SPS Vacuum Flange Impedance Reduction Project Status Vacuum

SPS – Vacuum Flange Impedance Reduction Project Status Vacuum, Surfaces & Coatings Group Technology Department

Outline Typical SSS layout configurations • Technical solutions • • • Vacuum flange shielding - strategy Bellows protoyping Cost estimates • Comments • Next steps • Vacuum, Surfaces & Coatings Group Technology Department 19 January 2022 J. Perez Espinos 2

SSS layout configuration 1 QD type Multiple configurations 10 convs. Common solution 10 convs. 4 convs. Enamelled flanges DIPOLE SSS QUADRUPOLE Vacuum, Surfaces & Coatings Group Technology Department 19 January 2022 J. Perez Espinos 3

SSS layout configuration 1 MBA/QF type Multiple configurations New interventions for pumping ports! 10 convs. 4 convs. Common solution 10 convs. Enamelled flanges DIPOLE SSS Finally, need of replacement of existing shielding! Diam. 219 QUADRUPOLE Vacuum, Surfaces & Coatings Group Technology Department 19 January 2022 J. Perez Espinos 4

Postions vs. vac. chambers • BE works with positions (usually integrating 2 vac. chambers) • VSC works with vac. chambers Vacuum, Surfaces & Coatings Group Technology Department 19 January 2022 author(s) 5

Technical solutions • QF/MBA • 2 technical solutions taken into account: • Vacuum flange shielding • Integration of bellows with shape similar to QF/MBA • QD • Integration of bellows with shape adapted to QD tube inside diameter Vacuum, Surfaces & Coatings Group Technology Department 19 January 2022 J. Perez Espinos 6

Vacuum flange shielding proposals • QF/MBA 4 mechanical proposals based on deformable structure 1 mechanical proposal based on sliding contact 1 mechanical proposal based on rigid structure • • • Goals (apart from impedance reduction): • • • Maximize reliability (e. g. no loss of contact by misalignment) Improve vacuum interventions (e. g. assembly of seals) Avoid short on enamelled positions Standard solution compatible for 4 and 10 convolutions QD • No shielding possible Vacuum, Surfaces & Coatings Group Technology Department 19 January 2022 J. Perez Espinos 7

Vacuum flange shielding analysis • Solutions proposed based on conservative approach: • • • Dimensions adapted to 4 convolutions solution (relative gain factor for 10 convs. to be better) Deformable structure to absorb bellows movement for 10 convs (+/-10 mm) No volume filling on opposite flange Flat solution instead of tube solution After analysis a preferred solution is to be studied in detail • Major contribution coming from non filled space: how much? ? ? Vacuum, Surfaces & Coatings Group Technology Department 19 January 2022 J. Perez Espinos 8

Shielding prototyping • A prototype will be generated for preferred solution: • 3 combinations to be integrated (to identify weak points and trace-out with theoretical analyses): • Tube-flat solution • Tube-tube solution • Gap vs. filled volume • • To be ready in 3 weeks time use of conservative approach for convolution Prototyping solution to be adapted from pumping port shielding design Vacuum, Surfaces & Coatings Group Technology Department 19 January 2022 J. Perez Espinos 9

Bellows prototyping • • Prototyping for both QD and QF/MBA bellows has been requested recently QD 1 bellows item found to be potentially used (TBC): 10 convs. If confirmed, prototype to be ready in 4 -5 weeks • • • QF/MBA Most complicated issue: 4 months for supply + very high cost (rough estimation: >6 -7 KCHF) Proposal: additive manufacturing by 3 D printing • • No option to extend/compress convolutions Electrical properties of material to be roughly the same Shape to be the same in nominal configuration Thickness of convolutions to be higher than those from a real bellows Anyway, need to study the best solution to be integrated and the manufacturability with the bellows supplier before any prototype solution Supply: 2 months for 3 D printing (TBC) Vacuum, Surfaces & Coatings Group Technology Department 19 January 2022 J. Perez Espinos 10

