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September 19-20, 2007 L. Snydstrup Structural Components WBS 1.1 Structural Components Status DOE Annual Review Lou Snydstrup September 19-20, 2007.

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Presentation on theme: "September 19-20, 2007 L. Snydstrup Structural Components WBS 1.1 Structural Components Status DOE Annual Review Lou Snydstrup September 19-20, 2007."— Presentation transcript:

1 September 19-20, 2007 L. Snydstrup Structural Components WBS 1.1 Structural Components Status DOE Annual Review Lou Snydstrup September 19-20, 2007

2 L. Snydstrup Structural Components EBIS RF StructuresLEBT Region - Electron Gun - RFQ- LEBT Chamber - SC Solenoid - Linac- Electrostatic Devices - Drift Tube Structure - Bunchers - I/S Switch Chamber - Vacuum Chambers - Electron Collector - Acceleration Tube WBS 1.1 Structural Components

3 September 19-20, 2007 L. Snydstrup Structural Components 3

4 September 19-20, 2007 L. Snydstrup Structural Components 4 EBIS Assembly E-Gun Drift Tube Structure Electron Collector Superconducting Solenoid Acceleration Tube

5 September 19-20, 2007 L. Snydstrup Structural Components 5 Superconducting Solenoid Magnet System Supplier: ACCEL Instruments ($409K)

6 September 19-20, 2007 L. Snydstrup Structural Components Superconducting Solenoid Magnet System June, 2006 - two engineers from ACCEL came to BNL for a detailed design review of the superconducting solenoid and a review by the Laboratory Cryogenic Safety Review Committee. July, 2007, prior to factory acceptance testing, the superconducting solenoid was operated at ACCEL at 5% over the design field of 6 T. –The helium evaporation rate was in an acceptable range –The measured field decay rate was satisfactory. –The magnet had successfully quenched at 99% of full field during training without damage. –The crash button (inducing a quench) was tested successfully at half field. 6

7 September 19-20, 2007 L. Snydstrup Structural Components 7 Superconducting Solenoid Magnet System Factory Test at Accel - 17-20 July –Performed a full field (6T) quench on 2 nd day. Upon repowering the magnet quenched at about 60% field (4 times). Factory test ended –Field measurements indicated misalignment of magnetic axis with warm bore axis Week of 13 August –ACCEL found damage on removable lead contacts. The leads were repaired. On ramp up, the magnet quenched at 73% (3X). Week of 10 September –ACCEL ramped magnet with high resolution data recording. Quench at 70% field localized to compensation coil.

8 September 19-20, 2007 L. Snydstrup Structural Components 8 Superconducting Solenoid Magnet System Full field, crash button quench

9 September 19-20, 2007 L. Snydstrup Structural Components 9 Superconducting Solenoid Magnet System Full field, crash button quench

10 September 19-20, 2007 L. Snydstrup Structural Components 10 Superconducting Solenoid Magnet System Cryocooler for Heat Shield Retractable Power Leads

11 September 19-20, 2007 L. Snydstrup Structural Components 11 Superconducting Solenoid Magnet System Immediate Plan: –ACCEL to open limited area of the magnet to look for any visible problem in the next week. –BNL Review Committee formed including management and our resident experts in superconducting magnet systems. Summary Magnet system is now 10 months late due to various causes. Best case scenario would be to perform a repair through the limited access opening (1-2 months). A repair requiring full opening of the magnet would take many months. ACCEL to confirm the time for these repair efforts.

12 September 19-20, 2007 L. Snydstrup Structural Components 12 Electron Collector Assembly Adapter-Deflector Ion Extractor Iron Shield Ion Lens Reflector Electron Collector (BeCu) Water Manifold

13 September 19-20, 2007 L. Snydstrup Structural Components 13 Electron Collector The collector procurement was started during R&D due to the recognized risk of possible difficulties in fabrication. Causes of Late Delivery: 1.Production delays of proprietary Hycon 3 beryllium copper cylinder and plate 2.Logistical difficulties handling BeCu material (0.35% Be) (Routing of EC to BNL for leak testing and to Elmore plant for cleaning.) 3.Welding problem

14 September 19-20, 2007 L. Snydstrup Structural Components 14 Electron Collector Supplier: Brush Wellman ($82K) Material: Beryllium Copper Vacuum Leak of EB Weld EB Weld Repair failed TIG Weld Repair failed

15 September 19-20, 2007 L. Snydstrup Structural Components 15 Electron Collector

16 September 19-20, 2007 L. Snydstrup Structural Components 16 Electron Collector Plan for Manufacture of EC: 1. Brush Wellman will continue to repair existing unit by installing a new back disk by brazing. Annealing and loss of material strength during brazing will be accepted by BNL. 2. BNL is manufacturing a second unit using zirconium chromium copper instead of beryllium copper. Test welding has been successfully completed.

