AMS Tracker Thermal Control System TTCS

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AMS Tracker Thermal Control System (TTCS) Tracker
Meeting 09-02-2005 TTCS Status and Integration
issues NLR-team J. van Es, M.P.A.M. Brouwer, B.
Verlaat (NIKHEF), A. Pauw, G. van Donk, T.
Zwartbol, CAM. Rens, SM. BardetSun Yat-Sen
University team ZH. He, KH. Guo, JQ. Ni, SS. Lu,
XZ. Wang, XM. Qi, TX. Li, YH Huang
INFN-AMS-team R. Batiston, M. Menichelli et
al.

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Contents

• System design integration
• Loop lay-out
• hydraulic connectors
• condenser manifolds
• Schedule criticalities
• Accumulator/cleanliness/filling system
• Pump schedule
• Safety progress
• Condenser
• Tracker radiator heaters
• Box structural
• Box thermal (hot case)

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System design Integration

• Hydraulic connectors
• Type Dynatube fitting, Resistoflex Aerospace
• Stainless Steel 15-5PH H1075 (-81 C to 343 C)
• No leaks (MIL-F-85720) upto 8000 psi
• Advantages Hydraulic connectors
• Simple integration Tracker
• Simple integration TTCS
• Disadvantages Hydraulic connectors
• Possible introduction of impurities in the system
• Large integration re-work in latest stage of AMS
  integration in case of failure/leakage
• On location leak testing is necessary (increasing
  integration complexity

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System design Integration

• Welding
• Advantages Welding
• Leak tight design
• Proven and preferred technology
• Less possibilities of leakage and introduction of
  impurities
• Disadvantages welding
• Not possible near the Magnetic flange
• Space requirements during integration (orbital
  welding equipment)
• large construction to be integrated at once
  (integration challenge)

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System design Integration

• TTCS baseline objectives
• Reduce the number of hydraulic connectors to
  minimum possible avoiding
• Only introduce hydraulic connectors when
  integration is impossible

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System design Integration

• Options for integration indicated in next graphs
• Option 1
• All welded design
• Integration challenge tube routing/integration
  procedures
• Option 2
• Hydraulic connectors at specific locations
• Welded connections at box (room should be
  available)
• Option 3
• Hydraulic connectors also at box
• Simple integration, large hazard of integration
  re-work and impurities in TTCS

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TTCS (Secondary) Loop Option 1 All welded
Secondary TTCS Component Box (Starboard Side)
APS
APS
Pumps
Ram heat pipe radiator
Wake heat pipe radiator
HX
Evaporator assembly
DPS
ACU
Condenser
DPS
Condenser
Condenser Manifolds
Welded connections
S1.4 opt 1 draft
Hydraulic connectors
07-02-05
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TTCS tube routing (schematic)
RAM
Condenser tubes supported by radiator diagonal
strut
Condenser manifold Circular tube routing using
former ACC/PMT mounting hole pattern
Weld near manifold welded near trunnion bridge
WAKE
Evaporator line
Condenser line
Two tube support beams
Primary TTCS
Welded connections made on site
Circular tube routing using outer cylinder
generic hole pattern
Secondary TTCS
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Option 1 Integration impact

• Assumptions/conclusions
• Prefabricated TTCS tubes welded off site at CERN
• Proposed option means long tubing to be
  integrated in one go
• Feasibility for the RAM condenser TTCS lines is
  questionable(first manifold fit and TTCS-line
  fit, then lift and weld it just 0.5 m away, but
  on site)
• WAKE condenser lines to the box seem feasible
• Feasibility top evaporator lines one part to box
  during integration questionable (large tubing
  adding complexity to integration)
• All tubes to be installed in the first stages of
  the integration
• 2 welds have to be done at trunnion bridge RAM
  side
• All welded design (preferred for cleanliness)

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Option 1 Integration impact
Are these blue structures required to keep USS in
position? In other words, is this blue structure
already in place before the TTCS tubing will be
integrated? If so option 1 is impossible.
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TTCS (Secondary) Loop Option 2 Welds at box
Secondary TTCS Component Box (Starboard Side)
APS
APS
Pumps
Ram heat pipe radiator
Wake heat pipe radiator
HX
Evaporator assembly
DPS
ACU
Condenser
DPS
Condenser
Condenser Manifolds
Welded connections
S1.4 opt 2 draft
Hydraulic connectors
07-02-05
12
TTCS tube routing (schematic)
RAM
Condenser tubes supported by radiator diagonal
strut
Condenser manifold Circular tube routing using
former ACC/PMT mounting hole pattern
WAKE
Also at bottom evaporator branch not shown
Evaporator line
Condenser line
Two tube support beams
Primary TTCS
Welded connections made on site
Hydraulic connectors
Circular tube routing using outer cylinder
generic hole pattern
Secondary TTCS
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Option 2 Integration impact

