Quads & Girders, Arc 10 and Hall D Layout Preliminary Design and Safety Review

1. 12GeV Upgrade - Beam Transport Quads & Girders,Arc 10 and Hall D LayoutPreliminary Design and Safety Review Quad Girders Michael Bevins May 3, 2007

2. Outline • Introduction & Scope • Requirements & Design Philosophy • Girder Count - Flavors • Girder Layouts • Bolted Plate Girder vs Extrusion • Safety Considerations • Cost Estimates & Schedule • Risk Assessment • Summary

3. Introduction & Scope • The12GeV upgrade requires an addition of ~91 quad girders • 74 of the 91 girders will be in the new ARC 10 and Hall D lines • 12GeV field strength requirements force us to modify 44 existing quad girders • Some quads will be replaced with higher strength quads (e.g., QA to QR) • Some girders will require an additional quad • Songsheet level layouts are being used to identify the number of girder flavors that will be required • We expect a number of custom designs will be needed in the spreader and recombiner regions • Girder requirements, design philosophy, flavors, & cost estimates will be presented today • An alternative to the CEBAF style extruded girder will also be presented

4. Requirements/Design Philosophy Same as CEBAF... • Structural • Support girder elements and maintain alignment during shipping and installation • Alignment • Quad +/- 0.5mm in x & y, 1.0mm in z • BPM relative to quad +/- 0.25mm in x & y • Diagnostics • Girders should support typical suit of diagnostics and correctors • BPM, Harp, Viewer, H & V correctors (BC, BD, …) • Provide means to support electronics packaging and wiring • Vacuum • Provide support for pumps, roughing valves, gauges • Handling • Provide tapped holes for commercial lifting rings • Complete double quad girder weighs ~1200lbs

5. Girder Count - Flavors

6. Girder Layouts – Typical CEBAF Quad Girder Viewer & Pump Drop Cross Bellows Quad Correctors BPM Alignment cartridge (support pt) Beamline Spt – “Goal Post Style” Extruded Aluminum “Girder” Beamline Spt – “V-block Style”

7. Girder Layouts Quad New 12GeV girders • Use basic CEBAF designs! • Maintain same quad position relative to alignment cartridge supports • Use only simple BPM style V-block supports • Like the FEL • Provide support for upstream bellows flange and downstream end of pump/viewer cross • Design new QR and QP quads to have same interface as QA’s • Reduces the number of flavors • Space quads on dbl girder so one design will suit QAQA, QAQR, QRQR, etc.. • Use mandrel to align girder elements (BPM, Viewer) relative to quad (same as CEBAF & FEL) Correctors Viewer BPM Bellows Vac pump drop Alignment Cartridge (support pt) Single Quad Girder Alignment Cartridge (support pt) Double Quad Girder

8. Girder Layouts • The swap from QA to QR quad represents 32 of the 44 existing girders that require modification • Tommy’s 14” QR drops right into the existing typical QA girder!

9. Bolted Plate Girder vs Extrusion • CEBAF extruded girder was manufactured by Alcoa • Alcoa no is longer in position to form this large hollow shape • Plant that produced girder for JLab closed shortly after last purchase of FEL girders in 1999 (plant has since re-opened) • CEBAF shape tooling no longer in Alcoa inventory • Requested quote from Alcoa for open shape consistent with JLab standard beamline supports CEBAF Extruded Shape Alternate Shape • Significantone time tooling cost for alternative shape!$40,000 • Explored alternative vendor --- no luck! This is a very large shape! • Would still expect large tooling cost even if another vendor capable of producing the section could be found • Decided to explore building up section from stock AL plate and bars

10. Bolted Plate Girder vs Extrusion • Principal area moments of inertia (resistance to bending) nearly identical to CEBAF shape • Torsional stiffness is reduced • Consulted with G. Biallas about original CEBAF specs and alternative bolted plate girder design • No specific requirement for torsional stiffness existed for CEBAF • Alternative looked reasonable to him! • Bolted plate girder turns out to be quite attractive from manufacturing perspective • Bar and plate can be handled on smaller less expensive ($/hr) machines • Reduces machining costs • All features can be machined on the plates prior to assembly • Double quad girder rails would require finish machining after assy (consistent with original CEBAF design) • Girders would be purchased assembled complete with beamline support hardware (cross bars, v-blocks, etc..) Bolted Plate Girder

11. Safety Considerations • Personnel Training • Jlab & sub-contractor • Radiation • Designated areas for containment and radiation survey of girders that will be removed from the tunnel • Material handling • Provide provisions for lifting • Electrical Hazards • Package and support electronics, power leads and terminal blocks to control electrical hazards

