1. NUMI Transmission Line (TL) Review WBS 1.1.3 Power Supply System Transmission Line (TL) Review Nancy Grossman FNAL April 23, 2003

2. NUMI Internal NuMI Review April 23, 2003 Transmission Line Review Page 2 Outline  Overview & Specifications (N. Grossman, 10’)  Scope of review  General Layout & Overall Specifications  Schedule, Concerns  Response to Recommendations (2/26/02 review) (N. Grossman, 10’)  Testing at MI8 (J. Hylen, 15’)  Remote clamp & joint testing so far  Future plans  Ionization Calculations (J. Hylen, 10’)  Cooling Calculations (A. Stefanik, 10’)  TL through Block & Beyond Design/Status (B. Boettinger, 45’)  Design (clamps, connection, supports)  Heating/cooling (expansion) & Vibration Issues  Service Considerations

3. NUMI Internal NuMI Review April 23, 2003 Transmission Line Review Page 3 Scope and Conceptual Layout: Target Hall Transmission Material: Aluminum, Dimensions: 12 inches wide by 3/8 inch thick Width: Stripline nominal width is 12 inches, reduce to 8” from below clamp to horns. Gap: Stripline nominal spacing between bars is 3/8 inch, can increase in flex region. HORN 1 JOINT HORN 2 JOINT REMOTE CLAMP ROCK WALL BETWEEN PS ROOM AND TARGET HALL- 23’ REMOVABLE Z-BAR REMOVABLE 28’ SECTION

4. NUMI Internal NuMI Review April 23, 2003 Transmission Line Review Page 4 Scope and Conceptual Layout: Target Hall Transmission

5. NUMI Internal NuMI Review April 23, 2003 Transmission Line Review Page 5 Scope/Charge to Group Scope Includes:  Transmission Line design from joint/remote clamp to connection at capacitor bank  Electrical Isolation Considerations  Heating/cooling (thermal expansion)  Vibration  Stands & support structures to hold transmission line in place  Wedge clamps in the transmission line block  Support stands in the target hall  Three point support structure in 24” round penetration from hall to PS room  Service Considerations  Removing the section through the wall  Horn replacement  Cover to protect transmission line – to be designed, simple slanted sheet metal Charge:  Look at overall design.  Consider QA, longevity, ESH issues.  Comment back to grossman@fnal.gov within a week.grossman@fnal.gov

6. NUMI Internal NuMI Review April 23, 2003 Transmission Line Review Page 6 MI-8 Fingers, Remote Clamp Remote clamp plugged in @ MI-8 Horn 1 joint/electrical plug @ MI-8 Routine pulsing of prototype horn 1, production horn 1 joint, remote clamp underway: ~370,000 pulses to date. Goal is 1 million pulses, 1/2 offset/flexed

7. NUMI Internal NuMI Review April 23, 2003 Transmission Line Review Page 7 Joints and Remote Clamp Horn 2 joint in machine shop (now done) Horn 1 joint, remote clamp at MI-8

8. NUMI Internal NuMI Review April 23, 2003 Transmission Line Review Page 8 Overall Specifications/Concerns 1. Lifetime:  Part of stripline connected to horn will be replaced each time a horn is replaced, ~>1 year.  Part of stripline within stripline block (includes clamp) does not have to be replaced every time a horn is replaced, but we will most likely have a spare just in case.  Lifetime of NuMI ~ 10 years 2.Radiation Environment such that ceramics must be used near the beam, but not necessary above the module/T-blocks.  Ceramics spacers from horn to top of module/block  G-10 spacers used beyond that as insulators 3.Vibration, keep to a minimum everywhere.  Biggest horn vibration is from stripline (MI8 measurements)  Not near horn natural frequencies (200 Hz), damping times short wrt rep-rate  Clamp every 12” in target hall  Pulsed for about 9.5 millions pulses at MI-8 (non-joint portion of transmission line) with no problems – clamping every 12”  More on recent vibration measurements from Jim.

9. NUMI Internal NuMI Review April 23, 2003 Transmission Line Review Page 9 Overall Specifications/Concerns 4. Cooling  Target chase cooled by ~24,000 cfm flowing in the beam direction in the horn region and back in the opposite direction between the top of the T- blocks and the concrete cap.  Beam heating: ~183 KW/m 3 (transmission line near the beam)  TL Electrical heating: ~27 KW/m 3 (flex joint number)  Assume air cooling from target chase is sufficient (A. Stefanik talk)  Want air flow through TL shield block from top of module to horn (this air flow cools stripline)  Air dam is needed at the H-block cover between the module and the stripline along the target hall wall (intended to contain air-borne radiation). 5. Service Considerations:  Must not block survey holes in T-blocks just off module ends, need direct vertical line of sight.  Two removable sections to allow removal of section through the wall (28’).  Removable “z-bar”s at top of module/block. Allows replacement of horns.