• Assumptions/conlcusions
• Prefabricated TTCS tubes are integrated with
  hydraulic connectors
• 6 hydraulic connectors per loop to avoid welding
  on magnet
• WAKE condenser lines to box in one go seem
  feasible (TBC)
• Only welding near box
• A compromise between integration hazard and
  hydraulic connector hazard

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TTCS Loop Option 3 Hydraulic connectors only
Secondary TTCS Component Box (Starboard Side)
APS
APS
Pumps
Ram heat pipe radiator
Wake heat pipe radiator
HX
Evaporator assembly
DPS
ACU
Condenser
DPS
Condenser
Condenser Manifolds
Welded connections
S1.4 opt 3 draft
Hydraulic connectors
07-02-05
15
TTCS tube routing (schematic)
RAM
Condenser tubes supported by radiator diagonal
strut
Condenser manifold Circular tube routing using
former ACC/PMT mounting hole pattern
WAKE
Also at bottom evaporator branch not shown
Evaporator line
Condenser line
Two tube support beams
Primary TTCS
Welded connections made on site
Hydraulic connectors
Circular tube routing using outer cylinder
generic hole pattern
Secondary TTCS
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Option 3 Integration impact

• Assumptions/conclusions
• Prefabricated TTCS tubes are integrated with
  hydraulic connectors
• 14 hydraulic connectors per loop
• No welding near box
• Hazard of too many connectors (leak, dirt,
  surfactants etc)

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System design Integration

• Manifold positions
• Location at upper trunnion bridges Tgt-40 in all
  cases
• Condenser lines from manifold to box T gt 40 C (no
  freezing)
• small length condenser parallel lines
• see also condenser progress

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TTCS tube routing (condenser manifold locations,
Robert Becker)
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TTCS Safety Schedule 09-01-05 issue 1
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TTCS Safety Schedule 09-01-05 issue 1
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TTCS Safety Schedule 09-01-05 issue 1
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TTCS Safety Schedule 09-01-05 issue 1
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TTCS Schedule Sep-05-end 09-01-05 issue 1
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TTCS Schedule Sep-05-end 09-01-05 issue 1
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TTCS Schedule Sep-05-end 09-01-05 issue 1
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Safety action items

• Action 1 Vented containers
• Box design to be finalised (i.e. also venting)
• MLI design box not finalised
• TTCE box CGS general
• Axial MLI venting for MLI around TTCS tubing
• Action 2 Rotating equipment
• pumps listed
• pump details to be delivered under PDT contract
• Action 3 Materials List
• A list will be delivered 21 February
• Aim is completion for components in 22 April 05
• Action 6 fasteners locking mechanisms
• Baseplate(box to USS) fasteners are defined
• Lock mechanisms can be delivered 21 Feb
• Internal box design not finalised

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Safety action items

• Action 19 MDP all loop elements
• Incorporated in System Design Description
  (AMSTR-NLR-TN-005-Issue02.doc p18)

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Safety action items

• Action 19 MDP all loop elements
• Closed Valves will not introduce enclosed volumes
  (loop lay-out)
• Internal valve enclosures should be proven by
  valve supplier
• Action 22
• Draft Verification/test plan provided.
• Action 41
• No TTCS high voltage lines are present
• Heater cabling are tracker radiator design
• Connectors will be located next to radiator
• liq. line heaters are 28 V TTCE heaters

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Safety Schedule Criticalities

• Pump safety
• (T(contract) 26 weeks EM delivery i.e. July 05
  )
• Accumulator safety items (KeRC meeting 3,4 Feb
  05)
• Accu volume lowered by lowering the max T (65 C)
  NLR
• Budget and technical challenge underestimated
• Severe cleanliness requirements for loop
• Filling becomes delicate (cleanliness,
  surfactants)
• Meeting needed to investigate options and solve
  technical-budget problem
• Condenser safety
• MDP (check with strain gauges)
• Procurement Inconel 718
• Top magnetic flange temperatures (above -45 C in
  all cases)
• Mechanical connectors liquid line with brackets

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Safety Schedule Criticalities

• Pump license issue
• Pump routing frozen (contractual)
• This implies following flow of activities
• EM tests _at_ SYSU and NLR
• QM and FM integration _at_ NLR, Env. Tests Perugia,
  Integrated tests _at_ SYSU
• Time critical inputs for thermal modelling
• USS temperatures (hot, cold and/or additional
  orbits)
• Additional orbital data (radiator transfer
  orbits)
• Manpower and manpower availability
• Limited parallel progress on components

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Safety Progress Condenser

• Approach for a freeze prove design
• Location manifold
• Condenser manifold on location AMS structure with
  T gt -45 C
• Cold case, Pheat leak in gt Pheat leak out (2
  Watt)tailoring of heat transfer interface
• Hot case, Pheat leak in acceptable (approx. 5
  Watt)
• Preliminary calculations feasibility design
• Freeze prove design
• Test plan written (under review)
• Location manifolds at upper trunnion bridges
• Location temperatures to be verified
• Number of parallel condenser lines
• Trade-off finalised 7 parallel lines with 6
  passages over condenser

