadsheet Calculations for DTL Drift Tubes---------358
21. Appendix H – Flexible Tubing Data---------------------------------------------------------366
22. Appendix I – Procurement Specification for the Water Purification System --------368
23. Appendix J – Resin Handling and Disposal Plan------------------------------------------376
24. Appendix K – Preliminary SystemView Calculations -----------------------------------379
References----------------------------------------------------------------------------------------------386
iv
1.0 Introduction
The Spallation Neutron Source (SNS) is an accelerator-based neutron research
facility being designed for scientific and industrial research and development.
Specifically, SNS will generate and use neutrons as a diagnostic tool, much like X-rays,
for medical purposes as well as physical, chemical, biological, and material sciences.
The SNS will produce neutrons by bombarding a heavy metal target with a high-energy
beam of protons, generated and accelerated with a linear particle accelerator, or linac. To
effectively accelerate the protons, the linac uses high electrical fields, established in
copper resonance cavities with Radio Frequency (RF) energy. The low energy end of the
SNS linac consists of a room temperature copper structure that dissipates roughly 60-80%
of the RF energy in the form of heat. To deal with this waste heat, a water cooling
system has been designed as an integral par of the room-temperature linac. The water
cooling system is responsible for removing the undesired RF waste heat and maintaining
the electrical resonance of the copper RF structures by manipulating their operating
temperature.
One of the two room-temperature accelerating structures in the SNS Linac, is the
Drift Tube Linac (DTL). The DTL accelerates the SNS proton beam from 2.5 MeV to 87
MeV, before injecting it into the second copper structure, the Coupled Cavity Linac
(CCL). The basic design criteria and features of the DTL can be found in [1.1, 1.2] and
are summarized briefly in Section 1.4 of this report. A preliminary design for the Drift
Tube Linac (DTL) water cooling and resonance control system was completed in August
of 2000, and documented in [1.3]. This report summarizes the final design of that DTL
water cooling and resonance control system.
1.1 Project Scope, Deliverables, and Design Criteria
The complete project scope associated with the DTL Water Cooling and
Resonance Control System includes the design, analyses, fabrication, assembly,
installation, testing, and certification of the cooling system components. The efforts
associated with this project scope include performing final design engineering
calculations and developing corresponding engineering drawings, preparation of
5
procurement packages, liaison with vendors and participation in assembly, installation,
and testing at Oak Ridge National Laboratory (ORNL).
This report covers the final design efforts, based on a preliminary design outlined
in [1.3]. To develop a functional, reliable, and affordable water cooling and resonance
control system, the following final design deliverables were identified [1.2]:
1. Revision of preliminary design aspects as directed by LANL SNS-PO following
the DTL Water Cooling and Resonance Control System PDR [1.4].
2. Completion of all engineering calculations and supporting R&D experimentation.
3. Completion of all water purification studies.
4. Completion of P&IDs as well as assembly and detail drawings for the water skids,
distribution manifolds, support fixtures, etc.
5. Complete design of instrumentation, controllers, and software for the local control
system and global control system integration plans.
6. Specifications and procedures for water cooling system material preparation,
cleaning, handling, and shipping.
7. Completion of detailed mechanical drawings and procurement plans with bill of
materials for procurement of off-the-shelf items and fabrication plans for
specialized components.
8. Completion of assembly, installation, testing, and certification/quality assurance
plans.
Table 1.1 lists the general design criteria that were applied to the SNS DTL water
cooling and resonance control system design. Each criterion has a brief description and a
weighting factor associated with it. The weighting factor is intended to give a measure of
the criterion’s importance in the overall DTL water cooling and resonance control system
design, and consequently, assist the engineering design team in selecting between various
design alternatives. An example of the use of the design criteria and weighting factors in
assessing two different design alternatives can be found in [1.2].
6
Table 1.1. SNS DTL water cooling and resonance control system design criteria.
Design Criteria
Functionality
Weighting
Factor♣
5
Description
•
•
•
Safety
5
•
Procurement,
Fabrication, Assembly
3
•
•
•
Durability/
Reliability
4
•
•
•
Cost
4
•
Maintainability
3
•
Consistency
2
•
♣
Resonance control criteria must be met (i.e. heat removal,
temperature stability, etc)
Water cooling system hardware must integrate with support
structure
Water system must be resilient to react to design and
operational beam line changes
Proper controls and safety features, following appropriate
DOE guidelines, should be employed to protect personnel
and the beam line (equipment and operation)
Design with standard, off-the-shelf parts
Avoid using exotic materials
Assembly and maintenance issues should be incorporated in
the design to ensure consistency with other subsystems (i.e,
support structure, vacuum system)
Best engineering practices should be employed in the
design of the water cooling system to maximize its
availability and reliability.
Pumps should be selected for 30 year lifetime and have a 5
year maintenance period.
Pumping redundancy should be considered in order to meet
the reliability and duty factor requirements of the
accelerator.
Optimize functionality to minimize procurement,
fabrication and assembly costs to fit within the allocated
budget (based on the conceptual design).
Pumps and hardware should be accessible for
maintenance/replacement with minimal impact on beam
down-time
Every effort should be made to use the same type of water
system components throughout the Linac. In addition,
these components should be consistent with those used
elsewhere in the SNS facility (i.e., RF systems, RFQ,
storage ring, target, etc)
5 = very important, 1 = least important
1.2 Drift Tube Linac (DTL) Water Cooled Environment
The SNS linear particle accelerator, or linac, is comprised of three main structures
including the Drift Tube Linac (DTL), the Coupled Cavity Linac (CCL), and the Super
Conducting Linac (SCL), as displayed in Figure 1.1.
The first proton accelerating
structure following the ion injector and RFQ, is the DTL. The 402.5 MHz Alverez DTL
[1.5], is used to accelerate the H- beam from 2.5 MeV to 86.8 MeV. The SNS DTL is
comprised of six tanks, the first of which is roughly 4 m in length, and the remainders are
approximately 6 m in length. Tank 1, as shown in Fig. 1.2{a), is made up of 2 seamless
copper-plated, carbon-steel cylinders that are bolted together with RF and vacuum seals
7
DTL
CCL
SCL1
SCL2
CCL
DTL
Proton
Beam
Tank 1
Tank 6
Module 1
36.5 m
6 R F cooling skids,
1 per tank for drift tubes,
for slug tuners,
post couplers, drive
loops, and tank walls
Module 4
56.5 m
4 modules, 12 segments/module, 8 cavities/segment
4 R F cooling skids (1/module)
1 EMQ cooling skid (1/ four modules)
Figure 1.1. General layout of the SNS Linac and basic descriptions of the water cooling systems.
8
(a)
(b)
Figure 1.2. The Drift Tube Linac R F structure, support structure, and main vacuum pumps for
(a) tank #1 and (b) tank #2..
9
at each joint, and tanks 2 through 6 are made up of 3 sections each, as shown in Fig
1.2(b). The RF structure provides a stable platform for an array of drift tubes, post
couplers, and slug tuners, all used to shape and tune the structure to maintain precise
resonance and optimal acceleration of the proton beam. These components, and other
design details, are shown in the cut-away view of tank #1 in Fig. 1.3. A more detailed
description of these components and their functionality can be found in [1.1] and [1.5].
Table 1.2 summarizes the number of tank sections, cells, drift tubes, post couplers, slug
tuners, and drive irises within each of the DTL tanks.
Table 1.2. Summary of DTL tank component distributions.
DTL
Tank #
Tank
section
#
# of
cells
# tank
wall
cooling
channels
1
”
”
2
1&2
1
2
1, 2, &
3
1
2
3
1, 2, &
3
1
2
3
1, 2, &
3
1
2
3
1, 2, &
3
1
2
3
1, 2, &
3
1
2
3
60
48
12
12
12
12
”
”
”
3
”
”
”
4
”
”
”
5
”
”
”
6
”
”
”
# of post
couplers
59
34
25
47
# of
endwall
noses
(half of
drift
tube)
2
1
1
2
20
11
9
23
8
4
4
12
1
0
1
1
34
12
12
12
12
19
15
13
33
1
0
1
2
9
8
6
16
4
4
4
12
0
1
0
1
28
12
12
12
12
12
11
10
27
1
0
1
2
6
5
5
27
4
4
4
12
0
1
0
1
24
12
12
12
12
9
10
8
23
1
0
1
2
9
10
8
23
4
4
4
12
0
1
0
1
22
12
12
12
12
8
8
7
21
1
0
1
2
8
8
7
21
4
4
4
12
0
1
0
1
12
12
12
7
7
7
1
0
1
7
7
7
4
4
4
0
1
0
# of
drift
tubes
10
# of
slug
tuners
# of
drive
irises
Figure 1.3. Cut-away details of DTL tank #1.
11
Under normal operation (beam on), approximately 60 to 80% of the RF power is
dissipated in the DTL copper structural components.
The dissipated power causes
thermal distortions (i. e., shape change) which result in a frequency shift of the RF
energy.
To maintain the desired resonant frequency, the thermal distortions of the
various DTL components are controlled by water forced-convection cooling. The water
cooled components include the tank wall sections, end walls, post couplers, slug tuners,
drive irises, drift tubes, RF windows, faraday cups, and dipole electro-magnets. Detailed
engineering frequency shift and thermal/fluid analyses have been conducted for each of
these DTL components and documented in [1.5]. Consequently, only brief descriptions
of these components are provided in this report.
Each tank section is cooled via 12 rectangular stainless-steel cooling channels (1
in wide by 0.5 inches deep) that are bonded and clamped in machined groves on the tank
walls, as shown in Figure 1.4. The tank endwalls are cooled by water flowing through a
series of machined cooling channels, as depicted in Figure 1.5.
The post coupler is used to tilt and adjust the shape of the standing RF field inside
the DTL tank. Figure 1.6 displays the construction of one such post coupler and its
internal water passages. The concentric water passages allow the cooling water to enter
the post coupler stem and pass along the outermost passage, turn around at the post
coupler tip, and return within the innermost water passage.
To further shape the RF field within the DTL tanks, several slug tuners are spaced
along the bottom of the DTL. A slug tuner is solid copper cylinder which extends several
inches into the tank body. RF energy creates waste-heat electrical currents in the slug
tuners. To remove this waste heat, cooling water is circulated through a circular cooling
channel machined in one end of the slug tuner, as displayed in Figure 1.7.
The drift tubes serve to form the RF cells which accelerate the packets of protons
and also shield the accelerating proton packets as they pass from one RF cell to another.
Quadrupole magnets, housed within each drift tube, provide the required focusing of the
proton beam. Each drift tube has cooling channels machined in its body, as shown in
Figure 1.8. The flow of water is fed through the outer tube of the stem, splits in half,
circulates around the drift tube body, and exits through the stem inner tube.
12
Cooling
Channel
Figure 1.4. Stainless steel water cooling channels mounted in grooves on a DTL tank
wall.
13
Steel alignment
Bushings
press-fit in place
SST coolant fittings
Copper tubing
Magnet housing
with coolant plenum
OFE copper
Endwall base
OFE copper
PMQ alignment
pin press-fit
into magnet housing
Be
am
Endwall coolant
passages
Cover plate
OFE copper
Exploded view
Figure 1.5. DTL tank end-wall cooling passage design.
14
Copper tip
Copper Stem
SST Coolant
fittings
Rf seal groove
Copper Body
Brazed Assembly
(a)
Water
Inlet
Flow
Diverter
Water
Outlet
(b)
Figure 1.6. (a) Solid model and (b) cross-section of a SNS DTL post coupler.
15
Copper Body and
flange
SST backing flange
For Rf seal
SST Coolant
fittings
Brazed - Welded Assembly
(a)
4.5 in
2.25 in
Cooling channel
(b)
Figure 1.7. (a) Solid model and (b) cross-section of a SNS DTL slug tuner.
16
All metal vacuum &
rf seal mount
assembly
Cooling/vacuum
manifold
Stem assembly
Samarium Cobalt
PMQ with
Aluminum yoke
Bore
tube
Body
Coolant channels
Figure 1.8. Assembly of a typical DTL drift tube.
17
RF power is transmitted to the DTL via rectangular gas-filled waveguides.
Separating the atmospheric pressure waveguide and the vacuum environment of the DTL
tank, is a ceramic RF window. On the DTL tank-side of the RF window is a narrow slit,
termed an iris, which allows the RF energy to pass into the DTL tank. The transition
waveguide which connects the RF window to the iris, is displayed in Figure 1.9. The RF
losses in the transition waveguide and iris must be removed with internal water cooling
channels. The RF window has a separate water cooling jacket.
Dynamically adjusting the cooling water temperature in the drift tubes and other
RF structural components will maintain resonance of the DTL. A uniform frequency
shift for all DTL cells can be obtained by balancing the water flow rate, tailoring the
cooling channels for each individual drift tube, and adjusting the water inlet temperature.
The heat loads and cooling water flow requirements for each of the DTL components are
contained in [1.2] and summarized in Section 1.4 of this report.
Rf Vacuum Pumping Grills
Turbo Pump Turbo-V70
Gate Valve
Cooling Tubes
Getter Pump Capacitor-B-1300-2
Figure 1.9. DTL RF window waveguide transition piece.
18
1.3 DTL Resonance Control
1.3.1 Basic Philosophy
The electromagnetic field resonant frequency of a particle accelerator is a
function of its internal geometry [1.11]. In the case of the DTL, the resonant frequency is
mainly a function of the geometry of the tank walls and drift tubes. In the CCL, the
resonant frequency is primarily a function of the geometry of the cavities, side coupling
cells, and bridge couplers. By manipulating the dimensions of these RF structures, the
resonant frequency of the particle accelerator can be finely adjusted and tuned. In
practice, resonance control of a room temperature linac is maintained by both the Low
Level RF (LLRF) control system and a water cooling system (RCCS). The goal of the
SNS resonance control systems is to resonate the DTL at 402.500 MHz and the CCL
cavities at 805.000 MHz under nominal loaded conditions.
In practice, the DTL will be designed and pre-tuned (with post couplers and slug
tuners) to a frequency which is offset from the desired resonant value of 402.5 MHz, with
coolant flowing through the structure at a temperature of 20.0°C and no RF heating
applied. This frequency offset, which is yet to be defined, will account for the expansion
of drift tubes, tank walls, and other tank components, as they heat up under RF power.
In practice, the CCL cavities will be designed, manufactured, and pre-tuned to a
frequency of 805.140 MHz, (140 kHz above the target frequency) with coolant flowing
through the structure at a temperature of 20.0°C and no RF heating applied. As RF
power is introduced into the cavity, the copper cavity will heat up, expand, and its
resonant frequency will decrease.
Engineering analyses have been performed and
estimate that the decrease in the cavity resonant frequency (due to RF heating) will be
approximately 140 kHz under full RF power and a coolant inlet temperature of 20.0°C.
The CCL’s steady-state operational resonant frequency, 805.00 MHz, is achieved and
maintained by manipulation of the CCL cavity dimensions (expansion/contraction) by
adjusting their wall temperatures with the Water Cooling System.
The LLRF Control and the RCCS share the responsibility of the resonance control
of the DTL and CCL. Consider the DTL as an example. From system start-up, when RF
power is gradually introduced to the DTL tank, to full-on steady-state accelerator
operation, there are many complicated thermal, fluidic, structural, and electrical
19
interactions occurring which influence the resonance of the DTL structure. To deal with
these effects, and achieve and maintain resonance of the DTL structure, the LLRF
Control and Water Cooling Systems have individual, as well as shared responsibilities.
Figure 1.10 displays the responsibilities of the LLRF Control and RCCS as a function of
the DTL resonant frequency.
RCCS / Agile combo.
Frequency Agile
only
Frequency Agile
only
Dead Band
outer
inner
FagF0 - 33kHz
FhiF0 - 10 kHz
Flo- F0 Flo+
402.5 MHz
Fhi+
F0 + 10 kHz
Fag+
F 0 + 33kHz
Frequency Agile only:
Water RCCS is inactive, holding at a saturation position of the valves,
while the Resonance Control Module brings the drive frequency
into the RCCS / Agile band.
RCCS / Agile Band:
RCM and the water RCCS act to control the cavity resonant frequency
and bring it into the deadband.
Dead Band:
LLRF control system locks to the fundamental frequency (master oscillator)
and the water RCCS takes over to control the cavity resonance within the
deadband limits (as determined by operator through the RCM).
Fno RF
F0 + 100 kHz
Figure 1.10 Resonance control responsibility diagram for the SNS DTL and CCL.
20
During the early stages of introducing RF power into the DTL RF structure, the
RF control system will monitor the structure’s resonant frequency and adjust the LLRF
Control system output drive frequency to the klystron to match it. The RF control system
will thus continuously change the RF frequency as the cavities warm up, and follow the
cavity resonant frequency to the desired operational resonant frequency (402.500 MHz).
This “chase the cavity’s resonance” activity is referred to as a frequency agile mode of
operation. The signal that determines the output RF drive frequency is also used to send
an error signal to the water system which indicates how far off the cavity resonant
frequency is from the desired operational resonant frequency, and in which direction. For
the DTL, a 0V to 10V analog signal, sent from the LLRF to the RCCS, will be used to
represent this frequency error. In particular, the analog signal ranges and resulting RCCS
actions are as follows:
0V to 0.5V ⇒ negative frequency saturation. RCCS: Cool the water and structure by
forcing all circulating water through heat exchanger.
0.5V to 5.0V ⇒ error signal is proportional to the -50 kHz to 0 kHz frequency error (the
lower frequency error limit is software selectable). RCCS: use PID algorithm to
gradually cool the structure and push the frequency error signal towards 5V, or zero
frequency error.
5.0V to 9.5V ⇒ error signal is proportional to the 0 kHz to 50 kHz frequency error (the
higher frequency error limit is software selectable). RCCS: use PID algorithm to
gradually warm the structure and push the frequency error signal towards 5V, or zero
frequency error.
9.5V to 10.0V ⇒ positive saturation. RCCS: Warm the water and structure by forcing
all circulating water through the heat exchanger by-pass line.
When the resonant frequency of the cavities gets within ±33 kHz of the
operational resonant frequency, Fo, the Water Cooling System begins to perform active
resonance control by adjusting a water mixing proportional valve in an attempt to bring
the cavity resonant frequency to Fo.
This ±33 kHz frequency band is termed the
RCCS/Agile Band. During this mode of operation, the LLRF Control System continues
to monitor the resonant frequency of the DTL and attempts to match the output RF drive
frequency to it. In addition, the Water Cooling System reads the operational resonant
21
frequency error from the LLRF Control System and attempts to adjust the DTL resonant
frequency by manipulating the water inlet temperature. The DTL resonant frequency
shift induced by a mean temperature change of the DTL drift tube copper is
approximately 6.5 kHz/°C. Thus by adjusting the cooling water temperature, the DTL
resonant frequency is brought closer to Fo, and the operational resonant frequency error is
reduced. This control logic, similar to that used for the Accelerator Production of
Tritium/Low Energy Demonstration Accelerator RFQ and CCDTL Hot Model resonance
control systems, is depicted in Figure 1.11. Note that this resonance control methodology
is much different from that used on the LANSCE accelerator, where a particular cooling
water temperature is sought, but no feedback is provided by the RF system.
operational resonant frequency, Fo, the LLRF Control System locks to the operational
resonant frequency and the Water Cooling System takes over active cavity resonance
control. This narrow frequency range is referred to as the Dead Band. Note that the
limits on the Dead Band will be software selectable.
1.3.2 Water Cooling Resonance Control Technique
In the case of the SNS DTL and CCL, a closed loop water cooling system extracts
heat from the RF structure and transfers it to a facility chilled water supply via a liquidliquid heat exchanger, as depicted in the P&ID diagram of Figure 1.12(a). In this closedloop circuit, water temperature control is achieved by manipulating the hot-side (Linac
side) heat exchanger water flow rate while holding the cold-side water inlet temperature
and flow rate constant. This is achieved by using a proportional control valve that
divides the circulating water between the heat exchanger and by-pass line, as shown in
Figure 1.12(a). By changing the hot-side water flow rate, the overall heat transfer
coefficient of the heat exchanger is varied. Since the heat removal rate must effectively
remain constant for quasi-steady-state conditions (heat rate into system equals heat rate
out of the system), the hot-side water temperature must change inversely to the overall
heat transfer coefficient to achieve a new operating condition. Consequently, increasing
the water flow through the heat exchanger results in an increase in the overall heat
transfer coefficient, and an associated decrease in the mean water temperature. And
22
conversely, decreasing the water flow through the heat exchanger results in a decrease in
the overall heat transfer coefficient, and an associated increase in the mean water
temperature. This water temperature dependence on heat exchanger hot-side flow rate is
depicted in Figure 1.12(b).
Choose frequency
gain or water
temperature gain
ef
Valve
(position)
PID
eT
-
Water Temp.
Set Point
Cavity
(temperature
and frequency)
Water
Temperature
+
Low Level
R F System
Figure 1.11. Resonance control system logic proposed for the SNS Linac RCCS.
23
While being robust and versatile, the water cooling systems for the DTL and CCL
will possess limited working ranges and stabilities in water temperature, flow rate, and
pressure drop. The nominal operating conditions that the water cooling systems are being
designed to are listed in the following section.
R F Structure
Water Inlet Manifold
By-Pass
Control
Valve
Water Inlet Temperature
Reservoir/
Expansion
Tank
Pump
Hot Side
Facility
Chilled
Water
Source
Cold Side
Heat Exchanger Hot Side Water Flow Rate
Heat Exchanger
(a)
(b)
Figure 1.12. (a) R F structure water cooling loop schematic and (b) Water temperature control through heat exchanger hot side
water flow rate manipulation.
24
1.4 DTL Cooling Requirements
As mentioned previously, the DTL water cooling system removes the waste heat
from the copper RF structure and maintains resonance through active temperature
control. In designing the water cooling system, the copper waste heat loads, RF structure
mean operating temperature, temperature range and sensitivity required for resonance
control, and control methodology (variable flow or variable temperature) needed to be
defined a priori. First of all, RF cavity physics computer codes were used to determine
the distribution of the RF waste heat in the DTL structural components. Next, a mean
DTL copper structure temperature was chosen along with the desired range and
resolution of the RF resonance control provided by the water cooling system. Finally,
finite element and computational fluid dynamics codes were employed to optimize the
design of the water cooling passages and determine the required water flow rates and
temperatures. Much of this is discussed in more detail in [1.2, 1.3].
The following tables give the heat loads, required cooling water flow rates and
supply temperatures, as well as flow pressure drop specifications for the DTL drift tubes,
post couplers, slug tuners, end and side walls, dipole electro-magnets, RF windows, and
Faraday cups. . All the heat loads reported in the tables assume a 7.02% RF duty factor.
A representative set of data for the heat load, water flow rates, water temperature,
and resonance control parameters for the DTL drift tubes is given in Table 1.3. A
complete listing of individual drift tube heat load and cooling flow requirements is given
in Appendix F. The frequency shift characteristics of the DTL in response to drift tube
water inlet temperature changes, in KHz/°C, are also given in Table 1.3. The maximum
range of frequency control, ±33 KHz, corresponds to an inlet water temperature range of
±5.1°C about the mean value of 20.0°C. The drift tube pressure drop corresponds to the
flow path between the inlet and outlet connectors on the drift tube stem. Note that the
heat dissipated on the drift tube outside wall increases as the energy level increases. To
avoid field errors and frequency mismatch, the frequency shift needs to be the same for
all the DTL cells. This will be achieved by properly tailoring the water flow rate to each
drift tube by using an orifice plate upstream of each individual drift tube.
25
Table 1.3. DTL drift tubes nominal water cooling system design and operation
parameters.
•
Parameter
Nominal heat load per drift
tube
•
Value
0.05-1.85 kW
Comments/References
Heat load is different for each
drift tube (see Tables 4.5 to 4.10
for individual heat loads)
Average drift tube operating
temperature is identical to
average CCL copper temperature.
Flow rate is adjusted for each
individual drift tube. A uniform
frequency shift for all cells within
a tank is obtained by balancing
the flow rate and tailoring the
cooling channels for each
individual drift tube.
Flow resistances for each drift
tube are estimated from standard
pipe flow correlations.
Tables 4.5 to 4.10 give flow rate
requirements and flow resistances
for each drift tube.
Initial drift tube water inlet
temperature chosen to equal mean
desired operating temperature.
Drift tube water inlet temperature
must remain constant as RF
power
is
introduced.
An
approximate ±8.3 oC band about
this mean temperature will be
required for full resonance
control (i.e. to get ±50 kHz
frequency adjustment).
Tables 4.5 to 4.10 give water
temperature rise for each drift
tube.
A 0.1 oC change in water
temperature corresponds to a
change in RF frequency of 0.6 to
0.7 KHz.
Resonance is maintained by
dynamically adjusting the water
temperature in the drift tube
circuit and the tank circuit
simultaneously.
•
Nominal average operating
temperature of drift tubes
•
26.6°C (79.9 oF)
•
Nominal water flow rate per
drift tube
•
0.13-3.22x10 -4 m3/s (0.2-5.1
gpm)
•
Water flow rate accuracy and
stability per drift tube
•
± 5%
•
Flow resistance across drift
tubes
•
1.06x1012-3.23x10 14 Pa/m6s
(0.61-186.7 psi/gpm2)
•
Drift tube water inlet
temperature prior to RF
power and during steadystate, full RF power
Temperature range of water
•
20.0°C (68.0 oF)
•
5.1 oC (9.2 oF) about mean
inlet temperature
•
Nominal temperature rise of
cooling water through 1 drift
tube
•
0.6-2.6 oC (1.1-4.7 oF)
•
Temperature accuracy
•
± 0.5oC
•
Temperature resolution
•
± 0.1oC
•
Temperature stability
•
± 0.1oC
•
Frequency shift per change
in water inlet temperature
Range of frequency control
Stability in frequency control
•
6-7 kHz/1oC
•
•
± 33 kHz
± 0.7 kHz
Chilled water supply
temperature
temperature stability
•
7.2 oC (45.0 oF)
•
±0.5°C (± 0.9oF)
•
•
•
•
•
26
The heat load and water cooling requirements for the tank walls are given in
Table 1.4. Note that the heat loads and water flow rate requirements vary for each tank.
The flow resistances for the cooling channels were estimated from standard pipe flow
correlations.
Table 1.4. DTL tank wall nominal water cooling system design and operation parameters
(parameters given per DTL tank).
Tank #
1
2
3
4
5
6
Heat
Load
(kW)
Water
flow
rate
(gpm)
Flow rate
accuracy/
stability
(gpm)
8
30
41
42
41
44
19.2
60.0
79.2
79.2
79.2
79.2
± 5%
± 5%
± 5%
± 5%
± 5%
± 5%
Flow
resistance
per unit
length of
channel
(psi/gpm2/
m)
0.018
0.018
0.018
0.018
0.018
0.018
Steadystate water
inlet temp.
(°C)
Nominal
water
temp. rise
(°C)
Water
temp.
accuracy/
stability
(°C)
20.0
20.0
20.0
20.0
20.0
20.0
1.6
1.9
2.0
2.0
2.0
2.1
0.5/0.1
0.5/0.1
0.5/0.1
0.5/0.1
0.5/0.1
0.5/0.1
The heat load and water cooling requirements for the DTL slug tuners are given in
Table 1.5. Note that the heat load on the slug tuner depends on it penetration length
inside the tank. The heat load given in Table 1.5 assumes a maximum slug tuner
penetration of 2.25 inches. The flow resistance for the slug tuners was estimated from a
standard pipe flow correlation.
Table 1.5. DTL slug tuner nominal water cooling system design and operation
parameters (parameters given per slug tuner).
Heat
Load
(kW)
0.64
Water
flow
rate
(gpm)
Flow rate
accuracy/
stability
(gpm)
Flow
resistance
(psi/gpm2)
Steadystate water
inlet temp.
(°C)
Nominal
water
temp. rise
(°C)
1.0
± 5%
1.4
20.0
2.4
Water
temp.
accuracy/
Stability
(°C)
0.5/0.5
The heat load and water cooling requirements for the DTL post couplers are given
in Table 1.6. Note that the heat load on the post coupler depends upon its penetration
length inside the tank. The heat load given in Table 1.6 assumes a maximum post
27
coupler penetration of 6.2 inches.
The flow resistance for the post couplers was
estimated from a standard pipe flow correlation.
Table 1.6. DTL post coupler nominal water cooling system design and operation
parameters (parameters given per post coupler).
Heat
Load
(kW)
Water
flow
rate
(gpm)
Flow rate
accuracy/
stability
(gpm)
Flow
resistance
(psi/gpm2)
Steadystate water
inlet temp.
(°C)
Nominal
water
temp. rise
(°C)
0.32
0.65
± 5%
7.1
20.0
1.9
Water
temp.
accuracy/
stability
(°C)
0.5/0.5
Tables 1.7, 1.8, and 1.9, give the heat loads and water cooling requirements of the
end walls, drive irises, and electromagnets, respectively.
Table 1.7. DTL end walls nominal water cooling system design and operation
parameters.
Tank #
Heat
Load
(kW)
1 front
1 end
2 front
2 end
3 front
3 end
4 front
4 end
5 front
5 end
6 front
6 end
0.114
0.890
0.912
1.491
1.643
1.840
1.847
1.997
2.002
2.115
2.121
2.410
Water
flow
rate
(gpm)
Flow rate
accuracy/
Stability
(gpm)
Flow
resistance
(psi/gpm2)
Steadystate water
inlet temp.
(°C)
Nominal
water
temp. rise
(°C)
0.2
1.0
0.5
1.0
1.0
1.0
1.0
1.0
1.0
1.0
1.0
1.0
± 5%
± 5%
± 5%
± 5%
± 5%
± 5%
± 5%
± 5%
± 5%
± 5%
± 5%
± 5%
16.10
11.33
13.12
11.33
11.33
11.33
11.33
11.33
11.33
11.33
11.33
11.33
20.0
20.0
20.0
20.0
20.0
20.0
20.0
20.0
20.0
20.0
20.0
20.0
2.2
3.4
7.2
5.7
6.3
7.0
7.0
7.6
7.6
8.0
8.1
9.2
Water
temp.
accuracy/
stability
(°C)
0.5/0.1
0.5/0.1
0.5/0.1
0.5/0.1
0.5/0.1
0.5/0.1
0.5/0.1
0.5/0.1
0.5/0.1
0.5/0.1
0.5/0.1
0.5/0.1
Table 1.8. DTL drive iris nominal water cooling system design and operation
parameters.
Heat
Load
(kW)
0.355
Water
flow
rate
(gpm)
Flow rate
accuracy/
Stability
(gpm)
Flow
resistance
(psi/gpm2)
Steadystate water
inlet temp.
(°C)
Nominal
water
temp. rise
(°C)
1.6
± 5%
0.13
20.0
0.5
28
Water
temp.
accuracy/
stability
(°C)
0.5/0.5
Table 1.9. DTL dipole electromagnet nominal water cooling system design and operation
parameters (two water passages in parallel per magnet).
•
•
•
•
•
•
•
•
•
•
•
•
Parameter
Nominal heat load per
magnet
Number of magnets
Value
Nominal water flow rate per
magnet (for 3.4°C rise in
water temp through magnet
at normal heat load). Water
passes through 2 coils in
series.
Pressure drop across magnet
at nominal water flow rate
Water flow rate accuracy and
stability per magnet
Magnet
water
inlet
temperature
Nominal temperature rise of
cooling water through 1
magnet
Temperature accuracy
Temperature resolution
Temperature stability
temperature
temperature stability
•
0.35 kW
•
24 magnets
•
2.4´10-3 m3/s (0.38 gpm) per
coil
2.4´10-3 m3/s (0.38 gpm) per
magnet
•
•
•
11.8 psi
•
± 5%
•
20.0°C
•
3.4°C
•
•
•
•
±0.5°C
±0.1°C
±0.5°C
7.2°C (45°F)
•
±0.5°C (±0.9°F)
Comments/References
Dipole magnet design excel
summary sheet provided by
Ted Hunter on 7/3/00.
•
Ted Hunter on 7/3/00
•
Ted Hunter on 7/3/00
Tables 1.10 and 1.11 give the heat load and cooling requirements for the DTL RF
window and Faraday Cup, respectively.
Table 1.10. DTL RF window nominal water cooling system design and operation
parameters.
Heat
Load
(kW)
0.1
Water
flow
rate
(gpm)
Flow rate
accuracy/
Stability
(gpm)
Flow
resistance
(psi/gpm2)
Steadystate water
inlet temp.
(°C)
Nominal
water
temp. rise
(°C)
1.0
± 5%
1.0
20.0
>0.1
29
Water
temp.
accuracy/
stability
(°C)
0.5/0.5
Table 1.11. DTL Faraday Cup nominal water cooling system design and operation
parameters.
Beam
Energy
(Far.
Cup)
(MeV)
7.5
22.8
39.8
56.6
72.5
Heat
Load
(kW)
0.014
0.041
0.080
0.130
0.145
Water
flow
rate *
(gpm)
Flow rate
accuracy/
Stability
(gpm)
Flow
resistance
(psi/gpm2)
Steadystate water
inlet temp.
(°C)
Nominal
water
temp. rise
(°C)
0.01
0.04
0.08
0.13
0.15
± 5%
± 5%
± 5%
± 5%
± 5%
TBD
TBD
TBD
TBD
TBD
20.0
20.0
20.0
20.0
20.0
4
4
4
4
4
Water
temp.
accuracy/
stability
(°C)
0.5/0.5
0.5/0.5
0.5/0.5
0.5/0.5
0.5/0.5
* A nominal 0.5 gpm flow rate will be used to cool each faraday cup.
From the water skid partitioning scheme along with the heat load and flow rate
data from Tables 1.3 through 1.11, the individual water skid performance specifications
were derived (water flow rate, water inlet temperature, total waste heat dissipation rate,
etc.).
These water skid performance specifications for the DTL RF structures are
summarized in Tables 1.12 through 1.13.
Table 1.12. Summary of heat loads for the DTL water pumping stations.
DTL Tank
#
1
2
3
4
5
6
Total
Drift
Tube and
Endwall
Nose
heat load
(kW)
11.3
32.7
35.7
35.6
34.7
37.2
Tank side
and endwall heat
load
(kW)
Total
Slug
Tuner
Heat
Load
(kW)
Total
Post
Coupler
Heat
Load
(kW)
Total
Drive Iris
Heat
Load
(kW)
Dipole
Magnet
Heat
Load
(kW)
Total RF
Module
Waste Heat
Load (kW)
9.0
32.4
44.5
45.8
41.2
48.5
5.1
7.7
7.7
7.7
7.7
7.7
9.6
7.7
5.1
4.5
3.8
3.2
0.35
0.35
0.35
0.35
0.35
0.35
1.4
1.4
1.4
1.4
1.4
1.4
36.8
82.3
94.8
95.4
89.2
98.4
30
Table 1.13. Summary of water flow rates and water inlet temperatures for the DTL water
pumping stations.
DTL Tank
#
1
2
3
4
5
6
Total
Drift
Tube and
Endwall
Nose
flow rate
(gpm)
69.4
70.2
129.2
110.4
95.6
80.2
Tank side
and endwall flow
rate
(gpm)
Total
Slug
Tuner
flow rate
(gpm)
Total
Post
Coupler
flow rate
(gpm)
Total
Drive Iris
flow rate
(gpm)
Dipole
Magnet
flow rate
(gpm)
Water
Inlet
Temp.
(oC)
Total
Tank
Water
Flow
Rate
(gpm)
20.4
61.5
81.2
81.2
81.2
81.2
8
12
12
12
12
12
19.5
15.6
10.4
9.1
7.8
7.2
1.6
1.6
1.6
1.6
1.6
1.6
1.5
1.5
1.5
1.5
1.5
1.5
20.0
20.0
20.0
20.0
20.0
20.0
120.4
162.4
235.9
215.6
199.5
183.7
Based upon the final design of the DTL water cooling systems, the water
capacities for each flow loop have been estimated and are summarized in Table 1.14.
Table 1.14. Water capacities of the DTL water cooling systems.
Water Cooling System
Flow Loop Water Capacity
(gallons)
DTL Tank 1
255
DTL Tank 2
280
DTL Tank 3
280
DTL Tank 4
280
DTL Tank 5
280
DTL Tank 6
280
31
1.5 Mechanical and Electrical Interfaces
The key mechanical interfaces between the DTL Water Cooling and Resonance
Control System hardware and the DTL RF structure are summarized in Table 1.15. All
mechanical connections on the DTL components, will not be the responsibility of the
DTL water cooling system design team.
Table 1.15. Mechanical Interfaces between the DTL Water Cooling and Resonance
Control System and DTL RF structure, magnets, and diagnostics.
Interface Description
Mechanical
Connection Supplied
on DTL Component
Stainless steel tube, ½”
•
Stainless steel tube, ¾”
•
Swagelok compression
fitting – 3/8”
•
Slug tuner water line
ports
fitting – 3/8”
•
Tank end wall water
line ports
fitting – 3/8”
•
Tank wall water line
ports
fitting – 1/2”
•
Dipole electro-magnet
water line ports
fitting – 3/16”
•
RF window water line
port
Male NPT
port - ½”
threaded
•
Drive iris water line
port
fitting – ½”
•
Faraday cup water line
port
DTL tank body
Presently not defined.
Assume ½” beaded tube
None
•
RF structure support
stand/manifolds
Pipe supports fastened
to the support stand
•
Drift tube water line
ports Tanks 1 and 2
Drift tube water line
ports Tanks 3 thru 6
Post coupler water line
ports
Water Cooling System Impact
•
32
Water cooling team will provide a 90° Swagelok
fitting and beaded for flexible hose attachment.
Water cooling team will provide a 90° Swagelok
fitting and beaded for flexible hose attachment.
Supply proper sized beaded tube for the interface
between the flex line and DTL compression
fitting.
fitting.
fitting.
fitting.
fitting.
Provide proper connectors that results in a beaded
hose connector for the supply and return flex
lines.
fitting.
TBD
There is currently no plan to support any of the
water cooling lines or manifolds off of the tank
body.
Main supply and return manifolds will be
mounted, one above the other, to the main
support structure running parallel to the beam
line. The manifolds will be attached with pipe
supports on the non-aisle side of the linac tunnel.
All sub-manifolds will be attached to pipe
supports that are connected to the RF stupport
structure.
All water cooling system equipment (pumps, instrumentation, valves, etc) shall
operate from the klystron gallery utilities. The SNS conventional facility requirements
for the Linac are specified in [1.10]. Table 1.16 summarizes the SNS facility chilled
water and electrical requirements for the DTL water cooling and resonance control
systems. Note that the electrical requirements listed in Table 1.16 do not include any
surpluses required by electrical codes and do not call for any “clean” electrical power.
Finally, In the event of an electrical power failure, uninterruptible electrical power
service (UPS) will not be required for the water cooling system diagnostics or PLC on the
DTL.
Table 1.16. Summary of utilities required for a single DTL tank water cooling system.
Linac
Chilled
Chilled
Chilled
Chilled
Electrical
Structure
Water
Water
Water
Water
(Qty/KVA/V/Phase)
Supply
Supply
Supply
Supply
Temp.
Mean Heat Mean Flow Pressure & Note that KVA is per
(°C)
Load
Rate
to Designed
unit
Removal
Water Skid
Pressure
Capacity
(GPM)
Loss (psig)
(kW)
Typical DTL 7.2 ±0.5
80
40
100/15
6/25/480/3 (pump)
Tank
6/30/480/3 (heater)
6/1.8/120/1 (water skid)
6/1.8/120/1 (elec. rack)
6/1.8/120/1 (elec. rack)
The communication interfaces between the DTL Vacuum Control System and the
SNS Global Control System are described in detail in Section 6 of this report.
All other facility-type interfaces are covered in Section 7 of this report.
1.6 Comments and Action Items from Preliminary Design Review
The DTL and CCL Water Cooling and Resonance Control System Preliminary
Design Review (PDR) committee’s comments and the corresponding design team
responses and/or action items are given in Table 1.17. Each item of concern that was
raised by the PDR committee has been addressed and documented in this final design
report.
33
Table 1.17. Preliminary design review committee comments and the corresponding
responses and/or actions taken during the final design of the DTL and CCL water cooling
systems.
Comment
#
1
2
Review Committee Comment
Two options for providing for make-up water, as well as filling and draining
It is recommended that the
the water systems were considered. The first was a permanent facility-based
make up water system for the
system, with water lines and fixtures incorporated in the facility design.
DI cooling loops be improved.
This option was rejected in favor of a portable water service cart, which
An option is to have a
recirculating DI loop to provide would be available throughout the facility for filling, treating, and draining
any and all water cooling systems. This service cart was beyond the scope
the make up for all loops. This
and budget of the DTL and CCL water cooling system designs. However, a
will help avoid loop
proposal (LANL-SNS Memo SNS-00-76) for the design and procurement of
contamination due to
such a cart was drafted and submitted to ORNL-SNS for review.
maintenance errors. In
addition, since recycling of
loop water is currently planned
(to reduce waste), reinjecting
this water back into the system
should be accommodated by
the design.
The loop heater may be used in system start up. However, the heat supplied
How the loop heater will be
to the water to heat up the DTL or CCL is relatively very small when
used during start up and during
compared to the RF waste heat dissipation rate of a DTL tank or CCL
events like RF trips should be
module.
investigated in more detail.
The heater operational
requirements resulting from
Q = mc p∆T
where m = ρV, cp=4179 J/Kg∗°K,
this investigation should define
∆T=(26-20)°K, ρ=1000Kg/m3
detail parameters like heater
Q = 1000Kg/m3 ∗ 1.48m3 ∗ 4179J/Kg∗°K ∗ (26-20)°K
power
Q=
37,109,520 J
3
How much RF power is
available as a function of
structure temperature should be
determined. This will
influence the control system
design and response.
4
The appropriate RF duty
factors that the cooling system
should be able to accommodate
and how it should respond,
should be more clearly defined.
Requirements in this area
should be developed in
conjunction with the SNS
division in OR.
The requirements for the
control systems of each cooling
system should be defined in
more detail. The following
5
Design Team Response or Action
For the Heater [Q] = w = J/s, [Q] ∗ ∆t = Q
[Q] = Q/∆t
Plot [Q] as a function of length of time.
Plot Cost ($) as a function of [Q].
Plot Cost (&) as a function of the length of time.
An evaluation of the heater hardware cost versus time to heat the volume of
water 6°C was performed to size the water skid’s inline electrical water
heater.
RF power is not a direct function of structure temperature, but rather of the
transfer matching between the RF drive frequency and the resonance
frequency of the cavities (the latter of which is a function of structure
temperature). The RF power and duty factors for steady-state operation are
currently well known and documented. These parameters are what the
current water cooling system is designed around. Lower RF power and duty
factors during early commissioning are expected and proper flexibility was
incorporated in the design of the water cooling and resonance control
systems to handle these off-normal conditions.
The RF power and duty factors for steady-state operation are currently well
known and documented. These parameters are what the current water
cooling system is designed around. Lower RF power and duty factors
during early commissioning are expected, but have not been specifically
defined or designed to. The water cooling skid has been designed with a
variable speed pump, and control valves on the hot and cold sides of the heat
exchanger, so as to have enough flexibility in handling off-normal heat loads
or operational conditions.
No additional water system requirements were given to the design team
from the operations or RF structures design teams. Consequently, the water
system design was based around the criteria and requirements given in the
latest “SNS DTL and CCL Water Cooling and Resonance Control System
34
6
7
operational requirement should
be defined:
• permissible time period to
attain design temperature
following a cold start
• permissible time period to
attain design temperature
following an RF trip (for
purposes of design, a “design
basis RF trip” should be
established with assistance
from the responsible
physicist and/or project
office to define a credible
trip scenario - if one does not
already exist – and any
requirements for thermal
transients)
• response time for minor
temperature transients in the
linac cooling loop
• required turndown for
temperature control system
(the minimum level of power
input – expressed as a
percentage of the design
value – at which the linac
cooling system must be able
to deliver water within the
specified temperature
tolerances on a continuous
basis)
Air eliminators are needed at
system high points. The float
type air eliminator has been
used successful at LANSCE.
The need for redundant pumps
(and other components) should
be considered in detail and if
not included in the design,
justification should be included
in the design documentation.
The RAMI allocation for the
cooling system should be part
of this assessment. It is noted
that all of the other cooling
systems for SNS (ring
component cooling systems,
target component cooling
systems, klystron cooling
systems, etc) have redundant
pumps. It is recommended that
the designers of the cooling
systems mentioned above, be
Description Document”.
Each of the operational issues presented by the PDR committee at left, have
been addressed and are contained in the DTL and CCL Water Cooling and
Resonance Control System Final Design Reports. The transient conditions
(start-up, RF trip, and minor temperature transients) were studied with a
Systemview model on both the DTL and CCL. Design features, including a
variable speed pump, water heater, and electrically actuated control valves
on the hot and cold sides of the heat exchanger, were incorporated in the
water skid design to handle off-normal operating conditions.
Air eliminators have been incorporated at the high point on each water skid.
We reviewed the LANSCE air eliminator devices which consist of a float
type device. We are also contacted vendors (Spirax Sarco and Nalco) for
product information. One brand in consideration is the Spriotherm Air
Eliminator, removes all air, including entrained microbubbles from the
cooling system with a patented screening process. This air eliminator also
has the float for air release and does not need the air separator component.
The air eliminators will be branched off the transfer main cooling lines at the
high point in parallel with a vent valve. Vent and drain valves, with quickconnect, non-leakage fittings, have been incorporated on each water skid as
well as each DTL tank and CCL module manifold system in the linac tunnel.
No requirement exists for a redundant system. However, in reviewing
systems that do have redundancy on LEDA (Power Supply Specifications
B5473 and E2289) and in talking with those engineers involved, redundancy
was designed into the system for either of two primary reasons. The failure
of the system could cause injury to personnel or cause significant damage to
the accelerator or the system itself. The failure of the water skid does not
meet this criterion. There are plenty of safety interlocks to shut down the
beam and RF power if the pump operation and cooling flow should cease.
Inclusion of a redundant system would result in a significant cost and
schedule impact. Additionally, a redundant system will significantly
increase the size of the skid that will have a detrimental affect on the layout
within the Klystron Gallery. Finally, the SNS RAMI program has been
replaced by “Best Engineering Practices”, and hence the need for pump
redundancy can not be incorporated into a full reliability and availability
analysis.
35
8
consulted regarding the
decision they made to include
redundant pumps.
error bands on thermal and
fluid analyses be quantified to
help determine if design and
safety margins are adequate.
9
Additional thought should be
given to how and if individual
circuit flow blockages might be
detected
10
The use of orifices to balance
the flow to individual circuits
should work well. However,
since changing one or more
orifices to correct for
unexpected hardware
differences will be time
consuming, verifying the flow
characteristics of individual
components will be important.
It is important that full scale
tests are performed (not just
component testing) to verify
the accuracy of the design
calculations.
11
It appears that the temperature
control limit previously
specified for the primary side
An uncertainty analysis on the SINDA/FLUINT modeling was
accomplished by comparing flow and pressure drop predictions (from a S/F
model), to empirical data obtained from the CCL hot model prototype water
cooling system. The comparison and a thorough discussion of agreements
and discrepancies are presented in the DTL and CCL Water Cooling and
Resonance Control Systems Final Design Reports.
The flow blockage problem is quite complicated and an easy and costeffective fix was not available. It is not cost effective, nor practical to supply
enough flow sensors for every piece of DTL hardware or CCL cooling
passage. Design alternatives included placing flow switches on each DTL
drift tube, and flow meters on every outlet line on the CCL. This was found
to be unrealistic due to cost implications. The design compromise, which
satisfies operations, safety, maintainability, and cost, was to use flow meters
on the DTL submanifold return lines, as well as the return lines on the CCL
cavity lines. These flow meters will allow operators to detect significant
flow blockages. Other design features include the use of screens at the
entrance to the main supply manifolds, and well as all drift tube sub
manifolds. RTDs will also be placed on each CCL segment and bridge
coupler, which will serve as a safety indicator of flow blockage on those
systems. In addition, several design features and detailed quality assurance
measures were defined such as filters, proper cleaning procedures, exclusion
of teflon tape sealant, high levels of water cleanliness, etc., to minimize the
chances of flow blockage. Flow checks of the individual pieces of the DTL
hardware and CCL segments will occur prior to assembly. Portable, nonintrusive ultrasonic flow meters, which attach to the outside of the water
lines, will be available to trouble shoot flow blockage problems, should they
arise.
The pressure drop across six prototype drift tubes will be measured using an
existing flow loop facility. The geometry of these prototypes is
representative of the different drift tubes. Based on the results of these tests,
analytical correlations to evaluate the pressure drop will be derived for all
the DTL drift tubes. Before final installation, the pressure drop across each
drift tube and orifice plate assembly will be checked at nominal flow rate.
Orifice plate tests have already been performed to insure that the empirical
correlation for orifice plate performance agrees with measured performance.
Flow tests have been performed on the CCL cavity cooling passages to
bench mark the numerically predicted pressure drop. Each of these tests
shows good agreement between experiments and analytical/numerical
models.
In regards to the CCL, full scale flow tests will be made on prototype full
scale segments (cavities and short coupling cells) and bridge coupler flow
lines. From this data, empirical flow resistance factors will be calculated
and compared against analytical valves used in the Sinda/Fluint flow
models. This will develop confidence in the accuracy of the Sinda/Fluint
models to correctly size orifice plates to correctly distribute the flow in the
CCL.
Finally, a flow test will be performed on the CCL during assembly in the
RATS building. Flow meters, incorporated on the outlet lines of the CCL
cavities, SCCs, and BCs, will be used to determine the adequacy of the flow
distribution being generated by the orifice plates. These tests will determine
if the orifice plates need to be revised for better flow distribution.
Flow tests on the DTL will be performed to set the flow control valves to
obtain desired water flows (measured with flow meters) in the various DTL
cooling passages.
Transient thermal modeling was performed to study the impact of
disturbances to the temperature of the cooling water on the facility-side of
the heat exchanger. Analyses indicate that temperature swings of +/- 2.0°F
36
12
13
14
15
16
of the heat exchanger (i.e.: +/0.5 F) can be loosened. Since
this will simplify the chiller
design, it is recommended that
the new limit be quantified and
conveyed to CF ASAP.
requirements for vibration
isolation be investigated in
more detail to determine
appropriate design features
(e.g.: should the entire cooling
skid be vibrationally isolated or
is it sufficient to only isolate
the pump). In addition, the
vibration issues associated with
the variable speed pump (wider
frequency range of operation
than fixed speed pumps) should
be investigated in more detail.
expected cooling system noise
level and sound attenuation
requirements be investigated in
more detail.
The “Design Pressures” for the
cooling loops (as defined by
the ASME code) should be
defined and specified so
structural calculations on
related systems can be
performed using the
appropriate pressure. In
addition, consider making the
design pressure of the process
water loop greater than the
shut-in (i.e. deadhead) pressure
of the pump plus any static
liquid head on the system plus
a comfortable safety margin.
This will help prevent nuisance
discharges of safety relief
valves.
Based on experience at
LANSCE, globe valves should
be avoided (they sometimes
lose their setting). A better
choice is a solid stem type
valve.
The design of the cooling skids
and how they are positioned in
the facility should facilitate
required maintenance activities
for both the pump and the DI
bottles. This may require
additional clear space on the
sides of the skid where these
items are located. A
(about the mean of supply temperature of 45°F) can be tolerated by the DTL
and CCL water cooling and resonance control systems.
No dynamic vibration requirement currently exists in the SNS Systems
Requirements Document. However, LANL will require that the pump be
mounted on dynamic isolators. The skid may be mounted on isolators and
will be a “recommendation” to the skid builder. No thorough analysis was
performed by LANL, however, a “water skid vibration reduction” memo
was drafted (LANL-SNS-00-80) which describes the vibration concerns and
design features/requirements to minimize the potential for undesired
vibrations.
No noise level or sound attenuation requirement exists in the SNS Systems
Requirements Document. However, LANL will require a “common sense”
requirement to the skid builder that follows OSHA regulations. A LANLSNS memo (SNS-00-83) describes in detail, the noise concerns, lack of SNS
requirements, and acceptable engineering practices and codes related to
noise levels and attenuation.
The design pressure for the cooling loops has been specified in the SNS
DTL and CCL Water Cooling and Resonance Control System Description
Document 150 psig. This is approximately 5 times greater than the largest
anticipated pressure at the RF structure water manifolds in the Linac tunnel,
and 2 times higher than anticipated maximum pressures in the water skids.
Valve closure times will be sufficiently large to prevent water hammer.
Pressure relief valves will be set at 100 psig (50 psi below the maximum
design pressure).
“Solid Stem” type globe valves should prevent the vibration loosening
observed on the LANSCE Linac water cooling system. Several vendors
(Warren Valves, Conval, and Flow serve) were contacted and supplied us
with design information on solid stem valves which have been designed to
eliminate valve position changes from vibrations. This requirement has
been included in a general globe valve specification document that will be
used for hardware procurement. Valve specification requirements also
included valve locking devices to prevent accidental movement of valve
setting positions.
A great deal of thought has been put into the layout of the skid with
reference to maintenance needs. The 2 items most likely to need
maintenance that are somewhat personnel intensive are the purification
system tanks and the pump motor. These have been located at the most
accessible side of the skid and will be a requirement for the supplier/builder
of the skid. Skids locations within the klystron gallery have been optimized
and incorporated in the facility layout drawings to allow for required
maintenance access. Maintenance of these components can usually occur
during scheduled maintenance periods, and should not cause a shut-down of
37
maintenance plan to replace a
skid, or components on the
skid, should also be developed.
This may influence the decision
to include redundant
components as part of the
design or not. It will also give
a check of the RAM analysis,
which can yield misleading
(fairy tale) results.
17
An updated list of spare parts
should be developed,
considering the current cooling
system design.
18
To stream line the procurement
process for the cooling system,
pre-qualifying vendors is
recommended.
19
Since 3-way valves are
complex components and can
be troublesome over time due
to dead heading and erosion,
alternate design options should
be considered. An alternative
design that could be considered
is to put a valve on the by-pass
line around the pump. Since
the flow will follow the least
resistant path, most will go to
the pump suction. Granted, not
all the flow will by-pass the
cooling circuit, but the
reliability issue may dictate not
using a 3-way valve.
20
To avoid contamination problems,
the oxygen scavenger bottle should
be upstream of the mixed bed resin
bottles.
21
Cooling the magnets in the SC
part of the tunnel with the same
loop as is used to cool the
magnets in the warm part of the
tunnel may reduce cost and
should be considered.
22
The issue of radionuclides
should be addressed in more
the accelerator operation.
A maintenance plan for component replacement will be developed during
the procurement phase. Replacement of the entire skid should not be
required and will not be part of any standard maintenance procedure.
Component redundancy usually driven by operational and safety
requirements. No specific requirements were given to warrant the inclusion
of redundant subsystems on the water skid.
The RAMI analysis, originally proposed by the ORNL SNS-PO, has been
replaced by “Best Engineering Practices”, due to man-power and budget
limitations. Consequently, the RAMI analysis will not be performed and
will not influence the water skid design.
A spare parts recommendation list was created, based on the final design,
and submitted to ORNL-SNS. These spare parts are only a
recommendation. No criteria, requests, or funding was made or allocated in
the DTL and CCL water cooling system work packages to acquire spare
parts.
A selected list of potential skid suppliers/builders was developed and vendor
survey forms were sent out to each of these companies via a LANL UC
buyer. Presently, this list for the water skid fabrication includes 12 very
interested and capable suppliers who work with very reputable component
suppliers. We are waiting on the responses of these surveys and will plan to
take facility inspection tours of down-selected vendors to review and assess
their fabrication/inspection/certification capabilities, before selecting the
final vendor(s).
Several valve suppliers have been contacted to supply design and
operational information on 3-way valves. These valves have been used in
various services for well over 50 years and show no significant problems
that would not be encountered with 2-way valves. In addition, the
incorporation of the 3-way valve offers a wider range of flow control
through or around the heat exchanger for standard and off-normal operating
conditions, than was available with a previous design which incorporated a
standard 2-way valve in the heat exchanger by-pass line. Several vendors
produce 3-way valves with design features that minimize erosion. In
addition, the normal operation of the 3-way valve will be to divide water
flow between the heat exchanger and by-pass line, and thus dead heading
will not be a regular occurance. Consequently, the design team has chosen
to use the 3-way valve for controlling flow through the heat exchanger.
The pump by-pass line has been removed since it is no longer required for
operation of the water cooling system. The 3-way valve can by-pass cooling
water around the heat exchanger if the need to prevent cooling to the DTL or
CCL arises. The pump is a variable speed type and thus will not need to
have a by-pass to control flow rate to the RF structures. Removal of the
pump by-pass also eliminates a dead leg line which could have been a
source for bacteria growth and dissolved oxygen.
We agree, and this change has been incorporated in the final design of the
water purification system.
We have decided to move ahead with our previous plan of keeping the CCL
and SCR magnets on separate cooling lines. Factors such as installation
schedule, system pressure drop, water manifold placements for the two
systems (on the support structure for the CCL and on the wall or floor for
the SRF), and differing magnet configurations on the CCL and SCL, have
led to two separate magnet cooling systems. We have decided to
consolidate the 2 SRF magnet cooling systems into a single cooling system.
We believe this will save both space and costs without a degradation in
performance.
•
The collection and disposal plan for the ion exchange resins will follow
that used by LANSCE (unless a better technique is found). The ion
38
detail. Joe DeVore (SNS OR)
should be consulted on this
topic. Specific issues which
should be dealt with are:
•
When will radionuclides
be collected for disposal?
•
How long are the resin
tanks estimated to last
before they are depleted?
•
Will the resin tanks
require shielding?
•
How will resin bottles be
handled?
•
Are there other sources of
radionuclides and what is
their impact?
23
24
The plan to integrate and test
the control system with the
cooling skid only after it has
been installed at the SNS site
will delay the uncovering of
problems and leave little time
for required modifications.
Ways to integrate the cooling
skid and controls earlier should
be considered.
Waveguide cooling requirements
(particularly in the chases) is still
an open issue. This should be
investigated by LANL and ORNLSNS so that the required capacity
can be included in the cooling
design as appropriate.
exchange bottles will be blown down and dried, sealed off, and be
allowed for burial. This process must occur each time the resins are
depleted. Cost of regenerating radioactive resins would be extremely
high and handling procedures would be difficult. We will not
recommend regeneration of the resins.
•
The 9” resin bottles on LANSCE are changed out every 8 to 12 months.
The SNS linac water cooling system will probably follow the same or
longer exchange period. The exact maintenance period will depend on
water/system cleanliness and will come from operational experience.
•
Radiological Control Technician measurements on the resin bottles
from the LANSCE water cooling system do not show significant
amounts of activation. Shielding is currently not required around the
LANSCE resin bottles and it is anticipated that shielding will not be
required for those on the SNS water cooling systems. ORNL
operations engineers have been contacted about the possibility of
activation of the resin bottles and water skid components. US DOE
regulations for radiation area designations have been discussed, but no
radiation level requirements have been specified by the ORNL SNSPO. We will follow the same design and operational procedure as used
on the LANSCE water cooling system water purification hardware and
recommend that a radiological scan be performed during operation of
SNS to ensure that radiation levels are sufficiently low. If the levels of
radiation are high on any point on the water skid, then shielding can be
added.
•
Resin handling and disposal plans have been adopted from LANSCE
and are included in the DTL and CCL Water Cooling and Resonance
Control System Final Design Reports.
•
There are no other sources of radionuclides that we are aware of.
Budget and schedule limitations will prevent full-scale testing of the water
control systems prior to installation in the klystron gallery. A compromise
was reached to perform the following tasks:
1.
Test the resonance control system logic on the CCL hot model water
cooling and resonance control system (using the Labview-based control
system), and gain valuable operations experience.
2. Develop a prototype water cooling and resonance control system
electronics rack, complete with PLC and touchscreen interface.
Incorporate this prototype system on the CCL hot model water cooling
system to test a minimal number of functional capabilities. Also use
these tests to interface with an SNS global control system IOC, running
EPICS, to test interfaces, communication drivers, etc.
3. Using the prototype control system developed in (2), test each water
skid’s basic functioning characteristics (pump and valve control,
instrumentation output, etc.) before shipment from the skid vendor to
ORNL.
4. Install a complete DTL water skid and corresponding electronics rack
in the RATS building to perform flow checks on each DTL tank and
CCL half-module, following the assembly process and prior to
installation. These tests will not allow for resonance control testing.
Resonance control tesing will occur following installation of the
systems in the Linac tunnel and klystron gallery. This is the current
agreement between LANL and the SNS Project Office at ORNL.
The waveguide cooling is a design requirement of the RF engineering team.
That team is responsible for cooling the klystrons, and other RF hardware
(up to the RF structures), with the exception of the RF windows, and has not
requested the RF structure water cooling system design team to deal with
waveguide cooling. To reduce the influence of undesired waveguide heat on
the water cooling lines in the waveguide chases, the water lines in those
sealed chases will be insulated.
39
2.0 DTL Water Cooling and Resonance Control System Design Summary
The SNS DTL water cooling and resonance control system is comprised of
multiple closed-loop water systems, one per DTL tank. Each loop is a modular system,
comprised of a water skid (pump, expansion tank, valves, heat exchanger, etc.), water
transfer lines, and manifolding/cooling passages at the DTL RF structure. Each loop
removes waste heat from a single DTL tank and transfers it to the SNS facility chilled
water source via a liquid-to-liquid heat exchanger. Since each modular water system is
close-looped, the water simply circulates between the DTL RF structure and the water
skid, and hence does not require continual make-up feed water. The closed-loop modular
water cooling system, similar to that used in the Advanced Photon Source design [1.6],
was chosen for the SNS linac over a fully integrated, open-loop design [1.7, 1.8, 1.9] for
the following reasons:
•
Modular, closed-loop design allows for enhanced temperature control and stability
during start-up and steady-state operation.
•
Modular water system is consistent with the modular design approach used on the
DTL and CCL RF structures. This modularity allows each water system to be
installed and commissioned with its corresponding RF structure tank or module.
•
Closed-loop systems mitigate spreading of contamination (radioactive, water purity).
•
Modular system provides consistency in design and ease of manufacturing and
installation.
•
Modular system lends itself to reduced manufacturing and assembly costs.
•
Modular design lends itself to easy maintenance (fixing leaks, performing scheduled
maintenance, maintaining spare parts, etc.).
2.1 Water System Layout
Each DTL tank water cooling system is responsible for removing the RF waste
heat from the tank’s copper structure and providing resonance control of the RF in the
DTL cells. The water cooling system configuration for a single DTL tank can be divided
into four main sections including the manifolding on the RF structure, water skid,
40
transition lines, and facility chilled water source. Summary details of each of these main
sections are provided below.
2.1.1 Manifolding on the RF Structure
The DTL RF structure, discussed previously, contains all of the water-cooled
components and the associated internal water passages, as well as the external plumbing
manifolds and water lines. Flow is distributed to the various components by way of a
water manifold and jumper line distribution system, and metered by valves/flow meters
and orifice plates. Figure 2.1 displays the flow diagram for the water cooling system on
DTL tank #1, and Figure 2.2 is a top level assembly drawing of the water cooling lines
attached to DTL tank #1. A pumping skid delivers water to a main supply manifold on
the DTL tank. From the main supply manifold, the water is diverted to a number of submanifolds, which in turn feed the drift tubes, post couplers, tank walls, slug tuners, dipole
electro-magnets, RF window, Faraday cup, and drive iris.
Proportional valves in
combination with flow meters are used to accurately meter the correct amount of water to
each sub-manifold. With the exception of the drift tubes, each DTL component in a
particular group (i.e., post couplers), has the same heat load and thus will require the
same cooling water flow rate. Consequently, all components in that group are ganged
together on a common supply sub-manifold and plumbed in parallel. This eliminates the
need of flow metering equipment for the majority of the RF structural components.
However, each drift tube has a slightly different heat load, and thus each requires a
unique cooling water flow rate.
This is accomplished by placing an orifice plate
upstream of each drift tube. The orifice plates contain a hole of a specified diameter to
meter the desired amount of flow to a particular drift tube from a common supply submanifold. To guard against flow blockage problems in the narrow drift tube channels or
orifice throats, a fine mesh screen filter is provided at the inlet to the drift tube supply
sub-manifold. Other design features include pressure and temperature transducers as well
as drain, vent, and pressure relief valves on the main supply and return manifolds. Flow
meters on the return lines of the various sub-manifolds are used to correctly distribute
coolant flow to the various components, and serve as safety interlocks should leaks or
blockages occur in the water lines. More details concerning the component sizing,
41
DTL Tank 1, 59 drift tubes, 2 endwall tubes,
2 tank sections, 20 post couplers, 8 slug tuners
4 dipole steering magnets, 1 R F window
and 1 drive iris
DTL PID - Tank 1
John Bernardin
Date Last Modified: 3-14-01
DTL Tank 1 Cooling Loop for Drift Tubes and Tank Walls
Vent
T
FM
FM
FM
Drain
FM
Orifice Plate
P
FM
Drift Tube Return Lines
Globe Valve
Ball Valve
FM
FS
Flow Meter
Flow Switch
P
Pressure Trans.
T
Temperature Trans.
0
58 59
2 3
60
Drift Tube Supply Lines
Vent
P
T
Drain
Vent
Water Skid #1
Faciltiy CW Inlet
Drain
Facility CW Outlet
DTL Tank 1 Cooling Loop for Post Couplers, Slug Tuners, and Drive Iris
T
FM FM FM
FM FM
P
FM
Drive Iris
Slug Tuners
Post Couplers
Dipole Electromagnets
R F Window
Vent
P
T
Drain
Vent
Water Skid #1
Faciltiy CW Inlet
Drain
Facility CW Outlet
Figure 2.1. Flow diagram for the water cooling system on DTL tank #1.
42
Figure 2.2. Water manifolds and lines on DTL tank #1.
plumbing materials, joining techniques, etc., will be covered in later sections of this
report.
2.1.2 Water Skid
The second major component of the water cooling system is the water skid,
shown in the flow diagram and model of Figure 2.3. The water skid is a self-contained
unit with all of the necessary plumbing, water treatment hardware, instrumentation, and
pumping/heat transfer equipment required for delivering water at a desired flow rate and
temperature to the DTL RF structural components.
A small capacity tank serves as a water reservoir and allows for expansion or
contraction of the water associated with temperature changes. The tank is equipped with
43
a Nitrogen gas source for controlling pressure and reducing the presence of dissolved
oxygen in the water. A pressure relief valve, vent valve, and a liquid low-level indicator
were added for safety purposes. The water reservoir feeds the main water line on the
suction side of the pump through a manual valve. The reservoir tank volume will be kept
to a small capacity (10-20 gallons) to minimize the effect of its large thermal mass on the
time response of the water loop’s temperature control system. A high capacity, variable
speed centrifugal pump and a flow meter connected to the programmable logic controller
(PLC), will be used to supply a constant water flow rate to the RF structure.
Consequently, flow loop pressure fluctuations induced by the by-pass control valve will
not upset the constant supply of water to the DTL.
To provide for heating of the water loop (preheating of the copper structure), an
inline electrical water heater was placed downstream of the pump. A solenoid valve,
plumbed in parallel with the heater, will be used to direct all of the water flow through
the heater when it is in use. To remove the waste heat from the cooling loop and
maintain the desired water temperature, a stainless steel flat plate counter-flowing heat
exchanger was incorporated.
