Transcript Hall D – Layouts

12GeV Upgrade - Beam Transport
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
Outline
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•
•
•
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
Introduction & Scope
• The 12GeV upgrade requires:
– Extensive modifications to the injection, five spreader
& recombiner, and 2nd 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)
Requirements & Specifications
Same as last year…
•
•
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
New:
•
Jlab structural weld design & inspection guidelines (Jlab EH&S Manual 6122)
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
• 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.)
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 1st BL
• The 123MeV spectrometer has been
relocated upbeam and the spectrometer
branch has been modified from a 20 degree
Injector & Reinjection
to a 25 degree angle to clear support stands
and arc girders
– Any upgrades & final configuration
pending release of Reza’s TN
Injection & Reinjection – Layouts
Current
Configuration
Existing injector
line running
under arc 8
12GeV
Configuration
Four Quad Girders (2 new, 2
rebuilt on short girders)
VERY congested area
– Surveys have been
completed in this
area to document
“as-built” locations
of stands
Shift quad
girders upbeam
with dipoles
BL dipole shifted
20.51m upbeam
Arc 10 four
meter dipoles
Arc 10 quad
girder
Spectrometer
shifted upbeam
Injection & Reinjection – Selected Images
Injector line
quad girder
Spectrometer
line
Arc 8 dipole
View looking downbeam
Injection & Reinjection – Selected Images
Injector line girders over transfer lines
Injection & Reinjection – Layouts
Detail of 4 front end girders is
shown on following slide
BL dipole shifted
20.51m upbeam
He Transfer Lines – Based on
survey data
Four Quad Girders (2 new, 2
rebuilt on short girders)
2 existing arc stands will have to
be field modified to allow the
newly shifted beam tube to pass
through them.
Arc 10 four
meter dipoles
Arc 10 quad
girder
79”
2 existing arc stands had to be redesigned due to interferences with 12
GeV girder locations.
Spectrometer
shifted upbeam
54”
The floor to ceiling stands shown have been
located based on data points gathered by the
survey and alignment group
54.5”
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.
Injection & Reinjection – First 4 Girders
Detail of typical QD girder
shown on following slide
Plan View
Elevation View
Injection & Reinjection – Typical Girder Assy
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, vblocks, etc.
Injection & Reinjection – Layouts
Quad girders
BL dipole
Current Configuration
BL dipole to
replace DK
(moved 20.51m
upbeam)
No change to
this BL dipole
or girder
Shift existing
girders
12GeV Configuration
Existing injector line
girders relocated over
transfer line
Injection & Reinjection – Layouts
BL dipole to replace DK
(moved 20.51m upbeam)
Detail of SLM
chamber on
following slide
Shift existing
girders
Plan View
Existing injector line
girders relocated over
transfer line
Elevation View
Since there were only z-translations, the level of detail for the girders
over the transfer lines was minimized
Injection & Reinjection – SLM Assembly
ME Group worked closely with CASA and the machine shop to develop and design the
SLM chamber for the 2nd BL that would allow for easy fabrication, alignment and
calibration.
Injection & Reinjection – Layouts
Current Configuration
No changes
between dipoles
12GeV Configuration
Modified reinjection chicane
girder
Injection & Reinjection – Reinjection Chicane
• 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
New
CB*
* The final design of the CB and CA magnets
are not complete. The configuration shown is
preliminary.
New
CA*
Re-use of existing stand and support
plate. The support plate will be
machined to accomodate new
mounting bracket locations.
Injection & Reinjection – ’07 Scope Comparisons
• 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 – Remaining Work/Summary
Summary:
•
•
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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.
North & South Linacs – Intro & Scope
•
• 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 reinjection chicane girder with
higher strength magnets
•
North Linac 1st 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
• 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
North & South Linac – NL, QB to QC Change
• MQB1L00 & MQB1L01 girder
modifications
– Replaced QB quads with higher
strength QCs
– Re-used support pedestals from 2
injector line girders that have been repositioned over the transfer lines.
MQB1L00
MQB1L01
View looking upbeam to MQB1L00 & 01 girders
North & South Linac – NL, QB to QC Change
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.
