UNIVERSITAT POLITÈCNICA DE VALÈNCIA
Depa amen o de Ingenie ía Mecánica y de Ma e iales
T abajo Fin de Más e en Ingenie ía Mecánica
DESIGN & DEVELOPMENT OF A HYDRAULIC TEST BENCH
FOR AN EROSION & CORROSION TEST
P esen ado po : D. Ped o Ca ió Pé ez
Di igido po : D . F ancisco Da id Denia Guzmán
Supe iso del CERN: Oli e Abe le
Valencia, Sep iemb e de 2017
ii
Ne e walk on he a elled pa h
because i only leads whe e o he s ha e been.
Alexande G aham Bell
iii
Abs ac
The neu on ime-o - ligh (n_TOF) acili y a CERN is a sou ce o high
lux o neu ons ob ained by he spalla ion p ocess o 20 GeV/c p o ons on o
a high pu i y (99.99 %) lead a ge . In 2008 he acili y, ha su e ed se e e
co osion a e ew yea s o ope a ion, was comple ely upg aded. I includes
now an aluminium alloy essel and a cooling ci cui wi h moni o ed oxygen
con en , and conduc i i y o he demine alized wa e used as coolan and
mode a o . Du ing Long Shu down (LS2) a hi d spalla ion a ge ( a ge #3)
will be ins alled in he acili y, in o de o subs i u e he p esen a ge which
will ha e eached i s end o li e. The a ge is p esen ly unde design. Va ious
ma e ials a e being in es iga ed o bo h he co e and he con ac pa wi h he
cooling wa e .
In he amewo k o he a ge upg ade ac i i ies, a new wa e
e osion/co osion es bench is equi ed, in o de o e alua e he compa ibili y
o a ious ma e ials in he n_TOF a ge egime.
The new es bench is in ended o be capable o being used o ca y ou
e osion and co osion es s, and check he changes o he ma e ials o alida e
he design o he new a ge . This es bench has been designed in a way ha
will be e sa ile and adap able o di e en ypes o es s and a ge s in he
u u e.
i
The idea is ha he design can modi y a iables such as he ci cui low,
empe a u e, luid conduc i i y and p essu e o di e en es s wi h good
eading ou and logging alues.
The p ojec o he es bench comp ises he concep ual o he de ailed
design and manu ac u e he de ice. This wo k has ca ied ou in collabo a ion
wi h se e al g oups ac oss CERN, in ol ed in he echnical speci ica ion,
analysis, design, manu ac u e and secu i y.
Key Wo ds
CERN, physics, pa icles, spalla ion, p o on synch o on, design
hyd aulic, es bench, e osion, co osion, demine alized wa e , conduc i i y,
hea , low, manu ac u ing.
Resumen
La ins alación de neu ones de iempo de uelo (n_TOF) en el CERN es
una uen e de al o lujo de neu ones ob enida po el p oceso de espalación de
20 GeV/c de p o ones sob e un obje i o de plomo de al a pu eza (99,99 %).
En 2008, la ins alación su ió una co osión se e a después de pocos años de
ope ación, és a ue comple amen e mejo ada. Incluye aho a un ecipien e de
aleación de aluminio y un ci cui o de e ige ación con con enido de oxígeno
y conduc i idad del agua desmine alizada, u ilizada como e ige an e y
mode ado , con olados. Du an e la pa ada la ga (LS2) se ins ala á un e ce
obje i o de espalación (obje i o #3) en la ins alación, pa a sus i ui al obje i o
ac ual que hab á alcanzado su in de ida ú il. El obje i o es á ac ualmen e
bajo diseño. Se es án in es igando a ios ma e iales pa a el núcleo y la pa e
en con ac o con el agua del sis ema de e ige ación.
En el ma co de las ac i idades de mejo a de obje i os, se equie e un
nue o banco de p uebas de e osión / co osión, con el in de e alua la
compa ibilidad de di e sos ma e iales en el égimen del obje i o n_TOF.
El nue o banco de p uebas es á des inado a se capaz de ealiza p uebas
de e osión y co osión, y e i ica los cambios de los ma e iales pa a alida
el diseño del nue o obje i o. Es e banco de p uebas ha sido diseñado de una
mane a que se á e sá il y adap able a di e en es ipos de p uebas y obje i os
en el u u o.

i
La idea es que el diseño puede modi ica a iables ales como el lujo del
ci cui o, la empe a u a, la conduc i idad del luido y la p esión pa a
di e en es p uebas con buenos alo es de lec u a y egis o.
El p oyec o del banco de p uebas comp ende del diseño concep ual al
diseño de allado y la ab icación del disposi i o. Es e abajo se ha lle ado a
cabo en colabo ación con a ios g upos del CERN, in oluc ados en la
especi icación écnica, análisis, diseño, ab icación y segu idad.
Palab as Cla e
CERN, ísica, pa ículas, espalación, p o on synch o on, diseño
hid áulico, banco de p uebas, e osión, co osión, agua desmine alizada,
conduc i idad, calo , caudal, ab icación.
ii
Resum
La ins al·lació de neu ons de emps de ol (n_TOF) al CERN és una on
d'al lux de neu ons ob inguda pel p océs d’espal·lació de 20 GeV/c de
p o ons sob e un objec iu de plom d'al a pu esa (99,99 %). El 2008, la
ins al·lació a pa i una co osió se e a desp és de pocs anys d'ope ació,
aques a a se comple amen millo ada. Inclou a a un ecipien d'alia ge
d'alumini i un ci cui de e ige ació amb con ingu d'oxigen i conduc i i a
de l'aigua desmine ali zada, u ili zada com a e ige an i mode ado ,
con ola s. Du an la pa ada lla ga (LS2) s'ins al·la à un e ce objec iu de
espal·lació (objec iu #3) en la ins al·lació, pe subs i ui l'objec iu ac ual que
hi hau à a iba al seu i de ida ú il. L'objec iu es à ac ualmen so a disseny.
S'es an in es igan di e sos ma e ials pe al nucli i la pa en con ac e amb
l'aigua del sis ema de e ige ació.
En el ma c de les ac i i a s de millo a d'objec ius, es eque eix un nou
banc de p o es d'e osió / co osió, pe al d'a alua la compa ibili a de
di e sos ma e ials en el ègim de l'objec iu n_TOF.
El nou banc de p o es es à des ina pe a se capaç de eali za p o es
d'e osió i co osió, i e i ica els can is dels ma e ials pe alida el disseny
del nou objec iu. Aques banc de p o es ha es a dissenya d'una mane a que
se à e sà il i adap able a di e en s ipus de p o es i objec ius en el u u .
iii
La idea és que el disseny po modi ica a iables com a a el lux del
ci cui , la empe a u a, la conduc i i a del luid i la p essió pe a di e en s
p o es amb bons alo s de lec u a i egis e.
El p ojec e del banc de p o es comp èn del disseny concep ual al disseny
de alla i la ab icació del disposi iu. Aques eball s'ha du a e me en
col·labo ació amb di e sos g ups del CERN, in oluc a s en l'especi icació
ècnica, anàlisi, disseny, ab icació i segu e a .
Pa aules Clau
CERN, ísica, pa ícules, espal·lació, p o on synch o on, disseny
hid àulic, banc de p o es, e osió, co osió, aigua desmine ali zada,
conduc i i a , calo , cabal, ab icació.
