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3-Jan-20

This document outlines the development progress of Horizontal Test Stand (HTS-2) for testing SCRF cavities, addressing operational problems, internal circuit design, frame bridge options, FEM simulations, vessel design parameters, calculations, and structural analysis.

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3-Jan-20

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  1. Status of Horizontal Test Stand (HTS-2) Development Efforts Pradeep Kush,Prashant Khare, RRCAT, India Team Members: S.Gilankar, Rupul Ghosh, R.Chaube Abhishek Jain A.Laxminarayanan 3-Jan-20 1

  2. Introduction to HTS Design Effort 3-Jan-20 2

  3. Introduction to the Task • A Horizontal Test Stand (HTS-2) is needed to test dressed SCRF cavities before they are finally placed in the cryomodule. • HTS-1 is working at FNAL (Testing single 1.3 GHz cavity). • HTS-2 has to fulfill following requirement, different from HTS-1: • To test: two SCRF cavities of 650 MHz or any combinations with 1.3 GHz cavities or SC Magnet at a time. • The cavities will operate in CW mode – higher cryogenic heat load. • Operational problems of HTS-1 should be addressed. • The task has become tough because: • A) Apart from document on engineering design of vacuum vessel no other report /design note etc is available on HTS-1. • B) Issues of Subsystems like power coupler, cryogenic circuit, magnet, feed box are now trickling in, when the vessel and other systems are already finalized. 1/3/2020 3

  4. Status of HTS Development 3-D Model completed to visualize component assembly. The diameter was taken as 46 inches Vacuum vessel design complete. 2-D drawings completed. Frame bridge design almost complete. Options considered: SS frame bridge - long cool down time. Aluminum frame bridge - A prototype in Al fabricated. Cryogenic Support post designed. Scaled down prototype tested. Focus of present work is designing of internal Cryogenic circuit .

  5. A. 3-D MODEL OF HTS FOR SCRF CAVITIES OF 1300 / 650MHZ 3-D MODEL OF HTS WITH TWO AVITIES OF650MHZ

  6. Dimensions of HTS-2 vessel (2nd Revision) Feed Can port Support Post Port 3-D model Of Vacuum Vessel with changes incorporated after feedback from FNAL (2rd revision)

  7. Dimensions of HTS-2 vessel (3rd Revision) 2574 mm O.D. 1168 mm 2557 mm 3500 mm 3-D model Of Vacuum Vessel with changes incorporated after feedback from FNAL (3rd revision)

  8. B. Vacuum Vessel Design Parameters Verified with ASME Boiler and Pressure Vessel Code Sec.VIII Div 1,(2004) It was suggested from FNAL that effect of weight of feed can on the vacuum vessel should be analyzed through FEA. This has been completed. (next slide)

  9. FEM Simulation for Vacuum Vessel Deflection 600 Kg of circumferential Load 500 Kg of Load on each support post Material : SS 304

  10. FEM Simulation for Vacuum Vessel Deflection Max. Deflection in vertical direction :- 87 Micron Max. Von-Mises Stress: 18 MPa

  11. Calculations Completed for Vacuum Vessel of HTS-2 • Following Calculations Have been completed for Vacuum Vessel of HTS-2 • Calculations for the Vacuum Vessel Cylindrical Shell Thickness • - As an external pressure vessel (as per UG-28 of ASME VIII, Div. I, Edition 2004 ) • Verified as internal pressure vessel (as per UG-27 of ASME VIII, Div. I ) • The Permissible Out of Roundness of the Vessel Cylindrical Shell • Thickness • (as per UG80 of ASME VIII Div. I Edition 2004) • Analysis and Calculations for the Stiffening Rings • (as per UG-29, ASME VIII, Div. 1) • Calculations and Analysis for all the vessel Shell Openings/Ports • - (external as well as for internal pressure)

  12. Design Calculations Ctd. • Discussions on the Saddle Support Design • Referred “Pressure Vessel Handbook” 7th edition by E. Megyesy, “Process equipment Design” book by Lloyd Brownell and Edwin H. publisher Young, Wiley Eastern Ltd. and Paper entitled “Stresses in large Horizontal Cylindrical pressure Vessel on two saddle Support” by Zick • Initial Relief System Calculations Referred Vacuum vessel engineering note for SMTA Horizontal test Cryostat (CGA-1.3-1995)

  13. C. Design of Frame Bridge FEA for cool down is in progress. Initial results show long cool down time for SS structure. We are evaluating options with aluminum. Structural analysis shows that both configurations are OK.

  14. Deflection pattern in HTS I type of SS structure 3 m long structure for HTS II using HTS I type box and rail section Material SS 304 Maximum deflection 150 micron

  15. Two Alternate schemes for HTS II structure Material SS 304 Replacing the box section of HTS- I by an ‘I’ section. SS 304 Maximum deflection value in this case is about 32 microns Material 6061-T6 Replacing the box- section of HTS- I by a ‘Box section’.Al 6061-T6 Maximum deflection value in this case is about 54.8 microns. The advantage of Al comes from faster cool down

  16. Full Scale Prototype under fabrication Al 6061 – T6

  17. D. Design of Cryogenic Support Post FiMax Axial Load Carried by Inner Joint FoMax Axial Load Carried by Outer Joint Pi Contact Pressure at Inner Joint Po Contact Pressure at Outer Joint ‘f’ -- Coefficient of Friction between G11 Tube and Disc/Ring δi Diametral Interference between Tube and Inner Disc ‘E’ -- Young’s Modulus ‘μ’ -- Poisson’s Ratio of Materials δo Diametral Clearance between Tube and Outer Ring January 3, 2020 17

  18. Design Complete- Spread Sheet awaiting final dimensions January 3, 2020 18

  19. E. Preliminary Cryogen Supply Scheme for Horizontal Test Stand Internal Cryogenic Circuit Discussion is going on to accommodate cryogenic circuit in the available space The space was kept with only one LL dewar like in HTS -1. But now due to this new cryogenic circuit we are trying to accommodate cryogenic circuit in the available space LL in the End

  20. LL in the middle

  21. LL Can Option 1 LL Can Option 2 LL Can Option 3(d=120mm, end of cyostat) (d=90mm, end of cyostat) (d=120mm, middle of cyostat)

  22. Above configuration Modeled at RRCAT Cavities as located in HTS 2

  23. Above configuration Modeled at RRCAT

  24. Above configuration Modeled at RRCAT 80K shield In this concept, pipes foul with thermal shield on actual modeling Other chimney

  25. Another Configuration proposed by RRCAT

  26. Another View Configuration proposed by RRCAT

  27. Configuration proposed by RRCAT

  28. Thank You

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