This type of heat exchanger is relatively cheap to
manufacture, compact, corrosion resistant and extremely efficient. The cold side of the
heat exchanger is fed with chilled 7.2°C (45°F) water from the SNS conventional
facilities.
To maintain steady flow on the conventional facility side of the heat
exchanger, a 2-way control valve, connected to a flow meter and the PLC, was
incorporated. A PLC will monitor the flow rate through the cold side of the heat
exchanger and adjust the control valve to maintain the desired flow rate. To minimize
contamination of the heat exchanger from the facility chilled water supply, a 100 mesh
filter was added to the upstream cold side of the heat exchanger. Flushing ports will be
incorporated on the cold side of the heat exchanger to allow acid cleaning to remove
potential scale build-up.
The water temperature in the flow loop is manipulated by adjusting the
distribution of water flow between the heat exchanger and the heat exchanger by-pass
line. This is achieved using a proportional 3-way valve on the return leg from the DTL
tank. The 3-way valve directs a portion of the water flow to the heat exchanger, and
directs the remainder of the flow through the heat exchanger by-pass line (see Fig. 2.3).
44
Steady-state operation requires that all of the waste heat from the DTL be transferred to
the facility’s chilled water. By raising or lowering the velocity of the hot water through
the heat exchanger (via the proportional by-pass valve), the overall heat transfer
coefficient of the heat exchanger is raised or lowered, respectively. The net effect is that
the effective thermal resistance between the DTL water and the facility’s chilled water is
inversely proportional to the hot water flow rate through the heat exchanger. If the
chilled water source temperature and flow rate, and the thermal load of the DTL are
constant, the DTL cooling water temperature (water temperature leaving the pump) will
increase with a decrease in hot side heat exchanger water flow rate, and decrease with an
increase in hot side heat exchanger water flow rate.
In the event of RF power failure or trip, and hence a loss of heat load to the water
cooling system, it is desirable not to continue to cool the DTL structure. The motivation
is to keep the RF structure as close to its resonance dimensions as possible during the RF
trip so that when RF power is restored, little time is lost trying to get the structure back to
its desired resonance frequency. To minimize cooling of the DTL during an RF trip, the
3-way valve upstream of the heat exchanger, will adjust its position and force all cooling
water to by-pass the heat exchanger and thus minimize the amount of heat loss from the
system. At the same instant, the 2-way control valve on the facility-side of the heat
exchanger, will close and prevent further cooling of the heat exchanger volume. Once
RF power is restored, the 2-way valve will open to its previous setting and the 3-way
valve will redirect cooling water through the heat exchanger.
45
Ball Valve
Filter
60 mesh
Pressure
Relief Valve
T
FM
Vent
Valve
Reservoir/
Expansion
Tank
Mixed
Carbon Ion Bed Cation
Bed
Resin Resin
5 µm
Filter
S
UV
5 µm Source
Filter
Filter
FM
FM
Fluid
Low-Level
Indicator
FM
Heat
Exchanger
Deoxygen.
In-Line Heater
N2
Reservoir/
Expansion
Tank
P
P
Heater
Heat Exchanger
By-Pass
Control
Valve
Variable-Speed
Pump
T
T
P
P P
Filter
100 mesh
FM
Heat Exchanger
T
Valve for
acid flush
T
Facility Chilled
Water Outlet
WP
Water Purity Transducer
(Ph, elect. Cond., Diss. O)
2
FM
Flow Meter
T
P
T
FM
Drain
Temperature Transducer (RTD)
P
Pressure Transducer
Pump
Flow
Control
Valve
Facility Chilled
Water Inlet
Water Purification
Equipment
(a)
(b)
Figure 2.3. (a) Flow diagram and (b) solid model representation of the DTL water skid.
46
A water purification system was included in the design of the water skid to minimize
the formation of deposits, scale buildup, biological growth, corrosion and activation, all
of which can be of significant threat to the performance of the SNS linac water cooling
system. This system consists of several filters for removal of debris, a carbon bed for
extraction of hydrocarbons, several ion exchange resins for the removal of salts, minerals,
dissolved oxygen, and radionuclides, and an ultraviolet lamp to kill bacteria. The water
treatment hardware was placed in a small side loop in which approximately 3% of the
total flow will be circulated. Electrical resistivity, pH, and dissolved oxygen sensors will
monitor the water purification system performance. Additional information concerning
water purification and related particle accelerator issues is provided in a later section of
this report.
2.1.3 Transfer Lines
Connecting the water skid to the RF structure manifolds, are water supply and
return lines. The transfer lines, shown in Figure 2.4 for a particular DTL system, are
routed from the klystron gallery to the linac tunnel, through circular chases. In the
klystron gallery, the transfer lines will need to be routed overhead, around other
plumbing, cable trays, waveguides, etc. In the Linac tunnel, the transfer lines will need to
be routed along the floor between the chase exit and the RF structure manifold junctions.
Cover plates can be used to avoid the potential tripping hazard caused by these lines on
the non-isle side of the accelerator. The transfer lines will contain isolation valves on
either end for maintenance purposes. In addition, they will contain short flexible sections
to aid in their installation and minimize the transmission of mechanical vibrations.
Figure 2.5 shows the routing of the water transfer lines between the water skids and RF
structures for all six DTL tanks.
47
Klystron Gallery
Waveguide
Chase
Water Skid
Water
Transfer
Lines
DTL Tank 3
Linac Tunnel
Figure 2.4. Water transfer line routing between a water skid and a DTL tank.
48
Figure 2.5. Water transfer line routing for the six DTL water cooling systems.
49
2.1.4 Facility Chilled Water Source
Chilled water from refrigerated source within the klystron gallery, will be used to
remove the waste heat from each DTL closed loop water system. The chilled water will
be drawn from a facility supply main to the water skid, pass through the counter-flow
heat exchanger, and exit to a facility return main.
The current SNS System
Requirement’s Document [2.1], specifies that chilled water will be supplied at a
temperature of 7.2°C (45°F), with a maximum deviation of ±0.56°C (±1.0°F). The total
mean heat removal of the six DTL water cooling systems is 472 kW, requiring a total
chilled water supply flow rate of approximately 250 gpm, and a maximum heat
exchanger pressure drop of 15 psi [1.2].
2.2 Instrumentation and Controls
A variety of transducers are strategically placed at various points in the water skid
to monitor pressure, temperature, and flow rate. Several of these transducers will be used
for control purposes during operation, while the remainder will be employed for system
monitoring during commissioning and trouble shooting situations. A programmable
logic controller (PLC), located in an electronics rack in the klystron gallery, will be
responsible for overseeing the operation of the water skid and logging necessary data.
Some of the PLC functions will include controlling the water temperature and resonance
of the DTL, maintaining desired water flow rates on the hot and cold sides of the heat
exchanger, monitoring and recording the water purification system parameters,
monitoring the flows, temperatures, and pressures at various locations throughout the
skid, and providing alarms for off-normal operating conditions. The PLC will possess
the ability to operate in a stand-alone mode for commissioning and maintenance
purposes, and will also have a direct interface to the SNS global control system for
steady-state operation. More detailed information concerning the instrumentation and
control system is provided in Section 6 of this report.
50
3.0 Water Cooling Analyses
3.1 DTL Water Cooling Loops – Lumped Parameter Flow Network Modeling
Numerical calculations from a lumped-parameter computer code were used to
compute all the pressures, temperatures, and flow rates for the SNS DTL water cooling
system models. The computer code used is called SINDA/FLUINT (Systems Improved
Numerical Differencing Analyzer with Fluid Integrator) [3.1]. This computer code is
ideally suited for piping networks that will be used to cool the RF structure. In a piping
network one has a length of pipe called a “path” and at each end of a path are points
called “junctions”. The path lines usually calculate flow, while at the junctions, values of
pressure and/or temperature are calculated. Figure 3.1 illustrates the correspondence
between a simple physical model and a SINDA/FLUINT representation.
The work discussed below, explains the SINDA/FlUINT modeling plan and the
results for the DTL water cooling system. The end goal was to have a master model of
an entire DTL water cooling system comprised of a series of sub-models (drift tube
cooling circuit, water skid, etc.). Subdividing the simulation of the DTL water cooling
system into separate, but coupled, models allowed the simulation to be efficient,
tractable, and convenient for debugging.
3.1.1 DTL RF Structure Cooling Loop
3.1.1.1 Design Goals
The design goal of this work was to specify the piping configuration of the SNS
Drift Tube Linac (DTL) and optimize their designs by performing engineering analyses
to determine the flow and pressure drops, as well as temperature distributions throughout
the systems. This task involved designing a system that provided the necessary water
flow to support cooling of the RF structure. In particular, a cooling loop had to be
designed to provide the required water cooling flow rate to each of the components in the
DTL structure. These components include the drift tubes, tank walls, slug tuners, post
couplers, dipole electric magnets, and drive iris. A more detailed discussion of the
cooling passages and cooling requirements for each DTL component, can be found in
Section 1 of this report. A cut-away view of DTL tank 1 is shown in Figure 3.2.
51
Heat
Exchanger
Tank
Pump
Pump
SINDA/FLUINT Representation
Flow System
Figure 3.1. Simple flow system and the corresponding SINDA/FLUINT representation.
52
Figure 3.2. Assembly drawing of DTL tank 1 (note that the water manifolds and lines are not included in the schematic).
53
Although there are 6 different tank sections that comprise the DTL, tank 3 was
selected as the representative structure and was modeled in detail. The results from tank
3, along with additional analyses necessary to model any significant differences, were
used to design the piping systems for the remaining tanks.
The focus of this work was to analyze each cooling loop with a computer model
to study fluid flow and pressure throughout the system. Pipe line sizes, orifice sizes for
flow control, and overall pressure drops throughout the fluid circuits were determined.
This information was required to size the pump, heat exchanger, flow control valves, etc.
The design goals for DTL RF structure model are summarized in Table 1.
Note that all line diameters listed in this section of the report correspond to
internal diameters. All water velocities correspond to mean or average flow rates through
a pipe of a given cross-section.
54
Table 3.1. SINDA/FLUINT modeling goals for the DTL RF structure model.
Design Goal
Outcome
Determine orifice plate sizes required to
properly distribute the water flow to the drift
tubes
Optimize supply and return main manifold
diameters to minimize pressure variations
along length and minimize overall cost
Optimize transfer line diameters to minimize
pressure drop, erosion, and cost
• From main manifolds to water skid
• From main manifolds to end walls
• From main manifolds to drive iris
• From main manifolds to RF window
• From main manifold to drift tube submanifold
• From main manifold to all other submanifolds
Optimize sub-manifold diameters for the
• drift tubes
• post couplers
• slug tuners
• tank walls
• DTL magnets
to minimize pressure variations, pressure
drops, and overall cost
Determine pressure distribution around the
flow loop and the maximum pressure drop
across the system (help size pump for flow
rate and pressure drop)
Repeat necessary analyses (from DTL tank
3) to meet the above mentioned design goals
for DTL tanks 1, 2, 4, 5, and 6
The orifice plates were sized to provide each drift
tube with its design flow rate. Values of β ranged
from 0.43 to 0.8.
3.5" ID minimum
4" ID minimum
0.5 " ID minimum
0.313" ID minimum
0.5" ID minimum
2.5" ID minimum
Same size as submanifold diameter
1.75" ID minimum
1.00" ID minimum
1.25" ID minimum
1.5" ID minimum
0.5" ID minimum
Pressure drop = approximately 24 psi
Required that post coupler sub-manifold be 1.25"
ID minimum.
3.1.1.2 Design Specifications
Reference [1.2] contains the design specifications for the DTL cooling loops.
Each module of the DTL is to have its own separate cooling loop complete with heat
exchanger, pump, and instrumentation, etc. A separate facility cooling supply of chilled
water is available with inlet temperature of 7.2°C, ±0.28°C. The temperature of cooling
water delivered to the DTL tanks is specified to be 20.0°C. The design flows specified
for the DTL tanks 1 through 6 include flows of 0.2 to 5.1 gpm to the drift tubes, flows of
19.2 to 79.2 gpm to the tank walls, a flow of 1.0 gpm to each slug tuner, a flow of 0.65
gpm for each post coupler, and flows ranging from 0.2 to 1.0 gpm for the end walls.
Section 1 of this report contains detailed descriptions of the heat loads and cooling
requirements for all of the DTL components. Separate supply and return sub-manifolds
55
are used to provide distribution of the cooling water to each of these subsystems for a
given tank. A single supply and return manifold combination will feed all sub-manifolds.
This large manifold will be connected to the water skid by transfer lines.
3.1.1.3 Tank 3 Global Model Description
A flow diagram in Figure 3.2 displays the water-cooled components and the water
distribution lines on DTL tank 3. A pumping skid delivers water to a main supply
manifold on the DTL tank. From the main supply manifold, the water is diverted to a
number of sub-manifolds, which in turn feed the drift tubes, post couplers, tank walls,
slug tuners, dipole electro-magnets, and drive iris. Proportional valves in combination
with flow meters are used to accurately meter the correct amount of water to each submanifold. With the exception of the drift tubes, each DTL component in a particular
group (i.e., post couplers), has the same heat load and thus will require the same cooling
water flow rate. Consequently, all components in that group are ganged together on a
common supply sub-manifold and plumbed in parallel. This eliminates the need of flow
metering equipment for the majority of the RF structural components. However, each
drift tube has a slightly different heat load, and thus each requires a unique cooling water
56
DTL Tank 3 Cooling Loop for Drift Tubes and Tank Walls
Vent
T
FM
FM
FM
Drain
FM
Orifice Plate
P
FM
FS FS
FS FS FS
Drift Tube Return Lines
FS
FS
Globe Valve
Ball Valve
FM
FS
Flow Meter
Flow Switch
P
Pressure Trans.
T
Temperature Trans.
0
2 3
32
Drift Tube Supply Lines
34
Vent
P
T
Drain
Vent
Water Skid #3
Faciltiy CW Inlet
Drain
Facility CW Outlet
DTL Tank 3 Cooling Loop for Post Couplers, Slug Tuners, and Drive Iris
T
FM FM
FM FM
P
FM
Drive Iris
Slug Tuners
Post Couplers
Dipole Electromagnets
Vent
P
T
Drain
Vent
Drain
Water Skid #3
Faciltiy CW Inlet
Facility CW Outlet
Figure 3.3. Flow diagram for DTL Tank 3.
57
flow rate. This is accomplished by placing an orifice plate upstream of each drift tube.
The orifice plates contain a hole of a specified diameter to meter the desired amount of
flow to a particular drift tube from a common supply sub-manifold.
The approach to modeling the maze of water lines on DTL tank 3, was to generate
a global model, comprised of a series of detailed sub-models for each subsystem of
components. Figure 3.4 displays a representation of the global model and its sub-model
construction for the DTL tank 3 water cooling system. The SINDA/FLUINT global
model for DTL tank 3 is displayed in Figure 3.5.
The sub-models were developed to optimize the water line geometries of the submanifolds, size orifice plates, and to determine subsystem pressure drops. Subsystem
models, once completed, were represented as a corresponding flow branch in the global
model. The pressure losses that occur in series through each branch of the global model,
are summed as follows:
∆P branch = ∆Psubsystem + ∆Pflow meter + ∆Pother losses (4 tees and line friction) + ∆Pvalve
where ∆Psubsystem is the pressure drop of a particular subsystem, determined from its
corresponding SINDA/FLUINT submodel, ∆Pflowmeter is the pressure drop of flow meter
in that branch, ∆Pother losses is the pressure drop of the supply and return plumbing not
included in the submodel, and ∆P valve is the pressure drop across the globe valve used to
meter the flow to that particular subsystem.
Note that the flow resistance coefficient of the branch valves were numerically
adjusted to obtain the desired flow rates through each subsystem.
58
Main Return Manifold
Flow
Meter
End Wall
Flow
Meter
Flow
Meter
Flow
Meter
Flow
Meter
Flow
Meter
Flow
Meter
Drift Tube
Sub-Model
Drive Iris
Sub-Model
Slug Tuner
Sub-Model
Post
Coupler
Sub-Model
Tank Walls
Sub-Model
Magnet
Sub-Model
Flow
Meter
Side Wall
Main Supply Manifold
Water
Cart
Junction
Junction
Junction
Junction
Junction
Junction
Junction
Flow
Meter
Flow
Meter
Flow
Meter
Flow
Meter
Flow
Meter
Flow
Meter
Flow
Meter
Flow
Meter
End Wall
Losses
Drift Tube
Losses
Drive Iris
Losses
Slug Tuner
Losses
Post
Coupler
Losses
Tank Wall
Losses
Magnet
Losses
Junction
Junction
Junction
Junction
Junction
Junction
Junction
Junction
Water
Skid
Losses
Junction
VF
Figure 3.4. Water-cooling system model representation for a single DTL tank.
59
Figure 3.5. SINDA/FLUINT global model for DTL Tank 3.
The next several sections will present the model descriptions and numerical
studies/results for each subsystem model.
These sections will be followed by a
discussion of the global model results.
3.1.1.3.1 Drift Tube Sub-model Description
As mentioned previously, each drift tube requires a different cooling water flow
rate. The first step in modeling the drift tube subsystem, therefore, was to determine the
orifice plate sizes needed to deliver the required water flow rate to each drift tube. To do
this, all K factors and flow resistances in the drift tube subsystem were calculated or
taken from reference [3.2]. Figure 3.6, a cross section of a DTL tank and drift tube,
displays the pressure loss components for a drift tube flow circuit.
60
Adapter Contraction
Elbows
Bends
Adapter Expansion
Flow Switch
Tube Contraction
Tube Expansion
Orifice Plate
Branch Out
Branch In
Drift Tube
Figure 3.6 Cross section of a DTL tank and drift tube flow circuit.
The following table displays the loss factor values and resistances used for the
drift tube circuits of DTL Tank 3.
61
Table 3.2. K factor values for the drift tube circuits of DTL Tank 3.
Loss
Factor
K1
Description
Dimensions (inches)
Inlet Tee
Loss
Value
(dimensionless)
1
1.75 Straight to .5
Branch
K2
Tee to Union
.5 to .62
.122
K3
Union to Orifice Fitting
.62 to .65
.008
K4
Orifice Plate
See Table 4
K5
Orifice Fitting to Union
.65 to .62
.04
K6
Union to Adapter
.62 to .59
.009
K7
Adapter
.59 to .63
.015
K8
Adapter to Tubing
.63 to .75
.09
K9
Tubing to Adapter
.75 to .63
.124
K10
Adapter
.63 to .59
.05
K11
Adapter to Elbow
.59 to .62
.04
K12
Elbow
.5
1.0
K13
Elbow to D.T.
.62 to .5
.15
K14*
Drift Tube Resistance
Varies
See Table
K15
D.T. to Elbow
.5 to .62
.122
K16
Elbow
.5
1.0
K17
Elbow to Adapter
.62 to .59
.04
K18
Adapter
.59 to .63
.015
K19
Adapter to Tubing
.63 to .75
.09
K20
Tubing to Adapter
.75 to .63
.124
K21
Adapter
.63 to .59
.05
K22
Adapter to Union
.59 to .62
.04
K23
Union to Flow Switch
.62 to .5
.15
K24
Flow Switch
.5" NPT
1.5 psi
K25
Flow Switch to Union
.5 to .62
.122
K26
Union to Tee
.62 to .5
.15
K27
Outlet Tee
.5 Branch to 1.75
1
Straight
K28
Straight Passage Tee
On sub-manifold
.2
*Drift tube losses given in [1.2] as a resistance with units of psi/gpm2.
Ref.
Parietti, L [3.3]
White, F [3.4]
White, F [3.4]
Idelchik [3.2]
White, F [3.4]
White, F [3.4]
White, F [3.4]
White, F [3.4]
White, F [3.4]
White, F [3.4]
White, F [3.4]
White, F [3.4]
White, F [3.4]
White, F [3.4]
White, F [3.4]
White, F [3.4]
White, F [3.4]
White, F [3.4]
White, F [3.4]
White, F [3.4]
White, F [3.4]
White, F [3.4]
White, F [3.4]
AutoFlow cat.
White, F [3.4]
White, F [3.4]
White, F [3.4]
White, F [3.4]
Once all losses were characterized, the pressure drop associated with each loss
was calculated. The following equation was employed:
∆PKi =
1
KρV 2
2
where,
∆P = pressure drop for each loss factor (psi)
K = loss factor (dimensionless)
ρ = density
62
(3.1)
V = water velocity
i = loss number (1 through 28)
The resistance values given in Reference [1.2] for each drift tube were converted
into pressure losses using the following relation:
∆Pdt = R * Fr 2
(3.2)
where,
∆P = pressure drop across a single drift tube (psi)
Fr = Flow rate through drift tube (gpm)
R = Resistance of flow through drift tube (psi/gpm2)
As mentioned previously, the drift tubes are plumbed in parallel branches. The
pressure losses that occurred in series through each branch were summed as follows:
∆P branch = ∆Pdt + ∆Pk1 + … + ∆Pk28
(3.3)
Next, equivalent overall loss or K factors were calculated to represent each branch
of the drift tube sub-manifold. This was accomplished by rearranging Equation (3.1),
substituting ∆P branch for ∆Pk, and solving for K.
The equivalent overall loss factor
calculated for losses through a single branch are presented in the Results section.
Once the equivalent loss factors were determined, a SINDA/FLUINT model was
developed for the drift tube subsystem. A graphical representation of this model is
shown in Figure 3.7. The equivalent loss or K factors for a drift tube branch, were
incorporated into the loss, or “L” components, of the model shown in Figure 3.7.
63
J
FS
FS
FS
Drift
Tube #1
FS
J
J
L
L
J
J
Sinda/Fluint
Model
Drift
Tube #34
Drift Tube Supply Manifold
L
L
J
J
Drift Tube Supply Manifold
Figure 3.7. Generic Sinda/Fluint model representation of the drift tube circuit for
DTL tank 3.
Figure 3.8 is the actual drift tube model created using the SINDA/FLUINT
computer code.
J
Drift Tube Return Manifold
SINDA/FLUINT models contain “junctions” (where pressure is
calculated) that are connected by “path” lines (where flow is calculated). The magnitude
of the flow in a path is also described with a line “thickness”—thicker lines denote larger
volumetric flow. Notice that the lines are described with a “T” meaning Tube, a “L”
meaning pressure loss to account for fittings, bends, reducers, etc, and a “VF” meaning a
constant volume pump. Although difficult to see from this image, the two rows of 35
junctions are connected together with tubes to form the supply and return manifolds.
Figure 3.8. SINDA/FLUINT model for the drift tube circuit of DTL tank 3.
64
VF
3.1.1.3.2 Drift Tube Sub-model Results
Orifice Plates
To fulfill the first modeling goal of determining the individual drift tube orifice
geometries, spreadsheet calculations were used. A portion of the spreadsheet calculation
is shown in Table 3.3. The flow calculations performed in the spreadsheet, predicted the
pressure drop for each of the drift tubes and their corresponding orifice plates and
inlet/outlet water lines, using the flow rates, passage geometries, flow resistance
coefficients, and Eqn. (3.3). The main objective of the spreadsheet calculations, was to
determine the orifice plate sizes required to get the correct flow rate through each drift
tube.
The drift tubes in Table 3.3 are numbered from 1 to 33. The end noses are
numbered 0 and 34. The flow rates required to achieve the desired hardware temperature
are shown in column 2. Column 4 represents the pressure loss across the flow switch.
Assuming an adjustable flow switch will be employed, a pressure drop across each flow
switch of 1.75 psi was assumed. The analytically determined flow resistance of each drift
tube is shown in column 5 in units of psi/gpm2. These resistances are multiplied by the
respective drift tube flow rate to determine the drift tube pressure drop. Using Eqn. (3.3),
and the flow resistance data presented previously, the orifice plate pressure drop and
hence the orifice plate geometry, required to give the desired drift tube flow rate could be
determined.
The sharp-edged orifice correlation from Reference [3.2] was used to calculate the
pressure drop for a given orifice-to-tube diameter ratio, β.
This empirically-based
correlation was found to have the best accuracy for β ranging from 0.2 to 0.8 [3.5]. Since
the last drift tube in a particular tank requires the greatest flow rate of the drift tubes in
that tank, it will have the largest corresponding β value for its orifice plate. Using
β=0.72 for the 33rd drift tube of tank 3, the pressure drop calculated for the orifice plate
was 0.58 psi, resulting in a total pressure drop for the 33rd drift tube of 12.49 psi. Orifice
plates for the remaining drift tubes and end noses were subsequently sized to match the
overall pressure drop of the 33rd drift tube. Based on these total pressure drop numbers,
the corresponding loss factors were then calculated based on a ½” ID tube size (last
65
column of Table 3.3). The results for the orifice plate sizes for tank 3 are given in Table
3.3. See Appendix G for drift tube orifice plate geometries for the additional five DTL
tanks.
Table 3.3. Orifice plate sizing spreadsheet for the tank 3 drift tube cooling system.
Drift Flow ∆Pbranch total
Tube Rate
# (gpm)
(psi)
0
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
0.7
2.6
2.7
2.8
2.8
2.9
3.0
3.1
3.1
3.2
3.3
3.4
3.5
3.5
3.6
3.7
3.8
3.9
3.9
4.0
4.1
4.2
4.2
4.3
4.4
4.5
4.6
4.6
4.7
4.8
4.9
4.9
5.0
5.1
1.4
0.09
1.20
1.27
1.35
1.43
1.51
1.59
1.67
1.76
1.85
1.94
2.03
2.13
2.22
2.32
2.43
2.53
2.63
2.74
2.85
2.97
3.08
3.20
3.32
3.44
3.56
3.68
3.81
3.94
4.07
4.21
4.34
4.48
4.62
0.35
∆Pflow
Rdrift tube
∆Pdrift tube Aorifice /Apipe
β
IDorifice ∆Porifice, ∆Ptotal Ktotal .5id
switch
required
(psi)
(psi/gpm2)
(psi)
1.75
1.75
1.75
1.75
1.75
1.75
1.75
1.75
1.75
1.75
1.75
1.75
1.75
1.75
1.75
1.75
1.75
1.75
1.75
1.75
1.75
1.75
1.75
1.75
1.75
1.75
1.75
1.75
1.75
1.75
1.75
1.75
1.75
1.75
1.75
4.90
0.18
0.19
0.19
0.19
0.19
0.19
0.19
0.19
0.19
0.19
0.20
0.20
0.20
0.20
0.20
0.20
0.20
0.20
0.20
0.20
0.21
0.21
0.21
0.21
0.21
0.22
0.21
0.21
0.22
0.21
0.21
0.22
0.21
2.37
2.40
1.23
1.36
1.41
1.50
1.65
1.70
1.80
1.91
2.02
2.13
2.24
2.36
2.48
2.61
2.73
2.86
3.00
3.13
3.27
3.42
3.56
3.71
3.99
4.02
4.17
4.48
4.50
4.66
5.00
5.01
5.18
5.54
5.54
4.65
66
0.032
0.111
0.116
0.120
0.124
0.129
0.133
0.137
0.142
0.147
0.152
0.157
0.163
0.169
0.175
0.181
0.188
0.195
0.202
0.210
0.218
0.227
0.237
0.251
0.259
0.272
0.293
0.303
0.322
0.356
0.371
0.406
0.483
0.518
0.074
0.179
0.334
0.340
0.346
0.352
0.359
0.364
0.370
0.377
0.383
0.390
0.397
0.404
0.411
0.418
0.425
0.433
0.441
0.449
0.458
0.467
0.477
0.487
0.501
0.509
0.522
0.541
0.551
0.568
0.597
0.609
0.637
0.695
0.720
0.273
(in)
(psi)
(psi)
0.117
0.217
0.221
0.225
0.229
0.233
0.237
0.241
0.245
0.249
0.253
0.258
0.262
0.267
0.272
0.277
0.282
0.287
0.292
0.298
0.304
0.310
0.317
0.326
0.331
0.339
0.352
0.358
0.369
0.388
0.396
0.414
0.452
0.468
0.177
8.25
8.31
8.11
7.99
7.81
7.58
7.46
7.27
7.08
6.88
6.68
6.47
6.26
6.04
5.81
5.58
5.35
5.11
4.87
4.62
4.36
4.10
3.84
3.44
3.29
3.01
2.58
2.43
2.14
1.67
1.53
1.22
0.72
0.58
5.75
12.49 1417.3
12.49 102.7
12.49
96.8
12.49
91.4
12.49
86.4
12.49
81.9
12.49
77.7
12.49
73.7
12.49
70.1
12.49
66.8
12.49
63.7
12.49
60.7
12.49
58.0
12.49
55.5
12.49
53.1
12.49
50.9
12.49
48.8
12.49
46.9
12.49
45.0
12.49
43.3
12.49
41.6
12.49
40.1
12.49
38.6
12.49
37.2
12.49
35.9
12.49
34.7
12.49
33.5
12.49
32.4
12.49
31.3
12.49
30.3
12.49
29.3
12.49
28.4
12.49
27.5
12.49
26.7
12.49 354.3
Inlet/Outlet locations
In an effort to create a uniform pressure profile along the drift tube supply and
return manifolds, while minimizing potential interference between flow ports and the
supply/return liens, it was decided that the manifold connections be placed where the
flow naturally splits or converges. The following table identifies the location for the
supply and return water line connections of each drift tube sub-manifold.
Table 3.4. Supply and return water line connection locations on the drift tube submanifolds of the six DTL tanks.
Tank Number
1
2
3
4
5
6
Inlet and Outlet Locations (from front of tank)
Between Drift Tubes 44 and 45
Sub-Manifold Sizing and Configuration
After the orifice plates and the inlet/outlet locations were characterized, the submanifolds were sized. Figure 3.9 shows the SINDA/FLUINT model predictions for the
flow rates and pressure drops in the drift tube cooling circuit of DTL Tank 3 with submanifold diameters of 1.25 inches.
67
Figure 3.9. SINDA/FLUINT model results for the drift tube cooling circuit of
DTL tank 3 (Units: Pressure = Pascals, Flow Rate = kg/s).
The color red denotes the highest value for both pressure and flow with blue
denoting the lowest value. The total flow rate within the model is 129.2 gpm. The supply
and return manifolds have been sized to an inside diameter of 1.25 inches. Using
SINDA/FLUINT, a series of runs were made with a varying manifold internal diameter
from 1 inch to 3 inches in ¼ in. increments. The results of this diameter study are shown
in Figure 3.10.
68
Line Size Effect on Flow Rate
15
1.25"
Difference from Required (%)
1.5"
10
1.75"
2"
2.25"
5
0
0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34
-5
-10
Drift Tube Number
Figure 3.10. Drift tube flow rate variance (from required value) versus drift tube number
for five different sub-manifold inner diameters for DTL tank 3.
As the sub-manifold diameter increases, the percentage difference between the
actual and required drift tube flow rates decreases.
This trend occurs because the
pressure in the sub-manifold becomes increasingly more uniform along its axis as the
manifold diameter increases. As the manifold pressure becomes more uniform, the flow
distribution within a given drift tube segment converges on the designed flow rate. For a
manifold diameter of 1.25 inch, the maximum flow deviation in the drift tube assembly
was 14.3 %. For a manifold diameter of 1.75-inch (ID), however, the maximum flow
deviation decreases to an acceptable level of 3.75 %. Therefore, a 1.75-in. inner diameter
is recommended for the drift tube supply and return sub-manifolds. A pressure drop of
12.9 psi exists when this diameter is employed for the drift tube system.
Summary
From the drift tube flow modeling studies discussed above, the following key
results were obtained:
69
•
Orifice plates hole diameters range from 0.12 to 0.47 inches for the drift tubes of
DTL tank 3. Orifice geometries of the remaining 5 DTL tanks are given in Appendix
G.
•
Locations for supply and return water line connection should follow that outlined in
Table 3.4.
•
The drift tube sub-manifold diameter must be a minimum of 1.75 inches ID to
produce a maximum flow deviation of approximately 3.75%. This will apply for all
6 DTL tanks.
•
The supply and return transfer lines for the drift tube submanifolds should have an
inner diameter of 2.5” to minimize pressure drop and erosion.
•
A pressure drop of 12.9 psi is produced through the system.
3.1.1.3.3 Slug Tuner Sub-model Description
The slug tuner cooling system for DTL tank 3 is represented in Figure 3.11.
Slug Tuners
Return Manifold
Supply Manifold
Figure 3.11. Generic representation of the slug tuner cooling system for tank 3.
70
The first step in modeling the slug tuner cooling system was to determine the
locations where pressure drop was expected. . Figure 3.12 labels the pressure loss
locations for a typical DTL post coupler and Table 3.5 assigns a loss factor to each
location.
Slug Tuner
Outlet
Manifold
Branch
Adapter
Adapter
Adapter
Adapter
Inlet
Manifold
Branch
Inlet
Manifold
Outlet
Manifold
Inlet
Union
Outlet
Union
Figure 3.12. Locations for pressure drops in the slug tuner cooling circuit.
Table 3.5. K factor values for the slug tuner cooling circuit of DTL Tank 3.
Loss
K1
Description
Inlet Tee
K2
K3
K4
K5
K6
K7
K8
K9
Rst
K10
K11
K12
K13
K14
K15
K16
K17
K18
Tee to Union
Union to Adapter
Adapter
Adapter to Tubing
Tubing to Adapter
Adapter
Adapter to Union
Union to S.T.
Resistance
S.T. to Union
Union to Adapter
Adapter
Adapter to Tubing
Tubing to Adapter
Adapter
Adapter to Union
Union to Outlet Tee
Outlet Tee
K19
K20
Elbow
Additional losses
Size (inches)
1.25 Straight to .25
Branch
.25 to .28
.28 to .28
.28 to .19
.19 to .25
.25 to .19
.19 to .28
.28 to .28
.28 to .25
.25 to .28
.28 to .28
.28 to .19
.19 to .25
.25 to .19
.19 to.28
.28 to .28
.28 to .25
1.25 Branch to .25
Straight
May not be used
71
Quantity
1
Value
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
.04
0
.23
.18
.18
.29
0
.09
1.4 psi/gpm2
.04
0
.23
.18
.18
.29
0
.09
1
2
1
.3
factor was calculated. The following equation was employed.
∆PKi =
1
KρV 2
2
(3.4)
where,
∆P = pressure drop
K = loss factor
ρ = density
V = velocity
i = loss factor number
The post coupler resistance value given in Table 3.5 was converted into a pressure
loss using the following relation:
∆Ppc = R * Fr 2
(3.5)
where,
∆P = pressure drop across slug tuner (psi)
Fr = Flow rate through slug tuner (gpm)
R = Resistance of flow through slug tuner (psi/gpm2)
The pressure losses that occurred in series through each sub-manifold branch
were summed as follows:
∆Pbranch = ∆Pst + ∆PK1 + … + ∆PK20
(3.6)
The total pressure drop across a single branch was calculated to be approximately
12.5 psi. Next, equivalent overall loss or K factors were calculated to represent each
branch of the slug tuner sub-manifold. This was accomplished by rearranging Equation
(3.4), substituting ∆Pbranch for ∆Pk, and solving for K.
72
Several SINDA/FLUINT models were created which employed losses (L) and
tubes (T) to characterize the slug tuner system.
From Figure 3.13, notice that the
SINDA/FLUINT models contain “junctions” (where pressure is calculated) that are
connected by “path” lines (where flow is calculated). Path lines are described with a “T”
meaning Tube, a “L” meaning loss to account for fittings, bends, reducers, etc, or a “VF”
meaning a constant volume pump. The two rows of 12 junctions are connected together
using a loss connector.
Since flow must be distributed evenly to each slug tuner, the ideal location for the
supply inlet exists at the center of the sub-manifold where flow evenly divides.
Similarly, the outlet may be ideally located at the center where flow converges evenly
from both sides of the return sub-manifold. Unfortunately, due to interference with other
objects on the DTL, it may not be possible for the supply inlet and return outlet to be
positioned at their ideal locations.
Subsequently, several different SINDA/FLUINT
models were created to study the effect of inlet and outlet placement on flow distribution.
Figure 3.13 displays some of the models created for studying the slug tuner cooling
system. Figure 3.13a allows the inlet and exit to be located at extreme opposites. This
configuration forces flow, through each post coupler, to travel the same distance. In
Figure 3.13b the inlet and outlet are located between slug tuner three and four. In Figure
3.13c the inlet is shifted over and located at the center of the sub-manifolds. In all cases,
the equivalent loss or K factors for a slug tuner branch as determined above, were
incorporated into the loss, or “L” components, of the model shown in Figure 3.13.
73
(A)
(B)
Figure 3.13. Various SINDA/FLUINT models of the slug tuner cooling system.
74
3.1.1.3.4 Slug Tuner Sub-model Results
Figure 3.14 compares the average flow rate error (difference between desired and
predicted flow rate) through each slug tuner branch as a function of sub-manifold
diameter for various supply and return water line connection location. Results from this
study confirm that the best location for the placement of the inlet and outlet are at the
center of the sub-manifolds.
If deviation from the central location is necessary to
accommodate other devices on DTL Tank 3, then, as Figure 3.14 indicates, an increase in
error for the average flow rate through each slug tuner will occur. This is especially
apparent when smaller diameter sub-manifolds are employed. This implies that the slug
tuner sub-manifold should have a minimum diameter of 1.25 inches so that inlet and
outlet placement does not have a major effect on flow distribution.
60
Side Entrance And Exit
55
Entrance And Exit Between Slug Tuners 2 & 3
Percent Error from Required Flow Rate
50
45
Entrance and Exit Between Slug Tuners 3 & 4
40
Entrance and Exit Between Slug Tuners 4 & 5
35
30
Center Entrance and Exit
25
20
15
10
5
0
0.5
0.75
1
Manifold Diameter (in)
1.25
1.5
Figure 3.14. Average flow error versus supply and return sub-manifold diameter for
different water line connection locations for the slug tuner cooling system.
75
Inlet and outlet placement has little effect on the overall error if a sub-manifold
diameter of at least 1.25 inches is employed. The Sinda/Fluint model with the centralized
inlet and outlet was chosen as a representative system to study the slug tuner system in
closer detail. This model investigated sub-manifold diameters ranging from 1.0 to 1.5
inches. Figure 3.15 displays the Sinda/Fluint model pressure and flow predictions for a
sub-manifold diameter of 1.25 inches.
Figure 3.15. SINDA/FLUINT predictions of slug tuner flow and pressure with 1.25 inch
sub-manifold diameters.
76
In Figure 3.15, the pressure drop as well as the flow rate are nearly equal for each
slug tuner.
Figure 3.16 shows the results for all sub-manifold diameters studied. Figure 3.16
shows that a sub-manifold with a diameter of 1 inch may allow over 3 % deviation in
required flow rate whereas a sub-manifold with a diameter of 1.5 inches will allow a
maximum deviation of less than .3%. A sub-manifold with a diameter with a minimum
diameter of 1.25 inches allows less than 1 % error and produces a pressure drop of 3.6 psi
exists across the model.
Line Size effect on Flow Rate
4
Flow Rate Difference From Required
(%)
1"
1.25"
3
1.5"
2
1
0
1
2
3
4
5
6
7
8
9
10
11
12
-1
-2
Slug Tuner Number
Figure 3.16. Slug tuner flow rate variance (from required value) versus slug tuner
number for three different sub-manifold inner diameters for DTL tank 3.
Summary
From the slug tuner flow modeling studies discussed above, the following key
results were obtained:
•
Water transfer line connection placement has little effect on the overall error if a submanifold diameter of at least 1.25 inches is employed.
•
A sub-manifold with a 1.25 inches or greater diameter will be required to achieve the
minimum amount of error in the system.
77
•
A pressure drop of 3.6 psi exists across the slug tuner cooling system.
•
Identical slug tuner sub-manifold diameters can be used for all six DTL tanks.
3.1.1.3.5 Post Coupler Sub-model Description
The post coupler cooling system for DTL tank 3 is represented in Figure 3.17.
Return
Supply
DTL Tank 3
Supply
Return
Figure 3.17. Generic representation of the post coupler cooling system for DTL tank 3.
The first step in modeling the slug tuner cooling system was to determine the
locations where pressure drop was expected. Figure 3.18 labels the pressure loss locations
for a typical DTL post coupler and Table 3.6 assigns a loss factor to each loss location.
78
Post Coupler
Elbow
Unions
&
Hose Adapters
Inlet
Branch
Tee
Outlet
Branch
Tee
Figure 3.18 Representation of a DTL post coupler and its flow path.
79
Table 3.6. Losses for the post coupler cooling circuit.
Loss
K1
K2
K3
K4
K5
K6
K7
K8
K9
Rpc
K10
K11
K12
K13
K14
K15
K16
K17
K18
Kelbow
Kadd
Description
Inlet Tee
Tee to Union
Union to Adapter
Adapter
Adapter to Tubing
Tubing to Adapter
Adapter
Adapter to Union
Union to S.T.
Resistance
S.T. to Union
Union to Adapter
Adapter
Adapter to Tubing
Tubing to Adapter
Adapter
Adapter to Union
Union to Outlet Tee
Outlet Tee
Elbow
Additional
Sizes (in)
.75 Straight to .25 Branch
.25 to .28
.28 to .28
.28 to .19
.19 to .25
.25 to .19
.19 to .28
.28 to .28
.28 to .25
.25 to .28
.28 to .28
.28 to .19
.19 to .25
.25 to .19
.19 to.28
.28 to .28
.28 to .25
.25 Branch to .75 Straight
May not be needed
Quantity
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
Value
1
.04
0
.23
.18
.18
.29
0
.09
7.1 psi/gpm2
.04
0
.23
.18
.18
.29
0
.09
1
.3
∆PKi =
1
KρV 2
2
(3.7)
where,
K = loss factor
ρ = density
V = velocity
The post coupler resistance value given in Table 3.6 was converted into a pressure
∆Ppc = R * Fr 2
80
(3.8)
where,
∆P = pressure drop across post coupler (psi)
Fr = Flow rate through post coupler (gpm)
R = Resistance of flow through post coupler (psi/gpm2)
The pressure losses that occurred in series through each sub-manifold branch
were summed as follows:
∆Pbranch = ∆P pc + ∆PK1 + … + ∆PK18
(3.9)
The total pressure drop for a post coupler branch was calculated to be 3.7 psi.
Next, equivalent overall loss or K factors were calculated to represent each branch of the
post coupler sub-manifold.
This was accomplished by rearranging Equation (3.7),
substituting ∆P branch for ∆Pk, and solving for K.
Next, several SINDA/FLUINT models were created which employed losses (L)
and tubes (T) to characterize the post coupler system. Since flow must be distributed
evenly to each post coupler, the ideal location for the supply inlet exists at the center of
the sub-manifold where flow evenly divides. Similarly, the outlet may be ideally located
at the center where flow converges evenly from both sides of the return sub-manifold.
Unfortunately, due to interference with other objects on the DTL, it may not be possible
for the supply inlet and return outlet to be positioned at their ideal locations.
Subsequently, several different SINDA/FLUINT models were created to study the effect
of inlet and outlet placement on flow distribution. In Figure 3.19a the inlet and outlet are
located between post coupler two and three. In Figure 3.19b the inlet is shifted over and
located between post coupler three and four. Figure 3.19c allows the inlet and exit to be
located at extreme opposites. This configuration forces flow, through each post coupler,
to travel the same distance. Finally, in Figure 3.19d, the inlet and outlet are located at the
center of the submanifold. In all cases, the equivalent loss or K factors for a post coupler
branch determined above, were incorporated into the loss, or “L” components, of the
model shown in Figure 3.19.
81
(A)
(B)
(C)
(D)
Figure 3.19. Various SINDA/FLUINT models created for the post coupler study.
82
3.1.1.3.6 Post Coupler Sub-model Results
Figure 3.20 compares the average flow rate error (difference between desired and
predicted flow rate) through each post coupler branch as a function of sub-manifold
diameter for various supply and return water line connection location. Results from this
study confirm that the best location for the placement of the inlet and outlet are at the
center of the submanifolds.
If deviation from the central location is necessary to
accommodate other devices on DTL Tank 3, then as Figure 3.20 indicates, an increase in
error for the average flow rate through the post couplers will occur. This is especially
apparent when smaller diameter submanifolds are employed. This implies that the post
coupler submanifold should have a minimum diameter of 0.75 inches so that inlet and
outlet placement does not have a major effect on flow distribution.
Inlet and Outlet Location Comparison
25
Between PC 2 and 3
Between PC 3 and 4
Extreme Oposites
20
Average Error (%)
Center
15
10
5
0
0.375
0.5
0.625
0.75
0.875
1
1.125
1.25
Sub-Manifold Diameter (inches)
Figure 3.20. Average flow error versus supply and return sub-manifold diameter for
different water line connection locations for the post coupler cooling system.
83
Inlet and outlet placement has little effect on the overall error if a sub-manifold
diameter of at least 0.75 inches is employed. The SINDA/FLUINT model with the
centralized inlet and outlet was chosen as a representative system to study the post
coupler system in closer detail. This model will look at sub-manifold diameters ranging
from 0.375 to 1.25 inches. Figure 3.21 is the SINDA/FLUINT model results for a submanifold diameter of 0.75 inches.
Figure 3.21. SINDA/FLUINT flow and pressure predictions for the post coupler cooling
circuit with a 0.75 inch sub-manifold diameter (Units: Pressure = Pascals, Flow Rate =
kg/s).
84
In Figure 3.21, the pressure drop as well as the flow rate are nearly equal for each branch.
Figure 3.22 flow rate variance as a function of post coupler location for five
Percent Error from required (%)
different sub-manifold diameters.
14
13
12
11
10
9
8
7
6
5
4
3
2
1
0
-1
-2 1
-3
-4
-5
-6
-7
-8
.375"
.5"
.75"
1"
1.25
2
3
4
5
6
7
8
Post Coupler Number
Figure 3.22. Post coupler flow rate variance (from required value) versus post coupler
number for five different sub-manifold inner diameters for DTL tank 3.
Figure 3.22 shows that a sub-manifold with a diameter of 0.375 inches may allow
over 12 % deviation in required flow rate whereas a sub-manifold with a diameter of 1.25
inches will allow a maximum deviation of less than 0.04%. A sub-manifold with a
minimum diameter of 0.75 inches allows less than 0.5 % error.
85
In an attempt to standardize all post coupler sub-manifold diameters, additional
studies were performed to determine whether the 0.75 inch diameter sub-manifold is
suitable for use on all DTL tanks. DTL tank 4, because it requires the largest number of
post couplers, recognizably presents the worst case for flow distribution. Therefore, an
additional model was created to study DTL tank 4. The new model resembled that used
to study tank 3, except the number of post couplers increased from 16 to 30. The submanifold inlet was placed between post couplers 8 and 9. Figure 3.23 shows the results
for the additional study of tank 4.
35
.375"
30
.5"
Percent Error from Required (%)
25
.75"
1"
20
1.25"
15
10
5
0
-5
1
2
3
4
5
6
7
8
9
10
11
12
13
14
-10
-15
-20
Post Coupler Number
Figure 3.23. Post coupler flow rate variance (from required value) versus post coupler
number for five different sub-manifold inner diameters for DTL tank 4.
86
15
Figure 3.23 indicates that a sub-manifold diameter of 1.0 inch will introduce less than 1
% error in the system. The results from this additional analysis indicate all post coupler
sub-manifolds require an internal diameter of 1.0 inch.
Summary
From the post coupler flow modeling studies discussed above, the following key
results were obtained
•
•
A post coupler sub-manifold with an internal diameter of 1.0 inch or greater will be
required to achieve proper flow distribution in the DTL.
•
A post coupler transfer water line with an internal diameter of 1.0 inch or greater will
be required to provide acceptable pressure drops and minimize erosion.
•
The pressure drop across the post coupler branch was calculated to be 3.7 psi.
•
Identical post coupler sub-manifold diameters can be used for all six DTL tanks.
3.1.1.3.7 Dipole Magnet Sub-model Description
The first step in modeling the magnet cooling system was to determine the
locations where pressure drop was expected.
Figure 3.24 labels the pressure loss
locations for a typical DTL magnet and Table 3.7 assigns a value to each loss location.
87
Outlet
Branch
Tee
Inlet
Branch
Tee
Unions
&
Hose Adapters
Magnet
Figure 3.24 Representation of a DTL magnet’s water flow path.
Table 3.7. Loss values for the magnet cooling circuit on DTL tank 3.
Loss
Description
Description
Quantity
K1
Inlet Tee
.75 straight to
1
.25 Branch
K2
Branch to Union
.25 to .19
1
K2
Union to Adapter
.19 to .19
K3
Adapter to Tubing
.19 to .25
1
K4
Tubing to Adapter
.25 to .19
1
K5
Adapter to Reducing Union
.19 to .12
1
K6
Reducing Union to Magnet
.12 to .125
1
Dpmag Magnet Pressure Drop
1
K7
Magnet to reducing Union
.125 to .12
1
K8
Reducing Union to Adapter
.12 to .19
1
K9
Adapter to Tubing
.19 to .25
1
K10
Tubing to Adapter
.25 to .19
1
K11
Adapter to Union
.19 to .19
1
K12
Union to Branch
.19 to .25
1
K13
Outlet Tee
.25 Branch to .75
1
Straight
Kadd
Additional losses
1
88
Value
1
.18
0
.18
.18
.25
0
11.8psi
.04
.36
.18
.18
0
.18
∆PKi =
1
KρV 2
2
(3.10)
where,
K = loss factor
ρ = density
V = velocity
The magnet flow resistance value given in Table 3.7 was converted into a
pressure loss using the following relation:
∆Pmag = R * Fr 2
(3.11)
where,
∆P = pressure drop across magnet (psi)
Fr = Flow rate through magnet (gpm)
R = Resistance of flow through magnet (psi/gpm2)
Finally, the pressure losses that occurred in series through each sub-manifold
branch were summed as follows:
∆Pbranch = ∆Pmag + ∆PK1 + … + ∆PK13
(3.12)
The total pressure drop across a single dipole magnet branch was calculated to be
approximately 12.5 psi. Next, equivalent overall loss or K factors were calculated to
represent each branch of the dipole magnet sub-manifold. This was accomplished by
rearranging Equation (3.10), substituting ∆Pbranch for ∆P k, and solving for K.
89
developed for the dipole magnet subsystem. A graphical representation of this model is
shown in Figure 3.25. Notice in Figure 3.25, that the SINDA/FLUINT models contain
“junctions” (where pressure is calculated) that are connected by “path” lines (where flow
is calculated). Path lines are described with a “T” meaning Tube, a “L” meaning loss to
account for fittings, bends, reducers, etc, or a “VF” meaning a constant volume pump.
The equivalent loss or K factors for a dipole magnet branch, were incorporated into the
loss, or “L” components, of the model shown in Figure 3.25.
Figure 3.25. SINDA/FLUINT model of the magnet cooling circuit for DTL tank 3.
Since flow must be distributed evenly to each magnet, the ideal location for the
supply inlet exists at the center of the sub-manifold where flow evenly divides.
Similarly, the outlet may be ideally located at the center where flow converges evenly
from both sides of the return sub-manifold.
90
3.1.1.3.8 Dipole Magnet Sub-model Results
Figure 3.26 is the SINDA/FLUINT model results for a sub-manifold diameter of
0.5 inches. As the figure indicates, the pressure drop as well as the flow rate, is nearly
equal for each magnet.
Figure 3.26. SINDA/FLUINT flow and pressure predictions for the DTL magnet water
circuit with a 0.5 inch sub-manifold diameter (Units: Pressure = Pascals, Flow Rate =
kg/s).
91
Figure 3.27 shows that a sub-manifold with a diameter of 0.25 inches may allow
over 0.2 % deviation in required flow rate whereas a sub-manifold with a diameter of
0.75 inches will allow a maximum deviation of less than 0.05 %. A sub-manifold with a
minimum diameter of 0.5 inches allows less than .05 % error and will be suitable for use
in the system.
0.25
.25"
.5"
0.2
.75"
0.15
0.1
0.05
0
1
1.5
2
2.5
3
3.5
4
-0.05
-0.1
-0.15
-0.2
Magnet Number
Figure 3.27. Magnet flow rate variance (from required value) versus magnet number for
three different sub-manifold inner diameters for DTL tank 3.
Summary
From the dipole magnet flow modeling studies discussed above, the following key
•
92
•
A sub-manifold with a diameter of 0.5 inches or greater diameter will provide
uniform flow to the magnets.
•
A magnet transfer water line with an internal diameter of 0.25 inch or greater will be
provide acceptable pressure drops and minimize erosion.
•
The pressure drop across a magnet water line branch was calculated to be 12.5 psi.
•
The identical sub-manifold diameter can be used for all magnet cooling circuits on all
six DTL tanks.
93
3.1.1.3.9 Tank Wall Sub-model Description
The first step in modeling the tank wall cooling system was to determine the
locations where pressure drop was expected. A value of .018 psi/gpm2/m was given for
flow resistance of each cooling channel in Reference [1.2]. Figure 3.28 displays the
locations for pressure loss components and Table 3.8 lists the particular loss coefficient
values.
Kbend
Kadptcont
Kexpansion
Kadptexp
Kcontraction
Kbranch
Figure 3.28. Representation of a DTL tank wall’s supply/return water line.
94
Table 3.8. Loss factors for the DTL tank wall cooling circuit.
Symbol
Description
Size (inches) Quantity Individ- Total
ual K K
factor factor
K1
Inlet Tee
1.5 Straight to
1
1
1
.5 Branch
K2
Tee to Union
.5 to .41
1
.14
.14
K3
Union to Adapter
.41 to .402
1
.009
.009
K4*
Adapter
.41 to .402
1
0
0
K5*
Adapter to Tubing
.402 to .5
1
.13
.13
K6*
Tubing to Adapter
.5 to .402
3
.15
.45
K7*
Adapter
.402 to .41
3
0
.0
K8*
Adapter to Elbow
.41 to .5
3
.11
.33
K9*
Elbow
.5
3
.9
2.1
K10*
Elbow to T.W.
.62 to .5
3
.15
.45
K11*
Tank Wall
3
See
Resistance
Table
K16*
T.W. to Elbow
.5 to .62
3
.122
.366
K17*
Elbow
.5
3
.7
2.1
K18*
Elbow to Adapter
.5 to .41
3
.14
.42
K19*
Adapter
.41 to .402
3
.0
K20*
Adapter to Tubing
.402 to .5
3
.13
.39
K21** Bend in Tubing
.5
2
.95
1.9
K22** Tubing to Adapter
.5 to .402
1
.15
.15
K23
Adapter
.402 to .41
1
0
0
K24
Adapter to Union
..41 to .62
1
.04
.04
K25
Union to Tee
.41 to .5
1
.11
.11
K26
Outlet Tee
.5 Branch to
1
1
1
1.5 Straight
** Occur twice in DTL Tank 3.
*Occur for each of the 3 sections that comprise DTL Tank 3.
∆PKi =
1
KρV 2
2
where,
K = loss factor
ρ = density
95
(3.13)
V = velocity
The tank wall resistance values given in Table 3.8 was converted into a pressure
∆Ptw = R * Fr 2 * L
(3.14)
where,
∆P = pressure drop through tank wall (psi)
Fr = Flow rate through tank wall (gpm)
R = Resistance of flow through tank wall (psi/gpm2)
L = Length of cooling channel
Finally, the pressure losses that occurred in series through each sub-manifold
branch were summed as follows:
∆Pbranch = ∆Ptw + ∆PK1 + … + ∆PK13
(3.15)
The total pressure drop across a single branch was calculated to be approximately
8.5 psi. Next, equivalent overall loss or K factors were calculated to represent each
branch of the tank wall sub-manifold. This was accomplished by rearranging Equation
(3.13), substituting ∆Pbranch for ∆P k, and solving for K.
developed for the tank wall cooling circuit, as shown in Figure 3.29. From Figure 3.29,
notice that the SINDA/FLUINT models contain “junctions” (where pressure is
calculated) that are connected by “path” lines (where flow is calculated). Path lines are
described with a “T” meaning Tube, a “L” meaning loss to account for fittings, bends,
reducers, etc, or a “VF” meaning a constant volume pump. The equivalent loss or K
factors for a tank wall branch, were incorporated into the loss, or “L” components, of the
96
Figure 3.29. SINDA/FLUINT model of the tank wall cooling circuit.
3.1.1.3.10 Tank Wall Sub-model Results
Figure 3.30 displays the SINDA/FLUINT model flow and pressure predictions for
a DTL tank wall cooling circuit with a sub-manifold diameter of 1.5 inches. As the
figure indicates, the pressure drops and flow rates across each tank wall cooling passage
branch, are identical.
97
Figure 3.30. SINDA/FLUINT model flow and pressure predictions of the DTL tank wall
cooling circuit with a 1.5-inch diameter sub-manifold (Units: Pressure = Pascals, Flow
Rate = kg/s).
Figure 3.31 is a plot of flow variance (% difference of predicted vs. desired flow)
in the tank wall cooling lines as a function of the line number over a range of submanifold line diameters. Figure 3.31 shows that a sub-manifold with a diameter of 0.75
inches will produce over 15 % deviation in required flow rate, while a sub-manifold with
a minimum diameter of 1.5 inches provides less than 1% error and will be suitable for use
in the cooling circuit.
98
Tube Diameter vs. Percent Error
20
15
10
5
0
1
2
3
4
5
6
-5
.75"
-10
1"
1.25"
-15
1.5"
-20
Tank Line Number
Figure 3.31. Tank wall flow rate variance (from required value) versus tank line number
for four different sub-manifold inner diameters for DTL tank 3.
Summary
•
A sub-manifold with a diameter of 1.5 inches or greater diameter will provide
uniform flow to the tank wall cooling passages.
•
A tank wall transfer water line with an internal diameter of 1.5 inch or greater will
provide acceptable pressure drops and minimize erosion.
•
The pressure drop across a tank wall water line branch was calculated to be 8.5 psi.
•
The identical sub-manifold diameter can be used for all tank wall cooling circuits on
all six DTL tanks.
3.1.1.3.11 End Wall Sub-model Description
The first step in modeling the end wall cooling system was to determine the
A value of 11.33 psi/gpm2 for flow
resistance in each end wall was taken from Reference [1.2].
99
Figure 3.32 is a
representation which shows the main components comprising the end wall cooling
system. Table 3.9 gives the loss values associated with each component.
Inlet
Tees
Adapter
Outlet
Union
End Wall
Figure 3.32. Representation of a DTL end wall cooling water flow path.
100
Table 3.9.
Loss
K1
K2
K3
K4
K5
K6
K7
K8*
Rend wall
K9*
K10
K11
K12
K13
K14
K15
K16
Losses for flow through the end wall cooling system.
Description
Size (inches)
Tee to Union
.25 to .28
Union to Adapter
.28 to .28
Adapter
.28 to .19
Adapter to Tubing
.19 to .25
Tubing to Adapter
.25 to .19
Adapter
.19 to .28
Adapter to Union
.28 to .28
Union to S.T.
.28 to .25
Resistance
S.T. to Union
Union to Adapter
Adapter
Adapter to Tubing
Tubing to Adapter
Adapter
Adapter to Union
Union to Outlet Tee
.25 to .28
.28 to .28
.28 to .19
.19 to .25
.25 to .19
.19 to.28
.28 to .28
.28 to .25
Quantity
1
1
1
1
1
1
1
1
11.33
psi/gpm2
1
1
1
1
1
1
1
1
Value
.04
0
.23
.18
.18
.29
0
.09
.04
0
.23
.18
.18
.29
0
.09
* Values change as transfer line size increases to account for contraction and expansion
∆PKi =
1
KρV 2
2
(3.16)
where,
K = loss factor
ρ = density
V = velocity
The end wall resistance value given in Table 2 was converted into a pressure loss
using the following relation:
101
∆Ptw = R * Fr 2 * L
(3.17)
where,
∆P = pressure drop across end wall (psi)
Fr = Flow rate through end wall (gpm)
R = Resistance of flow through end wall (psi/gpm2)
The pressure losses that occurred in series through the end wall system were
summed as follows:
∆Pbranch = ∆Pew + ∆PK1 + … + ∆PK16
(3.18)
A pressure drop of approximately 16.4 psi was calculated for each end wall.
Next, equivalent overall loss or K factors were calculated to represent each branch of the
tank endwall circuit. This was accomplished by rearranging Equation (3.16), substituting
∆Pbranch for ∆Pk, and solving for K.
developed for the tank endwall cooling circuit, as shown in Figure 3.33. From Figure
3.33, notice that the SINDA/FLUINT models contain “junctions” (where pressure is
factors for a tank wall branch, were incorporated into the loss, or “L” component, of the
102
Figure 3.33. SINDA/FLUINT model of the DTL end wall cooling system.
3.1.1.3.12 End Wall Sub-model Results
The results for this study are as expected. Since there is only one path for the
fluid to flow through, there is no concern that the required quantity of cooling water will
reach the end walls. Pressure loss was the criterion used in selecting the diameter of the
transfer lines to the end walls. Figure 3.34 plots the relationship between pressure drop
through the end wall system and transfer line diameter.
103
18.5
Pressure Drop (psi)
18
17.5
17
16.5
16
0.25
0.375
0.5
0.625
0.75
Transfer line Diameter (inches)
Figure 3.34. DTL end wall cooling system pressure drop versus line diameter.
From Figure 3.34, it is shown that a large system pressure drop occurs when the
transfer line diameter is less than 0.375 inches. A pressure drop of just over 18.3 psi
occurs when a line diameter of 0.25 inches is employed whereas a pressure drop of
approximately 16.5 psi occurs at diameters of 0.375 inches and above. Therefore, a
minimum internal diameter of 0.375 inches is required to produce a reasonable pressure
drop in the end wall system.
104
3.1.1.3.13 Drive Iris Sub-model Description
The first step in modeling the drive iris cooling system was to determine the
A value of 0.535 psi/gpm2 for flow
resistance in the drive iris was taken from Reference [1.2].
Figure 3.35 is a
representation of the main components comprising the drive iris cooling circuit. Table
3.10 gives the loss values associated with each component.
Outlet
Branch
Tee
Inlet
Branch
Tee
Unions
&
Hose Adapters
Figure 3.35. Representation of a DTL drive iris’s water flow path.
105
Table 3.10.
Loss
K1
K2
K3
K4
K5
K6
K7
K8*
Rend wall
Losses for flow through the drive iris cooling system.
Description
Size (inches)
Tee to Union
.25 to .28
Union to Adapter
.28 to .28
Adapter
.28 to .19
Adapter to Tubing
.19 to .25
Tubing to Adapter
.25 to .19
Adapter
.19 to .28
Adapter to Union
.28 to .28
Union to S.T.
.28 to .25
Resistance
K9*
K10
K11
K12
K13
K14
K15
K16
S.T. to Union
Union to Adapter
Adapter
Adapter to Tubing
Tubing to Adapter
Adapter
Adapter to Union
Union to Outlet Tee
.25 to .28
.28 to .28
.28 to .19
.19 to .25
.25 to .19
.19 to.28
.28 to .28
.28 to .25
Quantity
1
1
1
1
1
1
1
1
.535
psi/gpm2
1
1
1
1
1
1
1
1
Value
.04
0
.23
.18
.18
.29
0
.09
.04
0
.23
.18
.18
.29
0
.09
* Values change as transfer line size increases to account for contraction and expansion
∆PKi =
1
KρV 2
2
(3.19)
where,
K = loss factor
ρ = density
V = velocity
The drive iris resistance value given in Table 2 was converted into a pressure loss
using the following relation:
∆Ptw = R * Fr 2 * L
106
(3.20)
where,
∆P = pressure drop across drive iris (psi)
Fr = Flow rate through drive iris (gpm)
R = Resistance of flow through drive iris (psi/gpm2)
The pressure losses that occurred in series through the drive iris system were
summed as follows:
∆Pbranch = ∆P di + ∆PK1 + … + ∆PK16
(3.21)
A pressure drop of approximately 1.54 psi was calculated for the drive iris. Next,
equivalent overall loss or K factors were calculated to represent each branch of the drive
iris cooling circuit. This was accomplished by rearranging Equation (3.19), substituting
∆Pbranch for ∆Pk, and solving for K.
developed for the drive iris cooling circuit, as shown in Figure 3.36. From Figure 3.36,
notice that the SINDA/FLUINT models contain “junctions” (where pressure is
factors for a tank wall branch, were incorporated into the loss, or “L” component, of the
107
Figure 3.36. SINDA/FLUINT model of the DTL drive iris cooling circuit.
3.1.1.3.14 Drive Iris Sub-model Results
The results for this study are as expected. Since there is only one path for the
fluid to flow through, there is no concern that the required quantity of cooling water will
reach the drive iris. Pressure loss was the criterion used in selecting the diameter of the
drive iris’ supply and return lines. Figure 3.37 plots the relationship between pressure
drop through the drive iris circuit and transfer line diameter.
108
Pressure Loss Vs. Tube Diameter
Pressure Loss (psi)
7.3
6.3
5.3
Series1
4.3
3.3
2.3
1.3
0.25
0.375
0.5
0.625
0.75
0.875
1
Tube Diameter (in.)
Figure 3.37. Drive iris cooling system pressure drop versus line diameter.
From Figure 3.37, it is shown that a large system pressure drop occurs transfer
line diameters less than 0.5 inches. It may be apparent that a minimum diameter of 0.5
inches is required to fulfill this study’s goals (minimize pressure drop), however, since
the pressure drop induced by the 0.3125 (5/16") inch diameter line is still less than that
required for the DTL tank 3 system, the 0.3125 inch diameter line will be adequate for
use in cooling the drive iris. To be more specific, when all subsystems are combined in
parallel to form the entire cooling system for DTL tank 3, it is required that a uniform
pressure drop occurs across all systems. To achieve this, globe valves in place near the
entrances of each subsystem are opened or closed as needed. For the drive iris system,
some of the needed pressure drop is introduced by using a 0.3125 inch diameter line
instead of a 0.5 inch diameter. This means that less pressure drop occurs across the globe
valve.
109
3.1.1.4 Tank 3 Global Model Design Studies/Results
After the pressure loss and flow distribution through each DTL subsystem (drift
tubes, post couplers, etc.) was determined, the results were incorporated in the DTL tank
3 global model, described previously in Figures 3.4 and 3.5. Also required for the DTL
tank 3 global model, were the flow resistances of the flow meters, valves, and plumbing
components not included in the individual submodels. Table 3.11 summarizes pressure
drops and loss factors for each of the DTL subsystems, as well as the additional
components needed for the tank 3 global model. Note that since each DTL subsystem is
connected to common supply and return manifolds, the total pressure drop across each
DTL subsystem is required to be equivalent. This is achieved by using a proportional
globe valve on the supply line to each DTL subsystem. By adjusting the globe valve loss
factors, the flow and pressure drop across each subsystem could be adjusted to its correct
value. Table 3.11 displays the required globe valve loss factors (column 7) and the total
pressure drop of 19.37 psi across each subsystem.
From the system pressure drop, transfer line diameters, and flow velocities of the
DTL subsystems listed in Table 3.11, equivalent loss (K) factors were determined for
each subsystem branch. These K factors, listed in the last column of Table 3.11, were
input into the subsystem branch losses, or L’s, of the DTL tank 3 global SINDA/FLUINT
model, displayed previously in Figure 3.5. Using the global SINDA/FLUINT model, a
series of runs were made with varying supply and return manifold diameters from 2 inch
to 4 inches in 1/2 in. increments. Figure 3.38 displays the results of this trade study.