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Acknowledgemen s
The pe iod o his hesis b ough me aluable new expe iences in bo h a
scien i ic and pe sonal pe spec i e. This hesis would no ha e been possible
wi hou he cons an suppo and mo i a ion o many people.
Fi s ly, I would like o exp ess my since e g a i ude o my supe iso ,
Oli e Abe le. His wide knowledge and his expe ience ha e been a g ea
alue o me. His encou aging and pe sonal guidance ha e p o ided a good
backg ound o he p esen hesis.
Many hanks o he p o esso F ancisco Da id Denia Guzmán and Ma ia
Papamichali, o accep ing o e iew my wo k. Thei cons uc i e sugges ions
on he hesis a e eally app ecia ed o me. I am g a e ul ha in he mids o
hei ac i i ies, hey accep ed hese asks.
Du ing his pe iod, I ha e collabo a ed wi h many colleagues, om
di e en depa men s, he sec ion wo kshop and supplie s o whom I ha e
g ea ega d, and I wish o ex end my wa mes hanks o all hose who ha e
helped me om a p o essional and pe sonal poin o iew. Especially o
Ma co Cal iani, Damien G enie , Ch is ophe Claude Mi i io , Hube
Reymond, Domingo Gomez Dominguez, Yannic Body, Yann Lupkins,
Ramon Folch, Pie e B oussa , Edoua d G enie -Boley, Abdelhabib
Majbou , Edmundo Lopez Sola, Ra aele Esposi o, Tomasz Kazimie z
S zalka.
x i
Glossa y
CERN: Conseil Eu opéen pou la Reche che Nucléai e
LHC: La ge Had on Collide
LS: Long Shu down
PS: P o on Synch o on
PSB: P o on Synch o on Boos e
SPS: Supe P o on Synch o on
ALICE: A La ge Ion Collide Expe imen
ATLAS: A To oidal LHC Appa a uS
CMS: Compac Muon Solenoid
LHCb: La ge Had on Collide beau y expe imen
AD: An ip o on Decele a o
N_TOF: Neu on Time-O -Fligh
ECR: Elec on Cyclo on Resonance
RFQ: Radio F equency Quad upole
LEIR: Low Ene gy Ion Ring
RF: Radio F equency
HV: High Vol age

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To my amily…
x iii
1
Chap e 1
1. In oduc ion
1.1. CERN
The Eu opean O ganiza ion o Nuclea Resea ch is he wo ld’s
la ges pa icle physics labo a o y [1]. I is si ua ed a Gene a ac oss
he bo de be ween F ance and Swi ze land. The o igin o he name
comes om he F ench ac onyms “Conseil Eu opéen pou la
Reche che Nucléai e”.
I was ounded in 1954 by 12 membe s a es and nowadays he
membe s a e 22, bu i ga he s physicis s and enginee s om mo e han
100 coun ies in he wo ld.
13.7 billion o yea s ago he Uni e se s a ed wi h an explosion.
The ene gy, concen a ed in an in ini ely small space, coagula ed in
equal pa o ma e and an ima e . A CERN physicis s and enginee s
wo k o push mo e and mo e in he esea ch bounda ies p obing he
undamen al s uc u e o he Uni e se.
In o de o a ain his main goal, pa icle physics s udies he ines
objec o Na u e. Looking in o he e y small and undamen al is also
looking a back in o ime, jus a ew momen s a e he Big Bang [2].
2
The in es iga ion o he undamen al pa icle, he basic cons i uen
o he ma e , is made by he collision o wo pa icle beams in he LHC
(La ge Had on Collide ), he mos powe ul accele a o in he wo ld.
The empe a u e and ene gy densi y in he collision a e simila o
hose ha exis ed a ew momen s a e he Bing Bang, in his way
physicis s hope o disco e how he Uni e se e ol ed.
The CERN ac i i y is egula ed by an al e na ion o wo pe iods:
he “Run”, when he beams ci cula e in he unnel and he expe imen s
can collec he da a, and he “LS: Long Shu down” when he beams a e
s opped and i is possible o make he main enance and he upg ades o
he de ices inside he machines.
F om he beginning o he LHC ope a ion, in 2008, CERN has had
wo pe iods: he “Run1” and he “LS1”. The ene gy eached in he
collision o Run1 was 8 TeV and, hanks o his, he expe imen s ha e
made he e y impo an disco e y o he Higgs Boson, which
imp o es ou cu en unde s anding o he Uni e se, con i ming he
S anda d Model Theo y.
Du ing he wo yea s o he LS1 he powe o he machine was
inc eased up o an ene gy o collision o 14 TeV.
3
Nowadays, we a e in he Run2, ha is going o be concluded in he
middle o 2018, he LS2 will ollow and hen, he Run3 is o eseen o
2020.
1.1.1. The CERN's accele a o complex.
Be o e hei collision, he pa icles a e accele a ed o a speed e y
close o he speed o ligh . This is made by a succession o machines
ha , s ep by s ep b ings he pa icles o highe ene gies and speed, as
he Figu e 1 shows.
Figu e 1: Schema ic accele a o complex.

4
Each machine injec s he beam in o he nex one, which akes o e
o b ing he beam o an e en highe ene gy, and so on. The LHC is he
las elemen o he chain, he e he pa icle beams a e accele a ed in
o de o each he ene gy o 13 TeV.
The LHC s ands o La ge Had on Collide . La ge is due o i s size
abou 27 km in ci cum e ence, Had on is because i accele a es p o ons
o lead ions, which a e had ons, and Collide because he pa icles
a el in o wo beams in opposi e di ec ion and in ou poin s o he
ing hey collide.
The accele a o s inside he machine a e no mally ci cula unnels
in which he pa icles a e ben o ollow a ci cula ajec o y by he
dipole magne s.
The quad upole magne s a e used o ocus he beam down o he
smalles possible size be o e he collision poin , in o de o maximize
he chance o wo p o ons o smash wi h each o he . In he LHC he
supe conduc i e magne s use a c yogenic sys em wi h a pumping o
supe luid helium ha pe mi s o ope a e a a empe a u e o -273.1 °C,
which makes i one o he coldes places on Ea h. The Figu e 2 shows
a quad upole in he LHC.
5
Figu e 2: LHC.
The accele a ion, ins ead, is made by he ans e o he beam inside
he adio equency ca i ies. The elec ic ield, c ea ed wi hin he
ca i ies, changes pola i y wi h high equency. The incoming p o ons
a e a ac ed inside he ca i y when he posi i e sign o he elec ic ield
is in he same di ec ion o he beam, while when he sign is in he
opposi e di ec ion, he pa icles a e pushed wi h highe speed.
All o he physics s a s om a li le bo le o hyd ogen, he p o ons
o which a e aken by s ipping o bi ing elec ons. These p o ons a e
accele a ed o an ene gy o 50 MeV wi h a ise o he mass o he 5 %
in he Linac2, one o he only wo linea accele a o s o he chain.
