LWU Design Overview Paul Aden

BTM WP Scope To design, procurement and assemble; –2 Prototypes –3 Test Chambers –75 Linac Warm Units –52 Beam pipe modules –2 Differential pumping systems –4 mobile installation cleanrooms Total Cost £10.5m Approximately 30 FTEs

BTM WP Scope To design, procurement and assemble; –2 Prototypes –3 Test Chambers –75 Linac Warm Units –52 Beam pipe modules –2 Differential pumping systems –4 mobile installation cleanrooms Total Cost £10.5m Approximately 30 FTEs

Overview End of Hall before Target Source Warm Linac Spoke Linac Medium Beta High Beta Upgrade Region Dogleg / Dumpline 500m

Overview End of Hall before Target Source Warm Linac Spoke Linac Medium Beta High Beta Upgrade Region Dogleg / Dumpline 500m

Overview LWUs LWUs & Beam Pipe EVERYTHING Just the red bits LWUs LWUs & Beam Pipe Differential Pumping System Beam Pipe

Covered in this CDR LWUs Beam Pipes HEDP LEDP Not including, – Dump – Dogleg – A2T area

Overview LWUs LWUs & Beam Pipe CDR 2 CDR 1 LWUs LWUs & Beam Pipe Differential Pumping System Beam Pipe

3 rd Party Input Final magnet designs –Quads 19 th February 16 –Correctors 22 nd March 16 Final BPM designs supplied –26 th January 16 BCM Design Decision made –16 th February 16 Final Specifications agreed –24 th March 16 Most recent delivery schedule –3st March 16

Value Engineering Reduction of complicated parts Reduction of similar duplicated components Combining multiple chamber types to allow less chamber designs Standardising components wherever possible

Module Overview Aluminium slotted girder BPM on entrance or exit Semi–kinematic girder adjustment Pedestal s Quadrupole Magnets Fiducials, laser tracker alignment -50µm Accuracy Built in lifting points ‘Particle Free’ Chamber - ISO 5 or better

Design Sheet Chess Document – ESS

Design Sheet

Girder Design

Girder

Adjustment Fixed Length for all LWUs Slotted Girder allows for ‘unlimited’ ‘coarse’ on z Adjustment.

Space is tight - Elliptical 10mm 8mm 12mm

Adjustment Fixed Length for all LWUs Slotted Girder allows for ‘unlimited’ ‘coarse’ on z Adjustment. Mounting adjustment allows for ±15mm fine adjustment Kinematic mounts allow for vertical adjustment ±25mm on a fine M24 nut. ±50mm Girder Adjustment At the request of ESS Survey and alignment group horizontal girder adjustment is above vertical adjustment

Adjustment Slider Plate, Girder directly mounted to these steel plates

Semi Kinematic Adjustment Lifting Points Cone Adjusting Screw Vee Adjusting Screw Flat Adjusting Screw Horizontal Movement Clamps Girder Y,Z Plate

Y & Z Adjustment Adjusting Screws

Vertical Adjustment Vertical Adjustment on Semi-Kinematic mounts ± 50mm

Simplified Model

General Details ItemMass Girder110Kg Chamber, Max80Kg Girder, Chamber & Mounts215Kg Pedestal Assembly170Kg Complete LWU (assumes Q7 550Kg) 1700kg

Mesh Coarse Mesh Min size 3.8mm Max size 19mm

Setup

Static Structural

Stress

Static Results Girder Deflection –0.01mm Maximum Magnet Deflection –0.07mm Maximum local stress on mounting points –20MPa

Pedestal Positions Due to low deflection and requirement for Egress airy points have not been used. Pedestals have been placed directly under the main load, in the case the magnets.

Semi Kinematic Mounts ‘V’ ConeFlat M42 Tie Downs

Semi Kinematic Mounts ‘V’ Aligned with Cone ‘V’ Would need altering to change pedestal spacing

Egress 700mm x 880mm

Modal

450 mm 710mm Steel Box Section- hollow to allow for damping sand if needed Mount for central support and wheels Pedestals

Girder Lifting Mount Setup:

Girder Lifting Mount Lifting Pin inserted through the hole Pin contact area in lifting mount 30mm Diameter Steel Lifting Pin 2000N per mount

Girder Lifting Mount

Lifting Point Positions Adjustable to CoG

Adjustable Lifting Frame

Wheels

Installation Supports Fixes pedestals together to easy removal and replacement of girder whilst pedestals are not fixed to the floor

Design Based on many years experience developing accelerator modules Slotted girders allows for versatility Optimised for ground vibrations Fiducial mounts for survey and alignment –±100µm alignment to local girder network Girder adjustment ± 50mm Magnet/Chamber adjustment ± 25mm, ± 5mm due to other items Large space between pedestals for access/egress

Optimised for space Space for diagnostics

Thermal Knock on effects; –Re design of LWUs including heat transfer Approximately 6-9 months Approximate additional cost XXX Resources are now limited to do this work –Re Design of LWUs excluding heat transfer (i.e. pipe diameter changes) Approximately 2 months Approximate additional cost XXX

Survey & Alignment 4 x 6H7 Fiducial Mounting points at each corner of the girder. 4 x 6H7 Fiducial mounting points at each corner of the pedestal.