Figure 3.38 shows that as the main manifold diameters increase, the percent
difference in actual flow rate to the required flow rate, summarized across all DTL
subsystems, decreases.
This results because the pressure in the manifold becomes
increasingly uniform along its axis as its diameter increases. Or in other words, as the
manifold pressure becomes more uniform, the flow distribution within a given drift tube
segment converges on the design flow rate. For a manifold diameter of 3 inches (ID) or
greater, the maximum flow deviation decreases to an acceptable level of less than 1%.
Unfortunately, the use of a 3 inch main manifold creates flow velocities in excess of 3
m/s, which may cause undesired erosion of the manifold walls.
Therefore, it is
recommended that at least a 3.5 inch (ID) main manifold diameter is used to drop the
110
mean water velocity below 3 m/s in the manifolds. Figure 3.39 shows the results of a
SINDA/FLUINT calculation with a main manifold diameter of 3.5 inches.
In Figure 3.39, the color red denotes the highest value for both pressure and flow
with blue denoting the lowest pressure and lowest flow rate. The total flow rate within
the model is 240.9 gpm. The supply and return manifolds have been set to an inside
diameter of 3.5 inches. As seen in Figure 3.38, there is a system pressure loss of
approximately 21 psi.
111
Table 3.11. Summary of the optimized line sizes and pressure losses in the various subsystems of the DTL tank 3 cooling system.
System Information
System
ID Transfer
Line Size (in)
End Wall
Tank Wall
Post Coupler
Post Coupler
Drive Iris
Slug Tuner
Drift Tubes
Magnets
Tank Wall
End Wall
RF Window
0.38
1.50
1.00
1.00
0.31
1.25
2.50
0.50
1.50
0.38
0.50
Flow
Rate
(gpm)
Velocity
(m/s)
1.00
39.60
5.20
5.20
1.57
12.00
129.20
1.52
39.60
1.00
5.00
0.89
2.19
0.65
0.65
2.00
0.96
2.57
0.76
2.19
0.89
2.49
S/F models Tees & FrictionGlobe Valves
Flow Meters
Subsystem
Other
k Globe Globe Valve k Flow Flow Meter
Pressure
Pressure
Valve
Pressure
meter
Pressure
Loss (psi)
Losses (psi)
Loss (psi)
Loss (psi)
16.40
8.50
3.75
3.75
1.77
3.60
12.40
12.44
8.50
16.40
10.00
0.54
0.96
0.18
0.18
3.03
0.34
2.16
0.38
0.96
0.54
2.94
38.80
24.44
503.67
503.67
46.28
228.65
6.00
153.62
24.44
38.80
10.30
2.21
8.51
15.31
15.31
13.41
15.16
2.88
6.39
8.51
2.21
4.63
112
4.00
4.00
4.00
4.00
4.00
4.00
4.00
4.00
4.00
4.00
4.00
0.23
1.39
0.12
0.12
1.16
0.27
1.92
0.17
1.39
0.23
1.80
Branch
Pressure
Loss (psi)
Globe Valve
Pressure
Drop (psi)
Total
Pressure
Loss (psi)
k Total
17.16
10.86
4.06
4.06
5.96
4.21
19.37
12.98
10.86
17.16
14.74
2.21
8.51
15.31
15.31
13.41
15.16
2.88
6.39
8.51
2.21
4.63
19.37
19.37
19.37
19.37
19.37
19.37
19.37
19.37
19.37
19.37
19.37
340.66
55.61
637.08
637.08
66.82
292.06
40.31
466.01
55.61
340.66
43.07
6
2.5"
3"
3.5"
4
2"
3
2
-2
End Wall 2
Tank Wall 2
Magnets
Drift Tubes
Slug Tuner
RF Window
Drive Iris
Post Coupler 2
-1
Post Coupler 1
0
Tank Wall 1
1
End Wall 1
Percent Error in Required Flow Rate (%)
5
-3
DTL Subsystem
Figure 3.38. Percent difference between actual and required water flow rates for each
DTL sub-system in DTL tank 3 for various main supply and return manifold diameters.
Figure 3.39. SINDA/FLUINT model predictions of the flow rate and pressure
distribution in DTL tank 3 with 3.5 inch (ID) main manifolds (Units: Pressure = Pascals,
Flow rate = kg/s).
113
3.1.1.5 Summary
From the SINDA/FLUINT modeling studies discussed above, the following key
•
Sub-manifold and transfer line diameters as well as pressure drops for all the DTL
subsystems have been optimized and are listed in Table 3.11.
•
Connection locations for transfer lines on sub-manifolds for the DTL subsystems
have been optimized and are listed in Sections 3.1.1.3.1 through 3.1.1.3.14.
•
Locations for main supply and return manifold water transfer line connections should
be made near the midpoints of the manifolds where flow evenly splits/converges.
•
The DTL main supply and return manifold diameters must be a minimum of 3.5
inches to produce a maximum deviation of less than 1% between actual and required
flow rates of the subsystem components.
•
A pressure drop of 21 psi is produced across the DTL tank 3 water cooling circuit
(from the main supply manifold to the main return manifold).
114
3.1.2 DTL Water Skid
3.1.2.1 Design Goals
The water skid is responsible for delivering cooling water to the DTL structure. It
must actively adjust the temperature of the water sent to the DTL by manipulating a
control valve and bypassing an appropriate quantity of water through a heat exchanger to
be cooled. The design goal of this work is to size heat exchangers, pumps, and line sizes
for operation of the SNS DTL water skid system. This task involves designing a system
that provides the necessary water flow and water temperature to support cooling of each
DTL tank while minimizing pressure losses and material costs. Table 3.12 summarizes
the goals for this study.
Table 3.12. Water skid cooling system goals.
Water Skid Model Design Goal
Outcome
Optimize line diameters in skid to
minimize pressure drop, erosion, costs, and
ease the manufacturing of the plumbing.
Size heat exchanger for heat load and flow
rates.
For the heat exchanger, develop a
relationship between the hot side flow rate
and overall heat transfer coefficient.
Determine the pressure drop through the
skid for mean flow conditions (combine
with flow loop model to determine
pressure drop across the pump).
Determine the pressure drop versus flow
rate required for the proportional control
valve to give needed temperature control
(20 C +/- approximately 5 C).
Determine the water skid pressure drop
variance as a function of control valve
position (and hence flow rate variance
from the pump) and determine if action is
required to maintain constant water in the
loop.
Size pumps (based on flow rate and
pressure drop for DTL tank 3).
Line diameters within the skid to
connect the main components
will be 3.0 inch (ID) tubing
constructed of stainless steel.
A 10 inch x 20 inch FlatePlate
heat exchanger with 70 plates.
From the data supplied by the
manufacturer, relationship was
developed using a fifth degree
polynomial curve fit.
The DTL Tank 3 cooling system
produces a total pressure loss of
approximately 45 psi. When
operating at worst case (Tmix
=14oC) pressure drop is 55 psi.
See Figure 7 for pressure loss
across the pump with respect to
heat exchanger flow rate.
See Figure 10.
See Table 5 for pump
specifications.
115
3.1.2.2 Design Specifications
The design specifications for the DTL water skids were taken from the SNS Drift
Tube Linac and Coupled Cavity Linac Water Cooling and Resonance Control System
Description Document [1.2]. During steady state, full RF power, the target operating
temperature of cooling water delivered to the each DTL tank is specified to be 20.00 +/0.28°C, with an operational range between 14.9°C and 25.1°C required for resonance
control. The heat loads as well as the cooling water flow rates and temperatures for each
of the six DTL water cooling skids are summarized in Table 3.13.
Table 3.13. Nominal heat loads, total water flow rates, and water supply temperature
ranges for the DTL water skids.
Water Skid
Mean
Heat Total Cooling Mean Water Water Supply
Load (kW)
Water
Flow Supply
Temperature
Rate (gpm)
Temperature
Range (°C)
(°C)
DTL Tank 1
36.8
120.4
20.0
14.9 to 25.1
DTL Tank 2
82.3
162.4
20.0
14.9 to 25.1
DTL Tank 3
94.8
235.9
20.0
14.9 to 25.1
DTL Tank 4
95.4
215.6
20.0
14.9 to 25.1
DTL Tank 5
89.2
199.5
20.0
14.9 to 25.1
DTL Tank 6
98.4
183.7
20.0
14.9 to 25.1
3.1.2.3 Model Description
The water skid serves as the water supply for the RF structures and thus acts as a
key element in the closed-loop water cooling system. As discussed previously, the
primary water skid components consist of a heat exchanger, variable speed pump,
expansion tank, water purification system, and a control valve. A simplified schematic of
the basic water skid components are shown in Figure 3.40(a).
A variable speed pump was incorporated in the design to maintain a constant
desired flow rate. As discussed previously, water temperature control is maintained by
adjusting the proportion of the total system water flow between the heat exchanger and
the heat exchanger by-pass line. This is achieved by use of an electrically actuated
control valve located on the heat exchanger by-pass line. Since the focus of this study
deals with simulation of the water skid’s pressure drop and temperature control, the bypass water purification system was neglected in the current model. Additional water skid
116
features include control valves, temperature transducers, pressure transducers, and flow
meters, which are strategically placed in the system to provide a way of controlling and
monitoring the temperature, flow, and pressure through the system.
The objective of this analysis was to calculate the system parameters (flow,
pressure, and temperature) needed to size the plumbing and hardware components on the
water cooling skid. As described earlier, the SINDA/FLUINT computer code was used
to develop a network model of the water skid components.
Figure 3.40(b) is the
SINDA/FLUINT model representation of the water skid flow diagram shown in Figure
3.40(a). The water skid model in Fig. 3.40(b) is a numerical description of the system
shown in Fig. 3.40(a). Recall from the earlier description that the SINDA/FLUINT code
models a system as a combination of lumped-parameters. The fluid network is comprised
of flow lengths called paths that are joined at ends by points called junctions. In a similar
manner, the thermal part of the code uses conductors to describe thermal flow paths and
is joined at the ends at points called nodes. Values of mass flow rate and energy flow
rate are obtained from the path lines while the junctions and nodes give values of
pressure and temperature. The heat conductor lines are labeled as HUS and HN and
describe certain properties of the heat flow conductor. These connections are especially
important for the heat exchanger portion of the system. The diamond shaped symbols
represent connection points between the heat exchanger and the cold loop. The triangle
system is a plenum reference point for the hot side and the cold side of the system.
The simulation introduces the heat at only one point in the return manifold. This
approach was taken since the focus of the analysis was the water temperature control
capabilities associated with the water skid and not on the details of the heat transfer in the
RF structure.
117
R F Structure
R F Structure
Heat Input
FM
Filter
Proportional
Control Valve
Filter
Pump
Hot side of Heat Exchanger
FM
P
Heat Exchanger
P
T
By-Pass
Proportional
Control
Valve
T
Variable-Speed
Pump
T
T
FM
WP
P
P
WP
FM
Flow Meter
T
Heat Exchanger
P
Pressure Transducer
Cold side of Heat Exchanger
Facility Chilled
Water Outlet
Facility Chilled
Water Inlet
(b)
(a)
Figure 3.40. (a) Flow diagram and (b) corresponding SINDA/FLUINT model of the water skid.
118
Loss Factors
An important step in developing the SINDA/FLUINT modeling, was to properly
account for all of the pressure loss components within the water skid. All of the fittings,
valves, filters and instrument parts and their associated loss factors are identified in
Figure 3.41 and Table 3.14. These plumbing components were accounted for by placing
their loss factor, K, in the pipe or “path” lines of the SINDA/FLUINT water skid model.
A modeling simplification was made to account for the flow resistance of the
entire system of DTL tank cooling lines as a total pressure loss, L. The value of the
pressure loss was taken from Section 3.1.1 where the pressure drop across the RF
structure was calculated. This pressure loss was used to determine an equivalent K
factor, which was used as input to the SINDA/FLUINT model. It was also assumed that
for the analysis, a constant volume pump could be used to simulate the performance of a
variable speed pump to supply a constant flow rate.
To accurately represent the system pressure drop effects of the 70 plate heat
exchanger in the SINDA/FLUINT model, pressure drop values at different flow rates
across the hot side of the heat exchanger were obtained from the manufacturer. The
individual pressure drops were transformed into loss factors using the Equation 3.22. A 1
inch diameter line was assumed to calculate the fluid velocities.
∆PHE =
1
KρV 2
2
where,
K = loss factor
ρ = density
V = velocity
119
(3.22)
Water Skid K Factors
Kskid27
Kskid2
R F Structure
Kskid26
FM Kskid24
Kskid3
Kskid23
Filter
60 mesh
Kskid5
Kskid22
Kskid20
Kskid4 FM
Kskid17
P
Kskid6 Kskid7
Kskid18
Kskid15 Kskid16 P
Kskid21
T
By-Pass
Proportional
Control
Valve
Kskid19
T
Variable-Speed
Pump
Drain
Kskid14
WP
Kskid25
Kskid11
Kskid8
T
FM
T
Kskid9
Kskid10
Kskid12
P Kskid13
P
WP
2
FM
Flow Meter
T
P
Heat Exchanger
Facility Chilled
Water Outlet
Pressure Transducer
Facility Chilled
Water Inlet
Figure 3.41. Simplified flow diagram of a typical DTL water skid.
120
Table 3.14. Summary of loss factors for a typical DTL water skid (refer to Fig. 3.41).
Symbol
Kskid1
Kskid2
Kskid3
Kskid4
Kskid5
Kskid6
Kskid7
Kskid8
Kskid9
Kskid10
Kskid11
Kskid12
Kskid13
Kskid14
Kskid15
Kskid16
Kskid17
Kskid18
Kskid19
Kskid20
Kskid21
Kskid22
Kskid23
Kskid24
Kskid25
Kskid26
Kskid27
Description
DTL tank 3 total Loss
Supply Transfer Line
Ball Valve (100% open)
Flow Meter
Skid Water Line
Proportional Control Valve
2 two diameter bends
Flow Meter
Temp/Press Trans Port
Globe Valve (50% open)
1 two diameter bend
Size Transition (2.5” to 3”)
1 two diameter bend
Ball Valve (100% Open)
1 two diameter bend
Strainer/filter
Flow Meter
PH/O2 Measurement Port
Return Transfer Line
Diameter (in)
3
4
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
4
121
Length (m)
18.287
NA
NA
1.346
0.9398
NA
1.7526
NA
NA
NA
NA
NA
NA
1.4986
NA
0.1524
NA
1.143
NA
0.1524
1.346
NA
NA
2.1336
NA
18.287
K factor
26.5
S/F friction
.15
6.4
S/F friction
Variable
0.15
1.8
4.3
0.1
1.8
1.8
0.1
6.1
0.9
0.1
0.92
0.9
0.1
0.15
0.9
3.28
0.15
6.4
0.1
0.15
S/F friction
The loss factors associated with each flow rate were plotted against heat
exchanger flow rate to produce a relationship as given in Figure 3.42. Note that y
represents the loss factor and x represents the heat exchanger hot side flow rate.
1
5
4
3
2
y = -2E-05x + 0.0006x - 0.0069x + 0.04x - 0.1437x + 1.149
0.98
Loss Factor (k)
0.96
0.94
0.92
0.9
0.88
0.86
0.84
1
2
3
4
Flow Rate (kg/s)
5
6
7
Figure 3.42. Loss factor vs. mass flow rate for the hot side water flow in the 70 plate heat
exchanger.
The relationship in Figure 3.42 was put into the SINDA/FLUINT model to
represent the pressure drop across the heat exchanger.
The proportional valve to control the flow was modeled as a globe valve that
could be adjusted as needed to obtain the desired flow through the heat exchanger (and
hence obtain the desired water mix temperature). This operation will be discussed in
further detail below.
Heat Exchanger
As discussed previously, a closed loop water cooling system extracts heat from
the RF structure and transfers it to a facility chilled water supply via a liquid-liquid heat
exchanger, as depicted in the flow diagram of Figure 3.40(a). In this closed-loop circuit,
water temperature control is achieved by manipulating the hot-side (Linac side) heat
122
exchanger water flow rate while holding the cold-side water inlet temperature and flow
rate constant. This is achieved by using a proportional control valve that divides the
circulating water between the heat exchanger and by-pass line. By changing the hot-side
water flow rate, the overall heat transfer coefficient of the heat exchanger is varied.
Since the heat removal rate must effectively remain constant for quasi-steady-state
conditions (heat rate into system equals heat rate out of the system), the hot-side water
temperature must change inversely to the overall heat transfer coefficient to achieve a
new operating condition. Consequently, increasing the water flow through the heat
exchanger results in an increase in the overall heat transfer coefficient, and an associated
decrease in the mean water temperature. And conversely, decreasing the water flow
through the heat exchanger results in a decrease in the overall heat transfer coefficient,
and an associated increase in the mean water temperature.
The cooling performance of the water skid, including water temperature range,
accuracy, resolution, and stability, will be highly dependent on the design choice made
for the liquid-liquid heat exchanger. The heat load and flow requirements that the DTL
water cooling systems are being designed to were summarized previously in Table 3.13.
Note that the most significant variable in the resonance control is the water temperature
being delivered to the RF structure. In the case of the six tanks, the mean water delivery
or mixture temperature, Tmix, was specified to be 20.0°C, with a required range of ±6°C
about this mean value. In addition to those parameters listed in Table 3.13, the pressure
drop across the heat exchanger needed to be kept below 10 psi for maximum flow rates
for the cold side and 5 psi for the hot side. The water inlet temperature on the cold side
of the heat exchanger was specified as 7.2°C ± 0.5°C.
The next step, prior to initiating the numerical studies, was to size a commercially
available heat exchanger so that its performance could be included in the
SINDA/FLUINT model of the water skid. The steps used to size the heat exchanger were
as follows (Refer to Figure 3.43 to aid in the discussion):
1. For a known heat load, cold side inlet temperature, and hot side inlet temperature,
determine acceptable cold side and hot side flow rates that give the desired mixture
temperature of 20.0°C. The relationships used in these calculations included the
123
enthalpy balance on the hot side flow rates (Eqn. 3.23), and the energy balance for the
flow on either side of the heat exchanger (Eqn. 3.24)
mT cp Tmix = mh cp Tho + (m T - mh) cp Thi
(3.23)
mc = q/(cp (Tco – Tci)),
(3.24)
where the variables are
m = mass flow rate,
q = DTL Tank 3 heat dissipation: 95000W,
cp = heat capacity of water: 4,179 J/kgK,
T = water temperature,
and the subscripts correspond as follows:
c = cold side
h = hot side
mix = mixture of water to RF structure
T = total (to RF structure)
o = outlet condition
i = inlet condition
2. With the inlet and outlet temperatures known on each side of the heat exchanger for a
given set of flow rates and a known heat load, determine the heat exchanger’s overall
heat transfer coefficient, UA, from Eqn. (3.25) [3.6].
UA = q/((Tho – Tci) – (Thi – Tco))/ln((Tho – Tci)/(Thi – Tco))
(3.25)
3. Choose a commercial heat exchanger that satisfies the heat transfer coefficient and
temperature conditions from steps (1) and (2), while satisfying the pressure drop
limitations listed previously.
4. For the heat exchanger selected in step (3), vary the hot side flow rate and repeat
steps (1) and (2) for six more operating conditions. The vendor heat exchanger
performance criteria are needed to perform this step. From this step, a plot can be
generated of the heat exchanger’s overall heat transfer coefficient versus hot side flow
rate.
124
5. Repeat steps (1) through (4) for three other cold side flow rates to generate a family
of curves of overall heat transfer coefficient versus hot side flow rate.
6. Size heat exchangers for other DTL tanks.
Step (1)
By-Pass
Proportional
Control Valve
mT
mT
mh
Thi
Tho
q
Tco
Tci
mc
Heat Exchanger
Overall Heat Transfer Coefficient, UA
Step (4)
Heat Exchanger Hot Side Mass Flow Rate
Figure 3.43.
Pictorial representation of the heat exchanger sizing for the
SINDA/FLUINT modeling of the DTL water skids.
125
Using the heat load, flow rate, and water temperature ranges for DTL tank 3, the
heat exchanger was sized using the five steps listed above. The particulars of this
exercise were as follows:
1. The given variables included a mix water temperature of 20.0°C (delivered to the
structure), a hot side water inlet temperature of 21.5°C (this is the temperature of the
water leaving the RF structure after heating up from 20.0°C), a cold side inlet
temperature of 7.2°C, a heat load of 95 kW, and a total flow rate of 240.9 gpm (15.17
kg/s). Next, flow rates of 63.4 (4.00 kg/s)and 74.97 gpm (4.73 kg/s) were chosen for
the hot side and cold side flow rates, respectively. This resulted in a hot side outlet
temperature of 15.8°C and a cold side outlet temperature of 12.0°C.
2. With the inlet and outlet temperature as well as the heat load specified, the overall
heat transfer coefficient of the heat exchanger, UA, was calculated to be 10,506
W/°C.
3. A 10"x20"- 40 plate, counter-flow, compact, multi-pass heat exchanger from
FlatPlate Inc was identified by the manufacturer to satisfy these heat transfer
conditions. Unfortunately, the pressure loss limits were exceeded. The size of heat
exchanger was increased to accommodate the pressure limits. In doing so, an
oversized heat exchanger was selected which had approximately 262.6% additional
surface area than what was needed to provide for the overall heat transfer coefficient
identified in step 2 above. In particular, a flat plate heat exchanger with seventy
10”by20” (FP 10x20-70) stainless steel plates was selected. See the mechanical
design section of this report for the "new" sizing procedure.
4. After the heat exchanger was selected, several additional cases with different hot side
water flow rates were studied to obtain multiple values of UA. This information is
especially important since the variable flow on the hot side is used to control the
water temperature returned to the RF structure. Knowing the product of the heat
transfer coefficient and the surface area, as well as the flow rate information, an
126
EXCEL spreadsheet was used to plot these data, as shown in Fig. 3.27. A polynomial
least squares fit of the data produced the following relationship.
UA = 6.9126 m h5 – 182.13 m h4 + 1883.7 m h3 – 9885.2 m h2 + 29164 m h + 2.21,(3.26)
where UA is the product of heat transfer coefficient times the area, (W/°C) and mh is
the heat exchanger hot side water mass flow rate (Kg/s). At this point the heat
exchanger sub-model was ready for input into the SINDA-FLUINT model of the
water skid.
HUS heat transfer ties in the heat exchanger need a heat transfer versus flow rate
relationship and Eqn. (3.26) provides the HUS heat transfer tie to determine the heat
transfer as a function of hot side flow rate. Here the heat transfer tie (HUS) UA value
was adjusted to dissipate the heat between the eight nodes of the SINDA/FLUINT
model’s heat exchanger.
5. Steps (1) through (4) were repeated for cold side flow rates of 94.62 gpm (5.97 kg/s),
53.42 gpm (3.91 kg/s), and 52.94 gpm (3.34 kg/s) as given in Table 3.15.
6. Sized heat exchangers for other 5 DTL tanks.
See section of this report on
mechanical design.
Table 3.15. Cases studied for heat exchanger sizing on DTL tank 3.
Hot Side Flow Rate (kg/s)
Hot Side Flow Rate (gpm)
2.00
31.70
3.00
47.55
4.00
63.40
5.00
79.25
6.00
95.10
7.00
110.95
8.00
126.80
Tco (deg C.)
Cold Side Flow Rate(kg/s)
Cold Side Flow Rate(gpm)
11.00
5.97
94.62
11.00
5.97
94.62
11.00
5.97
94.62
11.00
5.97
94.62
11.00
5.97
94.62
11.00
5.97
94.62
11.00
5.97
94.62
Tco (deg C.)
12.00
4.73
74.97
12.00
4.73
74.97
12.00
4.73
74.97
12.00
4.73
74.97
12.00
4.73
74.97
12.00
4.73
74.97
12.00
4.73
74.97
Tco (deg C.)
13.00
3.91
61.97
13.00
3.91
61.97
13.00
3.91
61.97
13.00
3.91
61.97
13.00
3.91
61.97
13.00
3.91
61.97
13.00
3.91
61.97
Tco (deg C.)
14.00
3.34
52.94
14.00
3.34
52.94
14.00
3.34
52.94
14.00
3.34
52.94
14.00
3.34
52.94
14.00
3.34
52.94
14.00
3.34
52.94
127
Figure 3.44 displays the heat exchanger overall heat transfer coefficient (W/°C)
versus hot side mass flow rate (kg/s) for all cases listed in Table 3.15.
60000
Overall Heat Transfer Coefficient
50000
40000
30000
y = 6.8553x 5 - 180.99x 4 + 1879.3x 3 - 9897.3x 2 + 30073x + 2.1481
y = 6.9126x5 - 182.13x 4 + 1883.7x3 - 9835.2x 2 + 29164x + 2.2097
20000
y = 6.8738x 5 - 181.24x 4 + 1872.7x 3 - 9728x 2 + 28324x + 2.1948
12
y = 6.9125x 5 - 181.56x 4 + 1867.7x 3 - 9635.7x 2 + 27602x + 2.2493
14
10000
11
13
0
0
1
2
3
4
5
6
7
8
9
Flow Rate (kg/s)
Figure 3.44. Overall heat transfer coefficient (W/°C) versus heat exchanger hot side
mass flow rate (kg/s) for four heat exchanger cold side outlet temperatures for DTL tank
3.
3.1.2.4 Design Studies/Results
Temperatures
Figure 3.45 and 3.465 show the temperature predictions for the hot and cold side
of the heat exchanger at normal operating conditions (Tco =12 oC, Tho = 20 oC) for the
water skid associated with DTL tank 3.
128
Figure 3.45. SINDA/FLUINT temperature predictions on the hot side of the heat
exchanger for the water skid on DTL tank 3.
In Figure 3.45, notice the heat distribution through the system. A sudden rise in
temperature occurs at junction 1.
This is where waste heat from DTL tank 3 is
introduced into the system (95kW). The heated water is carried from junction 1 to
junction 3 where approximately 27.3 gpm (1.72 kg/s) of the flow is diverted to the heat
exchanger loop. This is done using control valves labeled as CT. To achieve the correct
flow to the heat exchanger and a Tmix (temperature at junction 10) temperature of 20oC ,
the K factor employed at the CT following junction 3 was set to 2.13. In addition, the CT
following junction 9 was set to 100. At junction 10, flow from the heat exchanger loop,
after being cooled, is recombined with the bypassed flow.
Figure 3.46 represents the cold side of the heat exchanger. Notice that the
temperatures range from 7.2 oC at the inlet to 12 oC at the outlet. A cold side flow rate of
approximately 75 gpm (4.72 kg/s) was employed to achieve the 12oC outlet temperature.
129
Figure 3.46. SINDA/FLUINT temperature predictions for the cold side of the heat
exchanger on the DTL tank 3 water skid.
The solver option in Sinda/Fluint was employed to adjust the K factor value
applied to the control valve, located immediately after junction 3, to achieve several
different flow rates, from17.9 to 95.2 gpm (1.13 to 6 kg/s), through the heat exchanger.
Doing this allows Tmix to satisfy the required temperature range of 20.0oC +/- 5.0oC.
Figure 3.47 shows the relationship between Tmix and the hot side flow rate through the
heat exchanger. Notice that valve control is more sensitive when the flow rate through the
heat exchanger is low. The curve is allowed to flatten out by changing the cold side flow
rate. Figure 3.47 also shows the additional temperatrue curves for the various cold side
flow rates.
130
70 Plate Heat Exchanger for DTL Tank 3
Tmix (deg. C)
28
12
26
14
24
11
13
22
20
18
16
14
12
10
0
1
2
3
4
5
6
Flow Rate (kg/s)
Figure 3.47. Tmix versus heat exchanger hot side flow rate for DTL tank 3.
Pressure Drop
A relationship of induced pressure versus flow rate through the hot side of the
heat exchanger is given in Figure 3.48. Note that a 3 inch diameter line was employed
for all water skid lines, excluding the 4 inch transfer line from the water skid to the DTL
RF structure.
131
70
60
Pressure Drop (psi)
50
40
Pump
Heat Exchanger
30
20
10
0
1
2
3
4
5
Flow Rate through Heat Exchanger (kg/s)
Figure 3.48. Induced pressure drop versus flow rate through the hot side of the heat
exchanger for Tco = 12oC.
With exception to the transfer lines between the water skid and the main
manifolds (4 ich), all lines within the water skid should be 3 inches internal diameter.
Figure 3.49 shows the pressure across the pump versus water skid line diameter.
132
6
140
Pressure Drop Across Pump (psi)
120
100
80
60
40
20
0
2
2.5
3
3.5
Internal Line Diameter (in)
Figure 3.49. Water skid line size versus pressure drop across the pump at normal
operating conditions (Tmix = 20oC, Tco =12oC).
Once the water skid lines were sized and set at 3" internal diameter, the water skid
transfer lines were studied. The transfer lines between the DTL structure and the water
skid should be at least 4 inches to keep pressure losses as low as possible. Figure 3.50
shows the relationship between the pressure drop and transfer line diameter.
133
4
58
Pressure Drop Across Pump (psi)
56
54
52
50
48
46
44
42
40
2
2.5
3
3.5
4
4.5
Transfer Line Internal Diameter (in)
Figure 3.50. Water skid transfer line diameter versus pressure drop across the pump at
normal operating condtions (Tmix = 20oC, Tco = 12oC)
Pump Sizing
The water skid pump size was based upon the worst case pressure drop scenario.
For the tank 3 water skid, this situation is expected to occur when 4.5 kg/s ( at Tco = 13
deg. C) of cooling water is passed through the heat exchanger and a resulting pressure
loss of approximately 55.6 psi is produced across the pump. The water skid pump was
sized using the following relations for a total flow rate of 241 gpm (15.2 kg/s). Equation
1 calculates the overall head loss to size the pump.
Power = ∆P * Q
where,
DP = Pressure loss in the water skid (psf)
Q = Volumetric flow rate (ft3/s)
134
(3.27)
Equation (3.27) yields the following for the pump power on the DTL tank 3 water
skid:
Power =
53lbf 144in 2 15. 2kg
m3
35.13 ft 3
ft * lbf
*
*
*
*
= 4238
= 7.6 horsepower
2
2
3
s
998 kg
s
in
ft
m
The total power required to deliver the required water flow is 7.6 horsepower.
Please note, however, that pumps are usually only around 75 % efficient and must be
sized according to a manufacturer's pump curve specifications. Pumps for all tanks
should be sized according to the selected manufacturer's curves for the following
specifications in Table 3.16.
Table 3.16. Pressure drop and flow rate specifications for all six DTL tanks.
Tank #
Flow rate
(gpm)
Velocity
∆P across Tank (psi)
Add ∆P through
system (psi)
System
k
1
2
3
4
5
6
120.4
162.4
235.9
215.6
199.5
183.7
1.66654721
2.24790089
3.26526982
2.98428221
2.76142997
2.54273025
18
18
19.5
18
18
18
2
2
2
2
2
2
99.288
54.573
27.804
30.964
36.163
42.651
∆P though water skid w/Hx
valve at k = 100 and Hx Flow
Rate = 4 kg/s
18
22.5
33.5
29.5
27
25
Approximate
Total ∆P (psi)
36
40.5
53
47.5
45
43
Control Valve
The control valve is responsible for sending the required amount of water to be
sent to the heat exchanger to the system water temperature. Figure 3.51 is a plot which
compares the control valve K factor to the flow rate sent to the heat exchanger for DTL
tank 3. This curve is produced based upon a cold side outlet temperature of 12 deg. C.
135
80
70
Control Valve K Factor
60
50
40
30
20
10
0
0
1
2
3
4
5
6
Flow Rate through Heat Exchanger (kg/s)
Figure 3.51. Control valve K factor vs. flow rate to the heat exchanger for DTL tank 3.
3.1.2.5 Summary
•
Normal operating conditions for tank 3 are achieved when a flow of 26.82 gpm (1.69
kg/s ) of water is bypassed to the heat exchanger and the cold side flow rate and outlet
temperature are 75 gpm (4.72 kg/s) and 12oC, respectively.
•
A FlatPlate Inc. heat exchanger, model FP 10x20-70, is smallest heat exchanger that
may be used on the water skid.
•
All water skid line sizes shall be 3" id min. with exception to the transfer lines to the
DTL, which shall be 4" id min.
•
Pressure drop across tank 3 will be a maximum of 60 psi.
•
The total power required to deliver the required water flow is 7.7 horsepower. Please
note, however, that pumps are usually only around 75 % efficient and must be sized
according to a manufacturer's pump curve specifications.
136
7
3.1.3 SINDA/FLUINT Uncertainty Analysis
The DTL water cooling system describe previously, is quite complex. In order to
construct manageable SINDA/FLUINT models which yield meaningful results, several
modeling simplifications and assumptions were required. Of greatest uncertainty in the
SINDA/FLUINT modeling, is the incorporation of empirical flow resistance coefficients
to describe the pressure drops across various pieces of plumbing hardware. Omission, or
incorrect application of these resistance values, can lead to significant modeling errors.
In order to determine the uncertainty in the SINDA/FLUINT modeling of the DTL water
cooling system, a comparison was made between flow and pressure drop predictions of a
SINDA/FLUINT model and empirical measurements from a prototype water cooling
system. Such a comparison will provide an assessment of the accuracy in the modeling
technique and the SINDA/FLUINT code.
The experimental results were taken from a prototype SNS Linac water cooling
system that was fabricated for an R&D effort on a CCL hot model comprised of two RF
segments of the CCL. The prototype water skid is shown in Figure 5.4. The flow
diagram of the prototype cooling system is shown in Figure 3.52.
The pressure
measurement locations are identified by the letter “P”, and the flow rate measurement
locations are designated by “FM”.
The pressure and flow measurement devices that were used in the experiment, had
the following specifications:
•
Pressure - pressure transducers (OmegaPX63-100G5V) 0-100 psig full scale,
accuracy is 0.4% full scale, or plus/minus 0.4 psi.
•
Flow in large water lines (1.5” and 2” diameter) - Paddle wheel flow meter: accuracy
of +/- 0.2 feet per second (this will have to be converted to gallons per minute by
multiplying it by the cross-sectional area of the pipe that the flow meter is inserted).
•
Flow in small lines (1” and 0.375” diameter) - Turbine flow meter: Accuracy = 1%
of reading.
137
P4
Fm9
Fm8
Fm7
Fm6
Fm5
Fm4
Fm3
Fm2
FM1
P3
FmT
Filter
60 mesh
P2
P1
Variable-Speed
Pump
Drain
Fmhx
Heat Exchanger
Facility Chilled
Water Outlet
FM
Flow Meter
T
By-Pass
Proportional
Control
Valve
P
Pressure Transducer
Facility Chilled
Water Inlet
Figure 3.52. Flow diagram of the prototype water cooling system for the CCL hot model.
138
The SINDA-FLUINT model representation of the prototype water cooling system
is shown in Figure 3.53. A modeling procedure, similar to that described previously in
this report, was used in developing and running the model depicted in Figure 3.53.
Figure 3.53. SINDA/FLUINT model representation of the prototype CCL hot model
water cooling system.
139
Table 3.17 shows a comparison between the experimental and numerically
predicted values of pressure drop and flow rate. The numerically predicted pressure
drops across the pump and water manifold system are within 4% of the empirical
measurements. The difference can be attributed primarily to the uncertainty in the
pressure measurement.
The numerically predicted flow rates through the pump and heat exchanger (FmT
and Fmhx) were also in good agreement (within 1.6%) with the experimental
measurements.
The agreement of the numerically predicted and experimentally
measured flows in the manifold line distribution system ranged from good to fair. The
predicted flows in the large lines
(diameter = 1”) were within 4 to 10 % of the
measurements, while the predicted flows in the small lines (diameter = 0.375”) differed
by 4 to 22 % from the experimental values.
It should be noted that the flow split for the SINDA-FLUINT values are exactly
equal as they should be for the 1” diameter lines and are all equal for the small 0.375 “
diameter lines in the cavity area. The fact that the experimental values do not measure
evenly indicates some variance in the experimental apparatus that are not brought out in
Table 3.17. For example FM1 and FM2 should have equal values, however they differ
by 3 percent. The small lines (0.375” diameter) should also divide evenly, but they vary
by as much as 10 percent.
These differences can be attributed to instrumentation
accuracy limitations and slight variations in flow-control globe valve settings.
In general, the SINDA-FLUINT results compared well with the experimental
values (in most cases, better than 10%). No effort was required in “tweaking” the
SINDA-FLUINT model to improve the comparison. Further, the K-factors were taken
from textbooks or estimated in the same procedure that was used in the modeling
procedure for the DTL and CCL water cooling systems. Consequently, the SINDAFLUINT modeling for the SNS DTL and CCL water cooling systems should yield
acceptable results for accurately sizing pumps, heat exchangers, and plumbing hardware.
140
Table 3.17. Comparison of the SINDA/FLUINT model predictions and experimental
measurements of flow and pressure for the prototype CCL hot model water cooling
system.
Parameter
P2-P1
P3-P4
FMhx
FMT
FM1
FM2
FM3
FM4
FM5
FM6
FM7
FM8
FM9
Empirical Value
81.5 psi +/- 0.3
19.8 psi +/- 0.1
34.5 gpm +/- 6.9
94.3 gpm +/- 18.9
19.0 gpm +/- 0.2
18.41 gpm +/- 0.2
3.24 gpm +/- 0.02
3.3 gpm +/- 0.03
3.56 gpm +/- 0.04
3.27 gpm +/- 0.03
3.45 gpm +/- 0.04
19.28 gpm +/- 0.2
18.6 gpm +/- 0.2
SINDA/FLUINT
Value
84.9
20.4
34.4 gpm
95.9 gpm
20.4 gpm
20.4 gpm
2.7 gpm
2.7 gpm
3.7 gpm
2.7 gpm
2.7 gpm
20.1 gpm
20.1 gpm
141
% Difference
4
3
0.3
1.6
7.4
10
17
18
4
17
22
4
8
3.2 DTL Water Cooling Loops – Stability and Response Modeling
The successful design of the DTL water cooling and resonance control system
relies on a number of key operating and performance conditions. These conditions
include the temperature and availability of the coolant, how fast the cooling system can
react to heat load changes, what happens if the facility water does not have a stable
temperature, etc. A delivery system for the coolant was designed and provisions made
for gathering the data required to understand whether the design would provide what is
required by the cavities under the desired rf loads. To keep the cavity tuned, it is
important that both the drift tubes and the tank itself be kept at stable temperatures as
both affect the cavity tune. This is complicated by the fact that the drive iris, the slug
tuners, the post couplers, and the dipole magnets are all cooled in the same cooling loop.
To aid in this design process, a dynamic control model was written that attempts to
simulate the process of maintenance of coolant temperature and availability, given the
diameters and lengths of the pipes in the cooling system, the characteristics of the control
valve, and the characteristics of the heat exchanger.
This numerical model was
developed in SystemView by Elanix ®.
3.2.1 Design Goals
The SystemView model allows various dynamic or transients conditions to be
investigated, such as the time required to reach a steady-state temperature condition for
the RF structure and water cooling system from start-up or a trip in RF power. This is
quite different from the steady-state analyses performed with the SINDA/FLUINT
models, which were used, in part, for sizing plumbing and hardware. The modeling goals
and outcomes for this work are summarized in Table 3.18.
142
Table 3.18. SystemView modeling goals for the DTL Tanks.
Design Goal
Outcome
Determine the transit time of water through
the cooling loop and components.
Transit times determined and listed on the
model figure
Estimate the thermal response time of the
copper drift tubes and tanks walls to changes
in either cooling water supply temperature or
RF heat load (i.e., response time per °C
change in cooling water temperature or per
Watt in heat load). Determine the
optimization techniques (i.e., shorten pipe
run lengths) needed to minimize the response
time, or suggest how this can be achieved
with the proper PID tuning.
Estimate the required start-up time of the RF
power and water cooling system to reach a
thermally steady-state operating condition.
Model has been developed and run for
several case studies. Indications are that the
system will perform satisfactorily in its
present configuration.
Determine stabilizing capability of cooling
system and cavities to a trip in RF power.
Create corrective measures to keep cavities
from over-cooling (i.e., add heater, open bypass valve fully, close solenoid valve on cold
side inlet to heat exchanger, etc.).
Estimate acceptable fluctuations (magnitude
and frequency) in the chilled water supply
temperature and flow rate, that do not have a
detrimental impact on the DTL resonance
control.
Model completed and run for a full RF
power-on condition. Model was also run for
various off-normal heat loads as would be
encountered during cavity conditioning or
linac tuning and commissioning resulting in
proper resonance control
Two conditions were studied, an RF trip of
10 seconds and an RF trip of several hours.
The resonance point will probably be at some
complicated combination of drift tube and
tank wall temperature. These simulations
show temperature control but can not show
the areas of resonance.
The model has been run for several different
test cases. Indications are that fluctuations
much larger than have been specified will not
have a detrimental impact on resonance
control.
3.2.2 Model Description
The nodal network SystemView model for the DTL tank 3 water cooling and
resonance control system is shown in Figure 3.54. The model includes nodes to account
for the drift tubes, tank walls, post couplers, slug tuners, iris, and dipole magnets. Each
of these nodes accounts for the thermal mass of its copper component, as well as the heat
143
Figure 3.54. Schematic representation of the SystemView model of DTL tank 3.
transfer coefficient between that component and the cooling water. The numerical model
also includes a pump, heat exchanger, variable control valve (controlled by an internal
PID algorithm), and all of the necessary plumbing.
Further specific details regarding the SystemView model are provided below.
Structure temperatures:
The temperature of the DTL structures can be calculated from the following
differential equation:
?CpV dT = Q + hA(T f – T)
dt
Converting the equation to a difference equation it becomes
Ti+1 = Ti + [Q + hA (Tf – Ti)] ?t
k
144
= Q ?t + hATf ?t +(k-hA ?t)Ti
k
where ? is the density of Cu, Cp is the heat capacity of Cu, V is the volume of the
structure, Q is the heat load input to the structure, h is the heat transfer coefficient of Cu,
A is the surface area in contact with the coolant, Ti is the temperature at the ith step, Tf is
the coolant temperature, and ?t is the time step.
Simulation:
The above equation is implemented as a time simulation in SystemView by
Elanix ®. The simulation follows the diagram above. The temperature of coolant at each
node in the diagram is time-dependent on the flow within the pipe and the diameter of the
pipe. These time dependencies are implemented as delays in the simulation. Each node
in the diagram is initialized at the holding temperature of the cavities, currently thought
to be 24°C. As coolant reaches the node from the previous node, the temperature is
released to whatever that previous node is supplying. A variable delay is implemented in
the leg that sends heated coolant through the heat exchanger. This variability is due to
the variable opening of the control valve that is controlled by a PID algorithm that is
controlling the temperature of the low energy full segment. A variable delay is also
implemented in the cold side of the heat exchanger to provide for different flows from the
facility side to the heat exchanger.
Heat Exchanger:
The heat exchanger is a flat-plate counter-flow heat exchanger.
balance equation describing this device follows:
Q = U?A(LMTD)
Where Q is the heat exchanged
U? is the overall heat transfer coefficient for the heat exchanger
A is the heat exchange area
LMTD is the log mean-temperature-difference.
145
The energy
U?A is estimated by the following fit to the vendor-supplied heat exchanger data.
U?A = 5.4382*mh5 – 143.34*mh4 + 1527.3*mh3 – 8489.4*mh2 + 27367*mh +
.00067
where mh is the water mass flow rate through the hot side of the heat exchanger and is in
kg/sec and U?A is in W/°C. This data was obtained with input temperature of the hot side
at 22.7°C.
LMTD = (Thi – Tco) – (Tho – Tci)
ln[(Thi – Tco)/(Tho-Tci)]
where Thi is the input temperature on the hot side,
Tci is the input temperature on the cold side,
Tho is the output temperature on the hot side,
Tco is the output temperature on the cold side.
Using
Q = U?A(LMTD) ,
Q = mh Cph (Thi – Tho) , and
Q = mc Cpc (Tco – Tci)
One can solve for Q and obtain
Q = mcmhCp(Thi – Tci)[eU?A (mc – mh)/(Cp mh mc) – 1]
mc eU?A (mc – mh)/(Cp mh mc) - mh
In the simulation, if the exponent on e becomes greater than 12, eU?A (mc – mh)/(Cp mh
mc)
can be considered large with respect to 1 and mc* eU?A
(mc – mh)/(Cp mh mc)
considered large with respect to m h. In this case the equation becomes
146
can be
Q = mhCp(Thi – Tci)
This avoids the problem of attempting to compute a number larger than the
computer can handle. One might ask how ave(Th) can be calculated since Tho is going to
be calculated given Thi and the flow rates. Ave(Th) is calculated using Thi in the current
time step and Tho from the previous time step.
In this simulation, the cold side mass flow rate through the heat exchanger, mc is
held constant at 2.82 kg/sec or 44.7 gal/min. This complies with the constant flow
regulating valve in the circuit leading to the cold side of the heat exchanger.
Variable Valve Control
The variable valve that controls coolant flow through the heat exchanger is
controlled by a PID algorithm whose input is taken from the average temperature of the
drift tubes. The value of the gain for the differential term is set to zero since this is a first
order system. Values for the other two terms were set to give good response. However,
they are not necessarily the best values. Use of the Ziegler-Nichols algorithm would give
optimum values.
Since the PID algorithm is controlling a physical valve, the characteristics of the
valve need to be included. The valve that was chosen for temperature control is actuated
by a stepping motor. The valve requires 500 steps from fully opened to fully closed and
vice versa. Depending on valve design, fully opened to fully closed can require from 15
to 27 seconds. 25 seconds was arbitrarily chosen because the actual valve has not yet
been identified. Using the 25 second actuation time, the motor is able to take 1 step
(1/500th of full actuation) every 0.05 seconds.
The values that the PID algorithm
generates are moderated to provide no faster response than 1 step every 0.05 seconds.
Thus, the physical characteristics of valve motion are included in the simulation. The
flow versus valve opening is assumed to be linear. This makes the computation a bit
easier but as long as the system is stable there is no requirement for linearity. The PID
algorithm is able to provide the necessary temperature control in either case.
A series of preliminary thermal engineering calculations were required to support
the SystemView model. These calculations are included in Appendix L.
147
3.2.3 Design Studies/Results
Profile of Startup and Stable Operation
These simulations were run using the temperature of the center drift tube (#17) as
input to the control valve. The initial temperature of the tank components was 20.0°C,
the desired setpoint temperature was 26.6°C, and the full rf power was introduced at time
= 0.0. In reality, the RF power will be gradually ramped up, however, for the purpose of
this simulation, the application of full RF power will be fairly representative of a normal
startup condition. The PID controller has gains that are optimized to provide as fast a
response as possible while maintaining stable operation. Temperatures of the lowest
energy and the highest energy drift tubes in the tank along with the center drift tube were
monitored. In addition, the temperature of the tank wall was monitored and is shown.
The temperatures of the drift tubes and the tank wall all contribute to the resonant
frequency of the tank.
The results of the transient simulation are displayed in Figure 3.55. With Tci set
to 7.2°C, the setpoint set to 26.6°C, the following steady-state conditions were found:
•
Temperature of the drift tube is 26.6°C, as expected. The temperature of the low
energy tube is slightly higher and the temperature of the high energy tube is
essentially identical.
•
Bypass valve operates at 88.7% open.
•
Tmix is 19.9°C.
•
Thi is 21.4°C.
148
Figure 3.55. Tank wall temperature, drift tube 1, 17, and 33 temperatures, and by-pass valve positioning versus time for a normal RF
startup condition of DTL tank 3.
149
As the startup simulation begins, the bypass valve starts to open and the applied
RF power heats the structures. Tube #17 approaches the setpoint in about 140 seconds.
Next, the bypass valve begins to close, anticipating the need for cooling. From this point,
another approximately 120 seconds are required to stabilize the temperature at the
setpoint of 26.6°C. Due to the tremendous difference in mass, the tank wall heats at a
much slower rate not quite coming to the target temperature (it reaches 25.7°C ) even at
the end of the simulation (1200 seconds). Note also the plateau that the drift tube
temperatures pass through. The drift tubes can react so quickly because of their small
thermal mass that the proportional gain of the PID algorithm must be kept very small.
Because of the small proportional gain the valve reacts very slowly. The drift tubes react
very quickly to the heat being applied by the rf. The tank wall is a large enough thermal
mass that it acts like a heat exchanger keeping the coolant temperature from rising. The
valve is still open enough to allow coolant from the actual heat exchanger into the drift
tubes. As the valve continues to close, the drift tubes are allowed to heat and finally
reach the setpoint.
Effects of Variation in Coolant Temperature
To explore the effects of variations of the SNS facility chilled water temperature
on the CCL cavity temperatures, a sine wave with an amplitude of 2.0ºC and a period of 8
seconds was imposed on the chilled water temperature.
The results of this simulation are displayed in Figure 3.56.
Note that this
variation in coolant temperature shows up as a small variation (about ±0.02°C) in the
temperature of the center drift tube. The variation also shows up as a variation in the
temperature of the other two monitored drift tubes leading one to the conclusion that it
will cause a variation in all the drift tubes in the tank. Note also that this variation
doesn’t affect the tank wall at all. This is due to the large mass of the tank wall. This
small variation in the drift tube temperature is so small as not to change the tune of the
cavity. However, it is obvious from the bypass valve action that the bypass valve would
be under continuous motion (±0.22% about 88.9%).
150
Figure 3.56. Tank wall temperature, drift tube 1, 17, and 33 temperatures, and by-pass valve positioning versus time for a sinusoidal
disturbance of the facility chilled water temperature (amplitude of 2.0°C and a period of 8 sec.) condition of DTL tank 3.
151
The simulation was repeated with a coolant temperature variation with the same
amplitude but a cycle time of 0.1 second. The results of this simulation are displayed in
Figure 3.57. The shorter cycle time introduce an alias into the signal which shows up as
an additional variation with a different cycle time.
Even a cycle time this short shows a small variation in the temperature of the drift
tube. This is most likely because the drift tube is small and will react to almost any
temperature change. It is interesting to note that the variation is damped. Since the tank
as a whole will respond to changes in temperature and those changes will cause changes
to the resonant frequency of the tank and that is the quantity of interest, it is likely that
the stability of the tank will offset the lack of stability of the drift tubes. At 8 seconds per
cycle the variation of temperature of the drift tubes pretty much disappears at or below a
coolant temperature variation of ±0.5°C.
152
Figure 3.57. Tank wall temperature, drift tube 1, 17, and 33 temperatures, and by-pass valve positioning versus time for a sinusoidal
disturbance of the facility chilled water temperature (amplitude of 2.0°C and a period of 0.1 sec.) condition of DTL tank 3.
153
Momentary Loss of Rf Power
A system such as the one described will lose rf power on occasion due to a spark
in a waveguide or in a klystron.
A question arises as to how much of an upset
(temperature and deviation) will such a loss cause. A 10 second loss of rf power was
input in the next simulation.
The results of this simulation are displayed in Figure 3.58. The power loss
(spark) was started at 800 seconds and lasted for 10 seconds. The temperature of the
middle drift tube drops to about 23.9°C.
The rf power comes back on and the
temperature increases, overshooting to about 27.8°C before stabilizing back to the
setpoint. Note that a 10 second rf power loss translates to approximately 200 seconds of
temperature upset to the controlled structure. The tank wall also reacts to the loss of rf
with a small drop in temperature. However, the loss is much less and the original
trajectory is regained much more quickly.
154
Figure 3.58. Tank wall temperature, drift tube 1, 17, and 33 temperatures, and by-pass valve positioning versus time for a momentary
loss of RF power condition in DTL tank 3.
155
Total Loss of Rf Power
Should there be a total loss of RF power, management of the temperature of the
structure becomes an important task. The lower the cavity temperature falls, the more
thermal stress will be applied to the structure and the further the system will deviate
from the steady-state resonance condition. For a brief period of time, the water cooling
system can minimize the temperature drop in the RF structure, however, at some point,
some other method of maintaining structure temperature must be applied.
In this simulation, the RF power was lost at time = 800 seconds. The results of
this simulation are displayed in Figure 3.59. The question here is, will something need to
be done to preserve the tank and drift tube temperature?
When the rf power is lost, the temperature of the controlling drift tube drops
almost immediately and within about 77 seconds has fallen to 20.7°C. The temperatures
in the other two drift tubes also drop copying the profile of the central drift tube. The
tank wall drops as well but not nearly so quickly. Because the three-way valve can
completely bypass the heat exchanger, the temperature in the drift tube tank can be
maintained. One could assume that after reaching a minimum, the temperatures will
slowly rise due to heat being added by the circulating pump. If that is indeed the case, it
might be prudent during such a loss of power, to change the setpoint to follow
temperature rather than the low-level rf error signal and to set the temperature to follow
to something less than the 26.6°C operating temperature so re-initiation of RF power will
again follow a normal pattern.
156
Figure 3.59. Tank wall temperature, drift tube 1, 17, and 33 temperatures, and by-pass valve positioning versus time for a total loss of
RF power condition in DTL tank 3.
157
Change of Copper Temperature Setpoint
In the next simulation, the copper setpoint temperature was increased by 1.0°C at
800 seconds. This simulates an operator’s decision to change the tuning of the device.
The question is how long will it take for the tank to stabilize after such a change?
The results of this simulation are displayed in Figure 3.60. The plots indicate that
when the setpoint is changed, the bypass valve reacts by opening to its full extent. The
drift tubes take about 150 seconds to settle to the new setpoint. The central drift tube lags
the change in the bypass valve by about 9 seconds. The bypass valve closes down by
about 0.1%. The tank wall shows a change in temperature trajectory and again shows an
asymptotic approach to the new temperature.
3.2.4 Summary
The results of these simulations indicate that the temperatures of the accelerating
structures for the DTL in the accelerator can be controlled to the specifications required
using the currently designed water cooling system. This system uses one control valve
that is manipulated by a PID algorithm. The coolant is supplied from the facility chilledwater system and is fed into a counter-flow, thin-plate heat exchanger. Start-up times, as
well as responses to thermal disturbances appear to be reasonable. It is well to note that
the structure seems to be riding on the edge of stability. Slight changes in either the
proportional or integral gains will send the unit into oscillation. In addition, if either gain
is reduced there seems to be a need to reduce the other to prevent the instability.
However, this may be an artifact of the numerical model, and may not be representative
of the actual structure. It is speculated that initial testing and commissioning of the actual
DTL water cooling systems will allow proper tuning of the control systems to occur and
provide stable and accurate operation.
158
Figure 3.60. Tank wall temperature, drift tube 1, 17, and 33 temperatures, and by-pass valve positioning versus time for a 1°C
increase in the copper setpoint temperature condition in DTL tank 3.
159
4.0 Mechanical Design
4.1 Introduction
This section of the report discusses many facets associated with the mechanical
design of the DTL water cooling system. These topics include the types and quantities of
engineering drawings being developed, engineering codes and drawing standards being
followed, and general mechanical design processes that were followed for the design of
the water cooling system hardware.
4.2 Engineering Codes and Drawing Standards
To ensure that the DTL water cooling system design meets reasonable reliability
and safety standards, design guidelines and specifications provided by the ASME Boiler
and Pressure Vessel [4.1] and ASME Piping Process (B31.3) [4.2] codes are being
followed. The ASME B31.3 codes are sponsored, published, and maintained by the
American Society of Mechanical Engineers (ASME). The scope of the codes as used in
this report, is to provide guidance for the design, fabrication, assembly, installation,
inspection, and testing of piping and piping components for the SNS Linac water cooling
system.
In Appendix A, B31.3 topics related to the design of the SNS Linac water cooling
system are listed, and where applicable, background information is presented. Failure
theories are discussed and their relationship to pipe stress equations and limits presented
in B31.3 are established. Welding practices and inspection techniques are some of the
major topics of concern in the water cooling system design. The ASME B31.3 is very
specific in discussing the various welding procedures including inspection and testing
techniques used in pipe fabrication.
It must be emphasized that the ASME B31.3 code does not serve as an instruction
list for design, rather it is provided to assist engineers and designers in their efforts to
produce a safe piping system.
It is the responsibility of the piping designer, the manufacturer, the fabricator, and
the installer, as applicable; to follow the guidelines set forth by the B31.3 code and
provide sufficient documentation of its implementation.
160
The main organizational
responsibilities, as they apply to the SNS Linac water cooling system, are summarized
below:
Vendor (Manufacturer and Fabricator):
Responsibilities of the vendors include
examinations and certification of all contracted work. The vendor shall provide certified
examiners and document all dates and results of examinations. Piping and piping
elements shall be visually examined to the extent necessary to satisfy the examiner that
components, materials, and workmanship conform to the requirements of the B31.3 code
and of engineering design. All records shall be made available to the LANL design team.
Los Alamos National Laboratory (LANL): The responsibilities of LANL’s design
team are to verify that all required examinations and testing have been completed and to
inspect the system to the extent necessary to be satisfied that is conforms to all applicable
examination requirements of the B31.3 code and the engineering design. LANL will also
conduct visual inspections during and after all stages of manufacturing, fabrication,
assembly, installation and testing. LANL will be responsible for final certification of all
equipment prior to facility operation.
Oak Ridge National Laboratory (ORNL): ORNL is the owner of the SNS project and
is responsible for all final inspections. ORNL’s Inspectors shall have access to any place
where work associated with piping installation is being performed. This includes
manufacture, fabrication, assembly, installtion, examination, and testing of the system.
ORNL inspectors shall have the right to audit any examination, to inspect the system
using any examination method specified by the engineering design, and review all
certifications and records necessary to satisfy the stated owners responsibility.
All engineering drawings generated for the DTL water cooling system will adhere
to the ESA-DE Drafting and Design Standards and Guidelines [4.3], which closely follow
the standards listed in the Global Engineering Drawing Requirements Manual [4.4]. The
formating standards used for the Piping and Instrumentation Diagrams (P&IDs), were
161
taken from Sherwood and Whistance [4.5], and the ISA –S5.5 [4.6] and ANSI Y32.11M
[4.7] national standards.
4.3 Plumbing Materials
Material selection for the SNS linac water cooling system plumbing is driven by a
number of design criteria such as functionality, strength, durability, radiation hardness,
cleanliness, manufacturing capability, maintainability, availability, and cost. Copper,
stainless steel, brass, carbon steel, and PVC have been evaluated for use as the primary
tubing material. Copper tubing is desirable because of its mechanical properties of high
strength and corrosion resistance, as well as being economical and easy to form and join.
For more specialized water transfer systems such as those found in chemical processing
facilities, microchip processing facilities, power plants, nuclear reactors, synchrotrons,
and particle accelerators, stainless steel is commonly used. Brass and mild carbon steels
are not recommended for water systems where high water purity is an issue as both of
these materials are susceptible to relatively high levels of corrosion or erosion. Plastic
and PVC materials are being avoided for several reasons including their lack of strength,
high diffusion coefficients for oxygen (oxygen promotes bacteria growth and enhances
corrosion of copper), and high susceptibility to radiation damage.
Selection of flexible hoses was also evaluated. Flexible hoses will serve both as
vibration and electrical isolators and allow for greater flexibility in the system design.
The engineering design tolerances for the assembly drawings may be relaxed and
potential plumbing misalignment can be absorbed during installation. These hoses will
greatly simplify assembly and installation of the water skids, manifolds, and
submanifolds.
Selected flexible polymers have been chosen for short jumper and
connection lines.
In identifying the correct material of hose, radiation affects,
compatibility with deionized water, oxygen permeability, and flexibility have been
considered.
4.3.1 Radiation Damage Assessment
The radiation emanating from a particle accelerator can degrade mechanical
properties of materials in close proximity to the beam line. The extent of this degradation
162
will depend on the dose rate and cumulative radiation dose, as well as other factors such
as operating temperature, mechanical stress, and exposure to air [4.8]. Scientists and
Engineers at CERN have compiled a fairly extensive database, which relates radiation
damage to cumulative dose rate for a variety of materials [4.9]. Table 4.1 lists the
radiation damage (cumulative radiation dose) limits for various materials used around
high-energy particle accelerators [4.9].
Table 4.1. Radiation damage limits for materials used around high-energy particle
accelerators [4.9].
Material
Cumulative Dose Limit (Rad)
Metals
1´1010
Polyvinyl Chloride (PVC)
1´108
Ethylene-Propylene Rubber (EPR)
8´107
Polyurethane Rubber (PUR)
7´107
Styrene-Butadiene Rubber (SBR)
4´107
Polychloroprene Rubber (Neoprene)
2´107
Chlorosulfonated Polyethylene (Hypalon)
2´107
Acrylonitrile Rubber (Buna-N)
2´107
Viton
1´107
Nylon
1´107
Plexiglass
1´107
Silicone Rubber (SIR)
9´106
Fluoro Rubber
9´106
Acrylic Rubber
8´106
Butyl Rubber
2´106
Phenolic Resin
1´106
Tefflon (PTFE)
1´105
Assuming a particle beam loss of 1 Watt/meter along the entire SNS linac, the
prompt radiation dose rate, at 1 foot from the beam line, will be approximately 1
Rad/hour at the low energy end (10 MeV) of the DTL, 8 Rad/hour at the high end energy
(80 MeV) of the DTL, and 18.5 Rad/hour at the high energy end (185 MeV) of the CCL
[4.10]. If the SNS accelerator were to run for 300 days/year, the maximum cumulative
dose for a year would be approximately 5.8´104 Rads in the DTL and 1.3´105 Rads in
the CCL.
To determine which materials will be acceptable for the water cooling system
tubing (from a radiation performance perspective), the material cumulative dose limits
need to be compared to the annual dose present during accelerator operation. Assuming a
163
thirty year desired lifetime for materials in the Linac water cooling system, the total
cumulative dose would be 1.7´106 Rads in the DTL and 3.9´106 Rads in the CCL. Thus
all water cooling system materials for the DTL and CCL linac beam line should be able
to withstand a radiation dose of at least 3.9´106 Rads. Referring to Table 4.1, the metals,
such as copper and stainless steel, as well as many of the nonmetallic materials such as
Buna-N, Hypalon, Nylon, Neoprene, meet the cumulative dose criteria. However, among
the nonmetallic materials, it is only Buna-N and Neoprene that have an historical usage
base to refer to. Both have been used on the LANSCE 800 MeV particle accelerator at
Los Alamos National Laboratory with good success. The flexible Buna-N lines on the
LANSCE CCL have been observed to harden over time by a combination of radiation
and atmospheric damage, however they have maintained working lifetimes of well over
ten years [4.11]. In addition, Buna-N/Neoprene hoses have been used as flexible jumper
lines for the majority of the focusing and steering magnets on the LANSCE accelerator
for the last twenty years [4.11]. Note that the annual cumulative dose rate estimated
above was based on the high-energy end of the SNS linac and is thus very conservative
for the majority of the room temperature linac structure.
Nonmetallic materials will also be needed as flange seals and thermal insulation
(within the chases) of water system components as well as electrically insulating the
power and signal lines. Components such as valves or flow meters are likely to require
some type of gasket material for sealing at the connections. Choices are often available
from a vendor and the selections will need to meet the radiation dose criteria of 3.9´106
Rads. Viton and Teflon are among the most common options however only Viton is
acceptable. Teflon should be avoided whenever possible. For insulation, selections will
need to be made by consulting Table 4.1. Due to the threat of leakage, threaded joints
will be avoided whenever possible but not in all situations. Teflon is a common thread
sealant but, as was stated earlier, is unacceptable due to material failure in the SNS
radiation environment. LANL recommends the usage of RectorSeal NO. 5 as the pipe
thread sealant.
164
4.3.2 Material Selection for Design
The design of the water cooling system for the room temperature linac will
require consistency between components on the DTL and CCL, and will necessitate a
clear definition of acceptable materials for the plumbing components. Various aspects of
the accelerator and water cooling system designs dictate a need for certain characteristics
in the plumbing material. For example, the water purification system requires clean,
corrosion resistant, and impermeable (to oxygen) tubing. The RF structure alignment
criterion makes the use of flexible jumper lines desirable. Flexible hoses also reduce
high tolerance requirements in positioning of the water skids relative to the transfer and
facility water lines. To satisfy these wide ranges of needs, it was necessary to define
acceptable water cooling system plumbing materials.
To determine the correct material for the water lines in this closed loop system,
water quality and purity has been identified as a significant factor. A comparison
between copper and stainless steel was diligently researched.
Stainless steel was
identified as the only acceptable material for several significant reasons. Although the
DTL and CCL tanks are made of copper, the percentage of surface area relative the
remaining portion of the cooling loop is small.
Therefore, this factor was not as
significant as several others were. The ultrapure deionized water is very aggressive and
will attack materials such as copper, brass, and bronze. The water will begin to remove
iron oxide particulates and allow them to reattach on other surfaces. This is called
“rouging” and can easily be recognized by a reddish tint in the water. This will directly
affect the efficiency and lifetime of critical components such as the pump, 3-way control
valve, heat exchanger, and inline heater. Additionally, these particulates are likely to
become activated and increase the handling risk of the water.
Cost was identified as another criterion. Copper tube and pipe is slightly less
expensive then stainless steel. To maintain material compatibility, fittings and valves
would be constructed from either bronze or brass, which is significantly less expensive
then stainless steel. However, brass is significantly more susceptible to the aggressive
nature of the ultrapure water. The use of these materials would require a periodic
flushing of the entire closed loop system to remove the iron oxide. This would increase
165
the system complexity, the system cost, and the system down time. The material cost
savings of copper is countered by the added requirements in maintaining a clean system.
System components such as the heat exchanger and the pump would be
constructed from stainless steel whether the piping system was copper or stainless steel.
This would require a galvanic insulating material to prevent corrosion at the joint if the
plumbing material were copper. Even copper to copper brazed or soldered joints may
create potential problems. Many of the standard flux materials used in solder joints are
susceptible to the aggressive nature of deionized water. Such joints may potentially
cause soldered particulates to break off and cause damage to the pump impeller or inhibit
flow through an orifice plate.
Having weighed the benefits and risks of both copper and stainless steel, the need
for a dependable and safe system requires LANL to employ only the stainless steel as the
piping and tubing material. From the complete criteria, which includes functionality,
durability, radiation hardness, cleanliness, manufacturability, maintainability, and cost,
the following materials have been deemed acceptable:
300 Series Stainless Steel
Stainless steel is extremely durable, strong, clean, and corrosion/erosion resistant.
While Stainless steel tubing is more difficult to form and join than copper tubing, its cost
per unit length and availability are similar. In addition, stainless steel will provide a
cleaner environment for the water purification system and be less susceptible to erosion
and radionuclide-induced corrosion than copper tubing [3.12].
For deionized water
systems, stainless steel joints that are welded will provide a more reliable leak-free
system compared to copper soldered joints. Most of the compression fittings, valves,
orifice plates and housings, and instrumentation probes will be fabricated from 300 series
stainless steels because of its strength and corrosion resistance.
Nonmetallic Hose
Several polymers are being considered for use as flexible jumper and connection
lines.
