1. EDM engineering review Oak Ridge, TN 12-15-2002, Infrastructure sub-system,
WBS-1.8
Walter Sondheim, LANL

2. WBS 1.8 sub-headings:
1.8.1 Platforms
1.8.2 Electrical Plant inside FNPB building
1.8.3 Plumbing Plant inside FNPB building
1.8.5 Counting House inside FNPB building
1.8.6 Experiment Mechanical Supports

3. 1.8.1 Mechanical Platforms:
Current projection;
2 – 3.ft height walking platforms to go along the side of the experiment’s shield package to assist with the assembly of the upper and lower halves of the mu-metal shield.
1 – 12.ft height main working platform that covers the entire lower shield package, cryostat, and magnet package – allows for work on the upper cryostat top plate as well as polarized Helium beam source.
1 – 14.5 ft height platform to support a shield room for Squid and conventional electronics.
1 – 14.5 ft height platform to support the 8X20X9 ft tall counting house
1 – 6 to 12 ft adjustable height platform to assemble the upper cryostat, with separate access to top plate for technicians

4. 1.8.1 Mechanical Platforms:
Projection continued;
All platforms will be designed using the criteria specified in the DOE order 10 CFR 851 – worker safety, as well OSHA regulation for construction scaffolding. This document sets appropriate safety factors for platforms based on assume loads of equipment and personnel.
The design for all platforms for personnel, will include safety railing as well as toe boards to prevent possible damage to equipment and personnel.

5. 1.8.1 Mechanical Platforms:
36” W X 192” L X 39” H, all Aluminum construction, one on either side of the lower cryostat/shield package for assembly of mu-metal magnetic shielding.

6. 1.8.1 Mechanical Platforms:

7. 1.8.1 Mechanical Platforms:
Main Platform; allows access to area above main cryostat – access to upper cryostat “top hat” and polarized Helium source. Primary location for cables, vacuum and cryogens into experimental volume.
Nominal platform size – 144” W X 244” L X 142” H, excluding the step out where the Atomic Beam Source is located. Access is via a “ships ladder”, cost for ladder - $2, Costs for 48” X 144” X .25” Aluminum diamond plate $735.00

8. 1.8.1 Mechanical Platform;

9. Main platform FEA analysis, Eric Olivas, LANL;
Used as an elevated work platform.
Must support a minimum uniformly distributed live loads and minimum concentrated live load of:
125 psi
2000 lbs
As required by IBC 2006 Table
Used to support the nEDM cryostat during Mu-metal assembly
nEDM Cryostat assembly weight is ~ 20,000 lbs.
Driving design requirement is the ~ lbs cryostat assembly weight.

10. Boundary Condition: Loading Scenario 1
Boundary Conditions:
Fixed restraints on the bottom columns (see figure).
Load distributions (see figure).
Material was assumed to be linear elastic.
Aluminum 6061-T6
Yield stress 40 ksi
Element Type;
Beam Elements
2 node linear beam
Notes:
Beam element have 6 DOF at each node.
Structure will behave like a welded or bonded structure.
High stress point will develop due to “fixed” end conditions (see note 1).
Bolted joints were not analyzed during this study.
Bending stress dominates stress results.
Bending and combined stresses (bending + direct) are well below the yield stress of 6061-T6.

11. FEM

12. Total Deformation

13. Maximum Bending Stress

14. Boundary Condition: Loading Scenario 2
Boundary Conditions:
Fixed restraints on the bottom columns (see figure).
Load distributions (see figure).
Material was assumed to be linear elastic.
Aluminum 6061-T6
Yield stress 40 ksi
Element Type;
Beam Elements
2 node linear beam
Notes:
Bolted joints were not analyzed during this study.
Bending stress dominates stress results.
Bending and combined stresses (bending + direct) are well below the yield stress of 6061-T6.

