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2008 Beam Transport Design Status and Safety Review Beam Transport - Layouts, Stands, Girders, Vacuum, etc… Mike Bevins, Ross Bailes & David Green For the Design Team Chase Dubbe, Paul Hansen, Gary Hays, Derrick James, Steve Mano, Floyd Martin, Brent Matsu, Jacki Smith, Dan Spell, Mike Tate, Rick Wolfley & Dennis Zekoff June 3, 2008 12GeV Upgrade - Beam Transport
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Outline Introduction & Scope Requirements & Specifications Machine Development & Configuration Control Design Status –Injector and Reinjection, N&S Linac – Ross Bailes –Extraction – David Green –Existing Arcs, Spreaders & Recombiners, ARC 10 & Hall D The Path Forward Summary
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Introduction & Scope The 12GeV upgrade requires: –Extensive modifications to the injection, five spreader & recombiner, and 2 nd extraction regions –New ARC (ARC 10) below the existing ARC 8 on the west side of the machine –New beamline to Hall D tagger building –Installation of ten new upgrade cryomodules PED effort spans all of FY08 & 09 –~516 person-weeks (10 person-years) of budgeted labor (engineering & design) $1.7M in procurements (stands, girders, & vacuum)
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Requirements & Specifications Alignment specs –Quads positioned to +/-0.5mm in x & y, +/- 9mm in z –Dipoles positioned to +/- 0.5mm in x & y, +/- 3mm in z Vacuum specs –Beam line partial pressure of hydrogen <10-6 torr –Total average pressure of all other constituents less than 5x10-7 torr –Special Case: Warm region girders between cryomodules - UHV –Fabrication, vacuum welding, cleaning & handling, and leak checking specs still apply 22631-S-001 Fabrication of Ultra-High Vacuum Equipment 22632-S-001 Cleaning and Handling of U.H.V. Components 22633-S-001 Welding Specification For U.H.V. Components 22634-S-001 Helium Leak Test For U.H.V. Components Same as last year… New: Jlab structural weld design & inspection guidelines (Jlab EH&S Manual 6122)
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To capture ALL quad, corrector, diagnostic, and vacuum element changes we developed the Element Control List (ECL) Songsheets level layouts have also been developed for 33 sections of the machine –Maintained revision history as machine definition evolved We have developed and maintain a webpage to consolidate the beam transport design documentation and enhance communication within MEG as well as with our friends throughout the lab (CASA, Power, I&C, Installation, Vacuum, etc.)webpage Machine Development & Configuration Control Our challenge on the Layouts, Girders, and Stands front: To manage the vast number of design changes that must take place to transform the existing machine to the 12GeV machine
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Injection & Reinjection – Intro & Scope To accommodate the new arc 10 line the injector line has been shifted over the transfer lines beginning 20.51m upbeam of the current position –Two existing quad girders have moved over the transfer lines –Three girders already over the transfer lines have been shifted to suit the new optics design Existing quad girders and diagnostics have been reused Two new quad girders have been installed b/w the DP station and the 1 st BL The 123MeV spectrometer has been relocated upbeam and the spectrometer branch has been modified from a 20 degree to a 25 degree angle to clear support stands and arc girders –Any upgrades & final configuration pending release of Reza’s TN Injector & Reinjection
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Spectrometer shifted upbeam Arc 10 four meter dipoles Four Quad Girders (2 new, 2 rebuilt on short girders) BL dipole shifted 20.51m upbeam Arc 10 quad girder 12GeV Configuration Current Configuration Existing injector line running under arc 8 Shift quad girders upbeam with dipoles VERY congested area –Surveys have been completed in this area to document “as-built” locations of stands Injection & Reinjection – Layouts
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View looking downbeam Spectrometer line Arc 8 dipole Injector line quad girder Injection & Reinjection – Selected Images
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Injector line girders over transfer lines Injection & Reinjection – Selected Images
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Spectrometer shifted upbeam Arc 10 four meter dipoles BL dipole shifted 20.51m upbeam Arc 10 quad girder 2 existing arc stands will have to be field modified to allow the newly shifted beam tube to pass through them. 54” 54.5” He Transfer Lines – Based on survey data The floor to ceiling stands shown have been located based on data points gathered by the survey and alignment group As a result of the surveys, the 0R02 Girder was rotated 180 degrees to eliminate the foul with an existing stand and to allow the re-use of an existing girder. Detail of 4 front end girders is shown on following slide 2 existing arc stands had to be re- designed due to interferences with 12 GeV girder locations. 79” Four Quad Girders (2 new, 2 rebuilt on short girders) Injection & Reinjection – Layouts
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Detail of typical QD girder shown on following slide Plan View Elevation View Injection & Reinjection – First 4 Girders
