Spreaders & RecombinersBeam Transport

Michael BevinsMay 30, 2007

12GeV Upgrade - Beam Transport

Spreader/Recombiner Dipoles and Layout, & Installation Labor

Preliminary Design and Safety Review

Outline

• Introduction & Scope• Requirements & Specifications• Beam Transport Layouts• Safety Considerations• Cost Estimates• Risk Assessment• Summary

Introduction & Scope

• 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

• The latest and greatest layouts for each of the five spreader & recombiner regions will be presented today along with cost estimates

• We expect these layouts to continue to evolve as we work with CASA to minimize the number of interferences as a result of beam transport geometry changes

• Cost and installation labor estimates that will be discussed today were developed based on layouts available in March

– Layouts have continued to be refined• Detailed design of these regions is scheduled to begin early next year and continue into

2009

Requirements & Specifications

• Alignment specs– Quads positioned to +/-0.5mm in x & y, +/- 1.0mm 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

• Fabrication, 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 – Note an update and modernization of our vacuum specs is underway

Same as CEBAF…

Beam Transport Layouts – Spreaders & Recombiners

• Two spreader regions– 1st and 2nd spreaders

• Three recombiner regions– 1st , 2nd and transport recombiners

Beam Transport Layouts – 1st Spreader

Current Configuration

12GeV Configuration

Relocate

Delete

New

Upgrade•Upgrade three QA quads to QRs and add H-steel to ten 1m dipoles

•Relocate twelve quad girders, two YR septa magnets and six 1m dipoles

•Elevation of the 2nd, 3rd, and 4th pass beams have changed between dipoles in the first step

•Delete three 1m dipoles and one quad girder

•Add two new curved dipoles, one 3m septa and the beamline to hall D

Changes…

Beam Transport Layouts – 1st Spreader

12GeV 1st Spreader Layout – Identified Interferences

•Songsheet level girder and dipole geometry used in layouts

•Detailed documentation of actual geometry is limited

•Compared songsheet geometry to photographs of each girder

•Will need to confirm geometry by measuring every girder in each spdr and recombiner

Beam Transport Layouts – 1st Spreader12GeV 1st Spreader Layout –Potential solutions…

•Identified potential solutions to eliminate interferences

•Some existing girders require modification to eliminate interference

•Will work with CASA to try and minimize alteration of existing girders by moving elements

Beam Transport Layouts – 1st Spreader

12GeV Layout with Existing Stands

•Replace 10 vertical stands, modify 2

•Reuse vertical stand ceiling and floor foundations

•Relocate if necessary

•Add 2 new pedestal style stands to support 3m septa

•Replace all girder to support stand brackets in first step between dipoles

Replace

Modify

No Change

Support stand modification assumptions for cost estimate…

Beam Transport Layouts – 1st Recombiner

Current Configuration

12GeV Configuration

•Upgrade three QA quads to QRs and add H-steel to ten 1m dipoles

•Relocate fourteen quad girders, one YR septa magnet and seven 1m dipoles

•Elevation of the 2nd, 3rd, and 4th pass beams have changed between dipoles in the first step

•Delete three 1m dipoles

•Add two new curved dipoles, one 3m septa

Changes…

Relocate

Delete

New

Upgrade

Beam Transport Layouts – 2nd Spreader

Current Configuration

12GeV Configuration

Relocate

Delete

New

Upgrade•Upgrade one QA quad to QR and add H-steel to eight 1m dipoles

•Relocate seven quad girders, and four 1m dipoles

•Elevation of the 4th pass beam has changed between dipoles in the first step

•Delete three 1m dipoles, two curved dipoles, and two septa magnets

•Add two new curved dipoles, two 3m septa, one 1.5m dipole, one 2m dipole, and two quad girders

Changes…

Beam Transport Layouts – 2nd Recombiner

Current Configuration

12GeV Configuration

Relocate

Delete

New

Upgrade

•Upgrade three QA quads to QRs, add QB to QC girder, and add H-steel to eight 1m dipoles

•Relocate fifteen quad girders, and four 1m dipoles

•Elevation of the 4th pass beam has changed between dipoles in the first step

•Delete one 1m dipole, two curved dipoles, and one YR septa

•Add two new curved dipoles, one 1.5m dipole, one 2m dipole, two 3m septa and the arc 10 beamline

Changes…

Beam Transport Layouts – Transport Recombiner

Current Configuration

12GeV Configuration

Relocate

Delete

New

Upgrade

•Upgrade two QA quads to QRs and add H-steel to eight 1m dipoles

•Remove 2nd quad from three dbl QC girders (install on three new 5th pass girders), relocate two YA septa magnets to the extraction region

•Elevation of the 4th pass beam has changed between dipoles in the first step

•Delete three 1m dipoles, two curved dipoles, two YR septas, and one quad girder

•Add three new QC girders, two new curved dipoles, two 3m septas, one 1.5m dipole, and one 2m dipole

Changes…

Beam Transport Layouts – Selected Images

Beam Transport Layouts – Selected Images

Beam Transport Layouts – Selected Images

Safety Considerations

• Personnel Training– Jlab & sub-contractor

• Radiation– Designated areas for containment and radiation survey

of material that will be removed from the tunnel• Material handling

– Provide provisions for lifting• Electrical Hazards

– Package and support electronics, power leads and terminal blocks to control electrical hazards

