Quad Girders

Michael Bevins

May 3, 2007

12GeV Upgrade - Beam Transport

Quads & Girders,Arc 10 and Hall D Layout

Preliminary Design and Safety Review

Outline

• Introduction & Scope

• Requirements & Design Philosophy

• Girder Count - Flavors

• Girder Layouts

• Bolted Plate Girder vs Extrusion

• Safety Considerations

• Cost Estimates & Schedule

• Risk Assessment

• Summary

Introduction & Scope

• The12GeV upgrade requires an addition of ~91 quad girders

• 74 of the 91 girders will be in the new ARC 10 and Hall D lines

• 12GeV field strength requirements force us to modify 44 existing quad girders

– Some quads will be replaced with higher strength quads (e.g., QA to QR)

– Some girders will require an additional quad

• Songsheet level layouts are being used to identify the number of girder flavors that will be required

– We expect a number of custom designs will be needed in the spreader and recombiner regions

• Girder requirements, design philosophy, flavors, & cost estimates will be presented today

• An alternative to the CEBAF style extruded girder will also be presented

Requirements/Design Philosophy

Same as CEBAF...• Structural

– Support girder elements and maintain alignment during shipping and installation

• Alignment– Quad +/- 0.5mm in x & y, 1.0mm in z – BPM relative to quad +/- 0.25mm in x & y

• Diagnostics– Girders should support typical suit of diagnostics and correctors

• BPM, Harp, Viewer, H & V correctors (BC, BD, …)– Provide means to support electronics packaging and wiring

• Vacuum– Provide support for pumps, roughing valves, gauges

• Handling– Provide tapped holes for commercial lifting rings

• Complete double quad girder weighs ~1200lbs

Girder Count - Flavors

RegionNew SingleQuad Girder

QTYNew DoubleQuad Girder

QTY Modified Girder QTY

Hall D 18 7QA 13 QA/QA 3QC 4 QP/QP 3QR 1 QR/QR 1

ARC 10 35 14QC 2 QP/QP 8QA 5 QA/QA 3QR 4 QB/QC 1QP 24 QR/QR 2

Linac 10 2QB wrm gdr 10 QB to QC 2

Injector & Re-Injection 2QD 2

Existing Arc & Hall Transport 20QA to QR 20

Sprdrs & Recombiners 5 22QA 1 QA to QR 12QC 4 QC to QB/QC 4

QA to QR/QR 1QA/QA to QA/QR 4QA/QA to QR/QR 1

New SingleQuad GirderTOTAL 70

New DoubleQuad GirderTOTAL 21

Modified GirderTOTAL 44

Girder Layouts – Typical CEBAF Quad Girder

BellowsBPM

Quad CorrectorsViewer & Pump

Drop Cross

Alignment cartridge

(support pt)

Extruded Aluminum “Girder”

Beamline Spt – “Goal Post Style”Beamline Spt –

“V-block Style”

Girder LayoutsNew 12GeV girders• Use basic CEBAF designs!• Maintain same quad position

relative to alignment cartridge supports

• Use only simple BPM style V-block supports– Like the FEL

• Provide support for upstream bellows flange and downstream end of pump/viewer cross

• Design new QR and QP quads to have same interface as QA’s– Reduces the number of

flavors• Space quads on dbl girder so

one design will suit QAQA, QAQR, QRQR, etc..

• Use mandrel to align girder elements (BPM, Viewer) relative to quad (same as CEBAF & FEL)

Double Quad Girder

Single Quad Girder

QuadBPM

Bellows

ViewerCorrectors

Alignment Cartridge (support pt)

Alignment Cartridge (support pt)

Vac pump drop

Girder Layouts

• The swap from QA to QR quad represents 32 of the 44 existing girders that require modification

• Tommy’s 14” QR drops right into the existing typical QA girder!

