1 Greg Hallewell / Thermosiphon sonars / ATLAS ID Thermosiphon Workshop, CERN, Oct 20, 2011 Greg...

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1 Greg Hallewell / Thermosiphon sonars / ATLAS ID Thermosiphon Workshop, CERN, Oct 20, 2011 Greg Hallewell Centre de Physique des Particules de Marseille Sonar instrumentation for thermosiphons

Transcript of 1 Greg Hallewell / Thermosiphon sonars / ATLAS ID Thermosiphon Workshop, CERN, Oct 20, 2011 Greg...

Page 1: 1 Greg Hallewell / Thermosiphon sonars / ATLAS ID Thermosiphon Workshop, CERN, Oct 20, 2011 Greg Hallewell Centre de Physique des Particules de Marseille.

1Greg Hallewell / Thermosiphon sonars / ATLAS ID Thermosiphon Workshop, CERN, Oct 20, 2011

Greg Hallewell

Centre de Physique des Particules de Marseille

Sonar instrumentation for

thermosiphons  

Page 2: 1 Greg Hallewell / Thermosiphon sonars / ATLAS ID Thermosiphon Workshop, CERN, Oct 20, 2011 Greg Hallewell Centre de Physique des Particules de Marseille.

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People involved:- Michele Battistin, Stephane Berry, Pierre Bonneau, Gennaro Bozza, Enrico daRiva, Jose Botelho Direito, Didier Lombard, Jan Godlewski team, Lukasz Zwalinski (CERN) - Nicolas Bousson, Greg Hallewell, Michel Mathieu & Sasha Rozanov (CPPM, Marseille)- Richard Bates & Alex Bitadze (Glasgow Univ.)- Kirill Egorov (Indiana Univ.)- Koichi Nagai (Tsukuba Univ.)- Rusty Boyd (Oklahoma State Univ.) - Sergei Katunin (PNPI St. Petersberg) - Martin Doubek, Vic Vacek & Michal Vitek (CTU, Prague)- Steve Mcmahon (RAL/STFC)- Cecilia Rossi (Genova Univ.)

Greg Hallewell ATLAS ID Thermosiphon Workshop, CERN, Oct 20, 2011

Sonars for flowmetry and mixture analysis

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Sonar R&D for C3F8/C2F6 blend studies Mixture analysis Flowmetry (so far low flows < 30gms-1; axial configuration)

Sonar R&D for thermosiphon application Flowmetry (high flows < 1.2kgms-1; angled configuration)

Mixture analysis (1) for C3F8/C2F6 if used, using angled configuration

(2) for detection of ingressed non-condensible vapour (air, N2…) in sub atmospheric pressure surface condenser.

Contents

Greg Hallewell ATLAS ID Thermosiphon Workshop, CERN, Oct 20, 2011

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(1) Flowmetry (so far flows < 30gms-1 (blender limit); axial config.)

(2) Mixture analysis

Sonar R&D for C3F8/C2F6 blend studies

Greg Hallewell ATLAS ID Thermosiphon Workshop, CERN, Oct 20, 2011

Gas analyzer

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Developed for air at atmospheric pressure,Developed for air at atmospheric pressure,0-60ºC but used in other gases 0-60ºC but used in other gases

(hydrocarbon & fluorocarbon-nitrogen (hydrocarbon & fluorocarbon-nitrogen mixtures from mid 1980s; Hallewell et al.) mixtures from mid 1980s; Hallewell et al.)

& far beyond this temp. & press. range:& far beyond this temp. & press. range:Open transducer construction: spiral grove Open transducer construction: spiral grove lets gas fill and evacuate from both sides of lets gas fill and evacuate from both sides of foil allowing high & low pressure operation.foil allowing high & low pressure operation.

The 50kHz ultrasonic transceiver has been around for >25 years!The 50kHz ultrasonic transceiver has been around for >25 years!first developed for Polaroid autofocus cameras (1980’s)first developed for Polaroid autofocus cameras (1980’s)

now mainly robotics – marketed by Senstech (600 series instrument grade)now mainly robotics – marketed by Senstech (600 series instrument grade)

Greg Hallewell ATLAS ID Thermosiphon Workshop, CERN, Oct 20, 2011

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Adapted from a slide by Mike Vitek (CTU Prague): presentation at ANIMMA 2011, Ghent 6-9 June 2011

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Two functions in one instrumentTwo functions in one instrument

