1. LWU Design Overview Paul Aden

2. 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 2016-2019

3. 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 2016-2019

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

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

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

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

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

9. 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

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

11. 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

12. Design Sheet Chess Document – ESS-0044812

13. Design Sheet

14. Girder Design

15. Girder

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

17. Space is tight - Elliptical 10mm 8mm 12mm

18. 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

19. Adjustment Slider Plate, Girder directly mounted to these steel plates

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

21. Y & Z Adjustment Adjusting Screws

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

23. Simplified Model

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

25. Mesh Coarse Mesh Min size 3.8mm Max size 19mm

26. Setup

27. Static Structural

28. Stress

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

31. 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.

32. Semi Kinematic Mounts ‘V’ ConeFlat M42 Tie Downs

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

34. Egress 700mm x 880mm

35. Modal

36. 450 mm 710mm Steel Box Section- hollow to allow for damping sand if needed Mount for central support and wheels Pedestals

37. Girder Lifting Mount Setup:

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

39. Girder Lifting Mount

41. Lifting Point Positions Adjustable to CoG

42. Adjustable Lifting Frame

43. Wheels

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

45. 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

46. Optimised for space Space for diagnostics

47. 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

48. 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.

49. Adjustment Individual item adjustment on three point kinematic mounts

50. Adjuster & Supports

51. Magnet Adjusters Q5 Magnet spacer

52. Chamber Adjusters

54. Scintillator Mounts

56. Chambers

57. All Welded

58. Chamber Designs

59. Bellows Life cycle Specs etc.

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

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

62. Bolt Extraction Bolt Extraction Direction Slotted CF Flange

63. 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

64. VAT Seal

65. Material Selection Tube & main chamber body; 316L Tube to be weld less. Tubes 3.2m, Magnetic permeability less than 1.005 after vacuum firing Flanges 316LN Bellows 316L

66. Pipe Diameters Spoke Section –ID 57.14 mm –OD 63.5 mm –Seamless 316L Elliptical –ID 100 mm –OD 108 mm

67. Chamber Stress

68. Chamber Deflection

69. Vacuum Analysis Checked worse case scenario for LWUS

70. Summary Looked at many conceptual designs

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

72. 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

73. BPM Test Rig

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

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

77. 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

78. Transport Method 78 Open plywood box with corner supports Plywood bottom with timber base for reinforcement Anti-Vibration Springs between module and box base 1 2 3 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

79. 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

80. Design Progress

81. Thank You

82. 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

83. 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

84. Diagnostics Chamber Steering Magnets Focusing Magnets LWUs