NUMI Transmission Line (TL) Review WBS Power Supply System Transmission Line (TL) Review Nancy Grossman FNAL April 23, 2003

NUMI Internal NuMI Review April 23, 2003 Transmission Line Review Page 2 Outline  Overview & Specifications (N. Grossman, 10’)  Scope of review  General Layout & Overall Specifications  Schedule, Concerns  Response to Recommendations (2/26/02 review) (N. Grossman, 10’)  Testing at MI8 (J. Hylen, 15’)  Remote clamp & joint testing so far  Future plans  Ionization Calculations (J. Hylen, 10’)  Cooling Calculations (A. Stefanik, 10’)  TL through Block & Beyond Design/Status (B. Boettinger, 45’)  Design (clamps, connection, supports)  Heating/cooling (expansion) & Vibration Issues  Service Considerations

NUMI Internal NuMI Review April 23, 2003 Transmission Line Review Page 3 Scope and Conceptual Layout: Target Hall Transmission Material: Aluminum, Dimensions: 12 inches wide by 3/8 inch thick Width: Stripline nominal width is 12 inches, reduce to 8” from below clamp to horns. Gap: Stripline nominal spacing between bars is 3/8 inch, can increase in flex region. HORN 1 JOINT HORN 2 JOINT REMOTE CLAMP ROCK WALL BETWEEN PS ROOM AND TARGET HALL- 23’ REMOVABLE Z-BAR REMOVABLE 28’ SECTION

NUMI Internal NuMI Review April 23, 2003 Transmission Line Review Page 4 Scope and Conceptual Layout: Target Hall Transmission

NUMI Internal NuMI Review April 23, 2003 Transmission Line Review Page 5 Scope/Charge to Group Scope Includes:  Transmission Line design from joint/remote clamp to connection at capacitor bank  Electrical Isolation Considerations  Heating/cooling (thermal expansion)  Vibration  Stands & support structures to hold transmission line in place  Wedge clamps in the transmission line block  Support stands in the target hall  Three point support structure in 24” round penetration from hall to PS room  Service Considerations  Removing the section through the wall  Horn replacement  Cover to protect transmission line – to be designed, simple slanted sheet metal Charge:  Look at overall design.  Consider QA, longevity, ESH issues.  Comment back to within a

NUMI Internal NuMI Review April 23, 2003 Transmission Line Review Page 6 MI-8 Fingers, Remote Clamp Remote clamp plugged MI-8 Horn 1 joint/electrical MI-8 Routine pulsing of prototype horn 1, production horn 1 joint, remote clamp underway: ~370,000 pulses to date. Goal is 1 million pulses, 1/2 offset/flexed

NUMI Internal NuMI Review April 23, 2003 Transmission Line Review Page 7 Joints and Remote Clamp Horn 2 joint in machine shop (now done) Horn 1 joint, remote clamp at MI-8

NUMI Internal NuMI Review April 23, 2003 Transmission Line Review Page 8 Overall Specifications/Concerns 1. Lifetime:  Part of stripline connected to horn will be replaced each time a horn is replaced, ~>1 year.  Part of stripline within stripline block (includes clamp) does not have to be replaced every time a horn is replaced, but we will most likely have a spare just in case.  Lifetime of NuMI ~ 10 years 2.Radiation Environment such that ceramics must be used near the beam, but not necessary above the module/T-blocks.  Ceramics spacers from horn to top of module/block  G-10 spacers used beyond that as insulators 3.Vibration, keep to a minimum everywhere.  Biggest horn vibration is from stripline (MI8 measurements)  Not near horn natural frequencies (200 Hz), damping times short wrt rep-rate  Clamp every 12” in target hall  Pulsed for about 9.5 millions pulses at MI-8 (non-joint portion of transmission line) with no problems – clamping every 12”  More on recent vibration measurements from Jim.

NUMI Internal NuMI Review April 23, 2003 Transmission Line Review Page 9 Overall Specifications/Concerns 4. Cooling  Target chase cooled by ~24,000 cfm flowing in the beam direction in the horn region and back in the opposite direction between the top of the T- blocks and the concrete cap.  Beam heating: ~183 KW/m 3 (transmission line near the beam)  TL Electrical heating: ~27 KW/m 3 (flex joint number)  Assume air cooling from target chase is sufficient (A. Stefanik talk)  Want air flow through TL shield block from top of module to horn (this air flow cools stripline)  Air dam is needed at the H-block cover between the module and the stripline along the target hall wall (intended to contain air-borne radiation). 5. Service Considerations:  Must not block survey holes in T-blocks just off module ends, need direct vertical line of sight.  Two removable sections to allow removal of section through the wall (28’).  Removable “z-bar”s at top of module/block. Allows replacement of horns.