•2 capacitative 50kHz ultrasonic transducers

• 2 PEEK flow deflectors

• Lateral tubes for calibration gas injection/ pressure sensing

• 6 NTC temperature sensors

Clock Starts Clock Stops

Transition time in direction A measured

Measuring cycle starts

Transition time in direction B measured

Greg Hallewell ATLAS ID Thermosiphon Workshop, CERN, Oct 20, 2011

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Electronics: Main components & functionalityElectronics: Main components & functionality

Vs = (t/0.66m)

50 kHz

40 MHz

Vs = ((N*25.10-9 s)/0.66m)

Analog Devices ADuC (or Microchip dsPIC33F) Analog Devices ADuC (or Microchip dsPIC33F) -controller -controller generates 50 kHz ultrasound 'chirps' & synchronously generates 50 kHz ultrasound 'chirps' & synchronously

starts 40 MHz transit time clockstarts 40 MHz transit time clock(later stopped by 1(later stopped by 1stst over-threshold sound pulse) over-threshold sound pulse)Then repeats in opposite direction: AThen repeats in opposite direction: ABB; ; BBA:A:

FIFO generates 20 averages/s of (TFIFO generates 20 averages/s of (TAABB, T, TBBAA, Temp, Press), Temp, Press)

Greg Hallewell ATLAS ID Thermosiphon Workshop, CERN, Oct 20, 2011

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SCADA Software

Ultrasonic flowmetry & gas mixture analysisUltrasonic flowmetry & gas mixture analysis

RS232/CAN BUS

PVSS-IIANALYSING SOFTWARE

Vs @ (% blend, P, T) DATABASE

MEASURING ELECTRONICS

V(T),V(P),Vbias, pulses

Measuring chain schematics

Greg Hallewell ATLAS ID Thermosiphon Workshop, CERN, Oct 20, 2011

A A SONAR TUBE BB

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Flowmetry: simple axial geometry:Flowmetry: simple axial geometry:

entire sound path in gas flow, whole flow entire sound path in gas flow, whole flow constrained to pass through cylinder defined by transducer cross section: constrained to pass through cylinder defined by transducer cross section:

Turbulence effects?Turbulence effects?

 

Greg Hallewell ATLAS ID Thermosiphon Workshop, CERN, Oct 20, 2011

Calculation of flow parameters : (Temp., Press. not needed)

*Speed of sound: c = L/2 * ((tA + tB)/ tA* tB) [ms-1]

*Gas flow velocity: v =L/2 * ((tA – tB)/ tA* tB) [ms-1]

*Volume flow: V = v * A [m3s-1]

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Calibration against Schlumberger Delta G16 gas meterCalibration against Schlumberger Delta G16 gas meter

Greg Hallewell ATLAS ID Thermosiphon Workshop, CERN, Oct 20, 2011

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Schlumberger G16 flow (l/min C3F8)

Ult

raso

nic

FM

flo

w (

l/min

C3F

8)

Greg Hallewell ATLAS ID Thermosiphon Workshop, CERN, Oct 20, 2011

UFM precision: 2% of full scale flowSD of datapoints w.r.t. fit line

Ultrasonic Flowmeter linearity & precision to Ultrasonic Flowmeter linearity & precision to 230 l.min230 l.min-1 -1 (30 g.s(30 g.s-1-1) in C) in C33FF88, 20°C, 1 bar, 20°C, 1 barabsabs

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% concentration of gas (A) in gas (B)

Sou

nd v

eloc

ity (

ms-1

) Mixture concentration uncertainty = sound velocity error/local gradient

Mixture AnalysisMixture Analysis

Compare sound velocity measured at known temperature, pressure with Compare sound velocity measured at known temperature, pressure with pre-stored database (determined from measurements in calibbration pre-stored database (determined from measurements in calibbration

mixtures or from theoretical predictionmixtures or from theoretical prediction

 

Greg Hallewell ATLAS ID Thermosiphon Workshop, CERN, Oct 20, 2011

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Verification measurementsComparison of measured and estimated sound velocities in pure C3F8 and C2F6

refrigerants

*Stable temperature

C3F8 - temperatures of 19.2-19.4°C

C2F6 - temperatures of 19.6-19.7°C

*Varying pressure

C3F8 – pressures from 0.4 to 2.5barabs

C2F6 – pressures from 1.3 to 2.7barabs

*Estimated values

Acquired from the PC-SAFT state equation

*Average difference between estimated and measured sound velocity <0.04%

(both gases)

