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MICE RFCC Module and 201 MHz Cavity Update

MICE RFCC Module and 201 MHz Cavity Update. Steve Virostek Lawrence Berkeley National Lab. MICE CM23 at ICST, Harbin January 15, 2009. Engineering design of the RFCC module has been under way at LBNL since early last year Preliminary and final design reviews were conducted last year

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MICE RFCC Module and 201 MHz Cavity Update

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  1. MICE RFCC Module and 201 MHz Cavity Update Steve Virostek Lawrence Berkeley National Lab MICE CM23 at ICST, Harbin January 15, 2009

  2. Engineering design of the RFCC module has been under way at LBNL since early last year Preliminary and final design reviews were conducted last year Coupling coil design and fabrication is being provided by ICST at Harbin (following talks) MICE cavity design is heavily based on the successful MuCool 201 MHz prototype RF cavity Fabrication techniques and post processing Engineering design of the RF cavity is complete Cavity fabrication contract to be placed soon Significant progress on RFCC module engineering design Complete CAD model of the cavity, tuners, support and vacuum Interfaces, shipping, assembly and installation (earlier talk) Overview Steve Virostek - Lawrence Berkeley National Lab - January 15, 2009

  3. SC coupling Coil Curved Be window Cavity Couplers Vacuum Pump 201-MHz cavity RFCC Module Steve Virostek - Lawrence Berkeley National Lab - January 15, 2009

  4. RFCC PDR and FDR completed during CM21 and CM22 201 MHz cavity detailed design and analysis is complete Qualification of three cavity fab vendors completed late last year RFP for cavity fab released by LBNL this week (responses due 1/30) Copper cavity material to arrive at LBNL next week Cavity tuner RF & structural analyses and CAD model are complete Structural analyses of cavity suspension system is complete RF coupler based on design previously developed for MuCool cavity Coupling coil interface agreed upon with ICST (a few details remain) Cavity cooling water feedthrough concept has been developed Conceptual design and CAD model of module vacuum vessel, vacuum system and support structure is complete Shipping, assembly and installation presented earlier this week Progress Summary Steve Virostek - Lawrence Berkeley National Lab - January 15, 2009

  5. Eight 201-MHz Cavities for MICE Eight201-MHz RF cavities RFCC modules Steve Virostek - Lawrence Berkeley National Lab - January 15, 2009

  6. MICE RF Cavity Summary • Design based on the successful US MuCool prototype • A slight reduction in cavity diameter to raise the frequency has been specified and analyzed • The fabrication techniques used to produce the prototype will be used to fabricate the MICE RF cavities • Final cavity design was reviewed at CM22 at RAL • Copper cavity material will arrive at LBNL next week • An RFP for cavity fabrication has been released, and a contract is expected to be placed next month • The first 5 cavities to be delivered by end of CY2009 Steve Virostek - Lawrence Berkeley National Lab - January 15, 2009

  7. MICE RF Cavity Design • 3-D Microwave Studio RF parameterized model including ports and curved Be windows to simulate frequency, Epeak, etc. • Frequencies variation between cavities should be within  100 kHz • Approach • Slightly modify prototype cavity diameter • Target a higher cavity frequency • Tune cavities close to design frequency by deformation of cavity body (if needed) • Tuners operate in the push-in mode only  lower frequency Steve Virostek - Lawrence Berkeley National Lab - January 15, 2009

  8. Cavity Design Parameters • The cavity design parameters • Frequency: 201.25 MHz • β = 0.87 • Shunt impedance (VT2/P): ~ 22 MΩ/m • Quality factor (Q0): ~ 53,500 • Be window diameter and thickness: 42-cm and 0.38-mm • Nominal parameters forMICEand cooling channels in a neutrino factory • 8 MV/m(~16 MV/m)peak accelerating field • Peak input RF power:1 MW(~4.6 MW)per cavity • Average power dissipation per cavity:1 kW(~8.4 kW) • Average power dissipation per Be window:12 w(~100 w) Steve Virostek - Lawrence Berkeley National Lab - January 15, 2009

  9. 201 MHz Cavity Concept Spinning of half shells using thin copper sheets and e-beam welding to join the shells; extruding of four ports; each cavity has two pre-curved beryllium windows, but also accommodates different windows Steve Virostek - Lawrence Berkeley National Lab - January 15, 2009

