Transcript Undulator Vacuum System

Undulator Vacuum System
Geoff Pile, Dean R. Walters, Soon-Hong Lee, James Bailey,
James Morgan, Dana Capatina, Scott Doran, ANL
October 30, 2007
Undulator Breakout
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Dean R. Walters
[email protected]
Undulator Vacuum System
Undulator Vacuum Chamber Support
Status
Production Schedule
Bellows Module
Testing: Combined Offset test and Surface Measurement
Production Plan
Quadrupole Spool
Design
Production Schedule
Long Break Spools
Standard Spool Design
Spools with Sector Valve
Production Plan
Beam Finder Wire
Status of Production
Modification to Chamber
Production Schedule
All Metal Chain Clamp Vacuum Seal
Testing Results
October 30, 2007
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Dean R. Walters
[email protected]
Undulator System Lattice
L14-200000
SA-381-003-01
Undulator CELL
L14-501000
SA-381-003-03
Long Break
Vacuum Spool
L14406-111000
SA-381-014-70
Support Mover System
L14-401000
SA-381-006-24
Girder Weldment
L1430401-100396
SA-381-002-76
Pedestal Assembly
L1430802-200000
SA-381-010-50
Long Break Iso
Vacuum Spool
L14406-112000
SA-381-014-81
Girder Assembly
L143-010000
SA-381-003-04
Undulator
L143-112000
SA-381-001-35
BFW Assembly
L14506-110000
SA-381-007-96
Quad Assembly
L1430501-100394
SA-381-012-74
RFBPM Assembly
L1450503-100000
SA-381-008-70
Control Assembly
L142-100060
SA-381-011-28
BFW Support
L14506-112000
SA-381-013-25
Quad Spool
L14405-117000
SA-381-013-97
RFBPM Receiver
L1450501-310000
SA-381-011-80
Vacuum Chamber
L1440202-200000
SA-381-0XX-XX
Bellows Module
L14403-110000
SA-381-0XX-XX
Ion Pump
L14405-104000
SA-381-013-40
RFBPM Support
L14505-104000
SA-381-014-39
October 30, 2007
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Long Break Diag.
Vacuum Spool
L14406-116000
SA-381-0XX-XX
Girder Weldment
L1430401-100396
SA-381-002-76
WPM-WLS
LMO-381-901-13
Sub-Assemblies in the Undulator Vacuum System
Bellows Module
Ion Pump
Undulator Magnet
Beam Finder Wire
Quadrupole Magnet
Vacuum Chamber and Support
RF Beam Position
Monitor
Wire Position Monitor
Girder
RF BPM
Electronics
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RF BPM
Waveguide
Tubing Support Structure
Production Status
Awarded to Walco Tool & Engineering (July, 2007).
Tubing material was changed to Aluminum 6061-T6 from
Steel due to a magnetic material risk. (August, 2007)
Raw material was ordered in Sept. 2007 and was arrived at
the vendor. (Oct. 18, 2007)
A first article is being fabricated to reduce the risk.
After rough machining, the tubing will be vibration stress
relieved.
Two weeks lead-time from the painter.
One week for final machining and assembly.
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Production Schedule
First Article Inspection
Support tubing will be inspected before starting the machining of
remaining 36 assemblies.
Expect in the week of November 19th, 2007.
Within 2 weeks after inspection, APS will allow the vendor to cut the
remaining materials.
Production completion
Lead time: 8 weeks after the first article inspection.
First Unit complete 12/10/2007
Completion of remaining 36 assemblies: Week of Feb 4th, ’08.
Will be directly sent to SLAC from the vendor.
Shipping Carriers
Co-worked with Pak-Rite Ltd. to design
the “Sure-Lok” shipping carrier.
10 carriers were delivered to Walco (Sept. 07)
October 30, 2007
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Bellows Module Design
Outer bellows assembly
EVAC flange with copper gasket and chain clamps
Removable tie rods for restraints to prevent damages
Travel Distance of a welded bellows (200-125-3-EE)
Travel length
Lateral offset
Bellows length
Extended
+6.5 mm
 5.08 mm
1.69 inch
Installed
0 mm
 3.56 mm
1.43 inch
Compressed
- 6.5 mm
 2.03 mm
1.17 inch
Angular
 35  without flange ends
Internal pipe assembly
Inner pipe assembly with ID 10 mm x OD 12 mm x
~ 68 mm long pipe/tube
No finger assembly for electric conductivity
Gap in the Bellows will be of 7.8 mm +/- 6.5 mm
Pipe axis in the Bellows will be aligned to the
Undulator within +/-100 m.
October 30, 2007
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Surface finish measurement - Internal pipe
ID 10 mm pipes were honed for 2, 4, and 8 -inch Ra finish.
Roughness data after 2nd degree LMS fitting (polynomial data fitting line to line)
show that either 2 -inch Ra or 4 -inch Ra honing process works fine.
RMS slope analysis shows that 2 -inch Ra is preferred and that 4 -inch Ra is
marginal.
