ALBA Synchrotron Light Source

Solving thermal instabilities

in the SR (Part 1)

Juan José Manotas Mazario

In collaboration with Marcos Quispe

MEDSI/Pan-American SRI 2008 Meeting

August 3th , 2018 June 10-13, 2008
V2rev1
Contents
1. The Problem: Pressure drop in aspiration
Thermal instabilities in Storage Ring
2. Current situation
2.1 Bypass Flow measurements in Storage ring circuit
3. Starting Data
3.1 Archived Data Storage Ring circuit
4. Analysis Strategy
4.1 Analysis Environment
4.2 Steps for valve design
5. Valve drawing and refining
6. Valve data and results (I) and (II)
7. Circuit boundary conditions
8. Parametric studies and Goals optimizations
9. Scenario 1: Open bypass – Flow balance
9.1 Pressure
9.2 Temperature
9.3 Data
10. Scenario 2: Closed bypass – Flow balance
10.1 Pressure
10.2 Temperature
10.3 Data
11. Open/Closed bypass – Pressure balance
12. Scenarios review output
13. Conclusions
14. Next steps
Page 2
15. Annex 1 and 2: mesh asymptotic study
1. The problem: Pressure drop in aspiration.
21st Meeting of the Alba Scientific Advisory Committe:
As a result of the problems detected during the cooling operation, it was discovered that the Storage ring
had less pressure on the pump suction than the rest of the circuits, which could affect the operation.

1. Open the by-pass at the three way valves to

ensure that the aspiration pressure of the
pumps was the same for the four circuits and
set to 2 bars. This action set the pumps to
operate properly, allowing operating the
pumps at much higher flow without risking
cavitation.

Page 3
1. The problem: Thermal instabilities in Storage Ring.
Due to the opening of the bypass valve the temperature instabilities in the storage ring increased. In
comparison with its own operation and with the rest of the circuits.

Rings BO, EH, SA and SR

Fig 3.2.1 The bypass opened that affect the

temperature regulation of the Storage Ring.

Page 4
2. Current Situation
2.1 Bypass Flow measurements in Storage Ring circuit
Measurement Mass balance
(with ultrasonic flowmeter)
433 ≈ 184+269

Cold Water Main Flow from ST4 =

433 m3/h

Flow towards to 3-way P08 valve

and P10-P07 pumps ≈ 269 m3/h

Water Flow with

Open Bypass =
184 m3/h
Accelerator SR flow ≈
282 m3/h

- Currently the main flow is divided between 3-Way valve and Open Bypass. The output of the 3-
way valve is mixed with the water coming from the open bypass, therefore the water that enters
the P08 (Storage) pumps, lacks a temperature control.
- 65.2% (184 m3/h) of water coming from ST4 goes through the bypass, and no temperature control
is applied.
- The temperature changes that occur in ST4 directly affect the temperature control of the Storage
Ring, due to the open bypass. Page 5
2. Current Situation
2.1 Bypass Flow measurements in Storage Ring circuit
Cold Water Main Flow from ST4 =
433 m3/h Flow towards to 3-way P08 valve
and P10-P07 pumps ≈ 269 m3/h

3-Way Valve Hot Water coming

Water Flow with from Accelerator
Open Bypass = (not measured)
184 m3/h

Accelerator SR flow ≈
282 m3/h
P08A

282 m3/h – 184 m3/h ≈ P08B

Measurement Mass balance
98 m3/h out from 3-WV P08C (with ultrasonic flowmeter)
433 ≈ 184+269

- Currently the main flow is divided between 3-Way valve and Open Bypass. The output of the 3-
way valve is mixed with the water coming from the open bypass, therefore the water that enters
the P08 (Storage) pumps, lacks a temperature control.
- 65.2% (184 m3/h) of water coming from ST4 goes through the bypass, and no temperature control
is applied.
- The temperature changes that occur in ST4 directly affect the temperature control of the Storage
Ring, due to the open bypass. Page 6
3. Starting Data
3.1 Archived Data Storage Ring circuit
Flow archived data
(30 days of beam line operation)

Pressure archived data

several months of operation

- Flow archived data mean: 283,57 m3/h = = 0,07876 m3/sg / 2 = 0,0393833 m3/sg (P08+P08)
- Pressure archived data mean:
- Inlet ST4 pressure = 1,78223 bar = 178223 Pa
- Inlet accelerator pressure = 1,82198 bar = 182198 Pa
Page 7
4. Analysis Strategy
4.1 Analysis environment
Using fluid flow analysis (Computational Fluid Dynamics) to obtain solutions to the full Navier-Stokes equations.
Flow Simulation (SOLIDWORKS).
We use CFD, because we need the highest precision for the proper selection of the mixer (3 way valve), due to
the impact it has on the positioning of the beam.
It allows to have a model for the different scenarios, because the consumption is growing in the Front ends.