  10. Cavity FEA Analysis • RF, thermal and structural cavity analyses carried out using a single ANSYS model • The thermal solution provides the temperature distribution throughout the cavity and Be window • Heat fluxes on inward curving windows are 60% higher than for outward curving windows (with correspondingly higher DT) • Peak temperature occurs at center of inwardly curved beryllium window (86 ºC) using “Nominal Neutrino Factory” parameters (MICE is 4 times lower) Cavity RF FEA Model Cavity Body FEA Model Temp plot w/window Temp plot w/o window Steve Virostek - Lawrence Berkeley National Lab - January 15, 2009

  11. Cavity Fabrication Drawings • Detailed fabrication drawings are complete • All steps of cavity fabrication process are detailed • Drawings provided to vendors for bidding process Steve Virostek - Lawrence Berkeley National Lab - January 15, 2009

  12. Cavity Fabrication Process Traveler Steve Virostek - Lawrence Berkeley National Lab - January 15, 2009

  13. Cavity Vendor Qualification • A series of vendor qualification visits were conducted • Applied Fusion - San Leandro, CA • e-beam welding, machining • Meyer Tool & Mfg., Inc. - Chicago, IL • machining • Roark Welding & Engineering - Indianapolis, IN • e-beam welding, machining • Sciaky, Inc. - Chicago, IL • e-beam welding • ACME Metal Spinning – Minneapolis, MN • cavity shell spinning • Midwest Metal Spinning, Inc. –Bedford, IN • cavity shell spinning Primary vendors Steve Virostek - Lawrence Berkeley National Lab - January 15, 2009

  14. Meyer Tool & Manufacturing Meyer Tool & Manufacturing, Inc. 4601 W. Southwest Highway Oak Lawn, Illinois 60453 • Meyer uses Sciaky’s e-beam welding service at the Sciaky factory close to Meyer Tool (Sciaky is a major e-beam welder manufacturer) • Meyer Tool has the machining equipment necessary to fabricate the complete RF cavity (minus spinning) • A complete drawing package, specification and request for quote has been presented to Meyer Tool Sciaky electron beam welding machine Steve Virostek - Lawrence Berkeley National Lab - January 15, 2009

  15. C.F. Roark Welding & Engineering Co, Inc. C.F. Roark Welding & Engineering Co, Inc.136 N. Green St.Brownsburg, IN 46112 • Roark Welding’s e-beam welder is a Sciaky machine and it is housed in an isolated room with a positive air flow to help maintain cleanliness • Roark Welding has the machining equipment necessary to fabricate the complete RF cavity (plus spinning at an outside vendor) • A complete drawing package, specification and request for quote has been presented to Roark Welding Sciaky electron beam welding machine at Roark Steve Virostek - Lawrence Berkeley National Lab - January 15, 2009

  16. Applied Fusion, Inc. Applied Fusion, Inc. 1915 Republic Ave. San Leandro, CA 94577 • Applied Fusion’s e-beam welder is a German made machine • Applied Fusion has the machining equipment necessary to fabricate the complete RF cavity (minus spinning) • A complete drawing package, specification and request for quote has been presented to Applied Fusion Electron beam welding machine Steve Virostek - Lawrence Berkeley National Lab - January 15, 2009

  17. Overall RFCC Module Design Mechanical Joining of the Coupling Coil and the Vacuum Vessel Dynamic Cavity Frequency Tuners RF Coupler Hexapod Strut Cavity Suspension RF Cavity Water Cooling Vacuum System Steve Virostek - Lawrence Berkeley National Lab - January 15, 2009

  18. Progress: Other Module Components • Design and analysis of the cavity frequency tuners is complete, drawings to be done soon • A hexapod cavity suspension system has been incorporated in the design • The RF coupler will be based on the SNS design using the off the shelf Toshiba RF window • The vacuum system includes an annular feature coupling the inside and the outside of the cavity • Vacuum vessel accommodates interface w/coupling coil • Beryllium window design is complete; windows are in the process of being ordered (8 per module needed) Steve Virostek - Lawrence Berkeley National Lab - January 15, 2009

  19. Cavity Tuner Configuration • Six tuners are spaced evenly every 60º around cavity • Clocking of tuner position between adjacent cavities avoids interference • No contact between pairs of close packed cavities • Tuners touch cavity and apply loads only at the stiffener rings • Tuners operate in “push” mode only (i.e. squeezing)‏ • Tuning automatically achieved through a feedback loop • Soft connection only (bellows) between tuner/actuators and vacuum vessel shell Steve Virostek - Lawrence Berkeley National Lab - January 15, 2009

