RHIC 56 MHz

HOM DamperFundamental Damper

Fundamental Power CouplerPick-ups

S. Bellavia

January 19th, 2010

Higher Order Mode (HOM) Damper

Higher Order Mode (HOM) Damper

HOM Thermal-Electric PerformanceSolid Model Assembly in Pro-E, Finite Element Model built in ANSYS 13.0

HOM Thermal-Electric Performance (cont.)Boundary Conditions:

• Surface RF Currents

• Dielectric (Joule) Heating of Sapphire

• Heat Leak from Ambient

HOM Thermal-Electric Performance (cont.)

Dielectric Heating of HOM Sapphire Break

Dielectric Heating of Sapphire Break (cont.)

HOM Thermal Performance (cont.)

Internal Components

HOM Thermal Performance (cont.)

Assembly with Heat-Stationed Cable

50K Heat StationFrom Heat Shield

HOM Cable

Joule Heating vs. Thermal Conductivity

OFHC Copper vs. 304 Stainless Steel

Thermal Conductivity of Cu vs SS

0.001

0.01

0.1

1

10

100

1000

0 50 100 150 200 250 300 350

Temperature (K)

Th

erm

al C

on

du

ctiv

ity

(W/c

m-K

)

Copper

SS 304

Electrical Resistivity of Cu vs. SS

1.0E-10

1.0E-09

1.0E-08

1.0E-07

1.0E-06

1 10 100 1000

Temperature (K)

Ele

ctr

ica

l Re

sis

itiv

ity

(o

hm

-m)

SS304

Cu

Cable Joule Heating Due to RF Current

Coaxial Cable Choices

Model for Calculations

FEA Model(s)

SS Conductors, Heat Station with Effect of Contact Resistance

These regions made 100X more thermally resistive than PTFE to simulate contact resistance

FEA Results

50K to Outer Shield

For 250 SS Cable - FEA performed on many types and sizes

FEA Results Summary

Coaxial Cable Comparison

0.000

0.200

0.400

0.600

0.800

1.000

1.200

.250 SS - SS .141 SS - SS .085 Cu Ctr, SSouter

.141 Cu Ctr, SSouter

.141 Cu - Cu

Cable

Hea

t (W

atts

)

Heat into cold end

Heat into Heat Station

HOM Cable-Connector Assembly

HOM Cable-Connector (cont.)

HOM Hex Seal

10 x 5/16-24 SS Bolts, Torqued to 113.1 in-lbs results in 1809.6 lbf (80% of yield)

Bolt Circle = x 3.700 = 11.62 inches

Linear Sealing Load = 10 x 1809.6 / 11.62 = 1557 lbf/inch

HOM Final Design / Fabrication / Procurement

• Full set of drawings being checked

• SOW and Specification to be released this week, followed by Purchase order / RFQ

• Parallel Effort to build “in-house” (BNL will manage piece-part fabrication)

- Quotation for brazing Sapphire break received

- Quotation for Custom Sapphire tubes received

- Awaiting Quotation for Stock Size Sapphire Tube

HOM Design / Fabrication

HOM Design / Fabrication (cont.)

HOM Filter Assembly

HOM Procurement

HOM Procurement (cont.)

HOM Procurement (cont.)Sapphire for Filter Components

HOM Schedule

• Jan 21 – Release of Drawings (numerical rev’s for quotation)• Jan 21 – Signature / release of SOW and Specifications• Jan 21 – Purchase order for building entire HOM assembly

– Phase 1 – Prototype / First Article (20 +2 weeks – June ‘11)

– Phase 2 – 6 follow-on HOM’s (36 +2 weeks – Oct ‘11)

• Feb 7 – P.O. for brazing of Sapphire-Niobium break• supply vendor with sapphire tubes and machined niobium parts (12 weeks –

April ‘11 )• purchase and receive brazed assemblies (16 weeks – May ‘11)• arrange machining of niobium components (12 weeks – April ’11)• send out machined parts and brazed assemblies for pre-cleaning, welding

and final cleaning, (most likely to AES). (32 weeks – Sep ’11)• Receive Final HOM’s (36 weeks – Oct ’11)

• Feb 21 – P.O. for Brazing of Filter Assembly

HOM Costs

• Sapphire tubes $ 15K

• Niobium (raw material) $ 10K

• Niobium machining $ 50K

• Brazed Break $ 20K

• Brazed Filter Assy $ 10K

• Welded Assemblies$200K

• Cleaned Assemblies $ 50K

• Total$355K

• First Article$150K

• 6 Final HOM’s $425K

• Total$575K

Done “In-house” by BNL Done by Outside Vendor

Fundamental Damper

Fundamental Damper (cont.)

Fundamental Damper (cont.)

Fundamental Damper Motion System

Fundamental Damper Motion System Costs

Motion System

• Feb ‘11 – Thermal / Structural Analysis• May ’11 – Detailed Design / Drawings

Fundamental Damper Schedule / Costs

Total Cost = $125K = 400 shop hours

Fundamental Power Coupler

FPC

Fundamental Power Coupler (cont.)

Fundamental Power Coupler (cont.)

Fundamental Power CouplerConnector

7/16 DIN Type N

Fundamental Power CouplerWeldable, UHV Compatible Connector / Window

Fundamental Power CouplerWeldable, UHV Compatible Connector / Window

Fundamental Power CouplerWeldable, UHV Compatible Connector / Window

Fundamental Power CouplerWeldable, UHV Compatible Connector / Window

Fundamental Power CouplerWeldable, UHV Compatible Connector / Window

• Total Cost = $95,600

Fundamental Power Coupler Schedule / Cost

• Mar ‘11 – Thermal / Structural Analysis• June ’11 – Detailed Design / Drawings

• Total Cost = $2,100

Pick-Ups Schedule / Cost