1. Assembly, Installation and Interfaces Steve Virostek Lawrence Berkeley National Lab RFCC Module Design Review October 21, 2008

2. MICE RFCC Module Design Review – Assembly, Installation and Interfaces Page 2Steve Virostek - Lawrence Berkeley National Lab - October 21, 2008 Topic Summary Packaging and delivery to RAL Moving into MICE hall Module re-assembly in MICE hall Module installation interfaces End flanges and seals Base mounting RF coupler connections Utility requirements Instrumentation & control

3. MICE RFCC Module Design Review – Assembly, Installation and Interfaces Page 3Steve Virostek - Lawrence Berkeley National Lab - October 21, 2008 Module Shipping Configuration Cavities, couplers, coolers & pumps removed Coupling coil shipped warm Vacuum vessel/magnet axis vertical during shipping Concerns about shipping loads on coupling coil Special shipping fixture will be required Cavities, couplers packaged to prevent damage RF, Be windows left in place w/appropriate protection Vacuum vessel, cavities and couplers will be blanked off and backfilled with N 2

4. MICE RFCC Module Design Review – Assembly, Installation and Interfaces Page 4Steve Virostek - Lawrence Berkeley National Lab - October 21, 2008 Delivery to RAL Arrives w/o cavities, coolers, couplers installed Moved into hall in vertical shipping orientation Height is expected to be ~2000 mm when vertical Height is 2844 mm if horizontal on a short stand MICE Hall door height: 3360 mm Roller dollies w/forklift used to move into hall ~100 mm tall Roller dollies

5. MICE RFCC Module Design Review – Assembly, Installation and Interfaces Page 5Steve Virostek - Lawrence Berkeley National Lab - October 21, 2008 Moving into MICE Hall Module short stand: Likely won’t be needed Vertical orientation shipping stand can also be used to move module into hall Cryocoolers removed Cavities removed Couplers removed Vacuum pumps removed

6. MICE RFCC Module Design Review – Assembly, Installation and Interfaces Page 6Steve Virostek - Lawrence Berkeley National Lab - October 21, 2008 MICE Hall Access

7. MICE RFCC Module Design Review – Assembly, Installation and Interfaces Page 7Steve Virostek - Lawrence Berkeley National Lab - October 21, 2008 Place operating stand on lateral tracks Load vacuum vessel/coupling coil onto support stand Erect portable clean room around module Unpack cavities, couplers, coolers, pumps Install six tuner assemblies on each cavity Insert cavities in vacuum vessel using special fixture Install couplers and tuner actuators after cavity is aligned and supported by struts Install vacuum pumps to complete module Perform final alignment before translation Re-assembly of Module at RAL

8. MICE RFCC Module Design Review – Assembly, Installation and Interfaces Page 8Steve Virostek - Lawrence Berkeley National Lab - October 21, 2008 Re-assembly of Module at RAL Support stand in place on rail platform

9. MICE RFCC Module Design Review – Assembly, Installation and Interfaces Page 9Steve Virostek - Lawrence Berkeley National Lab - October 21, 2008 Empty module lifted over support

10. MICE RFCC Module Design Review – Assembly, Installation and Interfaces Page 10Steve Virostek - Lawrence Berkeley National Lab - October 21, 2008 Re-assembly of Module at RAL Module lowered onto support

11. MICE RFCC Module Design Review – Assembly, Installation and Interfaces Page 11Steve Virostek - Lawrence Berkeley National Lab - October 21, 2008 Re-assembly of Module at RAL Support stand gussets added

12. MICE RFCC Module Design Review – Assembly, Installation and Interfaces Page 12Steve Virostek - Lawrence Berkeley National Lab - October 21, 2008 Re-assembly of Module at RAL Support stand gussets added

13. MICE RFCC Module Design Review – Assembly, Installation and Interfaces Page 13Steve Virostek - Lawrence Berkeley National Lab - October 21, 2008 Re-assembly of Module at RAL Cryocooler(s) installed

14. MICE RFCC Module Design Review – Assembly, Installation and Interfaces Page 14Steve Virostek - Lawrence Berkeley National Lab - October 21, 2008 Re-assembly of Module at RAL Cryocooler(s) installed

15. MICE RFCC Module Design Review – Assembly, Installation and Interfaces Page 15Steve Virostek - Lawrence Berkeley National Lab - October 21, 2008 Re-assembly of Module at RAL RF cavities installed from either end

16. MICE RFCC Module Design Review – Assembly, Installation and Interfaces Page 16Steve Virostek - Lawrence Berkeley National Lab - October 21, 2008 Re-assembly of Module at RAL Module with all four cavities installed

17. MICE RFCC Module Design Review – Assembly, Installation and Interfaces Page 17Steve Virostek - Lawrence Berkeley National Lab - October 21, 2008 Re-assembly of Module at RAL Cavity tuner actuators added

18. MICE RFCC Module Design Review – Assembly, Installation and Interfaces Page 18Steve Virostek - Lawrence Berkeley National Lab - October 21, 2008 Re-assembly of Module at RAL Cavity tuner actuators added

19. MICE RFCC Module Design Review – Assembly, Installation and Interfaces Page 19Steve Virostek - Lawrence Berkeley National Lab - October 21, 2008 Re-assembly of Module at RAL Module vacuum pumps installed

20. MICE RFCC Module Design Review – Assembly, Installation and Interfaces Page 20Steve Virostek - Lawrence Berkeley National Lab - October 21, 2008 Re-assembly of Module at RAL Module vacuum pumps installed