Extents for cost estimates • Interventions to be done in SSS and, potentially, in quadrupoles QF and QD Number of positions released • • • Type of design/intervention remains open Priorities remain open Limits: • • • [list released recently: 18% more positions for QF/MBA including intervention in pumping ports] Survey campaign not considered: cost impact to be analysed wrt final interventions RP impact to be considered on mechanical interventions: additional impact on cost? (e. g. cleaning, welding, etc. ) Space logistics cost to be analysed Spares not included in cost/unit [10% of spares to be considered as a baseline] Due to uncertainties in number of positions and solutions to be incorporated, cost breakdown given per intervention unit Technical assumptions: • • • Re-use of existing MBA, QF and QD tubes No particularities are considered (e. g. eccentric solutions, or new interventions foreseen for pumping ports) Due to impact in cost, enamelled and non-enamelled solutions will be distinguished Vacuum, Surfaces & Coatings Group Technology Department 19 January 2022 J. Perez Espinos 11

Scenarios for cost estimates • According to the final cost + integration workload, 2 bound scenarios are identified: Scenario 1 (upper bound): • • MBA/QF: • • • QD: • • Replacement of bellows to tube shape Flange manufacturing with no gap (opposite to bellows) Scenario 2 (lower bound): • • MBA/QF: • • • Installation of RF fingers (no existing solution) Gap filling in opposite flange to bellows QD: • • • Replacement of bellows to tube shape Flange manufacturing with no gap (opposite to bellows) Replacement of bellows to tube shape Gap filling in opposite flange to bellows Both scenarios assume interventions in every positions Lower cost if positions are not intervened Vacuum, Surfaces & Coatings Group Technology Department 19 January 2022 J. Perez Espinos 12

Cost estimates SCENARIO 1 QF/MBA Transport and logistics Magnets on girders (*) Quadrupoles 900 CHF 1500 CHF QD Transport and logistics Magnets on girders (*) Quadrupoles 900 CHF 1500 CHF Manufacturing Enamelled Non-enamelled 6700 CHF 5700 CHF 7600 CHF 6600 CHF 7200 CHF Manufacturing Enamelled Non-enamelled 5000 CHF 4400 CHF 5900 CHF 5300 CHF 5500 CHF SCENARIO 2 QF/MBA Transport and logistics Magnets on girders (**) Quadrupoles 400 CHF - QD Transport and logistics Magnets on girders (*) Quadrupoles 900 CHF 1500 CHF Manufacturing + assembly Enamelled Non-enamelled 2500 CHF 2900 CHF Manufacturing + assembly Enamelled Non-enamelled 3700 CHF 3200 CHF 4600 CHF 4100 CHF 4700 CHF (*) Transport and logistics of girder until/from workshop on surface + disassembly/assembly of individual magnet from/on girder (**) Disassembly/assembly of individual magnet from/on girder Vacuum, Surfaces & Coatings Group Technology Department 19 January 2022 J. Perez Espinos 13

Comments • Any scenarios for cost estimates should be fixed according to technical aspects: a functional specification needs to be generated!! • • • List of positions recently released to be considered as the baseline? TBC Transport and logistics cost estimates aligned with potential a. C project @ 6 dipoles/day (6 -7 months duration) • • Overall reduction needed for flanges? Contribution of QF/MBA vs. QD? Contribution of bellows 4 convs. 10 convs. ? … (1. 5 quadrupoles + 1, 5 SSSs)/day No extra cost for equipment if movement only applies to quadrupoles and SSSs Space logistics strongly depending on intervention: shielding? Bellows replacing? Quadrupole movement involves intensive survey • Need to adapt logistics for better approach? TBC, according to final interventions (QD+QF? , only QD? , only QF? ) Vacuum, Surfaces & Coatings Group Technology Department 19 January 2022 J. Perez Espinos 14

Next steps Confirm last list of positions as definitive • Fix prototyping • RF and impedance tests • Integrate cost estimate together with a. C project (to be presented in 2 weeks) • • • Big impact in logistics and transport cost Assess impact on survey tasks in terms of cost and logistics Vacuum, Surfaces & Coatings Group Technology Department 19 January 2022 J. Perez Espinos 15