Assembly, Installation and Interfaces
RFCC Module Design Review
October 21, 2008
Steve Virostek
Lawrence Berkeley National Lab
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
MICE RFCC Module Design Review – Assembly, Installation and Interfaces
Steve Virostek - Lawrence Berkeley National Lab - October 21, 2008
Page 2
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
MICE RFCC Module Design Review – Assembly, Installation and Interfaces
Steve Virostek - Lawrence Berkeley National Lab - October 21, 2008
Page 3
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
MICE RFCC Module Design Review – Assembly, Installation and Interfaces
Steve Virostek - Lawrence Berkeley National Lab - October 21, 2008
Page 4
Moving into MICE Hall
Cryocoolers removed
Cavities removed
Couplers removed
Vacuum pumps removed
Module short stand:
• Likely won’t be needed
• Vertical orientation shipping
stand can also be used to
move module into hall
MICE RFCC Module Design Review – Assembly, Installation and Interfaces
Steve Virostek - Lawrence Berkeley National Lab - October 21, 2008
Page 5
MICE Hall Access
MICE RFCC Module Design Review – Assembly, Installation and Interfaces
Steve Virostek - Lawrence Berkeley National Lab - October 21, 2008
Page 6
Re-assembly of Module at RAL
•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
MICE RFCC Module Design Review – Assembly, Installation and Interfaces
Steve Virostek - Lawrence Berkeley National Lab - October 21, 2008
Page 7
Re-assembly of Module at RAL
Support stand
in place on rail
platform
MICE RFCC Module Design Review – Assembly, Installation and Interfaces
Steve Virostek - Lawrence Berkeley National Lab - October 21, 2008
Page 8
Empty module
lifted over
support
MICE RFCC Module Design Review – Assembly, Installation and Interfaces
Steve Virostek - Lawrence Berkeley National Lab - October 21, 2008
Page 9
Re-assembly of Module at RAL
Module lowered
onto support
MICE RFCC Module Design Review – Assembly, Installation and Interfaces
Steve Virostek - Lawrence Berkeley National Lab - October 21, 2008
Page 10
Re-assembly of Module at RAL
Support stand
gussets added
MICE RFCC Module Design Review – Assembly, Installation and Interfaces
Steve Virostek - Lawrence Berkeley National Lab - October 21, 2008
Page 11
Re-assembly of Module at RAL
Support stand
gussets added
MICE RFCC Module Design Review – Assembly, Installation and Interfaces
Steve Virostek - Lawrence Berkeley National Lab - October 21, 2008
Page 12
Re-assembly of Module at RAL
Cryocooler(s)
installed
MICE RFCC Module Design Review – Assembly, Installation and Interfaces
Steve Virostek - Lawrence Berkeley National Lab - October 21, 2008
Page 13
Re-assembly of Module at RAL
Cryocooler(s)
installed
MICE RFCC Module Design Review – Assembly, Installation and Interfaces
Steve Virostek - Lawrence Berkeley National Lab - October 21, 2008
Page 14
Re-assembly of Module at RAL
RF cavities
installed from
either end
MICE RFCC Module Design Review – Assembly, Installation and Interfaces
Steve Virostek - Lawrence Berkeley National Lab - October 21, 2008
Page 15
Re-assembly of Module at RAL
Module with all
four cavities
installed
MICE RFCC Module Design Review – Assembly, Installation and Interfaces
Steve Virostek - Lawrence Berkeley National Lab - October 21, 2008
Page 16
Re-assembly of Module at RAL
Cavity tuner
actuators added
MICE RFCC Module Design Review – Assembly, Installation and Interfaces
Steve Virostek - Lawrence Berkeley National Lab - October 21, 2008
Page 17
Re-assembly of Module at RAL
Cavity tuner
actuators added
MICE RFCC Module Design Review – Assembly, Installation and Interfaces
Steve Virostek - Lawrence Berkeley National Lab - October 21, 2008
Page 18
Re-assembly of Module at RAL
Module vacuum
pumps installed
MICE RFCC Module Design Review – Assembly, Installation and Interfaces
Steve Virostek - Lawrence Berkeley National Lab - October 21, 2008
Page 19
Re-assembly of Module at RAL
Module vacuum
pumps installed
MICE RFCC Module Design Review – Assembly, Installation and Interfaces
Steve Virostek - Lawrence Berkeley National Lab - October 21, 2008
Page 20
Re-assembly of Module at RAL
RF couplers
installed
MICE RFCC Module Design Review – Assembly, Installation and Interfaces
Steve Virostek - Lawrence Berkeley National Lab - October 21, 2008
Page 21
Re-assembly of Module at RAL
RF couplers
installed
MICE RFCC Module Design Review – Assembly, Installation and Interfaces
Steve Virostek - Lawrence Berkeley National Lab - October 21, 2008
Page 22
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
MICE RFCC Module Design Review – Assembly, Installation and Interfaces
Steve Virostek - Lawrence Berkeley National Lab - October 21, 2008
Page 23
Module Flange Connection
End flange
O-ring seal
Formed
bellows
Flange
through
holes
MICE RFCC Module Design Review – Assembly, Installation and Interfaces
Steve Virostek - Lawrence Berkeley National Lab - October 21, 2008
Page 24
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
MICE RFCC Module Design Review – Assembly, Installation and Interfaces
Steve Virostek - Lawrence Berkeley National Lab - October 21, 2008
Page 25
RFCC Bellows and Flange
Elastomer or
Helicoflex allmetal O-ring
Bellows pull
back bolts
Clamping
bolts
MICEMICE
RF and
RFCC
Coupling
ModuleCoil
Design
Module
Review
– Summary
– Assembly,
of the
Installation
Design and
and
Fabrication
InterfacesPlan
Steve Virostek - Lawrence Berkeley National Lab - October 21, 2008
Page 26
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 allmetal Helicoflex seal for demonstration purposes
MICEMICE
RF and
RFCC
Coupling
ModuleCoil
Design
Module
Review
– Summary
– Assembly,
of the
Installation
Design and
and
Fabrication
InterfacesPlan
Steve Virostek - Lawrence Berkeley National Lab - October 21, 2008
Page 27
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
MICE RFCC Module Design Review – Assembly, Installation and Interfaces
Steve Virostek - Lawrence Berkeley National Lab - October 21, 2008
Page 28
Module Mounting Provision
•Six mounting plates to be
welded to the support stand
base for installation on rails
•Similar to spectrometer
solenoid mounting scheme
MICE RFCC Module Design Review – Assembly, Installation and Interfaces
Steve Virostek - Lawrence Berkeley National Lab - October 21, 2008
Page 29
Cavity RF Connections
RF feeds
•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
MICE RFCC Module Design Review – Assembly, Installation and Interfaces
Steve Virostek - Lawrence Berkeley National Lab - October 21, 2008
Page 30
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
MICE RFCC Module Design Review – Assembly, Installation and Interfaces
Steve Virostek - Lawrence Berkeley National Lab - October 21, 2008
Page 31
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
MICE RFCC Module Design Review – Assembly, Installation and Interfaces
Steve Virostek - Lawrence Berkeley National Lab - October 21, 2008
Page 32
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
MICE RFCC Module Design Review – Assembly, Installation and Interfaces
Steve Virostek - Lawrence Berkeley National Lab - October 21, 2008
Page 33