## **M.E. GROUP PRESENTATION**

**R. DORTWEGT**

**June 12, 2001**

**[SUMMARY]{.underline}**

-   Linac water systems

    -   Closed loop water stations

    -   Other systems

    -   Other work for Linac customers

-   SR vacuum chamber water

-   Process water quality

-   PAR vacuum chambers

-   Pressure Technology and Safety Committee (PTSC)

-   Mechanical safety

**[LINAC WATER SYSTEMS]{.underline}**

-   Closed loop water stations provide temperature conditioning for:

    -   Waveguides

    -   Accelerating structures

    -   SLED's

    -   RF loads

    -   RF windows

-   Other systems installed to provide D.I. water for:

    -   P.C. Gun

    -   Laser

    -   75^o^F water from primary loop for new power supplies for
        modulators

    -   APS injection guns (future) -- 2 separate loops for guns

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-   Assistance for Linac "customers"

    -   Mostly in the form of assistance with flowmetering and
        instrumentation

**[LINAC CLOSED LOOP SYSTEMS]{.underline}**

-   History

    -   Built by original APS Linac Group

    -   Temperature stability an issue at commissioning

    -   Change to Johnson Controls

    -   Big improvements early on were:

        -   Direct immersion RTD's (improves response time)

        -   Beginning of realization that loop tuning was important

    -   Control valve tuning class (you can adjust only the errors you
        can detect)

    -   Understanding the impact of signal resolution (i.e. detecting
        really small temperature changes)

    -   Prototype fix (stand-alone controller from Honeywell)

    -   Implementation of Allen-Bradley controls (Rick)

    -   Communications with EPICS (Rick with help from ASD Controls
        Group)

![](media/image1.jpeg){width="8.989583333333334in"
height="6.007638888888889in"}

### LINAC CLOSED LOOP SYSTEMS

-   Important things to understand

    -   Feedback loop principles

    -   Reduce time lag of error signal processing

    -   Direct immersion RTD vs. RTD in a thermowell

    -   Resolution of temperature changes

-   New requirements

    -   New water station to be built in FY-02 for Linac Sector 6

        -   Provide separate water loop for SLED (operate at different
            temperature)

        -   Quieter

        -   Smaller (??)

        -   All PLC control

        -   Location, location, location!!!!!

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-   Improve flow metering on closed loop stations using V-cones and
    DPT's

    -   Better reliability

    -   Install DPT's in tunnel to avoid failure in tunnel

![](media/image2.jpeg){width="8.948611111111111in"
height="6.893055555555556in"}

![](media/image3.jpeg){width="8.823611111111111in" height="6.89375in"}

**[OTHER LINAC SYSTEMS]{.underline}**

-   GOAL: to get away from custom designed systems (a la P.C. Gun) for
    miscellaneous items such as guns, lasers, etc.

    -   Less costly to obtain

    -   Less lead time to implement

    -   Standardized design

    -   Repairs do not impact larger PW secondary system

    -   \~K\$10

    -   First unit for gun testing work in Linac RF Test Room (delivery
        expected in August, '01)

    -   Vendor is Bay Voltex

    -   Standard design modified to achieve 140^o^F

    -   Stability to /-0.1 ^o^C (0.18F)

    -   Flow monitoring and water treatment done in-house

    -   Remote monitoring/control via EPICS

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-   Low pressure / cool water for Linac components from primary water
    (75F)

    -   Pumps P-PRMOD-1/2 (75 psig)

    -   Same pumps as SRVC cooling skids

    -   Pressure and temperature not as severe as secondary system

    -   All capacity taken by new modulator power supplies, RF loads and
        window

#### ![](media/image4.jpeg){width="5.295833333333333in" height="6.895833333333333in"}

#### [ASSISTANCE FOR LINAC "CUSTOMERS"]{.underline}

-   FLOW METERING PROJECTS

    -   Modulator power supplies

    -   Klystrons

-   Use of V-cones and Yokagawa DP transmitters

    -   Accuracy 1% or better

    -   Reliability

    -   10:1 turndown

    -   Standardization of components across ASD-ME and other groups

    -   No moving parts in water stream

    -   Built by our own technicians

![](media/image5.wmf)

![](media/image6.jpeg){width="8.991666666666667in"
height="5.997916666666667in"}

**[SR VACUUM CHAMBER COOLING]{.underline}**

-   COOLING SKIDS

    -   One skid for two SR sectors (20 skids)

    -   Mechanical mezzanine

    -   Separate water stations for aluminum vacuum chambers

    -   52 gpm @ 45 psig nominal operating point

    -   Low maintenance

    -   Will need to start replacing "sealed for life" bearings

-   FUTURE IMPROVEMENTS TO COOLING SKIDS

    -   "Clean-up" slipstream piping through resin tanks

    -   Install permanent resin tank for till connection

    -   Upgrade system monitoring

    -   Allen-Bradley temperature controls (95% complete)