North & South Linac – New Module/Girder Layouts
Layout of new modules & girders in linac
DP station
moved to end
of linac
Current Configuration (Zones 19 – 22)
12GeV Configuration (Zones 19 – 22)
New module
Replaced
module
baseplates
Current Configuration (Zones 23 – 26)
Four New
modules
12GeV Configuration (Zones 23 – 26)
Five New
warm girders
North & South Linac – Warm Region Girders
• 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
Viewer & pump
drop cross
Existing
baseplate
Old warm region girder
H&V nested
Air Core
correctors
over BPM
Quad
New
stand
New short warm region girder
North & South Linac – Summary/Remaining Work
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
Extraction – Intro & Scope
• The extraction region must be
upgraded to support transport of higher
energy beam to halls A, B, & C and 5th
pass beam to the new arc 10 to support
12GeV operations
Extraction Region
Extraction – System Diagram
Extraction – RF Separators
Current
Configuration
12GeV
Configuration
New quad girder
Relocated
New
Two new
pedestal stands
Existing supports
New quad
girder
Extraction – RF Separators
Two new pedestals
Existing supports
(gray)
Extraction – Septa Magnet Stacks
Current
Configuration
12GeV
Configuration
New quad
girder
Relocated
Two new
support stands
Two YBs
One relocated
and one new
support stand
New
Three YRs
Two new
pedestal stands
YA Septa Stacks
YB/YR Septa Stack
Extraction – Quad Girder
New AE01 Girder
• Replaces
existing hall
transport girder
New pedestal stands
not required -existing
stands have 5 arms
Extraction – YA Septa Magnet Stacks
Two relocated
supports
New pedestal
stand for AE02
girder
Two new
pedestal stands
Extraction – YB/YR Magnet Stacks
Existing YB
septa magnets
Three YR septas
(recycled from
S&Rs)
New upbeam
support stand
New
downbeam
support stands
Extraction – Dipole Magnet Stacks
Current
Configuration
12GeV
Configuration
New
Two new
support stands
Three BPs
New BP Dipole Stack
Extraction – Dipole Magnet Stacks
Current Configuration
12GeV Configuration
New
Extraction – Dipole Magnet Stacks
12GeV Configuration
Two existing
BQs
New
support
stand
Three new
BPs
New
New BP
BP Dipole Stack
Two new
pedestal
supports for
5th pass BP
New pedestal
for 5th pass BP
downbeam
support
BQ/BP Dipole Stack
Extraction – BP Dipole Magnet Stacks
ATLis task in place to
gather as-built locations of
ceiling penetrations in this
area
One new pedestal stand
Two new support
stands
Extraction - Dipole Magnet Stacks /Arc Recirculation
New Arc 10 four meter
dipole
New stand rotated to
accommodate new BP stack
New pedestal stand for
Arc 10, AA01 girder
Extraction - Overhead View of BP Stacks and Arc
Extraction – BQ/BP Dipole Magnet Stacks
Two existing BQ dipoles
New upbeam stand
Three new BP dipoles
New downbeam stand. This stand will
have two 1-hole arms for BQ and three
2-hole arms for BPs.
Extraction – RF Separators
Extraction – Septa Magnet Stacks
Existing YA Septa Stack
Existing YB Septa Stack
Extraction – Dipole Magnet Stacks
BP Stack
Existing BP Dipole Stack
BQ Stack
Existing BQ Dipole Stack
Extraction – ‘07 Scope Comparisons
• 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
5th pass BP magnet. This has been modified to utilize a single pedestal
stand due to space constraints.
• The 5th 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 – Remaining Work/Summary
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
Existing Arcs & Hall Transport– Intro & Scope
•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
West ARC Dipoles
Existing Arcs - H-style dipole interface
Prototype H-style dipole
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
INTERFERENCE
•Solution proposed last spring will be
revisited based on H steel
configuration change
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)
Machined
flats
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
Existing Arcs – New Alignment Scheme
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
Retro-reflector
nest
•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
Existing Arcs & Hall Transport – Summary/Remaining Work
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
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
ARC 10 – Intro & Scope
• 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
ARC 10
ARC 10
ARC 10 - Layouts
Typical segment from the west arc
Repeating structure
Four 4m
Dipoles
ARC 10
3 Single quad
girders
1 Double
quad girder
ARC 10 - Layouts
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#
Girder
pedestal
Existing stands
4m dipole
pedestals
ARC 10 - Layouts
•
•
•
•
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
ARC 10 – Remaining Work/Summary
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
Hall D – Intro & Scope
• 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)
Tagger Bldg
East
spreader
Hall D – Layouts, 1st Spreader
Hall D WBS
Hall D line ~7
inches from nominal
tunnel floor
Hall D – Layouts, 1st Extraction
QP quad girder
Fast feedback
correctors (H&V)
Hall D – Layouts
Point of
tangency
Insertable
Dump
Beam
stoppers
Fast Feed
Back Correctors
8 deg ramp to Hall D
4m
dipoles
Quad girders
Diffuser
Insertable Dump
Beam Current
Monitor
Beam Stoppers
Hall D – Layouts
Quad
girders
4m
dipoles
Cavity
BPM
Sliding
shield
wall
Hall D – Layouts
Hall D – Layouts
nA BPM Cavity
Stationary Shield Wall.
Supply/Return/Power lines
for the air handler and fan
Air handler and
Fan unit.
BEAM DIRECTION
Moveable
Shield Wall
Hall D – Layouts
Plan view:
Dump
Viewer
Beam
Dump
Steel
sheilding
Elevation:
Cavity
BPM
BPM &
BCM
14.8 ft
71 in
Hall D – Layouts
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/cm2
• 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
Hall D Line – Vacuum Design
Pavg = 2.7e-7 torr
12GeV
Hall D Beamline Pressure & Conductance Profiles
Pressure
6.10E-07
60
5.10E-07
50
4.10E-07
40
3.10E-07
30
2.10E-07
20
1.10E-07
10
1.00E-08
0
0
50
100
150
Distance [m]
Design meets specification - average pressure is < 5*10-7 torr
200
Conductance [m-L/s]
Pressure [torr]
Conductance
Hall D – Summary/Remaining Work
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 20th
• 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
The Path Forward
• The first procurement on the girder, stand, vacuum side of
things is the ARC 10 quad girder procurement scheduled
for 2nd 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
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