The stringent criterion in selecting the correct material quickly narrows the
possible choices. Selected hose materials will be the same for both the DTL and CCL
166
and must therefore meet the higher of the two dose rates (CCL portion of the linac). The
minimum survivable radiation dose is 3.9×106 Rads and the ultrapure water electrical
resistivity 10 to 15 MΩ. In addition, the hose must be reasonably flexible and its oxygen
permeability must be very low. These last two criteria are more subjective and result in a
list or ranking of potential materials (see Appendix H). Additionally, any history of use
for a given material in a similar environment will strongly be considered. From these
criteria, only Buna-N, Hypalon, Nylon, and Neoprene will be considered for flexible hose
material.
4.3.3 General Manufacturing and Assembly Techniques
Manufacturing techniques used to fabricate and join the water manifolds and
transfer lines may include the use of the T-Ball extrusion technique, welding, flanges,
threaded, and compression fittings. Qualified personnel will perform all manufacturing
processes and will follow procedures outlined under ASME B31.1 code of practice.
Many of the fluid lines require bending of the stainless steel tubing. All bends will
follow the SAE-AS33611 standard. The detailed plans for fabrication, assembly, and
installation for all water cooling system hardware can be found in Sections 9 and 10 of
this report. The general manufacturing and assembly techniques for the water manifolds
are defined below.
•
The T-Ball technique is used to produce multiple extruded flow ports in manifolds or
headers using a die to control the radii of the extrusion. The process involves drilling
a small hole in the side of a pipe and inserting a ball-shaped puller. The ball-shaped
puller is then extracted outward through a round die that is placed on the outside of
the manifold. As the ball is pulled through the die, metal is drawn with it to form a
cylindrical extruded outlet port. The extruded outlet port extends above the surface of
the header a distance at least equal to the external radius of the outlet.
This
manufacturing technique is especially useful for thin-walled manifolds in which it is
not possible to produce a tapped hole for a threaded fitting. This technique also
eliminates the need for welding or soldering a “T” fitting in place for a branch line.
167
Finally, the T-Ball technique also provides a rounded entrance to the extruded port,
thus creating a lower flow resistance than a standard “T” junction.
•
Welding procedures and welding operators will be in conformance with the rules
specified in AWS and ASME code standards. All stainless steel and steel tubing
joints will be welded with gas tungsten arc welding (GTAW), better know as TIG
welding.
In TIG welding, an electrical arc is established between the tungsten
electrode and the work-piece, resulting in heating of the base metal. If required, a
filler material is used. The weld area is shielded with an inert gas, usually argon or
helium. GTAW is ideally suited to weld nonferrous materials such as stainless steel,
and is very effective for joining thin-walled sections.
Welds used to fabricate
manifold support brackets made of mild steel, will be done with Gas Metal Arc
Welding (GMAW), better known as MIG welding. GMAW uses a solid metal cored
electrode and leaves no residual slag. The shielding gas may be carbon dioxide or a
blend of argon with carbon dioxide and/or oxygen. GMAW is ideal for welding thingage materials.
•
Compression Fittings provide a leak-proof, torque-free seal at all tubing connections
and reduce the possibility of costly, hazardous leaks in instrumentation and process
tubing. The joining action in the fitting moves along the tube axially instead of with a
rotary motion. Consequently, no torque is transmitted from the fitting to the tubing,
which eliminates any strain that may weaken the tubing. Compression fittings are
advantageous for joints that must be taken apart for inspection, replacement, or
maintenance purposes (i.e., instrumentation ports, water treatment hardware, etc.)
•
Flanged Fittings provide a very dependable and consistent joining method. For
components that may need to be inspected, removed or replaced, flanges are optimal.
ANSI flanges are the only acceptable types of flange because they call for specific
internal diameters, external diameters, hole pattern, quantity of fasteners, and material
type for each tube size. These requirements allow a smooth transition from piping to
tubing. Leakage is not a significant concern. Flange seals are available in acceptable
168
nonmetallic materials.
Rotatable flanges will be used when component or pipe
alignment is critical.
•
Threaded Fittings are a very common joining method but will only be used
sparingly. This joining method, versus the others discussed above, is the most likely
to leak.
For insertion RTDs, pressure transducers, pressure relief valves, and
potentially a few other components, threaded fittings can not easily be avoided. The
goal is to install them in a leak proof way. To do this, a sealant must be applied to the
threads to prevent galling. It is recommended that RectorSeal NO. 5 (MSDS0011)
be used because it is a soft setting sealant, its provides excellent sealing and antigalling characteristics, and has demonstrated very good performance on previous
projects.
•
Beaded Tube Ends will be used to attach all flexible hose not identified as requiring
quick disconnects. Document SAE AS5131 specifies bead requirements for tube
ends. The bead may be rolled at the end of a tube or a tube stub with a bead may be
welded into place. When connecting to a Swagelok fitting, a tube stub may be
inserted into one end and locked into place. The flexible hose is installed over the
tube end with the bead and then band clamped to lock into place.
4.4 DTL RF Structure Water Manifolds and Lines
As mentioned previously, there are a total of six independent DTL RF Structure
cooling loops.
This section describes the engineering design associated with those
cooling loops.
4.4.1 Piping and Instrumentation Diagrams
The DTL RF structure Process and Instrumentation Diagrams (P&IDs) are a
practicable way of showing the process flow as well as the instrumentation and controls,
the hardware, and show plumbing identification. P&IDs are tools that not only illustrate
the process in detail, but also provide information on equipment, valves, lines, and
instruments, what the industry commonly refers to as Intelligent P&ID'S.
169
These
diagrams can also be used for process safety management operational training and
maintenance.
The information from P&IDs allowed the design team to generate a detailed list
of components and instrumentation. Flow meters, valves, pressure transducers, RTDs,
etc. are identified in a table (see Section 4.6). The table provides information showing
the relationship between the actual components and the P&ID where it is identified.
Such information is the drawing number, page, and location where the component can be
found. Other essential information related to the component such as flow rate, pressure
rating or electrical requirements are provided.
Figure 4.1 displays the 4 sheets of the P&ID for the DTL RF structure cooling
loop on DTL Tank 1. One of the main features on the P&ID is the supply and return
process lines. These lines are called single line drawings. The single line drawings are
more compact and can represent more diagrams and instruments on less sheets verses the
double line P&ID drawings. DTL P&IDs show the supply coming from the water skid in
the center of the module process lines to ensure an even flow rates, and a mirror image
for the return process lines. The arrows indicate the flow direction.
The DTL P&IDs give each process line an ID naming convention. (e.g., 4”-WSDTL1-101-SS3). The first number in the ID label is the pipe diameter then after the dash
is the Water Supply, DTL RF Module number, process line number and the material
specification. Also labeled on the P&ID’s are the naming convention for the valves and
instrumentation.
DTL P&IDs contain diagrams of all supply and return process lines including
drain and vent valves. The vent valves are to be located at the high point of the process
system and the drain valves will be located at low points. This will insure proper
draining and purging of the water cooling system.
Valves indicated on the P&IDs are positioned so that the system can be
segmented if a section is to be removed or replaced. All valves are manually operated.
The DTL supply submanifold for the drift tubes is equipped with orifice plates to
distribute the desired amount of flow to each drift tube. These orifices are removable for
maintenance purposes.
170
Figure 4.1. Piping and instrumentation diagram for DTL tank 1.
171
Figure 4.1. Continued.
172
173
174
Instrumentation labeled on the P&ID’s are shown as balloons and also with a
numbering convention. These instruments will be electronic in nature and will send
signals back to the PLC for an accurate reading and a constant hazard control of the entire
DTL system. There will be temperature, pressure, and flow sensors on each DTL RF
tank.
4.4.2 Major Components
Orifice Plates
Swagelok VCR fittings will be used for retaining the orifice plates on the CCL.
The line sizing for tanks 1 and 2 is ½” tube and for tanks 3 through 6 is ¾” tube. A
detailed effort has been made to minimize the number of unique orifice diameters. A
maximum deviation from the analytical orifice diameter to that of the actual drill hole
diameter is 5%. Tanks 1 and 2 will require 21 drill hole sizes and tanks 3 through 6 will
require 12 drill hole sizes.
Orifice plates have unique installation requirements that must be adhered to.
Failure to follow these guidelines will result in poor performance or improper operation.
Orifice plates will primarily be used in the DTL portion of the linac but will also find
usage in the CCL. Each drift tube requires a specific volumetric flow rate to correctly
control the RF power. Fluid exiting the orifice must not create fluid cavitation. Straight
lengths of tube without any obstruction or disturbance to the flow will create smooth fluid
flow, both prior to the orifice as well as after the orifice. Specifically, a straight tube
length of 3 diameters upstream and 8 diameters downstream is the minimum installation
requirement.
Valves
Manual globe valves will allow for fine-tuning of the flow to the sub-manifolds.
The stem may be adjusted using a standard hand-wheel. At the point where the valve is
properly adjusted, a locking mechanism will ensure that no inadvertent contact would
alter the valve setting. All wetted metallic valve components will be 300 series stainless
steel and non-metallic O-rings will be of Viton. Due to potential sticking or turning of a
screwed bonnet, a bolted bonnet is preferred. The desired body end is flanged.
175
Manual ball valves are required to isolate sections of the water system for the
removal or replacement of system components and system drainage in this closed loop
system. The rotary-ball valve will function as a manual on/off flow isolator. The stem
rotation will be 90° open to close. The single-seat ‘eccentric’ version of this ball valve
will be used to insure that no leakage occurs. The ball is slightly offset so that it presses
into the seat on closure. The type will be a ball valve constructed from 316 or 316L
stainless steel.
All valves must have a lockout method to prevent unauthorized
adjustments.
Pressure relief valves will be used to protect the system from over-pressurization.
These valves will be set to release at a pressure below 100 psig, so that the system
pressure will not at any time exceed the maximum operating pressure of 150 psig.
Flow Meters
All flowmeters used in the Linac Tunnel will be of the turbine type. Turbine
flowmeters produce either a pulsed wave signal or a sine wave signal, the frequency of
which is proportional to flow rate. This type of flow meter possesses a reasonable flow
resistance and is reasonably priced. It is quite possible that electrical noise in the linac
tunnel and waveguide chases will disrupt the standard, low amplitude pulsed wave signal
eminating from the turbine flow meter head. Consequently, amplification of the pulsed
output signal or conversion of the pulsed signal to 4-20 mA output at the flowmeter is
required.
The electronics components required for the wave signal amplification or
conversion will be at risk due to the radiation environment in the linac tunel. The
radiation produced by the accelerator is comprised of Neutrons and Gamma rays.
Shielding of the flow meter electronics against the neutron radiation is not feasible.
Other types of flowmeters, which may not require radiation shilding, have too great a
pressure drop or are extremely expensive and beyond the allowable budget. The only
resolution is to plan for scheduled replacement of the electronic amplification or
conversion unit.
The anticipated prompt radiation dose along the SNS linac was discussed in
Section 4.3. At 100 MeV, the beam will produce 10 Rad/hr at a distance of 1 foot and at
176
200 MeV, the beam will produce 20 Rad/hr at a distance of 1 foot. Radiation levels drop
off proportionally at the rate of 1/r where r is defined as the distance from the beam
centerline in feet. For the DTL, the flow meter electronic components are 3 feet away
from the beam line and will see a dose rate of 3.33 Rad/hr. The accelerator will operate
300 days per year for 30 years. Consequently, the total radiation dose to the DTL flow
meter electronic components would be: 3.33 Rad/hr × 24 hr/day × 300 days/yr × 30 years
= 7.2 × 105 Rads over the accelerator’s lifetime.
Based from historical experience, electronics will survive and remain operable up
to a cumulative dose rate of 1.0 × 105 Rad [4.8]. Thus, the flowmeter electronics in the
DTL will have a lifetime range of 4.9 to 20 years. The quantity of flowmeters in the CCL
portion of the accelerator is less then is required for the DTL, which is of some relief.
Scheduled maintenance should correlate with these component lifetime expectations.
Turbine flowmeters have unique installation requirements that must be adhered
to.
Failure to follow these guidelines will result in poor performance or improper
operation. A minimum straight tube length both upstream and downstream will produce
accurate and consistent flow measurements. The installation requirement is 10 diameters
upstream and 5 diameters downstream as a minimum. If a partially closed globe valve, a
tight radius bend, or a tee intersection is part of the tube run, these minimum installation
requirements need to be increased.
4.4.3 Assemblies
Figure 4.2 displays a solid model of the water lines and manifolds mounted on the
DTL tank 1 support structure. The supply and return manifolds have been placed on the
back of the RF structure running in horizontal position and in-line vertically. The supply
will be the upper manifold and the return will be the lower manifold clocked. The return
manifold will be rotated 30° inwards to allow the process lines to be free of potential
damage from the work area. The process lines then will be routed over the RF structure
support to proper connectors. The support of the manifolds will necessitate standard
readily available support brackets with a means for adjustment and the ability to be
welded if required. The support structure will be fastened to the RF structure with
standard bolt fasteners. This will allow for slight adjustments longitudinally, laterally,
177
Figure 4.2. Water manifolds and lines on DTL tank 1 as seen from the front (aisle) and
back side of the accelerator.
178
and vertically. The key advantage of this support system is the elimination of prestressed joints on the manifolds and sub-manifolds. A secondary benefit is the angling of
the main manifold to allow for more efficient draining and venting of the cooling system
as required.
Additional examples of the subassembly and detailed drawings of the main
manifolds are presented in Appendix B. Similar drawings have been generated for all
submanifolds on DTL tank 1. Tabularized drawings, where appropriate, are being used
to dimension the remaining main and sub-manifolds for DTL tanks 2 through 6. A
representative tabularized drawing, which uses a table of dimensions to describe similar
manifolds from different DTL tanks, is shown in Appendix B.
4.5 Water Skid
The water skid is a modular unit containing various plumbing components (pump,
heat exchanger, etc.), a water treatment system, and instrumentation and controls. The
water skids for the DTL RF Structures, the CCL RF Structures, the CCL Quadrupole
Magnets, and the SCL Quadrupole Magnets will be very similar in function, layout, and
operation. The general features and processes are shown on the P&ID of Figure 4.3.
The DTL will require a total of 6 RF Structure water. The flow requirement for
the RF Structure is approximately 120 to 235. While the pumping requirements all of the
skids will be significantly different and may require different size components, it will be
desirable to maintain consistency in the design and component selection.
The goal of the water system team is to produce the greatest range in performance
for each closed loop system. Unfortunately, to produce the greatest amount of thermal
range for the cooling loops, twelve identical skids would not produce such result. The
significantly diverse range of water volume, flow rate, and heat transfer capabilities drive
the need for several unique water skids. Variables such as facility chilled water flow rate
and temperature, heat exchanger warm side flow rate and pressure loss, mixed
temperature from the heat exchanger and heat exchanger bypass, variable speed pump
capabilities are some of the complexities that are to be evaluated.
179
4.5.1 Piping and Instrumentation Diagrams
The Process and Instrumentation Diagram (P&ID) is a tool used to define the fluid
lines, direction of flow, instrumentation/control leads, and facility interfaces. Shown on
these diagrams are the components, drains, filters, etc. and it’s associated reference or
naming designation. The P&ID is created as a simplified layout form for ease of
understanding and is not to scale. The water skid P&ID is shown in Figure 4.3.
Each water skid contains an expansion tank that will serve as a water reservoir for
initially charging the flow loop and pressurizing the system with Nitrogen.
The
expansion tank is equipped with a water level indicator, a pressure relief valve, and a
Nitrogen gas purge.
The reservoir will be pressurized with Nitrogen to purge the
deionized water of potentially system damaging Oxygen. Additionally, the pressurizing
of the system insures a positive priming of the pump. The reservoir will include a
pressure relief valve, a flow limiting orifice and a vent valve to insure safety within the
system.
The water skid will contain the entire water purity system, which is required to
remove potential radionuclides (see Section 5 for details regarding water purification).
The water remains in continuous circulation driven by one magnetic drive sealess
centrifugal pump.
The function of the water skid is to produce a correctly tuned RF frequency in the
linear accelerator. Each water skid will provide a metered amount of cooling water to the
RF Structure, which is monitored by several flow meters along the water’s pathway. The
RF Structure return line is warm water and passes the first flow meter, which then tees
towards either the heat exchanger or to its bypass. The flow to the heat exchanger passes
through another flow meter prior to entering the heat exchanger. This second flow meter
assists in the temperature control of the system. An electronically actuated 3-way control
valve controls the amount of flow that will bypass the heat exchanger. Both flow paths
reconnect prior to entering the pump. Upon exiting the pump, the flow will tee into two
potential paths. The primary path bypasses an in-line circulation heater. The secondary
path is through this heater. The secondary path is likely to be used only when the desire
is to slowly raise the temperature of the particle accelerator. These three flow meters
within the water skid will help to control the DI water temperature and flow rate. These
180
Filter
60 mesh
Pressure
Relief Valve
T
FM
Vent
Valve
Reservoir/
Expansion
Tank
Mixed
Carbon Ion Bed Cation
Bed
Resin Resin
Deoxygen.
FM
UV
5 µm Source
Filter
5 µm
Filter
Fluid
Low-Level
Indicator
FM
S
FM
In-Line Heater
N2
P
P
Heat Exchanger
By-Pass
Control
Valve
Variable-Speed
Pump
P
P P
Filter
100 mesh
FM
Heat Exchanger
T
Valve for
acid flush
Flow
Control
Valve
T
Facility Chilled
Water Outlet
Facility Chilled
Water Inlet
Figure 4.3. Water skid piping and instrumentation diagram.
181
WP
2
FM
Flow Meter
T
T
T
P
T
FM
Drain
P
Pressure Transducer
two variables should allow for reasonable control the RF Structure temperature. In
theory, the flow rate will remain constant and the temperature to the RF Structure will be
controlled by the amount of water flowing to the heat exchanger. The end result is a
properly tuned RF Structure.
4.5.2 Performance Specifications
One procurement specification will be required for all of the DTL RF Structure,
CCL RF Structure, CCL Magnet, and SCL Magnet water skids. It will define the system
performance requirements, engineering codes that the system must be designed to,
fabrication and assembly requirements, and the required acceptability testing prior to
delivery. LANL will provide the P&ID to the manufacturer/assembler of the skid. All
potential vendors will meet applicable ASME Codes.
4.5.2.1 Vibration Isolation
No specific vibration isolation requirements have been specified in the SNS
requirement documents SNS108030000SR0001-R01 and SNS104000000-SR0001-R00
that would guide the design of the water pumping skids. Consequently, it was decided to
use best engineering practices to vibrationaly isolate the water skids from other
subsystems. On the water skid, the vibration generating components include the 3-way
control valve, the flow of water within the plumbing system, and the pump. The control
valve does not have an impact on dynamics but only impacts the system with respect to
noise levels and not vibration. The system flow will not create a significant dynamic
impact based on experience from previous accelerator designs and the engineers who
worked on those designs. The only significant source of vibration is the pump motor and
rotor.
Section 4.6.3.3 identifies pump isolation requirements that will be imposed on the
supplier of the water skid procurement. Additionally, LANL Memorandum SNS-00-80
goes into greater detail and discussion of the process and development of the vibration
isolation requirements for the water skid.
182
4.5.2.2 Noise Level Requirements
No specific noise level restrictions were specified in the SNS requirement
documents SNS108030000SR0001-R01 and SNS104000000-SR0001-R00 that would
guide the design of the water pumping skids. Consequently, it was decided to use best
engineering practices to design a water pumping system that generated reasonable noise
levels. With this in mind, the water skid was designed such that no personal protective
equipment will be required during system conditioning. The water skid supplier is
required to review document OSHA Regulations (Standards – 29 CFR) Occupational
noise exposure. – 1910.95 and meet the requirements therein. Another commonly used
resource is the American Industrial Hygiene Association (AIHA).
These two
associations have provided the foundation for what are acceptable noise levels of various
equipment for varying lengths of time.
An A-weighted response, denoted dBA, is often used because it simulates the
sensitivity of the human ear at moderate sound levels. To understand typical A-weighted
sound levels, freeway traffic at 50 meters produces 70 dBA and a loud lawnmower at the
operator’s ear produces 90 dBA. Two other components contribute significantly to the
noise level in a defined area. They are the exposure time and the cumulative noise level
affects of all equipment in the defined area. The OSHA and AIHA permissible noise
exposure for 8 hours is 90 dBA. To compute the cumulative affect of various noise
sources, an equation was developed. The front end of the Klystron Gallery has 6 noise
sources: water skid (qty 2), Klystron cooling skid (qty 2), Klystron transmitter tank (qty
2), SCR high voltage rectifier (qty 1), modulator equipment (qty 1), and equipment racks
(qty 3).
The equation yielded an allowable noise level of 73 dBA for each water skid.
Since exposure time may be greater then 8 hours during the accelerator commissioning,
the permissible noise exposure will be reduced to 70 dBA. Measurements may be taken
at any location outside the structural frame of the skid. For a more detailed review of the
noise requirements, see LANL Memorandum SNS-00-83.
183
4.5.3 Major Components and Specifications
The general layout configuration of the water skid is currently being developed. All
water skids should be similar in construction however it is likely that differences in pump
sizes, heat exchanger sizes, and pipe diameters between skids may be required due to
differences in required water flow rates and heat loads per module. Considerable effort
will be made to maintain consistency in water skid design features and components .
The following components have been defined as to the system performance and
will be specified in terms of company and model number to the water skid
manufacturer/supplier.
4.5.3.1 Structure
The supporting structure of the water skid will have a base constructed from a flat
plate material with supporting cage type structure for vertical attachments. The structure
will not corrode due to a moderately humid environment. Best engineering practices will
be used in all construction that includes ANSI B1.1 and ANSI B1.20.1. The support
structure will be painted using durable enamel as a protective measure to eliminate
potential corrosion and rust.
Ideally, carbon steel will be used as the construction material. The supplier will
follow ASTM guidelines including ASTM A276, ASTM A240, and ASTM A480.
A structural envelope will be no greater then 5 feet in width by 8 feet in length by
8½ feet in height. The goal of the supplier is to minimize the water skid envelope to as
small a package as possible. In reducing this envelope, the supplier will focus on the
reduction of the length and width. A size reduction of the skid will allow greater access
to components on the skid as well as more access to various systems in the Klystron
Gallery.
The orientation of certain components within the skid envelope is critical. LANL
anticipates the need for scheduled maintenance on the water purification/filtration unit.
Specifically, the carbon bed and mixed bed containers will need to be replaced to ensure
the purity of the deionized water. Easy and direct access is required. Due to the location
within the building that each skid is located, these containers will need to be accessible
on the short side (envelope width).
184
The pump is a critical component that will require proper orientation on the water
skid. Accessibility to the pump motor on the same short side (envelope width) as the
carbon bed and mixed bed containers is required. Although no scheduled maintenance
for the pump motor is anticipated, failure of this component has the highest probability of
all components within the water skid assembly.
The supplier shall develop and implement into the water skid design a method of
efficiently draining the system. The drainage system must prevent water from dripping
or draining onto the Klystron Gallery floor.
The draining/venting scheme must be efficient and simple for maintenance
personnel. All low points of the skid must have a method of draining that is valved. The
highest point on the skid must have a valved port to vent the system and increase systemdraining efficiency.
The structure of the skid must provide a collection tray for any inadvertent leaks
due to system water overfill, spillage occurring due to system draining, or an improperly
functioning valve. The base of the water skid may be designed to function as a spillage
tray.
4.5.3.2 Plumbing
All tubing design and construction will meet the requirements of ASTM A268,
A269, A511, and A554 documents.
The primary material used by the supplier to
design/fabricate the system will be stainless steel 316 or 316L. Viton is an acceptable
nonmetallic seal material. Other materials may be used provided they are commonly
used materials, are acceptable for use with deionized water, do not create galvanic
corrosion problems, and are acceptable in writing by LANL.
The method of joining tube-to-tube used by the supplier to design/fabricate the
system will be by compression fittings, welded joints whenever possible, and flanged
connections. The method of joining tube-to-components is the same as for tube-to-tube
methods however certain components may require threaded NPT connections. All
flanged joints will meet the requirements set forth in ANSI B1.20.3.
Whenever a
threaded fitting is required, a soft setting sealant shall be used. The recommended sealant
is RectorSeal NO. 5 (MSDS0011). Teflon does not perform well in the any radiation
185
environment and should be avoided. All dissimilar metals require nonconducting
dielectric connections and the written approval by LANL.
Tubing support shall be in accordance with Manufactures Standardization Society
(MSS) for the Valve and Fittings Industry, MSS SP-69. Supports shall be arranged to
insure that no structural load is transmitted to the equipment.
Based on extensive analysis by LANL, tube sizes have been identified and can
seen in the Process and Instrumentation Drawing (P&ID). All tubing will be installed
parallel and perpendicular to the skid base frame. Tube cutting will be with tube cutters
only. All cut edges will be reamed to remove all burrs. All defects caused by machining,
chipping, or grinding will be removed. All stainless steel components/sub-systems shall
follow the guideline set forth in document ASTM A380 for precleaning, descaling, and
cleaning. The water skid shall be cleaned per PFI ES-5.
Flow direction identification is very important to the proper installation of the
completed water skid. Each major tubing section shall have directional arrows indicating
the water flow path. A major section is defined as any tube length preceding and
following a tube intersection.
The cold side of the heat exchanger will have typical facility water flowing
through its plates. It is likely to cause water scaling and leave mineral deposits on the
inside of the heat exchanger. The scaling would have a detrimental affect on the heat
exchanger performance and will eventually lower the performance of the entire closed
loop system. Therefore, two connection ports are required to do periodic acid wash
cleaning on the cold side of the heat exchanger.
4.5.3.3 Pump
The pump will be a magnetic drive pump (MDP) and be of the horizontal sealless
type to maintain constant water flow to the RF Structure and the magnets. It will utilize
an outer ring of permanent magnets or electromagnets to drive an internal rotating
assembly consisting of an impeller, shaft, and inner drive member (torque ring or magnet
ring) through a corrosion resistant containment shell. A flow meter will be located just
downstream of the pump to monitor the flow rate.
186
The material of construction will be 316 or 316L stainless steel. The selection of
a pump will meet all of the requirements of document ASME B73.3M-1997 Specification
For Sealless Horizontal End Suction Centrifugal Pumps For Chemical Process. All
electric motors must be manufactured and operate per NEMA-MG-1. This document
specifies appropriate maximum vibration levels for electric motor assemblies.
Each pump assembly (including motor) will be installed on a conventional
machinery vibration isolation mount. The mount system must be sized to provide 95%
vibration isolation with respect to the pump’s fundamental rotational excitation
frequency. Isolation must be provided along two perpendicular axes that are in turn
perpendicular to the pump axis. Thus, the isolation mount for a horizontally mounted
pump could provide isolation vertically and laterally with respect to the pump axis.
Isolators may be mounted with their axes angled with respect to each other.
Conventional wire rope, helical spring, or isolator styles may be utilized.
Correct pump sizing is critical to the performance of the entire water cooling
system. Given that the pump manufacturer is not known at this time, an estimation of the
required pump sizes has been made. A standard pump performance curve (3 related
curves), as seen in Figure 4.4, was used. Along the abscissa is the flow in gallons per
minute and down the ordinate is the pressure loss in terms of Head (feet of water). The
intersection is found and a curve is selected, usually the curve directly above the point.
This curve is the required impeller size. Drawing a vertical line down to the next graph
will define the required motor in terms of horsepower. The correct curve is the one that
corresponds with the placement of the impeller curve relative to the other curves i.e. if it
is the 3rd curve on the pressure loss graph, use the 3rd curve on the horsepower graph.
The drawn vertical line continues down to the next graph, which identifies the pump
efficiency.
Selection of the correct curve follows the same steps as that for the
horsepower curve. From knowing the pressure loss across the pump in terms of psi and
converting it to Head by multiplying by the conversion factor 2.31 as well as knowing the
flow rate in terms of gpm, the impeller size, motor requirements, and efficiency can
easily be determined. Actual pump sizing will vary from this estimate because each
pump supplier has slightly different pump performance curves.
187
Figure 4.4. Pump performance curves for a typical centrifugal pump.
188
Upon review of standard pump curves, a total of three pump sizes will be required
for the twelve water skids. From the SINDA/FLUINT modeling, the flow rate and
pressure drop requirements for each closed loop system was determined.
This
information is available in Section 3 of this report. To allow for any assumption errors in
modeling and to allow for future system growth, the pump sizing used 125% of the
calculated pressure drop across the pump. The estimated horsepower requirements for
the pump motor are 6 hp (for DTL-1, CCL-MAG, and SCL-MAG), 12 hp (for CCL-1,
CCL-2, CCL-3, and CCL-4), and 20 hp (for DTL-1, DTL-2, DTL-3, DTL-4, DTL-5, and
DTL-6). The pump efficiency ranges from 53% to 74% for these cases.
The pump sizes required for the DTL water cooling systems are summarized in
Section 4.5.4 of this report.
4.5.3.4 Heat Exchanger
The water skid performance depends greatly on an efficient heat exchanger. A
stainless steel brazed plate heat exchanger will be selected. Plate-type heat exchangers
outperform traditional shell-and-tube heat exchangers and do so while reducing size and
weight. FlatePlate Inc. has been selected as the company to supply heat exchangers for
the SNS Linac water cooling systems based on their efficient design, heat transfer
characteristics, and history of outstanding performance.
Each skid must actively adjust the temperature of the water sent to its respective
tank, module, or magnets by remotely adjusting a control valve and bypassing an
appropriate quantity of water through a heat exchanger. This task involves the sizing of
heat exchangers to support active cooling/heating of the Linac while adhering to pressure
loss and temperature requirements.
The design specifications needed to size the heat exchangers were taken from the
SNS DTL and CCL Water Cooling and Resonance Control System Description
Document [1.2]. During steady state, full RF power, the temperature of cooling water
delivered to the each DTL tank is specified to be 20.0 +/- .28 °C. Furthermore, for the
six DTL tanks, the waste heat loads range between 34.2 and 96 kW and require 118.3 and
240 gpm of cooling water. A flat plate liquid-to-liquid heat exchanger was selected to
189
transfer the waste heat from the closed DTL water loop to chilled facility water. The
chilled facility water supply temperature was specified to be 7.2 oC.
Pressure drop through the hot side loop of the heat exchanger at extreme
operating conditions was limited to 5 psi.
This value was selected based upon
engineering judgement. For the facility side of the heat exchanger, a 10 psi limit was
imposed.
Selection of the appropriate heat exchangers for the SNS Linac water cooling
systems is critical for successful operation of the Linac. The size and quantity of plates
are the only two variables used in evaluating the heat transfer coefficient of potential heat
exchanger models. To proceed in sizing of the heat exchangers, the plates sizes were set
at 10” x 20” which allowed the heat exchanger sizing study to be based on the quantity of
plates. Added to the complexity of this analysis is the desire to minimize the number of
unique heat exchangers. This section demonstrates the process and reasoning behind the
selection of heat exchangers. The selection process is not trivial, however, and many
variables, shown in Figure 4.5, must be considered.
R F Structure
Tho
Thi
Qin
Tmix
FR total
By-Pass
Proportional
Control
Valve
FR hx
Qout
Variable-Speed
Pump
∆P hs
Heat Exchanger Size
∆P cs
Tco
Facility Chilled
Water Outlet
FR cs
Facility Chilled
Water Inlet
Tci
Figure 4.5. Water skid flow loop and the variables that influence the heat exchanger size.
190
The block diagram in Figure 4.6, shows the steps necessary to identify the correct
heat exchangers for each closed loop system. This method is trial-and-error approach
that is time consuming and requires set parameters to reach a conclusion.
SELECTING A HEAT EXCHANGER
STEP 1
Determine all cases to study
STEP 2
Determine cold side pressure drop
STEP 3
Is cold side pressure loss less
than 10 PSI?
YES
NO
STEP 4
Select heat exchanger to study
Consult manufacturer's data sheets for particular cases and
create a relationship for overall heat transfer coefficient vs.
heat exchanger flow rate
STEP 5
Input relationship, heat load, and flow rates into
Sinda/Fluint model and plot results
STEP 6
Determine hot side pressure drop for each case
at Tmix = 14 deg. C.
STEP 7
Is the hot side pressure drop determine in STEP
6 less than 5 psi?
YES
NO
All preliminary requirements
met for specific case
Eliminate case
STEP 8
Select next heat exchanger to study
Figure 4.6. Block diagram showing heat exchanger sizing procedure.
191
For this study, a heat exchanger was sized for DTL tank 3. It is appropriate to
study tank 3 since it represents the "worst case" (highest waste heat to cooing water ratio
95 kW/ 240gpm) situation for cooling in the DTL. The results from the tank 3 study
were adapted to size all other heat exchangers employed in the DTL. The heat exchanger
sizing study is outlined in the following eight steps:
Step 1: Determine all case for sizing the heat exchanger.
Result: Table 4.2 displays all cases considered for sizing a heat exchanger for DTL tank
3. Note that the heat exchanger size is characterized by the number of plates.
Cold Side Outlet
Temperatures
Table 4.2. Cases considered for sizing the DTL tank 3 heat exchanger
< 30
<10
10
11
12
13
14
16
>16
30
<10
10
11
12
13
14
16
>16
40
<10
10
11
12
13
14
16
>16
Number of Plates
50
60
<10
<10
10
10
11
11
12
12
13
13
14
14
16
16
>16
>16
70
<10
10
11
12
13
14
16
>16
80
<10
10
11
12
13
14
16
>16
Step 2: Determine cold side pressure drop for each case.
Results: See Figure 4.7 for cold side pressure drop information. Figure 4.7 shows that
the pressure drop in all cases becomes too large after a cold side flow rate of
approximately 8.5 kg/s.
192
90
<10
10
11
12
13
14
16
>16
Heat Exchanger Cold Side Pressure Drop
80
70
Pressure Drop (psi)
60
30 plate
40 plate
50
50 plate
40
60 plate
70 plate
30
90 plate
20
10
0
2.5
3.5
4.5
5.5
6.5
7.5
8.5
Flow Rate (kg/s)
Figure 4.7. Pressure loss across cold side of heat exchanger vs. cold side flow rate for
each heat exchanger size.
Step 3: Eliminate cases by determining which cases do not meet the 10 psi pressure drop
restriction imposed on the cold side.
Result: Table 4.3
Cold Side Outlet
Temperatures
Table 4.3. Evaluation of cases based upon cold side pressure drop criteria.
< 30
<10
10
11
12
13
14
16
>16
30
<10
10
11
12
13
14
16
>16
40
<10
10
11
12
13
14
16
>16
Number of Plates
50
60
<10
<10
10
10
11
11
12
12
13
13
14
14
16
16
>16
>16
70
<10
10
11
12
13
14
16
>16
Cold Side Pressure Drop Criteria Not Met
Hot Side Pressure Drop Criteria Not Met
Both Hot and Cold Side Pressure Drop Criteria Not Met
All Criteria Met
Have Not Been Studied
193
80
<10
10
11
12
13
14
16
>16
90
<10
10
11
12
13
14
16
>16
Step 4: Select a specific heat exchanger to study
Result: Selected a 70 plate heat exchanger with cold side outlet temperatures of 11, 12,
13, and 14 deg. C and created relationships between the overall heat transfer coefficients
and hot side flow rates. Refer to Figure 4.8.
60000
Overall Heat Transfer Coefficient
50000
40000
30000
y = 6.8553x 5 - 180.99x4 + 1879.3x 3 - 9897.3x2 + 30073x + 2.1481
y = 6.9126x5 - 182.13x4 + 1883.7x3 - 9835.2x2 + 29164x + 2.2097
20000
y = 6.8738x 5 - 181.24x4 + 1872.7x 3 - 9728x 2 + 28324x + 2.1948
12
y = 6.9125x5 - 181.56x 4 + 1867.7x3 - 9635.7x 2 + 27602x + 2.2493
10000
14
11
13
0
0
1
2
3
4
5
6
7
8
9
Flow Rate (kg/s)
Figure 4.8. Plot of the heat transfer relationships for a 70 plate heat exchanger.
Step 5: Input relationships into Sinda/Fluint model and vary the amount of water sent to
the heat exchanger to determine Tmix.
Result: Figure 4.9.
194
70 Plate Heat Exchanger for DTL Tank 3
28
26
Tmix (deg. C)
24
22
12
20
14
18
11
13
16
14
12
10
0
1
2
3
4
5
6
Flow Rate (kg/s)
Figure 4.9. Tmix vs. hot side flow rate for various cold side outlet temperatures.
Step 6: Determine hot side pressure drop for each case at Tmix = 14 deg. C.
Results: See Figure 4.10 for hot side pressure drop information. Figure 4.10 shows that
the pressure drop in all cases become too large after a flow rate of approximately 5.75
kg/s.
Hot Side Heat Exchanger Pressure Drop Comparison
35
Pressure Drop (psi)
30
25
30 plt
60 plt
20
90 plt
40 plt
15
50 plt
70 plt
10
5
0
0
1
2
3
4
5
6
7
8
Flow Rate (Kg/s)
Figure 4.10. Hot side pressure loss vs. flow rate for various heat exchangers.
195
Step 7: Eliminate cases by determining which cases do not meet the 5 psi pressure drop
restriction imposed on the hot side. Use appropriate data inferences to further eliminate
or accept other cases (i.e. if a 70 plate at Tco =12 deg. C is acceptable, then so must a 90
plate at Tco =12deg. C)
Results: Table 4.4.
Cold Side Outlet
Temperatures
Table 4.4. Evaluation of cases based upon hot side pressure drop criteria.
< 30
<10
10
11
12
13
14
16
>16
30
<10
10
11
12
13
14
16
>16
40
<10
10
11
12
13
14
16
>16
Number of Plates
50
60
<10
<10
10
10
11
11
12
12
13
13
14
14
16
16
>16
>16
All Criteria Met
Step 8: Repeat steps 4 - 9 for a 90 plate heat exchanger.
Results: Table 4.5
196
70
<10
10
11
12
13
14
16
>16
80
<10
10
11
12
13
14
16
>16
90
<10
10
11
12
13
14
16
>16
Cold Side Outlet
Temperatures
Table 4.5. Final results of heat exchanger size elimination.
< 30
<10
10
11
12
13
14
16
>16
30
<10
10
11
12
13
14
16
>16
40
<10
10
11
12
13
14
16
>16
Number of Plates
50
60
<10
<10
10
10
11
11
12
12
13
13
14
14
16
16
>16
>16
70
<10
10
11
12
13
14
16
>16
80
<10
10
11
12
13
14
16
>16
All Criteria Met
Table 4.5 shows that a heat exchanger with 60 or more plates satisfies all criteria.
Note however that a 60 plate heat exchanger does not have very much flexibility.
Therefore, it is recommended that at least a 70 plate heat exchanger be employed for use
in cooling DTL tank 3.
Rather than continuing through the costly and time consuming selection process
for every DTL tank, a 70-plate heat exchanger was selected for use on all DTL tanks. A
quick check was performed on tank 1. For tank 1, both a 30 and 90 plate heat exchanger
were modeled with the same cold side flow rates to determine the effect that an oversized
heat exchanger had on temperature. Figure 4.11 displays the results.
197
90
<10
10
11
12
13
14
16
>16
Tank 1 Heat Exchanger Comparison
30
t =12 90plt
Tmix (deg. C)
28
t =14 90 plt
26
t = 12 30plt
24
t = 14 30plt
22
20
18
16
14
12
10
0
1
2
3
4
5
Hot Side Flow Rate (kg/s)
Figure 4.11. Tank 1 heat exchanger comparison.
Figure 4.11 shows that there is not a significant difference between the curves.
Therefore, all DTL tanks may employ the same heat exchanger as that used on tank 3.
The heat exchanger sizes required for the DTL water cooling systems are
summarized in Section 4.5.4 of this report.
As a final note on the heate exchanger design, fouling of the heat exchanger
surfaces is of significant concern due to losses in heat transfer efficiency. In the case of
the linac water cooling systems, the hot side of the water skid’s heat exchanger is kept
clean of any potential deposits by the use of filters and a high quality water purification
system. However, this is not the case for the cold side flow from the facility supply.
Therefore, there is some concern about the effects of fouling on the cold side of the heat
exchangers.
a) Definition-The definition of heat exchanger fouling is deposition of an insulating
material on the heat transfer surfaces. These deposits can be biological, precipitation
of dissolved substance, accumulation of finely divided and suspended solids, and
chemical reactions [4.12]. Corrosion is also another form of fouling that can occur.
These types of fouling can occur separately or simultaneously.
198
b) Effect-The effect of insulated deposits on the heat exchanger surfaces is to reduce the
heat transfer and increase the pressure drop through the heat exchanger. Heat transfer
is impeded due to an added layer of material that must conduct the heat. Fouling
reduces the overall heat transfer coefficient by adding an insulating deposit that
increases the thermal resistance. If the flow area is significantly reduced and the
surface is roughened due to fouling deposits, this can cause the pressure drop to
increase. However, the velocity increases due to the reduced flow area and its effect
increase is directly proportional to velocity squared.
c) Fouling Factors-Fouling factors are multipliers of thermal resistance and as they
increase the thermal resistance increases. The authors of reference 1 present a table
that shows that fouling factors can range from 0.000088 m 2K/W to 0.0005 m 2K/W for
river water. Cooling tower treated makeup ranges from 0.000176 m2K/W for treated
makeup to 0.000528 m2K/W for untreated makeup. City or well water can range
from 0.000176 m2K/W to 0.000352 m2K/W depending on the velocity. Reference
[4.12] shows that a heat exchanger in a fouled condition can increase the pressure
drop by 70%.
d) Flat Plate Heat Exchangers-Extraction of heat deposited in the cooling water by the
CCL and DTL structures will be removed by flat plate heat exchangers. The cold
side supply will be chilled water at 7.2°C and may have outlet cold side temperatures
that range from 10°C to 17°C. Reference [4.12] discusses the performance of flat
plate heat exchangers and points out that these types of heat exchangers are used in
processing of foodstuffs where frequent cleaning is required. The corrugated and
torturous path leads to high heat transfer coefficients. The turbulence reduces the
potential for fouling of the heat transfer surfaces. Fig. 4.12 shows the data presented
by Cooper et al on a flat plate heat exchanger using cooling tower water [4.13]. This
data shows the relationship of fouling resistance as a function of velocity and
temperature. The point where the cold side water flow for the linac structures are
likely to be located is also shown on Fig 4.12. The temperature for the heat
exchangers is expected to be approximately 284 K and the velocity to be
approximately 0.26 m/s. This shows that the fouling resistance will be much less than
0.0001 for the temperature and velocity in the RF structure cooling loops. Therefore,
it can be concluded that heat exchanger cold side fouling is not likely to be a problem.
However, if it does become a problem a provision is included to flush the heat
exchanger with an acid solution.
199
Fouling in a plate heat exchanger
0.0005
Asymptotic Fouling Resistance (m2K/W)
334 K
midpoint surface temperature
0.0004
328 K
cooling tower water
0.0003
Ref: Cooper,Suitor, and Usher,
CoolingWater Fouling in
Flat Plate Heat Exchangers,
Heat Transfer Eng., Vol 1, No 3, 1980
0.0002
321 K
0.0001
0
0.15
CCL HX Data (284 K, V=0.26 m/s)
0.2
0.25
0.3
0.35
0.4
0.45
0.5
0.55
Velocity (m/s)
Figure 4.12. Effect of water velocity on fouling factor.
4.5.3.5 Control Valves
Two control valves are required for the water system. On the warm side of the
heat exchanger will be a 3-way electronically actuated valve. This is the primary control
valve that divides the water flow between the hot side of the heat exchanger and the bypass line. On the cold side of the heat exchanger will be a 2-way electronically actuated
valve. This valve will help maintain a desired chilled water flow rate through the cold
side of the heat exchanger. Both control valves shall meet applicable ANSI and ISA
requirements.
The primary control valve will be a 3-way diverging valve located at the heat
exchanger-to-heat exchanger bypass intersection. The valve will provide true linear
proportioning and a smooth gradual flow reduction when flow adjusting. The valve will
have stable transitioning when switching ports to prevent valve slamming and pipeline
water hammer. All wetted surfaces will be 316 stainless steel and packing/sealing made
from Teflon or Viton. Teflon is not recommended for a radiation environment however
200
the water skid, located in the Klystron Gallery, is well away from the potential damaging
radiation found in the Linac Tunnel. Additionally, this is a static seal, which will prevent
any significant wear. The valve will require a 100% duty cycle. The valve shall have at
least 200 incremental steps in it setting position to allow for sufficient flow control
resolution. The valve will have sufficient actuation speed so as to move across its full
range of motion in less than 60 seconds.
A 2-way electronically actuated flow control valve will be required prior to the
entrance on the cold side of the heat exchanger. This is facility-chilled water and is not
deionized.
This valve does not require 316 stainless steel, Teflon or Viton as
construction or housing materials. However, it is required to be compatible with the
tubing material and must be highly sturdy and reliable. The valve will require a 75%
duty cycle. The valve shall have at least 200 incremental steps in it setting position to
allow for sufficient flow control resolution. The valve will have sufficient actuation
speed so as to move across its full range of motion in less than 60 seconds.
The valves will be electronically actuated and will provide a position feedback
signal. Each will operate with a two-wire, 4 to 20 mA signal for both the input command
and the position feedback signals. The available input power will be 24 Vdc. Position
accuracy will be ± 1% of full actuator travel for the 3-way valve and ± 5% of full actuator
travel for the 2-way valve. The actuator housing for each valve will be NEMA type 4
requirements.
4.5.3.6 Heater
The inline water heater has been sized accoriding to the following analysis. The
primary use of the heater will be to heat the water and RF structures/magnets when RF
heating is not available. For example, during the alignment phase of the linac, the
structure will need to be at its mean operating tempertature, which is several degrees
Centigrade above room temperature. By heating the cooling water, the RF structure can
be brought up to temperature, and the alignment technicians can still have access to the
linac tunnel (which is not the case if high levels of RF energy are present).
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The heater sizing was based on the following calculation. Assuming that a typical
water loop contains about 300 gallons of water, and that the water needs to be heated 5°C
in less than one hour, determine the size of the water heater to accomplish this task.
q = mCp (∆T/dt) where q = 20 kW, m = 300 gallons, ∆T = 5°C
20,000 W = 300 gal/264.2 gal/m3 x 1 m3 x 1000 kg/m3 x 4180 m3/kg x 5 °C/dt
solving for dt
dt = 1185 seconds < 20 minutes for a 20 kW inline heater
dt = 1972 seconds < 33 minutes for a 12 kW inline heater
Based on actual usage, cost, size, and a reasonable time required for heating the
water, an inline between 12 kW and 20 kW will be sufficient.
As a final note, the desired water connection ports on the heater unit, will be
flanged for ease of removal. The ports shall be a minimum of 1” diameter and optimally
3” in diameter to reduce pressure drop.
4.5.3.7 Water Purification System
The Water Purification/Filtration System will be hard mounted directly to the
water skid structural frame. It will contain filters, mixed bed canisters, carbon bed
canisters, a flow meter, and will provide water purity status to the PLC. The purification
system will draw off a small portion (1-5%) of the water from the primary flow path,
treat and clean the water, and return this newly purified water back to the primary flow
loop. This purification loop functions within the overall closed loop system. For more
detail regarding the water purification system, refer to Section 5 of this report.
4.5.4 System Performance
The water cooling system performances are basedd on the cooling requirements
and thermal/fluid modeling as described in Sections 1 and 3 of this report. The critical
components in the water cooling systems are the heat exchanger and pump. Sections
4.5.3.3 and 4.5.3.4 describe the detailed process in selecting the pumps and heat
exchangers, respectively. In particular, the heat exchanger has many intricacies that
required detailed examination as well as many performance variables. Under steady state
conditions, the heat exchanger will have a performance range, controlled by the 3-way
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electronically actuated bypass control valve, that readily covers the temperature
performance requirements as specified in the associated SNS Linac Water Cooling and
Resonance Control Systems Description Document [1.2]. Based on steady state analysis,
the estimated number of different water skids, based on pump and heat exchanger sizes,
is three (See Table 4.6 below). Pump size estimates were made using a 25% extra
capacity in the pump pressure, over that predicted in the analyses of Section 3 of this
report. The increased pressure drop capacity will account for any uncertainties that may
exist in the SINDA/FLUINT modeling, future increase in the temperature range of
operation, and allow for increased potential cooling capabilities.
Table 4.6. Summary of heat exchanger and pump sizes for the DTL, CCL, and SCL
water cooling systems.
SKID
FLAT PLATE
HEAT EXCHANGER
FLOW 125% OF DELTA P
(GPM) (PSI) HEAD (Feet)
ESTIMATED PUMP
MOTOR (Hp) IMPELLER
DTL-1
FP10X20-70(2"MPT)
120.4
45.0
104.0
6
6.0
EFFICIENCY
%
3 x 1.5 x 6
70%
DTL-2
DTL-3
DTL-4
DTL-5
DTL-6
CCL-1
CCL-2
CCL-3
CCL-4
CCL-MAG
SCL-MAG
FP10X20-70(2"MPT)
FP10X20-70(2"MPT)
FP10X20-70(2"MPT)
FP10X20-70(2"MPT)
FP10X20-70(2"MPT)
FP10X20-90(2-1/2"MPT)
FP10X20-90(2-1/2"MPT)
FP10X20-90(2-1/2"MPT)
FP10X20-90(2-1/2"MPT)
FP10X20-70(2"MPT)
FP10X20-70(1-1/2"MPT)
162.4
235.9
215.6
199.5
183.7
218.9
257.0
257.0
257.0
59.5
70.4
50.6
66.3
59.4
56.3
53.8
40.0
49.3
49.3
49.3
46.3
56.3
117.0
153.0
137.0
130.0
124.0
92.0
114.0
114.0
114.0
107.0
130.0
20
20
20
20
20
12
12
12
12
6
6
7.0
7.0
7.0
7.0
7.0
6.3
6.3
6.3
6.3
6.0
6.0
3x2x6
3x2x8
3x2x8
3x2x8
3x2x8
3x2x6
3x2x6
3x2x6
3x2x6
3 x 1.5 x 6
3 x 1.5 x 6
SIZE
53%
60%
58%
55%
56%
74%
73%
73%
73%
60%
61%
In addition to the cooling water temperature and flow rate ranges supplied by the
selected heat exchangers and pumps, cooling performance and capacity can be influenced
significantly with the use of the inline water heater, and the two control valves located on
either side of the heat exchanger. Three off-normal operational conditions, which would
take advantage of the flexibility in the water cooling system, are the follwing:
RF power off, increase structure temperature
1] Turn power on for the inline heater.
2] Close manual inline heater bypass valve.
3] Adjust 3-way control valve to bypass 100% of flow to the heat exchanger.
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UNIQUE
SKID
A
B
B
B
B
B
C
C
C
C
A
A
RF power on, increase cooling to structure beyond system design temperature
1] Adjust 3-way control valve to increase flow to the heat exchanger.
2] Verify 2-way control valve on heat exchanger cold side is fully open.
3] Increase variable speed motor on pump.
RF power on, increase warming to structure beyond system design temperature
1] Adjust 3-way control valve to bypass 100% of flow to the heat exchanger.
2] Turn power on for the inline heater.
3] Close manual inline heater bypass valve.
The previously described scenarios are examples of how easily this system can be
adjusted to meet a variety of conditions. The system design was created with great
flexibility. As a final note, the number of unique water skids, based on heat exchanger
and pump size, is three. These skids are identified in the last column in the Table 4.6.
The SNS program will benefit by a reduction of required spare components with only
three unique skids.
4.6 Parts Database and Naming Convention
The DTL and CCL water system parts data bases were created to keep track of the
multitude of cooling system components, and serve as a library of information for the
entire design team.
The parts databases were developed from the P&ID’s and
continuously updated to reflect the present design.
These databases serve several
functions; as a documentation source for the hardware sizes determined from the
Sinda/Fluint numerical modeling, defining components (manufacturer/model number)
and their device names, providing a data base for component purchasing, and device
listing to facilitate PLC and global programming for the sub-systems controls. Device
names for the data base were selected using the SNS Device and Signal Naming
Convention and form the bases for overall system software development by identifying
names from actual device through user interface screens.
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The naming convention is mainly oriented to facility operations and has been
developed for the purpose of naming signals which come into the SNS integrated control
system which are then manipulated, displayed, archived, etc. Because signals are always
associated with equipment or devices, the signal names include the names of devices with
which they are associated. This syntax can also be used to name SNS equipment that
does not have associated signals in which the signal part of the name is simply omitted.
The general format of the SNS Device and Signal Naming Convention has the
form:
SystemPart:DevicePart:SignalPart
The three parts together constitute the complete signal name. The SystemPart is
made up of a System Name and optional Subsystem Name. The DevicePart is made up
of the Device Name and the System/System Name. The SignalPart is made up of the
System Name, Device Name and the Signal. Therefore:
System Name=System/SubSystem, Device Name=System/SubSystem+Device, Signal
Name=System/SubSystem+Device+Signal
Example using the first CCL RCCS water cart:
CCL_RCCS1:TT1:T
CCL is the system- RCCS1 is the subsystem; 1 indicating #1 RCCS system- TT1 is a
temperature transmitter of the water cart- T is the signal; temperature
What is shown is the basic organizational scheme using the P&ID and associated
spreadsheet database lists for the various systems. Since all the water carts are the same
in component count, the System and Subsystem denotes which system is referenced at the
control center or in the field during maintenance or trouble shooting periods.
Signal names were left off the excel database at this time but will be incorporated
after the control system is developed, then integrated into the data base. The controls
group will be developing a signal list for the many different signals types and provide the
appropriate signals for the excel database. The final excel data base will be incorporated
205
into the project configuration database using Oracle and will allow devices and signals to
be located throughout the linac.
The DTL parts database is contained in Appendix E.
206
5.0 Water System Purity
5.1 Introduction
Pure water is a necessary commodity demanded by nearly all of the World’s
industries. It is required to produce items that are bought and used everyday by millions
of people. Items such as intravenous injections by the medical industry, hardware by the
computer industry, and even usable energy by the power generation industry, are all
produced using pure, contaminant free water of different grades.
Although many
industrial processes require water that is pure and contaminant free, the level of purity
and the type and quantity of contaminants present in the water can vary greatly. This
implies that the pure water standards of one industry may not meet the pure water
standards of another.
Factors determining water purity for a particular application
include permissible impurities, corrosion or erosion of wetted materials susceptibility,
water availability, quantity, cost, etc. Each industry must define, implement and maintain
a specific level of water purity to ensure both product quality and efficiency at a
reasonable cost. Typical parameters used to measure or quantify water purity include pH,
electrical conductivity, total suspended and dissolved solids, dissolved oxygen content,
and radioactivity. Parameters of a specified value can be achieved by employing various
purification techniques and equipment. Common techniques such as microfiltration,
ultrafiltration, reverse osmosis, carbon adsorption, deoxygenation, ultraviolet radiation,
and ion exchange can be employed to purify water. Figure 5.1 illustrates a typical water
treatment system. Many of these technologies will be used to produce contaminant free
water for use in the SNS Linac cooling systems.
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Mixed Bed
Deionization
Reverse
Osmosis
Pretreatment
Pump
Raw
Water
Activated
Carbon
UV
Storage
Drain
Polishing Loop
Ultrafiltration
Drain
Microfiltration
Figure 5.1. Generic water treatment system (courtesy of Cartwright [5.3]).
5.2 Water Purification Techniques
This section describes several different water purification techniques commonly used
in industry.
Microfiltration
Microfiltration is a purification process employed to remove contaminant materials
from water including suspended solids, bacteria, colloids, etc., which are typically larger
than 0.02 microns. The microfiltration process can occur in the polishing loop (see
Figure 5.1) using either a dead end or cross flow filtration process. In the dead end
filtration process, contaminant particles too large to pass through the filter are trapped.
Heavy filter contaminant buildup will eventually occur and the filter will need to be
replaced. Unlike the dead end filtration process, the cross flow filtration process utilizes
a tangential water flow scheme to continuously “wash out” contaminants from the water
system. Due to the continual loss of water, cross flow filtration should not be employed
in completely closed water systems. Figure 5.2 illustrates both microfiltration processes.
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Filtered Water
Filtered Water
Key
Filters
Contaminants
Water Flow
a) Dead end
b) Cross Flow
Figure 5.2. Microfiltration processes.
Ultrafiltration
Ultrafiltration is a process, which utilizes membranes to remove non-ionic
contaminant particles ranging roughly from .002 to .02 microns in size. Ultrafiltration is
most effectively used for the removal of microorganisms, high molecular weight
contaminants, and colloidal material [5.3]. The ultrafiltration process requires a crossflow filtration scheme (similar to what may be used in microfiltration Figure 5.2(b) to
continually remove contaminants from the system. Ultrafiltration usually occurs in the
polishing loop of the water system as seen in Figure 5.1.
Reverse Osmosis
Reverse osmosis (RO) employs the properties of semi-permeable membranes to
purify water. Only selective materials, such as water and water-similar molecules (based
on size and molecular weight), may transcend the membrane. Typically, reverse osmosis
systems can remove 90 to 98 % of ionic contaminant [5.3]. The reverse osmosis process
usually occurs in the pre-treatment portion of the purification system. While effective,
due to its requirements for an additional pump and drain an RO system will not be
employed in the hot model purification loop.
Carbon Adsorption
Another commonly used process in water purification is carbon adsorption. Carbon
adsorption utilizes activated carbon (usually in powder or granular form) to remove high
molecular weight organic contaminants from water systems.
Another attractive
characteristic of this technology is the ability to remove chlorine and traces of certain
209
heavy metals from the water system. Since chlorine is harmful to most membranes used
in reverse osmosis, carbon adsorption is usually one of the initial purification processes.
Ultraviolet Radiation
Ultraviolet radiation exposure is another technology often used to reduce the number
of microorganisms present in water systems.
By taking advantage of the fact that
microorganisms, such as bacteria, have little or no resistance to intense ultraviolet
radiation, a simple, low-tech process can be employed to inhibit the propagation of
microorganisms.
Deoxygenation
Deoxygenation is a process of removing excess amounts of dissolved oxygen from
water.
In removing oxygen from the water system, both the corrosion and the
microorganism growth rates are decreased significantly [5.4]. Several methods exist for
removing oxygen gas from liquid. One deoxygenation method utilizes resins that act as
scavengers to remove oxygen from water. Another method employs a hydrophobic
microporous membrane. A fluid passes over the membrane a vacuum on the other side of
the membrane pulls the gas out of solution. Critics claim that the removal of excess
dissolved oxygen from water systems will have much better results in reducing biological
growth than ultraviolet radiation [5.4].
Ion exchange
Ion exchange is a purification process that employs special resins to remove
positively and negatively charged ions from solution. Resins are synthetic materials
composed of small beads and can be of either the cation or anion type. In a water
purification system, cation resins exchange hydrogen ions for unwanted cations, while
anion resins exchange hydroxyl ions for unwanted anions. Cation and anion resins can
be used individually or can be combined in a mixed bed system to purify water.
Typically, high water quality (resistivity of 18 MOhm-cm) can be achieved when an ion
exchange system is employed.
Ion exchange is an economical water purification
technology since resins can be repeatedly regenerated after they have become fouled.
210
Figure 5.3 compares the various purification technologies.
Contaminants
Retained
Colloids
Particles
Organics Salts
Distillation
Deionization
Ultrafiltration
Contaminants
Passed Through
Bacteria
Reverse Osmosis
Figure 5.3. Comparative purification technologies ( Courtesy of Cartwright [5.5]).
5.3 Particle Accelerator Specific Issues
A water purification system will be responsible for maintaining high quality cooling
water for the SNS linac. Water treatment is a necessary process for retaining high and
consistent system efficiency.
The formation of deposits, scale, biological growths,
corrosion and activation can be of significant threat to the performance of the SNS linac
water cooling system.
Corrosion
Corrosion must be limited in the SNS Linac water cooling system to maintain cooling
efficiency and minimize damage to accelerator comonents. Corrosion is the dissolution
of a solid in a fluid (in this case, metal in water). Corrosion in the cooling passages
promotes material build-up, thus reducing the heat transfer rate. One form of corrosion,
oxidation, occurs when dissolved oxygen in the water reacts with metal flow-passage
walls. Galvanic corrosion occurs when two or more dissimilar metals come in contact. It
211
may be reduced by several techniques. Minimizing dissolved oxygen and dissolved salts
in the water, employing compatible building materials, and providing a galvanic
insulation between dissimilar metals can significantly reduce the amount of corrosion. At
any rate, corrosion can cause a number of problems to occur within the SNS linac cooling
system, including flow rate restrictions, increased head loss, reduced heat transfer, pitting
and leakage.
Scaling
Scaling is the formation of deposits, including calcium and silica salts, on metal
surfaces. The formation of scale on pipe walls occurs as a result of large temperature
changes. Large temperature changes affect solubility, minerals and salts precipitate out
of solution and eventually build up on exposed metal surfaces.
Scaling can cause
problems in water systems by reducing flow rates and heat transfer rates. In the case of
the SNS linac cooling system, large temperature variations are not expected.
Consequently, scaling should not be a major concern in the SNS Linac water cooling
system.
Biological growth
Biological growth in water systems is very common. A water system is an ideal place
for microorganisms to grow and reproduce. If large amounts of microorganisms are
present in a water system, problems such as increased corrosion, water leaks, head loss,
and a reduction in heat transfer are likely. It is very important that biological growths
within the SNS cooling system remain at a minimal level. This can be accomplished by
reducing the dissolved oxygen content in the water to a level, at which microorganisms
cannot survive, or by passing the water through an ultraviolet light source [5.4]. Pipe
design also plays a roll in reducing bacterial growth. Piping will be designed as to
eliminate stagnation areas, or dead-legs, which are areas that have little or no flow. The
lack of motion or kinetic energy in the fluid provides a breeding ground for bacteria, both
due to the lack of fluid motion as well as a place to trap dissolved oxygen. Eliminating
dead-legs makes it much more difficult for bacteria to thrive. This will be done by
designing the piping such that there is flow into each run whenever possible. Carbon
212
based populations can be measured by taking water samples, and are counted as Total
Organic Carbon (TOC) represented as mg/L and Heterotroph Plate Counts (HPC)
represented as (Colony Forming Units) CFU/L.
Activation
During operation of the SNS accelerator, scattering of the proton beam may allow the
cooling water to be subjected to direct spallation and activation. Be-7 is a radionuclide
produced through the direct spallation of oxygen and is largely responsible for the
activity in the cooling water. In addition, spallation neutrons activate corrosion products
present in the water and in turn generate long-lived radionuclides including Co-60, Zn65, and Mn-54 [5.6]. Radioactivity in the cooling system is of concern due to the
potential for contamination of hardware and personnel.
Safe accelerator operation
demands that the quantity of activated water, caused primarily by Be-7, be minimized.
Deionization has proven to be a very effective process for the removal of Be-7 [5.6] from
accelerator cooling water. Entrapment of radionuclides in the resins used in a Linac
cooling system cannot be regenerated. Instead, they must be removed from the cooling
water system and replaced. The old resins will need to be dried and properly disposed as
low-level radioactive waste, unless surveys deem otherwise. Radiation levels are not
expected to be high in the purification system and therefore shielding will not be
required.
5.4 Operating Parameter Specifications
Features from current water treatment systems on particle accelerators were
considered for use in the SNS cooling water system. These included the Los Alamos
Neutron Science Center (LANSCE), the Accelerator Production of Tritium (APT), and
the Advanced Photon Source (APS).
The Linac water-cooling purification system was designed with the intent of
minimizing erosion, corrosion, scaling, biological growth, and hardware activation. Each
component was selected to target the removal of a specific impurity, and in some cases,
multiple impurities.
213
The basic mechanical design of the cooling loop has helped to minimize erosion and
scaling. Water flows in the cooling systems will be kept below 2.5 m/s on surface
impingement areas such as tees and elbows, and less than 5 m/s in straight sections to
reduce the effects of erosion. The narrow temperature band of the cooling water, 10 to
25ºC, reduces scaling.
Other critical parameters, which have been defined and will be controlled, include
electrical resistivity, pressure, pH, and dissolved O2 content. Typically an electrical
resistivity value above 6 MO drastically reduces scaling [5.9]. However, it is important
to keep the resistivity below 15 MO, particularly in copper structures and piping. Due to
the polar nature of ultrapure water, a very high resistivity tends to strip away ions from
the metal surface of piping, particularly copper when dissolved oxygen is present [5.10].
Maintaining the resistivity below 15 MO minimizes this effect. Analog pressure gauges
will be used to not only indicate system pressure, but also to indicate filter-loading
information for filter replacement. Approximately 1-5% of the main water flow will be
diverted to the water purification loop, the quantity being monitored with a flow meter.
The flow in this loop requires an oxygen content of less than 20 ppb to minimize
corrosion [5.1].
When copper is exposed, the corrosion is embodied as insoluble
particles of CuO and Cu2O, which amass in the system after removal from the parent
surface. Filtration is helpful in reducing this effect, however minimizing oxygen in the
system proves more effective [5.1].
Table 5.1 summarizes the water quality to be obtained from the water purification
system.
Table 5.1. Water purification parameters.
Parameter
Recommended Value
Flow rate
(through purification tanks)
pH
Electrical Resistivity
Dissolved Oxygen Content
Particulate size
Ref.
1-5 % of total flow
[5.7]
8±1
10-15 MO
< 20 ppb
= 1 micron
[5.2]
[5.10], [5.11]
[5.3]
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5.5 Water Purification System Design
The water purification system design is shown in Figure 5.4. It was designed to meet
the water purification specifications for the SNS linac system. Considerations included
minimizing the adverse effects of scaling, flow blockage, biological growth, activation,
and other forms of contamination, much of which is covered in section 5.2. Component
selection was made carefully to develop a lower maintenance passive system. Reverse
Osmosis was discarded for this application. While very useful and effective at removing
a variety of contaminants, it is a higher maintenance item with more moving parts than
other components. A 1-5% portion of the flow will be diverted from the main loop into
the purification or polishing loop.
A 5-micron pre-filter sieves out the largest
contaminants. Following the filter, the water will pass through an oxygen scavenger
resin canister, similar to the system used in the APS Linac Water Cooling System [5.1].
The carbon canisters remove hydrocarbon contaminants, including residual petroleum
products remaining in the piping from manufacturing processes. After passing through
the carbon adsorption canisters, the water then passes through the deionization canisters.
Here any free ions remaining in the system are removed, which left untreated could
contribute to scaling. Next, an ultraviolet light source is used to kill surviving bacteria,
which are then filtered out by a 1-micron filter. At this point in the system, the water is
quite pure. The pure or polished water will then be returned to the main loop. The
ultraviolet light source may be redundant.
It is believed that the oxygen removal
mechanism will be able to deprive oxygen supply to effectively eliminate organic growth.
At the time of this writing, the CCL hot model water cooling system is being used to
study this very issue.
5-µm
Filter
UV
Deionization
Carbon
Oxygen
Removal
Filter
Main flow
1-µm
Figure 5.4. Process flow through the water purification hardware for the DTL/CCL water
cooling systems.
215
The piping material will consist of stainless steel, which serves as an effective
barrier between the atmosphere and the cooling water, minimizing O2 permeation. Due to
the corrosive nature of deionized water, brass and carbon steel components are not
acceptable. Flexible tubing will be used as jumper or transfer lines to avoid the need for
high tolerances in the water line designs and to serve as vibration isolators. Several
flexible tube options were explored.
