Assembly, Installation and Interfaces Steve Virostek Lawrence Berkeley National Lab RFCC Module...

Assembly, Installation and Interfaces

Steve VirostekLawrence Berkeley National Lab

RFCC Module Design Review

October 21, 2008

MICE RFCC Module Design Review – Assembly, Installation and Interfaces

Steve Virostek - Lawrence Berkeley National Lab - October 21, 2008

Topic Summary

•Packaging and delivery to RAL

•Moving into MICE hall

•Module re-assembly in MICE hall

•Module installation interfaces•End flanges and seals•Base mounting•RF coupler connections

•Utility requirements

•Instrumentation & control



Module Shipping Configuration

•Cavities, couplers, coolers & pumps removed•Coupling coil shipped warm

•Vacuum vessel/magnet axis vertical during shipping•Concerns about shipping loads on coupling coil•Special shipping fixture will be required

•Cavities, couplers packaged to prevent damage•RF, Be windows left in place w/appropriate protection

•Vacuum vessel, cavities and couplers will be blanked off and backfilled with N2



Delivery to RAL

•Arrives w/o cavities, coolers, couplers installed

•Moved into hall in vertical shipping orientation•Height is expected to be ~2000 mm when vertical•Height is 2844 mm if horizontal on a short stand

•MICE Hall door height: 3360 mm

•Roller dollies w/forklift used to move into hall

~100 mm tall

Roller dollies



Moving into MICE Hall

Module short stand:•Likely won’t be needed•Vertical orientation shipping stand can also be used to move module into hall

Cryocoolers removed

Cavities removed

Couplers removed

Vacuum pumps removed



MICE Hall Access



•Place operating stand on lateral tracks•Load vacuum vessel/coupling coil onto support stand

•Erect portable clean room around module•Unpack cavities, couplers, coolers, pumps•Install six tuner assemblies on each cavity•Insert cavities in vacuum vessel using special fixture

•Install couplers and tuner actuators after cavity is aligned and supported by struts

•Install vacuum pumps to complete module•Perform final alignment before translation

Re-assembly of Module at RAL




Support stand in place on rail platform



Empty module lifted over support




Module lowered onto support




Support stand gussets added




Cryocooler(s) installed




RF cavities installed from either end




Module with all four cavities installed




Cavity tuner actuators added




Module vacuum pumps installed




RF couplers installed



Insertion into MICE Beamline

•Assemble module on lateral tracks

•Align and shim module to correct height

•Pull back bellows on both module ends with O-rings in place

•Translate module into position using rails

•Release bellows and connect flanges

•Lock out bellows using bridging bolts

•Connect RF, utilities and instrumentation



Module Flange Connection

End flange O-ring seal

Formed bellows

Flange through holes



End Flanges and Seals

•RFCC flanges mate with AFC module flanges

•AFC flanges have no O-ring grooves or bellows

•RFCC module flanges have bellows and O-ring grooves at both ends

•Bellows are spec’d for >1 cm of total travel

•Module relative alignment is driven by clearance in flange holes

•Bellows are locked out after installation to allow transmission of forces between modules



RFCC Bellows and Flange

MICE RF and Coupling Coil Module – Summary of the Design and Fabrication Plan

Elastomer or Helicoflex all-metal O-ring

Clamping bolts

Bellows pull back bolts



MICE RF and Coupling Coil Module – Summary of the Design and Fabrication Plan

Module Joint Sealing Issues

•MICE module joints likely to need relatively frequent disassembly (reconfiguring, maintenance, repair)

•Elastomer O-rings provide the most reliable and cost effective (inexpensive and re-useable) solution

•O-rings are acceptable for use in MICE environment

•But, MICE should demonstrate future machine technology including the use of radiation hard seals

•The RFCC flange groove is designed to accept an all-metal Helicoflex seal for demonstration purposes



Module Base Mounting

•RFCC module base connection to rails similar to that used on the Spectrometer Solenoid

•Six mounting plates are welded to the base of the module support stand

•Location of the mounting plates will be included in an interface document being developed

•Coupling coil magnetic loads are carried to the floor through the vacuum vessel/support stand/base mounting plates



Module Mounting Provision

•Six mounting plates to be welded to the support stand base for installation on rails

•Similar to spectrometer solenoid mounting scheme



Cavity RF Connections

•Eight RF feeds/module use standard 4” RF coax

•Cooling water for loop may be required (<<1 lpm each)

•Adapter attached to RF windows protects ceramic from installation forces

•Co-ax interface dimensions w.r.t. module center will be included in interface document

RF feeds



Module Utility Requirements

•Cryomech Model PT-415 cryocoolers (2 or 4 each total)

•50 Hz AC: 10.5 kW @ 200/220 or 380/420 V, 3 phase•Cooling: minimum 12 lpm of water @ 80ºF max

•300 A Power Supplies – American Magnetics (2 ea total)

•50-60 Hz AC: 3.5 kW @ 208 V, 3, forced air cooled, rack mnt.

•Vacuum: 10-3 torr @ startup thru a 25 mm flanged port

•Cavity cooling water: ~8 lpm/per cavity

•Getter pump regeneration power (100-210 VAC, 100 W)

•Liquid cryogens: LN, LHe for cooldown (100’s of liters)

•Pressurized N2: up to 300 psi for tuner actuators



Module Instrumentation & Control

•Coupling coil•Coil voltage taps•Thermocouples•LHe level•Vacuum pressure

•RF cavities•RF pickup loop•N2 pressure control for tuners (1 per cavity)•Cooling water temperature/flow

•Module vacuum•Getter pump power supply and controller•Pump thermocouple•Vacuum pressure



Summary

•Module to be shipped with all sensitive components removed and packaged separately

•Vertical shipping orientation also provides comfortable clearance through MICE Hall door

•Module re-assembly will require specially designed lifting fixtures

•Module interfaces will be defined in an interface document

•Utility requirements have been established

•Instrumentation & controls list being compiled

Assembly, Installation and Interfaces Steve Virostek Lawrence Berkeley National Lab RFCC Module...

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