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Shipping, Installation and Interfaces Steve Virostek Lawrence Berkeley National Lab RFCC Module Preliminary Design Review June 4, 2008 Topic Summary Module shipping logistics Delivery to RAL Module re-assembly at RAL Installation in MICE Hall Module interfaces Flanges and seals

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shipping installation and interfaces

Shipping, Installation and Interfaces

Steve Virostek

Lawrence Berkeley National Lab

RFCC Module Preliminary Design Review

June 4, 2008

slide2

Topic Summary

  • Module shipping logistics
  • Delivery to RAL
  • Module re-assembly at RAL
  • Installation in MICE Hall
  • Module interfaces
    • Flanges and seals
    • Base mounting
    • RF feeds
  • Utility requirements

Steve Virostek - Lawrence Berkeley National Lab - June 4, 2008

slide3

Module Shipping Logistics

  • Cavities, couplers, coolers & pumps removed
  • Vacuum vessel/magnet mounted on short stand
    • Short stand also used during assembly
  • Coupling coil magnet shipped warm without cryocoolers in place
  • Cavities and couplers will be packaged separately to prevent damage
  • Vacuum vessel and cavities are to be blanked off and backfilled with N2

Steve Virostek - Lawrence Berkeley National Lab - June 4, 2008

slide4

RFCC Module Shipping Configuration

Cryocoolers removed

Cavities removed

Couplers removed

Vacuum pumps removed

  • Module short stand used for:
  • Initial module assembly
  • Shipping to RAL
  • Moving into MICE Hall

Steve Virostek - Lawrence Berkeley National Lab - June 4, 2008

slide5

Delivery to RAL

  • Module arrives on short stand without cavities, coolers or couplers installed
  • MICE Hall door height: 3360 mm
  • Module height on short stand: 2844 mm
    • Height is without cryocoolers installed
  • Roller dollies w/forklift used to move into hall

~100 mm tall

Roller dollies

Steve Virostek - Lawrence Berkeley National Lab - June 4, 2008

slide6

MICE Hall Access

Steve Virostek - Lawrence Berkeley National Lab - June 4, 2008

slide7

Re-assembly of Module at RAL

  • Unpack cavities, couplers, coolers, pumps
  • Operating stand placed on lateral tracks
  • Vacuum vessel/coupling coil is loaded onto operating stand for final assembly
  • Portable clean room erected around module
  • Cavities are installed using special lift fixture
  • Couplers and tuner actuators are installed after cavity is aligned and supported w/struts
  • Vacuum pumps are added to complete module
  • Final alignment performed before translation