6
The p o ons a e hen injec ed in o he PS Boos e (PSB) ha
accele a es hem o 1.4 GeV and 91.6 % o he speed o ligh . A e , he
beam is going h ough he P o on Synch o on (PS) whe e i is
accele a ed o 25 GeV and 99.93 % o he speed o ligh . The Supe
P o on Synch o on (SPS) ollows, whe e he ene gy eaches 450 GeV.
Finally, a e i e accele a o s ha inc ease he mass o he p o ons
o 7000 imes and hei eloci y ill 99.9999991 % o he speed o ligh ,
he beam is ans e ed o he LHC in bo h di ec ions, clockwise and
an iclockwise. In he LHC hey a e accele a ed o 20 minu es o hei
nominal ene gy o 13 TeV. Beams will ci cula e o many hou s inside
he ul a-high acuum beam pipes unde no mal ope a ing condi ions.
The wo beams o he LHC collide only a ou speci ic poin s in
co espondence o he de ec o s. The de ec o s a e machines ha
ecognize and measu e p ope ies o he pa icles du ing he collisions,
ying o unde s and hei na u e. Each de ec o is ela ed o he one o
he main expe imen s a CERN: ALICE [3], ATLAS [4], CMS [5] and
LHCb [6].
In addi ion, mos o he accele a o s in he chain ha e hei own
expe imen al halls wi h a beam o lowe ene gy. Fo example he SPS
supplies se e al expe imen s, among hem ix a ge expe imen s a e
he No h A ea NA62 [7] o he COMPASS [8] expe imen s. SPS also
7
p o ides he pa icles o he HiRadMa [9] o expe imen s on ma e ials
hi by he beam; ins ead, he PS injec s he pa icles o he An ip o on
Decele a o (AD) [10] o o n_TOF [11]. In Figu e 3, wo pic u es o
he CMS and ATLAS colliding beam pa icle de ec o s can be seen.
Figu e 3: CMS and ATLAS expe imen a CERN
Mo eo e , he accele a o complex also accele a es lead ions. The
p oduc ion o he lead ions comes om a highly pu i ied lead sample,
he ECR (Elec on Cyclo on Resonance) [12] sou ce, which is hea ed
o a empe a u e o abou 500 °C.
The lead apou is ionized by an elec on cu en ; he sou ce
p o ides many di e en cha ge s a es, a spec um om Pb22+ o
Pb32+, wi h a maximum a ound Pb29+, which is he only o he
cha ged s a es selec ed immedia ely by a spec ome e . Now, he a el
o hese ions s a s om he linea s uc u es which accele a es he ions
o 4,2 MeV/u (ene gy pe nucleon): A Radio F equency Quad upole
(RFQ) and hen an in e -digi al Linea Accele a o , he Linac3, play
his ole.
14
Chap e 2
2. Desc ip ion o he ins alla ion
In he amewo k o he a ge upg ade ac i i ies, a new wa e
e osion/co osion es bench is equi ed, in o de o e alua e he
compa ibili y o a ious ma e ials in he n_TOF a ge egime.
The new es bench is in ended o be capable o being used o ca y
ou e osion and co osion es s, and check he changes in he
mic os uc u e o di e en ma e ials o alida e he design o he new
a ge . The es bench is designed o be as mos au oma ic as possible,
only equi ed om he ope a o he se ‐up o he ma e ials inside he
chambe , some manual al es and he manual s a o he es , i is
designed in a way ha i will be e sa ile and adap able o di e en
ypes o es s and a ge s.
The expe imen is ca ied ou inside a s ainless s eel chambe ,
whe e he a ge is ins alled. To ge all he special condi ions is needed
di e en de ices o i . The demine alized wa e is used in he eal
expe imen o a oid any ma e ial oxida ion in he a ge o in he ci cui
componen s. In his case is going o be used an Ion exchange equipmen
in s ainless s eel ha ul il all he equi emen s needed. The mixed bed
ion exchange s wo k acco ding o he ion exchange p inciple.

15
The idea o he es bench is he design can modi y a iables such
as he ci cui low, empe a u e, luid conduc i i y, and p essu e o
di e en es s wi h good eading ou and logging alues. To ge all o
hese op ions a ull ma ke esea ch has been done o ind he bes
comme cial componen s ha can achie e all he equi emen s. The
ci cui is composed by a hyd aulic pump ha gi es he low, a hea e
ha gi es he empe a u e, lowme e s and al es o con ol he low
and di e en senso s o con ol he conduc i i y and he p essu e.
E e y hing is placed on aluminium s uc u e, in o de o educe he
weigh , wi h ou wheels o make easie he placemen and o ind a
wa e ap connec ion. A ec angula design wi h wo aluminium shee s
o 10mm hickness ha e been chosen o make easie he design, he
assembly i sel , and he assembly o all he componen s, also, he space
o he elec onic de ices has been aken in o accoun .
16
The Figu e 6 p esen s he schema ic a ge and low impac inside
he chambe :
Figu e 6: Scheme o he a ge .
2.1. Tes p ocedu e
In o de o simula e as close as possible he condi ions p e ailing in
he eal n_TOF expe imen , a es loop using demine alized wa e as
p ocess luid was specially de eloped and connec ed on me al based
loop ci cui a ailable a CERN. The es loop is shown and desc ibed
in Figu e 7.
The Tes ‐Bench mus be ins alled in a loca ion wi h access o
no mal ap wa e , sewe o discha ge used wa e , 380 V iphasic
elec ic connec ion and E he ne connec ion o in e ne access.
10 mm
10 mm
17
As in he eal ci cui , wa e passes h ough a mixed-bed esin
ca idge in o de o keep conduc i i y as low as possible. Wi h a low
egula o al e, placed on he inle ca idge, is possible o con ol he
low once he conduc i i y is sui able. The wa e is hea ed up o 80 °C
o simula e he wa e empe a u e a he su ace o he es ma e ial,
whe e he beam hi s he a ge . The e a e wo empe a u e senso ha
will con ol he hea e ope a ion.
The wa e ci cui is spli in wo main b anches, one as a by-pass in
o de o adap he luid o he expe imen equi emen s and he o he
b anch has wo di e en injec ions poin s in a mock-up con aine .
Once he wa e is p epa ed wi h all equi emen s o he es
(p essu e, empe a u e, oxygen and conduc i i y), he al es V1 and
V2 will be opened manually o allow he luid o pass h ough he
second b anch o s a he p ocess. This is he mos impo an b anch
because all he expe imen depend on o main ain he low condi ions
in hese pipes. The al es VR2 and VR3 will be in cha ge o adjus ing
he p ope low h ough he es chambe . VR3 is a manual egula o
low al e ha will be se up a he beginning and VR2 will con ol he
low du ing all he expe imen as an au oma ic low egula o al e
(see Figu e 7).
18
The Tes ‐Bench was designed o send au oma ically he epo s,
wa nings/ale s o e email o he pe son in cha ge. Also, se e al
in e lock sys ems we e implemen ed o p e en and ale CERN abou
es bench inco ec use o mal unc ions.
P 1
CT 1
OT 1
ERA 1
TT 1
TT 2
Tes Chambe
Cons an T
Cons an
REA 1
PI 1
PT 1
V 4 Re illing
Expansion
Tank
5µm - 200µm
FOA 2
VR 1
200µm
DEMINERALIZED
WATER
10% o low
V 1
FT 1
FS 1
V 6
3 Ba
PI 2
V 3
FOA 1
V 2 VR 3
FT 2
VR 2
V 5
Figu e 7: Scheme o he hyd aulic sys em.
