12 Ge V Upgrade Beam Transport 2008 Beam

12 Ge. V Upgrade - Beam Transport 2008 Beam Transport Design Status and Safety Review Beam Transport Layouts, Stands, Girders, Vacuum, etc… Mike Bevins, Ross Bailes & David Green For the Design Team Chase Dubbe, Paul Hansen, Gary Hays, Derrick James, Steve Mano, Floyd Martin, Brent Matsu, Jacki Smith, Dan Spell, Mike Tate, Rick Wolfley & Dennis Zekoff June 3, 2008

Outline • • Introduction & Scope Requirements & Specifications Machine Development & Configuration Control Design Status – Injector and Reinjection, N&S Linac – Ross Bailes – Extraction – David Green – Existing Arcs, Spreaders & Recombiners, ARC 10 & Hall D • The Path Forward • Summary

Introduction & Scope • The 12 Ge. V upgrade requires: – Extensive modifications to the injection, five spreader & recombiner, and 2 nd extraction regions – New ARC (ARC 10) below the existing ARC 8 on the west side of the machine – New beamline to Hall D tagger building – Installation of ten new upgrade cryomodules • PED effort spans all of FY 08 & 09 – ~516 person-weeks (10 person-years) of budgeted labor (engineering & design) • $1. 7 M in procurements (stands, girders, & vacuum)

Requirements & Specifications Same as last year… • • Alignment specs – Quads positioned to +/-0. 5 mm in x & y, +/- 9 mm in z – Dipoles positioned to +/- 0. 5 mm in x & y, +/- 3 mm in z Vacuum specs – Beam line partial pressure of hydrogen <10 -6 torr – Total average pressure of all other constituents less than 5 x 10 -7 torr – Special Case: Warm region girders between cryomodules - UHV – Fabrication, vacuum 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 New: • Jlab structural weld design & inspection guidelines (Jlab EH&S Manual 6122)

Machine Development & Configuration Control Our challenge on the Layouts, Girders, and Stands front: To manage the vast number of design changes that must take place to transform the existing machine to the 12 Ge. V machine • To capture ALL quad, corrector, diagnostic, and vacuum element changes we developed the Element Control List (ECL) • Songsheets level layouts have also been developed for 33 sections of the machine – Maintained revision history as machine definition evolved • We have developed and maintain a webpage to consolidate the beam transport design documentation and enhance communication within MEG as well as with our friends throughout the lab (CASA, Power, I&C, Installation, Vacuum, etc. )

Injection & Reinjection – Intro & Scope • To accommodate the new arc 10 line the injector line has been shifted over the transfer lines beginning 20. 51 m upbeam of the current position – Two existing quad girders have moved over the transfer lines – Three girders already over the transfer lines have been shifted to suit the new optics design • Existing quad girders and diagnostics have been reused • Two new quad girders have been installed b/w the DP station and the 1 st BL • The 123 Me. V spectrometer has been relocated upbeam and the spectrometer branch has been modified from a 20 degree Injector & Reinjection to a 25 degree angle to clear support stands and arc girders – Any upgrades & final configuration pending release of Reza’s TN

Injection & Reinjection – Layouts Current Configuration Existing injector line running under arc 8 12 Ge. V Configuration Four Quad Girders (2 new, 2 rebuilt on short girders) VERY congested area – Surveys have been completed in this area to document “as -built” locations of stands Shift quad girders upbeam with dipoles BL dipole shifted 20. 51 m upbeam Arc 10 four meter dipoles Arc 10 quad girder Spectrometer shifted upbeam

Injection & Reinjection – Selected Images Injector line quad girder Spectrometer line Arc 8 dipole View looking downbeam

Injection & Reinjection – Selected Images Injector line girders over transfer lines

Injection & Reinjection – Layouts Detail of 4 front end girders is shown on following slide He Transfer Lines – Based on survey data BL dipole shifted 20. 51 m upbeam Four Quad Girders (2 new, 2 rebuilt on short girders) 2 existing arc stands will have to be field modified to allow the newly shifted beam tube to pass through them. Arc 10 four meter dipoles Arc 10 quad girder 79” 2 existing arc stands had to be redesigned due to interferences with 12 Ge. V girder locations. Spectrometer shifted upbeam 54” The floor to ceiling stands shown have been located based on data points gathered by the survey and alignment group 54. 5” As a result of the surveys, the 0 R 02 Girder was rotated 180 degrees to eliminate the foul with an existing stand to allow the re-use of an existing girder.