17 September 19-20, 2007 L. Snydstrup Structural Components 17 Electron Collector Metallurgy of BeCu versus ZrCrCu Both materials are used in high heat flux applications (e.g., ITER Fusion Reactor). The design goal is to minimize the life cycle cost of the electron collector. - BeCu has a high initial cost, but an expected longer life due to its high fatigue strength. -ZrCrCu has a high thermal conductivity (up to 85% of pure copper and four times the strength of pure copper), resulting in lower stresses from thermal loading. ZrCrCu does not have a published fatigue strength.

18 September 19-20, 2007 L. Snydstrup Structural Components 18 Second Electron Collector (BNL manufacturing) Specimens for test welding of ZrCrCu by Electron Beam welding ZrCrCu Electron Collector cylinder – post gun-drilling Metallographic Examination 145kV, 45mA

19 September 19-20, 2007 L. Snydstrup Structural Components 19 E-Gun First E-gun unit has been manufactured, and is currently being tested in the R&D EBIS Second unit will be made after testing is complete

20 September 19-20, 2007 L. Snydstrup Structural Components 20 Drift Tube Structure Drift tubes, support tray, and central vacuum chamber are in the Central Shop End vacuum chambers are being purchased

21 September 19-20, 2007 L. Snydstrup Structural Components 21 Acceleration Tube Supplier: Kyocera ($51.4K – 2 units) Delivery: 11/30/07

22 September 19-20, 2007 L. Snydstrup Structural Components 22 Radio Frequency Quadrupole Supplier: IAP* ($403K) Final Design at BNL on 23 November 06 Cavity machining completed Copper plating at GSI by end of Sept RF structure machining by end of Sept Delivery expected by January 2008 * Institut für Angewandte Physik (IAP), U. of Frankfurt

23 September 19-20, 2007 L. Snydstrup Structural Components 23 RFQ Cavity Machining Completed

24 September 19-20, 2007 L. Snydstrup Structural Components 24 RFQ 4 Rod/Support Structure

25 September 19-20, 2007 L. Snydstrup Structural Components 25 Linac Supplier: IAP* ($724K) Preliminary Design received from Ratzinger in August Telephone conference on 23 August on PD IAP expects to place order for Final Design and Production in September Present schedule has Linac shipment in March 2009, but IAP working to shorten production. Linac delivery is on the critical path. Upper Shell Center Frame Lower Shell

26 September 19-20, 2007 L. Snydstrup Structural Components 26 Linac – Preliminary Design Internal Quadrupole Triplet Initial plan for two internal quadrupole triplets has been changed to one internal and one external triplet. Internal triplet design exists, having been produced by Danfysik for other IH-Linacs.

27 September 19-20, 2007 L. Snydstrup Structural Components 27 LEBT/Ion Source Region

28 September 19-20, 2007 L. Snydstrup Structural Components 28 LEBT Chamber Time-of-Flight External Source LEBT Switchyard Chamber HV Acceleration Break EBIS Electron Collector Magnetic Solenoid Lens

29 September 19-20, 2007 L. Snydstrup Structural Components 29 LEBT Chamber Proto unit manufactured for test and evaluation on R&D EBIS Second unit to be made upon completion of testing. Top view showing deflectors

30 September 19-20, 2007 L. Snydstrup Structural Components 30 LEBT Chamber – Spherical Deflector

31 September 19-20, 2007 L. Snydstrup Structural Components 31 E/S Quadrupole

32 September 19-20, 2007 L. Snydstrup Structural Components 32 Ion Source Switch Chamber Physics simulation on switch chamber to be performed prior to completion of manufacturing drawing Deflector geometry identical to LEBT chamber deflectors being tested.

33 September 19-20, 2007 L. Snydstrup Structural Components 33 LEBT Component Acquisition Plan ComponentPrototypeAcquisition LEBT Chamber Done Mach Shop E/S Deflectors Done Mach Shop E/S Quadrupoles Done Mach Shop I/S Switch Chamber Mach Shop Einsel Lens Mach Shop Wien Filter Purchase

34 September 19-20, 2007 L. Snydstrup Structural Components 34 Summary for Structural Components Good progress has been made on most of the major technical components. Procurement contracts for major components have been placed: superconducting solenoid, RFQ, Linac, and acceleration tube. –Total Spent/Committed$1,718K –Total Expected Material Cost$2,157K –Percentage Spent/Committed80% The primary challenges remaining relate to the delivery schedules of the Superconducting Solenoid (SSMS) and the Linac. - If SSMS problems are solved soon, the assembly and test of the EBIS in the final site could be accomplished ahead of schedule. If it must be remanufactured, then although the date for project completion won’t slip, the slack time during which EBIS system testing could have been occurring will be reduced. - Linac progress will be monitored carefully to reduce the risk of further Linac schedule slips relative to the original contract.

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