The du a ion o he es is expec ed o be h ee mon hs o each
ma e ial. The amoun o e osion/co osion will be e i ied a he end o
he es by di e en p ocesses such as dimensional e i ica ion o
mic oscopy. The mos adap ed ma e ial will be chosen a e e alua ion
o he esul s.
19

20
Chap e 3
3. Ambi o he p ojec .
The p esen p ojec includes he design and manu ac u ing o he
mechanical pa o a hyd aulic es bench o check he e osion and
co osion o di e en ma e ials and hus alida e he nex a ge o he
n_TOF expe imen a CERN.
The es samples and he ins alla ion o hem inside he chambe a e
no conside ed pa o he p ojec .
Pa s o he elec onic design, so wa e design, and design o he
wi ing, p o ec ion and con ol elemen s a e no conside ed pa o he
p ojec . Howe e , hese elemen s mus comply wi h he IEC S anda ds.
The limi s o each sec ion a e speci ied in he poin s desc ibed
below.
3.1. Tes bench links.
Only he mechanical links o he bench es o he ou side will be
conside ed as belonging o he p esen p ojec . In his case i would be
he s anda d wa e inle / ou le connec ion and he ex ac ion al e in
he chambe .
21
The design o he inpu elec ical connec ion and i s sa e y ea u es
a e no conside ed as belonging o he p ojec .
4. Design o he ins alla ion
The design o he hyd aulic es bench began in Feb ua y 2016 wi h
he objec i e o de e mina e he bes ma e ial op ion o he new a ge
in e ms o e osion and co osion. The es bench should ec ea e, as
close as possible, he condi ions in he eal n_TOF expe imen .
4.1. Limi a ions o he sys em
• Fluid o use: Demine alized wa e
• Flow a e: 1-90 L/min
• Fluid empe a u e: 20 °C / 80 °C
• Wa e speed inside he chambe : 0.1 o 5 m/s
• P essu e inside he chambe : 1-3 ba
• O2 con en : ppm (1/10 o ppm)
• Conduc i i y: 0.175 µS/cm
• Tow impac angles: 90 deg. 0 deg.
• 10 mm je diame e
• Con aine sealed capable o eaching up o 100 °C
• Tes con aine : X: 30-40 cm; Y: 30-40 cm; Z: 15-30 cm
• S uc u e: X: 150-200 cm; Y: 80-100 cm; Z: 60-110 cm
22
Based on he gene al limi a ions posed by he sys em, a concep ual
design is ca ied ou . The comme cial de ices necessa y o achie e he
equi emen s a e ag eed upon, h ough discussions wi h o he sec ions
ha will con ibu e hei expe ience and wo k.
All he equipmen is moun ed on a ec angula s uc u e, able o
mo e easily. The selec ion o he equipmen is de e mined by he
es ablished equi emen s om he beginning, he equi emen s ha he
componen s hemsel es equi e and he amoun o wa e o be mo ed.
The hyd aulic es bench consis s o a hyd aulic pump, a hea e ,
elec ical esis ances, con ol and p o ec ion elemen s (manome e s,
he mome e s, il e s, compensa o s, elec o- al e, he mos a s,
esis o s and low swi ch), and sphe ical closing al es o low
adjus men and also he pipes.
The ci cui consis s o pipes in cha ge o p o iding he equi ed
p essu e o he chambe . The use is esponsible o make he pipe
connec ion. The en ance o he es bench ci cui is made by a quick
connec ion o 1".
23
To design all he sys em, he empe a u e, p essu e and low mus
be de e mined in a gene al way, aking in o accoun ha he mos
c i ical elemen is he chambe whe e he es s will be ca y ou .
4.2. Desc ip ion o he elemen s o he ins alla ion
This chap e will desc ibe he p ocess o he design o each
componen , he calcula ions de eloped, he componen s selec ed and
he solu ions ha ha e been adop ed. In he Figu e 8 one may isualize
he componen s o he ins alla ion o be designed.
Figu e 8: Tes bench design.
30
The equi emen s o he selec ion o he hyd aulic pump a e:
• Flow a e: 1-90 L/min
• Fluid empe a u e: 20 °C / 80 °C
• P essu e inside he chambe : 1-3 ba
• Ma e ial: s ainless s eel
Fo he design we chose he e ical pump, because o he inhe en
limi ed space o he s uc u e. The empe a u e and ma e ial
equi emen s a e qui e es ic i e and lea e us ew op ions in he
ma ke . The b and DAB is chosen, because i s eliabili y, based on
p e ious expe ience, he sho deli e y ime and he p ice.
The e a e wo sui able op ions o he design o he es bench
a ailable in he DAB ca alogue; KV 3/12 T and KV 3/15 T. The chosen
pump o his p ojec is KV 3/12 T because i wo ks p ope ly o he
design demands and i is he cheapes op ion. The Table 2 ep esen s
he pump ea u es.
Table 2: Hyd aulic pump ea u es.

31
4.2.3.2. Wa e ci cula ion hea e
Ci cula ion hea e s a e compac hea ing sys ems o luids and
gases, gene ally ha e mul iple elemen s moun ed on a sc ew plug o
lange i ing and placed in an insula ed essel h ough which liquids
passes. The medium is hea ed as i lows pas he hea ing elemen s.
These hea e s a e ideal o applica ions such as pu i ied and ine
gases, supe c i ical luids and liquids like de-ionized wa e o use in
semiconduc o and elec onics indus ies as well as o gene al liquid
and gas hea ing applica ions.
Elec ic hea e s wo k on he p inciple o esis i e hea ing in which
an elec ical cu en passing h ough a conduc o c ea es hea .
Acco ding o Joule’s Fi s Law, he hea p oduced by an elec ic cu en
is equal o he p oduc o he esis ance o he conduc o , he squa e o
he cu en , and he ime o which i lows.
Hea ing sys ems gene ally equi e p ecise ins umen s o each and
main ain app op ia e empe a u es and o con ol he la ge cu en load
need o c ea e hea om elec ici y. [17]
Ci cula ion hea e s a e made o a s eel o s ainless s eel essel
equipped wi h 3 nozzles (inpu -ou pu ) and wi h an imme sion hea e
32
(gene ally h eaded) equipped wi h space o add a con ol de ice
empe a u e. In ou case, a s ainless s eel essel was used in o de o
a oid changes in he composi ion o he demine alized wa e .
In his applica ion, a e de e mining he amoun o hea equi ed,
4.5 kW, and aking in o accoun he a ge empe a u e o be eached,
he needs o he ci cula ion hea e a e de ined and, conside ing also
he supplie s’ knowledge, he mos app op ia e de ice is he CETAL
RPM-C-045 (de ailed in o ma ion in he Wa e ci cula ion hea e
calcula ions chap e ). The Figu e 11 shows he hea e 3D model.
Figu e 11: Scheme o he hea e .
33
4.2.3.3. Flow secu i y
I is a con ol elemen ha is used o e i y ha he pump is pushing
wa e , o he wise i sends a signal o he equipmen and s ops i
immedia ely. Fo hese low con ol de ices, he KOBOLD b and has
been chosen o i s eliabili y and in his case he DUK-12G8H S300L.