• CEBAF extruded girder was manufactured by Alcoa– Alcoa no is longer in position to form this large hollow shape

• Plant that produced girder for JLab closed shortly after last purchase of FEL girders in 1999 (plant has since re-opened)

• CEBAF shape tooling no longer in Alcoa inventory• Requested quote from Alcoa for open shape consistent with JLab standard beamline

supports

Bolted Plate Girder vs Extrusion

CEBAF Extruded Shape Alternate Shape

• Significant one time tooling cost for alternative shape! $40,000• Explored alternative vendor --- no luck! This is a very large shape!• Would still expect large tooling cost even if another vendor capable of producing the

section could be found– Decided to explore building up section from stock AL plate and bars

Bolted Plate Girder vs Extrusion

Bolted Plate Girder

• Principal area moments of inertia (resistance to bending) nearly identical to CEBAF shape– Torsional stiffness is reduced

• Consulted with G. Biallas about original CEBAF specs and alternative bolted plate girder design– No specific requirement for torsional stiffness existed for CEBAF– Alternative looked reasonable to him!

• Bolted plate girder turns out to be quite attractive from manufacturing perspective– Bar and plate can be handled on smaller less expensive ($/hr) machines

• Reduces machining costs– All features can be machined on the plates prior to assembly

• Double quad girder rails would require finish machining after assy (consistent with original CEBAF design)

– Girders would be purchased assembled complete with beamline support hardware (cross bars, v-blocks, etc..)

Safety Considerations

• Personnel Training

– Jlab & sub-contractor

• Radiation

– Designated areas for containment and radiation survey of girders 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

• Sum of beam transport quad girder WBS procurements ~$450k• Cost estimates developed using existing girder assembly drawings• Estimates assume bolted plate girder design• Estimates are based on combination of vendor quotes, past purchases (FEL

costs, SL 21 warm region girder), Jlab machine shop estimates and engineering judgment

Girder TypeGirder Cost

[FY07$]

Typical Single Quad Girder 3349Supports & Hardware 2200Vacuum 1149

Typical Double Quad Girder 3849Cost of single quad girder 3349Quad alignment rails 500

Typical LINAC Warm Region Girder 6546Supports & Hardware 2350Vac (includes 40L/s ion pump & roughing valve) 4196

Schedule

• New girder procurements in time to support girder build up prior to major installation down

• Modified girder swap out and modifications during major down requires more detailed study

• Detailed reuse vs mod vs make plan TBD to optimize cost and schedule savings– Inventory of existing girder extrusion and support

hardware as well as a complete accounting of parts that will be removed from modified girders is planed

Risk Assessment

• Technical - Low

– Girders & Supports – very similar designs exist and are already proven

– Alignment - same as existing machine

• Procurement Schedule - Low

– No long-lead items identified

• Cost – Low– Linac warm region girder recently prototyped

– Vendor quotes for most vacuum elements

• Pumps, valves, spools, diag/pump cross

– Good cost estimates for machined parts

• Vendor & Jlab shop budgetary estimates

• Referenced recent FEL beam transport purchases

Summary

• The 12 GeV beam transport girder designs are more than 35% complete thus exceeding the goal set 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, I&C, magnet measurement, operations, procurement & facilities) as we move forward

• Detailed design will be complete in 2008 to support assembly and installation schedules

• We look forward to comments & recommendations from the committee

Arc 10 & Hall D

Michael Bevins

May 3, 2007

12GeV Upgrade - Beam Transport

Quads & Girders,Arc 10 and Hall D Layout

Preliminary Design and Safety Review

Outline

• Requirements & Specifications

• ARC 10

– Elements/Girder Count

– Beam Transport Layout

– Vacuum Analysis

– Highlighted Challenges

• Hall D

• Safety Considerations

• Cost & Risk Assessment

• Summary

Requirements & Specifications

• Alignment specs

– Quads and dioples 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

ARC 10 - Definition

ARC 10

ARC 10

• The ARC 10 line begins with the first quad in the west spreader and ends with the last quad in the north west recombiner