TempPress

c c ErrorMeasured Predicted Abs Rel

°C bara m.s-1 m.s-1 m.s-1 %

19.4 0.46 116.18 116.08 0.10 0.09

19.4 0.59 115.83 115.78 0.05 0.04

19.4 0.99 114.86 114.84 0.02 0.01

19.4 1.14 114.52 114.48 0.04 0.04

19.4 1.51 113.59 113.58 0.01 0.01

19.4 1.97 112.39 112.43 -0.04 -0.03

19.4 2.41 111.29 111.30 -0.01 -0.01

TempPress

c c ErrorMeasured

Predicted Abs Rel

°C bara m.s-1 m.s-1 m.s-1 %

19.6 1.31 136.72 136.73 -0.01 -0.0119.6 1.65 136.28 136.30 -0.02 -0.01

19.6 2.03 135.79 135.81 -0.02 -0.0219.6 2.27 135.46 135.50 -0.04 -0.03

19.6 2.39 135.26 135.34 -0.08 -0.0619.6 2.48 135.14 135.22 -0.08 -0.0619.6 2.68 134.94 134.96 -0.02 -0.02

C3F8

C2F6

Greg Hallewell ATLAS ID Thermosiphon Workshop, CERN, Oct 20, 2011

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Comparison of sound velocity measurement & theory predictions: C2F6/C3F8: molar concentrations of interest to the ATLAS project

Average difference between PC-SAFT (NIST REFPROP extended BWR) predictions & meas. sound velocities

< 0.5% (<0.05%) for P < 0.15 MPa & (0 ≤ %C2F6 ≤ 50).

Pre-stored database of sound velocity vs.% Conc. of gas A in gas B at process P, T; Set up from prior measurements or theory

Mixture concentration uncertainty = sound velocity error/local gradient0.05% sound vel. 0.3% in mix at

20%C2

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Mixture calculating algorithm (2)In mixtures containing non-ideal gases Cp/Cv variations with P, T (not just with the molar concentrations of the two components) can limit the instrument accuracy.

While the perfect sound velocity/concentration database corresponds to the process temperature and pressure, this may not be practical to implement if the process P, T change over a wide range in real time;

Search can be refined by targeting ‘local’ sound velocity/molar concentration curves close to the instantaneous process P,T conditions; ‘zooming’ among set of curves covering the entire expected P,T regime…

Zooming software gets the mixture composition corresponding to a minimized 3-norm, ni , in (conc, c, P, T) space, comparing running average process variables in sound vel, temp, Press with %conc curves at nearest P, T

2,3

2,2

2,1 ) - () - () - ( averagerunningtableiaveragerunningtableiaveragerunningtableii cckTTkppkn

Greg Hallewell ATLAS ID Thermosiphon Workshop, CERN, Oct 20, 2011

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Norm search in local (c Norm search in local (c vs. vs. %Conc., P, T) space%Conc., P, T) space

% concentration of gas (A) in gas (B)

So

un

d v

elo

city

(m

s-1)

Greg Hallewell ATLAS ID Thermosiphon Workshop, CERN, Oct 20, 2011

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3 axial flowmeters/3 axial flowmeters/analyzers built:analyzers built:

2kW TS surface condenser 2kW TS surface condenser & flow return sonar (with & flow return sonar (with

bypass) in point 1 cryo buildingbypass) in point 1 cryo building

Expected flowExpected flow< 40 gms< 40 gms-1-1

will give Cwill give C33FF88/C/C22FF66 analysis analysis

capability also, of coursecapability also, of course

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Vapour return #3 axial flowmeter/ analyzer sonar

with bypass

Greg Hallewell ATLAS ID Thermosiphon Workshop, CERN, Oct 20, 2011

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Vapour return

Vapour return

Liquid Out

Liquid Out

Greg Hallewell ATLAS ID Thermosiphon Workshop, CERN, Oct 20, 2011

Vent sonar will be installed above the highest point of condenserVent sonar will be installed above the highest point of condenser

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Will need to vent any uncondensible gas that Will need to vent any uncondensible gas that ingresses into the (sub-atmospheric pressure) ingresses into the (sub-atmospheric pressure)

thermosiphon surface condenserthermosiphon surface condenser

Sonar analysis ideal to sample the headspace gas and to trigger vent to vacuum.

Greg Hallewell ATLAS ID Thermosiphon Workshop, CERN, Oct 20, 2011

Page 20: 1 Greg Hallewell / Thermosiphon sonars / ATLAS ID Thermosiphon Workshop, CERN, Oct 20, 2011 Greg Hallewell Centre de Physique des Particules de Marseille.

