1 / 100

ILC cryomodule design task list

ILC cryomodule design task list. Tom Peterson, Fermilab ILC Cryomodule Meeting CERN, 16 - 17 January 2006. ILC cryomodule design task list introduction and tasks 1-3 (start 3-D CAD model, consider pipe sizes and segmentation) . Introduction: TTF cryomodule is our reference .

senona
Download Presentation

ILC cryomodule design task list

An Image/Link below is provided (as is) to download presentation Download Policy: Content on the Website is provided to you AS IS for your information and personal use and may not be sold / licensed / shared on other websites without getting consent from its author. Content is provided to you AS IS for your information and personal use only. Download presentation by click this link. While downloading, if for some reason you are not able to download a presentation, the publisher may have deleted the file from their server. During download, if you can't get a presentation, the file might be deleted by the publisher.

E N D

Presentation Transcript

  1. ILC cryomodule design task list Tom Peterson, Fermilab ILC Cryomodule Meeting CERN, 16 - 17 January 2006

  2. ILC cryomodule design task list introduction and tasks 1-3 (start 3-D CAD model, consider pipe sizes and segmentation) Tom Peterson

  3. Introduction: TTF cryomodule is our reference Tom Peterson

  4. TTF Module end Tom Peterson

  5. CERN meeting goals • Technical • Definition of what a T4CM is • Identification of a comprehensive list of tasks to be accomplished in working toward the T4CM design • Review the definition of the BCD module • Organizational • Formation of an international T4CM design team • Identify who will do what • Establish a timeline for T4CM design completion • Future meetings---discuss when, where, frequency, etc. Tom Peterson

  6. Module design tasks • Module design issues were collected by working groups at meetings, including but not limited to • SLAC (14 - 16 Oct 2004) • KEK (13 - 15 Nov 2004) • DESY (6 - 8 Dec 2004) • Snowmass (August 2005) • SMTF collaboration meeting (5 - 7 Oct 2005) • These issues were assembled into a draft list for this meeting Tom Peterson

  7. Draft list of technical issues and tasks for discussion at CERN • See MS Word document task summary • This is just an attempt to organize the ILC module design effort into separate tasks which we can fairly independently pursue • The list already includes a few names of people who have expressed interest in those topics • The list is not intended to be in any way exclusive in terms of what we do or who does what! Tom Peterson

  8. Draft list of technical issues and tasks for discussion at CERN, tasks 1 - 3 • Task 1: Begin a type IV 3-D model and drawing set by importing those features that will remain the same as type III+. • Task 2: Decide on pressure drop criteria and pipe sizes for the modules • Task 3: Design of a segmentation “spool” piece and other cryogenic boxes (included here to mention that a designs are needed and will interface with modules) Tom Peterson

  9. Tom Peterson

  10. Task 1: Type III ---> Type IV • We have a general consensus regarding what needs changing • Based largely on TTF experience, but also Jlab and others • Consensus collected by working groups at meetings, including but not limited to • SLAC (14 - 16 Oct 2004) • KEK (13 - 15 Nov 2004) • DESY (6 - 8 Dec 2004) • Snowmass (August 2005) • SMTF collaboration meeting (5 - 7 Oct 2005) Tom Peterson

  11. Features of type III cryomodule • Allows for fixed couplers • Invar rod and roller bearings allow cavities to remain axially fixed while the 300 mm tube shrinks • Smaller cross section results in standard pipe size for outer vessel • Axial position of last support changed to stiffen structure near quadrupole Tom Peterson

  12. Type IV cryomodule will includethe following features from Type III+ • 8 cavities per module • Same cooling scheme and cryogenic system concept • Same vacuum vessel diameter and 300 mm pipe diameter • Nearly the same pipe locations and arrangement • Same cavity centerline location relative to vacuum vessel • Same support posts • Same thermal shields concept, although coupler port locations move • Same cavity support detail (300 mm header as structural backbone with cavities held by roller bearings and invar rods) • Same input coupler (at least in terms of mounting and interface to vacuum vessel, cavity, and thermal shields) Tom Peterson

  13. Cryomodule III model -- helium vessels in the vacuum vessel CAD model based on DESY design imported and modified by Don Mitchell, Fermilab Tom Peterson

  14. Cryomodule III model -- helium vessels in the vacuum vessel with input couplers and quadrupole CAD model based on DESY design imported and modified by Don Mitchell, Fermilab Tom Peterson

