1. X PS Internal Dump Core Review François-Xavier Nuiry Giulia Romagnoli
Tobias Polzin
Edouard Grenier Boley
EN-STI-TCD
12/10/2016

2. PS Internal Dumps Review Objectives and Organisation
 Giving the status of the PS Internal dump core design;
Describing the Dump core design strategy;
Getting feedback on the work done so far, especially on:
- The thermo-mechanical simulations;
- The dump core material selection;
- The technologies proposed.
General presentation of the PS internal dump project
Thermo-mechanical simulations applied to the dump core
Presentation of three different designs
Ongoing thermal simulations
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PS Internal Dump Core Review

3. PS Internal Dumps – Project Objectives
 2 new PS dumps for run3 beams and compatible with PS operation modes
WHY changing?
Old dump not adapted to run3 beams
Very old equipment
Complex repair if needed
Not anymore suitable in case of failure of cooling system
Shielding handling improvements
PS DUMP
PS equipment used to dilute the beam for safety or operation reasons
Design
Prototyping & follow up
Installation
Commissioning
(removal of old dumps)
Maintenance
Maximum peak energy in the dump core with run3 beam parameters of 1.3 kJ/cm3/pulse
 Temperature increase in copper of 395 K/pulse [1]
Maximum service temperature copper ~ 300°C
Maximum peak energy in the dump core with present beam parameters of 255 J/cm3/pulse
 Temperature increase in copper of 79 K/pulse
[1] W. Kozlowska, M. Brugger, PS Internal Dump in the Fluka Monte Carlo simulations, Reference, EDMS V.1
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PS Internal Dump Core Review

4. PS Internal Dump Core Review
Current PS Dump Layout
Dump core: copper block 6kg
Metallic hollow arm
Vacuum tightness with bellows
Mechanism
140 mm
130 mm
40 mm
Bellows for vacuum tightness
Mechanism
Dump core
Dumping movement
Vacuum chamber
Beam direction
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PS Internal Dump Core Review

5. Current PS Dump Integration and Shielding
Dumps shielding 400mm thick
Painted Vaurion stone / concrete / marble blocks
SS48
Dump
Shielding
SS47
Dump installation with trolley system, rotating table and crane
Dump
mechanism
Vacuum chamber
Shielding
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PS Internal Dump Core Review

6. Current Dump Working Principle
Dump movement done by springs
Electro-magnet to hold back the dump
Backup motor in case of magnet failure
Power supply
SPRING
MOTOR
MAGNET
OUT
Move
Return
ARM IN
ARM OUT
Vacuum Chamber IN
Power supply
SPRING
MOTOR
MAGNET
OUT
Move
Return
ARM IN
ARM OUT
Vacuum Chamber IN
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PS Internal Dump Core Review

7. Current PS Internal Dump Cycle
1. Vacuum chamber
2. Dump entering the beam area
3. Dump fully in the beam area
4. Dump in top position
5. Dump exiting the chamber
6. End of the cycle
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PS Internal Dump Core Review

8. Project Main Requirements
Stroke and speed: about 80 mm in < 0.25 sec
cycles / year
Beam impact every 1.2s for several minutes
Limited proton leakage (~same as today)
High vacuum (10-9 mbar)
Geometrical constraints (max 955mm space in Z)
Lifetime until 2035
Short and punctual maintenance (1 per year)
Reference: PS Ring Internal Dump Functional Specifications, EDMS
Engineering challenges
Minimized dump core mass, considering also proton leakage
Thermal management
Stress evaluation
Cooling system inside the vacuum chamber
Reliable mechanism
Fatigue (mechanism, bellow…)
Highly radioactive environment
Precise mechanical dimensioning
Efficient modular shielding
Material ageing (Gas production and DPA)
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PS Internal Dump Core Review

9. New Dumps: Operation Modes 1/2
Beam Study Mode
- Commissioning of new beams
- Helping debugging issues
Machine Development Mode
Cycle in the supercycle not requested for extraction
Machine Protection Mode
Safety mode to protect the machine
- LHC beams dumped at any time
- n_TOF beams to East Area
- n_TOF beams in series in the machine
Problem /
DUMP
Reference: PS Ring Internal Dump Functional Specifications, EDMS
Magnetic field
Time
Injection
Extraction
26GeV
DUMP
Magnetic field
Time
n_TOF Beam
(~ GeV) X
East Area Beam
( GeV)
Sensor
DUMP
Magnetic field
Magnetic field
n_TOF Beam ( GeV)
Time
Time
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PS Internal Dump Core Review

10. New Dumps: Operation Modes 2/242
SEM Grids Positions 48 52
Beam PSB
SS12
“Ralentisseur” 54
“Ralentisseur” Mode
Protect the 3 SEM grids detectors after one beam turn
Ralentisseur (now in SS12)
20 mm thick tungsten plate
Secondary Emission Monitor Grids (SEM-Grids)
Ceramic frame with several wires to measure the beam density profile
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PS Internal Dump Core Review