Size of computacional domain

Page 8
4. Analysis Strategy
4.2 Steps for valve design
1. Draw a valve with similar geometric parameters to the current one (Detailed in spec above), in order to
simulate current situation (Kv =262 m3/h) with open and closed bypass.
 KV calculation – valve test design according to IEC 60534 International Standard - Industrial Process
control valves.

2. Test and refine design for searching goal: Kv = 262 m3/h, Pressure drop = 1 bar, like real one installed.

Manufacturer specs
P08 3-Way Valve
(Current Kv in Storage R)

P08 3-Way Valve

Page 9
5. Valve drawing and refining
Boundary conditions design KvA = ST4 side Boundary conditions design
KvB = Accelerator side

- Boundary conditions valve design: search Kv in both paths for pressure drop 1 bar, initial
pressure of 2bar.

Page 10
6. Valve data and results (I)
Test and Calculations Engineering Goals:
- KvA (ST4) = 262 m3/h
- KvB (Accelerator) = 262 m3/h

Results: The design valve

- KvA (ST4) = 260,9 m3/h is similar to real one.
- KvB (Accelerator) = 262,3 m3/h

The next step will be introduce the designed valve

into the circuit and simulate current situation with
open and closed bypass.

Page 11
6. Valve data and results (I)

KvA (ST4) = 260,9 m3/h KvB (Accelerator) = 262,3 m3/h

Page 12
6. Valve data and results (II)
Witch will be the pressure drop in the valve when flow is 283,57 m3/h?

After designing the valve for 262 m3/h, when we test the
valve with the actual flow value, 283 m3/h, the pressure
drop in the valve increases from design 1 bar to 1.23
bar and its Kv is reduced to 254 m3/h. So we see that it is
very important to select the correct Kv and also include the
increase in flow that the circuit may have in the future.

Page 13
7. Circuit boundary conditions

Butterfly valve The valve is placed inside the

circuit and tested in two scenarios:

Scenario 1: Open bypass (current)

Scenario 2: Closed bypass
3-way valve

P08A

P08B
P08C

- Real Wall Roughness chosen = 0,1 mm = 100 micra

- Real Flow: 283,57 m3/h = = 0,07876 m3/sg / 2 = 0,0393833 m3/sg (P08+P08)
- Real Pressure:
- Inlet ST4 pressure = 1,78223 bar = 178223 Pa
- Inlet accelerator pressure = 1,82198 bar = 182198 Pa

Page 14
8. Parametric studies and Goals optimizations
BF Angle calculation Shutter position calc.
Boundary conditions Boundary conditions

Parametrics studies:

Open bypass (current) Sc 1: Open bypass Sc 2: Closed bypass

1. Goal optimization (Open bypass): Search butterfly valve position to get Angle = 40º Angle = 0º
the angle that meets flow measured in open bypass = 184,86 m3/h = Q = 184,86 m3/h Q=0
0,0513523 m3/sg.
2. Goal optimization (Open bypass): with butterfly valve open, search
shutter (3Wv) position to reach T = 23±0,2ºC.

Closed bypass
1. Goal optimization: Search shutter position (3Wv) to obtain the
temperature of 23±0,2ºC.
Page 15
9. Scenario 1: Open bypass – Flow Balance

186,4 m3/h – 65,7 %

17,9 m3/h – 6,3 %

79,2 m3/h
27,9 %

QT = QByp + QST4+QAccSR

P08A
P08B
P08C

20,05 ºC
Page 16
 9.1. Scenario 1: Open bypass – Pressure

Off P08A On P08B On P08C

170333 Pa 165421 Pa 165888 Pa

Page 17
 9.2. Scenario 1: Open bypass – Temperature

IN ST4 = 20,05 ºC

IN ST4 = 20,05 ºC IN Acc-SR = 25,05 ºC

65,2 % of 34,8 % rest

total flow of flow

TT302
24,07 ºC
Point Goal

Off P08A On P08B On P08C

OUT 20,05 ºC OUT 20,50 ºC OUT 22,99 ºC

Page 18
9.3. Scenario 1: Open bypass – Data

Open Bypass Combinations

Page 19
10. Scenario 2: Closed bypass – Flow Balance

113,6 m3/h – 40,5 %

166,3 m3/h
59,3 %

QT = QByp + QST4+QAccSR

P08A
P08B
P08C

20,05 ºC
Page 20
10.1. Scenario 2: Closed bypass - Pressure

Off P08A On P08B On P08C

64698 Pa 62822 Pa 64883 Pa

Page 21
 10.2. Scenario 2: Closed bypass - Temperature

IN ST4 = 20,05 ºC IN ST4 = 20,05 ºC

IN Acc-SR = 25,05 ºC

Off P08A On P08B On P08C

OUT 20,05 ºC OUT 23,09 ºC OUT 23,00 ºC

Page 22
10.3. Scenario 2: Closed bypass – Data

Closed Bypass Combinations

Page 23
11. Open/Closed bypass – Pressure balance
Open Bypass Closed Bypass

Page 24
11. Open/Closed bypass – Pressure balance
The pressure drop of the fittings and pipes, is very small compared to that which occurs in the mixer.