4.2.3.4. Flowme e
I is a measu ing ins umen o he low o olume ic low o a
luid o he mass low. These de ices a e usually placed in line wi h he
pipe ha ca ies he luid. The e a e mechanical and elec ical e sions.
The la ge numbe o heo ies and models o lowme e s ha exis
con i m us ha he e is no ideal o mula o measu e low. The inal
decision mus be made based on he low a e, iscosi y, empe a u e,
chemical composi ion and p essu e o he luid we wish o measu e.
Each applica ion has a lowme e ha bes sui s you needs. In his case
we ha e decided o use he ul asonic lowme e o i s adap abili y o
he empe a u e, as well as because o he low a e and iscosi y o he
luid o be used.
KOBOLD DUK Se ies compac ul asonic lowme e s a e he
de ices chosen o ou es bench and a e used o measu ing,
moni o ing, and ba ching o low iscosi y (wa e -based) luids. These
34
compac ul asonic lowme e s wi h no mo ing pa s wo k on he
p inciple o un- ime di e ence. Ul asonic wa es in he media a e
in luenced by he a e o low. I ea u es wo senso s moun ed opposi e
one ano he in he pipeline, which unc ion simul aneously as
ansmi e and ecei e o ul asonic signals. I no low is p esen , he
un- imes o bo h signals a e iden ical. I he media is lowing, he un-
ime o he signal agains he low will be longe han he signal wi h
he low. This un- ime di e ence, de e mined by he KOBOLD DUK
Se ies compac ul asonic lowme e ’s mic op ocesso , is p opo ional
o low a e. [18]
Fo he design wo ul asonic lowme e s a e needed because o he
ac ha we wan o moni o , mainly, he inpu low o he chambe ,
and hen o con ol he es o he low.
4.2.3.5. Flow egula o al e
They a e de ices ha egula e o a ixed low, independen o he
luc ua ion o he wo king p essu es and s a low a es. They con ol
he ope a ion o pumps o egula e he pe o mance o all sys ems and
ins alla ions. Wi h hem one can con ol he p essu e and speed in each
b anch o he ins alla ion.
Fo he es bench h ee low egula o s ha e been ins alled, one
elec onic ha will be loca ed a he end o he ci cui and wo manuals,
35
one o hem will emain ixed once he sys em has been se up and
ano he will con ol he low o luid ha en e s he deionize o
main ain he same le el o conduc i i y in he wa e . The compu e
p og am will con ol he elec onic al e o decide he speed o he
luid impac ing agains he a ge s o he expe imen .
4.2.3.6. Senso s
As he idea o he design is ha i should modi y a iables such as
low, empe a u e, conduc i i y, oxygen con en and p essu e ( he low
is al eady con olled by he lowme e s), di e en senso s a e equi ed
in o de o ob ain good eadings and logging alues.
Fo he empe a u e, wo senso s a e chosen o be placed; one
be o e he inpu and he o he a e he ou pu o he hea e . The senso
be o e he inpu o he hea e will be he M12TXC-PT100-3MM-
24MM-G1/8 om OMEGA b and, because in his poin i is no needed
a lo o accu acy and his senso is jus a cheap ansmi e ha i is
possible o log he alues by he compu e . Fo he ou pu posi ion mo e
accu acy and isual logging a e needed, his poin will be he p ima y
in o ma ion abou he empe a u e, he KOBOLD TDA15H2R4 0 L3M
has been chosen.
A e a deep ma ke esea ch, conside ing all he high equi emen s
o he es bench, he conduc i i y and oxygen senso s ha e been

36
chosen in one ex e nal ansmi e , because i was he only op ion in he
ma ke ha ul illed all he equi emen s. These a e Dissol ed Oxygen
Senso HX438-01, Conduc i i y Senso 400VP-11 and In elligen Dual
Inpu Analyse 1056-03-20-35-HT om EMERSON b and.
The p essu e senso is a ansduce ha con e s p essu e in o an
analogue elec ical signal. Al hough he e a e a ious ypes o p essu e
ansduce s, one o he mos common is he s ain gauge based
ansduce .
The con e sion o p essu e in o an elec ical signal is achie ed by
he physical de o ma ion o s ain gauges which a e bonded in o he
diaph agm o he p essu e ansduce and wi ed in o a Whea s one
b idge con igu a ion. P essu e applied o he p essu e ansduce
p oduces a de lec ion o he diaph agm which in oduces s ain o he
gauges. The s ain will p oduce an elec ical esis ance change
p opo ional o he p essu e. The PXM309-007GI om OMEGA has
been chosen. Also, he e a e wo manome e s ins alled on he es bench
o gi e an easie isual con ol o he p essu e.
37
4.2.3.7. Fil e
Thei unc ion is o a oid pa icles in he ci cui s, which could
obs uc he ci cui o damage he hyd aulic pump. In his case, wo
il e s a e used, one a he end o he ci cui o collec he pa icles ha
can a i e om he e osion o he ma e ials o be es ed and ano he o
con ol he luid a e he ou le in he deionize .
The one ha is ins alled a he end o he ci cui consis s o a
s ainless s eel con aine in which he e is a ca idge o cellulose ibe
ha allows a il a ion o 50 μm. The ollowing is a special Y- il e o
demine alised wa e consis ing o an inne 0.5 mm mesh.
4.2.3.8. Piping and i ing
The design has been made based on he necessa y equi emen s in
he chambe , he minimum pipe sec ion wi h which he sys em can
ope a e was calcula ed and each pipe b anch was s udied sepa a ely in
o de o ob ain he op imal design. The size o he i ings is ob ained
by he pipe size.
38
4.2.4. Chambe
The chambe is a s ainless s eel p essu ed essel whe e he es wi h
he ma e ials will be pe o med. I will be placed on he op o he
aluminium s uc u e, be ween he wo holes because hey a e he access
o he pipes.
Two luid inle s will pe o m he je s which will allow he luid
impac on he ma e ials wall.
In he uppe pa wo co e s ha e been designed, one o which will
always emain closed by i s ixed connec ion wi h he ou le pipe and
he o he co e will be in cha ge o acili a ing access o he pa s o be
es ed.
4.3. Componen s calcula ions
In his chap e , he design decisions aken and calcula ions
pe o med in he design p ocess a e going o be desc ibed. In he Figu e
12 is possible o see all he componen s o he es bench.
39
Figu e 12: Tes bench componen s.
4.3.1. Calcula ion o he hyd aulic pump
The pump is esponsible o p o iding he necessa y p essu e o
he ci cula ion o he demine alized wa e in he closed ci cui o he
bench es . The p essu e o be supplied is a leas 4 ba as men ioned in
he Limi a ions o he Sys em The low o be d i en is he minimum
equi ed by he sys em equi emen s plus 20 % o o e size, 110 L/min.