10. NUMI Internal NuMI Review April 23, 2003 Transmission Line Review Page 10 Transmission Line: Through the Block

11. NUMI Internal NuMI Review April 23, 2003 Transmission Line Review Page 11 Transmission Line: Through the Block ( figure slightly out of date )

12. NUMI Internal NuMI Review April 23, 2003 Transmission Line Review Page 12 Transmission Line: Through the Block

13. NUMI Internal NuMI Review April 23, 2003 Transmission Line Review Page 13 Transmission Line: Beyond the Shielding

14. NUMI Internal NuMI Review April 23, 2003 Transmission Line Review Page 14 Transmission Line: Beyond the Shielding

15. NUMI Internal NuMI Review April 23, 2003 Transmission Line Review Page 15 Transmission Line: Beyond the Shielding

16. NUMI Internal NuMI Review April 23, 2003 Transmission Line Review Page 16 Transmission Line: Through the Rock Wall

17. NUMI Internal NuMI Review April 23, 2003 Transmission Line Review Page 17 Transmission Line: Through the Rock Wall

18. NUMI Internal NuMI Review April 23, 2003 Transmission Line Review Page 18 Response to Recommendations: Horn PS/TL Review (August 2001) Consider using a dynamic type fastener (e.g., spiralock nut) in the clamp joints and stripline support brackets.  This is being done, except in the block region where it is tack-welded to the fasteners. Consider measuring bolt preload in critical connections by measuring bolt stretch as opposed to bolt torque.  Not sure how to implement this – ideas? Consider longitudinal damping along the TL section along the Target Hall wall to damp out possible undamped vibrations from electrical pulsing.  Using polyeruthane isolators and swinging end-links (see Bill’s talk). Worry about scratching the silver-plating off the TL “fingers” when clamping/unclamping.  Have seen no damage in the silver-plating on the TL fingers out at MI-8 and they have been connected and disconnected a few times. (more from Jim)

19. NUMI Internal NuMI Review April 23, 2003 Transmission Line Review Page 19 Response to Recommendations: TL, Remote Clamp, TL Block Review (Feb. 2002) Flex Joint Comments (joint with slits)  No longer using a joint with slits. ANSYS shows we can get sufficient flexibility with the non-slitted design. Single strip force tests agree with the ANSYS analysis. Testing at MI-8 of the horn1 joint is going well. More from Jim – not specifically part of this review. Suggest quantitative measurements be made at MI-8 (deflection at specific points, resonant frequencies, etc.) to compare to ANSYS calculations (and any other calculations) and thus support longevity estimates.  We are making some quantitative measurements at MI-8 and will compare measurements with predictions– Jim will talk about this. Concerns abut a tight testing schedule at MI-8 which might be hard to meet if problems are encountered.  Agree. We have encountered problems, testing is tight, and we hope to make it (more from Jim). Can delay installation of horn PS & continue testing longer. Concerns with human resources – lack of.  This is a constant battle we continue to fight. Suggest pre-assemble entire setup (power supply to horns) at MI-8.  We will do this to the extent that we can.

20. NUMI Internal NuMI Review April 23, 2003 Transmission Line Review Page 20 Schedule & Concerns Schedule:  MI-8 testing until Horn PS removed for installation.  Test pulsing of horn 1 and horn 2 on test stand.

21. NUMI Internal NuMI Review April 23, 2003 Transmission Line Review Page 21 Schedule & Concerns Specific Concerns: Making sure all bolts on the TL clamps are tighten (and remain tightened)  Checkout checklist item  Periodic checks in Target Hall? QA that clamps are put together correctly  If doesn’t look like it is going together well, stop and ask expert.  Alignment rods at removable sections General Concerns: Resources (manpower)  Engineering/drafting to get the design done and parts ordered/made  Technicians to get it assembled and installed Fitting it all in with the target hall shield block installation & Module installation  Concerns about damaging the TL parts  Final connections of the TL to the horns/PS are near the critical path The transmission line (and joint) have always been underestimated in their complexity (cost, time to make, problems encountered in installation/testing).