  15. Helium vessel supports Tom Peterson

  16. Support posts Tom Peterson

  17. Thermal shield installation Tom Peterson

  18. Tom Peterson

  19. Task 2: Module pipe sizes • Compared to TESLA 500, heat loads for ILC are larger • Larger flow rates • Pressure drops and pipe sizes need review • The review should include pressure drop criteria -- what pressure drops to allow Tom Peterson

  20. ILC cryogenic system overview • Saturated He II cooled cavities @ 2 K • Helium gas thermal shield @ 5 - 8 K • Helium gas thermal shield @ 40 - 80 K • Two-phase line (liquid helium supply and concurrent vapor return) connects to each helium vessel • Two-phase line connects to gas return once per module • A small diameter warm-up/cool-down line connects the bottoms of the He vessels (primarily for warm-up) • Subcooled helium supply line connects to two-phase line via JT valve once per “string” (~12 modules) Tom Peterson

  21. Cryo-unit (bcd:main_linac:ilc_bcd_cryogenic_chapter_v3.doc) Tom Peterson

  22. Cryo-string Tom Peterson

  23. Module predicted heat loads Tom Peterson

  24. ILC cryogenic system much larger than TESLA 500 • 8 cryogenic plant locations • Approximately 5 km spacing • Each location with 2 cryogenic plants of about the maximum size -- each plant equivalent to about 24 kW at 4.5 K • Each plant about 6 MW “wall plug” power • ILC cryogenics about 100 MW total Tom Peterson

  25. Module pipe sizes increase Tom Peterson

  26. (Increase diameter beyond X-FEL) (Increase diameter beyond X-FEL) (Review 2-phase pipe size and effect of slope) Tom Peterson

  27. Task 3: Cryogenic unit segmentation and other cryogenic boxes • Segmentation issue is ultimately tied to reliability • To be conservative, BCD should include features for cryogenic unit and vacuum segmentation • Arbitrarily assume 5 segments per 2.5 km cryogenic unit, so about 500 m long on average • Cryogenic string supply and end boxes, which may be separate from modules, are also required within the ILC lattice • These all must be integrated with the module design Tom Peterson

  28. Segmentation concept • A box of slot length equal to one module • Can pass through cryogens or act as “turnaround” box from either side • Does not pass through 2-phase flow, so must act as a supply and/or end of a cryogenic string • Includes vacuum break for insulating vacuum • Includes fast-acting isolation valve for beam vac • May contain bayonet/U-tube connections between upstream and downstream for positive isolation • May also want external transfer line for 4 K “standby” operation (4 K only, no pumping line) Tom Peterson

  29. Segmentation box concept Tom Peterson

  30. ILC cryomodule design task list tasks 4 - 6 (cavity interconnect and tuners) Tom Peterson

  31. Draft list of technical issues and tasks for discussion at CERN, tasks 4 - 6 • See MS Word document task summary • Task 4: Design the intercavity connecting flange and bolting arrangement, detail the new spacing • Task 5: Modify the slow tuner design to allow closer cavity-to-cavity spacing • Task 6: Modify the fast tuner design for proper piezo function Tom Peterson

  32. Tom Peterson

  33. Task 4: cavity interconnect • Shorten cavity slot length • Cavity beam pipe length change • Bellows section -- minimum necessary • Flange bolt installation is a problem • Analyze slotted bellows flanges • Consider cleanliness of bolt installation • Consider effect on tuner (blade tuner ok?) • 283 mm iris-to-iris (from TDR) is baseline (chosen for BCD and type IV) Tom Peterson

  34. 344 Existing Desy Interconnect Design Salman Tariq Flange/Bellows Design Specs: • Bolted flange (12 bolts/flange) • Convoluted SS Bellows (10 waves, 54mm free length, ±25mm) -Length of bellows dictated by bolt length, old elastic parameters • Bellows elastic requirements: ±4mm (~1mm thermal + ~3mm tuning) • Aluminum Alloy 5052-H32 Diamond Hex Seal • 7 Ton (~15,000 lbs) clamping force, 35 N-m torque/bolt • Mechanical analysis done @ Desy, INFN (Cornelius Martens, Roberto Paulon) Interconnect: Tesla TDR: 283mm Currently 344mm Need to be verified Tom Peterson

  35. TDR: 344 mm reduced to 283 mm (110 63 110) Tom Peterson

  36. Cavity iris-to-iris length 1036 mm. Cavity flange-to-flange now 1283 mm, TDR 1256 mm due to shorter ends Tom Peterson