20From K. Egorov slides: 40th sonar meeting, September 28, 2011

Greg Hallewell ATLAS ID Thermosiphon Workshop, CERN, Oct 20, 2011

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Greg Hallewell ATLAS ID Thermosiphon Workshop, CERN, Oct 20, 2011

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22Greg Hallewell ATLAS ID Thermosiphon Workshop, CERN, Oct 20, 2011

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23Temp. (C)

Vs

(m/s

)

Superheated vapour Vs : of interest, with sonar tubeAbove condenser temperature (natural warming?)

Saturation Temp at 300mbar abs presssure

C3F8 with pressure set at 300 mbarabs look at sound velocity vs. temp (crossing from saturated to superheated)

NIST Refprop calculations

Greg Hallewell ATLAS ID Thermosiphon Workshop, CERN, Oct 20, 2011

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<10-4 precision possible at low C3F8 concentrations

Greg Hallewell ATLAS ID Thermosiphon Workshop, CERN, Oct 20, 2011

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For the big thermosiphon, with flow rates For the big thermosiphon, with flow rates around 1.2kg/sec we will need a much bigger around 1.2kg/sec we will need a much bigger

flowmeter/ analyzer in the primary flowmeter/ analyzer in the primary fluorocarbon gas circuit fluorocarbon gas circuit

Axial and angled geometries are being studiedin ~133mm & ~210mm ID tubes

using Computational Fluid Dynamics(G. Bozza and E. DaRiva)

Greg Hallewell ATLAS ID Thermosiphon Workshop, CERN, Oct 20, 2011

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EDMS Request to make Computational Fluid Dynamics Studies of Ultrasonic EDMS Request to make Computational Fluid Dynamics Studies of Ultrasonic Flowmeter geometries adapted to high flows (1.2 kgsFlowmeter geometries adapted to high flows (1.2 kgs-1-1 fluorocarbon) in the fluorocarbon) in the 60kW thermosiphon installation 60kW thermosiphon installation

Greg Hallewell ATLAS ID Thermosiphon Workshop, CERN, Oct 20, 2011

SEE FOLLOWINGTALK BY

GENNARO BOZZA

Page 27: 1 Greg Hallewell / Thermosiphon sonars / ATLAS ID Thermosiphon Workshop, CERN, Oct 20, 2011 Greg Hallewell Centre de Physique des Particules de Marseille.

Results for the Axial Flow Meter with transducers, D=211.6mm, L=5D with the k-ε turbulence model.

Greg Hallewell ATLAS ID Thermosiphon Workshop, CERN, Oct 20, 2011

Flow reading defecit due to turbulence behind upstream

transducerFlow profile across tube

mid way bewteen ultrasonictransducers

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Large bore axial geometries with fractional cross section sampling have two problems:

(1) flow deficit caused by turbulence following upstream transducer (non-linear with increasing flow: calibration would be problematic)

(2) transducers do not sample the full with of the flow in the tube

CFD simulations of angled flowmeter geometries

Greg Hallewell ATLAS ID Thermosiphon Workshop, CERN, Oct 20, 2011

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tdown = L / (c + v cosΦ) , tup = L / (c - v cosΦ);

Gas flow velocity v (m/s): v =L/2cosΦ * ((tu – td)/ tu* td) ;

Sound velocity c (m/s): c = L/2 * ((tu + td)/ tu* td);

Volume flow m3/s = v * A

Greg Hallewell ATLAS ID Thermosiphon Workshop, CERN, Oct 20, 2011

Ball valves allow isolation for transducer removalSound passes through valve aperture in operation

Angled sound path geometries for High flow thermosiphon

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(1) Sonar gas analysis has demonstrated high precision for C2F6/C3F8 & N2/fluorocarbon analysis;

(2) Pinched axial flowmeter/gas analyzer geometry demonstrated, and OK for the 2kW thermosiphon application (installed in 2kW TS vapour return);

(3) Angled ultrasonic flowmeter/gas analyzer geometry best adapted to high flow (60kW) thermosiphon application –

prototyping to start soon;

(4) Both geometries can provide a mixture analysis capability if C2F6/C3F8 blends used with a thermosiphon

(5) Headspace analysis necessary for air infiltration intosub-atmospheric surface condenser;

test first on 2kW thermosiphon – mechanical design under wayGreg Hallewell ATLAS ID Thermosiphon Workshop, CERN, Oct 20, 2011

ConclusionsConclusions

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Back-up slides

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44mm transducer attachment & centering via PEEK deflector cone(similar annular area to circular cross section between transducers) ;

wire routing toward electrical feed-through, port for evacuation & periodic calibration with reference gas (e.g. Xe)

Sonar fluorocarbon analyzer: ATLAS ID Thermosyphon Workshop, CERN, May 28, 2010

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