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The first four girders utilize the same extruded channel profile that is used for the warm region girders. This allows for the use of existing bracketry e.g. cross-bars, v- blocks, etc. Injection & Reinjection – Typical Girder Assy
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BL dipole to replace DK (moved 20.51m upbeam) Shift existing girders Current Configuration 12GeV Configuration BL dipole Quad girders Existing injector line girders relocated over transfer line No change to this BL dipole or girder Injection & Reinjection – Layouts
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BL dipole to replace DK (moved 20.51m upbeam) Shift existing girders Existing injector line girders relocated over transfer line Since there were only z-translations, the level of detail for the girders over the transfer lines was minimized Plan View Elevation View Detail of SLM chamber on following slide Injection & Reinjection – Layouts
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ME Group worked closely with CASA and the machine shop to develop and design the SLM chamber for the 2 nd BL that would allow for easy fabrication, alignment and calibration. Injection & Reinjection – SLM Assembly
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Modified re- injection chicane girder Current Configuration 12GeV Configuration No changes between dipoles Injection & Reinjection – Layouts
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Re-injection chicane girder modifications –Replaced dipoles with higher strength CB magnets –Used existing support stand –Modified existing support plate to accommodate new magnets Injection & Reinjection – Reinjection Chicane
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New CA* * The final design of the CB and CA magnets are not complete. The configuration shown is preliminary. Injection & Reinjection– Reinjection Chicane New CB* Re-use of existing stand and support plate. The support plate will be machined to accomodate new mounting bracket locations.
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Initial scope assumed the re-use of the 2 stands for the girders making the transition over the transfer lines 0R01 and 0R02. -Based on field surveys and the decision to rotate the 0R02 girder 180 degrees, the 0R02 stand cannot be used. A new stand is required. The 0R01 stand will be re-used. Initial scope assumed the re-use of the 2 stands used to support the 1L00 and 1L01 girders in the N. Linac. These stands cannot be used but we will be replaced with the 2 stands from injector line currently used to support the 0L09 and 0L10 girders. These two girders have been shifted over the transfer lines. No cost changes associated with this change-out. Initial scope assumed that 4 new vertical support stands would be required to accommodate interferences between the arcs and the injection area. After field surveys, only 2 new stands are required with straight forward field modifications to 3 additional stands. Injection & Reinjection – ’07 Scope Comparisons
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Summary: 3D model is complete. Songsheets have been developed Installation and alignment coordinates have been generated. 99% of drawings have been signed off and are ready for procurement, see remaining work for missing 1%. –New Drawings: 41 –Revised Drawings: 9 Where to from here: Design and layout work for the spectrometer branch has progressed based on discussions held in January of this year. We are expecting no surprises from Reza’s TN. Drawings ready for signature pending review of the TN. Detail design work has also been completed for the mini-chicane girder. –Drawings will be issued pending completion of CB magnet design. Formally document welds in accordance with JLAB EH&S 6122 Procurement Activities: Planning, Scope of Work Documents, etc. Injection & Reinjection – Remaining Work/Summary
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The12GeV upgrade requires an additional ten cryomodules –Five in the north linac and five in the south NEW modules are longer than the original CEBAF modules –Result: Warm region girders downstream of the new modules must be replaced with a new short girder Like downstream of SL21 12GeV field strength requirements forced us to replace two QB quads at the start of the linac with QCs and replace the dipoles on the re- injection chicane girder with higher strength magnets North Linac 1 st Section –QB to QC change at MQB1L00 & 01 N&S Linac Sections 3 & 4 –Add new modules in zones 22 through 25 –Replace warm region girders with new short girder North & South Linacs – Intro & Scope
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MQB1L00 & MQB1L01 girder modifications –Replaced QB quads with higher strength QCs –Re-used support pedestals from 2 injector line girders that have been re- positioned over the transfer lines. View looking upbeam to MQB1L00 & 01 girders MQB1L00MQB1L01 North & South Linac – NL, QB to QC Change
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New QC’s that replace existing QB’s These 2 stands are re-used from the 2 injector girders, 0L09 and 0L10, that got moved across the transfer lines. The existing stands have been field modified with outriggers that do not support the new girders.