12. Cost Estimates • Sum of beam transport quad girder WBS procurements ~$450k • Cost estimates developed using existing girder assembly drawings • Estimates assume bolted plate girder design • Estimates are based on combination of vendor quotes, past purchases (FEL costs, SL 21 warm region girder), Jlab machine shop estimates and engineering judgment

13. Schedule • New girder procurements in time to support girder build up prior to major installation down • Modified girder swap out and modifications during major down requires more detailed study • Detailed reuse vs mod vs make plan TBD to optimize cost and schedule savings • Inventory of existing girder extrusion and support hardware as well as a complete accounting of parts that will be removed from modified girders is planed

14. Risk Assessment • Technical - Low • Girders & Supports – very similar designs exist and are already proven • Alignment - same as existing machine • Procurement Schedule - Low • No long-lead items identified • Cost – Low • Linac warm region girder recently prototyped • Vendor quotes for most vacuum elements • Pumps, valves, spools, diag/pump cross • Good cost estimates for machined parts • Vendor & Jlab shop budgetary estimates • Referenced recent FEL beam transport purchases

15. Summary • The 12 GeV beam transport girder designs are more than 35% complete thus exceeding the goal set to support our DOE External Project Reviews this summer • We will continue to work closely with our friends throughout the lab (safety, CASA, installation, vacuum, alignment, I&C, magnet measurement, operations, procurement & facilities) as we move forward • Detailed design will be complete in 2008 to support assembly and installation schedules • We look forward to comments & recommendations from the committee

16. 12GeV Upgrade - Beam Transport Quads & Girders,Arc 10 and Hall D LayoutPreliminary Design and Safety Review Arc 10 & Hall D Michael Bevins May 3, 2007

17. Outline • Requirements & Specifications • ARC 10 • Elements/Girder Count • Beam Transport Layout • Vacuum Analysis • Highlighted Challenges • Hall D • Safety Considerations • Cost & Risk Assessment • Summary

18. Requirements & Specifications • Alignment specs • Quads and dioples positioned to +/-0.5mm in x & y, +/- 1.0mm in z • Vacuum specs • Beam line partial pressure of hydrogen <10-6 torr • Total average pressure of all other constituents less than 5x10-7 torr • Fabrication, welding, cleaning & handling, and leak checking specs still apply • 22631-S-001 Fabrication of Ultra-High Vacuum Equipment • 22632-S-001 Cleaning and Handling of U.H.V. Components • 22633-S-001 Welding Specification For U.H.V. Components • 22634-S-001 Helium Leak Test For U.H.V. Components • Note an update and modernization of our vacuum specs is underway

19. ARC 10 - Definition For this review ARC 10 is defined as: • The ARC 10 line begins with the first quad in the west spreader and ends with the last quad in the north west recombiner • Includes 3 quads in the extraction region ARC 10 ARC 10

20. ARC 10Elements/Girder Count • The ARC 10 line uses the same beam optics design as arcs 3-9 • Quads & correctors selected by MEG based on CASA field strength and aperture requirements • Diagnostics defined by Tech Note 05-053 • Vacuum elements (pumps, gauges, valves) qty & position follow existing arc design • Elements in red are part of I&C WBS

21. ARC 10Beam Transport Layout Typical segment from the west arc Repeating structure Four 4m Dipoles 3 Single quad girders 1 Double quad girder ARC 10

22. ARC 10Beam Transport Layout Dipole & girder supports Existing stands • New dipoles and girders will be supported by pedestals from the floor • Existing stands placed using alignment installation coordinates to identify potential interference with new pedestals • 4m dipoles and quad girders will be supported and aligned using our standard heavy duty alignment cartridges • 5000# load capacity per cartridge • 4m dipole weight ~7000# 4m dipole pedestals Girder pedestal

23. ARC 10Preliminary Vacuum Analysis • Beamline pressure spec and assumed outgassing rate are the same as CEBAF design • Average beamline pressure < 5*10-7 torr • Assumed outgassing: 10-10 torr-L/s/cm2 • Vacuum analysis conducted using VACCALC program • Developed by M. Sullivan at SLAC • 4m dipole chamber cross-section same as existing • Conductance of oval dipole chamber based on method from J.M. Lafferty, Vacuum Science text • Beamline drift tubes are same as existing arcs (3”OD) • Ion pump size - 15 L/s • Analysis does not include synchrotron radiation effects • 109 watts total (~0.4W/m)