Material selection was based on DI water
compatibility, low oxygen permeation rates, and resistance to radiation environments. A
comparison of various flexible tubing materials based on these parameters, is presented in
Appendix H. Many materials examined were found to meet one or two of our needs, but
only a few were found to meet all three. Those that met all three of our requirements
include Viton®, Nylon®, Hypalon®, and Buna,. Tubing manufactured from the first two
materials, may not possess a suitable pressure rating. A review of the various materials
found that neoprene does possess adequate radiation tolerance and provide adequate
pressure ratings, however, it does not provide an adequate barrier to O2 permeation.
Consequently, it may be advantageous to consider using a multi-ply hose or tubing with
Viton®, Nylon®, or Hypalon® as the wetted surface, with a neoprene sheath since the
neoprene sheath can provide the needed pressure rating and radiation resistance. Multiply hose and tubing of this type may be obtained from sources such as Goodyear, under
various trade names, as well as Boston Nyall and Thermoid/HBD Industries.
Various types of instrumentation will be used to monitor and record the
performance of the water purification system.
Instrumentation will be provided to
measure electrical resistivity, pressure, flow rate, pH, and dissolved O2 content.
Measuring each of these parameters will give feedback concerning the overall quality of
the water as well as alerting operators to component failure.
Much of the water quality data can be obtained from the instruments incorporated
within the system. However, parameters that cannot be easily monitored with sensors or
their capital costs make them prohibitive include particulate, bacteria, Total Organic
Carbon (TOC), heterotroph plate counts (HPC) and trace elements. Particulate sampling
will verify the filters are removing the desired particulate size. TOC and HPC testing
will indicate bacterial and carbon based populations. Testing for trace elements such as
216
iron, copper, and zinc, elements used in the piping system will indicate negative effects
of the DI water on the piping system. A water sample should be taken after initial startup, after water has circulated through the purification loop. Samples should also be taken
periodically and after major water system hardware configuration changes.
A draft procurement specification has been produced for the water purification
systems (see Appendix J). This procurement specification will be incorporated with the
over-all procurement document for the water skids.
5.6 Prototype Design and Testing
Prototype Design
To test the performance of various water purification techniques and hardware, and
thus optimize the design of the water purification system for the SNS linac, a prototype
water-pumping skid with the water purification system features shown previously in
Figure 5.4, has been developed for the CCL Hot Model. In regards to water quality,
experimental data was taken to optimize the performance and minimize the cost of the
purification system. The prototype purification system has been sized for a closed-loop
application utilizing ¾” piping for flow rates up to 3 gpm and is comprised of the
following components:
• A mixed-bed canister and a cation canister provide deionization for the cooling water.
The mixed bed canister contains resins for removing both cations and anions. As
mentioned earlier the SNS accelerator will require a Be-7 removal mechanism. A
cation resin, Amberlite® IR-120 in H+ form, which has been proven effective at
removing the Be-7 nuclide, was used [5.7]. Although Be-7 was not generated in the
hot model experiment, the Amberlite® IR-120 was incorporated into the hot model to
observe its performance as a cation resin.
• Two carbon canisters eliminated dissolved organics, such as soldering fluxes or
machining oil, and decrease biological growth build-up.
• An ultraviolet light source was provided to kill bacteria.
• A 5-µm filter upstream of the purification loop was used to remove large particulates
before they enter the purification loop. A 1-µm filter removed smaller particulate
217
matter, some large bacteria, and any resin material, which may have entered the loop
from the canisters.
• Two Liqui-Cel® contactors were required to achieve the dissolved oxygen content
requirement in the cooling water. The contactors, which are comprised of a large
number of very fine mesh polypropylene cross flow filters, allow only gases to pass
through. A small vacuum pump was used to pull dissolved gases out of the cooling
water along with a nitrogen sweep gas. The basic removal mechanism is shown in
Fig. 5.5. The Liqui-Cel® unit removed dissolved oxygen in the cooling water,
minimizing corrosive effects, and limiting bacterial growth.
• Nylon3® hoses with PVC reinforcement were used to connect the canisters where
flexible lines are needed. Nylon® derivatives are compatible with DI water and
minimize the diffusion of O2 from the outside environment [5.8]. Short runs of
Teflon® and polyethylene tubing were used on data acquisition insturmentation
sampling ports.
• Data acquisition hardware was an integral part of the purification loop on the hot
model.
Resistivity monitors, a pH meter, and a dissolved oxygen analyzer,
Orbisphere 3660, measured dissolved oxygen content in the system. Sensor model
#2952A, was selected in conjunction with the analyzer, which would also be a good
choice for the facility due to its maximum dose limit of 108 rad.
218
Figure 5.5. Gas removal mechanism in the Liqui-Cel® contactor [5.8]
The prototype CCL Hot Model water-pumping skid, which includes the purification
system can be seen in Figure 5.6.
219
Figure 5.6. CCL hot model water-pumping skid with water purification hardware in the
forefront.
220
Approximate hardware cost figures for the CCL Hot Model water purification
system is presented in Table 5.2.
Table 5.2. Water purification hardware costs.
System Component
Manufacturer
Water purification unit
CLW Systems Inc.
Cost
$9,200
Degassifier
Liqui-Cel® by Celgard
$3,000
Dissolved O2 monitor
Orbisphere 3660
$6,600
PH monitor
Omega
Water testing
Assaigai Analytical Laboratories
$550
$1,500
Prototype Testing
This section outlines the procedures used to operate and test the water purification
system on the SNS CCL Hot Model experiment.
The focus of this effort was to
manipulate various configurations of the water purification system to obtain the desired
purity while minimizing required hardware and costs in the facility design. All tests
began by using ultrapure electronics grade water that was transported from a clean room
water purification system. The order and purposes of the 7 tests (A through G) are
summarized in Table 5.3. As mentioned above, the first goal as to see if in fact the
system could obtain and maintain the purity specifications listed in Table 5.1, with
various configuration changes. The final test, which still needs to be performed, will
demonstrate how the purification system performs when tap water is used to charge the
water cooling system. If this latter test is successful, it will preclude the need for high
purity water being trucked to the SNS site, and possibly allow the use of on-site
municipal supplies.
Another goal is to verify that the purification system is providing adequate water
quality for the testing of the copper CCL accelerating structures. Each test recorded the
parameters specified in Table 5.1, namely pH, electrical resistivity, and dissolved oxygen.
221
Evidence of corrosion and bacterial growth in the system was investigated through
laboratory testing of water samples.
Table 5.4. Water purification test summary.
Test
Test Description
A
Initial water quality check after system was fully operational
B
Test A was rerun to verify the results were repeatable
C
Flow rate increased to 3 gpm to see if the DO concentration could be reduced
D
Flow rate further increased to 3.5 gpm, looking for DO concentration reduction
With the UV system off, the system was run and water samples were collected to
see how the lack of a UV system impacted the bacterial growth
Observe the effect on the carbon and bacterial growth counts when the UV and
one carbon bed is removed from the system
System water will be replaced with tap water and data will be compared with
previous samples.
E
F
G
Initial Start-Up and Water Quality Verification Testing
This section outlines the initial start-up and regular testing of the water
purification system. Tests A and B are included as part of the initial quality verification.
This procedure was followed the first time the system was brought on-line, and should be
used if the system has been inactive (water is not circulating through the system) for a
long period of time, typically more than a couple of months. Additionally the system
should be inspected for bacterial growth, as well as all sensors should be examined and
cleaned or replaced as necessary.
1)
A cursory check was made for loose wiring, including power and data
acquisition lines, and any evidence of leaks, or loose fittings. The CLW
system was pressure tested at the factory.
2)
Extra care should be taken if the system has not been circulated for a long
period of time or lines have been broken due to the addition of components
222
or soldering operations. Turn off valves to isolate the purification system
from the rest of the loop. Run water through the rest of the system to flush
out any large particles, fluxes, metal fragments from machining operations
etc. Volume will be determined by the appearance of the water. If the
system has been dormant for less than a couple of months, skip steps 2-4.
3)
Switch position of the valves to direct water into the purification system.
4)
Water was added to fill the system, and use air bleeds as necessary to get as
much gas out of the system as possible. Reducing the air in the system
reduces the amount of oxygen trapped in the piping, reducing bacterial
growth. Then the system is back-filled with nitrogen to purge the system of
any remaining oxygen not in solution.
5)
The power was switched on to the purification system as well as all monitors,
pH, resistivity and O2 concentration.
6)
Initially the time as well as all pressures from the pressure gauges, in
particular those that indicate the pressures across the filters were recorded.
Also the readings from the pH, resistivity and O2 monitors were noted. This
process was automated with the advent of LabView software to record all
needed data.
7)
Measurements were taken every 15 minutes initially, until measurements
appeared to stabilize or the trend began to slow.
223
System Performance Testing
After the initial start-up was been completed, various water purification hardware
configurations were tested, these included Tests C, D, and E. Tests F and G were not
completed at the time of this writing. It is suspected that water purification parameters
can be met without the UV source and possibly one carbon canister. In addition to
instrumentation monitoring, several water samples were taken and sent out for complete
chemical analysis. All data should indicate that the water quality is within acceptable
parameters prior to proceeding with another test.
Tests A and B (repeatability) were performed to observe the ability of the water
purification system to reduce and maintain the water’s dissolved O2 concentration to a
value of 20 ppb or less. As mentioned earlier, research indicated that a concentration
above 20 ppb could be a catalyst of corrosion on copper structures. Tests A and B each
consisted of a 2.5 gpm flow rate through the water purification system, the UV system
was switched on, and the Nitrogen sweep gas and vacuum pump for the degasifying
system was on as well. Based on the data obtained, it was conclude that the system in
this configuration could repeatedly obtain dissolved oxygen concentration to an
acceptable level, as shown in Figure 5.7.
224
Data A & B O2 Comparison at T=120
70
67
65
60
Data A
O2 Concentration (ppb)
55
Data B
50
45
39
40
32.5
35
30.3
36
30
31.8
29.6
25
29
27.9
28.4
27.5
20
15
Goal
10
5
0
120
150
180
210
240
270
300
330
360
390
420
Time (min)
Figure 5.7. O2 concentration versus time for two test runs (tests A and B)
To further enhance the performance of the oxygen degassing system, the flow rate
of the influent passing through the purification system was varied at 3 discrete values of
2.5 (Tests A and B), 3.0 (Test C) and 3.5 gpm (Test D). It was desired to see if the
degassing system performance was dependent on the flow rate through the water
purification hardware. Figure 5.8 shows the results after running the system for 120
minutes.
225
O2 Concentration vs. Flow Rate: B,C,D Data Sets T=120
70
67
O2 Concentration (ppb)
65
60
Data B - 2.5 gpm
55
Data C - 3.0 gpm
50
Data D - 3.5 gpm
45
39
40
35
32.5
31.8
30.3
29.1
30
27.4
26.6
26.1
30.2
25
27.8
26.8
25.7
25.7
25.5
29
27.9
24.9
25.2
25.2
24.8
20
15
Goal
10
5
0
120
150
180
210
240
270
300
330
360
390
420
450
Time (min)
Figure 5.8. O2 concentration vs. time for various water flow rates (Test C).
In reviewing the data, a small reduction in the dissolved O2 concentration was
observed, however it is too small to suggest there is any significant effect of water
flow rate on dissolved O2 concentration. Although the dissolved O2 concentration is
slightly above the design goal of 20ppb, water test samples showed no evidence of
copper corrosion. The current laboratory water sampling data can detect copper
oxide levels down to 10ppb, and thus far, have not detected any copper corrosion
products.
In tests A through E, the pH was maintained just below 7, which is consistent
with the desired operating range specified in Table 5.1. The electrical resistivity
values recorded for each of the tests were between 16.3 MO and 17.2 MO, slightly
higher than the desired upper limit of 15 MO specified in Table 5.1. This high
electrical resistivity was no doubt an artifact of the clean water that was used to fill
the system, which had an initial electrical resistivity around 18.1 MO. It is speculated
that the water which will be used to fill the SNS water cooling systems, will not have
such high purity, and thus the electrical resistivity range specified in Table 5.1 should
able to be met. Although the specific tests were not yet performed on the prototype
226
water purification system, it is speculated that the electrical resistivity will be able to
be adjusted by controlling the water flow rate through the purification hardware. As a
final note, water test samples showed no evidence of copper corrosion as a result of
the electrical resistivity values obtained in the current set of tests.
Chemical analysis data from the source water and the tests completed thus far,
are included in Table 5.5. The HPC’s and TOC’s are more of a relative measure. It
is more of a concern if these values show a rapid increase throughout the progress of
testing. This would indicate growth of the bacteria or heterotrophs. Thus far, the
HCP’s and TOC’s have been reported at relatively low values. The Test E data set
was essentially invalidated since the vacuum pump required service during the test
and had to be shut down. It should also be mentioned that the water in the SNS
Accelerator would be flowing for long periods of time. The prototype system water
does not run continuously for a long period of time. It is frequently shut down, which
gives bacteria the opportunity to repopulate.
Table 5.5. Water purification data summary for Tests A-E.
pH Electrical
Dis- Temp.
Cu
Heterotroph
Resistivity solved
(mg/L) Plate Count
ºF
Test
(MO)
O2
(CFU/mL)
(ppb)
Total
Organic
Carbon
(mg/L)
Source
-
18.0-18.2
-
-
ND
ND
ND
A
6.97
17.2
28.4
-
ND
47
0.8
B
6.95
17.2
27.9
66.1
-
-
-
C
6.92
17.0
24.0
65.4
-
-
-
D
6.88
16.6
24.9
66.1
ND
3
ND
E*
6.86
16.3
33.2
66.0
ND
97
ND
* Vacuum pump required service during test, degassing system not fully functional
ND = Not Detected
Additional tests are currently underway and include:
1) The functionality and necessity of the UV system will be studied. It may be
possible to eliminate bacteria by simply minimizing the O2 content of the water
and eliminating the UV system.
227
2) The size requirements of the carbon canisters will be studied to see if one canister
can be eliminated and thus reduce the size, cost, and complexity of the system.
3) Tap water will be placed in the prototype water purification system to determine
the ability of the system to deal with a relatively impure water source. This will
help to determine the consequences of using relatively impure water to fill the
SNS Linac water cooling systems.
4) The dependence of the pH, electrical resistivity, and dissolved oxygen on the
water flow rate through the purification system hardware will be studied in more
detail.
5.7 Facility-related Issues
Initial Start-Up and Water Quality Verification Testing
Initial start-up is expected to be similar to the prototype water purification system.
The water skid/purification system manufacturer will provide, a detailed start-up
procedure and a troubleshooting matrix to be used for diagnosing potential system
failures. The purification system will have been tested to provide the appropriate water
quality as well as an examination of workmanship for safety and quality, and will be
pressure tested. It is recommended that the piping of the main loops be flushed with tap
water prior to connecting and operating the purification system, to remove possible debris
remaining from the manufacturing process. Once complete, the entire system should be
brought on-line, and after a period of approximately 24 hours filters should be replaced
and water samples should be taken to verify purity. It has been suggested to use tap
water to fill the system as a cost reduction measure, rather than having water trucked to
the facility. Past experience on the LANCSE accelerator and the studies done with the
APT testing has shown this to be an effective source for water supply [5.13]. Samples
will need to be taken of the source to ensure the manufacturer can provide a system
compatible with the water. This particular test has not been completed on the prototype
system to compare water quality. In addition to the manufacturers procedures, the
following general guidelines are recommended to the start-up of the purification system.
228
1)
A cursory check was made for loose wiring, including power and data
acquisition lines, and any evidence of leaks, or loose fittings.
2)
Extra care should be taken if the system has not been circulated for a long
period of time or lines have been broken due to the addition of components
or soldering operations. Turn off valves to isolate the purification system
from the rest of the loop. Run water through the rest of the system to flush
out any large particles, fluxes, metal fragments from machining operations
etc. Volume will be determined by the appearance of the water. If the
system has been dormant for less than a couple of months, skip steps 2-4.
3)
Switch position of the valves to direct water into the purification system.
4)
Use air bleeds as necessary to get as much gas out of the system as possible.
Reducing the air in the system reduces the amount of oxygen trapped in the
piping, reducing bacterial growth. Then the system should be back-filled
with nitrogen to purge the system of any remaining oxygen not in solution.
229
System Operation and Maintenance
In general, the purification system is intended to operate with little or no operator
assistance after being brought on-line.
The system has been designed to require
maintenance annually, with maintenance schedules in the manufacturer’s maintenance
manual included with each purification system. Although very little or no levels of
radiation are anticipated in the water or to accumulate in the system components, it is still
recommended that each bottle be surveyed for activation. A general resin disposal
procedure is outlined in Appendix K, which will need to be revised to reflect ORNL’s
procedures.
Conclusion
Although prototype testing has not been completely finalized at the time of this
writing, it is believed the water purification system design will meet all of the functional
requirements needed for the SNS Linac water cooling systems. Preliminary prototype
tests show that the water purification system maintains the desired operational levels of
pH, electrical resistivity, and dissolved oxygen content. Water samples do not show any
significant levels of corrosion or bacterial growth. A procurement specification for the
water purification system has been drafted and will be modified as deemed necessary
following completion of the prototype tests.
Finally, operational and maintenance
activities for the water purification system, including handling and disposal procedures of
the water purification hardware, have been documented in this report.
230
6.0 Instrumentation and Controls
6.1 Local Controls
The DTL and CCL water cooling and resonance control systems will employ a
control system that can be operated by a local, programmable logic controller, interfaced
through a touchscreen interface, or it can be operated through the SNS global control
system network. This section discusses the features of the local control system, while the
next section discusses the global control system and interfaces.
6.1.1 Introduction and Design Requirements
There are two types of water cooling systems associated with the DTL and CCL
structures. The first is the Resonant Control Cooling System (RCCS), which serves to
keep the DTL tanks and CCL cavities in resonance by removing the RF waste heat from
the copper cavity structures. The resonance control is accomplished by manipulation of
the DTL drift tube/tank wall and CCL cavity dimensions (expansion/contraction) by
adjusting their wall temperatures with the RCCS. The DTL and CCL RCCS not only
performs resonance control of the RF structures, but, in addition, provides performance
assessment and diagnostics of the water cooling system and safety interlocking.
The second type of water skid, termed the Quarupole Magnet Cooling System
(QMCS), serves the CCL quadrupole electro-magnets that are located between each CCL
segment along the beam line. It is very similar to the RCCS except that the magnets
simply require constant temperature water.
quadrupole electro-magnets along the CCL.
One QMCS water skid will serve all
The CCL QMCS is responsible for
removing electrical waste heat from the magnet coils and maintaining the magnets at an
acceptable operating temperature. The control loop for the QMCS will be similar to the
RCCS except that it will be responding to water temperature measurements only instead
of both RF frequency error and water temperature.
The proceeding section will first discuss the types of instrumentation and control
hardware that will be used on the DTL and CCL RCCS systems. Next, the logic behind
the control system in maintaining the resonance of the DTL and CCL structures is
reviewed. Next, the safety features incorporated in the Resonant Control Cooling System
231
are presented and reviewed. Finally, the signal and device naming conventions used for
the control system will be discussed.
6.1.2 Instrumentation and Control System Architecture
The RCCS will be responsible for monitoring the performance of the water
cooling system, maintaining resonance of the RF structures, diagnosing the water cooling
system in case of off-normal operation, and providing proper safety interlocks in the
event of system failure. The final design of this system is shown in the layout of Figure
6.1, while a more detailed control system block diagram is shown in Figure 6.2.
main architectual features are discussed below.
Figure 6.1. Schematic of the DTL/CCL water cooling control system.
232
The
Figure 6.2. Block diagram of the DTL and CCL water cooling and control systems.
Programmable Logic Controller
The water cooling control system is being designed for local stand-alone
operation and for interface with the SNS global control EPICS system. The heart of the
local control system will consist of an Allen Bradley ControlLogix Programmable Logic
Controller (PLC) and a rack-mounted touchscreen operator interface. The PLC will be
programmed with Allen Bradley’s RSLogix5000 ladder code programming toolkit.
233
The RCCS control system will use the Allen Bradley ControlLogix architecture.
This equipment was selected from the SNS Control Standards Handbook. The controller
hardware will consist of the following modules:
•
1756-L1M1 Processor with 512K memory
•
1756-CNB Ethernet communications module
•
1756-IF16 16 Channel Analog Input module
•
1756-OF8 8 Channel Analog Output module
•
1756-IB32 32 Channel Digital Input module
•
1756-OB32 32 Channel Digital Output module
•
1756-IR6I 6 Channel RTD (temperature) module
The ControlLogix equipment will be installed in the RCCS equipment rack. For
each RCCS system, 2 PLC chassis will be used. The first chassis will contain the
modules for instrumentation and devices in the water skid. Since all DTL, CCL, and
SCL water skids are essentially the same, this chassis configuration will be the same for
all 12 (6 DTL, 5 CCL, and 1 SCL) water cooling systems. The second chassis will
contain the modules for the devices in the tunnel. This configuration varies for each
RCCS system. The appropriate module selection and chassis size will be implemented
based on the device requirements. For example, DTL#1 will have 2 chassis with the
configuration shown in Figure 6.3.
234
DTl#1 Chassis
Close up of Chassis
A
DTl#1 Chassis
Figure 6.3. ControlLogix Modules for a typical water cooling control system.
235
To simplify wiring and reduce installation costs, pre-wired cables and DIN rail
mounted Allen Bradley Interface Modules (IFMs) will be used to connect to the field
wiring.
The IFMs contain screw terminal, and may optionally contain fuses and
diagnostic LEDs. The field wiring will connect to the screw terminals of the IFMs, and
the signals will then reach the ControlLogix modules via the pre-made interface cables.
The IFMs will be mounted in the back of the rack for easy access and maintenance. See
Figure 6.4 for a typical IFM module installation.
Figure 6.4. Typical Interface Module (IFM)
Instrumentation
Digital signals will be 0/24VDC, with 0 V normally representing the OFF or
CLOSE state and 24V representing the ON or OPEN state. Analog signals will be 4 to
20 ma. All temperature signals will be 3 wire RTDs.
Instrumentation will be provided on each water skid and in the water supply
manifolds for control, diagnostic, and safety interlock purposes.
In particular, the
following instrumentation will be employed:
•
Pressure transducers:
Monitor local static pressure before and after the heat
exchanger and pump, within the reservoir/expansion tank, and at the inlet and outlet
heat exchanger manifolds.
236
•
RTDs: Monitor water temperature before and after the heat exchanger and pump,
within the reservoir/expansion tank, and at the inlet and outlet heat exchanger
manifolds.
•
Flow meters: Monitor water flow rates through the heat exchanger, out of the RF
structure, in the water purification and pump by-pass loops.
•
Water purification: Monitor the water’s electrical conductivity, pH, and dissolved
oxygen content.
•
Liquid low-level switch: Monitor the water level in the expansion tank.
Equipment Rack
The water cooling control system will be installed in a 19” equipment rack. The
re will be one rack for each water cooling system. The rack follows the SNS Basic Order
Agreement (BOA) #4200000028 for rack procurement. The rack provides 78.875 inches
of vertical equipment space, and contains a Lexan front door. For more details, refer to
the standard rack specification in the WBS 1.9 Integrated Control System “Control
Standards Handbook”, Section 3.4. The prototype RCCS rack is shown in Figure 6.5.
237
Figure 6.5. Prototype RCCS equipment rack.
The equipment rack will contain the Allen Bradley ControlLogix equipment,
power supplies, PanelView 1000E local operator interface, internal cabling, IFM
modules, and a cooling fan. Total heat generation of the rack is approximately 400 watts.
A single 6” fan will provide air circulation.
Cabling
Multiconductor cables will be used to carry signals from the RCCS rack to the
water skid and to the tunnel junction box. These cables will be tray-rated. Digital signal
cables will have an overall outside shield. RTDs and analog signals will have individual
shields. Table 6.1 provides a listing of the types of cables used.
238
Table 6.1. Cabling descriptions for the DTL and CCL water cooling control systems.
Trade
Number
1065A
Manufact. Conductors Description
Belden
8 pair
1067A
Belden
16 pair
1050A
Belden
8 pair
1052A
Belden
16 pair
1094A
Belden
8 triad
85230
Belden
1 pair
85240
Belden
1 triad
9322
Belden
1 pair
EXPP3CU-24S
Omega
1 triad
twisted pair, overall
shield
shield
twisted pair,
individual shield
twisted pair,
individual shield
twisted triad,
individual shield
shield
twisted triad,
overall shield
shield
standard RTD
extension wire
Usage
AWG
Jacket Code Rating
digital signals
18
PVC
digital signals
18
PVC
analog signals
18
PVC
analog signals
18
PVC
RTD
18
PVC
digital and analog
signals
RTD
20
Tefzel
NEC type TC
tray cable
NEC type TC
tray cable
NEC type TC
tray cable
NEC type TC
tray cable
NEC type TC
tray cable
n/a
20
Tefzel
n/a
digital and analog
signals
22
PVC
RTD
24
NEC type
PLTC tray
cable
Polyvinyl n/a
Dia.
Weight
(in) (lbs/1000ft)
0.599
197
0.793
339
0.654
236
0.898
455
0.751
324
0.182
32
0.193
34
0.2
23
0.166
14
Local Operator Interface
Based on the product evaluation described in the SNS DTL Water Cooling and
Resonance Control System Prelimiary Design Report, an Allen Bradley PanelView
1000E industrial operator terminal (Figure 6.6) will be installed in the equipment rack to
provide a local operator interface. This terminal uses a 10” color LCD touchscreen. It is
programmed using the Allen Bradley Panel Builder software development package. For
the prototype control system, the terminal will communicate with the ControlLogix
system using ControlNet. An Ethernet version of the terminal should be available from
the manufacturer by the middle of 2001. Based on this, the production RCCS control
systems will use the Ethernet version of the terminal. This will eliminate the need for a
ControlNet communications module in the ControlLogix chassis.
239
Figure 6.6. PanelView 1000E operator terminal.
The RCCS system will normally be operated in the global control mode via the
SNS EPICS control system. An IOC (Input/Output Controller) will be used as the
interface between the RCCS PLC and EPICS. The EPICS developers will provide a
software driver to read values to and from the PLC memory, via Ethernet or ControlNet,
and pass it along to EPICS.
6.1.3 Control Methodology and Logic
Resonance Control
As discussed previously, one of the primary functions of the Water Cooling and
Resonance Control System is to aid the LLRF control system in maintaining the
resonance of the DTL and CCL RF structures. Refer to Section 1.3 for more details on
the resonance control philosophy.
The LLRF Control and the RCCS share the responsibility of the resonance control
of the DTL and CCL. Consider the DTL as an example. From system start-up, when RF
power is gradually introduced to the DTL tank, to full-on steady-state accelerator
operation, there are many complicated thermal, fluidic, structural, and electrical
240
interactions occurring which influence the resonance of the DTL structure. To deal with
these effects, and achieve and maintain resonance of the DTL structure, the LLRF
Control and Water Cooling Systems have individual, as well as shared responsibilities.
Figure 6.7 displays the responsibilities of the LLRF Control and RCCS as a function of
the DTL resonant frequency.
RCCS / Agile combo.
Frequency Agile
only
Frequency Agile
only
Dead Band
outer
inner
FagF0 - 33kHz
FhiF0 - 10 kHz
Flo- F0 Flo+
402.5 MHz
Fhi+
F0 + 10 kHz
Fag+
F 0 + 33kHz
Frequency Agile only:
Water RCCS is inactive, holding at a saturation position of the valves,
while the Resonance Control Module brings the drive frequency
into the RCCS / Agile band.
RCCS / Agile Band:
RCM and the water RCCS act to control the cavity resonant frequency
and bring it into the deadband.
Dead Band:
LLRF control system locks to the fundamental frequency (master oscillator)
and the water RCCS takes over to control the cavity resonance within the
deadband limits (as determined by operator through the RCM).
Fno RF
F0 + 100 kHz
Figure 6.7. Resonance control responsibility diagram for the SNS DTL and CCL.
241
During the early stages of introducing RF power into the DTL RF structure, the
RF control system will monitor the structure’s resonant frequency and adjust the LLRF
Control system output drive frequency to the klystron to match it. The RF control system
will thus continuously change the RF frequency as the cavities warm up, and follow the
cavity resonant frequency to the desired operational resonant frequency (402.500 MHz).
This “chase the cavity’s resonance” activity is referred to as a frequency agile mode of
operation. The signal that determines the output RF drive frequency is also used to send
an error signal to the water system which indicates how far off the cavity resonant
frequency is from the desired operational resonant frequency, and in which direction. For
the DTL, a 0V to 10V analog signal, sent from the LLRF to the RCCS, will be used to
represent this frequency error. In particular, the analog signal ranges and resulting RCCS
actions are as follows:
0V to 0.5V ⇒ negative frequency saturation. RCCS: Cool the water and structure by
forcing all circulating water through heat exchanger.
0.5V to 5.0V ⇒ error signal is proportional to the -50 kHz to 0 kHz frequency error (the
lower frequency error limit is software selectable). RCCS: use PID algorithm to
gradually cool the structure and push the frequency error signal towards 5V, or zero
frequency error.
5.0V to 9.5V ⇒ error signal is proportional to the 0 kHz to 50 kHz frequency error (the
higher frequency error limit is software selectable). RCCS: use PID algorithm to
gradually warm the structure and push the frequency error signal towards 5V, or zero
frequency error.
9.5V to 10.0V ⇒ positive saturation. RCCS: Warm the water and structure by forcing
all circulating water through the heat exchanger by-pass line.
operational resonant frequency, Fo, the Water Cooling System begins to perform active
resonance control by adjusting a water mixing proportional valve in an attempt to bring
the cavity resonant frequency to Fo.
This ±33 kHz frequency band is termed the
RCCS/Agile Band. During this mode of operation, the LLRF Control System continues
to monitor the resonant frequency of the DTL and attempts to match the output RF drive
frequency to it. In addition, the Water Cooling System reads the operational resonant
242
frequency error from the LLRF Control System and attempts to adjust the DTL resonant
frequency by manipulating the water inlet temperature. The DTL resonant frequency
shift induced by a mean temperature change of the DTL drift tube copper is
approximately 6.5 kHz/°C. Thus by adjusting the cooling water temperature, the DTL
resonant frequency is brought closer to Fo, and the operational resonant frequency error is
reduced. This control logic, similar to that used for the Accelerator Production of
Tritium/Low Energy Demonstration Accelerator RFQ and CCDTL Hot Model resonance
control systems, is depicted in Figure 6.8. Note that this resonance control methodology
is much different from that used on the LANSCE accelerator, where a particular cooling
water temperature is sought, but no feedback is provided by the RF system.
operational resonant frequency, Fo, the LLRF Control System locks to the operational
resonant frequency and the Water Cooling System takes over active cavity resonance
control. This narrow frequency range is referred to as the Dead Band. Note that the
limits on the Dead Band will be software selectable.
Choose frequency
gain or water
temperature gain
ef
Valve
(position)
PID
eT
-
Water Temp.
Set Point
Cavity
(temperature
and frequency)
Water
Temperature
+
Low Level
R F System
Figure 6.8. Resonance control system logic proposed for the SNS Linac RCCS.
243
Modes of Operation
Depending on the operational requirements of the water cooling system, there will be
several different control modes for operations staff to select from. Several basic modes
of operation have been incorporated into the design to provide a flexible water cooling
and resonance control system that can be used for initial water system testing, linac
alignment and commissioning, low power testing, steady-state operations, and trouble
shooting. These operational modes of the water cooling system are discussed below and
are summarized in Table 6.2.
1A)
Temperature Control Mode – The operator selects a desired primary water
temperature exiting the water skid or entering the supply manifold at the Linac. A
PID routine is used to maintain the desired temperature. An expert screen allows for
the adjustment of the P, I and D terms.
1B) Temperature Control/Heater Function Mode - Heater is on/off.
Normally not
needed but available to operators if there is a need to raise water temperature if RF is
not present. The button will be on an operator screen, where you manually turn it on
and it automatically shuts off when the water reaches the desired temperature.
2A) Frequency Error Mode - Uses the 0.5 to 9.5 V frequency error signal from the Low
Level Radio Frequency (LLRF) controls. Attempts drive to and maintain this signal
at 5.00 V using a Proportional, Integral, and Differential (PID) control algorithm.
Again, an expert screen allows for the adjustment of the P, I, and D terms.
2B) RF Short Trip Mode - If the LLRF error signal is lost for less than a certain period of
time (user programmable) the control system holds everything (valves, pump, etc.) in
the mode/position it was last in when the signal was lost. The waiting time period
can be changed by an operator expert screen.
2C) RF Long Trip Mode - If the LLRF error signal does not return after a certain period
of time(user programmable), the control system will change over from the Frequency
Error Mode to the Temperature Control Mode, where it locks in to the last known
primary water delivery temperature when the signal was lost.
3) Manual Mode - No PID control, the operator manually adjusts valves, pump, and
heater. Used for installation and testing.
244
Table 6.2. Summary of operational modes for the DTL and CCL water cooling and resonance control systems
Heater
Condition
Mode
Mode Description
Typical Operating
Scenarios
Programmed
or Set-point
Variables
Feed-back
Variables
Pump
Condition
Hot-side
Control
Valve
Condition
Cold-side
Control
Valve
Condition
1A.
Temperature
Provide stable,
programmed water
flow and temperature
to RF structure
• Cleaning of water
system
• Checkout of water
cooling system
• Low RF power
testing
• Loss of RF power
• Primary
water flow
rate exiting
water skid
• Temperature
of primary
water exiting
water skid
• Facility
chilled water
flow rate
exiting water
skid
Pump speed
varied by
PID
algorithm to
achieve setpoint flow
rate
Valve
position
controlled by
PID algoritm
to obtain
desired
primary
water
temperature
at the outlet
of the water
skid
Heater
Valve
controlled by turned off.
PID
algorithm to
maintain a
desired
flowrate on
the cold side
of the heat
exchanger.
1B.
Temperature/
Heater
Provide stable,
• RF structure or
programmed water
magnet alignment
flow and temperature
to RF structure, with a
heater-supplied heat
load.
• Water flow
rate exiting
water skid
• Water flow
rate exiting
cold side of
heat
exchanger
• Water
temperature
exiting water
skid
• Primary
water flow
rate exiting
water skid
• Primary
water
temperatur
e exiting
water skid
• Facility
chilled
water flow
rate exiting
water skid
• Water flow
rate exiting
water skid
• Water flow
rate exiting
cold side of
heat
exchanger
• Water
temperatur
e exiting
water skid
Pump speed
varied by
PID
algorithm to
rate
Valve
position
controlled by
PID algoritm
to obtain
desired
primary
water
temperature
at the outlet
of the water
skid
Valve
Heater
controlled by turned on
PID
algorithm to
maintain a
desired
flowrate on
the cold side
of the heat
exchanger.
245
2A.
Frequency
Error
Provide stable,
programmed water
flow to RF structure,
adjust hot side control
valve to adjust water
temperature and drive
frequency error signal
to resonance value
(5V)
Low and high level
RF power.
2B.
Frequency
Error with
Short Term
RF Trip
If LLRF frequency
error signal is lost,
hold valves at last
known position..
Short term RF trip
2C.
Frequency
Error with
Long Term
RF Trip
If LLRF frequency
error signal is out of
range for greater than
allowable setpoint
time, change over to
temperature control
mode.
Manual control of
pump speed, valve
positions, and heater
setting
Long term RF trip
3. Manual
System checkout,
testing, or trouble
shooting
• Water flow
rate exiting
water skid
• Water flow
rate exiting
cold side of
heat
exchanger
• LLRF
frequency
error (5V)
• Water flow
rate exiting
water skid
• Water flow
rate exiting
cold side of
heat
exchanger
• LLRF
frequency
error (5V)
See
temperature
control mode
• Water flow
rate exiting
water skid
• Water flow
rate exiting
cold side of
heat
exchanger
• LLRF error
signal (010V)
• Water flow
rate exiting
water skid
• Water flow
rate exiting
cold side of
heat
exchanger
• LLRF error
signal (010V)
See
temperature
control mode
Pump speed
varied by
PID
algorithm to
rate
Valve
position
controlled by
PID algoritm
to obtain
desired
frequency
error set
point (5V)
Valve
Heater
controlled by turned off
PID
algorithm to
maintain a
desired
flowrate on
the cold side
of the heat
exchanger.
Pump speed
varied by
PID
algorithm to
rate
Valve
position held
at last
known value
Valve
position held
at last
known value
Heater
turned off
See
temperature
control
mode
See
temperature
control
mode
See
temperature
control
mode
Heater
turned off
None
None
Manual
setting
Manual
setting
Manual
setting
Manual
setting
246
Process Software
The actual code will reside in the ControlLogix Processor modules, also refereed
to as a “Programmable Logic Controller” (PLC). The software is developed on a PC
using the Allen Bradley RSLogix5000 software development package. The code consists
of Ladder Logic routines. Once completed, the code is downloaded to the Processor,
where it executes.
To simplify the coding effort and software maintenance, the code is written in
independent individual software modules. The following is a brief description of the
modules that will be developed:
1)
Start Up – Provides for processor initialization upon power-up. Preset registers
where needed.
2)
Status – Checks operation of the Processor and I/O modules. Monitors for major
and minor system faults.
3)
Read BI – Read the state of all digital inputs and store in the proper variables.
4)
Read RTD - Read the state of all RTD inputs and store in the proper variables.
5)
Read AI - Read the state of all analog inputs and store in the proper variables.
6)
Convert AI – Perform scaling and engineering units conversion for analog values.
7)
GCS Read – Reads values for Global Control System.
8)
Manual Mode – Allows for manual operation of system.
9)
Temperature Mode – Perform the control and PID functions for operating in the
Temperature mode.
10)
Frequency Mode - Perform the control and PID functions for operating in the
LLRF Frequency feedback mode.
11)
Heat Exchanger – Controls the facility water flow through the heat exchanger.
12)
Pump – Controls the pump speed and flow. Operates the pump motor starter.
13)
Alarms – Monitors values for out of range conditions and checks for interlocks.
14)
Shutdown – Performs shutdown of water skid
15)
Write BO - Write to the digital outputs
16)
Write AO - Write to the analog Outputs
17)
GCS Write – Writes values to Global Control System.
247
6.1.4 Safety Interlocks and Equipment Protection
The SNS Global Control System will perform the primary monitoring for alarm
states and incorporation of corrective action. For additional protection and for operating
the RCCS control system in stand-alone mode, the RCCS control system will also
provide for alarm condition processing. Alarms are typical indications of out-of- range
conditions, such as a temperature being too high (or too low), an excessive pressure, a
lack of water flow, etc.
In the event of improper initialization or malfunction of the water cooling control
system, safety interlock signals will be available to the SNS Global Control System to
prevent system start up or to shut down RF power during operation. Note that all water
system interlocks that influence other subsystems (i.e., RF power, magnet power
supplies, LLRF controls, etc.), will be sent to the SNS Global Control System. There will
be no “hardwiring” of equipment protection signals from the water cooling control
systems to other subsystems. Consequently, for complete coverage of equipment and
personnel protection, the SNS Global Control System must be operational. The particular
safety interlock instruments and their purposes are listed below:
•
Liquid low-level indicator on reservoir/expansion tank to indicate insufficient liquid
or liquid loss.
•
Flow meter on supply and return legs of the water skid to note any loss in water flow
from leaks or blockage.
•
Flow meters on various outlet lines of the DTL and CCL will detect minimum
required flow rate through heated components and prevent or shut down operation
due to such things as, flow line blockage, water line leaks or disconnect, accidental
valve closure, pump failure, etc.
•
Pressure transducers and pressure relief valves at various locations in the water
cooling circuit (located on sections that could potentially be isolated by valves) to
prevent over-pressurization of water lines.
•
Solenoid water valve on inlet to heat exchanger to shut off the facility chilled water
supply to the water skid in the event of RF shut down. This will be incorporated to
248
prevent the DTL or CCL from overcooling (and hence moving far from resonance
conditions) due to interruption or absence of applied RF power.
Alarms will have different levels of severity. There are normally 4 levels of
alarm conditions – HiHi, Hi, Lo, and LoLo.
Lo and Hi alarm states are Caution
(Yellow), primarily to warn operators as well as the Global Control System of an
impending problem. Usually, no action is needed by the control system. If the problem
is not corrected and continues to worsen, the alarm will change to a LoLo or HiHi Urgent
(Red) state - this will notify the Global Control System and in most cases, shut down the
water skid. An alarm list will be developed to indicate the desired action for the different
alarm conditions. See Table 6.3 for an example of DTL tank 1 alarm actions.
The values to trigger the different alarms are also being developed. These values
will be monitored and can be changed from the Global Control System. Table 6.4 shows
the alarm limit values for DTL tank 1 (an alarm list will be generated for all the RCCS
control systems).
249
Table 6.3. DTL tank 1 water cooling system alarm actions.
Type
Power Supplies
Resonance Control
Leak
Flow
Temperature
Pressure
pH
Dissolved Oxygen
Resistivity
Pump Speed
Condition
Units
PS < LoLo alarm value
volts
PS < Lo alarm value
volts
PS > Hi alarm value
volts
PS > HiHi alarm value
volts
LLRF Error <0.5 or >9.5, for volts
<1 minute
LLRF Error <0.5 or >9.5, for volts
>=1 minute
FT1-FT2 > TBD
gpm
FT < LoLo alarm value
gpm
FT < Lo alarm value
gpm
FT > Hi alarm value
gpm
FT > HiHi alarm value
gpm
TT < LoLo alarm value
degrees
TT < Lo alarm value
degrees
TT > Hi alarm value
degrees
TT > HiHi alarm value
degrees
PT < LoLo alarm value
psi
PT < Lo alarm value
psi
PT > Hi alarm value
psi
PT > HiHi alarm value
psi
PH < LoLo alarm value
gpm
PH < Lo alarm value
gpm
PH > Hi alarm value
gpm
PH > HiHi alarm value
gpm
O2 > Hi alarm value
ppb
O2 > HiHi alarm value
ppb
RE > Hi alarm value
Mohm
RE > HiHi alarm value
Mohm
PMP > Hi alarm value
rpm
PMP > HiHi alarm value
rpm
Description
Power Supplies too low
Power Supplies too low
Power Supplies too high
Power Supplies too high
Short loss of RF signal
Serevity
Urgent
Caution
Caution
Urgent
Caution
Long loss of RF signal
Caution
Leak in system
Flow too low
Flow too low
Flow too high
Flow too high
Temperature too low
Temperature too low
Temperature too high
Temperature too high
Pressure too low
Pressure too low
Pressure too high
Pressure too high
pH too low
pH too low
pH too high
pH too high
Oxygen too high
Oxygen too high
Resistivity too high
Resistivity too high
Pump Speed too high
Pump Speed too high
Urgent
Urgent
Caution
Caution
Urgent
Urgent
Caution
Caution
Urgent
Urgent
Caution
Caution
Urgent
Urgent
Caution
Caution
Urgent
Caution
Urgent
Caution
Urgent
Caution
Urgent
250
Action
Shut down skid
None
None
Shut down skid
Hold valve positions and pump
speeds
Disable Frequency mode, change to
Temperature mode
Shut down skid
Shut down skid
None
None
Shut down skid
Shut down skid
None
None
Shut down skid
Shut down skid
None
None
Shut down skid
Shut down skid
None
None
Shut down skid
None
Shut down skid
None
Shut down skid
None
Shut down skid
Table 6.4. DTL tank 1 water cooling system alarm limits.
SNS DTL #1 Resonant Control Cooling System (RCCS) Alarm List
System/
SubSystem
DTL_RCCS1
DTL_RCCS1
DTL_RCCS1
DTL_RCCS1
DTL_RCCS1
DTL_RCCS1
DTL_RCCS1
DTL_RCCS1
DTL_RCCS1
DTL_RCCS1
DTL_RCCS1
DTL_RCCS1
DTL_RCCS1
DTL_RCCS1
DTL_RCCS1
DTL_RCCS1
DTL_RCCS1
DTL_RCCS1
DTL_RCCS1
DTL_RCCS1
DTL_RCCS1
DTL_RCCS1
DTL_RCCS1
DTL_RCCS1
DTL_RCCS1
DTL_RCCS1
DTL_RCCS1
Device
Name
PS1
PS2
TT8
FT1
FT2
FT3
FT4
FT5
PT1
PT2
PT3
PT4
PT5
PT6
TT1
TT2
TT3
TT4
TT5
TT6
TT7
CV1
CV1
CV2
CV2
PH1
O21
Device
voltage
voltage
temperature transmitter
flow transmitter
flow transmitter
flow transmitter
flow transmitter
flow transmitter
pressure transmitter
3 way PID valve readback
3 way PID valve control
2 way PID valve readback
purity xducer
oxygen xducer
Location LoLo
rack
22
rack
22
rack
18
water skid
water skid
water skid
water skid
water skid
water skid
water skid
water skid
water skid
water skid
water skid
water skid 15
water skid 15
water skid 15
water skid 15
water skid 15
water skid 15
water skid 15
water skid
water skid
water skid
water skid
water skid 6.5
water skid
Lo
23
23
20
17
17
17
17
17
17
17
7
Hi
24.5
24.5
35
270
270
270
HiHi
25
25
40
290
290
290
Units
Volts
Volts
degrees C
gpm
gpm
gpm
270
90
90
90
90
90
90
25
25
25
25
25
25
25
290
110
110
110
110
110
110
28
28
28
28
28
28
28
gpm
psi
psi
psi
psi
psi
psi
degrees C
degrees C
degrees C
degrees C
degrees C
degrees C
degrees C
9
25
9.5
40
pH
ppb
251
Description
rack power supply #1
rack power supply #2
rack internal temperature
main return flow meter
flow meter loop of heat exchanger
flow meter at skid exit
water purity loop flow meter
flow meter out of heat exchanger back to CWS
inlet pressure of heat exchanger loop
outlet pressure of heat exchanger
inlet pressure to pump
outlet pressure from pump
inlet pressure to heat exchanger, facility
outlet pressure of heat exchanger, facility
inlet temperature of heat exchanger loop
outlet temperature of heat exchanger
inlet temperature to pump
outlet temperature from pump
inlet temperature to heat exchanger, facility
outlet temperature of heat exchanger, facility
outlet temperature of heater HTR-1
PID control valve - 3 way
PID 2 way valve, chilled water to hx flow controll
PID 2 way valve, chilled water to hx flow controll
main water PH transducer
main water oxygen transducer
System/
Device
SubSystem Name Device
DTL_RCCS1 PMP-1 pump
DTL_RCCS1 PMP-1 pump readback
DTL_RCCS1 LT1
fluid level
DTL_RCCS1 HTR-1 in-line heater
DTL_RCCS1 RE1
resistivity probe
DTL_RCCS1 RE2
resistivity probe
Tank 1-section A ---------------------DTL_TANK1 FT101 flow transmitter
DTL_TANK1 FT102 flow transmitter
DTL_TANK1 PT101 pressure transmitter
DTL_TANK1 TT101 temperature transmitter
Tank 1-section B ---------------------DTL_TANK1 FT106 flow transmitter
Location LoLo
water skid
water skid
water skid
water skid
water skid
3
water skid
3
*****
tunnel
tunnel
tunnel
tunnel
tunnel
tunnel
tunnel
tunnel
15
tunnel
15
*****
tunnel
tunnel
tunnel
tunnel
tunnel
tunnel
Lo
Hi
HiHi
Units
1000
Low
1100
rpm
5
5
20
20
30
30
Mohm
Mohm
17
17
270
270
270
270
270
90
90
25
25
290
290
290
290
290
110
110
28
28
gpm
gpm
gpm
gpm
gpm
psi
psi
degrees C
degrees C
270
270
270
270
270
270
290
290
290
290
290
290
gpm
gpm
gpm
gpm
gpm
gpm
252
Description
main loop pump variable speed
water purity loop reservoir tank fluid low-level indicator
in-line heater, manual remote control at MCC panel
resistivity probe @ center of water filtration system
resistivity probe post of water filtration system
main post coupler return flow meter
drift tube return flow meter
end wall return flow meter
post coupler return flow meter
slug tuner return flow meter
main supply pressure
main return pressure
main supply temperature
main return temperature
*****
end wall flow meter
flow meter
flow meter
flow meter
flow meter
flow meter
6.1.5 Signal List
The ControlLogix processor will contain a database consisting of all signals and
values processed and stored by the RCCS control system. This database is derived
primarily from the RCCS signal list. The signal list will contain the signal name, type,
description and location.
In addition, the signal list will contain ControlLogix I/O
designations, cabling information and signal routing. Complete cabling diagrams and
installation documentation will be generated from the signal list. The signal list for
DTL#1 is shown in Table 6.2.
253
Table 6.2 – DTL#1 signal list.
SNS DTL #1 Resonant Control Cooling System (RCCS) Signal List, Tank 1
System/
SubSystem
DTL_RCCS1
DTL_RCCS1
DTL_RCCS1
DTL_RCCS1
DTL_RCCS1
DTL_RCCS1
DTL_RCCS1
DTL_RCCS1
DTL_RCCS1
DTL_RCCS1
DTL_RCCS1
DTL_RCCS1
DTL_RCCS1
DTL_RCCS1
DTL_RCCS1
DTL_RCCS1
DTL_RCCS1
DTL_RCCS1
DTL_RCCS1
DTL_RCCS1
DTL_RCCS1
DTL_RCCS1
DTL_RCCS1
DTL_RCCS1
DTL_RCCS1
DTL_RCCS1
DTL_RCCS1
Device
Name
PS1
PS2
TT8
FT1
FT2
FT3
FT4
FT5
PT1
PT2
PT3
PT4
PT5
PT6
TT1
TT2
TT3
TT4
TT5
TT6
TT7
CV1
CV1
CV2
CV2
PH1
O21
Signal
Device
type Location
voltage
0-24VDC rack
voltage
0-24VDC rack
RTD
rack
flow transmitter
4-20mA water skid
flow transmitter
4-20mA water skid
flow transmitter
4-20mA water skid
flow transmitter
4-20mA water skid
flow transmitter
4-20mA water skid
4-20mA water skid
4-20mA water skid
4-20mA water skid
4-20mA water skid
4-20mA water skid
4-20mA water skid
RTD water skid
RTD water skid
RTD water skid
RTD water skid
RTD water skid
RTD water skid
RTD water skid
3 way PID valve readback 4-20mA water skid
4-20mA water skid
2 way PID valve readback 4-20mA water skid
4-20mA water skid
purity xducer
4-20mA water skid
oxygen xducer
4-20mA water skid
Module
Info
IF16-1
IF16-2
IRD6-1
IF16-3
IF16-4
IF16-5
IF16-6
IF16-7
IF16-8
IF16-9
IF16-10
IF16-11
IF16-12
IF16-13
IRD6-2
IRD6-3
IRD6-4
IRD6-5
IRD6-6
2-IRD6-1
2-IRD6-2
IF16-14
OF8-1
IF16-15
OF8-2
2-IF16-1
2-IF16-2
Cable/Pair Cable Type J-Box
1-PAIR-1 Belden 9341
*****
1-PAIR-1 Belden 9341
*****
1-PAIR-1 Omega 3CU-24S *****
1-PAIR-3 Belden 1052A D1-JB1
255
Tunnel
Chase
#
Cable/Pair Cable Type J-Box Description
*****
*****
*****
***** rack power supply #1
*****
*****
*****
***** rack power supply #2
*****
*****
*****
***** rack internal temperature
*****
*****
*****
***** main return flow meter
*****
*****
*****
***** flow meter loop of heat exchanger
*****
*****
*****
***** flow meter at skid exit
*****
*****
*****
***** water purity loop flow meter
*****
*****
*****
***** flow meter out of heat exchanger back to CWS
*****
*****
*****
***** inlet pressure of heat exchanger loop
*****
*****
*****
***** outlet pressure of heat exchanger
*****
*****
*****
***** inlet pressure to pump
*****
*****
*****
***** outlet pressure from pump
*****
*****
*****
***** inlet pressure to heat exchanger, facility
*****
*****
*****
***** outlet pressure of heat exchanger, facility
*****
*****
*****
***** inlet temperature of heat exchanger loop
*****
*****
*****
***** outlet temperature of heat exchanger
*****
*****
*****
***** inlet temperature to pump
*****
*****
*****
***** outlet temperature from pump
*****
*****
*****
***** inlet temperature to heat exchanger, facility
*****
*****
*****
***** outlet temperature of heat exchanger, facility
*****
*****
*****
***** outlet temperature of heater HTR-1
*****
*****
*****
***** PID control valve - 3 way
*****
*****
*****
***** PID control valve - 3 way
*****
*****
*****
***** PID 2 way valve, chilled water to hx flow controll
*****
*****
*****
***** PID 2 way valve, chilled water to hx flow controll
*****
*****
*****
***** main water PH transducer
*****
*****
*****
***** main water oxygen transducer
System/
Device
SubSystem Name Device
DTL_RCCS1 PMP-1 pump
DTL_RCCS1 PMP-1 pump readback
DTL_RCCS1 LT1
fluid level
DTL_RCCS1 HTR-1 in-line heater
DTL_RCCS1 RE1
resistivity probe
DTL_RCCS1 RE2
resistivity probe
Tank 1-section A ---------------------DTL_TANK1 FT101 flow transmitter
Tank 1-section B ---------------------DTL_TANK1 FT106 flow transmitter
Signal
type
4-20mA
4-20mA
24VDC
24VDC
4-20mA
4-20mA
*****
4-20mA
4-20mA
4-20mA
4-20mA
4-20mA
4-20mA
4-20mA
RTD
RTD
*****
4-20mA
4-20mA
4-20mA
4-20mA
4-20mA
4-20mA
Location
water skid
water skid
water skid
water skid
water skid
water skid
*****
tunnel
tunnel
tunnel
tunnel
tunnel
tunnel
tunnel
tunnel
tunnel
*****
tunnel
tunnel
tunnel
tunnel
tunnel
tunnel
Module
Info
2-IF16-3
OF8-3
IBD32-1
OBD32-1
2-IF16-4
2-IF16-5
Cable/Pair
2-PAIR-3
1-PAIR-3
1-PAIR-1
2-PAIR-1
2-PAIR-4
2-PAIR-5
Cable Type
Belden 1052A
Belden 1050A
Belden 1065A
Belden 1065A
Belden 1052A
Belden 1052A
J-Box
D1-JB1
D1-JB1
D1-JB1
D1-JB1
D1-JB1
D1-JB1
Chase
Tunnel
#
Cable/Pair Cable Type J-Box Description
*****
*****
*****
***** main loop pump variable speed
*****
*****
*****
***** main loop pump variable speed
*****
*****
*****
***** water purity loop reservoir tank fluid low-level indicator
*****
*****
*****
***** in-line heater, manual remote control at MCC panel
*****
*****
*****
***** resistivity probe @ center of water filtration system
*****
*****
*****
***** resistivity probe post of water filtration system
3-IF16-1
3-IF16-2
3-IF16-3
3-IF16-4
3-IF16-5
3-IF16-6
3-IF16-7
3-IRD6-1
3-IRD6-2
3-PAIR-1
3-PAIR-2
3-PAIR-3
3-PAIR-4
3-PAIR-5
3-PAIR-6
3-PAIR-7
3-PAIR-1
3-PAIR-2
Belden 1052A
Belden 1052A
Belden 1052A
Belden 1052A
Belden 1052A
Belden 1052A
Belden 1052A
Belden 1094A
Belden 1094A
D1-JB2
D1-JB2
D1-JB2
D1-JB2
D1-JB2
D1-JB2
D1-JB2
D1-JB2
D1-JB2
DTL-A
DTL-A
DTL-A
DTL-A
DTL-A
DTL-A
DTL-A
DTL-A
DTL-A
4-PAIR-1
4-PAIR-2
4-PAIR-3
4-PAIR-4
4-PAIR-5
4-PAIR-6
4-PAIR-7
4-PAIR-1
4-PAIR-2
Belden 1052A
Belden 1052A
Belden 1052A
Belden 1052A
Belden 1052A
Belden 1052A
Belden 1052A
Belden 1094A
Belden 1094A
D1-JB3
D1-JB3
D1-JB3
D1-JB3
D1-JB3
D1-JB3
D1-JB3
D1-JB3
D1-JB3
3-IF16-8
3-IF16-9
3-IF16-10
3-IF16-11
3-IF16-12
3-IF16-13
3-PAIR-8
3-PAIR-9
3-PAIR-10
3-PAIR-11
3-PAIR-12
3-PAIR-13
Belden 1052A
Belden 1052A
Belden 1052A
Belden 1052A
Belden 1052A
Belden 1052A
D1-JB2
D1-JB2
D1-JB2
D1-JB2
D1-JB2
D1-JB2
DTL-A
DTL-A
DTL-A
DTL-A
DTL-A
DTL-A
4-PAIR-8
4-PAIR-9
4-PAIR-10
4-PAIR-11
4-PAIR-12
4-PAIR-13
Belden 1052A
Belden 1052A
Belden 1052A
Belden 1052A
Belden 1052A
Belden 1052A
D1-JB3
D1-JB3
D1-JB3
D1-JB3
D1-JB3
D1-JB3
256
main post coupler return flow meter
*****
end wall flow meter
flow meter
flow meter
flow meter
flow meter
flow meter
6.2 Global Controls
The Global Controls System is a facility-wide system of networks, processors and
software that enables subsystem control systems to maintain local control but allows
sequential control, supervisory control, monitoring, data acquisition, archiving, alarm
management, and operator interfaces from other nodes on the network.
The software will be developed in the SNS standard development environment.
The EPICS (Experimental Physics and Industrial Control System) toolkit forms the
foundation of the standard providing a distributed processing architecture, tools and
software. Operator interface workstations will be Linux based.
Control system
configuration consisting of I/O channel specifics, conversions, alarm limits, control logic,
Channel Access process variable names, etc. will be managed using Oracle. Software
configuration management will be implemented with CVS.
6.2.1. Interfaces
The RCCS local control systems will interface to Global Controls via several
EPICS components known as IOCs (Input/Output Controller). The IOC is a VME
chassis with a single board PowerPC processor, VxWorks operating system and EPICS
software. The RCCS IOCs will be further populated with MPS (Machine Protection
System), Event Link/RTDL (Real-Time Data Link) and Ethernet network boards.
The EPICS software on the IOC consists of the Channel Database, iocCore,
Channel Access Server, Sequencer, driver support and device drivers.
Cooling IOC
Cooling PLCs
Global Controls
Processor
(RCCS and QMCS)
MPS
Machine Protection System
Utility
Event Link/RTDL
Figure 6.9. IOC interfaces.
257
Communication interface between the IOC and the rest of Global Controls is via
Ethernet – TCP/IP over the EPICS’ Channel Access protocol. Every field of every record
is available to all other nodes on the control system through Channel Access.
Communication between the IOC and the RCCS PLCs is via EtherNet/IP. EtherNet/IP is
the ControlNet on Ethernet implementation.
6.2.2. Configuration
There is a one-to-one relationship between the number of PLC-based RCCS
systems and DTL tanks and CCL modules. The design calls for six DTL tanks and four
CCL modules. Additionally there are two QMCS (Quadrupole Magnet Control System)
systems, each with a PLC-based control system.
The relationship between IOCs and PLCs is:
•
1 IOC for the six DTL RCCS PLCs
•
1 IOC for the four CCL RCCS PLCs and 1 CCL QMCS PLC and 1 SCL QMCS
PLC
Archivers
Operator
Interface
Workstations
Ethernet to Global Controls
MPS
Event Link/RTDL
EtherNet/IP
DTL1
RCCS
PLC
DTL2
RCCS
PLC
DTL3
RCCS
PLC
DTL4
RCCS
PLC
DTL5
RCCS
PLC
DTL
Cooling
IOC
In rack:
ctl:dtl6 cab01
Figure 6.10. IOC for DTL RCCS PLCs.
258
DTL6
RCCS
PLC
Archivers
Operator
Interface
Workstations
Ethernet to Global Controls
MPS
Event Link/RTDL
EtherNet/IP
CCL1
RCCS
PLC
CCL2
RCCS
PLC
CCL3
RCCS
PLC
CCL4
RCCS
PLC
CCL
QMCS
PLC
SCL
QMCS
PLC
CCL
Cooling
IOC
In rack:
ctl:ccl4 cab01
Figure 6.11. IOC for CCL RCCS PLCs, CCL QMCS PLC and SCL QMCS PLC.
6.2.3. Interlocks
Interlock specifics and details are in progress. To date the following interlocks
have been identified. All of these interlocks route through the IOC. The IOC transmits
or receives these interlock signals by way of the Channel Access (CA) client/server
software over the Global Controls networks.
Inbound (per RCCS PLC):
RF Error signal from associated LLRF
Outbound (per RCCS PLC):
RF Permit signal to LLRF
RF Windows Water Flow Signal to associated HPRF
Outbound (per RCCS PLC and per QMCS PLC)
Water OK signal to Magnet Power Supplies
259
6.2.4. Operator Interface
Operator interface screens are under development.
These screens will be
available on all Global Controls EPICS workstations in the facility. There are various
levels of screens planned at this time: high level monitoring showing composition results
of all RCCS and QMCS systems, monitoring screens of individual RCCS and QMCS
systems, tabular panel style operator control screens, P&ID representations with
numerical and graphical indicators and operator controls (buttons, sliders, setpoint entry,
etc.), and tabular parameter entry screens (i.e. alarm limits, PID parameters, etc.).
6.2.5. Archiving
Signals from the resonance cooling system are read into the IOCs and time
stamped. The time stamp is derived from the system-wide clock that is received by the
utility board over the event and RTDL links. The time stamped data can then be used to
determine any relationship between subsystem parameters.
6.2.6. Alarm Management
The management of alarms at the global level has not yet been determined. The
cooling system parameters can configured to be in a cooling only alarm configuration or
as part of the related beamline components: DTL and CCL, or both.
260
7.0 SNS Facility Interfaces
The design of the DTL water cooling and resonance control system requires multiple
mechanical and electrical interfaces with the SNS facility. Figure 7.1 shows a plan view
of the portion of the SNS facility corresponding to the drift tube linac. The DTL portion
of the facility is divided into two main structures. The first structure is the linac tunnel,
which contains the DTL RF structures and its subsystem components including beam
diagnostics, magnets, vacuum pumps and instrumentation, and the water manifolding
system. The second structure is the klystron gallery, which houses the klystron and RF
power systems, water skids, motor control centers, electronics racks, etc. Figure 7.2
shows a cross-section of the DTL facility structures. Running between the linac tunnel
and klystron gallery, are several chases, which carry in part, water transfer lines, as well
as water system instrumentation and electrical power lines.
Each of these facility
structures, and their various interfaces with the DTL water cooling systems, is described
in more detail in the following sections.
7.1 Klystron Gallery
The klystron gallery is 30 ft wide by 26 ft high and contains much of the hardware
and electronics for the various linac support systems (RF controls and power systems,
water cooling and resonance control, vacuum, etc.). In particular, the klystron gallery
houses six DTL water skids, and their corresponding electronics racks and pump
motor/water heater control centers. Each water skid and its corresponding electronics
rack and motor/heater control center, form the heart of a single DTL tank water cooling
system. As shown in Figure 6.1, the water cooling system’s skids and electronics racks
are distributed throughout the klystron gallery. The power and signal lines will run
between a water skid and its corresponding electronics rack in overhead cable trays. This
will also be true for power and communication cables between an electronics rack and its
corresponding DTL tank. In this case, cables will be routed through cable trays between
the rack and its corresponding waveguide chase, through which the cables will run to
reach the DTL tank. A cable junction box, located at the klystron gallery end of the
chase, will ease the routing of the cables into the chase conduits. For the six DTL water
skids, there will be six corresponding motor/heater control centers. These control centers
261
Figure 7.1. Plan-view of the SNS facility along the length of the DTL.
262
Figure 7.2. Cross-section of the SNS facility at the DTL.
263
Figure 7.3. Cross-section of the Linac tunnel at the DTL.
264
will be remotely grouped together in a single location along a wall in the klystron gallery.
This remoteness is necessary to maintain proper access clearance requirements dictated
by national electrical codes.
This will require the routing of electrical and
communication cables between the motor/heater control center, and the corresponding
water skid and electronics rack.
The facility routing of the DTL water cooling system power and communication
cables, as well as the water transfer lines, is part of an SNS facility-wide coordinated
effort and is not complete at this time. Factors that will influence these routings include
the following: Cable tray definitions and routings, waveguide layouts, chase shielding
blocks designs, junction box definitions, other water line routings, etc.
The LANL and ORNL facility interface issues related to the klystron gallery, are
summarized in Table 7.1.
265
Table 7.1. LANL and ORNL Klystron gallery design issues, as they pertain to the Linac water cooling systems.
Item
Design Issue
Description or Action
Status
1
Where are the connection
points/interfaces between the
water skid and facility chilled
water?
What do the facility interfaces
for the chilled water supply and
return look like? (flange type,
valve arrangement, etc.)
The water skid will have connections at the top of the skid. The approximate location is 8’ 6” above the
floor and 2’ to 4’ from the North wall. Each water skid location is defined on LANL drawing
155Y500006. Facility chilled water supply and return ports are noted on LANL drawing 155Y500006.
Closed
For each DTL water skid, there will be two 3” water lines running between the top of the skid and the
facility chilled water supply and return. ORNL facilities will need to provide flanged connections off of
the facility chilled water supply and return lines for each skid. These flanged connections should be
sized for a 3” pipe connection. ORNL facilities must also provide isolation valves on the facility side of
these connection flanges. LANL will be responsible for routing and providing the plumbing between the
water skid and facility chilled water ports.
The clearance is 3’ to the shielding blocks, 3’ to the electronic rack, 1’ from the North wall, and 2’ to the
next water skid.
Closed
The cable tray layouts are currently under development by ORNL and LANL.
Open
All electrical requirements for the Linac water cooling systems have been defined and are contained on
ORNL drawing # SK-GAJ-112800-01. For the racks, the power and signal lines will run along the
South wall, split 90° and run from overhead racks dropping down to the trays. For the water skid, the
electrical hook-ups will follow a similar path and drop from overhead trays.
All electrical requirements for the Linac water cooling systems have been defined and are contained on
ORNL drawing # SK-GAJ-112800-01. Wiring of the motor/heater control centers is still under
development.
The water skids, motor/heater control centers, and electronics racks, are identified on LANL drawing #
155Y500006.
Closed
A preliminary DTL water transfer line routing layout has been generated by LANL SNS. LANL plans
to generate single line diagrams to provide craft pipe fitters with to plumb the transfer lines. These
single line diagrams will be incorporated with the 3-D facility models (see LANL drawing #
155Y500006) as they are developed, to ensure proper clearance is maintained with other hardware.
The shielding is presently defined as concrete blocks.
Open
LANL
&
ORNL
Open
ORNL
2
3
4
How much clearance exists
around the water skids and
electronics racks for
maintenance?
Where are the cable trays
located?
5
Are the electrical requirements
and wiring layouts identified for
the electronic racks?
6
Are the electrical requirements
and wiring layouts identified for
the water skids?
Where are the locations of the
water skids, motor/heater control
centers, and electronics racks?
What is the routing plan for the
water transfer lines running
between the skids and the
chases?
What does the shielding look
like around the chase entrance?