    -   Disconnect switches for individual pumps

> ![](media/image7.jpeg){width="4.601388888888889in"
> height="6.8902777777777775in"}

**[SR VACUUM CHAMBER BAKEOUT]{.underline}**

-   BAKEOUT SKIDS

    -   One skid for two SR sectors (20 skids)

    -   SR Utility Aisle

    -   Uses same distribution piping as cooling skids

    -   \~25 gpm per sector at 110 psig and 135^o^C (275 ^o^F)

    -   Originally designed for 150^o^C (300 ^o^F)

    -   Vacuum group never uses temps that high

    -   High pressure to keep water from boiling and dissolved air from
        flashing

    -   Must be used with mobile cart for water purification

-   FUTURE IMPROVEMENTS TO BAKEOUT SKIDS

    -   Upgrade and automate monitoring

    -   Install permanent wiring for beacon system

    -   Install permanent signage for bakeout system

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-   MOBILE CART

    -   Used only when bakeout is ongoing

    -   HX for heat recovery

    -   Pumps 3 gpm of "clean" water from cooling skid to bakeout system

    -   Returns 3 gpm of "bakeout" water to cooling system to be
        purified

![](media/image8.jpeg){width="8.988194444444444in"
height="5.992361111111111in"}

![](media/image9.jpeg){width="8.988194444444444in"
height="5.992361111111111in"}

![](media/image10.jpeg){width="8.997222222222222in"
height="6.870833333333334in"}

**[WATER QUALITY AT APS]{.underline}**

-   Copper corrosion continues to be an issue at APS, but at manageable
    rates

-   Manageable corrosion rates have been achieved through filtration and
    oxygen control

-   Information on deaeration system at Building 450

    -   ASD invested \~K\$500 on improving this system

    -   Tripled the throughput (now 450 gpm)

    -   DO less than 5ppb coming out of degassifier

    -   System DO normally between 5-10ppb

    -   Transferred responsibility to PFS in February of this year

-   Focal point for ordering filters and chemical analyses

    -   Filters from US Filter-Filtration

    -   Analyses from McCrone Lab (Westmont)

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-   What we have learned about pH of DI water and impact on corrosion
    rate

-   DI water production

    -   Change to RO production in 1998

    -   System is leased from vendor with fixed monthly charges

    -   Learned that we must do maintenance only during 1^st^ week of
        shutdown

**[PAR VACUUM CHAMBERS]{.underline}**

-   Evaluation of spares inventory indicates a need for attention

    -   Several chambers not complete

    -   A few chambers not compatible with existing geometry

-   Inconel 625 formed/machined plate still on hand from 1993 effort

-   Bill Toter has all the E-B welding parameters on file

-   Learning how to work on "hot' chambers

**[ANL-E PRESSURE SAFETY COMMITTEE]{.underline}**

-   Committee was formed around 7-8 years ago

-   Goal was to develop a Pressure Safety Manual (PSM) for ANL-E

    -   Based on ASME

    -   DOE order 440.1 (mandatory)

-   First draft manual was complete \~2-3 years ago (done mostly by the
    Chair at the time)

-   Committee and divisional revolt (no buy-in)

-   New committee chair appointed (Bill Toter)

-   Draft manual completed two months ago

    -   Does not give rules on design and fabrication

    -   Does give guidelines on what things need to be considered

    -   Responsibility for pressure safety put on division Division
        director & line management

**[ANL-E PRESSURE SAFETY COMMITTEE (cont.)]{.underline}**

-   Every division to appoint a Pressure System Advisor (PSA)

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-   Pressure systems classified into 3 classes:

    -   Category A: significant risk

    -   Category B: relatively low or limited risk

    -   Category C: low-risk systems

-   Anticipate all (or most) of our systems to be Category B and C

-   The biggest impact on ASD will be:

    -   Documenting and testing current systems to ensure compliance

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    -   Implementing work rules that ensure compliance

**[ASD MECHANICAL SAFETY COMMITTEE]{.underline}**

-   R. Dortwegt participation upon request by Jim Lang

-   Current effort includes noise reduction of pump motors in building
    420 & 411

    -   Building 420:

        -   Current motors \~90-92dBA (noise from all 3 operating
            simultaneously)

        -   New motors (68dBA individually) could reduce noise to
            75-80dBA composite

        -   Noise generated mostly from fan blades

        -   Motors are larger, so either have to raise pump on baseplate
            or modify baseplate

        -   Figure \$2500 per motor

    -   Building 411:

        -   Current motors \~89dBA (noise from all 3 operating
            simultaneously)

        -   New motors (79dBA individually) would not reduce noise much

        -   Need another quote for quieter motor

**[MECHANICAL SUPPORT]{.underline}**

-   Lots of help received

    -   Technician labor

    -   From other staff

    -   From Jodi

    -   Thoughtfulness when needed

    -   Cheerfulness

    -   Chop-busting even when not needed

-   **[Many thanks]{.underline}**