NUMI Internal NuMI Review April 23, 2003 Transmission Line Review Page 10 Transmission Line: Through the Block

NUMI Internal NuMI Review April 23, 2003 Transmission Line Review Page 11 Transmission Line: Through the Block ( figure slightly out of date )

NUMI Internal NuMI Review April 23, 2003 Transmission Line Review Page 12 Transmission Line: Through the Block

NUMI Internal NuMI Review April 23, 2003 Transmission Line Review Page 13 Transmission Line: Beyond the Shielding

NUMI Internal NuMI Review April 23, 2003 Transmission Line Review Page 14 Transmission Line: Beyond the Shielding

NUMI Internal NuMI Review April 23, 2003 Transmission Line Review Page 15 Transmission Line: Beyond the Shielding

NUMI Internal NuMI Review April 23, 2003 Transmission Line Review Page 16 Transmission Line: Through the Rock Wall

NUMI Internal NuMI Review April 23, 2003 Transmission Line Review Page 17 Transmission Line: Through the Rock Wall

NUMI Internal NuMI Review April 23, 2003 Transmission Line Review Page 18 Response to Recommendations: Horn PS/TL Review (August 2001) Consider using a dynamic type fastener (e.g., spiralock nut) in the clamp joints and stripline support brackets.  This is being done, except in the block region where it is tack-welded to the fasteners. Consider measuring bolt preload in critical connections by measuring bolt stretch as opposed to bolt torque.  Not sure how to implement this – ideas? Consider longitudinal damping along the TL section along the Target Hall wall to damp out possible undamped vibrations from electrical pulsing.  Using polyeruthane isolators and swinging end-links (see Bill’s talk). Worry about scratching the silver-plating off the TL “fingers” when clamping/unclamping.  Have seen no damage in the silver-plating on the TL fingers out at MI-8 and they have been connected and disconnected a few times. (more from Jim)

NUMI Internal NuMI Review April 23, 2003 Transmission Line Review Page 19 Response to Recommendations: TL, Remote Clamp, TL Block Review (Feb. 2002) Flex Joint Comments (joint with slits)  No longer using a joint with slits. ANSYS shows we can get sufficient flexibility with the non-slitted design. Single strip force tests agree with the ANSYS analysis. Testing at MI-8 of the horn1 joint is going well. More from Jim – not specifically part of this review. Suggest quantitative measurements be made at MI-8 (deflection at specific points, resonant frequencies, etc.) to compare to ANSYS calculations (and any other calculations) and thus support longevity estimates.  We are making some quantitative measurements at MI-8 and will compare measurements with predictions– Jim will talk about this. Concerns abut a tight testing schedule at MI-8 which might be hard to meet if problems are encountered.  Agree. We have encountered problems, testing is tight, and we hope to make it (more from Jim). Can delay installation of horn PS & continue testing longer. Concerns with human resources – lack of.  This is a constant battle we continue to fight. Suggest pre-assemble entire setup (power supply to horns) at MI-8.  We will do this to the extent that we can.

NUMI Internal NuMI Review April 23, 2003 Transmission Line Review Page 20 Schedule & Concerns Schedule:  MI-8 testing until Horn PS removed for installation.  Test pulsing of horn 1 and horn 2 on test stand.

NUMI Internal NuMI Review April 23, 2003 Transmission Line Review Page 21 Schedule & Concerns Specific Concerns: Making sure all bolts on the TL clamps are tighten (and remain tightened)  Checkout checklist item  Periodic checks in Target Hall? QA that clamps are put together correctly  If doesn’t look like it is going together well, stop and ask expert.  Alignment rods at removable sections General Concerns: Resources (manpower)  Engineering/drafting to get the design done and parts ordered/made  Technicians to get it assembled and installed Fitting it all in with the target hall shield block installation & Module installation  Concerns about damaging the TL parts  Final connections of the TL to the horns/PS are near the critical path The transmission line (and joint) have always been underestimated in their complexity (cost, time to make, problems encountered in installation/testing).