Steve Virostek - Lawrence Berkeley National Lab - June 4, 2008

slide8

Re-assembly of Module at RAL

Support stand in place on rail platform

Steve Virostek - Lawrence Berkeley National Lab - June 4, 2008

slide9

Empty module lifted over support

Steve Virostek - Lawrence Berkeley National Lab - June 4, 2008

slide10

Re-assembly of Module at RAL

Module lowered onto support

Steve Virostek - Lawrence Berkeley National Lab - June 4, 2008

slide11

Re-assembly of Module at RAL

Support stand gussets added

Steve Virostek - Lawrence Berkeley National Lab - June 4, 2008

slide12

Re-assembly of Module at RAL

Support stand gussets added

Steve Virostek - Lawrence Berkeley National Lab - June 4, 2008

slide13

Re-assembly of Module at RAL

Cryocooler(s) installed

Steve Virostek - Lawrence Berkeley National Lab - June 4, 2008

slide14

Re-assembly of Module at RAL

Cryocooler(s) installed

Steve Virostek - Lawrence Berkeley National Lab - June 4, 2008

slide15

Re-assembly of Module at RAL

RF cavities installed from either end

Steve Virostek - Lawrence Berkeley National Lab - June 4, 2008

slide16

Re-assembly of Module at RAL

Module with all four cavities installed

Steve Virostek - Lawrence Berkeley National Lab - June 4, 2008

slide17

Re-assembly of Module at RAL

Cavity tuner actuators added

Steve Virostek - Lawrence Berkeley National Lab - June 4, 2008

slide18

Re-assembly of Module at RAL

Cavity tuner actuators added

Steve Virostek - Lawrence Berkeley National Lab - June 4, 2008

slide19

Re-assembly of Module at RAL

Module vacuum pumps installed

Steve Virostek - Lawrence Berkeley National Lab - June 4, 2008

slide20

Re-assembly of Module at RAL

Module vacuum pumps installed

Steve Virostek - Lawrence Berkeley National Lab - June 4, 2008

slide21

Re-assembly of Module at RAL

RF couplers installed

Steve Virostek - Lawrence Berkeley National Lab - June 4, 2008

slide22

Re-assembly of Module at RAL

RF couplers installed

Steve Virostek - Lawrence Berkeley National Lab - June 4, 2008

slide23

Installation in MICE Hall

  • Module assembled on lateral tracks
  • Module aligned and shimmed to correct height
  • Bellows on either end of module are pulled back into open position and O-ring in place
  • Moved into position w/rails for final alignment
  • Bellows are released and flanges are sealed
  • Bellows are locked out using bridging bolts
  • RF and utilities are connected to module

Steve Virostek - Lawrence Berkeley National Lab - June 4, 2008

slide24

Module Flange Connection

End flange O-ring seal

Formed bellows

Flange through holes

Steve Virostek - Lawrence Berkeley National Lab - June 4, 2008

slide25

Flanges and Seals

  • Flanges designed to mate with AFC module
  • AFC flanges are flat w/no grooves or bellows
  • RFCC modules have bellows and O-ring grooves on flanges at either end
  • Bellows have >1 cm of total travel
  • Bellows are locked out after installation to provide a means of transmitting forces between modules

Steve Virostek - Lawrence Berkeley National Lab - June 4, 2008

rfcc bellows and flange
RFCC Bellows and Flange

Bellows pull back bolts

Elastomer or Helicoflex all-metal O-ring

Clamping bolts

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

Steve Virostek - Lawrence Berkeley National Lab - June 4, 2008

Allan DeMello - Lawrence Berkeley National Lab - June 4, 2008

Page 26

slide27

Module Joint Sealing Issues

  • MICE module joints may need somewhat frequent disassembly (reconfiguring, maintenance, repair)
  • O-rings will 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 all technologies for a future machine including the use of metal seals
  • The O-ring groove is design to accept a Helicoflex all-metal O-ring for demonstration purposes

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

Steve Virostek - Lawrence Berkeley National Lab - June 4, 2008

Allan DeMello - Lawrence Berkeley National Lab - June 4, 2008

Page 27

module base mounting
Module Base Mounting
  • Module base connection to rails identical to that used on the Spectrometer Solenoid
  • Six mounting plates are welded to the base of the module support stand
  • Precise geometry and location of the mounting plates to be coordinated w/RAL during CM21
  • All magnetic loads are carried to the floor through the mounting plates

Steve Virostek - Lawrence Berkeley National Lab - June 4, 2008

slide29

Module Mounting Provision

  • Six mounting plates to be welded to the support stand base for installation on rails
  • Similar to spectrometer solenoid mounting scheme

Steve Virostek - Lawrence Berkeley National Lab - June 4, 2008

slide30

Cavity RF Feeds

  • Eight RF feeds/module use standard 4” RF coax
  • Cooling water for loop is required (<<1 lpm each)
  • Adapter on end of couplers isolates ceramic RF windows from forces during installation
  • Location of coax interface w.r.t. module center TBD

RF feeds

Steve Virostek - Lawrence Berkeley National Lab - June 4, 2008

module utility requirements
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
  • Power for periodic getter pump regeneration (TBD)
  • Liquid cryogens: LN2 and LHe for cooldown (qty TBD)
  • Instrumentation monitoring requirements
    • Various voltages, temperature, He level, heaters, pressure, vac.

Steve Virostek - Lawrence Berkeley National Lab - June 4, 2008

cryocooler compressor
Cryocooler Compressor
  • Dimensions:
  • 61x58x97 (LxWxH, cm)
  • On ~7 cm  wheels
  • Weight:
  • 223 kg
  • He flex line length:
  • 20 meters
  • Lifting eyes:
  • 4 ea on top (one/corner)
  • 6 meters min. to magnets

Steve Virostek - Lawrence Berkeley National Lab - June 4, 2008

slide33

Summary

  • Module to be shipped w/sensitive components removed and packaged separately
  • Short shipping stand provides comfortable clearance through MICE Hall door
  • Module re-assembly at RAL will require a portable clean room
  • Installation in MICE Hall
  • Module interfaces to be finalized soon
    • Flanges and seals, base mounting, RF feeds
  • Utility requirements have been established

Steve Virostek - Lawrence Berkeley National Lab - June 4, 2008