Adjustment Individual item adjustment on three point kinematic mounts

Adjuster & Supports

Magnet Adjusters Q5 Magnet spacer

Chamber Adjusters

Scintillator Mounts

Chambers

All Welded

Chamber Designs

Bellows Life cycle Specs etc.

Bellows Travel Required ±40mm Securing bolts do not pass flanges Not designed for Vibration

Custom Flange Clamping hole to prevent bellows moving through rotatable flange when the retracting the bellows

Bolt Extraction Bolt Extraction Direction Slotted CF Flange

VAT Seal Wire scanner diagnostics flange Square flange is the standard VAT flange used on series 35 gate valves We did investigate square CF flanges but there in frequent use and complicated design made it difficult to justify

VAT Seal

Material Selection Tube & main chamber body; 316L Tube to be weld less. Tubes 3.2m, Magnetic permeability less than after vacuum firing Flanges 316LN Bellows 316L

Pipe Diameters Spoke Section –ID mm –OD 63.5 mm –Seamless 316L Elliptical –ID 100 mm –OD 108 mm

Chamber Stress

Chamber Deflection

Vacuum Analysis Checked worse case scenario for LWUS

Summary Looked at many conceptual designs

Summary Looked at many conceptual designs Made modifications based upon prototype build

Design Based on many years experience developing accelerator modules Slotted girders allows for versatility Optimised modal response Fiducial mounts for survey and alignment –±50µm alignment to local girder network Girder adjustment ± 25mm Magnet/Chamber adjustment ± 25mm, ± 5mm due to other items Large space between pedestals for access/egress

BPM Test Rig

BPM Cassette XZ Stage Wire Clamp (Fixed) Wire Clamp (Spring Tensioned) Home Switches Stages – Dover Motion XYR 100 x 100 Travel

Access for cable connection Clamps Face Location Survey Targets 5 BPM’s loaded and surveyed relative to the fixture. BPM Cassette

Home switches (Baumer MyCom E) actuated by the wire location body. Relationship between homed position and BPM physical centre determined by CMM optical survey then offsets calculated. Home Switch

Transport Method 78 Open plywood box with corner supports Plywood bottom with timber base for reinforcement Anti-Vibration Springs between module and box base Lifting Points required on 3. Plywood lid Module Airide trailer for low road vibration transmission Springs between girder and box base for shock loads Quantity will depend on girder length & weight Spring dampers

Design tasks still to be carried out Finalise vessel drawings for: –Spoke X –Elliptical X Complete modal analysis for inclusion of sand Complete drawing package for BPM test Rig Complete specification for mobile cleanroom design Crate and transportation detailed design work

Design Progress

Thank You

Main Item List Main Chamber Bellows Assembly BPM Integration Particulate cleaning System Support Girder Pedestal frame Kinematic mounting for girder - type 1 Kinematic mounting for girder - type 2 Kinematic lock nut Washer Bolts Nuts Floor Plate Beam Adjustment Kinematic Adjuster - type 1 Kinematic Adjuster - type 2 M24 Fine Pitch Notch Nut Beam Support Plate Adjusting Plate Adjuster Block Clamp Washer Mount Cone Mount Vee Mount Flat Clamping Nuts Clamping Washers Vacuum measurement and Control Penning Gauge / IMG Thermo Couple / Pirani Gauge Penning Gauge controller / IMG Penning Gauge Cable TC / Pirani Gauge control TC / Pirani Gauge Cable Pumping Systems Ion Pump - 75l/s + Controller Pump Controller Pump Cables Valves VAT S54 Right Angled valves DN40 DN10 Venting valve - debate Soft Start Pumping/Vent Flanges, Connections & fittings Various Blanks Various Gaskets Misc Electrical Termination Mounts Electrical Tray Work Fasteners nuts & bolts

Additional Item List Misc Cleaning a consumables Vacuum testing consumables Shipping and Transport Costs Shipping Crates Shipping Packing/Mounts Shock Watch Transportation Crate Identification Test Equipment Vacuum Pumps Vacuum Gauges Test racks Pump Controllers Gauge Controllers

Diagnostics Chamber Steering Magnets Focusing Magnets LWUs