7
8
9
266
Action
for:
Closed
Open
LANL
&
ORNL
LANL
&
ORNL
Closed
7.2 Linac Tunnel
The linac tunnel is 14 ft wide by 12 ft high and contains the six DTL tanks and the
associated water manifolds, jumper lines, and instrumentation. As shown in Figure 7.3,
the proton beam line is 50 inches above the floor and 68 inches from the South wall. The
DTL support structure has a ground clearance of 23 inches and has a 4 foot spacing to the
South wall. The main supply and return manifolds will be mounted on the non-aisle side
of the DTL support structure. Access to this area will be required for manual operation
of the water distribution globe valves during system commissioning. Access will also be
required for periodic maintenance. Consequently, a coordinated effort by all hardware
and facility design teams will be required to ensure that proper access is available and
maintained behind the DTL.
The water cooling system cabling to/from the electronics racks will enter the
Linac tunnel at the base of the South wall through the chases. The chases are centered on
each of the DTL tanks. The exact routing of the cabling between the chase and the DTL
structure is currently under development. It is expected that the water cooling system
cabling will be routed overhead, via cable trays, between the DTL tank and the associated
chase entrance. A junction box, located at the chase entrance, will be utilized to ease
cable routing tasks.
RF shielding is required in the Linac tunnel at each chase entrance. The Linac
shielding will be similar to the shielding on the Klystron gallery side of the chase. The
shielding must provide feed-throughs for the water system cabling and water transfer
lines to pass through. The shielding requirement on the Linac side of the chase is under
design by ORNL SNS personnel.
The LANL and ORNL facility interface issues related to the linac tunnel, are
267
Table 7.2. LANL and ORNL Linac tunnel design issues, as they pertain to the Linac
water cooling systems.
Item
Design Issue
1
What is the routing plan for the
water transfer lines running
between the RF structures and
the chases?
2
Where are the cable trays
located?
3
What does the shielding look
like around the chase entrance?
What are the clearances around
the Linac for water line
installation and maintenance?
4
Response or Action
A preliminary DTL water transfer line routing
layout has been generated by LANL SNS. LANL
plans to generate single line diagrams to provide
craft pipe fitters with to plumb the transfer lines.
These single line diagrams will be incorporated
with the 3-D facility models (see LANL drawing #
155Y500006) as they are developed, to ensure
proper clearance is maintained with other
hardware.
The current tunnel design includes cable trays
extending overhead along the South wall of the
linac tunnel. The design of the trays and the
routing of the cables is still under design.
The shielding is presently defined as concrete
blocks.
The C/L of the beam is 50” above the floor and
68” from the South wall. The Linac support
structure has a ground clearance of 23” and has a
50” spacing from the South wall. The water
manifolds will be mounted on the non-aisle side of
the linac. Proper clearance must be maintained in
this area for operation of manual globe valves and
maintenance procedures.
Status
Open
Open
LANL &
ORNL
Open
ORNL
Closed
7.3 Chases
The chases will be located at an angle of 33.5° from the horizontal, running from the
Klystron gallery downward to the Linac tunnel, as shown previously in Fig 7.2. The
angled chase will have a length of approximately 20 feet. The chases will serve as
passageways for the RF waveguides, water cooling lines, and power/communication
cabling.
All water cooling system power and communications cables for instrumentation on
the DTL , will be routed between the tunnel and klystron gallery via the chases. To
simplify the wire routings in the chases and minimize the amount of time required for
pulling and routing cables, junction boxes will be utilized on both ends of the chases.
The junction boxes will be connected with specified numbers and types of cables, which
will be wired and routed prior to installation of the DTL water cooling system. The use
of junction boxes will eliminate the need to individually route standard cables and will
significantly shorten the required installation time of the vacuum control systems. The
installation teams will simply need to wire a water cooling system electronics rack up to
the corresponding junction box in the klystron gallery, as well as wire up the water
268
Action
for:
LANL &
ORNL
cooling system instrumentation to the matching junction box in the linac tunnel. More
specific details on cable types, quantities, sizes, etc., can be found in Section 6 of this
report.
The chases are currently under the design and responsibility of ORNL SNS. The
DTL water cooling system cable and transfer line sizes and quantities given in this report
have been submitted to ORNL SNS to incorporate proper quantities of electrical conduits
and water pipes in the chase designs. The numbering sequence for the various chases and
their contents, is also under development and will be integrated with the facility-wide
cable and transfer line layouts. Figure 7.4 summarizes all of the chase cross-sections,
contents, numbering sequence, etc. Figure 7.5 provides details of the chases containing
the DTL water cooling system water lines and power/communication cables for tanks 3
through 6.
The LANL and ORNL facility interface issues related to the chases, are
Table 7.3. LANL and ORNL chase design issues, as they pertain to the Linac water
cooling systems.
Item
Design Issue
1
How many chases are provided
and where are they located?
2
What is the size and orientation
of the chases?
What components reside in the
chases? (waveguides, water
pipes, signal lines, etc)
Is the environment of the chase
satisfactory for the water lines
and cables?
3
4
5
Is shielding of the analog signal
lines from RF waveguides
needed if both are placed in the
chase?
Response or Action
The chases are identified on LANL drawing #
155Y500006. Chase numbering has been
developed by ORNL and identified in ORNL
drawing # SK-GAJ-112800-01.
The chase size is identified in ORNL drawing #
SK-GAJ-112800-01.
The chase contents are identified in ORNL
drawing # SK-GAJ-112800-01.
Open
Action
for:
ORNL
Open
ORNL
Open
Currently, engineering calculations predict that,
for chases containing waveguides, the chase air
temperatures will exceed 50°C. This high air
temperature violates national electrical codes for
the intended cabling plan, as it seriously
deregulates the cable capacities and detrimentally
impacts the insulation properties of the cables.
The high air temperatures will also have a negative
impact on the water temperature of the resonance
control system’s transfer lines.
It is unclear whether or not the RF waveguides
will create undesirable noise in the signal cables,
running in the electrical conduits.
Open
LANL
&
ORNL
ORNL
269
Status
Open
LANL
&
ORNL
Figure 7.4. Chase cross-section details for the SNS facility.
270
Figure 7.5. Chase cross-section details for the DTL water cooling system’s tanks 3
through 6.
271
8.0 Safety
8.1 Hazard Analyses and Protective Measures
There are numerous safety issues and concerns associated with the design of the
DTL water cooling and resonance control system including mechanical, electrical, and
thermal. This section attempts to itemize the hazards associated with the water cooling
system design, and list protective measures that have been incorporated to mitigate them.
Some general hazards related to the DTL water cooling system design are
Potential mechanical and electrical failures that can be
detected and mitigated with the control system are summarized in Table 8.2.
Table 8.1. Summary of general hazards related to the DTL water cooling system design.
#
1
Hazard
Overpress
urization
of water
cooling
system.
2
Electrical
-High
voltage
(220 to
440 VAC)
for heater
and pump.
Water
purificatio
n resins
activation.
Water
system
plumbing
activation.
3
4
5
Chemicals
6
Water –
activation
7
Electrical
- racks
Mitigation Features
• Plumbing designed to withstand an operational pressure of at least 150 psig, following
the ASME B31.3 code.
• Pressure relief valves placed on the expansion tank and supply/return manifolds of the
Linac. Valves set to crack @ 100 psig.
• Flow throttling device placed on nitrogen pressurization source to limit the entering
gas flow to a value below the dissipation rate capacity of the pressure relief valves.
• An industry and UL approved control circuit will be used on both the electric heater
and pump. The pump’s motor controller will also have an overload protection circuit.
• Controllers for both devices will be placed in a motor/heater control center which has
proper access clearance according to the National Electrical Code for performing
electrical work on energized circuits.
• All electrical wiring will be protected with metal conduit and installed by qualified
crafts personnel.
• Some activation of the water purification resins will occur during operation of the
Linac water cooling system. These activation levels are expected to be quite low,
based on operational experience at LANSCE. A resin handling and disposal plan has
been generated and is contained within this report.
• Some activation of the water system plumbing will occur during operation of the Linac
water cooling system. These activation levels are expected to be quite low, based on
operational experience at LANSCE. Shielding is not expected to be required. DOE
approved, worker radiation safety protocals will need to be followed to work around
the water cooling systems.
• Piping dope, cleaning agents, water purification resins, etc., will require specific
handling procedures, personnel protective equipment, and training on proper use.
Administrative controls will need to be in place by ORNL-SNS management.
• MSDS sheets will be provided by chemical suppliers to ORNL-SNS.
• Leakless drain systems have been incorporated in the design of the water system.
• Training and administrative controls will be necessary for all maintenance work which
requires draining of the water cooling systems.
• Maintenance procedures will be documented in an operations and maintenance
manual.
Electronics racks will have access restrictions to prevent non-authorized personnel access.
The touchscreen interfaces will be password protected to limit accessibility.
272
Table 8.2. Summary of potential mechanical and electrical failures detected and
mitigated by the control system.
#
1
Failure Mode
Major Power
Failure to rack and
skid
2
3
Rack Power
Failure
Skid Power Failure
4
RTD failure
5
Pump Failure
6
Major Water Leak
7
Pump Failure
8
Heater Failure
9
LLRF error signal
range
Detection Method
No heartbeat signal
to the Global
Control System
(GCS)
No heartbeat signal
to GCS
Controller will
detect
disagreements
between setpoints
and readback
values
Controller will
record an out-of –
range value
Flowmeters will
detect loss of flow,
Difference in input
and output
flowmeters and
loss of pressure.
Pump readback
will disagree with
control setpoint
No rise in
temperature
detected
Voltage out of
range (<0.5V or >
9.5 V)
Result
Pump shuts off, heater shuts off.
Pump shuts off, heater shuts off.
Pump shuts off, heater shuts off, control system
generates alarm message to GCS
Generates an alarm message to GCS
Controller will shut down system and generate
alarm message to GCS
Controller will shut down system and generate
Controller will shut down pump and generate
Controller will shut off heater and generate alarm
message to GCS
Controller will decrease temperature of RCCS if
<0.5V, and increase temperature if > 9.5 V. A
message will be sent to GCS to indicate RCCS is
not in closed-loop mode.
8.2 Personnel Safety
In addition to the designed safety features and control system safety interlocks
mentioned previously in this report, the following personnel safety issues should be
considered by ORNL:
•
Proper ORNL safe operating procedures and hazard control plans (or similar
administrative controls) will be in place at the SNS facility for the assembly,
installation, testing, and operation of the water cooling systems.
•
All electrical work will be carried out in compliance with ORNL ES&H policies
which implement U.S. Department of Energy orders to comply with local, state and
federal regulations.
273
•
All water cooling system personnel will receive proper safety and site-specific
training as directed by ORNL ES&H guidelines.
•
All MSDS related to the water cooling system equipment shall be supplied to ORNL
SNS by the responsible vendors.
•
Water cooling system components will be subject to radiation activation from beam
scattering. Since water cooling system components will have to be serviced, repaired
or replaced, workers may be exposed to the induced radiation.
The hazard of
activation of the water cooling system components must be addressed in a separate
Radiation Protection Plan (e.g. safety plans, training, operating procedures, etc.) in
accordance with 10 CFR 835, Rev. 1, "Occupational Radiation Protection". The SNS
Facility Manager will need to develop and implement the Radiation Protection Plan.
•
ORNL SNS will be provided with assembly, installation, operations, and maintenance
manuals related to the DTL water cooling and resonance control system, by the
LANL SNS division.
274
9.0 Procurement
The water cooling system can be split into two major procurements, the water
skids and the water manifolds.
The procurement plan will not differ significantly
between DTL, CCL, and SCL water cooling systems.
The complexity of each
procurement, and therefore the procurement method, is vastly different when comparing
the requirements for the water skid and the water manifolds. Detailed comparison tables
were used to determine the procurement methods (See Tables 9.1 and 9.2). A criterion
was developed, scored and multiplied by a weighting factor to compare two different
procurement options.
The water skid contains all of the critical components for controlling the water
temperature and flow. However, the manifold system will contain flow, temperature, and
pressure monitoring equipment that will feed back to the PLC. In essence, the skid is the
heart of the closed loop system and the manifolds are the delivery portion of the system.
LANL’s analysis of the water skids and manifolds, supported by the Hot Model testing,
show that the SINDA/FLUINT estimates of line sizing, orifice plate diameters, etc. are
very accurate. As can be seen, the manifold design does not involve a large degree of
intricacy, which supports a build-to-print procurement. The Water skid design has great
design complexity, which supports a more flexible design method of procurement.
Table 9.1. Water skid procurement options†
Criteria
Individual Score
Option A
Option B
Functionality
Safety
Procurement,
Fabrication,
Assembly
Durability/
Reliability
Cost
Maintainability
Consistency
Weighting
Factor
Total Score
Option A
Option B
3
4
5
3
3
3
5
5
3
15
20
15
15
15
9
4
4
4
16
16
5
3
4
2
3
3
4
3
2
Grand Total
Score
20
9
8
103
8
9
6
78
275
Table 9.2. Water manifold procurement options †
Criteria
Individual Score
Weighting
Option A
Option B
Factor
Functionality
Safety
Procurement,
Fabrication,
Assembly
Durability/
Reliability
Cost
Maintainability
Consistency
†
Total Score
Option A
Option B
3
3
4
4
4
4
5
5
3
15
15
12
20
20
12
4
4
4
16
16
2
3
3
5
3
5
4
3
2
Grand Total
Score
8
9
6
81
20
9
10
107
Option A = LANL will provide all design requirements for all of the components
to be purchased by the supplier. The supplier will buy all system components
excluding the heat exchanger, flow control valve, and water purification system.
The supplier will provide all drawings for LANL approval as well as test the
system for leakage and functionality.
Option B = LANL will purchase and provide all components to the supplier. The
supplier will provide all drawings for LANL approval as well as test the system
for leakage and functionality.
The statement of work for both the skids and the manifolds will be sent out for
competitive bid to LANL specified vendors and purchased by the LANL procurement
department.
The vendor selection will be competitive and proposals submitted by
contractors will be reviewed and judged on a cost as well as an established technical
criterion. The potential vendors will be subject to approval by the technical review team
who will evaluate the design proposals and methods. The University of California
Technical Representative and Buyer from LANL will select the lowest cost responsible
bidder from those received.
Established LANL Quality Assurance Procedures (see
Section 9.3) will be followed
Vendor technical selection criteria will include:
•
Overall design expertise
•
Functionality
•
Basic fabrication, assembling, and testing capabilities
276
•
Reliability
•
Maintainability
•
Past performance history
•
Manufacturing and delivery plan (clear and concise? Risky?)
•
Subcontracting plans
•
Quality assurance program
•
Inspection and testing capabilities
•
Ability to meet staggered delivery schedule (see Section 8 of this report)
•
On-site survey of contractor facilities
9.1 Water Skid Procurement
LANL will develop all of the technical requirements for the water skid. These
requirements will be provided to the manufacturer/supplier in a detailed procurement
specification. This information will be the basis for developing the water skid. Some
freedom will be permissible for the supplier to optimize their design, but it will resemble
the water skid depicted in Figure 2.3(b). LANL will specify the manufacturer and model
type for the heat exchanger, but will supply specifications for all other water skid
components. The responsibility to purchase the heat exchanger will belong to the water
skid manufacturer. The manufacturer will select all other components provided they
meet the technical requirement explicitly defined in the procurement specification. The
technical statement of work for the procurement of the water skids is contained in
Appendix C.
The procurement specification contains an outline drawing, a P&ID, and the
testing requirements to the water skid manufacturer. LANL will not provide detailed
drawings. These drawings are the responsibility of the manufacturer to develop and
create based on their proposed design. LANL will retain drawing approval for assembly,
installation, and detail drawings.
The water skid manufacturer will provide a complete set of drawings for the
system design and the supporting structure. The support structure will have specified
requirements defining the envelope, mobility, stiffness, etc. Acceptance tests will be
required to verify the fluid system integrity. Test completion and acceptance will allow
277
for the certification of the water skid. Packaging and shipping to ORNL will complete
the responsibility of the manufacturer.
9.2 Water Manifold Procurement
LANL will develop all of the technical requirements for the water manifolds.
These requirements will be provided to potential vendors in a detailed procurement
specification. A technical evaluation will be made of the potential vendors to verify that
each proposal meets all of the technical requirements as specified in the procurement
specification. In evaluating potential vendors, the same technical criterion as that used
for the water skids and shown above will be implemented. From the technical evaluation
will be a ranking. The technical ranking will be compared to a cost ranking. The result
will produce the lowest cost responsible bidder.
The procurement specification will be the basis for fabrication of all of the water
manifold assemblies for the DTL, CCL and SCL. Some freedom will be permissible for
the vendor to optimize their design provided their selections meet the technical
requirements that have been specified and follow the guidelines defined in the P&IDs,
assembly drawings, subassembly drawings and detail drawings. Any desired deviations
will require written approval from LANL. The vendor will purchase all valves, flanges,
fittings, etc. provided this hardware meets the technical requirement explicitly defined in
the procurement specification.
The flowmeters are the only components that will be purchased by LANL and
provided to the manifold fabrication vendor. The layout design, primarily in the CCL
manifold system, is very space restrictive. The LANL designers have very little working
space due to the installation requirements of these flow meters, the closeness to the
support structure, the closeness to the tank segment, and the quantity of required
submanifolds. The total cost of the flowmeters requires a competitive bid process to get
the best value for the SNS program.
Additionally, the electronic conversion units
mounted on the flowmeter, which converts a pulsed signal to a 4 to 20 mA signal output,
must be allotted for in the design. End fittings, whether threaded, flared, or flanged must
be identified and incorporated into the design.
278
Acceptance tests will be required to verify the fluid system integrity.
Test
completion and acceptance will allow for the certification of the water manifolds.
Packaging and shipping to ORNL will complete the responsibility of the vendor.
9.3 Hardware Costs
With the exception of the plumbing lines and water skid support structure, all
water system components are standard catalog items that do not require any additional
design development by a vendor. Table 9.3 is a summary of the major DTL water
cooling system procurements. A more detailed cost break-down is provided in Appendix
D.
Spare parts are not included in this estimate.
The supplier will provide a
recommended spare parts list to assist ORNL in evaluating the need for various spare
parts. It must be emphasized that listed vendors and hardware costs are for reference
only.
Similar components by other manufacturers will be considered during a
competitive bidding process.
Table 9.3. Summary of DTL Water Cooling System components and unburdened costs.
Item # Description
1
2
3
4
5
Qty Unit Cost Cost Source
($)
Drift tube Water skid
6
85,071 catalog & eng.
Judge.
Drift tube Manifolds & Trans. Lines
6
Judge.
RF struct. Manifolds & Trans.
6
Lines
Judge.
PLCs, Computers, software
7
$25,500 catalog & eng.
Judge.
Electronics rack & equipment
7
$1,157 catalog & eng.
Judge.
GRAND TOTAL
Net Cost ($)
510,428
219,513
278,930
178,500
8,099
1,195,470
9.4 Delivery and Inspection
All water manifolds and water skids will be delivered to the SNS Receiving,
Acceptance, and Testing (RATS) building at ORNL for inspection and storage prior to
assembly. The delivery schedule for this equipment is presented in Section 13. The
inspection at the point of delivery will be performed to check for obvious mechanical
damage due to shipping problems. Operational or functional inspections will not occur
until the entire water system equipment has been assembled to the DTL RF structure.
279
Several months of storage for water system hardware may be required prior to assembly
and equipment operational checkout.
9.5 Quality Assurance
To ensure the procurement and successful operation of a high quality water
cooling system, a quality assurance (QA) plan has been developed. The QA plan is
comprised of four segments that correspond to the major activities defined in the DTL
water
system
work
package;
final
design,
procurement,
delivery,
assembly/installation/testing.
To initiate the QA plan, this final design report will function as the guide for
generating a document identifying the parameters and requirements, equipment layouts,
engineering calculations, drawings, facility interfaces, control system architecture,
procurement/assembly/installation plans, safety features, costs, schedule, etc.
The QA components of these SOWs will be as follows:
1) QA Program and Procedures:
Vendor shall furnish copies of its latest quality
assurance inspection and test policies and procedures. Their QA program will be
reviewed to determine its adequacy and relevance.
2) Vendor Facilities: To verify production, inspection, testing, and QA/certification
capabilities, the vendors will be requested to submit references and provide for onsite visits by LANL personnel. Such personnel shall be allowed full access to witness
all operations/tests involved in the performance of the SOW.
LANL will maintain
vendor and program surveillance to evaluate program progress.
3) Qualification and Certification of Personnel:
Vendor personnel shall have the
necessary qualifications and certifications as defined in the SOW to perform the
necessary manufacturing, testing, inspection, and certification procedures (i.e.,
professional engineers, certified welders, etc.).
The Vendor shall provide
qualification and certification records.
4) Design Review Prior to Production: For the water skid procurement, the vendor shall
provide for scheduled design reviews as identified in the statement of work.
Notification of design reviews shall include the proposed agenda, and reproducible
280
paper and electronic copies of each document that constitutes the design or helps to
demonstrate that the design meets the LANL requirements specified in the SOW.
The water manifold procurement will be less formal but no less important. No
design reviews will be required therefore LANL’s review process is significantly
simplified. LANL will review the vendor’s schedule and maintain manufacturing
progress evaluations. Full and complete documentation will be imposed.
5) Inspection and Testing Procedures/Reports:
Vendor shall prepare and maintain
written and detailed inspection and testing procedures that show how the procured
items will be verified that they conform to the requirements or specifications in the
SOW. These procedures shall be reviewed and approved by LANL. Upon shipment,
the vendor shall provide reports of inspections, tests, and certification of
conformance. These reports shall be signed by the vendor’s authorized personnel and
shall be traceable to each shipment.
Any deviations from the SOW technical
requirements that are noted in these reports must be approved by LANL prior to
shipment.
6) Engineering Drawings: For the water skid procurement, the vendor shall provide all
engineering drawings (both in electronic and paper formats) as specified in the SOW.
LANL will be providing all drawings to the vendor for the water manifold
procurement.
7) Certifications of Calibration and Conformance: Vendor shall provide with each
shipment, when applicable, a certificate of calibration traceable to the shipment and
the National Institute of Standards and Technology procedure for calibrating such a
device.
Vendor shall also provide with each shipment, a “Certificate of
Conformance” that is traceable to the shipment stating that the material conforms in
all respects with the SOW requirements (i.e., drawings, materials, specifications,
inspections, tests, etc.). The vendor’s authorized representative as defined in the
vendor’s QA program shall sign the certificate.
8) Failure/Nonconformance Reporting: The vendor shall notify LANL of each failure
or nonconformance against contractually agreed upon engineering, inspection, or test
requirements within 3 working days of the occurrence. Notice shall consist of a
281
written description of the failure or nonconformance, an assessment of the cause, and
the proposed corrective action.
9) Corrective
Action
to
Failure/Nonconformance:
Following
a
“notice
of
failure/nonconformance” from the vendor, LANL will submit a request for corrective
action. For the water skid only, a written response indicating the corrective action
taken by the vendor must be received within 5 working days of receipt of the request.
The water manifold vendor will not be given this freedom. The vendor will be
directed as to the corrective action that they must perform to resolve any
nonconformance. The vendor will take no action until such action is approved by
LANL.
10) Manuals: For the water skid procurement only, the vendor shall submit manuals that
identify installation procedures, testing procedures undertaken, any special
instructions, maintenance requirements, estimated failure rates, operating procedures,
safety precautions, trouble shooting guides, as well as warranty and contact
information.
The manuals shall be written in clear, concise language, readily
understandable by a technician or craftsman, and it shall conform to the industry
standards that prevail for the preparation of such documents.
For the water manifold procurement, the vendor will provide no manuals.
11) Warranties:
For standard off-the-shelf parts, vendors must supply LANL with
warranties that account for the potentially length time a system may remain unused in
the RATS building. LANL, in the defined SOW, has increased the length of the
standard warranty requirement to include the potential that system operation may be
delayed by as much as 1 year. This will protect the project against buying faulty
equipment that is outside a warranty period, simply because it has been in storage
prior to operation. The terms of these warranties and the extent of the storage time
will need to be agreed upon with the vendors.
12) Packaging: Items to be shipped shall be packaged according to size, manufacturer,
dimensional and manufacturer lot number. Packages of mixed lots, sizes, or products
are not acceptable and will be returned to the vendor at vendor’s expense. Packages
shall be closed and labeled in a manner that identifies the item, dimensions (where
applicable), quantity, seller’s name and address, manufacturer’s name, and shipment
282
address. When required, as specified in the SOW, the packages will be provided with
special handling fixtures (i.e., crane and forklift lifting fixtures), have proper
insulation against damage, and have shipping insurance.
Upon delivery of the components to ORNL, a visual inspection and component
count shall be performed. This inspection will verify the quantity of items delivered
including the receipt of required QA documents, MSDS sheets, engineering drawings,
and manuals. The inspection will also check for damage due to shipping, and check to
see that all dimensional and cleaning requirements have been met. An inspection report
shall be generated to indicate the conformance/nonconformance of the shipment. If a
nonconformance is indicated, the vendor shall be contacted to perform corrective action
to meet the delivery requirements specified in the SOW. Upon successful delivery and
inspection of the vacuum hardware, the equipment will be stored in the RATS building
until required for assembly.
The water manifold equipment will be assembled on the RF structures and tested
for functional and operational compliance.
The water skids will arrive completely
assembled. The specific testing and documentation procedures will be specified in the
SOW by the LANL.
A testing report shall be generated to indicate the
conformance/nonconformance of the hardware functionality to the SOW specifications.
If a nonconformance is indicated, the vendor shall be contacted to perform corrective
action to meet the requirements specified in the SOW. Upon successful testing of the
water manifolds and water skids, a certification document will be completed and signed
to indicate the compliance of the vendor supplied material.
While the vendor supplied material may be certified for conformance, the
integrated control system, as designed by participating SNS laboratories, will require
certification of operation prior to acceptance by the SNS operations team.
The
testing/certification procedures and documents for this process will be generated
following completion of the DTL/CCL Water Cooling Systems Final Design Review.
283
10.0 Assembly, Installation, and Certification Plans
Following fabrication, delivery, and inspection of all DTL water cooling system
hardware, the assembly tasks for the DTL water cooling system will take place as an
integrated effort in the assembly of each DTL tank. The water cooling system assembly
tasks will take place in the SNS Receiving, Acceptance, and Testing (RATS) building at
ORNL. The anticipated assembly tasks for the DTL water cooling systems are as
follows:
•
Assemble the electronics rack, including PLC, touchscreen, DC power supplies, etc.
in the rack factory.
This includes mounting of components in the rack and
completing all inter-component wiring according to the rack layout and wiring
diagrams.
•
Receive and inspect the water skid.
•
Position and wire up a water skid, motor/heater control center, and electronics rack in
the RATS building. These components will be used to flow test each DTL tank and
CCL module. Wire components to facility electrical sources and plumb water skid to
chilled water source.
•
Mount all water manifold supports to the DTL support structure.
•
Mount sub-manifolds and connect flexible jumper lines for the drift tubes, dipole
magnets, post couplers, slug tuners, tank walls, etc. Note that the flexible coolant
lines to the drift tubes will be attached at LANL prior to DTL alignment and tuning
activities. Following the completion of the alignment and tuning procedures, the drift
tube jumper lines will remain in place during shipment to ORNL. This will reduce
the possibility of damaging the drift tube alignment as the water system lines are
assembled at ORNL.
•
Assemble and mount main supply and return manifolds to the support structure and
connect flexible jumper lines to sub-manifolds.
•
Connect flexible jumper lines between main manifolds and the end walls, drive iris,
RF window, and Faraday cup.
•
Connect instrumentation on the RF structure water lines to the control system.
•
Connect water transfer lines between the water skid and RF structure.
284
•
Leak check the RF structure water lines and connections with pressurized gas.
•
Fill water system, clean, drain, refill, and bleed out any air.
•
Perform flow test to set all valve positions and check flow distribution to all
submanifolds. Also check flow distribution on drift tubes to determine accuracy of
orifice plate selections and document the results. Change out orifice plates if needed.
•
Drain water from entire system and disconnect water skid transfer lines.
•
Disconnect instrumentation cables between RF structure and electronics rack.
•
Remove main supply and return manifolds for transportation to the Linac tunnel.
•
Cap or seal all open water lines and manifolds with bags, plugs, or blanks.
•
Sign-off on the assembly completion certification document to ensure that the
assembly process, vacuum equipment check out, and leak check test have been
completed per requirements.
•
Repeat for the remaining five DTL tanks.
To accomplish the DTL water cooling system assembly tasks, the RATS building
must be equipped with the following:
•
Storage space for water cooling system components, including fully assembled water
skids, electronics racks, and boxes of water manifolds, flexible hoses, fittings, etc.
•
Nitrogen bottles (99.9% N2), equipped with coarse and fine gas regulators for purging
the water cooling system for leak checks and displacing atmospheric air.
•
Handling and cleaning procedures/equipment for a deionized water system (detergent
rinse baths, brushes, clean compressed air supply, rubber gloves).
•
Standard tools required for assembling water plumbing components (i.e., open and
box-end wrenches, pipe wrenches, band-clamp devices, etc.).
•
Electrical power needed for a complete DTL water cooling system, as specified in
Section 1.5.
•
Trained and qualified mechanical and electrical technicians, capable of cleaning,
assembling, inspecting, leak checking, and testing a complete water cooling system.
285
•
A temperature controlled environment to avoid damage to water cooling system
components (i.e., freezing of water left in lines).
The installation of the DTL tank and supporting subsystems will take place
immediately following certification of the entire DTL assembly and testing process. The
installation of the DTL includes transporting the DTL tank, assorted subsystem
components, and control system racks from the RATS building, over to the klystron
gallery and linac tunnel. The entire installation plan for the DTL is currently incomplete,
as the design of the DTL is still in process. The anticipated installation tasks for the DTL
water cooling system components are as follows:
Klystron Gallery:
•
Install the motor/heater control center and route electrical wiring to facility sources.
•
Place water skid in position and complete the following subtasks:
•
Complete electrical wiring from pump and heater to the motor/heater control
center
•
•
Connect plumbing between water skid and facility chilled water ports
•
Connect plumbing between water skid and chase transfer lines
•
Leak check water skid and transfer line plumbing
Place electronics rack in position and complete the following subtasks
•
Complete electrical wiring from rack to facility sources
•
Run signal and power cables from rack to junction box and chase conduits
•
Run signal and power cables from rack to water skid
•
Run signal cables to global control system IOC
Chase:
•
Route cables through conduits
•
Install junction boxes at chase ends, connect chase conduit cables to junction box
terminals, and perform electrical continuity check
286
Linac Tunnel:
•
Connect main supply and return manifolds to DTL support structure.
Connect
flexible jumper lines between main and submanifolds.
•
Connect water transfer lines between RF structure and chase transfer lines.
•
Leak check main manifold water line connections with pressurized gas.
•
Connect signal and power cables between RF structure and junction box and chase
conduits.
Complete System:
•
Fill system with water, circulate to clean, drain, and refill system.
•
Perform tests to observe hardware operation, instrumentation continuity and
operation, flow distribution, control system software functionality, and water
purification. Adjust valve settings on tank sub-manifolds if needed.
•
Connect local control system to the global IOC and perform SNS Global Control
EPICS interface tests.
•
Sign-off on the installation completion certification document to ensure that the
installation process, water cooling system equipment check out, leak check tests, etc.,
have been completed per requirements.
•
Repeat for the remaining five DTL tanks.
At the time of the writing of this document, the design of the DTL RF structure
has not been finalized. Consequently, detailed integrated assembly and installation plans
have not been written. Upon completion of both the final design of the DTL RF structure
and its subsystems (i.e. water, vacuum, magnets, diagnostics, etc.), a DTL Water Cooling
System Assembly, Installation, Testing and Certification Manual will be developed to
describe the above tasks and certification procedures in more detail.
287
11.0 Operation, Reliability, and Maintenance
11.1 Operation
The operation of the DTL water cooling and resonance control systems can be
divided into the following three distinct operating modes:
1. Water System Testing Mode: In this mode, the water cooling system is operating in
either a stand-alone controls mode, or is being supervised by the SNS Global Control
System (GCS). In either case, the water system is being tested for functionality and is
not performing resonance control. This mode would occur following installation of
the water cooling system or upon completion of a major maintenance procedure. This
mode may also be used to pre-heat the RF structure or magnets for alignment
procedures. During this operational phase, observations may be made of pump and/or
heater operation, instrumentation performance, water flow distribution, water
purification equipment performance, etc.
2. Linac Comissioning and Low RF Power Testing Mode: In this mode, each DTL
water cooling system is operating under the supervision of the SNS Global Control
System (GCS). This GCS supervision is necessary to ensure that all equipment and
personnel protection interlocks are in place between all linac subsystems. The water
system will be used for resonance control, operating under either a temperature or
frequency error control mode. Tuning of the controller’s PID parameters will be
required to obtain resonable stability and response of the water cooling and resonance
control system.
3. High RF Power/Steady-State Operations Mode:
In this mode, each DTL water
cooling system is operating under the supervision of the SNS Global Control System
(GCS). This GCS supervision is necessary to ensure that all equipment and personnel
protection interlocks are in place between all linac subsystems. The water system
will be used for resonance control, operating under a frequency error control mode.
288
Tuning of the controller’s PID parameters will be required to obtain resonable
stability and response of the water cooling and resonance control system.
More details about the resonance control system functionality and its sub-modes of
operation, are provided in Section 6 of this report.
Following completion of the DTL water cooling and resonance control system
final design and the control system development phase, a detailed operations manual will
be developed. The operations manual will include the following:
•
Piping and instrumentation diagrams and system descriptions.
•
Charging, draining, and venting procedures.
•
Start-up procedures and equipment/installation checklists.
•
Control system block diagrams, signal lists, etc.
•
Control system operations screens descriptions.
•
Control system methodology and ladder logic descriptions.
•
Control system “mode-of-operation” descriptions and detailed procedures.
•
Trouble shooting guidelines.
•
Shut-down procedures and checklists.
11.2 Reliability
A measure of the performance in the DTL water cooling and resonance control
system is the ratio of the time that the system is working satisfactorily, to the time that the
beam is shut down due to a DTL water system failure. This performance measure is
traditionally made through a reliability, availability, maintainability, and inspectability
(RAMI) program. These terms, as they apply to the DTL water cooling and resonance
control system, are defined below [11.1]:
•
Reliabiltiy: Probability that the water cooling and resonance control system will
perform as expected for a period of time.
289
•
Availability: The amount of time that the water cooling and resonance control system
is operating as required, divided by the operating time plus down or maintenance
time.
•
Maintainability: Probability that the water cooling and resonance control system can
be returned or restored to operating conditions when maintenance is performed.
•
Inspectability: A measure of the ability to determine if or when maintenance is
required to maintain the availability of the water cooling and resonance control
system.
A RAMI program for ensuring a high availability of 85% for the SNS was
previously outlined in [11.1]. To meet the 85% availability for SNS, this program
required 94.6% to 99.5% availabilities for each of the major SNS subsystems (i.e., from
end, Linac, storage ring, conventional facilities, etc.). The SNS Linac was specified as
needing to have an availability of 96.1%, which in turn would required even higher
availabilities for each of the subsystems (i.e., RF power, LLRF controls, vacuum, water
cooling, magnets, diagnostics, etc.). Unfortunately, budget and manpower restrictions
eliminated the incorporation of the RAMI plan for the SNS. Consequently, there were no
availability or reliability guidelines established for the DTL water cooling and resonance
control systems.
While there are no established reliability requirements for the DTL water cooling
and resonance control systems, best engineering practices were exercised in the design
phase to ensure that negative impacts of equipment failure were minimized. First of all,
previous particle accelerator water cooling and resonance control system designs were
used as a baseline to develop optimize the design and reliability of the DTL water cooling
and resonance control system [1.6, 1.7, 1.8, 1.9]. The latest engineering computer tools
including CFD, network nodal, and FEM computer programs, were used to determine
water cooling needs and size the cooling system components.
Experiments were
performed to benchmark the computer models and determine modeling uncertainties. A
prototype water cooling system has been designed and built, and is currently undergoing
a variety of tests of the system performance and control algorithms. These engineering
efforts are summarized throughout this report. The preliminary DTL water cooling and
290
resonance control system design was peer reviewed [1.4], as discussed previously in
Section 1 of this report.
The review committee consisted of accelerator vacuum
engineers and technicians from six different National Laboratories.
This expert
committee related their design and operation experiences from several accelerator
projects, including LANSCE, APT, APT/LEDA, and APS, to strengthen the design and
reliability of the SNS DTL water cooling and resonance control system.
The following design features or practices were incorporated to ensure high
availability of the DTL water cooling and resonance control systems:
•
Stainless steel has been chosen as the primary plumbing material. Stainless steel is
highly resistant to erosion and corrosion, is extremely clean and compatible with
deionized water.
•
The majority of the hard plumbing connections will be made with flanges,
compression fittings, or welds. Where threaded connections are required, a anti-gall
compound will be used instead of Teflon tape, which has a tendency to find its way
into the flow lines and create blockages.
•
A water purification system has been included in the design of each water flow loop.
This water purification hardware will maintain and monitor water purity levels, which
will in turn protect the plumbing hardware from unnecessary corrosion, scaling,
activation, and/or bacteria growth. Flow strainers have been provided in primary
flow lines to catch particulates that could block narrow flow passages in the RF
structures, magnets, orifice plates, valves, or heat exchanger.
•
The plumbing geometry has been designed to maintain acceptable water velocities
and minimize the risks associated with water-flow-induced erosion.
•
A rugged, durable, and industry proven PLC has been selected for controlling the
water cooling systems. A significant amount of redundant instrumentation has been
incorporated to monitor and provide alarms for off-normal operating conditions
including flow blockage, leaks, pump failure, etc. More detailed discussions of the
control system, alarms, and interlocks can be found in the section of this report
entitled Instrumentation and Controls.
291
•
A leak-less magnetic drive pump was selected for the water skid design.
This
eliminates the need to replace seals on the pump head. Motor bearing replacements
can take place during regularly scheduled maintenance periods.
•
All polymer materials used in the Linac tunnel will be radiation hardened, as
specified in Section 4 of this report. This will reduce the likely-hood of flex line
leakage due to radiation damage.
•
Solid-stem type globe valves were specified for providing manual flow control. The
valve procurement specification will indicate the requirement that the valve setting
not change due to flow-induced vibrations.
•
All manual valves will have lock-out attachments to prevent the undesired tampering
of valve settings.
•
Engineering codes and standards have been followed in the development of the
engineering design drawings and the manufacturing specifications.
•
A detailed quality assurance plan has been generated for hardware procurements, as
summarized in Section 9 of this report.
11.3 Maintenance
Following completion of the DTL water cooling and resonance control system
final design and the control system development phase, a detailed maintenance manual
will be developed. The maintenance manual will include the following:
•
Trouble shooting guidelines
•
Vendor-supplied maintenance procedures for primary pieces of water cooling system
hardware including the pump, control valves, heater, heat exchanger, water
purification system, etc.
•
Handling and disposal procedures for water purification system resins.
•
Water cleaning procedures for the plumbing components in the water flow loop.
•
Acid cleaning procedures for the heat exchanger.
•
Charging, draining, and venting procedures.
292
•
The following drawings to assist in maintenance procedures:
piping and
instrumentation diagrams, water system assembly diagrams, rack wiring diagrams,
cable layout diarams, etc.
•
Scheduled maintenance recommendations for such things as the pump motor, flow
meters, water purification equipment, filters, etc.
293
12.0 Decommissioning
Decommissioning of the SNS will require disconnection and recycling/disposing of
the water cooling system components. It is speculated, based on operational experience
on the LANSCE accelerator [1.7], that the water purification hardware, water skid
plumbing components, manifolds and lines, as well as instrumentation, will become
radioactively contaminated and will need to be treated as low level radioactive waste.
Consequently, disposal of these items will need to follow proper U.S. Department of
Energy guidelines for such hardware. The cooling water will be continuously activated
with short-lived radionuclides, as discussed in Section 5 of this report. This water can be
placed in a holding tank for sufficient time to allow the radionuclides to decay to a safe
level, prior to disposal. ORNL waste-water disposal procedures should be referenced for
further information.
294
13.0 Project Summary and Schedule
13.1 Project Summary and Ongoing Work
The design of the DTL water cooling and resonance control system has been
finalized and documented. In particular, the following activities have been completed:
•
All cooling requirements, interfaces, and performance specifications for the DTL
water cooling and resonance control systems have been identified and documented.
•
The water cooling system hardware layouts have been completed including the
identification of all water lines and associated plumbing components, the water skid
(pump, heat exchanger, control valves, water purification equipment, etc.),
instrumentation and controls. These layouts have been documented in the form of
Piping and Instrumentation Diagrams and a parts database. Specification sheets have
been developed for all major pieces of hardware in preparation for the procurement
activities that will follow the completion of the final design.
•
The water cooling system steady-state flow analyses were performed to determine
line sizes, orifice plate geometries, system pressure drops, heat exchanger and pump
sizing, control valve and temperature control performance, etc.
•
The water cooling system transient thermal analyses were performed to observe
response times and characteristics associated with system start-up, set point changes,
RF trips, and cooling water temperature disturbances.
•
The mechanical designs for the water manifolds and supports, as well as the water
skids have been completed. Material selections and strength issues have been studied
and documented. All components have been appropriately sized (i.e., line diameters,
heat exchanger size, pump capacity and motor size, orifice plate geometries,
instrumentation ranges, etc.).
•
The drawing tree has been developed. Most top level and sub-assembly drawings
have been completed and detail drawings have been initiated.
•
The control system architecture has been finalized and is consistent in its general
form with those from other SNS subsystems (i.e., linac vacuum system).
The
interfaces between the local control system and global controls have been identified.
295
The control methodology, safety interlocks, and protection equipment facets have
been identified. A signal and device spreadsheet for each DTL water cooling and
resonance control system has been generated according to SNS standards. A facilityintegrated cabling plan has been devised and is under development.
•
All facility interfaces (i.e., electrical, water, etc.) have been identified and
documented. All water cooling system equipment (water skids, electronics racks, and
water transfer lines) has been identified on the appropriate facility layout drawings.
•
A water cooling system hazard analysis has been performed and protective measures
to mitigate these hazards have been developed.
•
Procurement and fabrication plans have been devised for the DTL water cooling
system equipment. These plans have been integrated with the CCL water cooling
system procurements.
•
Assembly, installation, and certification plans have been developed to fit within the
SNS integrated project schedule.
•
Basic operation, reliability, and maintenance plans have been drafted.
While the final design of the DTL water cooling and resonance control system has
been completed, there are a number of engineering tasks that are still ongoing or need to
be initiated prior to delivery of hardware to ORNL.
•
All DTL water cooling system subassembly and detail drawings need to be finalized,
checked, corrected, and signed off. These tasks are approximately 75% complete.
•
A prototype control system, including the PLC, I/O Cards, touchscreen, etc. has been
procured. The programming of the PLC ladder logic is under development. This
prototype control system will be interfaced with EPICs and tested out on the CCL hot
model water cooling and resonance control system at LANL. This prototype control
system will be the model for all of the DTL and CCL water cooling and resonance
control systems.
•
The electronics rack layouts and wiring diagrams for the DTL water cooling and
resonance control systems need to be generated. These will be used by the rack
296
factory at ORNL to assemble the water cooling system racks prior to installation in
the klystron gallery.
•
SNS facility drawings need to be generated that include the cable and water transfer
line layouts for the DTL water cooling systems. This is currently outside the scope of
the DTL water cooling and resonance control system work package.
•
The assembly and installation procedures for the DTL RF structures are still under
development. Consequently, the water cooling system assembly and installation
plans may need to be adjusted to fully integrate with the needs of the DTL.
•
Assembly, installation, operation, and maintenance manuals for the DTL water
cooling and resonance control systems need to be generated.
•
Procurement specifications for the water skid, including the water purification
hardware, pump, heat exchanger, control valve, plumbing, and instrumentation have
been drafted.
Upon completion of the final design review, complete hardware
specifications will be generated for all water cooling system hardware and
incorporated with drawing packages and statements of work. These packages will be
submitted to down-selected vendors for bids and eventual contract awards.
13.2 Cost Summary
The labor and hardware costs for the design and procurement of the DTL water
cooling and resonance control systems are summarized in Tables 13.1 and 13.2,
respectively. Note that these costs are based on the latest LANL updated work packages
and reflect the LANL internal baseline costs. These costs are not currently consistent
with the ORNL SNS project baseline costs. The costs differences (current LANL SNS
internal costs – ORNL SNS baseline costs) have been included in two project change
requests, one of which has been approved, and one which is under review.
297
Table 13.1. Labor cost summaries for the design and procurement activities of the DTL
water cooling and resonance control systems.
Activity
Preliminary
Design
Final Design
Control System
Development
Procurement
Development
Documentation
Fabrication
Travel
Total
Req’d
Manhours
2830
Baseline
Costs ($k)
(with
PCRs)
185.7
Expenditures
to Date ($k)
Total
Expenditures
($k)
Overrun (-)
or Savings
(+)($k)
224.6
Additional
Expenditures
Expected
($k)
0.0
224.6
-38.9
6620
488
443.9
0.0
349.2
0.0
80.0
47.4
429.2
47.4
14.7
-47.4
400
23.6
0.0
0.0
23.6
0.0
100
396
N/A
6.6
23.4
6.0
0.0
0.0
6.0
0.0
0.0
0.0
6.6
23.4
6.0
0.0
0.0
0.0
Table 13.2. Burdened hardware procurement cost summaries for the DTL water cooling
and resonance control systems.
Equipment
Water skids
Drift tube
manifolds and
lines
RF structure
manifolds and
lines
PLCs,
computers,
software
Electronics racks
Unit Costs
($k)
90.0
Quantity
6
Total
Costs ($k)
539.7
Comments
40.0
6
240.1
50.2
6
301.3
15% decrease in costs from original baseline.
Cost decrease accounted for in latest PCR.
28.3
7
197.9
20% increase in costs from original baseline.
PCR approved for cost increase.
1.4
7
9.5
Quantity of skids decreased from 9 to 6, but
original baseline unit cost of a skid increased
by 40% as design progressed to account for
drawings, manufacturing hours, water
purification and instrumentation cost
increases, and shipping. PCR approved for
cost increase.
10% increase in costs from original baseline.
PCR approved for cost increase.
No significant cost change from original
baseline.
1,288.5
TOTAL
13.3 Schedule
The project schedule for the procurement, delivery, assembly, and installation of
the DTL water cooling and resonance control systems is shown in Table 13.3. These
dates come from a detailed and fully integrated SNS project schedule. In addition, the
298
procurement dates of the DTL water cooling and resonance control system hardware have
been coordinated with similar procurements of the CCL water cooling system hardware.
The early start and finish dates listed in Table 13.3 are linked to project activities
that occur prior in the project time-line. These are the desired dates for which the DTL
water cooling and resonance control system design team will strive for. The late start and
end dates represent the latest time that these activities can take place without becoming
an SNS project critical path activity.
Further descriptions and details regarding the procurement, assembly and
installation tasks can be found in previous sections of this report.
299
Table 13.3. Schedule for the procurement, delivery, and assembly of the DTL water
cooling and resonance control systems.
Activity
Early Start
Early
Late Start
Late End
Date
Finish Date
Date
Date
Documentation & Manuals
Control System Programming
Water Skid Purchase Request to PO
Water Line Purchase Request to PO
Rack Purchase Request to PO
Controls Purchase Request to PO
Tank 3 Water Skid Fab & Ship
Tank 3 Water Line Fab & Ship
Tank 3 Controls/Racks Fab/Ship
Tank 3 Water Line Assembly
Tank 3 Water System Installation
10/16/01
11/13/01
7/14/03
8/8/03
23-Jan-01
01-May-01
01-Jul-01
23-Oct-01
7/6/01
5/9/01
5/3/01
5/3/01
10/1/01
3/6/02
5/1/02
6/27/02
8/23/02
10/22/02
10/16/01
12/14/01
2/5/02
3/20/02
5/1/02
6/13/02
7/30/01
12/24/01
1/30/02
2/28/02
3/28/02
4/25/02
12/14/01
2/5/02
3/20/02
5/1/02
6/13/02
7/26/02
1/15/02
4/16/02
2/28/02
5/23/02
7/9/02
8/19/02
9/14/01
6/6/01
7/13/01
7/13/01
3/5/02
4/30/02
6/26/02
8/22/02
10/21/02
12/19/02
12/13/01
2/4/02
3/19/02
4/30/02
6/12/02
7/25/02
12/21/01
1/29/02
2/27/02
3/27/02
4/24/02
5/22/02
1/14/02
2/27/02
4/15/02
5/22/02
7/8/02
8/16/02
2/15/02
5/15/02
3/27/02
6/20/02
8/6/02
9/17/02
7/6/01
1/4/02
1/29/02
1/29/02
3/27/02
8/16/02
1/22/03
3/20/03
5/15/03
7/14/03
5/14/02
7/11/02
12/2/02
3/11/03
4/22/03
6/4/03
4/24/02
9/16/02
2/20/03
6/6/03
7/7/03
8/11/03
12/3/02
8/22/02
1/22/03
6/12/03
6/10/03
7/17/03
1/2/03
2/18/03
9/16/02
7/7/03
7/3/03
8/8/03
9/14/01
5/13/02
4/9/02
4/9/02
8/15/02
10/11/02
3/19/03
5/14/03
7/11/03
9/8/03
7/10/02
8/21/02
1/21/03
4/21/03
6/3/03
7/16/03
9/13/02
10/11/02
3/19/03
7/3/03
8/1/03
9/8/03
12/31/02
9/13/02
2/17/03
7/3/03
7/2/03
8/7/03
2/4/03
3/19/03
10/14/02
8/1/03
8/1/03
9/8/03
300
14.0 Appendix A – ASME B31.3 Code Tables
Table A.1.
ASME B31.3
Code and Its Applicability to DTL/CCL Water Cooling Systems
Design Scope
and Definitions
Conditions and Criteria
301.2 Design Pressure
Applicability
Significance
1 Low, 3 High
3
301.3 Design Temperature
301.5 Dynamic Affects
301.5.4 Vibration
301.7 Thermal Expansion
1
1
2
1
301.9 Reduced Ductility
301.10 Cyclic Effects
301.11 Condensation Effects
302.2.4 Pressure, Temp
Variation
302.2.5 Ratings at Junction
2
1
1
2
302.3 Allowable Stresses &
Limit
302.4 Allowances
3
Comments
Required pressure containment and relief
valves
Small temperatures range 10º-30ºC
Impact, wind and earthquake minimal
Support, eliminate excessive vibration
Minimal due to small temp. changes or
gradients
Welding, bending & low temperature
Pressure cycling is minimal
Condensation & oxygen enrichment
Pressure not to exceed test pressure
2
Pressures on each side of junction
components
Concentrations stress near weld &
components
Wall thickness
3
Table A.2.
ASME B31.3
Design Scope
and Definitions
Pressure Design of
Components
304.1. General Pipe
Applicability
Significance
1 Low, 3 High
3
304.5 Pressure Design of
Flanges
304.7.3 Metallic/Nonmetallic
2
304.7.4 Expansion Joints
3
Service Requirements for
Piping
305.2.3 Cyclic Conditions
306 Fittings, Bends,
Connections
Comments
Required thickness to provide pressure
rating of psi
Design gage pressure
3
Evaluated by applicable water purity &
strength requirements
Slip type components and instruments
1 Low, 3 High
1
3
Tubing grade is sufficient
Listed fittings and bends suitable for fluid
service
301
308 Flanges and Gaskets
3
308.2 Requirements for
Flanges
309 Bolting
309.2 Specific Bolting
3
Listed components suitable for normal fluid
service
Flange facings subject to sever erosion &
corrosion
Listed bolting for components
Bolting for metallic flange
2
3
Table A.3.
ASME B31.3
Design Scope
and Definitions
Requirements for Piping Joints
310 General
311 Welded Joints
312 Flange Joints
312.1 Flanges of Different
Rating
313 Expanded Joints
314 Threaded Joints
316 Caulked Joints
317 Soldered & Brazed Joints
318 Special Joints
Applicability
Significance
1 Low, 3 High
3
3
3
2
Flexibility and Support
319 Piping Flexibility
319.3.1 Thermal Expansion
319.3.4 Allowable Stress
321 Piping Support
321.1.4 materials
1 Low, 3 High
3
1
2
3
3
321.3 Structural Attachments
321.4 Structural Connection
Comments
Conditions of pressure & temperature
Welding procedures
Type of flange
Ratings
3
2
1
3
3
Do not use if possible
Permissible for our application
No need
In accordance with provisions
Listed joints
3
3
Basic requirements
Temp. & stress range are minimal
Bending and torsion
Piping stresses should be minimized
Suitable material to support weight & 30
year lifetime
Flattering of tubing
Load
Table A.4.
ASME B31.3
Design Scope
and Definitions
Systems
322 Specific Piping Systems
322.3.1 Definition
322.3.2 Requirements
322.6 Pressure relieving
Applicability
Significance
1 Low, 3 High
3
3
3
3
302
Comments
Instrumentation piping
Components connect to instruments
Instrumentation piping should meet all
requirements
Discharge piping with cracking pressures set
System
Materials
323 General requirements
323.1 Materials &
Specifications
323.1.3 Unknown Materials
323.2.2 Lower Temperature
323.2.3 Unlisted Materials
323.3 Impact Testing
323.3.1 General
323.3.2 Procedure
323.3.4 Test Temperatures
323.3.5 Acceptance Criteria
323.4 Fluid Service
Requirements
323.5 Deterioration in Service
325 Materials Miscellaneous
to? psig
1 Low, 3 High
3
3
3
3
2
3
3
3
3
3
1
Limitations and qualifications
Conform to listed specification table 323.2.2
Unknown specification should be used
Listed materials
Temperature limits
Acceptance criteria
In accordance with table 323.3.1
ASTM Spec. No. Tube A 334
Temperature criteria Table 323.3.4
Weld impact test
Materials used for support, steel, stainless
steel
Resist deterioration, corrosion, and erosion
Joining and auxiliary materials
1
2
Table A.5.
ASME B31.3
Design Scope
and Definitions
Standards for Piping
Components
326 Dimensions & Ratings
326.1.3 Threads
362.2 Ratings
Applicability
Significance
1 Low, 3 High
Fabrication, Assembly,
Erection
327 General
1 Low, 3 High
328 Welding
328.1 Welding Responsibility
328.2 Welding Qualifications
328.2.1 Qualification Require
328.2.2 Procedure
Qualifications
328.2.3Performance
328.3 Welding materials
328.3.1 Filler Metal
328.3.2 Weld backing
Material
1
1
1
Comments
Table 326.1
Table 326.1
Table 326.1
2
3
3
3
3
3
Fabrication, assembly & erection prepared
same
Accordance with applicable requirements
Employer is responsible
Welding shall conform to 328.1- 328.6
Qualification of the welding procedures
Employer is responsible for sub-contract
3
3
3
3
Qualification test record of sub-contract
Metal shall conform to requirements
Conform to requirements
Conform to requirements
303
328.4 Preparation for Welding
328.4.1 Cleaning
328.4.2 End Preparation
328.5.3 Seal Welds
328.5.4 Branch Connections
328.6 Weld repair
330 Preheating
3
3
2
3
3
1
1
Cleaning internal & external
Internal and external surfaces
Reasonably smooth & true
Qualified welder
Important welds for system
Welding procedure
Preheating is not a requirement on this
application
Table A.6.
ASME B31.3
Design Scope
and Definitions
Fabrication, Assembly,
Erection
332 Bending and Forming
332.1 General
333 Soldering
Applicability
Significance
1 Low, 3 High
333.3.1 Surface Preparation
3
333.4 Requirements
3
335 Assembly and Erection
3
335.1.1 Alignment
335.2 Flanged joints
335.2.2 Bolting Torque
335.3 Threaded Joints
334.4 Tubing Joints
335.6 Expanded Joints
335.9 Cleaning of Pipe
3
3
2
1
2
1
3
3
3
3
Comments
Formed by any hot or cold method
Wall thickness not thinner than design
Operator requirements, BPV code, section
IX, Part QB
Suitable chemical or mechanical cleaning
method
Follow procedure in copper tube hand book
of the copper development association
Before assembly any joints to be cold
sprung, guides, supports, and anchors shall
be examined
Piping distortions
Preparation for assembly
Tightening to be predetermined torque
Thread compound and lubricant
Flared tubing joints
As by engineering design
Table A.7.
ASME B31.3
Design Scope
and Definitions
Inspection, Examination,
Testing
340.2 Responsibility
Inspection
340.4 Qualifications
Applicability
Significance
1 Low, 3 High
Comments
3
Owners responsibility
3
Owners designated inspector/LANL
304
341 Examination
341.3.2 Acceptance
341.4 Examination required
3
3
3
342 Examination personnel
343 Examination Procedures
3
3
344.2 Visual Examination
3
345 Testing
345.1 Leak Test
345.2 Test Requirements
345.3 Preparation for test
346 Records/Responsibility
3
3
3
3
3
Quality Control performed by manufacture
Acceptance criteria table 341.3.2
Examined to the extent of engineering
design
Experience/personnel qualifications
Procedures shall be as required BPV code,
section V, Article 1, T-150
View before, during, & after manufacturing,
fabrication, assembly, erection,
examination, or testing, verification/LANL
Hydrostatic testing, accordance 345.5
Mandatory
Limitations on pressure
All joints exposed
Designer, manufacture, fabricator, erector to
prepare records
305
ASME B31.3
Definition- Inspection/Examination
SNS Cooling Team/LANL distinguishes examination from inspection by establishing different
responsibilities and qualifications for each.
Inspection Applies to functions performed for the project owner [ORNL/LANL] by the owner’s
inspector. [340.2] The responsibility of the owner’s inspector is to verify that all required
examinations and testing have been completed and to inspect the SNS cooling system to the
extent necessary to be satisfied that it conforms to all applicable examination requirements of the
code and of the engineering design. This verification may include positive material identification
of piping and piping components, verification that piping components were manufactured to
standards as specified by engineering design, and that piping and piping components were
supplied by approved manufactures in the correct heat treatment condition.
The owner’s inspector’s for SNS cooling system shall be designated by LANL/ORNL from
engineering design within the lab or an employee of an engineering or scientific organization, or a
recognized inspection company. The inspector shall not represent nor is an employee of subcontractor performing work on SNS cooling system, including tubing/piping manufacture,
fabricator, installation, or testing unless the owner is also the manufacture, fabricator, installer,
and conducting testing.
Examination definition is that examination is associated with the quality control function for the
sub-contractor of the manufacturing of the SNS cooling system, or for fabricators, or installers.
The responsibility of the examiner [341.2] is to:
1. Assure materials, components, and workmanship is in accordance with the requirements
of the code,
2. Perform all required examinations,
3. Prepare suitable records of examination and testing for the inspector’s use.
SNS cooling system including components and workmanship shall be examined prior to initial
industrial operations in accordance with the requirements of the code and as required by
LANL/ORNL engineering design [341.3.1]. The acceptance criteria to be applied for this
examination shall also be specified.
306
15.0 Appendix B – Engineering Drawings
307
Figure B.1. Main supply water manifold on DTL tank 1.
308
Figure B.2. Main return water manifold for DTL tank 1.
309
Figure B.3. Detail drawing of a portion of the main water supply manifold on DTL tank 1.
310
Figure B.4. Detail drawing of a portion of the main water supply manifold on DTL tank 1.
311
16.0 Appendix C – Water Skid Specifications
1.1 Statement Of Work
This portion of the document defines the minimum technical requirements and the scope of work
for the deionized water cooling skid for the Spallation Neutron Source’s (SNS) Drift Tube Linac
(DTL), Coupled Cavity Linac (CCL), and Super Conducting Linac (SCL). The scope of work
includes, but may not be limited to, design layout, development, documentation and reports,
assembling, testing, and delivery of the water skid.
1.2 Deliverable Items
The supplier’s scope of work includes procurement of all equipment (unless otherwise specified),
materials, parts, fabrication, testing, inspections and transportation required to deliver all tested
equipment to the specified location.
Identification No.
Quantity
1
1
1
1
1
1
1
1
1
1
1
1
Drawing No.
155Y510015
155Y510016
155Y510017
155Y510018
155Y510019
155Y510020
155Y517209
155Y517210
155Y517211
155Y517212
155Y517213
Description
DTL-1 RF Structure Water Skid
CCL-1 RF Structure Water Skid
CCL-MAG Magnet Water Skid
SCL-MAG Magnet Water Skid
1.3 System Overview
This procurement specification provides the requirements for a deionized water cooling skid for
the Spallation Neutron Source (SNS) accelerator project located at the Oak Ridge National
Laboratory (ORNL) facility in Oak Ridge, Tennessee. The skid’s function is to maintain a
constant water temperature and flow rate to the RF structure or to a group of quadrupole magnets.
This will require 12 water skids with each of the 12 functioning as an independent closed loop
system. The loop will consist of water flowing from the water skid, through transfer lines, to the
RF structure and returning to the water skid. The each skid will be designed to have a minimum
lifetime of 30 years.
Each skid will have four fluid line connections to outside sources. Connections, supply and
return, to the water transfer lines going to the source which requires cooling, either the RF
structure or to the quadrupole magnets, are the primary interface points. The interface requires an
ANSI flanged joint. The closed loop flow rate will be held steady by a variable speed pump.
Temperature adjustments will be made by redirecting a portion of the flow to the heat exchanger
or by bypassing the heat exchanger. Flow distribution to the heat exchanger, not flow rate, will be
the only variable used to adjust water temperature in the system.
The supply and return fluid connections on the cold side of the heat exchanger will connect to the
facility piping system. ORNL will provide chilled water that is not deionized. This circuit is
separate from the primary closed loop-cooling loop and the fact that the water is not deionized
312
creates no problems. Flexible hose will be used to mate the facility-chilled water to the water
skid. This will allow for minor end-point location deviations.
A water purification/filtration system has been developed to maintain the cleanliness and purity of
the closed loop deionized water. This unit will bleed approximately 1% to 5% of the water
continuously. The purification unit will draw the water near the exit line of the pump. The water
will be filtered and purified prior to being fed into a reservoir tank and then be delivered to the
supply side of the pump.
Figure 1 illustrates all the major components that make up the water skid. Additionally, this
Piping and Instrumentation Diagram (P&ID) identifies the flow direction and system control
components. All components will be purchased by the supplier to meet the requirements of this
specification and with the approval of LANL.
1.3.1
Supplier Management
Supplier management requires a defined program plan. Customer visits, schedule, and monthly
reports shall be strictly adhered to as defined.
1.3.1.1 Program Plan
The plan shall include a detailed schedule, manpower loading, and spending profiles. The supplier
shall designate contacts for contractual and technical matters.
1.3.1.2 Customer Visits
LANL representatives may visit the supplier’s facility to assess program status. The
representatives shall have full access to all areas pertinent to the program. Notification to the
supplier will be provided at least 3 working days prior to a visit.
1.3.1.3 Schedule
The order shall be for a total of 12 water skids. The delivery of the first 2 units shall be to the
ORNL site and shall be 4 months after contract award. The subsequent units shall be delivered to
the ORNL site based on the delivery schedule provided.
ITEM NUMBER
1
2
3
4
5
6
7
8
9
10
11
12
SKID NOMENCLATURE
CCL-2
CCL-MAG
DTL-3
DTL-1
CCL-3
DTL-2
CCL-4
DTL-5
CCL-1
DTL-6
DTL-4
SCL-1
ORNL ON-DOCK DATE
15 December 2001
15 December 2001
15 February 2002
15 April 2002
15 April 2002
01 June 2002
15 June 2002
01 August 2002
15 August 2002
01 October 2002
15 October 2002
01 November 2002
1.3.1.4 Monthly Reports
Status reports shall be submitted monthly, starting 15 days after contract award, for the duration of
the contract. Progress with respect to plan shall be addressed in narrative and schedule format.
313
Significant accomplishments as well as problem areas shall be addressed in the reports. Work
around plans shall be submitted for any problem areas.
1.3.2
Reviews
The following 3 reviews and review schedules shall be followed. All reviews shall be conducted
at the supplier’s facility. The supplier shall take the meeting minutes, notes and action items for
all reviews at their facility. The minutes and action items shall be published and distributed to all
meeting attendees.
Review
Preliminary Design Review (PDR)
Schedule
30 days following contract award
Final Design Review (FDR)
Test Plan Review (TPR)
30 days following PDR approval
30 days following FDR approval
1.3.2.1 Preliminary Design Review
This review is at the block diagram and system overview level. It shall illustrate the major
components and subsystems of the design. The supplier program plan shall be presented. All
long lead items, which may require the purchase of equipment prior to the FDR, shall be
identified. This review shall also address how the requirements of the water skid specification
shall be met.
1.3.2.2 Final Design Review
The final design details shall be presented prior to the manufacturing and build process. Final
analysis will be complete and shall be presented showing that all requirements of this specification
have been met or how they shall be met. Optional methods may include demonstration, further
analysis not yet complete due to lack of available information, or testing. Prior to delivery, all
requirements must be met and must be shown as to the method they have been met.
The supplier shall submit a priced recommended spare parts list concurrent with the FDR.
1.3.2.3 Test Plan Review
The test plan shall describe how all of the testing requirements of this specification shall be
recorded and verified. The test plan shall be provided to LANL 10 working days prior to the TPR
and LANL shall return comments/changes 3working days prior to the review. The purpose of the
TPR is to resolve any open issues regarding testing requirements stated in Section 5.0. At the
conclusion of the TPR, the test plan will be modified to reflect all required changes necessary for
supplier and LANL approval. Testing may not begin without LANL approval of the test plan.
1.3.3
Meetings
A kick-off meeting, progress meetings, and closeout meetings shall be held during the system
development, fabrication and testing. Meeting minutes shall be recorded by the supplier and
submitted to LANL for approval. Meeting minutes shall include action items with assignment of
responsibility and assignment due dates. Action items are to be recorded in a log maintained by
the supplier. The log is to be reviewed at each subsequent meeting. Meeting minutes and the
action item log are to be included in the Final Data Package for this procurement.
1.3.3.1 Kick-Off Meeting
314
A project kick-off meeting shall be held after the awarding of the contract at the supplier’s facility.
The time of the meeting shall be no later then 2 weeks after contract award. The purpose of the
meeting shall be to review the project schedule, design documents, and quality assurance/control
methods. The supplier shall prepare a revised schedule reflecting the actual order placement date,
as well as a shop traveler. These are to be transmitted to LANL at least 2 days prior to the
meeting. The supplier is encouraged to ask questions of clarification and to recommend design
alterations and suggestions that would improve the system design.
1.3.3.2 Progress Meetings
A progress meeting may be requested by either the supplier or by LANL. Progress meetings are
to be at the supplier’s facility. The purpose of these meetings shall be to review the
schedule/progress status, to review the in-process fabrication, to review the in-process quality
assurance/control inspections and records management, and to review design issues that may arise.
1.3.3.3 Closeout Meetings
Upon completion of acceptance testing for each of the twelve (12) water skids, a closeout meeting
will occur. At this meeting, the supplier will present all documentation relating to each unit
verifying the completion of all requirements and the closeout of all issues.
1.3.4
Equipment
Component and part selection shall be made based on a criterion where system performance and
functionality are given the greatest weighting. The design, reliability, maintainability, and
fabrication methods must also be part of the selection process. Proper operation of the LANL
specified components is the responsibility of LANL. An accurate and concise equipment manual,
including all components, will be required by the supplier. To properly maintain the system, a
maintenance manual will also be required. To ensure minimal accelerator downtime, the supplier
will provide a recommended spare parts list.