11. PS Dumps Possible Future Locations
42 (SEM-grid)
SS48 (SEM-grid)
52 (SEM-grid)
BEAM from PSB
SS12 (Ralentisseur)
71 (kicker)
SS75
SS31
SS47 65 15
High radiation zone
54 (SEM-grid)
SS47
Current dump position
SS75
Free space
See Space reservation Request EDMS v.1.0
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PS Internal Dump Core Review

12. PS Internal Dump Core Review
PS Internal dump project can be divided in 4 main sub-parts:
Dump CORE
Review on different designs
Vacuum flange and vacuum vessel
First design based on old dump
Mechanism
Analytical calculations started – design started based on old dump mechanism
Shielding
Preliminary design validated by RP
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PS Internal Dump Core Review

13. Dump Core - Beam Parameters [run 3]
ACCIDENTAL SCENARIO
Protons
26 GeV
5×1013
σ = 1.8 mm x 4.7 mm
Pulse time 2.1 µs
Pulse period 2.4 s
3 consecutive pulses
SFTPRO BEAM
Protons
14 GeV
2×1013
σ = 2 mm x 3.7 mm
Pulse time 2.1 µs
Pulse period 1.2 s
2 consecutive pulses then cooldown time of 15 s
LHC 25ns BEAM
Protons
26 GeV
2.3×1013
σ = 1 mm x 4.7 mm
Pulse time 2.1 µs
Pulse period 3.6 s
5 consecutive pulses then cooling down time of 20 s
The occurrence of these beam parameters is still under discussion and study. In order to move on in the project, it is studied after how many times the LHC 25 ns beam parameters can be repeated with a given dump design.
A requirement (occurrence) would be helpful.
PROTON LEAKAGE
Present Dump
New Dump
26GeV
(Present maximum)
0.4×1013
0.1×1013
26 GeV
(LIU max)
2.0×1013
0.55×1013
Design shown on the next slide
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PS Internal Dump Core Review

14. Dump Core Ongoing Thermo-Mechanical Simulations
Use of FEM simulations to find materials:
(See presentation about Thermo-mechanical simulations)
Present core “sandwich” studied:
14 Ti (Ti6Al4V) blocks total length: 350 mm
6 Rene41 (NiCr) blocks total length: 114 mm
Ti housing
Ti flange 20 mm thick to cover big beam areas
Ti6Al4V housing
14 Ti6Al4V blocks
6 NiCr blocks
Ti housing
14 Ti6Al4V blocks
6 NiCr blocks
BEAM
500 mm
70 mm
Ti6Al4V flange to cover the bigger beam area at injection
80 mm
Total weight: ~10 kg
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PS Internal Dump Core Review

15. Dump Core Design – Thermal Management
Based on the current sandwich study, three core designs are studied in order to extract the power deposited by the beam (~2500W for LHC 25 ns):
Soldered tube solution
Deep hole drilling solution
Additive manufacturing
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PS Internal Dump Core Review

16. PS Internal Dump Core Review
Shielding Studies
Based on [1], a first shielding design has been proposed to RP to check the feasibility
Shielding:
Iron box
Tungsten for downstream protection
Concrete
Marble box
Marble
Concrete W Fe
Driving criteria:
Radiation protection
Protection of downstream equipment
Plug and place system for maintenance
[1] W. Kozlowska, M. Brugger, PS Internal Dump in the Fluka Monte Carlo simulations, Reference, EDMS V.1
Metallic frame for dump and mechanism: possible to be replaced in 2 steps
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PS Internal Dump Core Review

17. PS Internal Dump Core Review
RP Aspects
To calculate the residual dose rate, the following beam distribution (CONSERVATIVE APPROACH) was taken into account, in agreement with BE-OP:
1.25×1018 protons over 9 months of regular operation
Dose Rate assessed along SS75 at ~90 cm distance from the beam line, at the beam level, i.e. along the red arrow indicated in the left figure
Present dump RP survey: 14/09/2016, at 40cm of the beam line inside the ring:
SS47 Upstream: 47 µSv/h Downstream: 48 µSv/h. SS48: Upstream: 33 µSv/h Downstream: 72 µSv/h.
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PS Internal Dump Core Review

18. Mechanism - Preliminary Design
Different solutions have been considered for the mechanism:
Linear actuators
Brushless motors
Current mechanism with spring and magnet
Several constraints are influencing the design choice: See slide 8.
Ongoing study:
Upsizing of the present mechanism concept to adapt to the new dump mass.
Motivations:
Good level of reliability over 40 years of service;
Radiation hard design;
No maintenance;
Required speed should be achievable.
Particular attention to bellows is foreseen.
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PS Internal Dump Core Review

19. Detailed Design with MME on going…
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PS Internal Dump Core Review

20. Project Provisional Planning
2016
2017
2018
2019
Feb
Mar
Apr
Aug
Sep
Oct
Nov
Dec
Jan
May
Jun
Jul
Power deposition studies
Material selection for the dump core
Control Systems Definition
Dump Design Definition
EN-MME 3D Detailed Design
Prototype and tests
Design review
PRODUCTION
(Procurement and manufacturing, Quality checking, Assembly and tests)
Current DUMP Removal
INSTALLATION
Transport, Alignment and Commissioning
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PS Internal Dump Core Review

21. PS Internal Dump Core ReviewX X
Thank you!
12/10/2016
PS Internal Dump Core Review