AMS Tracker Thermal Control System TTCS

1
AMS Tracker Thermal Control System (TTCS) TTCS
Progress Report TIM CERN April 2005 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.CASC-team Z. Hou et al.

2
Contents

• System design status
• Loop lay-out
• Management status
• Planning
• Pump
• Accumulator
• APS/DPS and other components
• Design Status
• Heat Exchanger
• Condenser (freezing)
• Box (Subcontract NIKHEF)
• Integration
• Thermal Modelling Safety status
• Design Challenges

3
(No Transcript)
4
(No Transcript)
5
Loop lay-out

• Tracker radiator heater design fixed
• All Pt1000 and DS locations determined (component
  list)
• Software requirements finalised (will be
  discussed with Lebedev et al Tuesday)

Architectural overview
Operational modes
6
Planning
7
Planning
8
Planning (Electronics)
9
Planning (Components)
10
Planning remarks

• Tight Schedule with no margin
• Main Components procurement plan has to be
  decided during this TIM
• On-board S/W and Electronics have been extremely
  simplified however no margin is foreseen for
  (major) changes in QM TTCE design.

11
Management Status

• Pump Contract
• Contract PDT signed
• First Data Drop Last week Pump PDR
• QM electronics design will start next week
• Planning EM delivery August 2005
• Planning QM June 2006
• Planning FM June 2006 (assuming a successful QM
  test)
• Accumulator filling system
• Chinese Academy of Space Technology (CAST)
• Fruitful technical discussions in Beijing in
  March
• Accumulator proposal made
• Design activities started

12
Management Status

• Valves
• Proposals Bradford Engineering BV (delivered)
• valves with motors
• price high compared to allocated budget
• Polyflex ROM-proposal received
• latch valves (technically preferred)
• detailed proposal pending
• Decision on valves in FM after EM model tests
  (possible reduction of cost)
• APS DPS
• Bradford Engineering proposal (delivered),
  feasible
• For many other companies the number was too small
  to do a bid.

13
Design Status Heat Exchanger
approx 68

• two-phase to single phase plate type heat
  exchanger
• welded housing
• soldered stack of plates

weld
approx 87
14
Design status Heat Exchanger

• soldered stack of plates
• Soldering tests will be performed as soon as
  solder is delivered

bottom view
15
Design Status Heat Exchanger

• Heat exchanger design is updated for box tubing
• Strength calculations show 4 mm wall thickness is
  required
• Material is stainless steel
• The weld cannot be done by orbital welding (4 mm)
• EM prototype is planned end of April
• depends on a successful soldering test of stack
  of plates

16
Condenser tube routing

• Condenser design
• 14 capillary Inconel tubes (7 feed and 7 return
  lines) from each manifold to the condensers (Di
  1mm, Do2-3 mm
• Each capillary tube is wired with a wire heater
  to thaw the line after AMS02 complete power down.
• Tubes are wrapped in MLI to minimise
  environmental heat leak.
• Each radiator is equipped with 2 x 3 redundant
  Pt1000s for switching.
• Each radiator is also equipped with heater
  cabling A B for health heaters.
• Electrical connectors located on a bracket boxes
  at main radiators

17
Condenser tubing

• Manifold positions
• Location at upper trunnion bridges Tgt-40 in all
  cases
• Condenser lines from manifold to box T gt 40 C (no
  freezing)
• Parallel condenser lines are installed together
  with condenser
• Manifold design Y\Projects\AMS-Tracker\Technical
  \Components\condensers\CondenserManifold25feb05.pd
  f
• brazed and welded design
• Manifold orientation should be convenient for
  tube routing.
• the manifold has a stainless steel tube end
  attached on the box side
• tube end is orbital welded to the tube routed to
  the box right after installation of the condenser

18
Condenser manifold locations
19
Condenser Manifold location (detail)
Upper trunnion bridge
20
Condenser tube routing

• Electrical connectors (terminal blocks) are
  located on a bracket boxes at main radiators