21. MICE RFCC Module Design Review – Assembly, Installation and Interfaces Page 21Steve Virostek - Lawrence Berkeley National Lab - October 21, 2008 Re-assembly of Module at RAL RF couplers installed

22. MICE RFCC Module Design Review – Assembly, Installation and Interfaces Page 22Steve Virostek - Lawrence Berkeley National Lab - October 21, 2008 Re-assembly of Module at RAL RF couplers installed

23. MICE RFCC Module Design Review – Assembly, Installation and Interfaces Page 23Steve Virostek - Lawrence Berkeley National Lab - October 21, 2008 Insertion into MICE Beamline Assemble module on lateral tracks Align and shim module to correct height Pull back bellows on both module ends with O-rings in place Translate module into position using rails Release bellows and connect flanges Lock out bellows using bridging bolts Connect RF, utilities and instrumentation

24. MICE RFCC Module Design Review – Assembly, Installation and Interfaces Page 24Steve Virostek - Lawrence Berkeley National Lab - October 21, 2008 Module Flange Connection End flange O-ring seal Formed bellows Flange through holes

25. MICE RFCC Module Design Review – Assembly, Installation and Interfaces Page 25Steve Virostek - Lawrence Berkeley National Lab - October 21, 2008 End Flanges and Seals RFCC flanges mate with AFC module flanges AFC flanges have no O-ring grooves or bellows RFCC module flanges have bellows and O-ring grooves at both ends Bellows are spec’d for >1 cm of total travel Module relative alignment is driven by clearance in flange holes Bellows are locked out after installation to allow transmission of forces between modules

26. MICE RFCC Module Design Review – Assembly, Installation and Interfaces Page 26Steve Virostek - Lawrence Berkeley National Lab - October 21, 2008 RFCC Bellows and Flange MICE RF and Coupling Coil Module – Summary of the Design and Fabrication Plan Elastomer or Helicoflex all- metal O-ring Clamping bolts Bellows pull back bolts

27. MICE RFCC Module Design Review – Assembly, Installation and Interfaces Page 27Steve Virostek - Lawrence Berkeley National Lab - October 21, 2008 MICE RF and Coupling Coil Module – Summary of the Design and Fabrication Plan Module Joint Sealing Issues MICE module joints likely to need relatively frequent disassembly (reconfiguring, maintenance, repair) Elastomer O-rings provide the most reliable and cost effective (inexpensive and re-useable) solution O-rings are acceptable for use in MICE environment But, MICE should demonstrate future machine technology including the use of radiation hard seals The RFCC flange groove is designed to accept an all- metal Helicoflex seal for demonstration purposes

28. MICE RFCC Module Design Review – Assembly, Installation and Interfaces Page 28Steve Virostek - Lawrence Berkeley National Lab - October 21, 2008 Module Base Mounting RFCC module base connection to rails similar to that used on the Spectrometer Solenoid Six mounting plates are welded to the base of the module support stand Location of the mounting plates will be included in an interface document being developed Coupling coil magnetic loads are carried to the floor through the vacuum vessel/support stand/base mounting plates

29. MICE RFCC Module Design Review – Assembly, Installation and Interfaces Page 29Steve Virostek - Lawrence Berkeley National Lab - October 21, 2008 Module Mounting Provision Six mounting plates to be welded to the support stand base for installation on rails Similar to spectrometer solenoid mounting scheme

30. MICE RFCC Module Design Review – Assembly, Installation and Interfaces Page 30Steve Virostek - Lawrence Berkeley National Lab - October 21, 2008 Cavity RF Connections Eight RF feeds/module use standard 4” RF coax Cooling water for loop may be required (<<1 lpm each) Adapter attached to RF windows protects ceramic from installation forces Co-ax interface dimensions w.r.t. module center will be included in interface document RF feeds

31. MICE RFCC Module Design Review – Assembly, Installation and Interfaces Page 31Steve Virostek - Lawrence Berkeley National Lab - October 21, 2008 Module Utility Requirements Cryomech Model PT-415 cryocoolers (2 or 4 each total) 50 Hz AC: 10.5 kW @ 200/220 or 380/420 V, 3 phase Cooling: minimum 12 lpm of water @ 80ºF max 300 A Power Supplies – American Magnetics (2 ea total) 50-60 Hz AC: 3.5 kW @ 208 V, 3 , forced air cooled, rack mnt. Vacuum: 10 -3 torr @ startup thru a 25 mm flanged port Cavity cooling water: ~8 lpm/per cavity Getter pump regeneration power (100-210 VAC, 100 W) Liquid cryogens: LN, LHe for cooldown (100’s of liters) Pressurized N 2 : up to 300 psi for tuner actuators

32. MICE RFCC Module Design Review – Assembly, Installation and Interfaces Page 32Steve Virostek - Lawrence Berkeley National Lab - October 21, 2008 Module Instrumentation & Control Coupling coil Coil voltage taps Thermocouples LHe level Vacuum pressure RF cavities RF pickup loop N 2 pressure control for tuners (1 per cavity) Cooling water temperature/flow Module vacuum Getter pump power supply and controller Pump thermocouple Vacuum pressure

33. MICE RFCC Module Design Review – Assembly, Installation and Interfaces Page 33Steve Virostek - Lawrence Berkeley National Lab - October 21, 2008 Summary Module to be shipped with all sensitive components removed and packaged separately Vertical shipping orientation also provides comfortable clearance through MICE Hall door Module re-assembly will require specially designed lifting fixtures Module interfaces will be defined in an interface document Utility requirements have been established Instrumentation & controls list being compiled