1.3.4.1 Fabrication
The supplier shall be responsible for the fabrication and assembly of twelve (12) water skids in
strict accordance with this specification, supplier contract drawings, data sheets listed in appendix
TBD. The work shall include the fabrication and integration of all mechanical assemblies,
individual components, monitoring devices, skid structure, skid drainage, and tube manufacturing
into a fully functional unit. Unless otherwise stated, the supplier shall be responsible for the
procurement of all associated equipment, materials or supplies necessary to complete the work.
1.3.4.2 Drawings
The supplier shall provide all contract drawings, as-built drawings, and shop drawings to LANL
for approval and acceptance. Approval of the drawings by LANL does not relieve the supplier of
their overall responsibility to perform to this specification. All drawings shall follow ANSI
drawing requirements. All drawings, upon project completion, will be the property of LANL.
1.3.4.3 Maintenance Manual
Three copies of the maintenance manual shall be provided with the first unit. A single copy of the
maintenance manual shall be provided with each subsequent unit once the initial manual is
approved by LANL. The maintenance manual shall include but not limited to:
•
•
A detailed discussion of the electronic operation of each major block or module in the system.
A trouble shooting guide for possible malfunctions to be updated on a quarterly basis.
315
•
•
•
•
Addresses, phone numbers, and FAX numbers of the technical people who can assist in
specific problems.
Complete listings of addresses, phone numbers, and FAX numbers for sources of major
components in the system.
Safe maintenance procedures
Preventative maintenance schedules and procedures.
1.3.4.4 Equipment Manual
The supplier shall provide an operation manual, a maintenance manual, and an installation manual
compiled in an Equipment Manual for all equipment as described in Section 7.0 and indexed with
the recommended Table of Contents in Appendix TBD. An equipment manual shall be provided
with each water skid. As this includes the maintenance manual they should be combined into one
paragraph. Where are the details of the ops and instl manuals? Are these the operating instructions
(section 9)?
1.3.4.5 Recommended Spare Parts List
The supplier shall submit a priced recommended spare parts list concurrent with the final design
review.
1.3.5
Equipment Acceptance Testing
The supplier shall provide a written test plan/procedure and will perform tests to verify and
demonstrate the functionality of each of the water skids as required by this specification. The
supplier shall furnish the test data required by this specification to document the completion of all
required. These documents shall be in the form of testing plans, procedures, and reports.
The supplier shall perform a leak test and a proof of operation test as described in Section 6.0 of
this specification. The supplier shall provide all necessary test fixtures to perform the tests.
Detailed test procedures are to be prepared by the supplier and submitted for approval prior to
initial testing. Test reports are to be prepared by the supplier and submitted for acceptance.
1.3.6
Packaging and shipping
The supplier shall be responsible for the packaging, shipping, and delivery of the water skids to
the Oak Ridge National Laboratory (ORNL) facility in accordance with this specification. Refer
to Section 11.0 for detailed requirements.
1.3.7
Quality Assurance/Control
The supplier shall provide a Quality Assurance/Control Program in accordance with Appendix
TBD, Form 838c. This document identifies a complete listing of requirements. The objective of
the supplier is to provide an effective management system to reduce the risk of potential failures
related to the quality of the water skid. This system shall provide planning, organization,
direction, control, and support to meet the requirements identified in Form 838c.
1.3.8
Conflicts
In the event of a conflict between any portion of this specification and the LANL’s Request for
Proposal (RFP), the RFP shall take precedence on contractual/legal requirements. This
specification shall take precedence on all technical requirements.
In the event of a conflict between this specification and information provided elsewhere in the
design package, the information elsewhere, if written and signed by LANL, shall take precedence.
316
All other conflicts amongst any and all of the design documents shall be referred to LANL for
resolution. All conflicting statements shall be decided upon by a LANL technical representative
and coordinated through the LANL contract administrator.
1.4 Design Documentation
The supplier shall provide equipment fabricated in accordance with the following design
documents.
1.4.1
Contract Drawings
The equipment shall be fabricated in accordance to the contract drawings produced by the
supplier. LANL will provide the Piping and Instrumentation Drawing (P&ID) required to identify
system layout requirements. All contract drawings require LANL approval.
Drawings shall conform to best commercial standards and shall be legible if reduced to B-size.
Complete parts lists for all components in the drawings shall be provided. Top-level mechanical
assembly drawings shall also be provided. They shall be of sufficient detail to locate all
components and fittings. Detail drawings shall be provided in sufficient detail to insure that the
mating components or fittings can be purchased or fabricated.
The supplier shall provide 1 reproducible and 3 copies concurrent with the delivery of the first
unit. A single copy of the drawings shall be provided with each subsequent unit once the initial
drawings are approved by LANL.
1.4.2
Shop Drawings
The supplier shall prepare shop drawings where details are not shown on contract drawings or
where the contract drawings or specifications call for field determination. The shop drawings
shall be submitted with a drawing list to LANL for approval, prior to the start of fabrication.
1.4.3
As-Built Drawings
The supplier, for recording as-built changes, shall maintain specially designated sets of drawings
for each water skid. The supplier shall indicate approved changes by updating the version drawing
files that will be provided to the supplier by LANL.
1.4.4
Specifications
The equipment shall be fabricated and tested per the requirements of this specification and it’s
referenced specifications and standards. The supplier shall request clarification from LANL in the
event of a conflict between the drawings and specifications.
1.4.5
Engineering Change Notices and Supplier Disposition Requests
It is the intention of LANL that all information in the design package for the water skid to be
correct and free from errors in equipment placement, system interference, etc. The supplier shall
formally request, in writing, a disposition of any unresolved questions, concerns, or change
requests. Requests may be the result of requirements imposed on the supplier for approval of data
required in this specification, the result of design error correction, or the result of supplier requests
to ease or improve production of the equipment. Any design improvement suggestions by the
supplier is anticipated and desired by LANL. Specific procedures for modifications to design
documents and/or disposition to corrections of errors and omissions shall be provided by LANL.
1.5 Certification
317
The supplier shall certify all documentation, reports, and records and submit them for review and
approval.
The supplier shall submit the material certifications for all stainless steel tubing and all other
materials that will be in contact with the deionized water. This includes, but is not limited to,
welding filler rods, fasteners, seals, etc.
The supplier is responsible for ensuring that all personnel assigned to skid fabrication, including
welding, assembly, testing, and inspection are fully qualified to perform their respective job
functions. The supplier shall provide the certifications for each individual performing the work
such as welding, testing, or inspecting.
1.6 Substitution Policy
The supplier may, upon LANL approval, substitute equivalent parts for those specified in the Bill
of Materials on the contract drawings and in the specification. Proof of equivalency shall be the
burden of the supplier. Any design changes required to incorporate the substitution of a part
shall be the responsibility of the supplier. Any substitution requests shall be formally submitted to
LANL for approval. The supplier shall indicate approved substitutes and design changes on the
associated redlined as-built drawings.
1.7 New Parts
The supplier shall use only new parts and materials.
1.8 Warranty
The supplier shall warranty the entire water skid assembly, including all parts and workmanship,
for 3 years after delivery of the equipment to ORNL. The supplier shall also provide an optional
warranty extension to bring the full warranty to 5 years.
1.9 Supplier Exceptions
If the supplier plans to make any exceptions or proposes any changes to this procurement
specification, the modification shall be clarified before the contract is awarded and any work
begins.
Each exception or change shall:
•
•
•
•
Identify the specification and revision number.
Identify (by section and subsection number) the criteria that cannot be met or needs alteration.
Summarize the reason for the exception or change.
Present a proposal for resolution.
Exceptions and changes agreed to during the bidding process shall be incorporated into the
procurement specification prior to the contract award. This information will be made available to
all potential suppliers prior to the final bid.
LANL recognizes that as the design of the water skid matures potential specification requirements
and expectations may need amending. Changes agreed to after the contract is awarded to a
supplier shall be incorporated into the specification or as accompanying documentation before a
deliverable will be accepted by LANL.
1.10Definitions
ANSI: American National Standards Institute
318
API: American Petroleum Institute
ASME: American Society of Mechanical Engineers
ASTM: American Society for Testing and Materials
CCL: Coupled-Cavity Linac
DTL: Drift Tube Linac
FDR: Final Design Review
IEC: International Electrotechnical Commission
LANL: Los Alamos National Laboratory
MDP: magnetic drive pump
MSS: Manufacturers’ Standardization Society of the Valve and Fittings Industry
ORNL: Oak Ridge National Laboratory
PDR: Preliminary Design Review
PFI: Pipe Fabrication Institute
P&ID: Piping and Instrumentation Drawing
PO: Purchase Order
RF: Radio Frequency
RFP: Request for Proposal
RTD: Resistance Temperature Detectors
SNS: Spallation Neutron Source
SRR: System Requirements Review
Supplier: The successful bidder who accepts the responsibility to fulfill the overall requirements
of this specification.
TPR: Test Plan Review
Water Skid: An assembly of components, tubing, monitoring equipment, etc. designed to control
the resonant frequency for the linac on the SNS Program.
1.11References
All equipment shall be designed and furnished in accordance with the references listed below. All
codes and standards referenced refer to the latest accepted revision at the time of contract award.
Any conflict between referenced documents shall be brought to the attention of LANL for
resolution prior to proceeding with the work.
319
1.11.1
1.11.2
1.11.3
American National Standards Institute (ANSI)
B1.1
Unified Inch Screw Threads (UN & UNR Thread Form)
B1.20.3
Dryseal Pipe Threads (Inch)
B16.10
Face-to-Face and End-to-End Dimensions for Ferrous Valves, Classes 125 thru
2500 (Gate, Globe, Plug, Ball, and Check Valves)
Y14.1
Drawing Sheet Size and Format
Y14.2
Line Conventions, Sectioning and Lettering
Y14.3
Multi and Sectional View Drawings
Y14.4
Pictorial Drawing
Y14.5
Dimensioning and Tolerancing for Engineering Drawings
Y14.6
Screw Thread Representation
American Society of Mechanical Engineers (ASME)
B16.5
Pipe Flanges and Flanged Fittings (ANSI Approved)
B31.1
Power Piping (ANSI Approved)
B31.3
Chemical Plant and Petroleum Refinery Piping (ANSI Approved)
American Society of Nondestructive Testing (ASNT)
2025
1.11.4
Recommended Practice (also known as SNT-TC-1A)
American Society for Testing and Materials (ASTM)
A240
Standard Specification for Heat-Resisting Chromium and Chromium-Nickel
Stainless Steel Plate, Sheet, and Strip for Pressure Vessels
A268
Standard Specification for Seamless and Welded Ferritic and Martensistic
Stainless Steel for General Service
A269
Standard Specification for Seamless and Welded Austenitic Stainless Steel for
General Service
A276
Standard Specification for Stainless Steel Bars and Shapes
A380
Standard Practice for Cleaning, Descaling, and Passivation of Stainless Steel
Parts, Equipment, and Systems
A480
Standard Specification for General Requirements for Flat-Rolled Stainless and
Heat-Resisting Steel Plate, Sheet, and Strip
A511
Standard Specification for Seamless Stainless Steel Mechanical Tubing
A554
Standard Specification for Welded Stainless Steel Mechanical Tubing
320
1.11.5
International Electrotechnical Commission (IEC)
60751
1.11.6
Industrial Platinum Resistance Thermometer Sensors First Edition; Amendment
1-1986; Amendment 2-1995; BS EN 60751: 1996
Instrument Society of America (ISA)
S75.03
1.11.7
1.11.8
Face-to-Face Dimensions for Flanged Globe Style Control Valve Bodies (ANSI
Classes 125, 150, 250, 300, and 600)
Manufacturers’ Standardization Society of the Valve and Fittings Industry (MSS)
SP-69
Pipe Hangers and Supports – Selection and Application
SP-72
Ball Valves With Flanged or Buttwelding Ends for General Service
Pipe Fabrication Institute (PFI)
ES-5
2.0
Cleaning of Fabricated Pipe
Operational/Performance Requirements
The work to be performed requires the prospective supplier to produce a single design, fabrication
and shipment of 12 water skids that meet the requirements contained within this document and any
accompanying attachments. Over the thirty-year lifetime, the system may be subjected to low
levels of radiation from particulates in the water. In addition, the system requires the wetted
surfaces maintain a low Oxygen permeability from seals and flexible hoses as well as being
compatible with deionized water.
2.1
System Operations Description
The water skid is used to control the resonance frequency on various portions of a linear
accelerator. This accounts for ten water skids (DTL-1 through DTL-6 and CCL-1 through CCL4). Two additional water skids are used for cooling of the quadrupole magnets (CCL-MAG and
SCL-MAG). Any deionized water leakage is defined as hazardous waste and must be treated as
such. Therefore, leakage is a significant concern of LANL.
All water skid construction and design must meet ASME B31.1 and ASME B31.3 requirements.
Applicable ASME, ASTM, ANSI, and ASNT reference documents shall be used as best practice
for all water skid work.
2.2
Physical Layout
The assembled skid shall fit within an envelope size no greater then 5 feet in width by 8 feet in
length by 8½ feet in height. It is the responsibility of the supplier to meet this requirement and it is
the goal of the supplier to minimize the water skid envelope to as small a package as possible. In
reducing this envelope, the supplier should focus on the reduction of the length and width.
However, safety and ease of repair and maintenance should not be compromised.
2.2.1
Component Orientation
The orientation of certain components within the skid envelope is critical. LANL anticipates the
need for scheduled maintenance on the water purification/filtration unit. Specifically, the carbon
bed and mixed bed containers will need to be replaced to ensure the purity of the deionized water.
Easy and direct access is required. Due to the location within the building that each skid is
located, these containers will need to be accessible on the short side (envelope width).
321
The pump is a critical component that will require proper orientation on the water skid.
Accessibility to the pump motor on the same short side (envelope width) as the carbon bed and
mixed bed containers is required. Although no scheduled maintenance for the pump motor is
anticipated, failure of this component has the highest probability of all components within the
water skid assembly.
2.3
Reliability
The supplier shall use best engineering practices in all areas of the design and build of each water
skid assembly as they relate to reliability. At the FDR, the supplier shall provide the calculated
mean time between failure (MTBF) for the entire skid system. The MTBF of individual
components shall also be presented at the FDR.
2.4
Maintainability
The supplier shall use best engineering practices in all areas of the design and build of each water
skid assembly as they relate to maintainability. The water skid shall be designed in a modular
fashion so that a faulty component may be quickly identified and replaced. The mean time to
repair (MTTR) for the water skid system shall be calculated by analysis and presented at the FDR.
Additionally, the supplier shall provide a list of failure modes and the calculations that substantiate
the design decisions made to be in compliance with this requirement.
2.5
Temperature
The primary function of the entire water skid is to control the temperature exiting the skid.
Accuracy and stability of the water temperature must be optimized. By choosing efficient
components and high quality RTDs, the best thermal system resolution will be achieved.
The water temperature exiting each of the twelve (12) skids shall be 20.0 °C. The required
accuracy and stability are both ± 0.5 °C. The range in which the exit temperature must function is
± 8.3 °C. The facility-chilled water on the cold side of the heat exchanger will be provided at 7.2
± 1°C.
2.6
Flow Rate and Volume
The flow rate will vary for each of the twelve (12) water skids. Holding the flow at a specified
rate will, in effect, make it a constant and remove it as a variable. Although the accuracy and
stability allowance is generous, the goal of the supplier is to reduce any variance from the defined
flow rate. Thus, the only variable in tuning the particle accelerator beam will be the exit water
temperature from the water skid.
The volume of each closed loop system will vary. Much of this volume is contained in the
transfer lines and the manifolds and not part of the water skid design. The water volume, though
not part of the responsibility of the water skid supplier, will be a factor in thermal response time
and it is important for the supplier to recognize the importance of the system response time.
SKID
DTL-1
DTL-2
DTL-3
DTL-4
DTL-5
DTL-6
FLOW RATE
(GPM)
118.3
160.3
233.8
213.7
197.6
181.6
STABILITY
(GPM)
± 5.0
± 5.0
± 5.0
± 5.0
± 5.0
± 5.0
322
ACCURACY
(GPM)
± 5.0
± 5.0
± 5.0
± 5.0
± 5.0
± 5.0
VOLUME
(GALLONS)
256
281
281
281
281
281
CCL-1
CCL-2
CCL-3
CCL-4
CCL-MAG
SCL-MAG
2.7
± 5.0
± 5.0
± 5.0
± 5.0
± 5.0
± 5.0
218.9
257.0
257.0
257.0
60.8
± 5.0
± 5.0
± 5.0
± 5.0
± 5.0
± 5.0
308
308
308
308
359
912
Vibration
Vibration isolation requirements are directly imposed on the pump. This will be sufficient to
prevent any measurable or significant vibration transfer to the Klystron Gallery. No skid isolation
is required by the supplier however, the supplier may choose to isolate the entire skid based upon
previous experience. Section 3.2 provides pump vibration isolation requirements.
2.8
Noise
The supplier shall design the skid such that no personal protective equipment shall be required.
The supplier shall review document OSHA Regulations (Standards – 29 CFR) Occupational noise
exposure. – 1910.95 and meet the requirements therein. The permissible noise exposure shall be
70 dBA. Measurements may be taken at any location outside the structural frame of the skid.
2.9
Water Drainage
The supplier shall develop and implement into the water skid design a method of efficiently
draining the system. The drainage system must prevent water from dripping or draining onto the
Klystron Gallery floor.
The draining/venting scheme must be efficient and simple for maintenance personnel. All low
points of the skid must have a method of draining that is valved. The highest point on the skid
must have a valved port to vent the system and increase system-draining efficiency.
The structure of the skid must provide a collection tray for any inadvertent leaks due to an
improperly functioning valve. LANL will accept the use of the base of the water skid to function
as an overfill spillage tray.
2.10
Connection Interfaces
Flexible nonmetallic tubing will be used for the supply and return water line connections for the
facility chilled water lines. These ends will require a beaded end for a flex line attachment by a
band clamp during the skid installation at ORNL. The supply and return tube ends that connect to
the transfer lines of the closed loop deionized water system shall be a standard ANSI flange for a
3” diameter tube. The location of these interface points will be at the top of the water skid
envelope. This will allow for easy drop-down connections from the facility water lines and the
water transfer lines. The supplier will provide coordinate locations for each of the four (4)
connections and will identify these interface points on their top assembly drawing.
2.11
Pressure Drop
The skid shall not have a total pressure drop greater then 15 psi. This value must be determined
by analysis at PDR and again at FDR. Design approval by LANL is required prior to skid build. A
pressure drop test across the entire skid is required to verify the pressure drop analysis.
2.12
Support Structure
323
The supporting structure of the water skid shall be a flat plate material with supporting cage type
structure for vertical attachments. The structure shall not corrode due to a moderately humid
environment. Construction of the support structure shall use best engineering practice that
includes ANSI B1.1 and ANSI B1.20.1.
When materials for the support structure are not specified the following shall apply:
•
•
•
Structural shapes shall be type 304L stainless steel per ASTM A276.
Sheet and plate shall be type 304L stainless steel per ASTM A240.
Stainless steel surface finishes shall be in accordance with ASTM A480.
2.12.1
Paint
Upon the build completion of the support structure, it shall be painted as a protective measure to
eliminate corrosion and rust. The paint shall be highly durable enamel. The color may be either
white or black. Why paint stainless?
2.13
Seismic Parameters
The equipment shall remain in place and in operational condition during the following earthquake
parameters: seismic zone 2B, peak ground acceleration (Z) 0.20 G, and a damping factor of 5%.
2.14
Construction, Floor Loading, and Floor Quality
The design of the equipment rack shall be such that it may be moved via forklift (from any of the
four sides), air bearings, or overhead crane. The floor loading distribution, calculated when the
skid is full with water, shall be no greater than 500 lbs. per square foot. Total weight, balance,
center-of-gravity, and overall sturdiness must be a significant part of any and all design
considerations. The supplier may assume that the floor over which the water skid will be moved
shall…
…be a smooth trowel finish concrete floor,
…be sealed with concrete sealer,
…be flat and level within 0.25 inches within 10 feet in any direction,
…be free of cracks, chips, seams or gouges,
…be free of vertical projections and step changes in plane,
…have all construction joints filled in and ground smooth.
3.0
Equipment
The supplier shall be responsible for all equipment. Equipment is defined as purchased parts,
hardware, components, control devices, etc. All purchased parts must meet ASME codes and the
defined requirements stated in this document. Supplier responsibility includes component
verification documents.
3.1
Reservoir Expansion Tank
The reservoir expansion tank shall meet the codes as specified in ASME B31.3 and shall be
constructed of 316 or 316L stainless steel. It shall have a minimum volume of 10 gallons. The
tank will be pressurized by Nitrogen gas to a pressure of XX psig. It shall have a fluid level
switch located at the ¾ volume point of the chosen tank. Located at the top of the tank will be an
over pressurization relief valve, a Nitrogen fill port, and a deionized water fill port.
The ideal tank location for the supplier is to situate the tank at as high a point as possible. This
will create increased head pressure flowing into the pump. This is a goal for the supplier.
324
3.1.1
Nitrogen Purge System
A dry Nitrogen gas bottle (99.999% N2) serves as the pressurized source. Dry Nitrogen will be
used to purge the Oxygen from the system. Two gas pressure regulators (course and fine)
connected to the outlet of the N2 gas bottle have been incorporated by the ORNL facility
equipment group to step down the gas bottle pressure from several thousand psig to less than 5
psig.
On the reservoir expansion tank side of the N2 gas pressurization system (supplier’s
responsibility), a gas pressurization metering valve is requisite. LANL recommends a valve
manufactured by Nupro. An orifice plate gas throttling mechanism is essential to limit the gas
flow rate from the N2 bottle. From LANL calculations, the required orifice hole diameter is 0.020
inches. A manual isolation ball valve will be used to prevent any N2 gas leakage from the tank
once the system is pressurized. The operating pressure will be less than 2 psig. The pressure
relief valve setting will be 1 to 2 psig. The system will be located at the top of the reservoir
expansion tank.
3.1.2
Fluid Level Switch
The fluid level switch shall be a contact closure on/off type. A continuous 4-20 mA output signal
shall indicate that the fluid level is at or above its required level. All wetted surfaces shall be
stainless steel with the O-ring made of Viton.
3.2
Pump
The pump shall be a magnetic drive pump (MDP) and be of the horizontal sealless type. It shall
utilize an outer ring of permanent magnets or electromagnets to drive an internal rotating assembly
consisting of an impeller, shaft, and inner drive member (torque ring or magnet ring) through a
corrosion resistant containment shell. All nomenclature and definitions of pump components shall
be in accordance with ANSI/HI 5.1 through 5.6.
The material of construction shall be 316 or 316L stainless steel. The selection of a pump must
meet all of the requirements of document ASME B73.3M-1997 Specification For Sealless
Horizontal End Suction Centrifugal Pumps For Chemical Process.
All electric motors must be manufactured and operate per NEMA-MG-1. This document specifies
appropriate maximum vibration levels for electric motor assemblies.
Each pump assembly (including motor) must be mounted on a conventional machinery vibration
isolation mount. The mount system must be sized to provide 95% vibration isolation with respect
to the pump fundamental rotational excitation frequency. Isolation must be provided along two
perpendicular axes that are in turn perpendicular to the pump axis. Thus the isolation mount for a
horizontally mounted pump could provide isolation vertically and laterally with respect to the
pump axis. Isolators may be mounted with their axes inclined with respect to each
other.Conventional wire rope, helical spring, or isolators shall be utilized. The isolation system
must not be structurally short-circuited with rigid plumbing electrical conduit connections.
Flexible hose assemblies must be utilized for pump interfacing. Flexible electrical conduit with
appropriate wiring must be utilized for all electrical connections.
The pump shall have a variable speed controller with the ability to remotely control the pump
impeller speed. The controller will be placed along a wall within a Motor Control Center (MCC)
away from the actual water skid. The controller shall have a lockout in the open (unenergized)
position. This requirement is a noted exception to NEC 430-102.
3.3
Water Purification/Filtration System
325
The water system shall be designed to continuously maintain water purity in the SNS Accelerator.
The work to be performed requires the supplier to produce a single design and fabrication of 12
water purification units meeting the requirements contained within this section of this statement of
work as well as any accompanying attachments.
One (1) spare set of filters shall be shipped with each unit.
3.3.1
System Requirements
•
System requirements shall include a passive system; no drains will be available.
•
Draining of the system shall be via a 1” Hansen stainless steel quick disconnect, or
compatible, and shall be installed at the lowest point in the system.
•
To maintain purity in the cooling loops, the purification system shall be continuously
purifying 1-5% of the total coolant flow rate.
•
The system shall be designed to meet a internal pressure of 150 psig.
•
Upon passing through the purification system, the water shall have achieved the following
criteria:
Parameter
Flow Rate Through Purification Loop
Required Value
1 – 5% of total flow through the skid (minimum
of 2.6 – 3.1 GPM)
8±1
10 – 14 MΩ
< 20 parts per billion (ppb)
≤ 1 micron
≤ 0.5 mil/year
pH Level
Particulate Size
Corrosion
•
Water system shall maintain the desired purity without calibration, component or material
replacement for a minimum of one year.
•
Information in the following table shall be used in the design of the water purification system.
Each system shall continuously purify water at a minimum range of 2.6 – 3.1gpm.
Unit
ID Number
System Flow rate
(gpm)
Purification System
Flow range (gpm)
System Volume
(gallons)
1
2
3
4
5
6
7
8
9
10
11
12
DTL – 1
DTL – 2
DTL – 3
DTL – 4
DTL – 5
DTL – 6
CCL – 1
CCL – 2
CCL – 3
CCL – 4
CCL – Mag
SCL – Mag
119
161
234
214
198
182
219
257
257
257
61
TBD
1.2 – 6.0
1.6 – 8.1
2.3 – 11.7
2.1 – 10.7
2.0 – 9.9
1.8 – 9.1
2.2 – 11.0
2.6 – 12.9
2.6 – 12.9
2.6 – 12.9
0.6 – 3.1
TBD
256
281
281
281
281
281
308
308
308
308
359
912
326
3.3.2
3.3.3
3.3.4
3.3.5
3.3.6
•
Operating temperature of the water and surrounding environment will be 68±6°F.
•
Each unit shall have a corrosion resistant metal tag with its Identification Number, as shown
in the above table, imprinted and clearly visible and mounted on the frame of the unit.
•
All components shall be mounted to a Stainless Steel frame. Frame design shall allow easy
transport by forklift, and not hamper maintenance or installation.
•
All components and piping shall be easily removable by use of simple hand tools.
Materials
•
All materials shall be new.
•
All wetted materials shall be Buna-N, Viton®, Neoprene, Hypalon®, or Stainless Steel.
Filter and Filter Housings
•
Filter housings shall be fabricated using corrosion resistant 316L stainless steel.
•
Filter removal shall be accomplished by removal of the casing, vertically exposing the
cartridge.
•
Filter housings shall allow cartridge change without disrupting inlet/outlet piping.
•
Housings shall be of the T-type design with inlet and outlet on the same centerline.
•
The housing head shall clamp to the bowl with a Viton®, Neoprene, or Hypalon® O-ring
seal.
•
A stainless steel spring against the closed end of the filter cartridge shall maintain the
cartridge seal.
•
Seller shall provide redundant parallel filters. All filters shall be replaceable without shutting
the system down. A 5-micron filter shall be installed at the entrance into the purification
system. A 1-micron filter shall be installed at the exit of the purification system. Both filters
shall be constructed of ceramic or stainless steel.
Flow Control
•
A mechanical flow control device shall be added to regulate flow rate.
•
A total of two sample ports will be included in each unit. One sample port shall be located
upstream of any water treatment component and the other sample port shall be located
downstream immediately after all treatment components.
Resin Tank
•
A minimum of one resin tank shall consist of Amberlite® IR-120 in H+ form, and shall be
placed up stream of additional resin tanks.
•
All tanks shall have a rubber base and be designed for a minimum 150 psig operating pressure
and 120 degrees F operating temperature.
Hoses
327
3.3.7
3.4
•
Flexible hoses shall be manufactured with Viton®, Neoprene, Buna-N, Hypalon® or
University approved equivalent.
•
Hose ends shall be of a quick-disconnect type allowing easy replacement/refurbishment of
resin tanks.
Instrumentation & Electrical
•
The preferred output signal type will be 4-20mA, with 0-10 VDC being an alternative.
•
Instrumentation shall measure pH, resistivity, and dissolved O2 concentration.
•
See the P&ID for sensor locations. Provide adequate cabling for routing between instrument
and sensor.
•
Supplier’s measurements shall be taken downstream of the purification system.
•
All electrically powered items shall utilize power from 120VAC, current not to exceed 10
amps, with a 24VDC, current not to exceed 10 amps, power source as an alternate.
Flow Meters
The flow meters shall optimally have as low a pressure drop as possible. The accuracy shall be
atleast ±1% or better for each water skid flow requirements. The power requirement availability is
24 volts dc. The output signal shall be 4-20 mA dc, 2-wire configuration.
3.5
Valves
Valve design and selection shall meet the requirements of ANSI B16.10, API 608, MSS SP-72,
ISA S75.03, ISA S75.04, and ISA S75.14.
3.5.1
Electronically Actuated Control Valves
The primary control valve will be a 3-way diverging valve located at the heat exchanger-to-heat
exchanger bypass intersection. The valve will provide true linear proportioning and a smooth
gradual flow reduction when flow adjusting. The valve will have stable transitioning when
switching ports to prevent valve slamming and pipeline water hammer. All wetted surfaces will
be 316 stainless steel and packing made from Teflon or Viton.
The linear valve actuator will be electronically actuated. It will operate with a two-wire 4 to 20
mA signal for both the input command signal and the feedback signal. The input available power
will be 24 Vdc. Position accuracy will be ±1% of full actuator travel. The valve will require a
100% duty cycle. The actuation speed shall be no slower then 32 s/in. The actuator housing will
be NEMA type 4 requirements.
A 2-way electronically actuated flow control valve will be required prior to the entrance on the
cold side of the heat exchanger. This is facility-chilled water and is not deionized water. This
valve does not require 316 stainless steel, Teflon or Viton as construction or housing materials.
However, it is required to be compatible with the tubing material and must be highly sturdy and
reliable. It will operate with a two-wire 4 to 20 mA signal for both the input command signal and
the feedback signal. The input available power will be 24 Vdc. Position accuracy will be ±5% of
full actuator travel. The valve will require a 75% duty cycle. The actuation speed shall be no
slower then 64 s/in. The actuator housing will be NEMA type 4 requirements.
328
3.5.2
Manual Globe Valve
The single globe valve will regulate the flow manually. All wetted metallic valve components
will be 316 stainless steel and non-metallics will be of Viton. The stem will be adjusted using a
standard hand-wheel. At the point where the valve is properly adjusted, a locking mechanism will
ensure that no inadvertent contact would alter the valve setting. Due to potential sticking or
turning of a screwed bonnet, a bolted bonnet is preferred. The desired body end is flanged.
3.5.3
Manual Ball Valves
A total nine (9) of manual ball valves are required in the closed loop portion of the water skid.
The rotary-ball valve will function as a manual on/off flow isolator. The stem rotation will be 90°
open to close. The single-seat ‘eccentric’ version of this ball valve will be used to insure that no
leakage occurs. The ball is slightly offset so that it presses into the seat on closure. The type will
be a ball valve constructed from 316 or 316L stainless steel.
An additional five (5) ball valves are required on the facility chilled water side of the heat
exchanger. These valves shall have sturdy and reliable isolation capabilities. Since this water is
not deionized, the valves may be constructed from a material other then stainless steel however,
they must be compatible with the stainless steel heat exchanger.
All valves must have a lockout method to prevent unauthorized adjustments.
3.5.4
Pressure Relief Valves
Two pressure relief valves will be used to protect the system from over-pressurization. A pressure
relief valve shall be located on the top of the reservoir tank. This valve will be set to release at a
pressure such that the system pressure will not at any time exceed the maximum operating
pressure of 150 psig. The second pressure relief valve will be located on either end of the inline
heater and will have the same pressure relief set point.
3.5.5
Method of Installation
The valves, whenever possible, shall be installed using compression fittings or flanges. All
dissimilar metals require nonconducting dielectric connections and the written approval by LANL.
Viton seals may be used if required. Any deviation from these requirements must have written
approval from LANL.
3.6
Heat Exchanger
The heat exchanger will be from Flat Plate Heat Exchanger Company model TBD.
LANL will be responsible for the heat exchanger analysis and the choice of heat exchanger. The
heat exchanger will be procurement responsibility of the supplier. The supplier will have sole
responsibility for the installation into the system.
3.7
Air Separator
An air separator is required in the closed loop system for air removal. Spirotherm, Inc. has a unit
referred to as a Spirovent that is representative of the type of component LANL is recommending.
Another separator may be used provided it functions similarly. The component selection requires
LANL approval.
3.8
Air Eliminator
329
An air eliminator will be used at the air elimination port on the air separator. It may be mounted
directly to the air separator or to a stainless steel tube that is routed between the air separator and
the air eliminator. The air eliminator design shall allow no water leakage. The separator shall be
located at the highest point on the skid. Spirotherm, Inc. has a unit referred to as a Spirotop and
Spirax Sarco, Inc. has a unit referred to an Automatic Air Vent both of which are representative
of the type of component LANL is recommending. Another eliminator may be used provided it
functions similarly. The component selection requires LANL approval.
3.9
Resistance Temperature Detectors (RTDs)
RTDs shall be used for temperature measurement because of the need for high accuracy,
repeatability, and stability. The probe shall be ¼” in diameter to prevent damage due to the high
flow rates and constructed of platinum wire wound about a ceramic of glass core and hermetically
sealed within a ceramic or glass capsule. All wetted surfaces shall be stainless steel and no Teflon
may be used. A 3-wire configuration (style 2) shall be used. The output signal shall be 4-20 mA.
3.10
Pressure Transducers
The transducer shall measure gage pressure. The calibrated total error band shall be no greater
than 1.5 % root-sum-square (RSS). The output shall be a 2-wire, 4-20 mA signal. The available
power supply is 24 Vdc. The construction of the transducer shall be stainless steel.
3.11
In-Line Heater
The inline heater shall be a minimum of 12 kW and a maximum of 20 kW. The water connection
ports shall be flanged for ease of removal. The ports shall be a minimum of 1” diameter and
optimally 3” in diameter to reduce pressure drop.
The heater shall have a controller with the ability to remotely control the on/off capabilities of the
heater. The controller will be placed along a wall within a Motor Control Center (MCC) away
from the actual water skid. The controller shall have a lockout in the open (unenergized) position.
This requirement is a noted exception to NEC 430-102.
3.12
Strainer
A 100-mesh particulate strainer is required upstream to the electronically actuated 2-way control
valve. A 100-mesh strainer removes any particulate greater then .0059 inches (149 micron). The
desired strainer will be a basket type for easy cleaning. The filtering material, as well as any
wetted surfaces, must be compatible with a standard acid wash liquid that will be used periodically
to clean the interior surfaces of the heat exchanger.
3.13
Tubing
All tubing design and construction must meet the requirements of ASTM A268, A269, A511, and
A554 documents.
3.13.1
Material
The primary material used by the supplier to design/fabricate the system shall be stainless steel
316 or 316L. Viton is an acceptable nonmetallic seal material. Other materials may be used
provided they are commonly used materials, are acceptable for use with deionized water, do not
create galvanic corrosion problems, and are acceptable in writing by LANL.
3.13.2
Acid Wash Ports
330
Two connection ports are required to do a periodic acid wash cleaning of the cold side heat
exchanger. The water flowing through this half of the heat exchanger is facility city water. It is
likely that this water will leave mineral deposits on the interior surface of the heat exchanger.
These deposits will have a direct detrimental affect on the heat exchanger efficiency and will
eventually lower the performance of the entire closed loop system.
The ports will be of type and size TBD.
3.13.3
Joining Methods
The method of joining tube-to-tube used by the supplier to design/fabricate the system shall be by
compression fittings or welded joints whenever possible. The method of joining tube-tocomponents shall be by compression fittings, flanges or NPT. All flanged joints shall meet the
requirements set forth in ANSI B1.20.3. Whenever a threaded fitting is required, a soft setting
sealant shall be used. The recommended sealant is RectorSeal NO. 5 (MSDS0011). Teflon
does not perform well in the any radiation environment and is not an acceptable sealant. All
dissimilar metals require nonconducting dielectric connections and the written approval by LANL.
Refer to ASME B16.5 document for the desired flanged fittings.
3.13.4
Method of Support
Tubing support shall be in accordance with Manufactures Standardization Society for the Valve
and Fittings Industry (MSS), MSS SP-69. Supports shall be arranged to insure that no structural
load is transmitted to the equipment.
3.13.5
Tube Sizing
Tube sizes shall be defined by LANL. Refer to the Process and Instrumentation Drawing (P&ID).
The wall thickness for all stainless steel tubing shall be TBD.
3.13.6
Cutting
Cutting method shall be with tube cutters only. All cut edges shall be reamed to remove all burrs.
All defects caused by machining, chipping, or grinding shall be removed.
3.13.7
Installation
All tubing shall be installed parallel and perpendicular to the skid base frame. Any variation from
these requirements requires written approval by LANL. Skid fabrication shall be in accordance
with ASME B31.9, Building Service Piping.
3.13.8
Labeling
Each major tubing section shall have directional arrows indicating the water flow path. A major
section is defined as any tube length preceding and following a tube intersection.
4.0
Cleaning
All stainless steel components/sub-systems shall follow the guideline set forth in document ASTM
A380 for precleaning, descaling, and cleaning. The water skid shall be cleaned per PFI ES-5.
5.0
Equipment Acceptance Tests Requirements
All water skid units shall be inspected, examined, and tested in accordance with ASME B31.3.
All testing shall follow the guidelines set forth in ASNT 2055. Inspection, examination, and
331
testing shall include a visual examination, a hydrostatic system leak test, and a system
functionality test.
The supplier shall provide all required equipment and facilities (including calibrated equipment) to
carry out acceptance testing at the supplier’s facility. LANL representatives may elect to witness
the test and therefore shall be informed at least 10 days in advance of the start of testing. Each
water skid shall undergo acceptance testing and demonstrate compliance with the requirements of
this procurement specification. The supplier shall not be held responsible should LANL supplied
components fail during testing however the supplier maintains responsibility for the connections
and wiring of the supplied components.
5.1 Visual Examination
Each water skid shall undergo a detailed visual examination upon the completion of the build and
prior to the system leak test and the system functionality test. The supplier will develop a detailed
visual inspection checklist that must be signed off by qualified personnel. The checklist shall
include inspection of workmanship, weld inspection per ASME codes, all joints, all permanent
valving, and correct labeling of flow direction but is not limited to these items.
5.2 System Pressure Drop Test
A pressure drop test shall be performed on the first deliverable water skid. Water shall be flowing
at the specified design flow rate. The pressure drop across the water skid on the warm side of the
heat exchanger shall be measured. Additionally, the pressure drop shall be measure at 80% flow,
120% flow, and 150% flow.
5.3 Hydrostatic System Leak Test
The system leak test shall be performed in accordance with the Power Piping Standard of the
American National Standards Institute (ANSI) and the American Society of Mechanical Engineers
(ASME). The test of the entire system shall be a hydrostatic leak test. The two (2) supply and the
two (2) return lines shall be temporarily capped off or sealed for the test. The system shall be
pressurized to 225 psig. The fluid temperature shall coincide with actual system requirements.
The fluid shall be water of the following quality.
Parameter
pH Level
Particulate Size
Required Quality
8±1
10 – 14 MΩ
< 20 ppb
< 1 micron
Any joints covered by insulation must be temporarily pealed back or removed to see potential
leaks. A temporary relief valve shall be installed if the pressure testing equipment may possibly
produce excessive pressure. As much air must be removed from the system when it is filled with
deionized water. Given that air is compressible and water is only slightly compressible, any air
that remains in the system when it is pressurized may cause injury to personnel, damage to
equipment, or non-recognition of a small leak. The test pressure shall be continuously maintained
for a minimum of thirty (30) minutes before starting the examination for leakage. All joints and
connections, valve packing, and pump shaft seals in the system should be examined. There shall
be no indication of leakage or weeping.
A restoration checklist shall be prepared by the supplier to verify that all plugs, temporary
supports, temporary relief valves, etc. are removed from the skid at the completion of the test. The
system shall be blown out and dried.
332
5.4 System Functionality Test
The system functionality test shall be performed in accordance with ANSI and ASME Standards
where applicable. The testing shall verify the functionality of the entire system including all
system components and monitoring components. The test temperature and pressure shall simulate
the actual system requirements. The fluid shall be water of the same quality as that used for the
leak test.
The fluid flow to and from the RF Structure shall be simulated. The testing shall also verify the
functionality of all system components.
6.0
Personnel Qualifications
Qualifications of testing personnel shall comply with those requirements outlined in the ASME
B31.3.
7.0
Test Reports
Test Reports shall be generated and submitted by the supplier for all inspection, examination, and
testing performed and required by ASME B31.3. Test reports are required for each of the twelve
(12) systems tested.
Test reports shall be provided which include all data taken during acceptance testing. Each report
shall include the supplier’s written certificate of compliance to the requirements of this
procurement specification. Two (2) hard copies of the test report and one (1) electronic copy shall
be supplied concurrent with the delivery of each system. The test report shall include as a
minimum the following information:
System Identification (Tag Number)
Date of test
Test method and acceptance criteria used
Name and signature of the qualified test operator
Make, model, and serial number of test equipment used
Calibration dates of test equipment
Description of test article and all other fixtures and components used
Time, location of leaks (or other failures), and corrective action taken
Record of time, temperature, and internal pressure
Calibrated leak data
Signature of witness
8.0
Data Requirements
All data shall be provided in hardcopy and electronic media. The electronic media shall use
Adobe “…pdf” files. Data requirements shall conform to the requirements set forth in the
Program Plan, the Monthly Report, the Design Review Data Package, the Test Plans, the Test
Reports, the Drawings, the Installation and Operating Instructions, the Recommended Spare Parts
List, the software documentation, and the Maintenance Manual.
9.0
Marking/Identification
Each water skid shall be identified by a nameplate sealwelded to the front of the skid structure
located near eye level. The nameplate material shall be any 300 series stainless steel. The
following information shall be stamped or etched on the nameplate using atleast ½” high lettering:
Facility:
Project:
Oak Ridge National Laboratory in Oak Ridge, TN
333
Contract Specification:
Identification No.:
Description:
10.0
TBD
See Section 1.2
See Section 1.2
Installation and Operating Instructions
Concurrent with the first unit, the supplier shall provide 3 sets of installation and operating
instructions. A single copy of the instructions shall be provided with each subsequent unit once
the initial manuals are approved by LANL. These instructions shall include but not limited to:
•
•
•
•
•
11.0
Unpacking and handling instructions
Installation procedures
Normal operating procedures
Shutdown procedures
Safety procedures and cautions
Packaging
Packaging, shipping, and transportation is the responsibility of the supplier. Best comercial
practices are to be used.
11.1 Container Construction
The water skids shall be packaged individually. The packaging structure shall not be the frame
and support structure of the skid. Each skid shall be packaged in wooden shipping containers with
proper bracing and placed on wooden platforms to avoid any damage during handling and
shipping. Potential contact points between the skid and the crate shall be padded to prevent
damage during shipping. The exterior of the container must provide access and method for
moving of the container by forklift.
11.2 Packaging Preparations
The supplier shall be responsible for adequate packaging to assure safe arrival at the designated
shipping location. Each skid shall be shipped in a single container with one skid per container. A
shock watch and tilt watch shall be included on the packaging to indicate any mishandling during
shipment. So what is the shock indicator for? (the vendor has the responsibility and if he wants to
put one on or not should be his decision as to how he’s going to argue with the shipper for damage
claims.
Particular care shall be expended to assure that the cleanliness, dimensional stability, and overall
integrity of the equipment achieved during fabrication are not affected during shipment. The
assembly shall be thoroughly cleaned to remove any dirt that may have accumulated on the
equipment during testing. No water shall remain within the water skid tubing or components. All
tube ends shall be sealed to prevent ingress of dirt into the system. These openings shall be sealed
with temporary covers, polyethyene sheet, or other equivalent protection. Any tape used shall be
low chloride (<250 PPM). Defects in the paint shall be touched-up and repaired.
11.3 Container Labeling
Containers shall be properly and clearly marked on the top and all four sides using a stencil with
the following information:
Facility:
Project:
Contract Specification:
Oak Ridge National Laboratory in Oak Ridge, TN
TBD
334
Identification No.:
Description:
See Section 1.2
See Section 1.2
Additional information such as the actual weight of the container, the orientation of the equipment
within the container, and any other information the supplier deems necessary shall also be labeled.
11.4 Shipping
The supplier shall assure that the shipment is with an insured carrier. The carrier shall provide
exclusive use of the trucks for shipment. Are you asking for an exclusive use shipment?
Containers shall be covered for protection from weather during shipping. Covering may be an
enclosed trailer or other sheeting drawn over the containers. The truck driver shall carry a data
package (is this listed under deliverables?) to be delivered to the destination supervisor. As a
minimum, the data package must contain the bill of lading for each shippable unit and one copy of
the Final Data Package. Prior to the equipment being prepared for shipping, the supplier shall
obtain approval from LANL to ship.
335
17.0 Appendix D – Hardware Costs
DTL Water Cooling System Hardware Costs
SUMMARY
Item # Description
Quantity
1 Drift tube Water skid
Supplier
6 Parts list (see
below)
6 Parts list (see
below)
6 Parts list (see
below)
7 Parts list (see
below)
7 Parts list (see
below)
2 Drift tube Manifolds & Trans. Lines
3 RF struct. Manifolds & Trans.
Lines
4 PLCs, Computers, software
5 Electronics rack & equipment
DETAILED LISTINGS for 1 UNIT
1 RF Structure & Magnet Water Skid Components
Component or Grouping
Item
Pump
Quantity
Heat Exchanger
Expansion Tank
Inline Heater
I&C
Unit Cost ($) Extended Cost Cost Source
($)
85,071
510428.232 catalog & eng.
Judge.
36,586
219513 catalog & eng.
Judge.
46,488
278929.5 catalog & eng.
Judge.
$25,500
178500 catalog & eng.
Judge.
$1,157
8099 catalog & eng.
Judge.
GRAND TOTAL
Supplier
1 MP Pumps
Inc.
1 Flat Plate
1
1
5
8
Flowmeters
Pressure
Transducers
Thermocouples
Liquid level switch
APC
Omega
Omega
Omega
8 Omega
1 Omega
Plumbing
Pipes/Fittings
1 Quotes per
336
Net Cost ($)
510,428
219,513
278,930
178,500
8,099
1,195,470
Unit Price ($)
15 % Discount ($) Price ($)
$
$1,238
$7,013
8,250
$
$1,175
$6,661
7,836
$2,725
$409
$2,316
$3,473
$521
$2,952
$2,000
$300
$8,500
$180
$27
$1,224
$75
$225
$11
$34
$510
$191
$8,400
$1,260
$7,140
JIT
Valves
Air separator
Press. relief & air
eliminators
Manual Valves (3"
ball)
Proportional Valves
(elect)
1 spriotherm
6 Alb. Valve &
Fitting
12 Dahl
Plumbing
2 Worcester
Cont.
1
Water Treatment Hardware & Inst.
400
$
150
$
343
$
9,000
$
13,000
$
4,500
$
9,600
$60
$23
$340
$765
$51
$3,500
$1,350
$15,300
$1,950
$11,050
0
$4,500
0
$9,600
Structure
1
Structure assembly, fab. & check-out man-hours
1
160 man-hours at $60/hr
Assembly & detail drawings (6 drawings)
1
$
1,310
0
$1,310
40 hrs/drawing = 240 man-hours at $60/hr, divide by 11 skids
Documentation, testing, certification (20 hrs at $60/hr)
Shipping & Insurance
1
1
$1,200
$1,000
0
0
$1,200
$1,000
$85,071
SUBTOTAL
2 Drift Tube Manifolds
Item
Manifolds
Qty in ft, Price per ft
0.375" Buna-N hose
2" Cu sub-manifolds
Qty is total number
Orifice plates and
fittings
Quantity
Supplier
200 McMaster
Carr
100 McMaster
Carr
50
337
Unit Price ($)
15 % unit Discount Price ($)
($)
0.35
0.0525
$60
7.6
1.14
$646
100
15
$4,250
Qty is total number
Stainless steel
valves
Various copper
fittings
Various stainless
steel fit.
Instr. (flow, press.,
temp.)
Supports, bolt sets,
misc.
60 man-hours at $60/hr
2 Alb. Valve &
Fittings
1 McMaster
Carr
1 Alb. Valve &
Fittings
1 Omega
400
60
$680
5000
750
$4,250
10000
1500
$8,500
15000
2250
$12,750
1
1000
150
$850
1
$3,600
0
$3,600
1
$1,000
0
$1,000
$36,586
SUBTOTAL
3 RF Structure Manifolds and Transfer Lines
Item
Transfer Lines
4" Cu Tubing
0.5" Cu tubing
0.375" Cu tubing
0.5" Buna-N hose
0.375" Buna-N hose
Manifolds
Quantity
3" Cu manifold
suply & return
2" Cu sub-manifolds
338
Supplier
Unit Price ($)
15 % unit Discount Price ($)
($)
250 McMaster
Carr
400 McMaster
Carr
400 McMaster
Carr
200 McMaster
Carr
100 McMaster
Carr
10.2
1.53
$2,168
2.4
0.36
$816
1.8
0.27
$612
0.5
0.075
$85
0.35
0.0525
$30
200 McMaster
Carr
200 McMaster
Carr
10.8
1.62
$1,836
7.6
1.14
$1,292
Qty is total number
Stainless steel
valves
Various copper
fittings
Various stainless
steel fit.
Instr. (flow, press.,
temp.)
Supports, bolt sets,
misc.
120 Man-hours at $60/hr
10 Alb. Valve &
Fittings
1 McMaster
Carr
1 Alb. Valve &
Fittings
1 Omega
400
60
$3,400
10000
1500
$8,500
12000
1800
$10,200
8000
1200
$6,800
1
3000
450
$2,550
1
$7,200
0
$7,200
1
$1,000
0
$1,000
$46,488
SUBTOTAL
4 PLCs, Computers, software per skid
Component #
Item
Quantity
1 PLC (plus cards,
input & output
connect)
2 Electrical hardware
(cables, pwr sup.)
3 Local computer
4 Software (labview,
PLC, etc.)
Supplier
1 (N/A)
Unit Price ($) Price ($)
$10,000
$10,000
1 (N/A)
$10,000
$10,000
1 (N/A)
1 (N/A)
$3,500
$2,000
$3,500
$2,000
SUBTOTAL
5 Electronics rack & equipment per skid
Component #
Item
1 Equipment Rack
Quantity
2 Equipment Rack
Fan
3 Power Strip
339
Supplier
1 Premier
Metal
1 Premier
Metal
1 Premier
$25,500
Unit Price ($) Price ($)
$825
$825
$257
$257
$75
$75
Metal
SUBTOTAL
340
$1,157
18.0 Appendix E – Parts Database/Device Name List for DTL Tank 1
341
SNS DTL Resonant Control Cooling System (RCCS) Master Data Base for Resonant Control Cooling System 1 and Tank 1, sections A & B
System Name=System/SubSystem, Device Name=System/SubSystem+Device, Signal Name=System/SubSystem+Device+Signal
System/SubSystem
Device Name Device
Manufacturer
Model #
Signal type
Module Info
Cable/Pair
DTL_RCCS1
MV1
manual ball valve
TBD
DTL_RCCS1
MV2
manual ball valve
TBD
DTL_RCCS1
MV3
manual ball valve
DTL_RCCS1
MV4
DTL_RCCS1
TBD
N/A
*****
*****
main skid return valve from DT
TBD
N/A
*****
*****
heat exchanger loop valve
TBD
TBD
N/A
*****
*****
main loop drain valve, N.C.
manual ball valve
TBD
TBD
N/A
*****
*****
main supply valve, heater by-pa
MV5
manual ball valve
TBD
TBD
N/A
*****
*****
main skid supply valve
DTL_RCCS1
MV6
manual globe valve
TBD
TBD
N/A
*****
*****
inlet valve to water purity loop
DTL_RCCS1
MV7
manual ball valve
TBD
TBD
N/A
*****
*****
water purity loop manual valve
DTL_RCCS1
MV8
manual ball valve
TBD
TBD
N/A
*****
*****
reservoir tank valve
DTL_RCCS1
MV9
manual ball valve
TBD
TBD
N/A
*****
*****
reservoir tank vent valve, N.C.
DTL_RCCS1
MV10
manual ball valve
TBD
TBD
N/A
*****
*****
h-x unit supply acid wash port m
DTL_RCCS1
MV11
manual ball valve
TBD
TBD
N/A
*****
*****
reservoir tank nitrogen valve, N
DTL_RCCS1
MV12
manual ball valve
TBD
TBD
N/A
*****
*****
h-x unit return acid wash port m
DTL_RCCS1
MV13
manual ball valve
TBD
TBD
N/A
*****
*****
outlet valve from heat exchange
DTL_RCCS1
MV14
manual ball valve
TBD
TBD
N/A
*****
*****
outlet valve to heat exchanger fr
DTL_RCCS1
FT1
flow transmitter
TBD
TBD
4-20mA
TBD
TBD
main return flow meter
DTL_RCCS1
FT2
flow transmitter
TBD
TBD
4-20mA
TBD
TBD
flow meter loop of heat exchang
DTL_RCCS1
FT3
flow transmitter
TBD
TBD
4-20mA
TBD
TBD
flow meter at skid exit
DTL_RCCS1
FT4
flow transmitter
TBD
TBD
4-20mA
TBD
TBD
water purity loop flow meter
DTL_RCCS1
FT5
flow transmitter
TBD
TBD
4-20mA
TBD
TBD
flow meter out of heat exchange
DTL_RCCS1
PT1
TBD
TBD
4-20mA
TBD
TBD
inlet pressure of heat exchanger
DTL_RCCS1
PT2
TBD
TBD
4-20mA
TBD
TBD
outlet pressure of heat exchange
DTL_RCCS1
PT3
TBD
TBD
4-20mA
TBD
TBD
inlet pressure to pump
DTL_RCCS1
PT4
TBD
TBD
4-20mA
TBD
TBD
outlet pressure from pump
DTL_RCCS1
PT5
TBD
TBD
4-20mA
TBD
TBD
inlet pressure to heat exchanger
342
Description
DTL_RCCS1
PT6
TBD
TBD
4-20mA
TBD
TBD
outlet pressure of heat exchange
DTL_RCCS1
TT1
TBD
TBD
4-20mA
TBD
TBD
inlet temperature of heat exchan
DTL_RCCS1
TT2
TBD
TBD
4-20mA
TBD
TBD
outlet temperature of heat excha
DTL_RCCS1
TT3
TBD
TBD
4-20mA
TBD
TBD
inlet temperature to pump
DTL_RCCS1
TT4
TBD
TBD
4-20mA
TBD
TBD
outlet temperature from pump
DTL_RCCS1
TT5
TBD
TBD
4-20mA
TBD
TBD
inlet temperature to heat exchan
DTL_RCCS1
TT6
TBD
TBD
4-20mA
TBD
TBD
outlet temperature of heat excha
DTL_RCCS1
TT7
TBD
TBD
4-20mA
TBD
TBD
outlet temperature of heater HT
DTL_RCCS1
CV1
3 way PID valve
TBD
TBD
4-20mA
TBD
TBD
DTL_RCCS1
CV2
2 way PID valve
TBD
TBD
4-20mA
TBD
TBD
PID 2 way valve, chilled water
DTL_RCCS1
PSV1
pressure relief valve
TBD
TBD
N/A
*****
*****
water purity loop reservoir tank
DTL_RCCS1
PSV2
TBD
TBD
N/A
*****
*****
in-line heater pressure relief val
DTL_RCCS1
STR-1
strainer
TBD
TBD
N/A
*****
*****
strainer, 100 mesh at heat excha
DTL_RCCS1
HX-1
heat exchanger
TBD
TBD
N/A
*****
*****
heat exchanger unit
DTL_RCCS1
PH1
purity xducer
TBD
TBD
4-20mA
TBD
TBD
main water PH transducer
DTL_RCCS1
O21
oxygen xducer
TBD
TBD
4-20mA
TBD
TBD
main water oxygen transducer
DTL_RCCS1
PMP-1
pump
TBD
TBD
24VDC
TBD
TBD
DTL_RCCS1
LT1
fluid level
TBD
TBD
24VDC
TBD
TBD
water purity loop reservoir tank
DTL_RCCS1
HTR-1
in-line heater
TBD
TBD
24VDC
TBD
TBD
in-line heater, manual remote co
DTL_RCCS1
RE1
resistivity probe
TBD
TBD
4-20mA
TBD
TBD
resistivity probe @ center of wa
DTL_RCCS1
RE2
resistivity probe
TBD
TBD
4-20mA
TBD
TBD
resistivity probe post of water fi
DTL_RCCS1
TK-1
Reservoir Expansion Tank TBD
TBD
N/A
TBD
TBD
Reservoir Expansion tank
DTL_RCCS1
AS-1
Air Seperator
TBD
TBD
N/A
TBD
TBD
Air Seperator
DTL_RCCS1
AE-1
Air Eliminator
TBD
TBD
N/A
TBD
TBD
Air Eliminator
*****
*****
*****
Tank 1-section A ----------------------
*****
*****
*****
DTL_TANK1
MV101
manual ball valve
TBD
TBD
N/A
N/A
N/A
main isolation supply valve
DTL_TANK1
MV102
manual ball valve
TBD
TBD
N/A
N/A
N/A
main isolation return valve
343
DTL_TANK1
MV103
manual ball valve
TBD
TBD
N/A
N/A
N/A
supply vent valve, N.C.
DTL_TANK1
MV104
manual ball valve
TBD
TBD
N/A
N/A
N/A
return vent valve, N.C.
DTL_TANK1
MV105
manual ball valve
TBD
TBD
N/A
N/A
N/A
pre strainer isolation supply valv
DTL_TANK1
MV106
manual ball valve
TBD
TBD
N/A
N/A
N/A
return isolation valve
DTL_TANK1
MV107
manual ball valve
TBD
TBD
N/A
N/A
N/A
post strainer isolation supply va
DTL_TANK1
MV108
manual ball valve
TBD
TBD
N/A
N/A
N/A
return drain valve, N.C.
DTL_TANK1
MV109
manual globe valve
TBD
TBD
N/A
N/A
N/A
slug tunner supply isolation valv
DTL_TANK1
MV110
manual ball valve
TBD
TBD
N/A
N/A
N/A
return vent valve, N.C.
DTL_TANK1
MV111
manual globe valve
TBD
TBD
N/A
N/A
N/A
post coupler supply isolation va
DTL_TANK1
MV112
manual globe valve
TBD
TBD
N/A
N/A
N/A
drift tube supply valve
DTL_TANK1
MV113
manual globe valve
TBD
TBD
N/A
N/A
N/A
end wall drift tube supply valve
DTL_TANK1
MV114
manual globe valve
TBD
TBD
N/A
N/A
N/A
post coupler supply isolation va
DTL_TANK1
MV115
manual ball valve
TBD
TBD
N/A
N/A
N/A
supply drain valve, N.C.
DTL_TANK1
MV116
manual ball valve
TBD
TBD
N/A
N/A
N/A
supply vent valve, N.C.
DTL_TANK1
FT101
flow transmitter
TBD
TBD
4-20mA
TBD
TBD
main post coupler return flow m
DTL_TANK1
FT102
flow transmitter
TBD
TBD
4-20mA
TBD
TBD
DTL_TANK1
FT103
flow transmitter
TBD
TBD
4-20mA
TBD
TBD
DTL_TANK1
FT104
flow transmitter
TBD
TBD
4-20mA
TBD
TBD
344
4-20mA
TBD
TBD
post coupler
N/A
N/A
N/A
post coupler
PC102
post coupler
N/A
N/A
N/A
post coupler
DTL_TANK1
PC103
post coupler
N/A
N/A
N/A
post coupler
DTL_TANK1
PC104
post coupler
N/A
N/A
N/A
post coupler
DTL_TANK1
PC105
post coupler
N/A
N/A
N/A
post coupler
DTL_TANK1
PC106
post coupler
N/A
N/A
N/A
post coupler
DTL_TANK1
PC107
post coupler
N/A
N/A
N/A
post coupler
DTL_TANK1
PC108
post coupler
N/A
N/A
N/A
post coupler
DTL_TANK1
PC109
post coupler
N/A
N/A
N/A
post coupler
DTL_TANK1
PC110
post coupler
N/A
N/A
N/A
post coupler
DTL_TANK1
PC111
post coupler
N/A
N/A
N/A
post coupler
DTL_TANK1
ST101
slug tuner
N/A
N/A
N/A
slug tuner
DTL_TANK1
ST102
slug tuner
N/A
N/A
N/A
slug tuner
DTL_TANK1
ST103
slug tuner
N/A
N/A
N/A
slug tuner
DTL_TANK1
ST104
slug tuner
N/A
N/A
N/A
slug tuner
DTL_TANK1
PSV101
TBD
TBD
N/A
N/A
N/A
main supply pressure relief valv
DTL_TANK1
PSV102
TBD
TBD
N/A
N/A
N/A
main return pressure relief valve
DTL_TANK1
FT105
flow transmitter
DTL_TANK1
PC101
DTL_TANK1
TBD
TBD
345
DTL_TANK1
PT101
TBD
TBD
4-20mA
TBD
TBD
DTL_TANK1
PT102
TBD
TBD
4-20mA
TBD
TBD
DTL_TANK1
TT101
TBD
TBD
4-20mA
TBD
TBD
DTL_TANK1
TT102
TBD
TBD
4-20mA
TBD
TBD
DTL_TANK1
STR-101
strainer
TBD
TBD
N/A
N/A
main water supply strainer, 60 m
*****
*****
*****
*****
*****
Tank 1-section A ----------------------
*****
N/A
DTL_TANK1
FO100
orifice plate
N/A
N/A
N/A
orifice plate
DTL_TANK1
FO101
orifice plate
N/A
N/A
N/A
orifice plate
DTL_TANK1
FO102
orifice plate
N/A
N/A
N/A
orifice plate
DTL_TANK1
FO103
orifice plate
N/A
N/A
N/A
orifice plate
DTL_TANK1
FO104
orifice plate
N/A
N/A
N/A
orifice plate
DTL_TANK1
FO105
orifice plate
N/A
N/A
N/A
orifice plate
DTL_TANK1
FO106
orifice plate
N/A
N/A
N/A
orifice plate
DTL_TANK1
FO107
orifice plate
N/A
N/A
N/A
orifice plate
DTL_TANK1
FO108
orifice plate
N/A
N/A
N/A
orifice plate
DTL_TANK1
FO109
orifice plate
N/A
N/A
N/A
orifice plate
DTL_TANK1
FO110
orifice plate
N/A
N/A
N/A
orifice plate
DTL_TANK1
FO111
orifice plate
N/A
N/A
N/A
orifice plate
DTL_TANK1
FO112
orifice plate
N/A
N/A
N/A
orifice plate
346
DTL_TANK1
FO113
orifice plate
N/A
N/A
N/A
orifice plate
DTL_TANK1
FO114
orifice plate
N/A
N/A
N/A
orifice plate
DTL_TANK1
FO115
orifice plate
N/A
N/A
N/A
orifice plate
DTL_TANK1
FO116
orifice plate
N/A
N/A
N/A
orifice plate
DTL_TANK1
FO117
orifice plate
N/A
N/A
N/A
orifice plate
DTL_TANK1
FO118
orifice plate
N/A
N/A
N/A
orifice plate
DTL_TANK1
FO119
orifice plate
N/A
N/A
N/A
orifice plate
DTL_TANK1
FO120
orifice plate
N/A
N/A
N/A
orifice plate
DTL_TANK1
FO121
orifice plate
N/A
N/A
N/A
orifice plate
DTL_TANK1
FO122
orifice plate
N/A
N/A
N/A
orifice plate
DTL_TANK1
FO123
orifice plate
N/A
N/A
N/A
orifice plate
DTL_TANK1
FO124
orifice plate
N/A
N/A
N/A
orifice plate
DTL_TANK1
FO125
orifice plate
N/A
N/A
N/A
orifice plate
DTL_TANK1
FO126
orifice plate
N/A
N/A
N/A
orifice plate
DTL_TANK1
FO127
orifice plate
N/A
N/A
N/A
orifice plate
DTL_TANK1
FO128
orifice plate
N/A
N/A
N/A
orifice plate
DTL_TANK1
FO129
orifice plate
N/A
N/A
N/A
orifice plate
DTL_TANK1
FO130
orifice plate
N/A
N/A
N/A
orifice plate
347
DTL_TANK1
FO131
orifice plate
N/A
N/A
N/A
orifice plate
DTL_TANK1
FO132
orifice plate
N/A
N/A
N/A
orifice plate
DTL_TANK1
FO133
orifice plate
N/A
N/A
N/A
orifice plate
DTL_TANK1
FO134
orifice plate
N/A
N/A
N/A
orifice plate
DTL_TANK1
MV123
manual ball valve
TBD
TBD
N/A
N/A
N/A
drift tube supply valve, pre strai
DTL_TANK1
MV124
manual ball valve
TBD
TBD
N/A
N/A
N/A
drift tube supply valve, post stra
DTL_TANK1
STR-102
strainer
TBD
TBD
N/A
N/A
N/A
drift tube strainer, 60 mesh
Tank 1-section B ----------------------
*****
*****
*****
*****
*****
DTL_TANK1
MV117
manual globe valve
*****
TBD
TBD
N/A
N/A
N/A
drive iris supply valve
DTL_TANK1
MV118
manual globe valve
TBD
TBD
N/A
N/A
N/A
RFW supply valve
DTL_TANK1
MV119
manual globe valve
TBD
TBD
N/A
N/A
N/A
end wall drift tube supply valve
DTL_TANK1
MV120
manual globe valve
TBD
TBD
N/A
N/A
N/A
DTL_TANK1
MV121
manual globe valve
TBD
TBD
N/A
N/A
N/A
dipole electromagnet supply val
DTL_TANK1
MV122
manual globe valve
TBD
TBD
N/A
N/A
N/A
DTL_TANK1
FT106
flow transmitter
TBD
TBD
4-20mA
TBD
TBD
end wall flow meter
DTL_TANK1
FT107
flow transmitter
TBD
TBD
4-20mA
TBD
TBD
flow meter
DTL_TANK1
FT108
flow transmitter
TBD
TBD
4-20mA
TBD
TBD
flow meter
DTL_TANK1
FT109
flow transmitter
TBD
TBD
4-20mA
TBD
TBD
flow meter
348
DTL_TANK1
FT110
flow transmitter
TBD
TBD
4-20mA
TBD
TBD
flow meter
DTL_TANK1
FT111
flow transmitter
TBD
TBD
4-20mA
TBD
TBD
flow meter
DTL_TANK1
PC112
post coupler
N/A
N/A
N/A
post coupler
DTL_TANK1
PC113
post coupler
N/A
N/A
N/A
post coupler
DTL_TANK1
PC114
post coupler
N/A
N/A
N/A
post coupler
DTL_TANK1
PC115
post coupler
N/A
N/A
N/A
post coupler
DTL_TANK1
PC116
post coupler
N/A
N/A
N/A
post coupler
DTL_TANK1
PC117
post coupler
N/A
N/A
N/A
post coupler
DTL_TANK1
PC118
post coupler
N/A
N/A
N/A
post coupler
DTL_TANK1
PC119
post coupler
N/A
N/A
N/A
post coupler
DTL_TANK1
ST105
slug tuner
N/A
N/A
N/A
slug tuner
DTL_TANK1
ST106
slug tuner
N/A
N/A
N/A
slug tuner
DTL_TANK1
ST107
slug tuner
N/A
N/A
N/A
slug tuner
DTL_TANK1
ST108
slug tuner
N/A
N/A
N/A
slug tuner
DTL_TANK1
RFW101
RF window
N/A
N/A
N/A
RF window
DTL_TANK1
DI101
drive iris
N/A
N/A
N/A
drive iris
*****
*****
*****
TANK 1-section B ---------------------
*****
*****
*****
DTL_TANK1
FO135
orifice plate
N/A
N/A
N/A
orifice plate
DTL_TANK1
FO136
orifice plate
N/A
N/A
N/A
orifice plate
349
DTL_TANK1
FO137
orifice plate
N/A
N/A
N/A
orifice plate
DTL_TANK1
FO138
orifice plate
N/A
N/A
N/A
orifice plate
DTL_TANK1
FO139
orifice plate
N/A
N/A
N/A
orifice plate
DTL_TANK1
FO140
orifice plate
N/A
N/A
N/A
orifice plate
DTL_TANK1
FO141
orifice plate
N/A
N/A
N/A
orifice plate
DTL_TANK1
FO142
orifice plate
N/A
N/A
N/A
orifice plate
DTL_TANK1
FO143
orifice plate
N/A
N/A
N/A
orifice plate
DTL_TANK1
FO144
orifice plate
N/A
N/A
N/A
orifice plate
DTL_TANK1
FO145
orifice plate
N/A
N/A
N/A
orifice plate
DTL_TANK1
FO146
orifice plate
N/A
N/A
N/A
orifice plate
DTL_TANK1
FO147
orifice plate
N/A
N/A
N/A
orifice plate
DTL_TANK1
FO148
orifice plate
N/A
N/A
N/A
orifice plate
DTL_TANK1
FO149
orifice plate
N/A
N/A
N/A
orifice plate
DTL_TANK1
FO150
orifice plate
N/A
N/A
N/A
orifice plate
DTL_TANK1
FO151
orifice plate
N/A
N/A
N/A
orifice plate
DTL_TANK1
FO152
orifice plate
N/A
N/A
N/A
orifice plate
DTL_TANK1
FO153
orifice plate
N/A
N/A
N/A
orifice plate
DTL_TANK1
FO154
orifice plate
N/A
N/A
N/A
orifice plate
350
DTL_TANK1
FO155
orifice plate
N/A
N/A
N/A
orifice plate
DTL_TANK1
FO156
orifice plate
N/A
N/A
N/A
orifice plate
DTL_TANK1
FO157
orifice plate
N/A
N/A
N/A
orifice plate
DTL_TANK1
FO158
orifice plate
N/A
N/A
N/A
orifice plate
DTL_TANK1
FO159
orifice plate
N/A
N/A
N/A
orifice plate
DTL_TANK1
FO160
orifice plate
N/A
N/A
N/A
orifice plate
DTL_TANK1
FC101
faraday cup
N/A
N/A
N/A
faraday cup
DTL_TANK1
FT112
flow transmitter
4-20mA
TBD
TBD
faraday cup flow meter
TBD
TBD
351
19.0 Appendix F – DTL Drift Tube Heat Load and Cooling Requirements
Table F.1. DTL tank #1 drift tube flow rate, heat load, coolant temperature rise, and
pressure drop specifications.