  20. Cavity Tuner Components - Section View Tuner actuator Pivot pin Dual bellows vacuum sealing Ceramic contact wear plate between actuator ball end and tuner arm Fixed (bolted)‏ connection Ball contact only Steve Virostek - Lawrence Berkeley National Lab - January 15, 2009

  21. Tuner Component Details Actuator with integrated bellows assembly Fixed arm Pivot pin Cylinder attachment bracket Screws to attach tuner to the cavity stiffener ring Pivoting arm Forces are transmitted to the stiffener ring by means of “push” loads applied to the tuner lever arms by the actuator assembly Steve Virostek - Lawrence Berkeley National Lab - January 15, 2009

  22. Tuner Actuator Design • Actuator design uses dual bellows vacuum-to-air sealing (no rubber) • Actuator is “soft” mounted to the vacuum vessel with a bellows • Senior Aerospace Bellows will supply the actuators (near off the shelf) Hemisphere on actuator rod end Ceramic plate on tuner arm Steve Virostek - Lawrence Berkeley National Lab - January 15, 2009

  23. Cavity Tuning Parameters The following parameters are based on a finite element analysis of the cavity shell. Tuning range is limited by material yield stress. • Overall cavity stiffness: 7953 N/mm • Tuning sensitivity: +230 kHz/mm per side • Tuning range: 0 to -460 kHz (0 to -2 mm per side)‏ • Number of tuners: 6 • Maximum ring load/tuner: 5.3 kN • Max actuator press. (100 mm): 1.38 MPa (200 psi)‏ Steve Virostek - Lawrence Berkeley National Lab - January 15, 2009

  24. Tuner System Analysis • Model of overall cavity tuning displacements • Maximum distortion of 0.05 mm (0.002”) in the stiffener ring • One tuner FEA of 1/6 cavity segment • Maximum cavity stress is 100 MPa • Cavity will not yield when compressed to full tuning range Steve Virostek - Lawrence Berkeley National Lab - January 15, 2009

  25. Cavity Support: Hexapod Strut System • Dedicated six-strut hexapod system for each cavity will provide kinematic support • This system spreads the cavity weight across several struts • Strut arrangement provides stiff and accurate cavity support • Kinematic mounts prevent high cavity stresses due to thermal distortion and over-constraint Example of a hexapod stage Steve Virostek - Lawrence Berkeley National Lab - January 15, 2009

  26. Hexapod Strut Cavity Mounts • Copper mounting block will be e-beam welded directly to the RF cavity • The cavity is very stiff at mounting block location • Opposite end of strut connects to stainless steel mounting block welded to the vacuum vessel Steve Virostek - Lawrence Berkeley National Lab - January 15, 2009

  27. Hexapod Strut Mounting to Vessel Copper strut mounts e-beam welded to the outside of the cavity Stainless steel strut mounts welded to the inside of the vacuum vessel Steve Virostek - Lawrence Berkeley National Lab - January 15, 2009

  28. Cavity Suspension Analysis Stress Analysis • Peak cavity stress due to gravity is the 20-30 MPa (~10% of yield) Deflection Analysis • Total mass of cavity assembly is ~410 kg‏ • Peak deflection: 115 mm Modal Analysis • First mode frequency: 43 Hz Steve Virostek - Lawrence Berkeley National Lab - January 15, 2009

  29. Cavity Cooling System • Single circuit water cooling tube for each cavity • One inlet and one outlet • 8 penetrations in the vacuum vessel Steve Virostek - Lawrence Berkeley National Lab - January 15, 2009

  30. Cavity Cooling Water Feedthroughs • Continuous water tube wrapped around the cavity • Compliance coil inside of the vacuum vessel • One inlet and one outlet per cavity • All cavity water connections are made outside of the vacuum vessel Steve Virostek - Lawrence Berkeley National Lab - January 15, 2009

  31. Section View of Water Feedthroughs • A conflat flange is welded into the wall of the vacuum vessel Air side • Ends of copper tubes are brazed into a 2nd special conflat flange • The flange is fastened from the outside of the vacuum vessel Vacuum side Steve Virostek - Lawrence Berkeley National Lab - January 15, 2009