Wi h hese da a and aking in o accoun ha he elec ical
connec ions a ailable a e 400 V and 50 Hz, conside ing he DAB
46
Thus, o he low a e o 90 L/min o be pumped, by imposing he
maximum speed he eo , he minimum diame e o he pipe is
de e mined immedia ely, which in his case co esponds o a nominal
diame e o DN25 mm o 1 in:
𝑆 = 𝑣
𝑄= 𝜋× (𝐷
2)2 (Eq.3)
Whe e:
Q: Flow
𝒗: Speed
S: Sec ion
D: Diame e
In any case, he no malized diame e should be chosen immedia ely
abo e he minimum alue. This alue is wha is known as he op imum
diame e o he pipe, because i ep esen s he lowes possible cos ,
mee ing he equi emen s as o he maximum speed o ci cula ion o
he luid h ough i .
Due o he design equi emen s o some de ices ha ha e been
p e iously selec ed, he pipes o DN40 mm o 1-1/2 in mus be chosen
in some sec ions. The Table 4 shows he connec ions o each elemen
o he ins alla ion.

47
Componen
Connexion
P essu e indica o
G 1/2 Male
P essu e ansmi e PXM309-007GI
G 1/4 Male
Tempe a u e ansmi e M12TXC-PT100-3MM-24MM-G1/8
G1/8 Male
Tempe a u e ansmi e M12TXSS-PT100-24MM-G1/8
G1/8 Male
Tempe a u e ansmi e TDA15H2R4 0 L3M
G 1/2 Male
Flow ansmi e DUK-12G8H C34PL
G 1" 1/2 Female
Flow secu i y DUK-12G8H S300L
G 1" 1/2 Female
Oxygen ansmi e
G1/8 Male
Conduc i i y
3/4" NPT Male
Pump
G 1" ¼ Female
Fil e s 5 µm – 200 µm
1" NPT Female
Hea e
G 1" Female
Expansion ank
G 1" Male
Wa e deionize
G 1/2 Male
Flow egula o au oma ic al e
G 1" 1/2 Female
Table 4: Connexion o he componen s.
Due o space limi a ions, he en i e ci cui mus be inse ed in o he
aluminium s uc u e and his means ha he e a e some changes o
di ec ion wi h hei consequen losses being will be s udied la e .
48
A his poin , each sec ion o pipeline o he ins alla ion will be
s udied. The Figu e 16 shows he inal layou o he bench es .
Figu e 16: Tes Bench design.
The i s sec ion, showed in he Figu e 17, consis s o he pump
ou pu o he hea e inle . The sec ions will always be designed as
s aigh as possible. In his sec ion, he low secu i y de ice DUK-
12G8H S300L is ins alled wi h which he low passage is con olled
o sa e y, hus a oiding a possible ailu e o he pump when i is in
ope a ion and he e is no low.
49
Due o he design es ic ions ha he sa e y de ice gi es us, we
will ha e o use a pipe wi h a diame e o 1-1/2 in and a leas 500 mm
o pipe leng h be o e and a e his o i s co ec ope a ion. Then, we
ha e ha he ou pu o he pipe is 1-1/4 in, we will use a educ ion
i ing om 1-1/2 in o 1-1/4 in. A e wa ds a lexible s ainless s eel
pipe will be used o abso b he possible ib a ions o he pump, hen
he sa e y lowme e is ins alled and inally a s ainless s eel pipe ixed
o he hea e . Fo he connec ion o he hea e , a educ ion a io o 1-
1/2 in o 1 in will be used. The empe a u e ansmi e M12TXC-
PT100-3MM-24MM-G1/8 is also ins alled in his sec ion.
Figu e 17: Fi s sec ion.
50
The second sec ion, showed in he Figu e 18, o piping would be
p o ided om he hea e ou le o he pump inle . In his sec ion one o
he low ansmi e DUK-12G8H C34PL is o be ins alled, so ha he
same es ic ions o sec ion 1 ha e been e-es ablished, he pipe has o
be 1-1/2 in and 500 mm be o e and a e he lowme e .
A he ou le o he hea e , a 1-1/2 in o 1 in educ ion i ing will be
used o connec he pipe o he de ice, hen he empe a u e ansmi e
TDA15H2R4 0 L3M will be ins alled and hen a T-connec ion will be
added, wi h an ou pu o 1 in which will be add essed in sec ion 3.
Con inuing wi h sec ion 2, he conduc i i y senso will be ins alled in
he nex co ne and hen a T-connec ion will be added, wi h an ou pu
o 1 in, o be explained in he sec ion 5.
Now he 500 mm inpu o he lowme e is conside ed, hen he
same a he ou pu and he di ec ion is aken o he pump wi h a sligh
inclina ion. In he las pa o his sec ion, he ollowing de ices will be
ins alled in his o de : low egula o au oma ic al e, 1-1/2 in T, 1-1/2
in o 1 in T, il e , 1-1/2 in o 1 in T and manome e . The connec ion
wi h he pump will be done by a lexible pipe o a oid he pump
ib a ions.
51
Figu e 18: Second sec ion.
The hi d sec ion, showed in he Figu e 19, s a s om he i s T
a e he hea e o he en ance o he chambe o he es bench. In his
case a 1-n pipeline will be used since we ha e no es ic ions due o he
equipmen ins alled and as p e iously es ima ed, he low necessa y o
each 5 m/s in he je s will be 50 L/min, so i is on he side o secu i y.
The p essu e ansmi e PXM309-007GI is ins alled in his line o log
he p essu e a he chambe inle . A 1-in al e is also ins alled o isola e
he chambe once he es is comple e.

52
Figu e 19: Thi d sec ion.
Sec ion ou , showed in he Figu e 20, consis s o he pipe
connec ing he chambe ou le o he hi d T-join o sec ion 2. In his
sec ion, a al e o isola e he chambe once he es is comple e is
ins alled, a manually low egula o al e is se up a he beginning o
he p ocess, he elec o al e con ols he low. The second low
ansmi e DUK-12G8H C34PL is ins alled o con ol he low h ough
he chambe . Following he equi emen s o he lowme e design, i
has o be conside ed a pipe o 1-1/2 in and 500 mm be o e and a e he
lowme e .
53
Figu e 20: Fo h sec ion.
The las sec ion consis s o a 1-in pipe ha connec s he second T-
connec ion o sec ion 2 wi h he ou h o i . This bypass has been made
o a oid, as a as possible, ha he oxygen senso suppo s oo much
p essu e since i s limi is 4 ba (Figu e 21).
54
Figu e 21: Fi h sec ion.
4.3.3.1. S ainless s eel pipe hickness
In his chap e , he calcula ions o he pipe hickness a e
demons a ed base on he in e nal p essu e using he ASME Code
B31.3 no ms.
The ma e ial selec ed o he pipes is de e mined by he expe imen
because he luid used is demine alized wa e and s ainless s eel is no
going o modi y he wa e cha ac e is ics.
The basic o mula o de e mining pipe wall hickness is he gene al
hoop s ess o mula o hin-wall cylinde s, which is s a ed as:
55
𝑡 = 𝑃𝑑𝑜
2(𝑆𝐸+𝑃𝑌) (Eq.4)
Whe e:
: pipe wall hickness, in.
P: in e nal p essu e o he pipe, psi.
dO: ou side diame e o pipe, in.
S: allowable s ess o pipe, psi.
E: longi udinal weld-join ac o .
Y: de a ing ac o .