15. Total Deformation

16. Maximum Bending Stress

17. Summary from analysis;
Analysis consisted of FEA modeling of the nEDM Outrigger Support assembly. The Al 6061-T6 material was assumed to be linear elastic and at room temperature. As it was shown in the analysis, the stress results were all well below specified materials yield strength.
Future work consisting of:
Higher order stress analysis.
Include bolted joints and frictionless contact.
Analyze the outrigger support per IBC 2006.
Buckling and Modal analysis.

18. View of EDM on FNPB floor:
Shield Room
Counting House
Access to target hall mezzanine
Main Platform

19. Working on lower shield package:
Upper platform is not fully assembled to put the two halves of the lower shield package together. Aluminum diamond plate is removed as well as some of the horizontal I-beams. Additional platform may be needed to make-up lower Big-T shield.

20. 1.8.1 Mechanical Platforms;
RF shield room with 6 electronic racks, located adjacent to counting house at same level, 14.5 ft above FNPB floor – access through the counting house.

21. 1.8.1 Mechanical Platforms;
Dimensions for RF shield room stand, load analysis still needed

22. 1.8.1 Mechanical Platforms;
Counting house support stand will be a part of counting house procurement package with vendor, desired design load limit per square foot will be provided.

23. 1.8.1 Mechanical Platform;
The upper cryostat will be assembled separately from the main cryostat – then inserted and attached from the downstream end.
This assembly is large (see next slide) and weighs 2,500 pounds.
An adjustable height stand will allow this assembly to be raised from 6 to 12 feet off the floor.
Access to the side and top is required for assembly.

24. 1.8.1 Mechanical Platforms;
Total volume 6 X 7.5 feet, both 4K and 50K need to be brought up from bottom, DR inserted through top plate.

25. 1.8.2 Electrical Service:
Power requirements for EDM experiment 3 phase, 250kWatts.
FNPB building is designed with three power sources available from the SNS target hall;
175A, kVA, 480 – 208/120V
50A, 30.0 kVA, 480 – 208/120V clean power
225A, 480/277V
EDM engineering team recommends using type K-13 transformers, low noise and heating.
FNPB – EDM electrical layout will be specified to meet the NFPA-70 National Electrical Code guidelines.
Batteries will be use as a power source for squid detectors, they will need to be recharged periodically.

26. 1.8.2 Electrical Service;
The current lists of major electrical equipment projected to be a part of the EDM experiment, inside the FNPB building at the SNS;
Dilution refrigerator system:
Helium 3 pump system; power water cooling air cooling
Edwards EH 4200 (2X) 22. kW 2.2 gal/min 2.2 kW
Edwards EH 1200 (2X) 6.0 kW 1.1 gal/min .6 kW
Edwards GX100L (2X) 2.0 kW 2.0 l/min .2 kW
Helium 4 pump system;
Edwards EH kW 1.1 gal/min 1.1kW
Edwards EH kW kW
Auxiliary power for the DR systems, including 2 gas carts – 4. kW

27. 1.8.2 Electrical Service;
Linde L70 helium liquefier system*; purifier option, oil separator
CSD 122 Kaeser compressor
power cooling air cooling *45. psig delta between
75. kW/ea gpm kW/ea supply and 75. F
(delta T =15 degrees C)
Liquefier control unit
power cooling air cooling
5. kW LN2 – 45.l/hr .5kW
Auxiliary pump
5. kW TBD .5 kW
Helium 3 polarized Source: power cooling air cooling
Janus RDK 415D cold head 8.5 kW l/min .8 kW
Varian V2000 turbo pump 3. kW
Varian V1000 turbo pump 2. kW
Edwards XDS35 Scroll (2X) 1.5 kW none kW
*based on estimate supplied by Quantum.

28. 1.8.2 Electrical Service; EDM Beam-line: power cooling air-cooling
Edwards XDS10 scroll (2X) kW none kW
CTI Cryotorr (2X) kW none kW
Miscellaneous:
Leak Detector kW kW
High Voltage Power supply kW kW
Edwards IH 600 pump system 6.2 kW l/min kW
Edwards XDS 10 Scroll (2X) kW kW
Varian V1000 Turbo kW kW
Edwards XDS35 Scroll kW kW
TOTALS: kW kW
Electrical Service installation will be supervised by infrastructure engineer with SNS engineering.

