KOPIO Vacuum Subsystem WBS 1'2'1

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KOPIO Vacuum SubsystemWBS 1.2.1

• RSVP LOG Review
• January 18, 2005
• Ralph L. Brown

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Scope of Vacuum Subsystem

• The KOPIO Detector decay volume and the Neutral
  Beam path upstream to the spoiler must be at high
  vacuum (10-7 Torr) in order to suppress
  background from interactions residual gas. The
  upstream vacuum vessel and entering/exiting beam
  pipes must present on average 5 of a radiation
  length of low-Z material. The scope of this
  subsystem includes the engineering, design,
  fabrication, procurement and delivery to BNL of
  all hardware associated with the detector decay
  volume. This includes the upstream vacuum vessel
  and entering/exiting beam pipes, vacuum
  transitions, D4 vacuum box, downstream vacuum
  vessel, vacuum pumping stations and management
  activities. Although the neutral beam will be
  evacuated as part of the detector decay volume,
  all hardware for this area is part of the neutral
  beam subsystem.

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KOPIO Vacuum Subsystem 1.2.1
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WBS 1.2.1.1 U/S Vacuum Vessel

• The scope of effort is the engineering, design,
  and multi-phase-procurement of the upstream
  composite material decay vacuum vessel. This
  3-phase procurement consists of 1/5 scale
  prototype vessels, full scale prototype vessels,
  and operational vessels, all pressure tested for
  buckling stability to 3.5 FOS. It includes vessel
  supports, flanges and pump-out ports, vacuum
  feed-thru adapter rings, internal CPV support
  geometry, and transportation and installation
  fixtures. Labor requirements are an engineering
  estimate, while materials is based on estimate
  from IHEP collaborators.

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WBS 1.2.1.2 Vacuum Transitions

• The scope of effort includes the engineering,
  design, procurement, and technical assembly of an
  internal vacuum membrane between high and low
  vacuum volumes in the U/S decay vessel. It
  includes the cost for both a prototype and
  operational membrane design. This also includes
  the U/S and D/S vacuum window assemblies for the
  U/S decay vessel. This is based on an engineering
  estimate of both labor and materials.

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WBS 1.2.1.3 D4 Vacuum Box

• The scope of effort includes the engineering,
  design, procurement and fabrication of a
  non-magnetic material vacuum box located in the
  magnetic gap of the D4 sweeping magnet D/S of the
  Calorimeter. It includes U/S vacuum bellows
  transition and support of beam pipe and D/S
  transition connection to the D/S decay vessel.
  This is based on an engineering estimate of both
  labor and materials.

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WBS 1.2.1.4 D/S Vacuum Vessel

• The scope of effort includes the engineering,
  design, procurement, and fabrication of
  structural metal vacuum vessel. This is a large
  volume tank with personnel access ports, U/S and
  D/S flange connections, internal veto counter
  support, pump-out ports, and electrical/fiber
  feed-thru. It includes and integral vessel
  support system and lifting fixture for
  installation. This is based on an engineering
  estimate of both labor and materials.

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WBS 1.2.1.5 Vacuum Pumping Sta.

• The scope of effort includes the engineering,
  design, procurement, fabrication, technical
  assembly and testing of vacuum pumping stations.
  This will service the vacuum requirements for
  both high and low vacuum volumes in the neutral
  beam, U/S decay vessel, D4 vacuum box, and D/S
  decay vessel. This will include all pump skid
  hardware, valves, gauges, flanges, controls and
  interlocks, piping and transition ports. This is
  based on an engineering estimate from the C-A
  Vacuum Group that will be tasked with this design
  effort.

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WBS 1.2.1.6 Management Activities

• The scope of effort includes a subsystem manager
  (scientist) and project engineer to develop and
  implement a project plan, and report monthly
  performance measures for cost and schedule. They
  are responsible for the management of all
  deliverables and supervision of all resources
  involved in this effort and the technical
  oversight of all procurement and fabrication
  contracts. This is based on an engineering
  estimate for both labor and materials.

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Status

• We are in an RD prototype fabrication phase
  with a Russian Aerospace firm to produce and
  pressure test (5) 1/5 scale composite upstream
  vacuum vessel and entering/exiting beam pipes to
  verify material technology and analytical models.
  IHEP collaborators are working on vessel
  engineering analysis and monitoring the Russian
  vendor. We are in contact with interested US
  vendor who has submitted a draft
  design/fabrication proposal for a composite
  upstream vacuum vessel. A recent hire of a
  consultant engineer at BNL is analyzing various
  vessel geometries and materials for the upstream
  vacuum vessel and entering/exiting beam pipes.

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Issues

• This subsystem needs a Subsystem Manager and
  Project Engineer to plan and coordinate a
  critical design effort for the detector decay
  volume hardware. Funding is needed to hire
  appropriate resources to begin engineering RD
  effort on the many technical challenges. The
  upstream vacuum vessel (3m Ø x 4m lg. x thin
  wall) offers the greatest technical design risk
  due to buckling instability of the geometry. The
  entering/exiting beam pipes with wide aspect
  ratio requires reinforced structural ribs of
  low-Z material and must accommodate interlaced
  detector elements and pump-out ports. The CPV
  detector located in the upstream vacuum vessel
  must be isolated from the high vacuum decay
  region by a thin vacuum membrane. All of these
  efforts will require extensive design, analysis,
  prototyping, and testing to develop a workable
  solution.