Once he hickness esul s a e ob ained wi h Equa ion 4, one may
de e mine he minimum hickness conside ing he co osion and
e osion allowance. This is an ex a hickness called "co osion
allowance" and i is added o he wall hickness o compensa e he me al
expec ed o be los o e he li e o he equipmen . In his case, since
s ainless s eel and demine alized wa e a e used, he co osion is eally
low.
Compa ing he minimum hickness ob ained by he design wi h he
comme cial hickness o he pipes om he supplie s, he sa e y ac o
o 6.46 is sa e enough. The calcula ions a e pe o med in he Table 5.
62
This esul could be also app oxima ed analy ically aking in o
accoun he a ea o he inle s, 7.85·10-5 m2, and he olume ic low,
6.66·10-4 m3/s, hen:
𝑣 = 𝑉󰇗𝐴
⁄= 8.5 𝑚/𝑠. (Eq.5)
As can be seen in he Pic u e 26, whe e he eloci y dis ibu ion in
he a ge wall is shown, he maximum speed eached is 2.7 m/s, which
is lowe han he desi ed maximum alue o 5 m/s.
Figu e 26: Veloci y dis ibu ion in he a ge wall, i s i e a ion
con igu a ion.
The eloci y dis ibu ion along he wall can be also app ecia ed in
he ollowing g aph, whe e he wa e speed is displayed along a

63
ho izon al line loca ed in he a ge wall plane a he wa e inle s heigh
(shown in igu e 27). The a ge wall is delimi ed by wo lines, and i
can be seen once again ha he maximum eloci y eached by he wa e
impac ing he wall is a ound 2.7 m/s.
Figu e 27: Veloci y dis ibu ion along a ho izon al line placed in he a ge
wall. Maximum speed = 2.7 m/s.
These calcula ions a e done conside ing a wa e low o 80 L/min,
which is al eady close o he maximum alues ha will be used in
ope a ion. The e o e, he nex s ep o he analysis is o es ima e he
necessa y dis ance be ween he a ge wall and he box in o de o
ob ain he equi ed 5 m/s eloci y.
2.7 m/s
64
I is possible o ob ain he eloci y e olu ion along a ho izon al line
s a ing in each one o he wa e inle s and inishing in he a ge wall,
one igh in he co ne and he o he in he wall i sel , as shown in igu e
28.
Figu e 28: Ho izon al lines along wa e ajec o y used o ob ain he
eloci y e olu ion.
The Figu es 29 and 30 ep esen he eloci y e olu ion o he wa e
low along he wo lines. The eloci y o he wa e a Y=-0.15 m is
app oxima ely 5 m/s in bo h cases, which ep esen s a dis ance o 20
mm be ween he a ge and he box wall.
65
The e o e, he nex s ep o he analysis is o epea he calcula ions
wi h he a ge placed a a dis ance o 20 mm om he inle s, so ha he
wa e impac s he a ge wall wi h he equi ed speed o 5 m/s.
Figu e 29: Wa e low eloci y e olu ion along Y axis, om he inle o he
a ge co ne .
66
Figu e 30: Wa e low eloci y e olu ion along Y axis, om he inle o he
a ge cen e.
Final con igu a ion esul s
New CFD calcula ions a e pe o med wi h his con igu a ion, wi h
a dis ance be ween he a ge wall and he box inle s o 20 mm.
The wa e speed dis ibu ion in a XY plane coinciden wi h he
wa e inle s is shown in igu e 31. The maximum speed eached by he
wa e in he ci cui is a ound 10 m/s in his case. The eason is ha e en
i he inle a ea and he olume ic low a e he same, he p oximi y o
he a ge induces highe eloci ies o he wa e je coming om he
inle s.
67
Figu e 31: XY-plane eloci y dis ibu ion, a ge placed 20 mm a om he
box wall. 80 L/min wa e low.
Wi h his con igu a ion, he maximum eloci y eached in he a ge
wall is a ound 5 m/s as desi ed, which is shown in he Pic u e 32 and
33, whe eas p e iously he wa e eloci y dis ibu ion along he a ge
wall is displayed.

68
Figu e 32: Veloci y dis ibu ion in he a ge wall, inal con igu a ion.
Figu e 33: Veloci y dis ibu ion along a ho izon al line placed in he a ge
wall. 80 L/min. Maximum speed ~ 5 m/s.
5 m/s
69
As a i s conclusion o his calcula ions, wi h a wa e low o 80
L/min and a dis ance be ween he a ge and he box wall o 20 mm,
he equi ed 5 m/s eloci y o he wa e impac ing he a ge wall can
be eached. The eloci y o he wa e impac ing he co ne o he a ge
is sligh ly lowe han 5 m/s, howe e a highe alue could be eached
by inc easing he wa e low.
These calcula ions a e epea ed wi h a wa e low o 50 L/min and
25 L/min o ha e an idea abou he eloci ies ha would be eached in
he a ge wall o lowe wa e lows.
A 50 L/min he maximum eloci ies a e a ound 3 m/s, and a 25
L/min hey each 1.5 m/s, which is he minimum wa e speed
conside ed o he ope a ion o he es bench.
Figu e 34: Veloci y dis ibu ion along a ho izon al line placed in he a ge
wall. 50 L/min. Maximum speed ~ 3 m/s.
3
m/s
70
Figu e 35: Veloci y dis ibu ion along a ho izon al line placed in he a ge
wall. 25 L/min. Maximum speed ~ 1.5 m/s.
Conclusions
The CFD calcula ions pe o med allowed o de ine he necessa y
a ge dis ance o he a ge box wall (20 mm) in o de o ob ain he
equi ed wa e eloci ies impac ing he a ge . These eloci ies can be
ob ained by a ia ing he wa e low om 25 L/min o 80 L/min.
1.5 m/s
71
4.4. Sys em equi emen s.
The sys em o med by he hyd aulic bench es , objec o his
p ojec , p esen s he ollowing condi ions equi ed o i s co ec
ope a ion:
4.4.1. Powe supply o he sys em.
Fo he design o he powe supply o he es bench i mus be aken
in o accoun ha he powe abso bed by he main de ices is showed in
he Table 6.
Hyd aulic pump
1.5 kW
Hea e
4.5 kW
To al Powe
6 kW
Table 6: Powe supply componen s.
The e a e o he de ices ha wo k wi h elec ic cu en al hough i s
consump ion is negligible in his case. Following he ins uc ions o
ICE S anda d his consump ion is co e ed.
The sys em will be connec ed o a dis ibu ion boa d, which
acco ding o he IEC 62305 ins uc ions, mus ha e a gene al
omnipola sa e y swi ch, as well as sho -ci cui p o ec ion, o e load
78
4.8. Legal scope o he machine.
This ins alla ion is designed and manu ac u ed aking in o accoun
he ollowing s anda ds:
• EN 13480 S anda d. Me allic indus ial piping
• EN 13445: 2002 - Un i ed P essu e Vessels
• BS EN 286: 1991 Simple Un i ed P essu e Vessels
• EN ISO 12100 – Sa e y o machine y – Gene al
p inciples o design – Risk assessmen and isk educ ion
(Eu ope).
• DIRECTIVE 2014/68/EU OF THE EUROPEAN
PARLIAMENT AND OF THE COUNCIL (h p://eu -
lex.eu opa.eu/legal-
con en /EN/TXT/PDF/?u i=CELEX:32014L0068& om=ES)
Rega dless o wha is es ablished in his speci ica ion, all p o isions
on wo king condi ions, sa e y measu es, p oduc ion and manu ac u ing
p ocedu es e c, ully comply wi h he Regula ions, O dinances and
Laws in o ce.