– Includes 3 quads in the extraction region

For this review ARC 10 is defined as:

ARC 10 Elements/Girder Count

• The ARC 10 line uses the same beam optics design as arcs 3-9

• Quads & correctors selected by MEG based on CASA field strength and aperture requirements

• Diagnostics defined by Tech Note 05-053

Element QtyQuads 64

QA 12QP 40QR 8QB 1QC 3

Correctors 72

BD Horizontal 37BD Vertical 35

Dipoles 32

4m 32

Element QtyDiagnostics

BPM 46Viewer 9SLM 1

Dump

Insertable 1Vacuum

Ion Pump 37Convectron Gauge 3Beam Valves 4Roughing Valve 2

QtyQuad Girders 54

Single Quad Girders 40

QA 10QR 4

QP 24QC 2

Double Quad Girders 14

QA/QA 3

QR/QR 2QP/QP 8QB/QC 1

• Vacuum elements (pumps, gauges, valves) qty & position follow existing arc design

• Elements in red are part of I&C WBS

ARC 10 Beam Transport Layout Typical segment from the west arc

3 Single quad girders 1 Double

quad girderARC 10

Four 4m Dipoles

Repeating structure

ARC 10 Beam Transport Layout

4m dipole pedestals Girder

pedestal

Existing standsDipole & girder supports• New dipoles and girders will

be 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 will be supported and aligned using our standard heavy duty alignment cartridges

– 5000# load capacity per cartridge

– 4m dipole weight ~7000#

ARC 10 Preliminary Vacuum Analysis • 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 same as existing arcs (3”OD)

• Ion pump size - 15 L/s

• Analysis does not include synchrotron radiation effects

– 109 watts total (~0.4W/m)

Repeating structure

• Design meets specification– Average pressure is < 5*10-7 torr

ARC 10 Preliminary Vacuum Analysis

ARC 10 Beamline Pressure & Conductance Profiles

0.00E+00

1.00E-07

2.00E-07

3.00E-07

4.00E-07

5.00E-07

6.00E-07

0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31

Distance [m]

Pre

ss

ure

[to

rr]

05101520253035404550

Co

nd

uc

tan

ce

[m

-L/s

]

Pressure

Conductance

ARC 10 Highlighted Challenges

• Identify interference between the arc 10 line and the existing stands in the extraction and injector/re-injection region

– Some of the stands in these regions were modified in the field - documentation is incomplete

– Plan to work with the alignment group to obtain as built coordinates of suspect areas

Hall D - Definition

Tagger Bldg

• The Hall D line begins with the first quad in the east spreader and ends at the beam dump in Hall D tagger building

For this review Hall D is defined as:

East spreader

Hall D Elements/Girder Count

• Quads & correctors selected by MEG based on CASA field strength and aperture requirements

• Diagnostics defined by Tech Note 05-053

• Vacuum elements (pumps, gauges, valves) qty & position/spacing based on CEBAF existing hall transport lines

• All dipoles and girders will be supported by pedestals from the floor

• Elements in red are in I&C WBS

Element QtyQuads 32

QA 19QP 6QR 3QC 4

Correctors 52

BD Horizontal 26BD Vertical 26

Dipoles 5

2m 14m 4

QtyQuad Girders 25

Single Quad Girders 18

QA 13QR 1QC 4

Double Quad Girders 7

QA/QA 3QR/QR 1QP/QP 3

Element QtyDiagnostics

BPM 29Viewer 7Harp 4SLM 2BCM 2Cavity BPM 2

Dumps

Insertable 1Beam Stopper Sys 1High Power Dump 1

Vacuum

Ion Pump 25Convectron Gauge 6Beam Valves 7Roughing Valve 6

Hall D Beam Transport Layout

Hall D WBS

Hall D line ~7 inches from nominal tunnel floor

Hall D Beam Transport Layout

Drift 8 Single Quad Girders

Hall D Beam Transport Layout

10deg ramp to Hall D Point of tangency Insertable

DumpBeam stoppers

4m dipoles

6 Quad girders

SLM

8 Quad girders

4m dipoles

Sliding shield wall

Cavity BPM

Hall D Beam Transport Layout

SLM

Hall D Beam Transport Layout - Tagger BldgTagger Bldg Plan view:

Elevation:Cavity BPM

Beam Dump

2.8M lbs of Steel sheilding

BPM & BCM

71 in14.8 ft

Dump Viewer

Hall D Preliminary Vacuum Analysis

• 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 same as existing arcs (3”OD)

• Number of pumps based on CEBAF

– Detailed analysis TBD

Hall D Highlighted Challenges

Identify potential interference between Hall D line and existing machine elements

Dog Leg Section Dipole stand interference

• Hall D line runs through existing dog leg dipole support stand

– Plan to bore hole through stand for beam pipe

• Required reinforcement TBD

Bore Hole Here

Hall D Highlighted Challenges

Identify interference between Hall D line and existing stands

Apparent Dipole stand interference

Possible stand interference

• Hall D line appears to run through at least one of the existing arc dipole stands (maybe two)

– Plan to ask survey & alignment to verify stand positions

View from NE stub

Hall D Highlighted Challenges Mount girder 1.32in off nominal girder floor!!• Initially envisioned upside down girder

• But old CEBAF style “drop girder” turned out to be far more attractive

Upside Down Girder

“Drop Girder” 3 Point Mount to Girder

Hall D Highlighted Challenges Conceptual design for Hall D line floor girder

• ~1inch allowance for grout under foundation plates

• Scheme allows full range of alignment cartridge adjustment

• Plan to get actual floor position information to confirm clearance

Safety Considerations

• Personnel Training– Jlab & sub-contractor

• Radiation– Removal and relocation of north east stub dump to tagger bldg– Designated areas for containment and radiation survey of

materials that will be removed from the tunnel– In situ modification of stands

• Coordination with civil and Hall D installation • Material handling

– Working on 10deg slope– Shielding removal and installation

• Potential hot work• Electrical Hazards

Cost Estimates

12GeV Beam Transport Scope, Labor & Procurement Estimate

D/PM & J Material

1.3.4.5 ARC 10 AND HALL D 119.6 50.8 284.4 454.8 115.6 4816.1 1167.4 453.7 19.0 4.8

1.3.4.5.1 DIPOLES 42.1 6.2 14.9 63.2 15.8 2214.8 553.7 285.2 19.0 4.8

1.3.4.5.2QUADS &CORRECTORS

16.7 11.0 12.0 39.7 9.9 1542.6 385.7 168.5 0.0 0.0

1.3.4.5.4GIRDERS & STANDS

17.4 13.1 11.0 41.5 10.4 489.1 116.0 0.0 0.0 0.0

1.3.4.5.6 VACUUM 16.0 11.0 43.6 70.6 17.6 300.3 62.7 0.0 0.0 0.0

1.3.4.5.8INSTALLATION &ALIGNMENT

27.4 9.5 202.9 239.8 62.0 269.4 49.4 0.0 0.0 0.0

ELEMENTWBS Total Contingency

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

ContingencyTotalContingencyTotalMTMDME

WBS Elements I have covered today

Risk Assessment

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

already proven– Vacuum – design consistent with existing machine – Alignment - same as existing machine

• Procurement Schedule - Low– No long-lead items identified

• Cost – Low– Good girder, stand and alignment cartridge cost

estimates– Good estimates for vacuum tubes, flanges, pumps,

valves

Summary

• The arc 10 and hall D beam transport designs are 35% complete thus meeting the goal set 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, I&C, magnet measurement, operations, procurement & facilities) as we move forward

• Detailed design will be complete in 2009 to support assembly and installation schedules

• We look forward to comments & recommendations from the committee