Drift tube
Flow rate
Heat load
0 (end nose)
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
(gpm)
0.05
0.2
0.2
0.2
0.2
0.3
0.3
0.3
0.3
0.3
0.3
0.3
0.4
0.4
0.4
0.4
0.4
0.5
0.5
0.5
0.5
0.6
0.6
0.6
0.6
0.7
0.7
0.7
0.7
0.8
0.8
0.8
0.9
0.9
1.0
1.0
1.1
1.1
1.2
1.2
1.3
(W)
15.6
48.3
51.1
54.0
56.8
59.6
62.4
65.3
68.1
70.9
73.8
76.6
79.4
82.2
85.1
87.9
92.3
96.7
101.2
105.6
110.0
114.4
118.8
123.3
127.7
132.1
136.5
140.9
145.4
149.8
154.2
161.5
168.9
176.2
183.5
190.8
198.2
205.5
212.8
220.1
227.5
352
Coolant
temperature rise
(oC)
0.8
0.92
0.97
1.02
1.08
0.75
0.79
0.83
0.86
0.9
0.93
0.97
0.75
0.78
0.81
0.83
0.88
0.73
0.77
0.8
0.83
0.72
0.75
0.78
0.81
0.72
0.74
0.76
0.79
0.71
0.73
0.77
0.71
0.74
0.7
0.72
0.68
0.71
0.67
0.7
0.66
Pressure Drop
(psi)
0.7
1.1
1.2
1.2
1.3
1.3
1.4
1.4
1.4
1.4
1.5
1.5
1.5
1.5
1.5
1.5
1.6
1.6
1.7
1.8
1.8
2.1
2.2
2.2
2.3
2.3
2.4
2.1
2.1
2.1
2.2
2.3
2.4
2.5
2.6
2.7
2.9
3.0
3.1
3.2
3.3
41
42
43
44
45
46
47
48
49
50
51
52
53
54
55
56
57
58
59
60 (end nose)
1.3
1.4
1.4
1.5
1.5
1.5
1.6
1.6
1.7
1.7
1.8
1.8
1.8
1.9
1.9
2.0
2.0
2.1
2.1
1.4
234.8
242.1
249.4
256.8
264.1
276.5
288.9
301.4
313.8
326.2
338.6
351.1
363.5
375.9
388.3
400.7
413.2
425.6
438.0
165.2
0.69
0.66
0.68
0.65
0.67
0.7
0.68
0.71
0.7
0.73
0.71
0.74
0.77
0.75
0.78
0.76
0.78
0.77
0.79
0.3
3.4
3.6
3.7
3.8
4.0
4.1
4.2
4.3
4.4
4.6
4.7
4.9
5.0
5.2
5.3
5.5
5.7
5.8
6.0
8.3
Drift tube
Flow rate
Heat load
0 (end nose)
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
(gpm)
0.25
0.9
0.9
0.9
1.0
1.0
1.0
1.0
1.0
1.0
1.1
1.1
1.1
1.1
1.1
1.2
1.2
1.2
1.2
1.2
1.2
1.3
(W)
170.2
465.3
472.7
480.2
487.6
495.1
502.5
509.9
517.4
524.8
532.2
539.7
547.1
554.6
562.0
571.9
581.9
591.8
601.7
611.7
621.6
631.6
353
Coolant
temperature rise
(oC)
1.7
1.96
1.99
2.02
1.85
1.88
1.91
1.93
1.96
1.99
1.84
1.86
1.89
1.91
1.94
1.81
1.84
1.87
1.9
1.93
1.96
1.84
Pressure Drop
(psi)
1.4
1.5
1.6
1.6
1.6
1.7
1.7
1.8
1.8
1.8
1.9
1.9
2.0
2.0
2.1
2.1
2.1
2.2
2.2
2.3
2.3
2.4
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48 (end nose)
1.3
1.3
1.3
1.3
1.4
1.4
1.4
1.4
1.5
1.5
1.5
1.6
1.6
1.6
1.7
1.7
1.8
1.8
1.9
1.9
2.0
2.0
2.1
2.1
2.2
2.2
0.9
641.5
651.4
661.4
671.3
683.8
696.4
708.9
721.4
734.0
746.5
759.0
771.5
784.1
796.6
810.5
824.5
838.4
852.3
866.2
880.2
894.1
908.0
921.9
935.9
949.8
963.7
390.0
1.87
1.9
1.93
1.96
1.85
1.89
1.92
1.95
1.86
1.89
1.92
1.83
1.86
1.89
1.81
1.84
1.77
1.8
1.73
1.76
1.7
1.72
1.67
1.69
1.64
1.66
1.1
2.4
2.5
2.5
2.6
2.7
2.8
2.9
3.0
3.1
3.2
3.3
3.4
3.5
3.6
3.7
3.9
4.1
4.3
4.6
4.8
5.0
5.3
5.5
5.7
6.0
6.2
3.8
Drift tube
Flow rate
Heat load
0 (end nose)
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
(gpm)
0.7
2.4
2.5
2.6
2.7
2.7
2.8
2.9
3.0
3.1
3.2
3.2
3.3
3.4
3.5
3.6
(W)
341.2
945.6
952.5
959.3
966.2
973.0
979.8
986.7
993.5
1000.4
1007.2
1014.1
1020.9
1027.7
1034.6
1041.4
354
Coolant
temperature rise
(oC)
1.2
1.49
1.45
1.4
1.36
1.37
1.33
1.29
1.26
1.22
1.19
1.2
1.17
1.15
1.12
1.1
Pressure Drop
(psi)
2.4
0.9
1.0
1.0
1.0
1.2
1.2
1.3
1.3
1.4
1.5
1.6
1.6
1.7
1.8
1.9
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34 (end nose)
3.7
3.8
3.8
3.9
4.0
4.1
4.2
4.3
4.3
4.4
4.5
4.6
4.7
4.8
4.8
4.9
5.0
5.1
1.4
1048.3
1055.1
1062.3
1069.5
1076.7
1083.9
1091.1
1098.3
1105.5
1112.8
1120.0
1127.2
1134.4
1141.6
1148.8
1156.0
1163.2
1170.4
449.6
1.07
1.05
1.06
1.04
1.02
1
0.99
0.97
0.98
0.96
0.94
0.93
0.92
0.9
0.91
0.89
0.88
0.87
0.8
2.0
2.1
2.2
2.3
2.4
2.5
2.6
2.8
2.8
2.9
3.2
3.1
3.3
3.5
3.5
3.6
3.9
3.9
4.6
Drift tube
Flow rate
Heat load
0 (end nose)
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
(gpm)
0.9
2.8
2.9
3.0
3.1
3.2
3.2
3.3
3.4
3.5
3.6
3.7
3.8
3.9
4.0
4.0
4.1
4.2
4.3
4.4
4.5
4.6
4.7
4.7
4.8
(W)
453.2
1170.4
1179.6
1188.8
1198.1
1207.3
1216.5
1225.7
1235.0
1244.2
1253.4
1262.6
1271.9
1281.1
1290.3
1296.8
1303.2
1309.7
1316.1
1322.6
1329.1
1335.5
1342.0
1348.5
1354.9
355
Coolant
temperature rise
(oC)
1.2
1.59
1.54
1.5
1.47
1.43
1.44
1.41
1.38
1.35
1.32
1.29
1.27
1.25
1.22
1.23
1.21
1.18
1.16
1.14
1.12
1.1
1.08
1.09
1.07
Pressure Drop
(psi)
2.2
1.2
1.2
1.4
1.4
1.5
1.6
1.7
1.7
1.8
1.9
2.0
2.1
2.2
2.3
2.4
2.5
2.6
2.9
2.9
3.0
3.3
3.2
3.4
3.6
25
26
27
28 (end nose)
4.9
5.0
5.1
1.5
1361.4
1367.8
1374.3
543.2
1.05
1.04
1.02
0.9
3.6
3.7
4.1
5.3
Drift tube
Flow rate
Heat load
0 (end nose)
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24 (end nose)
(gpm)
0.9
3.0
3.1
3.2
3.3
3.4
3.5
3.6
3.7
3.8
3.9
4.0
4.1
4.1
4.2
4.3
4.4
4.5
4.6
4.7
4.8
4.9
5.0
5.1
1.5
(W)
546.6
1374.3
1382.1
1389.9
1397.8
1405.6
1413.4
1421.2
1429.0
1436.8
1444.7
1452.5
1460.3
1468.3
1476.4
1484.4
1492.5
1500.5
1508.6
1516.6
1524.7
1532.7
1540.8
1548.8
622.3
Coolant
temperature rise
(oC)
1.5
1.74
1.69
1.65
1.61
1.57
1.53
1.5
1.47
1.43
1.41
1.38
1.35
1.36
1.33
1.31
1.29
1.26
1.24
1.22
1.2
1.19
1.17
1.15
1.0
Pressure Drop
(psi)
2.2
1.4
1.4
1.5
1.7
1.7
1.8
1.9
2.0
2.1
2.2
2.3
2.4
2.7
2.7
2.8
3.1
3.1
3.2
3.5
3.4
3.6
3.9
3.9
5.3
Drift tube
Flow rate
Heat load
0 (end nose)
1
2
3
4
5
6
7
(gpm)
0.7
2.1
2.2
2.2
2.3
2.4
2.5
2.5
(W)
625.6
1548.8
1565.4
1582.0
1598.6
1615.2
1631.8
1648.4
356
Coolant
temperature rise
(oC)
2.2
2.8
2.7
2.73
2.64
2.55
2.48
2.5
Pressure Drop
(psi)
1.4
0.7
0.7
0.8
0.8
0.8
0.9
0.9
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22 (end nose)
2.6
2.7
2.7
2.8
3.0
3.3
3.5
3.7
4.0
4.2
4.4
4.6
4.9
5.1
1.8
1665.0
1681.6
1698.2
1714.8
1727.9
1741.0
1754.1
1767.2
1780.3
1793.4
1806.5
1819.6
1832.7
1845.8
754.6
357
2.43
2.36
2.39
2.32
2.18
2
1.9
1.81
1.69
1.62
1.56
1.5
1.42
1.37
1.0
1.0
1.1
1.1
1.2
1.4
1.6
1.8
2.2
2.3
2.6
3.0
3.2
3.5
4.1
7.3
20.0 Appendix G - Orifice Plate Spreadsheet Calculations for DTL Drift Tubes
358
TANK 1
Drift Tube Flow Rate ∆pbranch total ∆Pflow switch
Rdrift tube
∆Pdrift tube
(psi/gpm2)
260
28.6
30.0
31.2
14.3
14.8
15.2
15.5
15.8
16.0
9.1
9.2
9.2
9.3
9.3
5.9
6.2
6.5
6.9
4.9
5.1
5.8
4.4
4.5
4.7
3.7
3.8
3.2
3.3
(psi)
0.65
1.1
1.2
1.2
1.3
1.3
1.4
1.4
1.4
1.4
1.5
1.5
1.5
1.5
1.5
1.5
1.6
1.6
1.7
1.8
1.8
2.1
2.2
2.2
2.3
2.3
2.4
2.1
2.1
Aorifice /Apipe
β
IDorifice
0.07041
0.14179
0.14200
0.14217
0.17371
0.17389
0.17405
0.17418
0.17429
0.17438
0.20079
0.20085
0.20089
0.20093
0.20094
0.22398
0.22440
0.22479
0.22535
0.24660
0.24701
0.24866
0.26840
0.26889
0.26937
0.28779
0.28828
0.28558
0.28580
(in)
0.028
0.057
0.057
0.057
0.069
0.070
0.070
0.070
0.070
0.070
0.080
0.080
0.080
0.080
0.080
0.090
0.090
0.090
0.090
0.099
0.099
0.099
0.107
0.108
0.108
0.115
0.115
0.114
0.114
∆Porifice,
∆Ptotal
Ktotal .375id
(psi)
12.526
12.526
12.526
12.526
12.526
12.526
12.526
12.526
12.526
12.526
12.526
12.526
12.526
12.526
12.526
12.526
12.526
12.526
12.526
12.526
12.526
12.526
12.526
12.526
12.526
12.526
12.526
12.526
12.526
88127.169
5507.948
5507.948
5507.948
2447.977
2447.977
2447.977
2447.977
2447.977
2447.977
1376.987
1376.987
1376.987
1376.987
1376.987
881.272
881.272
881.272
881.272
611.994
611.994
611.994
449.628
449.628
449.628
344.247
344.247
344.247
344.247
required
#
0
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
(gpm)
0.05
0.2
0.2
0.2
0.3
0.3
0.3
0.3
0.3
0.3
0.4
0.4
0.4
0.4
0.4
0.5
0.5
0.5
0.5
0.6
0.6
0.6
0.7
0.7
0.7
0.8
0.8
0.8
0.8
(psi)
0.00
0.02
0.02
0.02
0.04
0.04
0.04
0.04
0.04
0.04
0.07
0.07
0.07
0.07
0.07
0.10
0.10
0.10
0.10
0.15
0.15
0.15
0.20
0.20
0.20
0.27
0.27
0.27
0.27
(psi)
1.75
1.75
1.75
1.75
1.75
1.75
1.75
1.75
1.75
1.75
1.75
1.75
1.75
1.75
1.75
1.75
1.75
1.75
1.75
1.75
1.75
1.75
1.75
1.75
1.75
1.75
1.75
1.75
1.75
0.00495786
0.02010531
0.02016384
0.02021288
0.03017573
0.03023719
0.03029232
0.03033845
0.03037704
0.03040872
0.04031464
0.04033919
0.04035772
0.04037099
0.04037665
0.0501675
0.05035416
0.05053018
0.05078442
0.06081109
0.06101353
0.06183188
0.07203785
0.07230314
0.07256212
0.08282323
0.08310622
0.08155375
0.08168343
359
(psi)
10.125
9.614
9.558
9.511
9.447
9.408
9.373
9.344
9.319
9.299
9.255
9.243
9.234
9.228
9.225
9.187
9.116
9.050
8.956
8.845
8.783
8.540
8.418
8.352
8.289
8.166
8.106
8.440
8.411
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
49
50
51
52
53
54
55
56
57
58
59
60
0.9
0.9
1.0
1.0
1.1
1.1
1.2
1.3
1.3
1.4
1.4
1.5
1.6
1.6
1.7
1.7
1.8
1.9
1.9
2
2.1
2.1
2.2
2.3
2.3
2.4
2.4
2.5
2.6
2.6
2.7
1.4
0.34
0.34
0.42
0.42
0.50
0.50
0.60
0.70
0.70
0.81
0.81
0.93
1.06
1.06
1.20
1.20
1.35
1.50
1.50
1.66
1.83
1.83
2.01
2.20
2.20
2.39
2.39
2.60
2.81
2.81
3.03
0.81
1.75
1.75
1.75
1.75
1.75
1.75
1.75
1.75
1.75
1.75
1.75
1.75
1.75
1.75
1.75
1.75
1.75
1.75
1.75
1.75
1.75
1.75
1.75
1.75
1.75
1.75
1.75
1.75
1.75
1.75
1.75
1.75
2.6
2.7
2.3
2.4
2.1
2.2
1.9
1.7
1.8
1.6
1.6
1.5
1.3
1.4
1.3
1.3
1.2
1.1
1.2
1.1
1.0
1.0
1.0
0.9
0.9
0.9
0.9
0.9
0.8
0.9
0.8
4.2
2.1
2.2
2.3
2.4
2.5
2.6
2.7
2.9
3.0
3.1
3.2
3.3
3.4
3.6
3.7
3.8
4.0
4.1
4.2
4.3
4.4
4.6
4.7
4.9
5.0
5.2
5.3
5.5
5.7
5.8
6.0
8.27
0.091642
0.09177508
0.10228422
0.10297921
0.11367695
0.11445826
0.12538988
0.1365033
0.13748278
0.14892253
0.15004604
0.16189128
0.17402496
0.17551519
0.18834641
0.19016079
0.20372388
0.21762891
0.21980058
0.23470106
0.25027157
0.253525
0.27088266
0.2894362
0.29409773
0.31547588
0.32119027
0.34638553
0.37522456
0.38511654
0.58
0.26731981
360
0.30272
0.30294
0.31982
0.32090
0.33716
0.33832
0.35410
0.36946
0.37079
0.38590
0.38736
0.40236
0.41716
0.41895
0.43399
0.43607
0.45136
0.46651
0.46883
0.48446
0.50027
0.50351
0.52046
0.53799
0.54231
0.56167
0.56674
0.58855
0.61256
0.62058
0.760
0.51703
0.121
0.121
0.128
0.128
0.135
0.135
0.142
0.148
0.148
0.154
0.155
0.161
0.167
0.168
0.174
0.174
0.181
0.187
0.188
0.194
0.200
0.201
0.208
0.215
0.217
0.225
0.227
0.235
0.245
0.248
0.304
0.207
8.314
8.288
8.088
7.969
7.766
7.649
7.439
7.220
7.105
6.877
6.761
6.522
6.277
6.154
5.887
5.755
5.475
5.201
5.077
4.788
4.497
4.353
4.035
3.712
3.559
3.212
3.059
2.693
2.316
2.146
1.75
1.690
12.526
12.526
12.526
12.526
12.526
12.526
12.526
12.526
12.526
12.526
12.526
12.526
12.526
12.526
12.526
12.526
12.526
12.526
12.526
12.526
12.526
12.526
12.526
12.526
12.526
12.526
12.526
12.526
12.526
12.526
12.526
12.526
271.997
271.997
220.318
220.318
182.081
182.081
152.999
130.366
130.366
112.407
112.407
97.919
86.062
86.062
76.235
76.235
67.999
61.030
61.030
55.079
49.959
49.959
45.520
41.648
41.648
38.250
38.250
35.251
32.591
32.591
30.222
112.407
TANK 2
Drift Tube Flow Rate DP branch total ∆Pflow switch
Rdrift tube
∆pdrift tube
(psi/gpm2)
21.76
1.9
1.9
1.8
1.8
1.8
1.7
1.7
1.7
1.7
1.6
1.6
1.6
1.6
1.6
1.5
1.5
1.5
1.4
1.4
1.4
1.4
1.4
1.3
1.3
1.3
1.3
1.2
1.2
(psi)
1.36
1.5
1.6
1.6
1.6
1.7
1.7
1.8
1.8
1.8
1.9
1.9
2.0
2.0
2.1
2.1
2.1
2.2
2.2
2.3
2.3
2.4
2.4
2.5
2.5
2.6
2.7
2.8
2.9
Aorifice /Apipe
β
IDorifice
0.15940
0.29958
0.30300
0.30630
0.30981
0.31319
0.31645
0.31993
0.32329
0.32663
0.32997
0.33331
0.33664
0.33992
0.34320
0.34700
0.35079
0.35458
0.35836
0.36215
0.36594
0.36973
0.37352
0.37733
0.38114
0.38551
0.39440
0.40111
0.40789
(in)
0.064
0.120
0.121
0.123
0.124
0.125
0.127
0.128
0.129
0.131
0.132
0.133
0.135
0.136
0.137
0.139
0.140
0.142
0.143
0.145
0.146
0.148
0.149
0.151
0.152
0.154
0.158
0.160
0.163
∆porifice,
∆ptotal
Ktotal .4id
(psi)
12.488
12.488
12.488
12.488
12.488
12.488
12.488
12.488
12.488
12.488
12.488
12.488
12.488
12.488
12.488
12.488
12.488
12.488
12.488
12.488
12.488
12.488
12.488
12.488
12.488
12.488
12.488
12.488
12.488
3514.581
271.187
259.959
249.414
239.498
230.162
221.361
213.055
205.209
197.788
190.762
184.104
177.789
171.793
166.096
159.720
153.705
148.023
142.651
137.565
132.747
128.178
123.841
119.720
115.801
112.072
103.883
98.603
93.715
required
#
0
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
(gpm)
0.25
0.9
0.9
0.9
1.0
1.0
1.0
1.0
1.0
1.1
1.1
1.1
1.1
1.1
1.2
1.2
1.2
1.2
1.2
1.3
1.3
1.3
1.3
1.4
1.4
1.4
1.5
1.5
1.5
(psi)
0.04
0.34
0.35
0.37
0.38
0.40
0.41
0.43
0.44
0.46
0.48
0.50
0.51
0.53
0.55
0.57
0.59
0.62
0.64
0.66
0.69
0.71
0.74
0.76
0.79
0.81
0.88
0.93
0.97
(psi)
1.75
1.75
1.75
1.75
1.75
1.75
1.75
1.75
1.75
1.75
1.75
1.75
1.75
1.75
1.75
1.75
1.75
1.75
1.75
1.75
1.75
1.75
1.75
1.75
1.75
1.75
1.75
1.75
1.75
0.02540844
0.08974626
0.09180911
0.09382191
0.09598224
0.09809052
0.10014228
0.10235728
0.10451352
0.10668772
0.10888084
0.11109255
0.11332478
0.11554501
0.11778485
0.12040599
0.1230524
0.12572462
0.12842401
0.13115155
0.13390871
0.13669797
0.13951982
0.14237579
0.14526755
0.14861474
0.15555017
0.16088902
0.16637433
361
(psi)
9.325
8.697
8.639
8.592
8.517
8.455
8.404
8.326
8.260
8.192
8.124
8.054
7.984
7.917
7.848
7.774
7.698
7.620
7.542
7.462
7.381
7.298
7.214
7.129
7.042
6.910
6.718
6.550
6.379
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
1.6
1.6
1.6
1.7
1.7
1.76157
1.8
1.833333
1.866667
1.9
1.933333
1.966667
2
2.033333
2.066667
2.1
2.133333
2.166667
2.2
0.9
1.02
1.07
1.13
1.18
1.23
1.29
1.35
1.40
1.45
1.50
1.55
1.61
1.66
1.72
1.77
1.83
1.89
1.95
2.01
0.51
1.75
1.75
1.75
1.75
1.75
1.75
1.75
1.75
1.75
1.75
1.75
1.75
1.75
1.75
1.75
1.75
1.75
1.75
1.75
1.75
1.2
1.2
1.2
1.2
1.1
1.1
1.1
1.1
1.1
1.1
1.2
1.2
1.2
1.2
1.2
1.2
1.3
1.3
1.3
4.7
3.0
3.1
3.2
3.3
3.4
3.5
3.6
3.7
3.9
4.1
4.3
4.6
4.8
5.0
5.3
5.5
5.7
6.0
6.2
3.77
0.17201884
0.17783704
0.18384544
0.19006142
0.19650475
0.20319867
0.21016958
0.21656006
0.22534171
0.23463959
0.24459756
0.25584225
0.26810847
0.28174814
0.29736069
0.31524417
0.3364254
0.36160108
0.61
0.10424426
362
0.41475
0.42171
0.42877
0.43596
0.44329
0.45078
0.45844
0.46536
0.47470
0.48440
0.49457
0.50581
0.51779
0.53080
0.54531
0.56147
0.58002
0.60133
0.778
0.32287
0.166
0.169
0.172
0.174
0.177
0.180
0.183
0.186
0.190
0.194
0.198
0.202
0.207
0.212
0.218
0.225
0.232
0.241
0.311
0.129
6.205
6.026
5.844
5.659
5.469
5.276
5.080
4.901
4.611
4.324
4.037
3.731
3.424
3.113
2.791
2.464
2.127
1.790
1.44
6.285
12.488
12.488
12.488
12.488
12.488
12.488
12.488
12.488
12.488
12.488
12.488
12.488
12.488
12.488
12.488
12.488
12.488
12.488
12.488
12.488
89.181
84.969
81.049
77.393
73.980
70.787
67.797
65.354
63.041
60.848
58.768
56.793
54.915
53.130
51.430
49.810
48.265
46.792
45.385
271.187
TANK 4
Drift Tube Flow Rate ∆P branch total
∆Pflow
Rdrift tube
∆Pdrift tube Aorifice /Apipe
β
IDorifice
(gpm)
0.9
2.9
3.0
3.1
3.2
3.2
3.3
3.4
3.5
3.6
3.7
3.7
3.8
3.9
4.0
4.1
4.2
4.3
4.3
4.4
4.5
4.6
4.7
4.8
4.8
4.9
5.0
5.1
(psi)
0.0311853
0.3237884
0.3465037
0.3699889
0.3942442
0.3942442
0.4192695
0.4450647
0.47163
0.4989653
0.5270706
0.5270706
0.5559459
0.5855912
0.6160066
0.6471919
0.6791472
0.7118726
0.7118726
0.7453679
0.7796333
0.8146687
0.850474
0.8870494
0.8870494
0.9243948
0.9625102
1.0013956
(psi)
1.75
1.75
1.75
1.75
1.75
1.75
1.75
1.75
1.75
1.75
1.75
1.75
1.75
1.75
1.75
1.75
1.75
1.75
1.75
1.75
1.75
1.75
1.75
1.75
1.75
1.75
1.75
1.75
∆Ptotal
Ktotal .5id
(psi)
12.499
12.499
12.499
12.499
12.499
12.499
12.499
12.499
12.499
12.499
12.499
12.499
12.499
12.499
12.499
12.499
12.499
12.499
12.499
12.499
12.499
12.499
12.499
12.499
12.499
12.499
12.499
12.499
857.8
82.6
77.2
72.3
67.9
67.9
63.8
60.1
56.7
53.6
50.8
50.8
48.1
45.7
43.4
41.3
39.4
37.6
37.6
35.9
34.3
32.8
31.5
30.2
30.2
28.9
27.8
26.7
required
switch
#
0
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
∆Porifice,
2
(psi/gpm )
2.7
0.1
0.1
0.1
0.1
0.1
0.2
0.1
0.1
0.1
0.1
0.1
0.1
0.1
0.1
0.1
0.1
0.1
0.2
0.1
0.1
0.2
0.1
0.1
0.2
0.2
0.1
0.2
(psi)
2.19
1.2
1.2
1.4
1.4
1.5
1.6
1.7
1.7
1.8
1.9
2.0
2.1
2.2
2.3
2.4
2.5
2.6
2.9
2.9
3.0
3.3
3.2
3.4
3.6
3.6
3.7
4.1
0.040439636
0.117921971
0.122247072
0.127025239
0.131033843
0.131584463
0.136630448
0.140661598
0.145291381
0.149988044
0.154756523
0.155569251
0.160471921
0.165461075
0.170543142
0.175725069
0.181014393
0.186419308
0.189230469
0.193308273
0.199068027
0.206994946
0.211057829
0.217314564
0.221765725
0.225781244
0.23259718
0.24
363
0.20110
0.34340
0.34964
0.35641
0.36199
0.36275
0.36964
0.37505
0.38117
0.38728
0.39339
0.39442
0.40059
0.40677
0.41297
0.41920
0.42546
0.43176
0.43501
0.43967
0.44617
0.45497
0.45941
0.46617
0.47092
0.47516
0.48228
0.493
(in)
0.131
0.223
0.227
0.232
0.235
0.236
0.240
0.244
0.248
0.252
0.256
0.256
0.260
0.264
0.268
0.272
0.277
0.281
0.283
0.286
0.290
0.296
0.299
0.303
0.306
0.309
0.313
0.320
(psi)
8.516
9.106
8.998
8.823
8.771
8.689
8.493
8.444
8.316
8.185
8.050
7.954
7.814
7.670
7.522
7.371
7.217
7.059
6.814
6.783
6.616
6.296
6.271
6.094
5.800
5.784
5.598
5.22
28
1.5
0.0866259
TANK 5
Drift Tube Flow Rate ∆Pbranch total
1.75
2.3
5.27
0.082060575 0.28646
∆Pflow switch
Rdrift tube
∆Pdrift tube
1.75
1.75
1.75
1.75
1.75
1.75
1.75
1.75
1.75
1.75
1.75
1.75
1.75
1.75
1.75
1.75
1.75
1.75
1.75
1.75
1.75
1.75
1.75
1.75
1.75
(psi/gpm2)
2.7
0.2
0.1
0.1
0.2
0.1
0.1
0.1
0.1
0.1
0.1
0.1
0.1
0.2
0.2
0.2
0.2
0.2
0.2
0.2
0.1
0.1
0.2
0.1
2.3
(psi)
2.19
1.4
1.4
1.5
1.7
1.7
1.8
1.9
2.0
2.1
2.2
2.3
2.4
2.7
2.7
2.8
3.1
3.1
3.2
3.5
3.4
3.6
3.9
3.9
5.27
Aorifice /Apipe
0.186
β
IDorifice
0.20180
0.35956
0.36609
0.37331
0.38148
0.38795
0.39540
0.40295
0.41063
0.41845
0.42645
0.43464
0.44305
0.44707
0.45381
0.46296
0.47535
0.48240
0.49282
0.50790
0.51547
0.52794
0.54750
0.556
0.29122
(in)
0.131
0.234
0.238
0.243
0.248
0.252
0.257
0.262
0.267
0.272
0.277
0.283
0.288
0.291
0.295
0.301
0.309
0.314
0.320
0.330
0.335
0.343
0.356
0.361
0.189
5.36
∆Porifice,
12.499
308.8
∆Ptotal
Ktotal .5id
(psi)
12.5137
12.5137
12.5137
12.5137
12.5137
12.5137
12.5137
12.5137
12.5137
12.5137
12.5137
12.5137
12.5137
12.5137
12.5137
12.5137
12.5137
12.5137
12.5137
12.5137
12.5137
12.5137
12.5137
12.5137
12.5137
858.8
77.3
72.4
67.9
63.9
60.2
56.8
53.7
50.8
48.2
45.7
43.5
41.4
41.4
39.4
37.6
35.9
34.4
32.9
31.5
30.2
29.0
27.8
26.7
309.2
required
#
0
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
(gpm)
0.9
3.0
3.1
3.2
3.3
3.4
3.5
3.6
3.7
3.8
3.9
4.0
4.1
4.1
4.2
4.3
4.4
4.5
4.6
4.7
4.8
4.9
5.0
5.1
1.5
psi
0.127363057
0.799866698
0.854079885
0.910070554
0.967838705
1.027384337
1.08870745
1.151808045
1.216686122
1.28334168
1.35177472
1.421985241
1.493973244
1.493973244
1.567738728
1.643281694
1.720602141
1.79970007
1.880575481
1.963228373
2.047658747
2.133866602
2.221851939
2.311614757
0.353786268
0.04072246
0.12928397
0.13402174
0.13936313
0.14552355
0.15050618
0.15633827
0.16236746
0.16861417
0.17510157
0.18185615
0.1889084
0.19629363
0.19987584
0.2059465
0.21433246
0.22596186
0.2327102
0.24287002
0.25796344
0.26571101
0.27872031
0.2997601
0.31
0.08481001
364
(psi)
8.394
7.944
7.826
7.638
7.366
7.244
7.038
6.826
6.608
6.385
6.155
5.920
5.679
5.439
5.313
5.057
4.655
4.529
4.255
3.817
3.692
3.401
2.925
2.80
4.99
TANK 6
Drift Tube Flow Rate ∆P branch total ∆Pflow switch Rdrift tube
∆Pdrift tube
Aorifice /Apipe
β
IDorifice
∆porifice,
∆Ptotal
Ktotal .5id
(psi)
12.49
12.49
12.49
12.49
12.49
12.49
12.49
12.49
12.49
12.49
12.49
12.49
12.49
12.49
12.49
12.49
12.49
12.49
12.49
12.49
12.49
12.49
12.49
1417.2
131.3
120.6
102.7
95.3
82.6
77.2
72.3
63.8
60.1
53.6
50.7
48.1
43.4
41.3
37.6
35.9
34.3
31.4
30.1
27.8
26.7
214.3
required
#
0
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
(gpm)
0.7
2.3
2.4
2.6
2.7
2.9
3.0
3.1
3.3
3.4
3.6
3.7
3.8
4.0
4.1
4.3
4.4
4.5
4.7
4.8
5.0
5.1
1.8
(psi)
0.043548298
0.47014387
0.511914687
0.600788764
0.647892025
0.747430992
0.799866698
0.854079885
0.967838705
1.027384337
1.151808045
1.216686122
1.28334168
1.421985241
1.493973244
1.643281694
1.720602141
1.79970007
1.963228373
2.047658747
2.221851939
2.311614757
0.287952011
(psi)
1.75
1.75
1.75
1.75
1.75
1.75
1.75
1.75
1.75
1.75
1.75
1.75
1.75
1.75
1.75
1.75
1.75
1.75
1.75
1.75
1.75
1.75
1.75
2
(psi/gpm )
2.76
0.1
0.1
0.1
0.1
0.1
0.1
0.1
0.1
0.1
0.1
0.1
0.1
0.1
0.1
0.1
0.1
0.1
0.1
0.1
0.1
0.2
2.3
(psi)
1.35
0.7
0.7
0.8
0.8
0.8
0.9
0.9
1.0
1.1
1.1
1.2
1.4
1.6
1.8
2.2
2.3
2.6
3.0
3.2
3.5
4.1
7.29
0.03032771
0.09469176
0.09906859
0.10791682
0.11223983
0.12116009
0.12615524
0.13065121
0.14006602
0.14510114
0.1549881
0.16033452
0.16790042
0.17986545
0.18806546
0.20432573
0.21300772
0.22431506
0.24757606
0.25968188
0.28700873
0.32
0.12764372
365
0.17415
0.30772
0.31475
0.32851
0.33502
0.34808
0.35518
0.36146
0.37425
0.38092
0.39369
0.40042
0.40976
0.42411
0.43367
0.45202
0.46153
0.47362
0.49757
0.50959
0.53573
0.564
0.35727
(in)
0.113
0.200
0.205
0.214
0.218
0.226
0.231
0.235
0.243
0.248
0.256
0.260
0.266
0.276
0.282
0.294
0.300
0.308
0.323
0.331
0.348
0.367
0.232
(psi)
9.313
9.254
9.135
8.896
8.801
8.576
8.390
8.286
8.031
7.871
7.595
7.422
7.039
6.644
6.286
5.675
5.375
4.957
4.234
3.914
3.281
2.59
2.94
21. Appendix H – Flexible Tubing Data
Tubing Material
metals
polyvinylidene chloride (Saran)
Nylon
Polychloro trifluoroethylene (Kel-F), CTFE?
Polyvinyl fluoride (Tedlar)
Polyethylene Terephthalate (mylar)
Polyvinyl chloride (non-plasticized)
Polyacetal (Delrin)
Ethylene/Monochlorotrifluoroethylene
copolymer (Halar)
Ethylene/Tetrafluoroethylene copolymer
(Tefzel)
High density polyethylene (opaque)
Polypropylene
High density polyethylene (clear)
Polycarbonate (Lexan)
Polystyrene
Low density polyethylene
Fluorinated ethylene/propylene (FEP)
Tetrafluoroethylene (PTFE)
Natural rubber (Latex)
Silicone rubber (Silastic)
Permeability
Allowable
Radiation
dose in Rads
(1)
1x10^10
Least
permeable
ND
1x10^7
ND
ND
ND
ND
ND
ND
ND
ND
ND
ND
ND
ND
ND
ND
1x10^5
ND
ND
Viton
Ethylene-Propylene Rubber (EPR)
Butyl Rubber
Chlorosulfonated Polyethylene (Hypalon)
Hypalon w/ Neoprene cover
Nylon tube w/ Neoprene cover (Boston
Nyall)
Styrene-Butadiene Rubber (SBR)
Acrylonitrile Rubber (Buna-N)
Silicone Rubber (SIR)
Ethylene Propylene Copolymer (EPDM)
Neoprene
Polyisoprene
Polyurethane Rubber (PUR)
Polychloroprene Rubber (Neoprene)
Plexiglass
1x10^7
8x10^7
2x10^6
2x10^7
4x10^7
2x10^7
9x10^6
ND
ND
ND
7x10^7
2x10^7
1x10^7
366
(2)
Most
permeable
excellent (3)
very low (3)
very low (3)
good (3)
good
good
fair (3)
fair (3)
fair (3)
fair (4)
fair (4)
fair (4)
ND
ND
ND
DI
Compatibility
(5)
varies
ND
A1
A1
ND
ND
ND
ND
ND
ND
ND
ND
ND
ND
ND
ND
ND
A2
A
ND
A1
ND
ND
A2
A2
A1
ND
A1
ND
A1
A
ND
ND
ND
ND
Fluoro Rubber
Acrylic Rubber
Phenolic Resin
Polyvinyl Chloride (PVC)
9x10^6
8x10^6
1x10^6
1x10^6
(1) CERN 82-10
(2) Orbisphere
(3) Baxter Rubber Co.
(4) Rubber Engineering Guide,
molders.com
(5) Cole-Parmer Chemical Resistance
Chart
'A1=Satisfactory to 72F
A2=Satisfactory to 120F
A=No effect
ND=No Data
inc=inconclusive
367
ND
ND
ND
ND
ND
ND
ND
A2
22. Appendix I – Procurement Specification for the Water Purification System
01. WATER PURIFICATION SYSTEM SPECIFICATION
1.0
INTRODUCTION
This document is the technical specification for the water purification systems needed for
the cooling system of the SNS (Spallation Neutron Source) Accelerator. The water
system shall be designed to continuously maintain water purity in the SNS Accelerator.
The system may be subjected to low levels of radiation, 4.3 x 106 rads over a thirty-year
lifetime. In addition, the system requires the wetted surfaces maintain a low permeability
and shall be deionized water compatible.
2.0
SCOPE
The work to be performed requires the prospective seller to produce a single design,
fabrication and shipment of 12 water purification units meeting the requirements
contained within this document and any accompanying attachments.
3.0
SUBMITTALS
3.1 For all submittals, the attached Submittal Routing Sheet shall be used.
3.2 With seller’s bid, the following shall be submitted to the University of
California, Los Alamos:
3.2.1 Brief system description; include any suggestions regarding schedule
and cost reduction, and quality improvement.
3.2.2 Submit catalog data on all components. Include any shelf life for
components.
3.2.3 Furnish manufacturer’s maintenance logbook with listed scheduled
maintenance and normal system operating conditions.
3.2.4 Drawings showing connection points and overall system dimensions,
including tank capacities and exterior tank dimensions.
3.2.5 PID (piping & instrumentation diagram).
3.2.6 Cost breakdown with individual costs or testing, drawing development,
fabrication, shipping as well as total project cost.
368
3.2.7 Schedule showing milestones including 100% submittal, delivery of
each unit, test period, and delivery of final documentation; all based on
date of contract award.
3.2.8 Electrical load summary to include the power requirement for each
electrically powered item as well as the total power requirement for the
water purification system.
3.2.9 A copy of applicable MSDS (Material Safety Data Sheets)
3.2.10 Provide a brief list of no less than three projects demonstrating the
contractor has provided similar systems. The University may request
references.
3.3 Contractor shall provide the University with a 100% submittal for review
3.3.1 No more than 25 calendar days after contract award, the contractor
shall submit to the University for review as a 100% complete design, a
PID, drawings, and an electrical load summary as described in 3.2 of
this document.
3.3.2 Schedule showing milestones including dates for delivery of each unit,
test period of each unit, and delivery of final documentation based on
contract award date.
3.3.3 The University will utilize no more than 10 calendar days, beginning
on the day of receipt of the documentation, to review and submit
comments and change requests to the 100% submittal. No assembly
shall proceed until mutual agreement of the 100% submittal by the
University and the contractor.
3.4 Submittal of Test Report
3.4.1 A written test report for each unit shall be submitted and received by
the University no more than 10 calendar days from the date of the test.
3.5 Final Submittal
3.5.1 A minimum of 3 copies of the Final Submittal shall be delivered to the
University, in addition to the documentation delivered with each
system. All items shall be bound in a three ring binder.
3.5.2 The Final Submittal shall include:
3.5.2.1 Installation and Operation Manual. Manual shall include
detailed information to allow an outside licensed mechanical
and electrical contractor to install each unit. Manual shall
include the system dry weight, tank capacities, lift points
369
showing how the system can be moved using a forklift or
pallet jack. Power requirements and plumbing connection
points and sizes shall be indicated. The operation section shall
include a detailed start-up procedure and a troubleshooting
matrix to be used for diagnosing potential system failures.
3.5.2.2 Manufacturer’s Maintenance logbook with listed scheduled
maintenance and part identification. Normal system operating
conditions shall be indicated. A recommended spare parts list
to include as a minimum, a description of the part,
manufacturer’s part number, and manufacturer’s phone
number.
3.5.2.3 Drawings showing connection points and overall system
dimensions, and exterior tank dimensions stamped and signed
by a Professional Engineer. Drawings may be folded and
inserted into binder side pocket.
3.5.2.4 PID (plumbing & instrumentation diagram) with each
component identified.
PID stamped and signed by a
Professional Engineer. PID may be folded and inserted into
binder side pocket.
3.5.2.5 Electrical load summary for the water purification unit to
include the power requirement for each electrically powered
item as well as the total power requirement for the water
purification system. Stamped and signed by a Professional
Engineer.
3.5.2.6 A copy of applicable MSDS (Material Safety Data Sheets).
3.5.2.7 CD-ROM’s, each containing all Final Submittal data in
Adobe® *.pdf format.
4.0
DELIVERABLES
4.1 Twelve water purification systems as described by this document the first to
be received at ORNL (Oak Ridge National Laboratory – Oak Ridge, TN) no
more than 70 calendar days after contract award.
4.2 Three copies of the final submittal delivered to the University.
4.3 One (1) spare set of filters shall be shipped with each unit.
5.0
QUALITY ASSURANCE
5.1 Label all major components with class and applicable standard.
370
5.2 All instrumentation shall be calibrated in accordance to the manufacturer
recommendation. Documentation of the calibration shall be provided with
each unit, which shall include date of calibration; manufacturer’s
recommended calibration schedule, documentation showing the item’s serial
number and evidence showing the instrument passed the calibration.
5.3 All fasteners utilized for system assembly shall be stainless steel and shall
adhere to ANSI/ASME B18.3, ANSI B18.2.1 and ANSI/ASME B18.2.2.
5.4 All plumbing components shall adhere to ASME Boiler and Pressure Vessel
code and the ASME B31.3 piping code.
5.5 All electrical materials, appliances, equipment or devices shall conform to the
applicable standards of the Underwriters Laboratories (UL) and NFPA 70,
National Electric Code.
6.0
TESTING AND INSPECTION
6.1 The water system shall be tested, and the contractor shall notify the University
no less than 10 calendar days prior to the expected test date(s).
6.2 Testing shall take place no more the 50 calendar days after contract award.
6.3 The University reserves the right to witness the on-site testing and inspection.
6.4 Each unit shall be tested, testing shall include as a minimum:
6.4.1 A water sample of the influent, similar in make-up of the water for
proposed use in the SNS Accelerator
6.4.2 A water sample of the effluent, leaving the purification system.
6.4.3 Visual inspection for fit and finish, and compliance with all applicable
mechanical and electrical codes.
6.4.4 A review of instrument calibration documentation.
6.4.5 Review of as-built drawings and PID. As-builts and calibration data
may be submitted prior to on-site inspection.
6.4.6 Water shall flow through the system continuously for a period of not
less than 4 hours at a pressure of not less than 150 psi. Water
temperature shall be maintained within 60-80°F with no visible
leakage.
6.4.7 During the 4-hour test, the flow rate of the system must be adjusted
between a minimum range of 2.5-5.0 gpm with no visible leakage.
371
6.4.8 The University will review and submit comments and change requests
within 10 calendar days of the completion of testing and receipt of all
testing documentation.
6.5 Retesting
6.5.1 If a system does not pass the test, seller shall make repairs to the system
with new materials and retest. The University shall approve any
system modifications.
7.0
WARRANTY
7.1 Seller shall warrant all components for a period of one year from date of subcontractor installation.
8.0
SYSTEM REQUIREMENTS
8.1 System requirements shall include a passive system; no drains will be
available.
8.2 To maintain purity in the cooling loops, the purification system shall be
continuously purifying 1-5% of the total coolant flow rate.
8.3 The system shall be designed to handle a static pressure of not less than 150
psig.
8.4 Upon passing through the purification system, the water shall have achieved
the following criteria:
Parameter
Required Value
Flow rate
(through system)
pH
Particulate size
Corrosion
1-5 % of total flow,
minimum of 2.6-3.1gpm
8±1
10-14 MO
< 20 ppb
= 1 micron
= 0.5 mil/year
8.5 Water system shall maintain the desired purity without calibration, component
or material replacement for no less than one year.
8.6 First tested system shall be received at ORNL no more than 70 days after
contract award. Each additional system shall be received at ORNL at a rate
not to exceed 14-days/unit beginning with the delivery of the first unit.
372
8.7 Information in the following table shall be used in the design of the water
purification system. Each system shall continuously purify water at a
minimum range of 2.6 – 3.1gpm.
Unit
ID Number
System Flow
Purification System
System Volume
rate (gpm)
Flow range (gpm)
(gallons)
1
DTL – 1
119
1.2 – 6.0
256
2
DTL – 2
161
1.6 – 8.1
281
3
DTL – 3
234
2.3 – 11.7
281
4
DTL – 4
214
2.1 – 10.7
281
5
DTL – 5
198
2.0 – 9.9
281
6
DTL – 6
182
1.8 – 9.1
281
7
CCL – 1
219
2.2 – 11.0
308
8
CCL – 2
257
2.6 – 12.9
308
9
CCL – 3
257
2.6 – 12.9
308
10
CCL – 4
257
2.6 – 12.9
308
11
CCL – Mag
61
0.6 – 3.1
359
12
SCL – Mag
TBD
TBD
912
8.8 Operating temperature of the water and surrounding environment will be
68±6°F.
8.9 Each unit shall have a corrosion resistant metal tag with its Identification
Number, as shown in the above table, imprinted and clearly visible and
mounted on the frame of the unit.
8.10 All components shall be mounted to a Stainless Steel frame. Frame design
shall allow easy transport by forklift, and not hamper maintenance or
installation.
8.11 All components and piping shall be easily removable by use of simple hand
tools.
8.12 A means of draining the piping shall be included without the separation of
piping joints.
8.13 The system shall fit into the defined space envelope on the following page:
373
9.0
MATERIALS
9.1 All materials shall be new.
9.2 All wetted materials shall be Viton®, Neoprene, Hypalon®, or Stainless Steel.
9.2.1 Non-wetted water system components shall be made of Viton®,
Neoprene, Hypalon®, or Stainless Steel or University approved
equivalent.
9.3 Filter and Filter Housings
9.3.1 Filter housings shall be fabricated using corrosion resistant 316L
stainless steel.
9.3.1.1 Housings shall allow cartridge change without disrupting
inlet/outlet piping
9.3.1.2 Filter removal shall be accomplished by removal of the casing,
vertically exposing the cartridge
9.3.2 Housings shall be of the T-type design with inlet and outlet on the same
centerline.
9.3.2.1 The head shall clamp to the bowl with a Viton®, Neoprene, or
Hypalon® O-ring seal
9.3.2.2 A stainless steel spring against the closed end of the filter
cartridge shall maintain the cartridge seal.
9.3.3 Seller shall provide redundant parallel filters.
replaceable without shutting the system down.
All filters shall be
9.3.4 Filter: 5 micron with a ceramic or stainless steel element
9.3.5 Filter: 1 micron with a ceramic or stainless steel element
9.4 Flow control
9.4.1 If needed, a mechanical flow control device may be added to regulate
flow rate.
9.4.2 Seller will provide a rotameter that shall be installed upstream of any
water treatment components to monitor water flow rate going into the
purification system. Rotameter shall be mounted vertically with a
minimum range of 0-10 gpm.
374
9.5 Resin tank
9.5.1 A minimum of one resin tank shall consist of Amberlite® IR-120 in H+
form, and shall be placed up stream of additional resin tanks.
9.5.2 All tanks shall have a rubber base and be designed for a minimum 150
psig operating pressure and 120 degrees F operating temperature.
9.6 Hoses
9.6.1 Flexible hoses shall be manufactured with Viton®, Neoprene, or
Hypalon® or University approved equivalent.
9.6.2 Hose ends shall be of a quick-disconnect type allowing easy
replacement/refurbishment of resin tanks.
9.7 Instrumentation & Electrical
9.7.1 The preferred output signal type will be 4-20mA, with 0-10 VDC being
an alternative.
9.7.2 Instrumentation shall measure pH, resistivity, and dissolved O2
concentration.
9.7.3 Acceptable instrumentation manufacturers include Martek, Orbisphere,
Thornton, and Omega. Other manufacturers may be acceptable only
after written submittal and written approval by the university.
9.7.4 Sellers measurements shall be taken downstream of the purification
system.
10.0 All electrically powered items shall utilize power from 120VAC, current not to
exceed 10 amps, with a 24VDC, current not to exceed 10 amps, power source as an
alternate.
375
23. Appendix J – Resin Handling and Disposal Plan
Resin Bottle Processing Plan
1.0
INTRODUCTION
Water treatment bottles are used in the SNS (Spallation Neutron Source) Linac for
maintaining de-ionized cooling water purity.
replacement.
Periodically, the bottles will need
Some bottles, identified by ORNL, as being free from radioactive
contamination may be returned to the contractor for refurbishment. Others will need to
be retained by ORNL (Oak Ridge National Laboratory) and disposed of in accordance
with current ORNL protocol for low level radioactive waste. Attention and careful
monitoring are needed to ensure bottle contamination levels are accurately identified and
processed appropriately.
2.0
PURPOSE
This document is intended to serve as a starting point for ORNL to aid in their
development of a water bottle processing and disposal plan. This document should be
reviewed and amended to reflect current ORNL policies regarding safety and the
handling of hazardous materials.
3.0
SCOPE
This procedure applies to all water treatment bottles located in the DTL, CCL, SCL water cooling
systems and to all personnel who may be handling them for return and refurbishment or disposal.
Any contamination must be accurately identified and properly disposed. It is possible that one or
more of the bottles may contain low levels of one or more of the following isotopes:
Tritium
Beryllium – 7
Cobalt – 56-58, 60
Manganese – 56
Vanadium – 58
Chromium – 51
Scandium – 46
Sodium – 22
Zinc - 65
4.0
RESPONSIBILITIES
4.1.
4.2.
Survey Personnel
l
Perform surveys and tag/label water treatment bottles.
l
Properly document and report surveys to SNS operations personnel.
Supervisors
376
5.0
l
Ensure that surveys are performed in accordance with this and all appropriate ORNL
procedures.
l
Ensure surveys and labeling of water treatment bottles are carried out only by properly
trained and qualified personnel.
l
Review all documentation produced by this procedure for completeness and accuracy.
l
Periodically review/modify this and other associated procedures to accurately reflect
local safety needs and ORNL procedures.
RECOMMENDATIONS
Survey personnel need to be aware of the importance of following established procedures for
handling water treatment bottles. All nuclear safety guidelines should be strictly adhered to, up to
and including the Price-Anderson Amendments Act1.
6.0
l
Only properly calibrated and functioning instruments should be used to perform surveys.
l
Treatment bottles utilized on non-contaminated systems should be surveyed in confined
areas specified by ORNL.
l
Bottles utilized in contaminated water systems shall be purged (Argon gas being the
recommended medium), sealed and disposed of as radioactive waste in a manner and
location designated by ORNL under DOE guidelines. All hoses, fittings, and other
attachments connected to these bottles should be smeared for radioactive contamination.
All lines, which contaminated gases or water pass, must be tagged as internally
contaminated and handled accordingly.
l
Any radioactively contaminated bottle(s) must be isolated, tagged and eliminated from
further processing.
PROCEDURES
A number of supplies will be needed to accurately survey and clearly mark the
treatment bottles. The following list is offered as a suggestion, and should be reviewed
and updated to meet the needs at ORNL.
Beta/gamma count rate instruments
Radioactive material stickers or tags
Large plastic bags
Tape
Gloves
Smears and smear folders
Bottles for smears
Boxes for smear bottles
Marker
Logbook
377
6.1.
Processing and Disposing of Contaminated Water Treatment Bottles
6.1.1
Survey bottles prior to loading for transport off-site. Perform surveys in accordance
will all applicable ORNL procedures regarding external radiation.
6.1.2
All bottles surveyed will be tagged in accordance with ORNL contamination control
procedures. Bottles with removable contamination will be bagged prior to transport.
6.1.3
Each surveyed bottle should be logged in the logbook with the following minimum
information
•
•
•
•
•
6.2.
Date of survey
Bottle ID number
Survey instrument used including model and property or serial number
Signature or initials of surveying technician
Location of bottle during last usage
6.1.4
At the location of the change out, mark each new bottle with appropriate internal
radiation contamination identification.
6.1.5
All bottles to be removed should be free of removable contamination, or packaged for
transport. All bottles should be appropriately tagged.
6.1.6
Bottle(s) should be taken to a contaminated drain and purged, using Argon in bottles
containing high radiation, immediately after removal. Purging is accomplished by
pumping a gas through the bottle, forcing water out and drying the bottle. Smears
should be taken on all fittings, hoses, and the exhaust system of the pumping device.
6.1.7
Seal and dispose bottles at a site designated by ORNL.
Processing and Disposing of Non-Contaminated Water Treatment Bottles
6.2.1
Survey bottles prior to loading for transport off-site. Perform surveys in accordance
will all applicable ORNL procedures regarding external radiation.
6.2.2
Each surveyed bottle should be logged in the logbook with the following minimum
information
•
•
•
•
•
Date of survey
Bottle ID number
Survey instrument used including model and property or serial number
Signature or initials of surveying technician
Location of bottle during last usage
6.2.3
At the location of the change out, mark each new bottle with appropriate internal
radiation contamination identification.
6.2.4
Seal and dispose bottles at a site designated by ORNL.
378
24. Appendix K – Preliminary SystemView Calculations
Preliminary Calculations to Support the SystemView Simulation of DTL Tank 3
To prepare this simulation, another set of assumptions are required. For example,
to calculate how long it takes to move water from point A to point B, given the pumping
speed in gallons per minute, one needs to know the volume of the pipe between point A
and point B. These assumptions are listed.
Assumptions made for DTL model:
• Facility temperature with power off: 20°C
• Temperature of coolant water supplied to the heat exchanger: 7.2°C
• Coolant water supplied to the cold side of the heat exchanger at a constant flow of 44.7 gpm
• There is no heat loss in the piping of the cooling loop
In addition, certain characteristics need to be known in order to calculate the necessary constants.
Constants:
•
Density of Cu – 8.93 gm/cm 3 (CRC Handbook)
•
Specific heat of Cu (Cp) – 460.22 W-sec/kg-°C
•
Specific heat of H2O – 15838.2 W-sec/gal-°C
Given the assumptions and constants, a set of knowns can be calculated that supports the
simulation.
Calculated:
Drift Tube Heat load
(W)
1
945.6
2
952.5
3
959.3
4
966.2
5
973
6
979.8
7
986.7
8
993.5
9
1000.4
10
1007.2
11
1014.1
12
1020.9
13
1027.7
14
1034.6
15
1041.4
16
1048.3
17
1055.1
DT
(deg C)
1.377779
1.336431
1.297902
1.307237
1.271043
1.237262
1.205782
1.214092
1.18432
1.156238
1.129919
1.104996
1.112356
1.088718
1.066255
1.045075
1.024883
frac W
0.0105169
0.0105936
0.0106693
0.010746
0.0108216
0.0108973
0.010974
0.0110496
0.0111264
0.011202
0.0112788
0.0113544
0.01143
0.0115068
0.0115824
0.0116591
0.0117348
379
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
•
•
•
•
1062.3
1069.5
1076.7
1083.9
1091.1
1098.3
1105.5
1112.8
1120
1127.2
1134.4
1141.6
1148.8
1156
1163.2
1170.4
Sum Q
(W)
34868
1.031877
1.012899
0.994847
0.977654
0.984149
0.967605
0.951813
0.936807
0.922371
0.9283
0.914353
0.900986
0.888165
0.893732
0.881312
0.86938
0.0118148
0.0118949
0.011975
0.0120551
0.0121351
0.0122152
0.0122953
0.0123765
0.0124566
0.0125366
0.0126167
0.0126968
0.0127769
0.012857
0.012937
0.0130171
Gallons /inch of 3 inch (ID) Cu pipe
Volume/inch = p*(1.5 in)2 * 1 in
= 7.069 in 3 / (231 in3/gal)
= .0306 gal / in
Volume of Heat Exchanger
Hot Side
4956cc / 3785.41 cc/gal = 1.309 gal
Cold Side
5239cc / 3785.41 cc/gal = 1.384 gal
Transit time in Heat Exchanger
Cold-side – 1.384 gal / 44.7 gal/min * 60 sec/min = 1.858 sec
Transit time per 7.32 inches of 1.75 inch Cu pipe
Manifold
flow
(gpm)
3.3
6
8.8
11.6
14.5
17.5
20.6
23.7
26.9
30.2
33.6
37.1
40.6
44.2
47.9
51.7
55.6
59.5
Time
Manifold
(sec)
1.3861246
0.7623685
0.5197967
0.3943285
0.3154628
0.2613835
0.2220491
0.1930047
0.170045
0.1514639
0.1361372
0.1232941
0.1126653
0.1034889
0.095495
0.088476
0.08227
0.0768775
in
380
63.5
65.7
61.6
57.4
53.2
48.9
44.5
40
35.4
30.8
26.1
21.3
16.4
11.5
6.5
•
•
0.0360174
0.0348113
0.0742567
0.0796901
0.0859814
0.0935421
0.1027913
0.1143553
0.129215
0.1485133
0.1752571
0.2147517
0.2789153
0.3977575
0.7037248
Transit time per inch of 3 inch Cu pipe @ 235.32 gal/min = .0078 sec
600 inches = 4.68sec
290 inches = 2.262 sec
185 inches = 1.443 sec
97 inches = .7566 sec
Transit times through drift tubes@ various flow rates
Drift Tube Flow rate
Time in
Transit + Out
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
2.6
2.7
2.8
2.8
2.9
3
3.1
3.1
3.2
3.3
3.4
3.5
3.5
3.6
3.7
3.8
3.9
3.9
4
4.1
4.2
4.2
4.3
4.4
4.5
4.6
4.6
4.7
4.8
4.9
0.7063146
0.6801548
0.6558636
0.6558636
0.6332476
0.6121393
0.5923929
0.5923929
0.5738806
0.5564903
0.5401229
0.5246909
0.5246909
0.5101161
0.4963292
0.4832679
0.4708764
0.4708764
0.4591045
0.4479068
0.4372424
0.4372424
0.427074
0.4173677
0.4080929
0.3992213
0.3992213
0.3907272
0.3825871
0.3747792
1.4493915
1.3957104
1.3458636
1.3458636
1.2994545
1.2561393
1.2156187
1.2156187
1.1776306
1.1419448
1.1083582
1.0766909
1.0766909
1.0467828
1.0184913
0.9916889
0.966261
0.966261
0.9421045
0.9191263
0.8972424
0.8972424
0.8763763
0.8564586
0.8374262
0.8192213
0.8192213
0.8017911
0.7850871
0.7690649
381
31
32
33
4.9
5
5.1
0.3747792
0.3672836
0.360082
0.7690649
0.7536836
0.7389055
•
Variable Transit time through the heat exchanger bypass, pump flow of 235.32
gpm
Given the length of 90 inches of 3.0 inch pipe for the bypass and an allowable
fractional flow, w, through the bypass, the transit time is .702/w sec.
Given allowable fractional flows of .00001 to .99999,
max delay is .702/.00001 = 70200. sec, min delay is .702/.99999 = .702 sec.
Fractional delay = .702 – .702
w .99999
.702 – .702
.00001 .99999
= .99999 – w * 1.00002 x 10-5
w
•
Variable Transit time from the bypass to the heat exchanger, pump flow of
235.32 gpm
Given the length of 55 inches of 3.0 inch pipe and using the same argument as in the
previous bullet:
maximum delay is 42900 sec, minimum delay is .429 sec, and
fractional delay = w - .00001 * 1.00002 x 10-5
1- w
•
Variable Transit time from the heat exchanger to the bypass, pump flow of
235.32 gpm
Given the length of 48 inches of 3.0 inch pipe and again using the same
argument:
maximum delay is 37440. sec, minimum delay is .3744 sec, and
fractional delay has the same form as from the bypass to the heat
exchanger.
•
Variable Transit time for coolant through the heat exchanger, hot-side, pump flow
of 235.32 gpm
Given the volume of the hot side of the heat exchanger, the maximum delay through
the heat exchanger is 33380. sec and the minimum delay through the heat exchanger is
.3338 sec. The fractional delay has the same form as from the bypass to the heat
exchanger.
• Calculated heat transfer constants
hA is determined by using the differential equation:
382
?CpV
dT
= Q + hA(Tf – T)
dt
In steady state, the left side of the equation goes to zero giving:
0 = Q + hA(Tf-Td)
where Tf is the temperature of the fluid and Td is the temperature of the
cooled device. In steady state, both temperatures are constant.
Drift Tube:
Drift tube #1 –
hA = 945.6 W/ (26.6°C-20.0°C)
= 143.27 W/°C
Drift tube #17 –
hA = 1055.1 W/ (26.6°C-20.0°C)
= 159.86 W/°C
Drift tube #33 –
hA = 1170.4 W/ (26.6°C-20.0°C)
= 177.33 W/°C
For stainless k = ?CpV = (8000 kg/m3)(460 W-sec/kg-°C)(.000193 m 3)
= 710.2 W-sec/°C
For copper k = ?CpV = (8940 kg/m3)(385 W-sec/kg-°C)(.000678 m 3)
= 2333.6 W-sec/°C
For total drift tube: 710.2 + 2333.6 = 3043.8 W-sec/°C
Tank Wall:
hA = 41000 W/ (26.6°C-20.0°C)
= 6121.12 W/°C
Tank 3a –
k = ?CpV = (7830 kg/m3)(460 W-sec/kg-°C)(.17154 m 3)
= 617852.00 W-sec/°C
Tank 3b –
= 595836.45 W-sec/°C
Tank 3c –
383
= 621570.45 W-sec/°C
Stainless steel channels –
k = ?CpV = (8000 kg/m3)(460 W-sec/kg-°C)(. 008714 m3)
= 32068.42 W-sec/°C
Total tank = 617852 + 595836.45 + 621570.45 + 32068.42
= 1867327.31 W-sec/°C
End Walls:
hA = 400 W/(26.6°C – 20.0°C)
= 60.61W/°C
Upstream –
k = ?CpV = (8940 kg/m3)(385 W-sec/kg-°C)(. 00603 m 3)
= 20756.17 W-sec/°C
Downstream –
= 21489.4 W-sec/°C
Total for end walls = 20756.17 + 21489.4 = 42245.57 W-sec/°C
Slug Tuners:
hA = 7680 W/(26.6°C – 20.0°C)
= 1163.64 W/°C
k = ?CpV = (8940 kg/m3)(385 W-sec/kg-°C)(. 001196 m3/tuner)
= 4116.51 W-sec/°C/tuner
Total for 12 tuners = 49408.71W-sec/°C
Post Couplers:
hA = 5120 W/(26.6°C – 20.0°C)
= 775.76 W/°C
k = ?CpV = (8940 kg/m3)(385 W-sec/kg-°C)(. 00018 m 3)
= 619.54 W-sec/°C/coupler
Total for 16 post couplers = 9926.86 W-sec/°C
Iris:
hA = 140 W/(26.6°C – 20.0°C)
= 21.21W/°C
384
= 15172.31 W-sec/°C
Dipole Magnets:
hA = 704 W/(26.6°C – 20.0°C)
= 106.67 W/°C
Note: In the simulation, the differential equation is solved only for those devices whose
temperature is graphed. For all other devices, the calculation involves just the adjustment
of the temperature of the coolant is it propagates through the device.
385
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389

Spallation Neutron Source Drift Tube Linac Water Cooling and

Transcription

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