Samples
Sample 2Ra
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Sample 4Ra
Sample 8Ra
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Bellows Tests and Results
Original Tests (DCN 14403-0001).
Focused on internal sliding parts (RF and Spring Fingers).
±2 mm X-Y offset with 0.5°angular offset x 2000 cycles.
Tests were completed. Internal parts met specification.
Sliding internal parts no longer used. New tests focused on maximum
possible rotational and X-Y offset.
Flange rotation of ±~ 0.8° is possible with < 75 in-lb of torque. 2000 cycles
were run. Leak check showed no leaks.
X-Y offset of ±10 mm is possible with ~ 10 lb of force. 2000 cycles were run.
Leak check showed no leaks.
Further motion analysis showed rotational and X-Y offset may be
simultaneously possible, but very unlikely.
Flange rotation of ~ 0.8° plus X-Y offset of ±9 mm is possible without
permanently deforming the bellows. 50 cycles were run. Leak check
showed no leaks.
October 30, 2007
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[email protected]
Production Status
Outer bellows assembly
Edge-welded Bellows were received from Standard Bellows Company.
Welded flange (flange + adapter)
EVAC flange and its hardware were received from EVAC Inc.
Weld shrinkage of the flange sealing diameter must be
compensated.
Drawings and SOW for production are complete.
Weld Bead
st
Lead time 6 weeks for the 1 articles (2 ea), 8 weeks for the
remaining balance.
Flange with weld-neck
Expect less shrinkage, but flange delivery for production will take 7 weeks ARO.
4 custom-flanges with weld-neck will be weld tested.
Internal pipe assembly
Drawings and SOW for production are complete.
Internal surface finishing process is being tested.
Honing process was done. (honing oil - Perkins 284)
Vacuum cleaning-baking-RGA process is on progress.
Lead time 3 weeks for the 1st articles (2 ea), then 3 weeks for the remaining balance.
Production Schedule
First Articles complete on 1/31/2008
35 completed units on 3/25/2008
October 30, 2007
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Short Break Sub-Assembly
Quadrupole
RF BPM
Magnet
Undulator
BFW
Undulator
Beam
Girder
Girder
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Quadrupole Spool Design
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Quad Spool Redesign and Production
Schedule
New Requirements from Short Break Test
“Driveshaft” design with a small bellows on each end.
±0.15° angular offset possible at each end.
0.03” compression possible at both ends.
“Driveshaft” design allows X-Y offset > allowable from Quad.
Production Schedule
Design complete. All parts and fabrication on order. Small bellows delivery
is driving the schedule. Bellows delivery scheduled for 11/7.
Ship bellows and flanges for first three units on 11/10 to AES for laser
welding and post welding electro-polish.
Ship bellows to Alumiplate for interior aluminum plating.
First three units are scheduled for completion on 12/1.
If no design/QA problems are encountered, two additional production runs
of 17 pieces each should be completed by 1/31.
October 30, 2007
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Long Break Subassembly
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Long Break
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Long Break Spool
With Pump Down Valve
and Sector Valve
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BFW Assembly Mounted on Adjustable Support
Electrical Connectors
for Wire Signals
Potentiometer
Pneumatic Solenoid Valve
Compression Spring Positioner
Air Supply Shut Off Valve
Precision Screw
Card Position Monitor
(Limit switches)
Frame
Housing
Alignment Fiducials
Pneumatic Cylinder
Vacuum Pump
Connector (2.75” Conflat
Flange)
Vacuum Chamber Connection
Flange
(NW-50 CeFix w/Clamp)
Adjustable Mounting
Support
Beam Port
October 30, 2007
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Dean R. Walters
[email protected]
Status
Catalog Items– Delivery Complete
Machined Parts– Delivery Complete
Shaft Frame Weldment– First Article Delivered and
Approved by ANL
BFW Vacuum Chamber– Contract Awarded. Delivery of 1st
Lot within 5 weeks
Started Assembly of First Article at ANL
Assembly and Alignment Procedures— Completed Draft
Vacuum Test and Bake-out Procedures– Completed Draft
In Field Alignment Procedure– Conceptually Planned
Deliverables Drawing– Completed Draft
October 30, 2007
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[email protected]
Significant Issues
Currently developing electrical interfaces with control group
Need to develop pneumatic interface
Need to develop wire signal interface
Need to develop protection cover strategy
Complete Assembly and Testing of the First Article
Modified beam tube to accommodate new BLM design
Modifed Ion Pump connection to allow space for BLM
Wire Card Installation
Schedule for Completed BFW Assemblies
w/ Supports to SLAC
Deliver 1st Lot (3) --- 12/12/07
Deliver 2nd Lot (10) --- 1/14/08
Deliver 3rd Lot (10) --- 2/11/08
Deliver 4th Lot (14) --- 3/20/08
October 30, 2007
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[email protected]
All Metal Chain Clamp Vacuum Seal
October 30, 2007
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Short Break Test System
2
3
4
5
O-ring seal
on hose to
leak detector
1
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Dean R. Walters
[email protected]
Test Procedure
Initial tests (number #1-14) were conducted on individual seals to work
out assembly technique.