Picture CGS (Assenza)
21
Condenser design
capillary tubing
340 mm
460 mm
22
Design Status Condenser design MDP determination

• Measurement section, here drawn without
  cooling/heating part
• 8 strain gauges
• 3 temperature sensors
• one tube is representative for the condenser
• prior to testing the strain gauges are calibrated
  by an external pressure
• Feasibility for strain gauge tests are performed
  successfully

23
Design Status Condenser design Freezing test
set-up
Strain gauge feasibility test with Do2 mm at
ambient
24
Design Status Condenser design Freezing test
activities

• Special strain gauges for low temperatures are
  now being tested
• Test set-up is finalised
• Tube coming in next week
• Preparation of strain gauges (1 week)
• Test preparation and test (2 weeks)

25
Design Status Oscillating Heat Pipe

• Working Fluid FC-87 (inert, non-toxic)
• Volume tubing 2.3 ml
• Fill rate 70 (i.e. 1.6 ml FC-87)
• Heat supply by Minco foil heater Minco
  foil K5229 type 1 see specs below
• Cooling by two-phase line
• Operation only in cold orbits at set-points
  below 5 C Default disabled
• Construction needs to be ruggedized by a TBD
  frame

26
TTCS box design and modelling Interface with USS

• Preliminary CGS with TTCS box results show
• Interface temperatures for USS with MLI max. 19
  ºC min -11 ºC
• Case definition results unknown
• Hot orbit (yes)
• Only AMS health/survival heaters on ??
• or more heaters and systems on??
• Tracker on ??
• Requirement in hot orbit (after power down)
  TTCS has to start-up as one of the first
  subsystems.

27
TTCS box design and modelling

• Operational modes encounter no problem
• Loop cools down its own components during
  operation
• Safety Cold Case
• Lowest environment T-11ºC
• Safety heaters small (if any) T gt -40ºC
• No problem expected of freezing in box
• Safety Hot Case
• Solved by thermostats on power lines
• Safety requirement Tlt 65 ºC therefore easily met
  

28
TTCS box design and modelling

• Plans
• Investigation I/F data USS (SYSU-designer(s) at
  CGS)
• New lay-out to be modelled
• Thermal model started (baseplate)
• Heat leak into loop during operation
• Accumulator control check (heat leak)
• Detailed Two-phase model (pending)
• Verify operational modes
• Use for input accumulator model
• Accumulator model
• verify accumulator control during extreme cases

29
Thermal modelling Safety Approach (thermal
aspects)

• Safety requirement box -40 ?C ltT lt 65 ?C
• hot case has to be solved by thermostats on power
  line (see lay-out) or components.
• cold case solved by USS worst case cold
  temperature and safety heaters as back-up (to
  avoid freezing and for electronics survival)
• Safety requirement radiator -40 ?C ltT lt 80 ?C
• hot case shown by analysis (this afternoon)
• cold case solved by health heaters

30
Thermal modelling Safety Approach (thermal
aspects)

• 9 parallel heater lines on PDS switch (redundant
  9A and 9B)
• 5 parallel lines on radiator
• 4 parallel lines on condensers
• Switch control by TTCE
• 6 Pt1000s (3A and 3B)
• Switch performed by PDS

31
Integration aspects (welding/hydraulic connectors)

• 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
• Technical reply supplier (expected any moment)
• Micro-welding
• Swagelock offers a new micro-welding technique
• A meeting between AMS02 integration specialists
  and swagelock weld specialists is proposed to
  investigate the feasibility of this method

32
Design Challenges/Risks

• Interface temperature USS
• Start-up at 10 C USS is extreme
• TEC coolers next to the pumps are foreseen in
  case margin is small
• Accumulator (design performed by CAST)
• During launch temperatures above T(critical) can
  easily occur
• Concern about bubbles in accumulator
• CAST is investigating this issue by test
• Freezing
• Freezing test to measure MDP
• More in separate presentation