Injection & Reinjection – First 4 Girders Detail of typical QD girder shown on following slide Plan View Elevation View

Injection & Reinjection – Typical Girder Assy Beam Direction The first four girders utilize the same extruded channel profile that is used for the warm region girders. This allows for the use of existing bracketry e. g. cross-bars, vblocks, etc.

Injection & Reinjection – Layouts Quad girders BL dipole Current Configuration BL dipole to replace DK (moved 20. 51 m upbeam) No change to this BL dipole or girder Shift existing girders 12 Ge. V Configuration Existing injector line girders relocated over transfer line

Injection & Reinjection – Layouts BL dipole to replace DK (moved 20. 51 m upbeam) Detail of SLM chamber on following slide Shift existing girders Plan View Existing injector line girders relocated over transfer line Elevation View Since there were only z-translations, the level of detail for the girders over the transfer lines was minimized

Injection & Reinjection – SLM Assembly ME Group worked closely with CASA and the machine shop to develop and design the SLM chamber for the 2 nd BL that would allow for easy fabrication, alignment and calibration.

Injection & Reinjection – Layouts Current Configuration No changes between dipoles 12 Ge. V Configuration Modified reinjection chicane girder

Injection & Reinjection – Reinjection Chicane • Re-injection chicane girder modifications – Replaced dipoles with higher strength CB magnets – Used existing support stand – Modified existing support plate to accommodate new magnets

Injection & Reinjection– Reinjection Chicane New CB* * The final design of the CB and CA magnets are not complete. The configuration shown is preliminary. New CA* Re-use of existing stand support plate. The support plate will be machined to accomodate new mounting bracket locations.

Injection & Reinjection – ’ 07 Scope Comparisons • Initial scope assumed the re-use of the 2 stands for the girders making the transition over the transfer lines 0 R 01 and 0 R 02. - Based on field surveys and the decision to rotate the 0 R 02 girder 180 degrees, the 0 R 02 stand cannot be used. A new stand is required. The 0 R 01 stand will be re-used. • Initial scope assumed the re-use of the 2 stands used to support the 1 L 00 and 1 L 01 girders in the N. Linac. These stands cannot be used but we will be replaced with the 2 stands from injector line currently used to support the 0 L 09 and 0 L 10 girders. These two girders have been shifted over the transfer lines. No cost changes associated with this change-out. • Initial scope assumed that 4 new vertical support stands would be required to accommodate interferences between the arcs and the injection area. After field surveys, only 2 new stands are required with straight forward field modifications to 3 additional stands.

Injection & Reinjection – Remaining Work/Summary: • • 3 D model is complete. Songsheets have been developed Installation and alignment coordinates have been generated. 99% of drawings have been signed off and are ready for procurement, see remaining work for missing 1%. – New Drawings: 41 – Revised Drawings: 9 Where to from here: • Design and layout work for the spectrometer branch has progressed based on discussions held in January of this year. We are expecting no surprises from Reza’s TN. Drawings ready for signature pending review of the TN. • Detail design work has also been completed for the mini-chicane girder. – Drawings will be issued pending completion of CB magnet design. • Formally document welds in accordance with JLAB EH&S 6122 • Procurement Activities: Planning, Scope of Work Documents, etc.