29. Shield room located on floor FNPB building:
RF shield room 8X16X10 ft high – model # USC RA Mayes. Six open electronic racks, 24” wide X 45U X 30” deep, mfg Electrorack.
Battery packs will be used to power squid detectors and electronics. The batteries will be located in the upper cryostat top hat. Optical fibers will run from top hat tot shield room.

30. 1.8.3 Plumbing Plant;
FNPB building base requirement is 250 kW of cooling capability
Pipe routing on the FNPB floor, will be set by final layout of experimental apparatus.
Cooling supply and returns, will be available on the wall to allow for testing of sub-assemblies that may require it.
Additional line;
Dry air – supplied from SNS target hall
Liquid nitrogen supplied from external dewar to Linde L70, dry nitrogen gas supplied from evaporator on dewar
Cooling an heating lines from FNPB supply for heat exchanger on counting house
Secondary vent for nitrogen return from 4K shield to outside
Emergency vent for helium from main cryostat to outside*
*FNPB building has emergency ventilation fan on wall above shield room

31. 1.8.3 Plumbing; EDM experimental equipment water cooling requirement;
Dilution refrigerator system –
Helium 3 pump system -
Edwards EH 4200 (2X) gpm
Edwards EH 1200 (2X) gpm
Edwards GX 100L (2X) gpm
Helium 4 pump system –
Edwards EH gpm
Linde L70 cryogenic system
Compressor gpm
Auxiliary pump gpm
Miscellaneous
Edward IH 600 pump system gpm
Installation of plumbing will be supervised by infrastructure engineer along with SNS engineering

32. 1.8.5 Counting House;
Free standing mezzanine used to support the shown hutch. Footprint for stand; 20.ft long X 8.ft wide X 15.88ft off the floor. The hutch itself has 9.ft ceiling height.
Storage Solutions Inc. in Knoxville, Tennessee has supplied me with an initial cost estimate of $26, This costs includes stamped drawings and calculation with a peer review. This cost estimate includes the fabrication of the support stand to locate the counting house 14.5 feet off the floor.
A connecting fixed platform between the counting house and the stairs leading to the target hall mezzanine is not included.
The counting house will have lighting, heat and air cooling, telephone, clean 110V power outlets, computer communication links.

33. Experiment on floor in FNPB building;
Interior space of FNPB building with experimental model and beamline. Building volume;
45.ft W X 60.ft L X 39.5ft H.
Stairs to target hall
Counting House

34. 1.8.6 Mechanical fixtures; Removal of central volume fixture;
This device may become much simpler from the original cantilevered concept – have central volume “roll-out” on balls. On going discussion with Jan, John, Tito, Martin and Walt.
Starting to look at fixtures needed to remove and install mu-metal chimney and downstream end cap. Each of these is made of four layers, they are not attached as an assembly.
Chimney – 920 pounds for 4 layers
Downstream endcap – 893 pounds for 4 layers
Atomic Beam Source has a sled mounted to the upper platform for removal and installation, see next slide.
Carts and cradles to support vacuum can, inner shield assembly, magnet package, and central detector volume – for installation and maintenance.
All fixtures will be designed with a safety factor of 3 and FEA analyzed prior to manufacturer. Load tests at SNS may be required prior to approval for use.

35. Mu-metal assembly; 1475. pounds 875. pounds 4004. pounds 650. pounds
3654. pound w/o cradle

36. He3 polarized source sled;

37. FNPB building with inner volume on floor;
Inner shields shown adjacent to main vacuum vessel on carts. Hamilton makes carts that have a load capacity to 10,000 pounds. Two carts will be needed to translate the vacuum vessel assembly with inner shield plus magnet package along the beam axis.

38. Drawing of FNPB building, plan and side views;

39. Drawing of FNPB building, plan and side view;