Copper seals were used in tests #1-5
Aluminum seals were used in tests #6-10
Step #1 installed gasket at 60 in-lb
Step #2 Leak check
Step #3 increase torque 75 in-lb
Step #4 Leak check
Step #5 If it still leaks replace gasket and repeat steps #1-4
Second round tests (number #15-27)
In this set of test all five gaskets were replaced using 75 in-lb of torque
In reporting the results only the leaks were noted.
Background of the leak detector was equal or lower that 1 X 10-10 mbarlit/sec of helium
Leaks were defined as any reproducible meter deflection on any scale.
On test #18 the entire assembly was helium bagged for 10 minutes without
any leak detector response. The results of the bagging of test #27 are
shown in a later slide.
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[email protected]
Friday
Friday
Friday
Friday
Friday
Seal Mat'l
Copper
Copper
Copper
Copper
Copper
Test
No.
1
2
3
4
5
Saturday
Saturday
Saturday
Saturday
Aluminum
Aluminum
Aluminum
Aluminum
6
7
8
9
Monday
Monday
Monday
Monday
Monday
Aluminum
Aluminum
Copper
Aluminum
Copper
10
11
12
13
14
Tuesday
Tuesday
Tuesday
Tuesday
Tuesday
Tuesday
Tuesday
Copper
Copper
Copper
Copper
Copper
Copper
Copper
15
16
17
18
19
20
21
Wednesday
Wednesday
Wednesday
Wednesday
Wednesday
Wednesday
Copper
Copper
Copper
Copper
Copper
Copper
22
23
24
25
26
27
Log Bood
No.
1
2
3
4
Test Results
Seal #1
Ok
OK Cu - not rplc
OK Cu - not rplc
NA
NA
Seal #2
Ok
OK Cu - not rplc
Leak
Leak
NA
Seal #3
Ok
OK Cu - not rplc
Leak
Leak
OK
Seal #4
Leak
Leak new chain
OK
NA
OK
Seal #5
Ok
OK Cu - not rplc
OK Cu - not rplc Initial Failure Rate
NA
46.2%
OK Cu - not rplc
NA
NA
NA
NA
NA
NA
NA
NA
Leak
Leak
Leak
Leak
Leak
Leak
Leak
Leak
OK Cu - not rplc
OK Cu - not rplc
OK Cu - not rplc
OK Cu - not rplc
NA
NA
NA
NA
OK Cu - not rplc
NA
NA
NA
NA
OK
Leak
Leak
OK
Leak
OK
Leak
Leak
OK
OK - Cu
Lk
OK Cu - not rplc
OK Cu - not rplc
OK Cu - not rplc
OK Cu - not rplc
OK Cu - not rplc
1
2
3
4
5
6
7
B1
Lk - bellows B1 flg
Lk - bellows B1 flg
replc w/ B2
B2
B2
B2
OK - New chain
8
9
10
11
12
13
B2
B1
B1
Leak B1
Leak
Ok - new chain B1 Ok - new chain
B1
No. of Times the Chains are used:
Leak
Ok - new chain
15
Failure rate in the formal test
65
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2
24
2
1
12
11
2
14
5
7.7%
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Transportation Test
Moved assembly onto
hard wheel roller cart
Rolled around APS ring
Probe leak check
No leaks at 5 X 10-11
Bagged the assembly
After 7 minutes a rise was
noted
At 10 minutes leak rate
rose to 5 X 10-10
Loose tape seal around
bag could be evidence of
permeability of vacuum
hose o-ring.
October 30, 2007
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Dean R. Walters
[email protected]
Induced Deflection Test & Aluminum Gaskets
Set-up
This is a test where a known leak tight assembly has a single component shifted 2
mm (.08”) and then re-leak checked.
Three test were performed
Each with a new gaskets to the component which in this case is the RFBPM
The assembly was leak tested
The component was moved 2 mm
Test #1 it was moved 2 mm in X direction
Test #2 it was moved 2 mm in Y direction
Test #3 it was moved -2 mm in Y direction
The assembly was leak checked again after moving
In all cases the assembly was leak free.
Transportation Test
At the end of Test #1 the assembly was rolled around the APS ring, greater than 1
km, and then leak checked one more time, no leaks.
ALUMINUM GASKETS
EVAC supplied replacement gaskets to replace the initial set
Tested 15 standard thickness gaskets, 2.17 mm, torqued to 39 in-lbs finding no leaks
Tested 5 extra thick gaskets, 2.36 mm, and were successful in 4 of 5.
These tests were conducted with Dicronite dry lubricant on the chains.
In further testing Armoloy XADC lubricated chains will be tried.
October 30, 2007
Undulator Breakout
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Dean R. Walters
[email protected]