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CFD Simulations of a Novel “Squirt-Nozzle and Water Bath” Cooling System for the RFQ

CFD Simulations of a Novel “Squirt-Nozzle and Water Bath” Cooling System for the RFQ. Tuner & Coupler Ports. Vacuum Pump Flange. Potentially Bolted Together. Vanes. Vacuum Flange Coolant Manifold. Water Baths Milled Into Vanes. Tuner & Coupler Ports. Vane End.

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CFD Simulations of a Novel “Squirt-Nozzle and Water Bath” Cooling System for the RFQ

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  1. CFD Simulations of a Novel“Squirt-Nozzle and Water Bath” Cooling System for the RFQ

  2. Tuner & Coupler Ports Vacuum Pump Flange Potentially Bolted Together Vanes Vacuum Flange Coolant Manifold Water Baths Milled Into Vanes

  3. Tuner & Coupler Ports Vane End Water Bath Shaped to Follow Vane Cut-Back Vane Cut-Back O-Ring Joint to Mount to End Wall

  4. Temperature vs. Input Power Outer Wall Vane Tip

  5. Thermal Solver Solution Really need to directly cool the vane tips! Temperature / °C Total Heat Load on Walls = 1 MW Water-bath Heat Transfer Coefficient = 3000 W m-2 K-1

  6. Squirt Nozzles

  7. Squirt Nozzle Inserted Squirt Nozzle HTC: 0 Wm-2K-1 Input Power: 500 kW

  8. Squirt Nozzle Inserted Squirt Nozzle HTC: 1000 Wm-2K-1 Input Power: 500 kW

  9. Squirt Nozzle Inserted Squirt Nozzle HTC: 2000 Wm-2K-1 Input Power: 500 kW

  10. Squirt Nozzle Inserted Squirt Nozzle HTC: 3000 Wm-2K-1 Input Power: 500 kW

  11. Squirt Nozzle Inserted Squirt Nozzle HTC: 4000 Wm-2K-1 Input Power: 500 kW

  12. Squirt Nozzle Inserted Squirt Nozzle HTC: 5000 Wm-2K-1 Input Power: 500 kW

  13. Squirt Nozzle Inserted Squirt Nozzle HTC: 7500 Wm-2K-1 Input Power: 500 kW

  14. Squirt Nozzle Inserted Squirt Nozzle HTC: 10000 Wm-2K-1 Input Power: 500 kW

  15. Variation with Squirt Nozzle HTC Water bath HTC: 1000 Wm-2K-1 Tuner, Coupler & Vacuum Port HTC: 3000 Wm-2K-1 Input Power: 500 kW

  16. Are these HTCs Achievable? Water bath HTC: 1000 W m-2 K-1 Squirt Tube HTC: 3000 W m-2 K-1

  17. How to Manufacturea Squirt Nozzle

  18. Squirt Nozzle Design 1

  19. Squirt Nozzle Design 1 Tapers up to 6.0 mm channel 1.0 mm-thick walls 1.64 mm bore 4.0 mm channel

  20. Comments on Design 1

  21. Squirt Nozzle Design 2 Objectives: • Ease of manufacture • Based on tried and tested designs • More symmetrical flow pattern • Analytically predictable • High water velocity and HTCs at vane tip • Sensible mass flow rate and pressure drop

  22. Squirt Nozzle Design 2 Minor Vane as designed with bath milled into it.

  23. Squirt Nozzle Design 2 Cover bath with an inlet/outlet plate.

  24. Squirt Nozzle Design 2 Make a baffle, attached to the cover plate, to completely fill the bath. Note: baffle can be any shape we like to direct the water.

  25. Squirt Nozzle Design 2 Close up of baffle.

  26. Squirt Nozzle Design 2 Mill a 5mm square channel along the baffle’s length.

  27. Squirt Nozzle Design 2 Mill up the side as well.

  28. Squirt Nozzle Design 2 Top view, with finished channel carried up to inlet/outlet hole in cover plate. Note: baffle could be any shape, so overhang on end is not necessary.

  29. Squirt Nozzle Design 2 View into bath in the vane.

  30. Squirt Nozzle Design 2 Drill 7mm diameter hole down into vane toward it’s tip.

  31. Squirt Nozzle Design 2 Fit 6mm outer diameter tube into hole to make the squirt nozzle.

  32. Squirt Nozzle Design 2 Side view of squirt nozzle inserted into vane. Hole drilled only as far as will allow a minimum of 1mm clearance all round.

  33. Squirt Nozzle Design 2 Underside of baffle where squirt nozzle will be inserted.

  34. Squirt Nozzle Design 2 Drill 6mm diameter hole into baffle. I.e. same O.D. as squirt nozzle. Nozzle will be brazed into this hole. Drill 1cm deeper than nozzle will extend.

  35. Squirt Nozzle Design 2 Nozzle inserted into vane and baffle.

  36. Squirt Nozzle Design 2 Need a way to fill inside of nozzle and allow water to leave the outside, but keep these areas physically separate.

  37. Squirt Nozzle Design 2 Close up of where nozzle will eventually go in the baffle. See also the milled channel to the right.

  38. Squirt Nozzle Design 2 Mill another block out to allow water flowing around outside of nozzle to recombine before proceeding down main channel.

  39. Squirt Nozzle Design 2 Nozzle now needs a way to be filled from the inside.

  40. Squirt Nozzle Design 2 Drill 5mm diameter hole in to meet the 1cm gap left at top of nozzle. Mill inlet channel to meet this hole. Nozzle inner can now be filled.

  41. Squirt Nozzle Design 2 62mm 6mm 0.5mm 7mm

  42. Squirt Nozzle Design 2 Cover Plate Baffle Tube Inserted 1cm into Baffle and Brazed in Place Water Squirt Tube Vane Final flow path of water: Inlet  Nozzle inner  Bottom of nozzle  Nozzle outer  Recombine  Proceed along vane length.

  43. Predicting andSimulating the Flow

  44. Flow Equations Used

  45. Main Structures Used Inlet and outlet Holes: Pipe diameter of 1 cm  Flow area of 0.79 cm2. If inlet velocity = 0.6 m/s  Mass flow rate = 0.047 kg/s = 2.8 L/min. If power removed per channel = 1,562 W  Water temperature rise ΔT ~ 8°C. . . m m Coaxial Squirt Nozzle: Total flow length through outer annulus is 7 cm. Hydraulic diameter of annulus, DH = Do – Di = 7 – 6 = 1 mm. For estimated flow velocity in annulus of 5 m/s, this gives: Δp ≈ 0.34 Bar Re ≈ 5,500 HTC ~ 30,000 Wm-2 K-1 Di DH Do Square Cross-Section Milled Main Flow Channel: Hydraulic diameter of 5 mm square pipe is same as circular pipe ∴ DH = 5 mm. For constant mass flow rate in all sections,  expected flow velocity ≈ 2.4 m/s. For total milled length = 0.5 m, this gives: Δp ≈ 0.09 Bar Re ≈ 13,000 HTC ~ 11,500 Wm-2 K-1 DH

  46. Water Flow Velocity 0.039 kg/s in & out 1.98 m/s 4.96 m/s

  47. Water Pressure Total Pressure Difference = 0.43 Bar ΔP = 0.04 Bar ΔP = 0.39 Bar

  48. Water Heat Transfer Coefficient 11,000 Wm-2 K-1 39,000 Wm-2 K-1

  49. Copper Temperature

  50. Water Flow StreamlinesColoured By Water Temperature

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