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New module Four New modules Layout of new modules & girders in linac Current Configuration (Zones 19 – 22) 12GeV Configuration (Zones 19 – 22) Current Configuration (Zones 23 – 26) 12GeV Configuration (Zones 23 – 26) Five New warm girders DP station moved to end of linac Replaced module baseplates North & South Linac – New Module/Girder Layouts
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Old warm region girder New short warm region girder Viewer & pump drop cross H&V nested Air Core correctors over BPM Quad Existing baseplate New stand Warm girder design was reviewed in Oct 2004 Prototyped and installed at SL21 Designed to accommodate multiple combinations of cryomodule configurations Quad, BPM, and alignment cartridges will be reused on new short girders North & South Linac – Warm Region Girders
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Summary: Detailed design and drawings for the 1L00 & 1L01 girders is complete Songsheets have been developed Installation and alignment coordinates have been generated. Warm girder design and associated detail drawings are complete No scope changes from last year North & South Linac – Summary/Remaining Work
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Extraction – Intro & Scope The extraction region must be upgraded to support transport of higher energy beam to halls A, B, & C and 5 th pass beam to the new arc 10 to support 12GeV operations Extraction Region
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Extraction – System Diagram
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Extraction – RF Separators 12GeV Configuration Current Configuration Relocated New Two new pedestal stands Existing supports New quad girder
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Extraction – RF Separators Two new pedestals Existing supports (gray)
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Extraction – Septa Magnet Stacks 12GeV Configuration Current Configuration Relocated New Two new pedestal stands YA Septa Stacks YB/YR Septa Stack New quad girder Two YBs Three YRs One relocated and one new support stand Two new support stands
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Extraction – Quad Girder New pedestal stands not required -existing stands have 5 arms New AE01 Girder Replaces existing hall transport girder
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Extraction – YA Septa Magnet Stacks New pedestal stand for AE02 girder Two relocated supports Two new pedestal stands
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Extraction – YB/YR Magnet Stacks New downbeam support stands New upbeam support stand Existing YB septa magnets Three YR septas (recycled from S&Rs)
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Extraction – Dipole Magnet Stacks 12GeV Configuration Current Configuration New Two new support stands New BP Dipole Stack Three BPs
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Extraction – Dipole Magnet Stacks 12GeV Configuration Current Configuration New
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Extraction – Dipole Magnet Stacks New New support stand BQ/BP Dipole Stack Three new BPs 12GeV Configuration New pedestal for 5 th pass BP downbeam support Two existing BQs BP Dipole Stack New BP Two new pedestal supports for 5 th pass BP
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Extraction – BP Dipole Magnet Stacks One new pedestal stand Two new support stands ATLis task in place to gather as-built locations of ceiling penetrations in this area
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Extraction - Dipole Magnet Stacks /Arc Recirculation New stand rotated to accommodate new BP stack New pedestal stand for Arc 10, AA01 girder New Arc 10 four meter dipole
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Extraction - Overhead View of BP Stacks and Arc
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Extraction – BQ/BP Dipole Magnet Stacks New upbeam stand New downbeam stand. This stand will have two 1-hole arms for BQ and three 2-hole arms for BPs. Three new BP dipoles Two existing BQ dipoles
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Extraction – RF Separators
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Extraction – Septa Magnet Stacks Existing YA Septa StackExisting YB Septa Stack
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Extraction – Dipole Magnet Stacks Existing BP Dipole Stack Existing BQ Dipole Stack BP StackBQ Stack
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Initial scope called for adding a QB to the 8E01 and installing a QB/QC girder at AE01. Final design leaves 8E01 as is and installs single QC at AE01 Initial scope for YA magnets was to add one new support and one relocated support. Final design uses two relocated supports from the existing YB stack. Initial scope specified two new pedestal supports for the downstream 5 th pass BP magnet. This has been modified to utilize a single pedestal stand due to space constraints. The 5 th pass BP pedestal for the BQ/BP stack has been eliminated in favor of a new stand designed to accommodate BQ and BP supports. Extraction – ‘ 07 Scope Comparisons