Closed Bypass

Pdrop =
0,03 bar
2,3 %

Pdrop =
1,23 bar
94,6 %

Pdrop =
0,04 bar
3%

Page 25
12. Scenarios review output

Open bypass (current)

1. When the bypass is open, more than 65% of cool water flow (ST4) passes through it,
so the temperature control is not in the 3-Way valve is in bypass valve, that does not
have any temperature control. We know that the temperature supplied by ST4 has
significant temperature changes, so these are copied into the systems of accelerator.

2. The circuit lacks a temperature control when the butterfly valve is open. This and no
other is the main problem of temperature without control, the temperature map when
the bypass is open is very unbalanced between the pumps, that are in operation (P08B
20,5ºC and P08C 22,99ºC will mixed upstream) and between the desired setpoint of 23ºC,
regardless of the couple of pumps that are running. The water temperature value is not the
design value in any case. In the study, a point goal has been placed, just where the current
probe that controls the 3-W valve is located, it can be seen that the design value of 23ºC, is
not achieved (24,7ºC), since subsequently, there will be a mixture between the water coming
from the bypass to more low temperature and water coming from SRing. Added to the above,
this mixture causes, an incorrect measurement of the temperature probe TT303 and an
incorrect setting of the 3W valve.

3. In this case, the pressures supplied to the pumps are correct for its operation.
Closed bypass
1. When the bypass is closed, all the water flow, only goes through the 3-W control valve, so the system is under
control.

2. The temperatures are balanced between the two pumps in operation and the setpoint value is achieved with
precision (error less than ±0,2ºC).

3. In this case, the pressure is not sufficient for the operation, being in an area close to the cavitation pumps.
Page 26
13. Conclusions

1. It has to work with the closed bypass, it is the configuration that guarantees temperature control and
balance, sending water to the Storage Ring.

Open Bypas
Closed Bypas

2. The temperature control must be carried out through the TT303 probe, as seen the reason for
temperature variation is not because for the position of the probe, is motivated by working with the open
bypass.

Closed Bypas Open Bypas

Page 27
13. Conclusions

3. Only the pressure drop in the 3W-valve (1,23bar at flow of 283 m3/h), itself explains the low pressure at
the pump inlet 0,62-0,64 bar. (No sponge).

4. With closed bypass a higher pumps suction pressure is necessary. The 3W-valve must be dimensioned to a
larger one in order to reduce the pressure drop with the same flow rate. If the flow is to increase in the
next few years, we must anticipate and know the value to avoid encountering the same problem in the future.

Closed Bypas

Page 28
13. Conclusions

5. As can be seen in the manufacturer's specifications, the 3-W valve installed, is designed for a flow of Kv =
262 m3/h, with a pressure drop of 1 bar, current flow is higher: 283 m3/h so the pressure drop is even higher
= 1,24 bar. That’s indicate that the valve is small. Theorical Kv = 254 m3/h in these conditions.

6. Also the design pressure is 10 bar when, in fact we do not reach 2 bar in the inlet ways. This pressure is
used for the force, that the pneumatic actuator must apply, which only influences the sizing and the initial
cost. Now it is no longer a problem. As the pneumatic actuator was already acquired and will work properly
up to an input pressure of 10 bar that we will never have.

Page 29
13. Conclusions

7. Point 1, does not guarantee the correct operation always. There are time zones of the operation of ST4,
which do not meet the agreed specifications. If the cooling temperature sent by ST4 exceeds 23°C or less
(depend de load from accelerator), the cooling water does not have enough energy to cool the accelerator.
The solution to this problem is beyond the scope of this document. It is mandatory to ensure that the
cooling water below 23ºC and its corresponding flow is 24 hours x 7 days. ST4 must meet the agreed
delivery specifications. That’s affected no only Storage Ring, also the rest of cooling circuits.

Page 30
14. Next steps

The study is not finished, there are four more parts.

1. Part 1. This document itself.

2. Part 2. Setting the valve to the next commercial size DN200 and test its operation under the same conditions,
with the closed bypass, to determine if it reaches, a pressure in the suction of pumps of at least 1.8 bar or more if
it’s possible, with the current flow of 283 m3/h. Setting the Kv necessary to perform the adjustment of the valve to
the necessary size.

3. Part 3. Know the growth of water consumption in the next years, in the Storage Ring and check, if the size of the
valve is adequate for the future.

4. Part 4. Perform the search for offers that allows the change of the valve, including the modification of the circuit,
(pipes), that allows to comply with the new requirements. Installation Project (Cost and Schedule).

Page 31
ALBA Synchrotron Light Source

Thank you
15. Annex 1: Mesh asymptotic study
Analyzed 49 different mesh scenarios

Asymptotic study to find the best performance between calculation and time. Consist in mesh parametric
study with 49 scenarios, and several points goals to check stability of the result versus the quality of the
mesh.

Page 33
15. Annex 2: Mesh asymptotic study

Page 34