  37. Cavity slot length • Now 1036.2 +105.6 + 97 + 141.6 = 1380.4 • Suggest (from Helen Edwards) 1036.2 + 105.6 + 77 + 105.6 = 1324.4 • Gain ~4%, which may not seem like much, but gain ~ 1km for 20000 cav • But also, the lambda/2 or not question • Latest dimensions from Don Mitchell -- 1036.2 + 105.6 + 71.8 + 105.6 = 1319.2 • Note that 105.6 + 71.8 + 105.6 = 283 mm Tom Peterson

  38. Cavity Interconnect Tom Peterson

  39. Experiences from Desy Propose a parallel effort here in trying to minimize cavity interconnect length: Salman Tariq A. Optimize existing Desy design (shorter time frame- SMTF ’06 Mod #1?) We know this design works, lets try to see if we can further refine it: - Develop a comprehensive nonlinear (contact) FEA model using Ansys - Understand stresses, deflections, and most importantly contact pressure on sealing surfaces @ cryogenic temperatures - Use these results as a benchmark to evaluate future modified designs Possible design changes being looked at: 1. Completely slotting bolt holes (could reduce length by 20-30mm) 2. Reducing flange thickness 3. … (open to suggestions) New Saclay Tuner(s) compatability? B. Evaluate alternative clamp systems & seal design (longer time frame) - Quick disconnect type (ILC industrialization) (e.g. JLab Radial Wedge Flange Clamp) Issues of concern: cleanliness (friction=particulates) difficult to get off once clamped - Niobium bellows? Welded connections eventually…? Tom Peterson

  40. Task 5: Modify slow tuner design • Present lever tuner design takes cavity interconnect space. Need modification for closer cavity-to-cavity spacing. • Could modify lever tuner design • Or go to blade tuner for type IV. There appear to be some interferences. • Reliability. Are cold stepping motors a problem? Feature like a port on module for access? (Not for BCD; this is a longer term issue.) Tom Peterson

  41. Tom Peterson

  42. Blade tuner concept Tom Peterson

  43. Invar rod interference with blade tuner (Don Mitchell) Tom Peterson

  44. Other slow tuner options • Modified Saclay lever tuner • KEK slide jack tuner • KEK coaxial ball screw tuner • TJNAF Renascence tuner modified for ILC cryostat (“Renascence” is the Jlab 12 Gev upgrade module) Tom Peterson

  45. CC2 Tuner Analysis Work Salman Tariq Kinematics & Mechanics of Tuner: • Properly understand kinematics of Saclay Lateral Tuner • Geometric modeling in IDEAS • Actual measurements using digital dial indicators Stiffness measurements: • FEA of 9-cell cavity reveals stiffness of: 3,438N/mm (warm); 3,883 N/mm (cold) [Desy ~3KN/mm) • Cavity shrinks 1.857mm from RT to 2K (need to verify this with Desy?) • Tuner mechanism/support stiffness to be measured experimentally using load cell and applied displacement • Plan to develop FEA model of cavity–helium vessel assembly and simulate cryogenic/thermal loads from RT down to 1.8K. Apply tuning loads. Study the effects of bellows and Ti vessel, plus evaluate integrity of end cone (flange) design. Determine ‘equivalent’ stiffness of cavity assembly. Tom Peterson

  46. Task 6: Modify fast tuner design • Modify the fast tuner design for proper piezo-electric actuator function • Support structure • Tuning range • Also consider modifications to the design for magnetostrictive fast tuner • Fermilab has a fairly large effort on fast tuner designs Tom Peterson

  47. Tom Peterson

  48. Piezo Fast Tuner Work Problems/Issues: • Piezo preload not clearly defined • Large coarse tuning parameters (cavity in compression) • Cryo/vacuum loads during cool down not clearly understood • Results in large tensile loads on piezo bracket = loss in preload • Also side loads on Piezo bracket an issue with this tuner design Salman Tariq • Part of ongoing work on Capture Cavity 2 • Using Saclay Lateral Tuner 1 (below) with Piezoelectric fast tuning (below right) Tom Peterson

  49. Piezoelectric Fast Tuner Piezo-Actuator: l=39mm Umax=150V  l=3m at 2K fmax,static=500Hz Courtesy: Lutz Lilje, Desy (5-10-2005) Tom Peterson

  50. We have developed an instrumented Piezo Bracket to understand force loads: • Design is an instrumented version of the Desy single Piezo fixture • Addition of “bullet” piece (instrumented with strain gages) in line with piezo • Strain gages also mounted on tie rods and top bracket at clevis end • Warm testing starting this week Salman Tariq Ruben Carcagno And others Tom Peterson

More Related