24. ARC 10Preliminary Vacuum Analysis Repeating structure • Design meets specification • Average pressure is < 5*10-7 torr

25. ARC 10 Highlighted Challenges • Identify interference between the arc 10 line and the existing stands in the extraction and injector/re-injection region • Some of the stands in these regions were modified in the field - documentation is incomplete • Plan to work with the alignment group to obtain as built coordinates of suspect areas

26. Hall D - Definition For this review Hall D is defined as: Tagger Bldg • The Hall D line begins with the first quad in the east spreader and ends at the beam dump in Hall D tagger building East spreader

27. Hall DElements/Girder Count • Quads & correctors selected by MEG based on CASA field strength and aperture requirements • Diagnostics defined by Tech Note 05-053 • Vacuum elements (pumps, gauges, valves) qty & position/spacing based on CEBAF existing hall transport lines • All dipoles and girders will be supported by pedestals from the floor • Elements in red are in I&C WBS

28. Hall DBeam Transport Layout Hall D WBS Hall D line ~7 inches from nominal tunnel floor

29. Hall DBeam Transport Layout Drift 8 Single Quad Girders

30. Hall DBeam Transport Layout 10deg ramp to Hall D Point of tangency 4m dipoles Insertable Dump Beam stoppers SLM 6 Quad girders

31. Hall DBeam Transport Layout 4m dipoles Sliding shield wall 8 Quad girders Cavity BPM SLM

32. Hall DBeam Transport Layout - Tagger Bldg Plan view: Beam Dump Dump Viewer 2.8M lbs of Steel sheilding BPM & BCM Cavity BPM Elevation: 71 in 14.8 ft

33. Hall DPreliminary Vacuum Analysis • Beamline pressure spec and assumed outgassing rate are the same as CEBAF design • Average beamline pressure < 5*10-7 torr • Assumed outgassing: 10-10 torr-L/s/cm2 • Vacuum analysis conducted using VACCALC program • Developed by M. Sullivan at SLAC • 4m dipole chamber cross-section same as existing • Conductance of oval dipole chamber based on method from J.M. Lafferty, Vacuum Science text • Beamline drift tubes are same as existing arcs (3”OD) • Number of pumps based on CEBAF • Detailed analysis TBD

34. Hall D Highlighted Challenges Identify potential interference between Hall D line and existing machine elements • Hall D line runs through existing dog leg dipole support stand • Plan to bore hole through stand for beam pipe • Required reinforcement TBD Bore Hole Here Dog Leg Section Dipole stand interference

35. Hall D Highlighted Challenges Identify interference between Hall D line and existing stands • Hall D line appears to run through at least one of the existing arc dipole stands (maybe two) • Plan to ask survey & alignment to verify stand positions Possible stand interference Apparent Dipole stand interference View from NE stub

36. Hall D Highlighted Challenges Mount girder 1.32in off nominal girder floor!! • Initially envisioned upside down girder • But old CEBAF style “drop girder” turned out to be far more attractive Upside Down Girder “Drop Girder” 3 Point Mount to Girder

37. Hall D Highlighted Challenges Conceptual design for Hall D line floor girder • ~1inch allowance for grout under foundation plates • Scheme allows full range of alignment cartridge adjustment • Plan to get actual floor position information to confirm clearance

38. Safety Considerations • Personnel Training • Jlab & sub-contractor • Radiation • Removal and relocation of north east stub dump to tagger bldg • Designated areas for containment and radiation survey of materials that will be removed from the tunnel • In situ modification of stands • Coordination with civil and Hall D installation • Material handling • Working on 10deg slope • Shielding removal and installation • Potential hot work • Electrical Hazards

39. Cost Estimates WBS Elements I have covered today

40. Risk Assessment • Technical - Low • Girders & Supports – very similar designs exist and are already proven • Vacuum – design consistent with existing machine • Alignment - same as existing machine • Procurement Schedule - Low • No long-lead items identified • Cost – Low • Good girder, stand and alignment cartridge cost estimates • Good estimates for vacuum tubes, flanges, pumps, valves

41. Summary • The arc 10 and hall D beam transport designs are 35% complete thus meeting the goal set to support our DOE External Project Reviews this summer • We will continue to work closely with our friends throughout the lab (safety, CASA, installation, vacuum, alignment, I&C, magnet measurement, operations, procurement & facilities) as we move forward • Detailed design will be complete in 2009 to support assembly and installation schedules • We look forward to comments & recommendations from the committee