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Summary: 3D model of extraction region is 80% complete Detail design work has been completed for several of the new/relocated support stands Where to from here: Awaiting updated optics deck from CASA to… Complete extraction and recirculation layouts Begin YR vacuum chamber design Update songsheets to reflect change to single quad girders at 8E and AE01 and add RF Separator calibration magnets to 12 GeV songsheet Formally document welds in accordance with JLAB EH&S 6122 Extraction – Remaining Work/Summary
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Existing Arcs & Hall Transport– Intro & Scope West ARC Dipoles Accommodate the addition of the H-steel on Arc dipoles Swap QA quad with QR at 32 locations Install new correctors on 3 girders Develop songsheets that reflect 12GeV quad, corrector, and power supply upgrades
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Existing Arcs - H-style dipole interface Prototype H-style dipole INTERFERENCE H-steel interferes with existing outrigger support H-steel runs directly through the holes tapped into the magnet core used to support the outrigger Prefer not to cut away H-steel to clear existing support Solution proposed last spring will be revisited based on H steel configuration change
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Existing Arcs – Existing Alignment Scheme Existing C-style dipole alignment scheme Alignment fixture indexes on machined flats on each end of the magnet Two bolts are used to fasten the fixture to the magnet (mounting holes tapped into upper machined surface on the magnet core) Problems - Lab alignment group reports that it can be difficult to ensure that the fixture is seated properly against the magnet Scheme only provides two alignment points on each magnet Fixtures would require modification to eliminate interference with new H-steel dipoles Existing C-style ARC dipole Existing C-style dipole up-beam alignment fixture dipole Prototype H-style dipole Machined flats
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Use threaded retro-reflector nests in old fixture fastening holes Provides four points for alignment Alignment group has done mock-up to confirm line-of-sight with the addition of H-steel Plan uses tapped holes on the machined flats that were not intended as alignment reference The Alignment group measured 28 dipoles of four different styles during the summer 2007 shutdown Results show no significant problems with repeatability of the target C-style ARC dipole with retro-reflector nests installed Retro-reflector nest Existing Arcs – New Alignment Scheme
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Summary: We have developed songsheets that reflect all 12GeV element and power supply changes All layouts and element changes are available on our webpage New alignment scheme looks good Remaining Work: Re-visit the outrigger support design Develop girder modification designs to accommodate the new correctors – minimal effort required This is likely a field mod to the girder Existing Arcs & Hall Transport – Summary/Remaining Work
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Spreaders & Recombiners The 12GeV upgrade requires extensive modifications to the spreader and recombiner regions of the machine These are the most congested regions in the beam transport system S&R region optics and magnet design has not progressed far enough along to begin detailed 3D beam transport design We have focused our resources on well defined regions of the machine We will begin these designs with a trained staff and a library of 3D assemblies, parts & drawings
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ARC 10 – Intro & Scope ARC 10 The ARC 10 line will be installed below the existing arc 8 line on the west side of the machine The line includes (tangent to tangent): 32 new QP girders (24 single and 8 double) 32 new four meter dipoles
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Typical segment from the west arc 3 Single quad girders 1 Double quad girder ARC 10 Four 4m Dipoles Repeating structure ARC 10 - Layouts
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4m dipole pedestals Girder pedestal Existing stands Dipole & girder supports New dipoles and girders are supported by pedestals from the floor Existing stands placed using alignment installation coordinates to identify potential interference with new pedestals 4m dipoles and quad girders are supported and aligned using our standard heavy duty alignment cartridges –5000# load capacity per cartridge –4m dipole weight ~7000# ARC 10 - Layouts
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Requirements drove the design of 12 different girder flavors for arc 10 They share 3 common girder sub-assemblies Short single quad girder Standard single quad girder Double quad girder All girders use the same pedestal design All 4m dipoles use the same set of stands