79
80
Chap e 4
5. Conclusions
The wo k o his hesis ocuses on he design o he hyd aulic es
bench o he e osion and co osion es in o de o e alua e he
compa ibili y o a ious ma e ials in he n_TOF a ge egime.
A p esen , he a ge is unde design and a ious ma e ials a e
being in es iga ed o bo h he co e and he con ac pa wi h he
cooling wa e , in o de o subs i u e he p esen a ge which will ha e
eached i s end o li e.
The p ojec o he es bench, om he concep ual o he de ailed
design and manu ac u e he de ice, has been de eloped in
app oxima ely one yea .
The wo k has ca ied ou in collabo a ion wi h se e al g oups
ac oss CERN, in ol ed in he echnical speci ica ion, analysis, design
and manu ac u e.
The main phases o he p ojec can be summa ized in he ollowing
s eps:
81
• Analysis o he echnical speci ica ion and a
consequen ly ca e ul ma e ial choice;
• Concep ual design wi h Au odesk In en o ;
• Nume ical s udy, based on he Fini e Elemen Me hod,
o he implemen a ion o he p oblem in ANSYS;
• Selec ion o all he equipmen used;
• Discussion wi h he supplie s o he bes op ions;
• De ailed design o manu ac u e;
• P epa ing he echnical d awings o manu ac u e;
• In con ac wi h he echnical employees o he p ope
assembly.
The inal p oposal o his p ojec is a hyd aulic es bench based on
s ainless s eel any de ice in con ac wi h he luid o no modi y he
conduc i i y o his. All his moun ed on an easily mo ing aluminium
s uc u e.
The ci cui has a o al olume o 96 L, dis ibu ed in 50 L he ion
exchange , 21 L he chambe , 24 L he expansion ank, 1 L he piping
sys em. All his wi h a maximum p essu e o 4ba due o he es ic ion
o he oxygen senso .
82
A e di e en es s o he se -up, i is possible o say ha e e y hing
wo ks pe ec ly and ha , also, i is possible o ge he da a needed o
ca y ou he necessa y expe imen s success ully.
In he u u e, i could be a good idea o ins all a hea exchange o
con ol he low empe a u es, a his momen he hea e is ins alled and
i is possible o hea up he luid bu no cool down (jus spending ime
wi h he hea e u ned o ). Also, he pump gene a es hea so he luid
has a empe a u e es ablished by he de ice.
83

84
Chap e 5
6. Appendix
6.1. Ha dwa e manual.
This manual is a quick guide o he ins alla ion and use o he Tes
bench ha dwa e o he alida ion o he e osion and co osion o he
new n_TOF a ge . Fo addi ional in o ma ion/doub s he esponsible
pe son o he Tes bench a CERN mus be con ac ed.
6.1.1. Impo an no es
I is impo an o s ess ha he Tes bench is a p o o ype and is on
an ea ly s age o de elopmen .
Du ing ope a ion i does no equi e pe manen igilance o he
ope a o bu a pe iodic check is s ongly ad ised.
The Tes bench was designed o au oma ically send he epo s,
wa nings/ale s o e e-mail o he pe son in cha ge. Also, se e al
in e lock sys ems we e implemen ed in o de o p e en and ale
CERN abou Tes bench inco ec use o mal unc ions.
6.1.2. Tes bench ins alla ion and se up
The Tes bench mus be ins alled in a loca ion wi h access o no mal
ap wa e , sewe o discha ge used wa e , 380V iphasic elec ic
connec ion and E he ne connec ion o in e ne access.
85
Be o e using he Tes bench he ope a o mus pe o m se e al
ope a ions and e i ica ions. These ope a ions a e desc ibed in he nex
lis . De ailed explana ions o all he s eps a e p esen ed in he
subsec ions bellow. I any doub a ises du ing he usage o he Tes
bench, he pe son in cha ge o he Tes bench a CERN mus be
con ac ed.
1. Connec he chambe o he Tes bench.
2. Ins all he a ge pieces inside he chambe .
3. Open he al es V1, V2, V3, V4, V6, V7, VR1, VR2 and VR3
and close V5
4. Connec and/o u n on he cooling ap wa e .
5. Fill he ci cui wi h ap wa e un il 3-4 ba .
6. Connec he powe cable.
7. Tu n on he es bench.
8. Run he p og am.
6.1.3. Connec he chambe
The chambe mus be placed in posi ion on he Tes bench be o e
illing all he hyd aulic ci cui :
1. Place he chambe in he Tes bench acco ding o Figu e 39.
86
2. Sc ew he wo inne connec ions and he ou e connec ion.
Figu e 39: Tes chambe and connec ions.
6.1.4. Ins all he a ge pieces
The a ge s will be ins alled inside he chambe as decided be o e
he expe imen , as shown in Figu e 40.
87
Figu e 40: Schema ic p ocedu e o he es .
Then, he chambe mus be closed p ope ly. You should be su e ha
he O- ings a e p ope ly inse ed and sc ew all he bol s.
6.1.5. Val es
Make su e ha he al es V1, V2, V3, V4, V6, VR1, VR2 and VR3
a e open and he V5 al e is closed.
Figu e 41: Val e 1.
Figu e 42: Val e 2.
94
7. Re e ences
[1] "h p://home.web.ce n.ch/"
[2] C. Le e e, LHC: he guide.
[3] "h ps://home.ce n/abou /expe imen s/alice"
[4] "h ps://home.ce n/abou /expe imen s/a las"
[5] "h ps://home.ce n/abou /expe imen s/cms"
[6] "h ps://home.ce n/abou /expe imen s/lhcb"
[7] “h ps://na62.web.ce n.ch/na62/”
[8] “h p://wwwcompass.ce n.ch/”
[9] “h ps://espace.ce n.ch/hi adma -sps/Wiki%20Pages/Home.aspx”
[10] h ps://home.ce n/abou /accele a o s/an ip o on-decele a o
[11] h ps://n o -exp.web.ce n.ch/n o -exp/
[12] T. Thuillie , “Elec on Cyclo on Resonance Sou ce De elopmen
Lpsc”, G enoble Cedex, 38026, F ance
[13] h ps://home.ce n/abou /accele a o s/low-ene gy-ion- ing
[14] S. Sgobba, L. Ma ques An unes Fe ei a, “Ma e ial Selec ion and
Co osion S udies o a High Ene gy Physics Expe imen : The
Neu on Time-o -Fligh Facili y a CERN,” NACE Con e ence
Pape s: NACE In e na ional, pp. 1-15, 1 Ma ch 2011.

95
[15] “Repo o he Ex e nal Re iew Panel on he Design o he
Upg aded Lead Ta ge o he N-TOF acili y 14.2.2008,” Gene a,
2008.
[16] “h p://www.en ica esys ems.com/demine aliza ion-wa e -
ea men -plan s-pune.h ml”
[17] “h ps://www.elec ical4u.com/joules-law/”
[18] “h p://www.omega.com/ echnical-lea ning/ low-and-le el-
measu emen .h ml”