  32. Prototype Cavity RF Couplers • Coupling loops are fabricated using standard copper co-ax • Parts to be joined by e-beam welding (where possible) and torch brazing • Coupling loop has integrated cooling • The RF coupler will be based on the SNS design using the off the shelf Toshiba RF window Steve Virostek - Lawrence Berkeley National Lab - January 15, 2009

  33. MICE Cavity RF Couplers • A bellows connection between the coupler and the vacuum vessel provides compliance for mating with the cavity Steve Virostek - Lawrence Berkeley National Lab - January 15, 2009

  34. MICE Cavity RF Couplers Off the shelf flange “V” clamp secures RF coupler to cavity Steve Virostek - Lawrence Berkeley National Lab - January 15, 2009

  35. Cross-sectional view of vacuum system Vacuum System NEG (non-evaporable getter) pump • A NEG pump has been chosen because it will be unaffected by the large magnetic field • A vacuum path between the inside and outside of the cavity eliminates the risk of high pressure differentials and the possible rupture of the thin beryllium window Steve Virostek - Lawrence Berkeley National Lab - January 15, 2009

  36. Main 1400mm rolled tube Bellows flange Smaller diameter rolled tube Vacuum Vessel Fabrication • Vacuum vessel material must be non-magnetic and strong therefore 304 stainless steel will be used • The vacuum vessel will be fabricated by rolling stainless steel sheets into cylinders • Two identical vessel halves will be fabricated with all ports and feedthroughs Steve Virostek - Lawrence Berkeley National Lab - January 15, 2009

  37. Two Halves Joined (w/o coupling coil) • Central under-cut provides clearance for the coupling coil Steve Virostek - Lawrence Berkeley National Lab - January 15, 2009

  38. Vacuum Vessel and Coupling Coil Steve Virostek - Lawrence Berkeley National Lab - January 15, 2009

  39. Vacuum Vessel Interface to Coupling Coil • LBNL will weld two 25 mm thick special gussets, which are designed to match the gusset welded to the coupling coil at Harbin, to the vacuum vessel Steve Virostek - Lawrence Berkeley National Lab - January 15, 2009

  40. Vacuum Vessel Interface to Coupling Coil • Sixteen gussets will be used, 8 on each side of coupling coil Steve Virostek - Lawrence Berkeley National Lab - January 15, 2009

  41. RFCC Module Support Stand • Because a special skid will be used for shipping and moving the RFCC into the experiment hall, the permanent support stand is bolted onto the vacuum vessel (not welded) • The support stand will be fabricated of stainless steel Steve Virostek - Lawrence Berkeley National Lab - January 15, 2009

  42. RFCC Attachment to Support Stand • The vacuum vessel is bolted to a saddle made of stainlesssteel plates welded to the support stand • Stainless steel bars are welded onto the vacuum vessel for attaching bolted gusset plates Bolted gusset mounting bars Steve Virostek - Lawrence Berkeley National Lab - January 15, 2009

  43. RFCC Support Stand • RFCC support stand must withstand a longitudinal force of 50 tons transferred from the coupling coil • Bolted gussets and cross bracing provide shear strength in the axial direction (analysis will be done to confirm this stand design)‏ Steve Virostek - Lawrence Berkeley National Lab - January 15, 2009

  44. Schedule Overview • RFCC design and fabrication project originally expected to be a 3–year project (10/06 to 10/09) • Coupling coil effort began in 2006 at ICST (Harbin) • Design and fabrication of other RFCC module components was scheduled to begin 10/07 • Start was delayed due to lack of availability of qualified manpower • Earlier last year, mechanical engineer A. DeMello joined MICE to work on RFCC module design (FTE) • Some additional (part-time) manpower now available Steve Virostek - Lawrence Berkeley National Lab - January 15, 2009

  45. Manpower Summary • Allan DeMello: lead ME for RFCC Module design & fab • 3D engineering CAD model, cavity analysis, design & fab • Full-time on RFCC module design • Nord Andresen: design/fab of module subcomponents • Cavity tuners, support structure, vacuum vessel, procurements • generation of fabrication drawings • 50% time design/engineering support • Steve Virostek: engineering oversight for MICE at LBNL • Derun Li: cavity physics design and oversight • Mike Green: coupling coil design & interface with module Steve Virostek - Lawrence Berkeley National Lab - January 15, 2009

  46. Schedule Summary Steve Virostek - Lawrence Berkeley National Lab - January 15, 2009

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