North & South Linacs – Intro & Scope • • 12 Ge. V field strength requirements forced us to replace two QB quads at the start of the linac with QCs and replace the dipoles on the reinjection chicane girder with higher strength magnets • North Linac 1 st Section – QB to QC change at MQB 1 L 00 & 01 N&S Linac Sections 3 & 4 – Add new modules in zones 22 through 25 – Replace warm region girders with new short girder • The 12 Ge. V upgrade requires an additional ten cryomodules – Five in the north linac and five in the south • NEW modules are longer than the original CEBAF modules – Result: Warm region girders downstream of the new modules must be replaced with a new short girder • Like downstream of SL 21

North & South Linac – NL, QB to QC Change • MQB 1 L 00 & MQB 1 L 01 girder modifications – Replaced QB quads with higher strength QCs – Re-used support pedestals from 2 injector line girders that have been repositioned over the transfer lines. MQB 1 L 00 MQB 1 L 01 View looking upbeam to MQB 1 L 00 & 01 girders

North & South Linac – NL, QB to QC Change New QC’s that replace existing QB’s These 2 stands are re-used from the 2 injector girders , 0 L 09 and 0 L 10, that got moved across the transfer lines. The existing stands have been field modified with outriggers that do not support the new girders.

North & South Linac – New Module/Girder Layouts Layout of new modules & girders in linac DP station moved to end of linac Current Configuration (Zones 19 – 22) 12 Ge. V Configuration (Zones 19 – 22) New module Replaced module baseplates Current Configuration (Zones 23 – 26) Four New modules 12 Ge. V Configuration (Zones 23 – 26) Five New warm girders

North & South Linac – Warm Region Girders • Warm girder design was reviewed in Oct 2004 • Prototyped and installed at SL 21 • Designed to accommodate multiple combinations of cryomodule configurations • Quad, BPM, and alignment cartridges will be reused on new short girders Viewer & pump drop cross Existing baseplate Old warm region girder H&V nested Air Core correctors over BPM Quad New stand New short warm region girder

North & South Linac – Summary/Remaining Work Summary: • Detailed design and drawings for the 1 L 00 & 1 L 01 girders is complete • Songsheets have been developed • Installation and alignment coordinates have been generated. • Warm girder design and associated detail drawings are complete • No scope changes from last year

Extraction – Intro & Scope • The extraction region must be upgraded to support transport of higher energy beam to halls A, B, & C and 5 th pass beam to the new arc 10 to support 12 Ge. V operations Extraction Region

Extraction – System Diagram

Extraction – RF Separators Current Configuration 12 Ge. V Configuration New quad girder Relocated New Two new pedestal stands Existing supports New quad girder

Extraction – RF Separators Two new pedestals Existing supports (gray)

Extraction – Septa Magnet Stacks Current Configuration 12 Ge. V Configuration New quad girder Two YBs Relocated One relocated and one new support stand New Two new pedestal stands Two new support stands Three YRs YA Septa Stacks YB/YR Septa Stack

Extraction – Quad Girder New AE 01 Girder • Replaces existing hall transport girder New pedestal stands not required -existing stands have 5 arms

Extraction – YA Septa Magnet Stacks Two relocated supports New pedestal stand for AE 02 girder Two new pedestal stands

Extraction – YB/YR Magnet Stacks Existing YB septa magnets Three YR septas (recycled from S&Rs) New upbeam support stand New downbeam support stands

Extraction – Dipole Magnet Stacks Current Configuration 12 Ge. V Configuration New Two new support stands Three BPs New BP Dipole Stack

Extraction – Dipole Magnet Stacks Current Configuration 12 Ge. V Configuration New

Extraction – Dipole Magnet Stacks 12 Ge. V Configuration Two existing BQs New support stand Three new BPs New BP BP Dipole Stack Two new pedestal supports for 5 th pass BP New pedestal for 5 th pass BP downbeam support BQ/BP Dipole Stack

Extraction – BP Dipole Magnet Stacks ATLis task in place to gather as-built locations of ceiling penetrations in this area One new pedestal stand Two new support stands

Extraction - Dipole Magnet Stacks /Arc Recirculation New Arc 10 four meter dipole New stand rotated to accommodate new BP stack New pedestal stand for Arc 10, AA 01 girder

Extraction - Overhead View of BP Stacks and Arc

Extraction – BQ/BP Dipole Magnet Stacks Two existing BQ dipoles New upbeam stand Three new BP dipoles New downbeam stand. This stand will have two 1 -hole arms for BQ and three 2 -hole arms for BPs.