Cost Estimates – Spreader & Recombiner WBS Rollup

WBS Elements I have covered today

12GeV Beam Transport Scope, Labor & Procurement Estimate

D/PM & J Material

1.3.4.1SPREADERS & RECOMBINERS 186.0 47.6 431.9 660.7 162.7 1937.8 484.8 185.6 54.0 13.5

1.3.4.1.1 DIPOLES 110.7 20.3 86.9 213.1 51.0 1374.5 324.6 185.6 54.0 13.5

1.3.4.1.2 QUADS &CORRECTORS 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0

1.3.4.1.4 GIRDERS & STANDS 11.6 7.5 3.5 22.6 5.4 232.3 65.4 0.0 0.0 0.0

1.3.4.1.6 VACUUM 17.5 7.8 66.9 92.2 23.1 234.0 80.9 0.0 0.0 0.0

1.3.4.1.7 INSTALLATION &ALIGNMENT 46.2 12.0 274.6 332.8 83.2 96.9 13.9 0.0 0.0 0.0

TotalContingency

Total Contingency

LABOR [Man Wks] PROCUREMENTS [$k] EXPENSES [$k]

WBS ELEMENT ME MD MT Total Contingency

Cost Estimates - Highlighted WBS

Girders & Stands - Procurements

WBS ELEMENT /Activity ID ACTIVITY DEFINITION / SCOPE ITEMS Basis D/PM J D/PM & J

Total [$k]

1.3.4.1.4 GIRDERS & STANDS 232.3 65.4

2 Vend Fab New S/R Stands (S/R Stands) 151.5 37.9m Procure new stands for NE sprdr, NW, and AT recombiners 3560 30 106.8 eng jud 0.25 26.7m Procure new stands for SW sprdr & SE recombiner 3560 8 28.5 eng jud 0.25 7.1

mProcure new pedestal stands for NE sprdr, NW, and AT recombiners 900 6 5.4 eng jud 0.25 1.4

m Procure new pedestal stands for SW sprdr 900 4 3.6 eng jud 0.25 0.9m Procure new pedestal stands for SE recombiner 900 2 1.8 eng jud 0.25 0.5m Procure new quad pedestal stands for 5th pass AT line 900 6 5.4 eng jud 0.25 1.44 Vend Fab Modified S/R Stands (S/R Stands) 7.5 2.6m Modify existing S/R stands 7500 1 7.5 eng jud 0.35 2.65 Vend Fab S/R Cartridges & Brackets (S/R Stands) 73.4 0.34 24.9

mProcure brackets for relocated quad girders in first step of each spreader and recombiner (assume 15 per region) 800 75 60.0 eng jud 0.35 21.0

mProcure brackets for (1) additional QA/QA girder and (2) QA girders 800 3 2.4 eng jud 0.35 0.8

m Procure brackets for 1m H-style dipoles 800 9 7.2 eng jud 0.35 2.5m Procure alignment cartridges 150 25 3.8 eng jud 0.15 0.6

PROCUREMENTS

Unit Cost [$]

ContingencyQTY Total

[$k]

Cost Estimates - Highlighted WBS

Vacuum - Procurements

WBS ELEMENT /Activity ID ACTIVITY DEFINITION / SCOPE ITEMS Basis D/PM J D/PM & J

Total [$k]1.3.4.1.6 VACUUM 234.0 80.9

2 Vend Fab S/R Dipole Chambers (S/R Vac) 155.6 54.5m Procure new chambers for relocated septa magnets 8650 3 26.0 eng jud 0.35 9.1m Procure chambers for new 3m septa magnets 8650 8 69.2 eng jud 0.35 24.2m Procure chambers for new banana magnets 2774 10 27.7 eng jud 0.35 9.7m Procure chambers for dipoles (due to bending radius mod) 2182 15 32.7 eng jud 0.35 11.53 Vend Fab Misc Drift Chambers & Vac Matrl's (S/R Vac) 73.4 25.7m Procure new drift tubes 405 75 30.4 eng jud 0.35 10.6m Procure new bellows 400 50 20.0 eng jud 0.35 7.0m Procure CF flange pair gaskets & hardware 7500 1 7.5 eng jud 0.35 2.6m Procure CF flanges to mod drift tubes 5500 1 5.5 eng jud 0.35 1.9

misc Vacuum supplies 2000 5 10.0 eng jud 0.35 3.56 Reinstall & Cmmssn Vac Sys (S/R Vac) 5.0 0.8

Summary 5000.0 1 5.0 c/d 0.15 0.8

PROCUREMENTS

Unit Cost [$]

ContingencyQTY Total

[$k]

Risk Assessment

• Technical - Low– Girders & Supports – very similar designs exist and are

already proven– Alignment - same as existing machine

• Schedule– Procurement - Low

• No long-lead items identified– Installation – Low

• Cost – Low– Good cost estimates for machined parts

• Vendor & Jlab shop budgetary estimates

Summary

• Preliminary spreader/recombiner beam transport layouts, cost and installation estimates to support CEBAF at 12GeV are complete based on present scope

• We are in a good position to support our DOE External Project Reviews this summer

• 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

• Detailed design will be completed to support assembly and installation schedules

• We look forward to comments & recommendations from the committee