RHIC 56 MHz HOM Damper Fundamental Damper Fundamental Power Coupler Pick-ups S. Bellavia January 19 th, 2010

Higher Order Mode (HOM) Damper

HOM Thermal-Electric Performance Solid Model Assembly in Pro-E, Finite Element Model built in ANSYS 13.0

HOM Thermal-Electric Performance (cont.) Boundary Conditions: Surface RF Currents Dielectric (Joule) Heating of Sapphire Heat Leak from Ambient

HOM Thermal-Electric Performance (cont.)

Dielectric Heating of HOM Sapphire Break

Dielectric Heating of Sapphire Break (cont.)

HOM Thermal Performance (cont.) Internal Components

HOM Thermal Performance (cont.) Assembly with Heat-Stationed Cable 50K Heat Station From Heat Shield

HOM Cable Joule Heating vs. Thermal Conductivity OFHC Copper vs. 304 Stainless Steel

Cable Joule Heating Due to RF Current

Coaxial Cable Choices

Model for Calculations

FEA Model(s) SS Conductors, Heat Station with Effect of Contact Resistance These regions made 100X more thermally resistive than PTFE to simulate contact resistance

FEA Results 50K to Outer Shield For 250 SS Cable - FEA performed on many types and sizes

FEA Results Summary

HOM Cable-Connector Assembly

HOM Cable-Connector (cont.)

HOM Hex Seal 10 x 5/16-24 SS Bolts, Torqued to in-lbs results in lbf (80% of yield) Bolt Circle =  x = inches Linear Sealing Load = 10 x / = 1557 lb f /inch

HOM Final Design / Fabrication / Procurement Full set of drawings being checked SOW and Specification to be released this week, followed by Purchase order / RFQ Parallel Effort to build “in-house” (BNL will manage piece-part fabrication) - Quotation for brazing Sapphire break received - Quotation for Custom Sapphire tubes received - Awaiting Quotation for Stock Size Sapphire Tube

HOM Design / Fabrication

HOM Design / Fabrication (cont.)

HOM Filter Assembly

HOM Procurement

HOM Procurement (cont.)

Sapphire for Filter Components

HOM Schedule Jan 21 – Release of Drawings (numerical rev’s for quotation) Jan 21 – Signature / release of SOW and Specifications Jan 21 – Purchase order for building entire HOM assembly –Phase 1 – Prototype / First Article (20 +2 weeks – June ‘11) –Phase 2 – 6 follow-on HOM’s (36 +2 weeks – Oct ‘11) Feb 7 – P.O. for brazing of Sapphire-Niobium break supply vendor with sapphire tubes and machined niobium parts (12 weeks – April ‘11 ) purchase and receive brazed assemblies (16 weeks – May ‘11) arrange machining of niobium components (12 weeks – April ’11) send out machined parts and brazed assemblies for pre-cleaning, welding and final cleaning, (most likely to AES). (32 weeks – Sep ’11) Receive Final HOM’s (36 weeks – Oct ’11) Feb 21 – P.O. for Brazing of Filter Assembly

HOM Costs Sapphire tubes $ 15K Niobium (raw material) $ 10K Niobium machining$ 50K Brazed Break$ 20K Brazed Filter Assy$ 10K Welded Assemblies$200K Cleaned Assemblies$ 50K Total$355K First Article$150K 6 Final HOM’s $425K Total$575K Done “In-house” by BNLDone by Outside Vendor

Fundamental Damper

Fundamental Damper (cont.)

Fundamental Damper Motion System

Fundamental Damper Motion System Costs Motion System

Feb ‘11 – Thermal / Structural Analysis May ’11 – Detailed Design / Drawings Fundamental Damper Schedule / Costs Total Cost = $125K = 400 shop hours

Fundamental Power Coupler FPC

Fundamental Power Coupler (cont.)

Fundamental Power Coupler Connector 7/16 DINType N

Fundamental Power Coupler Weldable, UHV Compatible Connector / Window

Total Cost = $95,600 Fundamental Power Coupler Schedule / Cost Mar ‘11 – Thermal / Structural Analysis June ’11 – Detailed Design / Drawings

Total Cost = $2,100 Pick-Ups Schedule / Cost