Extraction – RF Separators

Extraction – Septa Magnet Stacks Existing YA Septa Stack Existing YB Septa Stack

Extraction – Dipole Magnet Stacks BP Stack Existing BP Dipole Stack BQ Stack Existing BQ Dipole Stack

Extraction – ‘ 07 Scope Comparisons • Initial scope called for adding a QB to the 8 E 01 and installing a QB/QC girder at AE 01. Final design leaves 8 E 01 as is and installs single QC at AE 01 • Initial scope for YA magnets was to add one new support and one relocated support. Final design uses two relocated supports from the existing YB stack. • Initial scope specified two new pedestal supports for the downstream 5 th pass BP magnet. This has been modified to utilize a single pedestal stand due to space constraints. • The 5 th pass BP pedestal for the BQ/BP stack has been eliminated in favor of a new stand designed to accommodate BQ and BP supports.

Extraction – Remaining Work/Summary: • 3 D model of extraction region is 80% complete • Detail design work has been completed for several of the new/relocated support stands Where to from here: • Awaiting updated optics deck from CASA to… • Complete extraction and recirculation layouts • Begin YR vacuum chamber design • Update songsheets to reflect change to single quad girders at 8 E and AE 01 and add RF Separator calibration magnets to 12 Ge. V songsheet • Formally document welds in accordance with JLAB EH&S 6122

Existing Arcs & Hall Transport– Intro & Scope • Accommodate the addition of the H-steel on Arc dipoles • Swap QA quad with QR at 32 locations • Install new correctors on 3 girders • Develop songsheets that reflect 12 Ge. V quad, corrector, and power supply upgrades West ARC Dipoles

Existing Arcs - H-style dipole interface Prototype H-style dipole H-steel interferes with existing outrigger support • H-steel runs directly through the holes tapped into the magnet core used to support the outrigger • Prefer not to cut away H-steel to clear existing support INTERFERENCE • Solution proposed last spring will be revisited based on H steel configuration change

Existing Arcs – Existing Alignment Scheme Existing C-style dipole alignment scheme • Alignment fixture indexes on machined flats on each end of the magnet • Two bolts are used to fasten the fixture to the magnet (mounting holes tapped into upper machined surface on the magnet core) Machined flats Problems - • Lab alignment group reports that it can be difficult to ensure that the fixture is seated properly against the magnet • Scheme only provides two alignment points on each magnet • Fixtures would require modification to eliminate interference with new H-steel dipoles Existing C-style ARC dipole Existing C-style dipole up-beam alignment fixture dipole Prototype H-style dipole

Existing Arcs – New Alignment Scheme Use threaded retro-reflector nests in old fixture fastening holes • Provides four points for alignment • Alignment group has done mock-up to confirm line-of-sight with the addition of H-steel Retro-reflector nest • Plan uses tapped holes on the machined flats that were not intended as alignment reference • The Alignment group measured 28 dipoles of four different styles during the summer 2007 shutdown • Results show no significant problems with repeatability of the target C-style ARC dipole with retro-reflector nests installed

Existing Arcs & Hall Transport – Summary/Remaining Work Summary: • We have developed songsheets that reflect all 12 Ge. V element and power supply changes • All layouts and element changes are available on our webpage • New alignment scheme looks good Remaining Work: • Re-visit the outrigger support design • Develop girder modification designs to accommodate the new correctors – minimal effort required • This is likely a field mod to the girder

Spreaders & Recombiners • The 12 Ge. V upgrade requires extensive modifications to the spreader and recombiner regions of the machine • These are the most congested regions in the beam transport system • S&R region optics and magnet design has not progressed far enough along to begin detailed 3 D beam transport design • We have focused our resources on well defined regions of the machine • We will begin these designs with a trained staff and a library of 3 D assemblies, parts & drawings

ARC 10 – Intro & Scope • The ARC 10 line will be installed below the existing arc 8 line on the west side of the machine • The line includes (tangent to tangent): • 32 new QP girders (24 single and 8 double) • 32 new four meter dipoles ARC 10

ARC 10 - Layouts Typical segment from the west arc Repeating structure Four 4 m Dipoles ARC 10 3 Single quad girders 1 Double quad girder

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

ARC 10 - Layouts • • Requirements drove the design of 12 different girder flavors for arc 10 They share 3 common girder sub-assemblies • Short single quad girder • Standard single quad girder • Double quad girder All girders use the same pedestal design All 4 m dipoles use the same set of stands