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Summary: Quad girder designs, assembly, and associated detail drawings are DONE! 12 assembly & 33 detail drawings Pedestal designs (girder and dipole) are DONE! 3D assembly of the entire west arc has been developed We have checked for interferences with existing support stands and Arc eight girders (pump drops, alignment cartridges) Installation coordinates have been developed for all quads and dipoles (pedestal bolt and alignment cartridge) Where to from here: Develop Arc 10 region assembly drawings to document installation data Incorporate likely mod to baseline 4m dipole design Complete design of the 4m dipole chamber (w/SLM port at AA29 dipole) Formally document welds in accordance with JLAB EH&S 6122 ARC 10 – Remaining Work/Summary
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Hall D – Intro & Scope Tagger Bldg The Hall D line begins with the first quad in the east spreader and ends at the beam dump in Hall D tagger building The line includes: One new 2m dipole 21 quad girders (QAs & QPs) Four 4m dipoles Several diagnostics girders Insertable dump & beam stopper system Sliding shield wall (similar to Hall A & C lines) East spreader
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Hall D WBS Hall D line ~7 inches from nominal tunnel floor Hall D – Layouts, 1 st Spreader
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Hall D – Layouts, 1 st Extraction Fast feedback correctors (H&V) QP quad girder
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8 deg ramp to Hall D Point of tangency Insertable Dump Beam stoppers 4m dipoles Quad girders Hall D – Layouts Fast Feed Back Correctors Beam Current Monitor Insertable Dump Diffuser Beam Stoppers
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Quad girders 4m dipoles Sliding shield wall Cavity BPM Hall D – Layouts
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Air handler and Fan unit. Moveable Shield Wall Stationary Shield Wall. Supply/Return/Power lines for the air handler and fan nA BPM Cavity BEAM DIRECTION Hall D – Layouts
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Plan view: Elevation: Cavity BPM Beam Dump Steel sheilding BPM & BCM 71 in 14.8 ft Dump Viewer Hall D – Layouts
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Hall D – Vacuum Design Number of vacuum pumps in 07 cost book based on rough hand calc and scaling existing CEBAF design Subsequent detailed analysis validated pump quantity and optimized position along beamline Beamline pressure spec and assumed outgassing rate are the same as CEBAF design –Average beamline pressure < 5*10 -7 torr –Assumed outgassing: 10 -10 torr-L/s/cm 2 Vacuum analysis conducted using VACCALC program –Developed by M. Sullivan at SLAC 4m dipole chamber cross-section same as existing –Conductance of oval dipole chamber based on method from J.M. Lafferty, Vacuum Science text Beamline drift tubes are 3”OD
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Hall D Line – Vacuum Design Design meets specification - average pressure is < 5*10 -7 torr
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Summary: The Hall D line 3D model is 60% complete Successfully leveraged off arc 10 girder & stand designs Vacuum system design is complete Songsheets have been developed Where to from here: On track to complete all quad and diagnostic girder drawings and associated details on June 20 th Develop region assembly/installation drawings Gathering existing stand and floor elevation data during summer down Develop detailed layout of Tagger dump area Formally document welds in accordance with JLAB EH&S 6122 Hall D – Summary/Remaining Work
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The first procurement on the girder, stand, vacuum side of things is the ARC 10 quad girder procurement scheduled for 2 nd quarter of FY09 – No problem... all girder and associated drawings are complete! Balance of girder, stand, and vacuum procurements scheduled for FY10 We will begin developing SOWs and detailed procurement plan in parallel with installation planning during FY09 The Path Forward
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Summary Assembly and Installation detail drawing package for the Injection and Reinjection region area completed on schedule! –Was our first major milestone on the beam transport side of things ARC 10 3D model complete. All girder assembly and associated drawings have been reviewed and signed off. Installation points have been generated. Hall D line development is progressing well (ahead of schedule) We have released ~100 drawings The Extraction region design is 80% complete and we expect to close out this effort in FY08 (one year early) We will continue to work closely with our friends throughout the lab (safety, CASA, installation, vacuum, alignment, RadCon, I&C, magnet measurement, operations, procurement & facilities) as we move forward Remaining efforts WILL be completed to support procurement, assembly and installation schedules We look forward to comments from the committee
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