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LCLS DOE Review Fixed Support Design & Testing Brian Rusthoven Sushil Sharma V. Ravindranath

LCLS DOE Review Fixed Support Design & Testing Brian Rusthoven Sushil Sharma V. Ravindranath M. Bracken Acknowledgment C. LeCocq, R. Boyce, F. Peters G. Pile, H. Friedsam, E. Trakhtenberg. Topics. Background Relevant Design Specifications Engineering Design Installation Concept

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LCLS DOE Review Fixed Support Design & Testing Brian Rusthoven Sushil Sharma V. Ravindranath

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  1. LCLS DOE Review Fixed Support Design & Testing Brian Rusthoven Sushil Sharma V. Ravindranath M. Bracken Acknowledgment C. LeCocq, R. Boyce, F. Peters G. Pile, H. Friedsam, E. Trakhtenberg

  2. Topics • Background • Relevant Design Specifications • Engineering Design • Installation Concept • Summary • Thermal Stability • Dynamic Stability • Design Details • Alignment : 3 or 4 Support Points • Preliminary tests

  3. Original Baseline – Spring 2005 Undulator Quad Fixed Support Cam Mover • 12 meter long granite girders, each supporting 3 undulators and 3 quads. • Approximate cost of 0.8 m x 0.8 m x 12 m granite block: $40,000 each. • The Granite girder was to be enclosed in water-cooled thermal insulation. • The girder rested on kinematic supports.

  4. Background • Original calculations were based on 20 µm of random floor settlement between BBA sessions. • 1 µm per day per 10 m for 20 days • Those calculations were redone using more realistic floor settlement numbers from the APS. • Based on the second calculations, no advantage was seen in using 12 m long girders as compared to 3 m long girders.

  5. Relevant Design Specifications • LCLS Specification PRD #1.4 -001 • Short term (10 h) BPM and quad stability: ± 2 μm • Long term (24 h) BPM and quad stability: ± 5 μm • BPM and quad stability to position sensors : 2 μm • Relative floor settlement at 10 m (LCLS-TN-04-14): ~ ± 1 μm / day • Undulator tunnel temperature stability: ± 0.56º C • Max. floor settlement (LCLS-TN-04-14): ± 25 mm • Initial Concrete Pour + Life of Machine Engineering Specifications: ± 1/2” (12.7mm) beam direction alignment ± 1/2” (12.7mm) transverse alignment Height adjustment: ± 1” (25.4 mm) Mechanical alignment tolerance: < 20 μm Beam Centerline of 1.4 m

  6. Fixed Support / Girder Assembly Cam Movers Undulator Girder Connecting Plate Interface Plate Fixed Supports Design of the Fixed Support, Interface Plate and Connecting Plate for SUT

  7. Thermal Stability Transient Heat Transfer to Sandstone Initial Sandstone Temperature = 18 0C Temperature Contours Large thermal mass and low thermal conductivity of concrete/sandstone ensures thermal stability of the floor once steady state is reached. Steady State is reached in 150 days ~ 5 months Attach fixed supports to the floor

  8. Temporal Temperature Stability No temporal temperature stability specification has been established to date. So as a baseline assume at any one location in the tunnel, the floor and air temperatures change by 0.1 °C over 12 hours. Sand Steel Insulation Short term (10h) BPM and quad position stability: ± 2μm

  9. Finite Element Thermal Analysis (Temporal Temperature Stability) Thermal insulation and sand reduce the fixed support temperature rise by a factor of 2.

  10. Finite Element Thermal Analysis (Temporal Temperature Stability) • BPM and Quad positions change by: • 1.68 μm in 10 h • 3.36 μm in 24 h • Both short term and long term stability specifications have been met. • Specification requires: • Short term (10 h) BPM and quad stability: ± 2 μm • Long term (24 h) BPM and quad stability: ± 5 μm

  11. Comparison with Experiment (Temporal Temperature Stability)

  12. Dynamic Stability Seryi [2003] http://www.desy.de/~njwalker/uspas/coursemat/pp/unit_8.ppt#10 • Resonances above 30 Hz do not significantly affect dynamic stability, because of low ambient ground motion.

  13. Dynamic Stability (Resonances) Mode-1 (67.9 Hz) Mode-2 (76.9 Hz) Mode-3 (79.8 Hz) Mode-1 (521.18 Hz) Mode-2 (526.98 Hz) Mode-3 (783.88 Hz) No resonance below 30 Hz for the Fixed Support or the Girder / Undulator assembly. There is a possibility of resonance below 30 Hz coming from the Cam Movers or the Translation Stages.

  14. Dynamic Stability (<30Hz) √2 • Visco-elastic damping pads can be used if there are resonances below the 30 Hz range due to Cam Movers and Translation Stages. • Dampening pads reduced the original broadband quad motion at APS by a factor of 3 (4-50Hz).

  15. Alignment (3 or 4 Support Points) 4 points have been chosen for the Fixed Support: Pros - Improved dynamic stability and no interference with the girder. Cons - An over-constrained system requiring more time for alignment.

  16. Dynamic Stability (Redundant Support Point Benefits) SRRC SPring-8 * Similar to SUT design of the LCLS Fixed Support Reference: Sharma et al., “Ground Vibration Problems at the Light Sources,” GMV Workshop, November 6-9, 2000, SLAC

  17. Fixed Support Design - (Components) 1 ½” Interface Plate 1 ½” Top Plate 18” Schedule 40 Pipe 3” Fiber Wool Insulation 1”- 14 Base Leveling / Anchor Bolts Stand Cap 1 ½” Bottom Plate Non Shrinking Grout Silica Sand

  18. Fixed Support Design (Adjustment Method) • Engineering Specifications: • ± 1/2” (12.7mm) beam direction alignment • ± 1/2” (12.7mm) transverse alignment • Height adjustment: ± 1” (25.4 mm) Adjustment Point Upper Lock Nut Spherical Washer Pusher Block Spherical Support Nut (Pinned to Rod) Height Motion Point (Threaded Plate) Lower Lock Nut Height Adjustment Rod

  19. Alignment and Lifting Tests (Preliminary Designs) • Preliminary testing shows that it is possible to level the top plate and set the height to within ±10 µm. • Effort: 7 – 8 minutes for one mechanical technician with feedback from a designer. • Tested repeatedly using two different technicians with similar results. • Fixed Support design will be tested once prototypes have been built. Confidence is high that these results can be easily repeated with the design for SUT.

  20. Installation Concept Install and grout stands into location using the tunnel lattice.

  21. Installation Concept Fill stands with silica sand, cap and insulate them.

  22. Installation Concept Add Interface Plate Hardware and Interface Plate, Level Interface Plate

  23. Installation Concept Install Connecting Plate and Cam Movers on Interface Plate

  24. Installation Concept Place Girder/Undulator Assembly onto Cam Movers

  25. Summary • The design of the fixed supports for the Girder-Undulator system has been developed to meet stability, assembly and alignment specifications. • Support stands are grouted directly to the floor for thermal stability. • All alignment motions have been moved to the top of the support stand. • ΔT change of ± 0.56 ºC results in BPM and Quad displacements of ± 3.36 µm in 24 hrs. Both short term and long term specifications have been met. • The SUT design was deemed acceptable in an Internal Design Review (IDR) that was held on 1/12/06. • Fixed supports for 2 Girder-Undulator SUT assemblies are in fabrication, with an expected delivery of 2/17/06. • Following the SUT and Final Design Review, any design improvements will be identified and implemented.

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