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Safety Progress Condenser Manifold (preliminary)

• Soldered construction Stainless Steel/Inconel

Condenser manifoldEngineering model, preliminary
design, issue 1G. van Donk, NLR, dec 2004
soldered
A
weld
4 mm
2.6 mm
No joint, one piece
A
Section A-A
Put through, Integration sequence such
that visual inspection is possible after soldering
7 x tube inconel Din1.0mm Dout2.0mm
Minimise volume
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TTCS tube routing (condenser manifold locations,
Robert Becker)
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Safety Progress Condenser design

• Location manifolds at upper trunnion bridges
• Location temperatures to be/being verified (CGS)
• Number of parallel condenser lines
• Trade-off finalised
• Criteria
• Condenser Mass
• Hydraulic resistance (pressure head)
• Heater connection to parallel lines
• Subcooling
• Conclusion 7 parallel lines with 6 condenser
  passages

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Safety Progress Condenser design

• Number of parallel condenser lines
• Trade-off finalised 7 parallel lines with 6
  condenser passages
• Soldering Inconel/aluminium feasible
• Company HST, Heat Surface Treatment b.v.
• Tests are planned
• EM will be manufactured from Stainless steel
  (mechanically similar)
• Freezing test including MDP estimation with
  strain gauges
• strain gauge tests are set-up

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Tracker Ram and Wake RadiatorsHealth heaters

• Health heaters
• New calculated inconel mass and a T-gradient of
  1K/min 4.7 Watts per condenser --gt 4 x 4.7 Watt
  18.8 Watt. For a lower gradient the power is even
  less.
• Heater set-up
• Tracker radiator heaters A (155 Watt preferred or
  137 Watt)Tracker radiator heaters B (155 Watt
  preferred or 137 Watt)
• Wake radiator heaters A (155 Watt preferred or
  137 Watt)Wake radiator heaters B (155 Watt
  preferred or 137 Watt)
• 2 lines 10 Watt liq. Line heaters Primary A, B
  (TTCE 28 Volt)
• 2 lines 10 Watt liq. Line heaters Secondary A, B
  (TTCE 28 Volt)each (splitting in parallel
  branches) and control with Pt1000's.

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Tracker Ram and Wake RadiatorsHealth heaters

• Advantages
• Seperate control radiators and liquid lines again
  possible after deletion of thermostats from
  design
• Seperate control RAM and WAKE (no unbalance)
• Free choice of system designers (Mike /or CGS)
  for 155 W (full redundancy) or 137 W
  (single-point of failure for coldest orbit)
• Disadvantages
• TCS overall depends on TTCS and more specific
  TTCE
• Additional 40 Watt on 28 Volt line and not 120 V
  --gt influence PDS hot case calculation

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Tracker radiator heater sizing conclusion

• Heater sizing finished
• P 155 Watt required gt 137 Watt reserved
• Heating along heat pipe and on condenser plates
• Hot case full power lt 80 ºC (P 155 Watt)
• Agreed with Safety (Leland Hill) during Orlando
  TIM. No operating TTCS for hot safety case for
  radiators needed.
• Rationale that three safeguards will avoid TTCS
  working above 33 C is sufficient.

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TTCS Safety Progress Mechanics

• Baseplate designed incl. structure verification
• Structural requirements are met
• Margin safety margin for component shifts
• Left to do
• Final bolt calculation
• Fasteners locking mech.
• Fracture analysis
• Open is detailed design box
• I/F components
• MLI
• Venting

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Safety Progress TTCS Box thermal design

• Preliminary results show
• Start-up impossible with current ISS temperature
  in hot case USS temperature 55 ºC
• Interface temperatures for USS with MLI should
  aim for max. 10 º C
• Case definition
• Hot orbit
• Only AMS health/survival heaters on
• Requirement in hot orbit (after power down) will
  be TTCS has to start-up as one of the first
  subsystems.
• Operational modes encounter no problem
• Loop cools down its own components during
  operation
• Hot case requires thermostat on power line for Tlt
  80 ºC
• Based on the above TTCS should operate preferably
  without interruptions

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Other Integration issues

• TTCS Assembly and Integration
• No welding but hydraulic connectors during
  integration(however as little as possible as it
  increases design risk and cost!)
• Radiator integration sequence
• Start-up during TTCS integration
• 10 ºC USS temperature required for start-up
• Humidity at integration facility (condensation
  risk
• It seems feasible and more practicle not using
  TTCS during Tracker Beam Tests (or any ambient
  test)
• Convection air/nitrogen cooling seems feasible
  (please consider)