ARC 10 – Remaining Work/Summary: • Quad girder designs, assembly, and associated detail drawings are DONE! • 12 assembly & 33 detail drawings • Pedestal designs (girder and dipole) are DONE! • 3 D assembly of the entire west arc has been developed • We have checked for interferences with existing support stands and Arc eight girders (pump drops, alignment cartridges) • Installation coordinates have been developed for all quads and dipoles (pedestal bolt and alignment cartridge) Where to from here: • • Develop Arc 10 region assembly drawings to document installation data Incorporate likely mod to baseline 4 m dipole design Complete design of the 4 m dipole chamber (w/SLM port at AA 29 dipole) Formally document welds in accordance with JLAB EH&S 6122

Hall D – Intro & Scope • The Hall D line begins with the first quad in the east spreader and ends at the beam dump in Hall D tagger building • The line includes: • One new 2 m dipole • 21 quad girders (QAs & QPs) • Four 4 m dipoles • Several diagnostics girders • Insertable dump & beam stopper system • Sliding shield wall (similar to Hall A & C lines) Tagger Bldg East spreader

Hall D – Layouts, 1 st Spreader Hall D WBS Hall D line ~7 inches from nominal tunnel floor

Hall D – Layouts, 1 st Extraction QP quad girder Fast feedback correctors (H&V)

Hall D – Layouts Point of tangency Insertable Dump Beam stoppers Fast Feed Back Correctors 8 deg ramp to Hall D 4 m dipoles Quad girders Diffuser Insertable Dump Beam Current Monitor Beam Stoppers

Hall D – Layouts Quad girders 4 m dipoles Cavity BPM Sliding shield wall

Hall D – Layouts

Hall D – Layouts n. A BPM Cavity Stationary Shield Wall. Supply/Return/Power lines for the air handler and fan Air handler and Fan unit. BEAM DIRECTION Moveable Shield Wall

Hall D – Layouts Plan view: Dump Viewer Beam Dump Steel sheilding Elevation: Cavity BPM & BCM 14. 8 ft 71 in

Hall D – Layouts

Hall D – Vacuum Design • Number of vacuum pumps in 07 cost book based on rough hand calc and scaling existing CEBAF design • Subsequent detailed analysis validated pump quantity and optimized position along beamline • 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/cm 2 • Vacuum analysis conducted using VACCALC program – Developed by M. Sullivan at SLAC • 4 m 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 3”OD

Hall D Line – Vacuum Design meets specification - average pressure is < 5*10 -7 torr

Hall D – Summary/Remaining Work Summary: • • The Hall D line 3 D model is 60% complete Successfully leveraged off arc 10 girder & stand designs Vacuum system design is complete Songsheets have been developed Where to from here: • On track to complete all quad and diagnostic girder drawings and associated details on June 20 th • Develop region assembly/installation drawings • Gathering existing stand floor elevation data during summer down • Develop detailed layout of Tagger dump area • Formally document welds in accordance with JLAB EH&S 6122

The Path Forward • The first procurement on the girder, stand, vacuum side of things is the ARC 10 quad girder procurement scheduled for 2 nd quarter of FY 09 – No problem. . . all girder and associated drawings are complete! • Balance of girder, stand, and vacuum procurements scheduled for FY 10 • We will begin developing SOWs and detailed procurement plan in parallel with installation planning during FY 09

Summary • Assembly and Installation detail drawing package for the Injection and Reinjection region area completed on schedule! – Was our first major milestone on the beam transport side of things • ARC 10 3 D model complete. All girder assembly and associated drawings have been reviewed and signed off. Installation points have been generated. • Hall D line development is progressing well (ahead of schedule) • We have released ~100 drawings • The Extraction region design is 80% complete and we expect to close out this effort in FY 08 (one year early) • We will continue to work closely with our friends throughout the lab (safety, CASA, installation, vacuum, alignment, Rad. Con, I&C, magnet measurement, operations, procurement & facilities) as we move forward • Remaining efforts WILL be completed to support procurement, assembly and installation schedules • We look forward to comments from the committee