# Presentation: 927353

## MERIT Hg SystemFinal Design Review

**Hg Target System Design**
**V.B. Graves**
**P.T. Spampinato**
**T.A. Gabriel**
**MERIT Collaboration Meeting**
**MIT Plasma Science & Fusion Center**
**Oct 5, 2005**

## Outline - Component Details

**Syringe**
**Primary containment**
**Secondary containment**
**Baseplates**

## Hg Delivery System

**Capacity 23liters Hg (~760 lbs)**
**Provides 1cm dia, 20m/s jet for up to 12 sec**
**Secondary containment size 960mm x 1475mm x 960mm**
**Estimated weight 2T with Hg**

## Hg Syringe System

## Hg Syringe System

**Hg flow rate 1.6liter/s (24.9gpm)**
**Piston velocity 3.0cm/s (1.2in/sec)**
**Hg cylinder force 525kN (118kip)**

## Fathom Flow Simulation

**System diagram for Hg flow**
**Results indicate maximum pressure requirement of ~780 psi (50 bar) for baseline plenum/nozzle configuration**
**Design system for max pressure of 1000 psig (70 bar)**

## Fathom Details

## Other Fathom Simulations

**1/2" tubing bend**
**Cylinder pressure 1200 psi (83 bar)**
**No-bend short 1/2" tube**
**Cylinder pressure 710 psi (48 bar)**
**1" tubing bend**
**Cylinder pressure 780 psi (54 bar)**
**All 1/2" tubing from end of flex metal hose, no plenum**
**Cylinder pressure 1910 psi (130 bar)**
**Any non-plenum design should minimize number of bends & length of nozzle tubing**
**Don't let syringe pump limit nozzle configuration - recommend changing system design pressure to 1500 psi (103 bar) to match Hg cylinder rating**

## Non-Plenum Nozzles

**Room is available to eliminate plenum, keep tubing under beam**
**Flow streamlines become more of an issue**
**Desire to move bend further from nozzle**

## Syringe Procurement

**Complete system design based on specified requirements**
**Piston pump (inside secondary containment)**
**One 10-inch Hg Pump Cylinder**
**Two 6-inch Drive Cylinders (one with integrated position sensor)**
**Tie beam**
**Baseplate**
**Hydraulic hoses inside secondary for operating Drive Cylinders**
**Hydraulic pump (outside secondary containment)**
**Pump, motor, reservoir**
**Proportional, directional control valve**
**Hydraulic hoses between pump & secondary containment**
**Motor controller**
**Variable voltage transformer for U.S. and European operation**
**Hydraulic fluid (drum)**
**Integration of system components**
**System testing with water**

## Syringe Procurement Status

**RFQ sent to 5 vendors, 4 submitted quotes**
**Requested prices for std cylinders & SS cylinders**
**Low bid: $60K (std), $68K (SS)**
**Subcontract awarded to Airline Hydraulics (Edison, NJ)**
**Chose SS cylinder option**
**Kickoff meeting being scheduled for next week**
**Vendor required to host a syringe design review 30 days after contract award, prior to ordering materials**

## Syringe Hydraulic Schematic

## Primary Containment

**Hg supply flow path**
**1-inch Sch 40 pipe**
**1-inch flex metal hose w/sanitary fittings**
**1-inch, 0.065-wall rigid tubing**
**5-inch diameter plenum**
**12mm-dia, 1mm-wall rigid tubing**
**Hg jet return path**
**1/4-inch plate weldment chamber**
**6-inch to 2-1/2-inch eccentric reducer**
**2-1/2-inch flex metal hose w/sanitary fittings**
**Sump tank**

## Normal Syringe Operations

**Slowly extend cylinder to fill Hg cylinder from sump**
**Slowly retract cylinder to starting position & prefill Hg supply piping**
**Some time after trigger is received, ramp cylinder to full speed**
**Need engineering solution to prevent possibility of sudden cylinder start – will discuss with syringe vendor**
**Steady-state jet for 1sec**
**Ramp cylinder to zero velocity**
**Sudden stop can cause flow separation & Hg hammer**

## Sump Tank

**Fabrication: 1/4" plate SS304L/316L**
**Ports for Hg fill & extraction, Hg level sensor, syringe vents, breather checkvalves, supply line relief**

## Sump Tank Analysis

**800-lb Hg load on tank bottom**
**Min FOS > 9**

## Manifold

**Designed for socket weld fabrication, SS304L/316L**
**Channels**
**Flow – 1" pipe**
**Hg cylinder vent – 1/2" tube**
**Sump drain – 3/4" pipe**
**Pressure transducer – 1/2" tube**
**Relief valve – 3/4" tube**
**FEA results**
**FOS = 4.8 for 1000 psi**
**Will be redesigned for 1500 psi**

## Hg Plenum

**Fabrication incorporates nozzle, beam window, and Hg supply tubing**
**Replaceable module**

## Hg Plenum Analysis

- Red: FOS<3

**Based on static 800 psig internal pressure, no dynamic loading**
**Min FOS = 0.51, further design required**

## Primary Containment Pressure Ratings

_**[Pressure Ratings Table](file:///../../../Hg%20System/Pressure%20Ratings%20Table.doc)**_

## Primary Containment Beam Windows

**Single layer Ti6Al4V, 1mm thick**
**Hg deflector acts as beam window, made from same material**
**Horizontal beam kick**
**6mm @ primary window**
**18mm @ secondary window**** **
**Downstream window sized to accommodate horizontal beam kick and small changes in magnet tilt**

## Hg Deflector

**Simplifying analysis indicates imparted force on plate of 425N (95lb)**
**Using Ti6Al4V thickness of 1mm gives a safety factor < 1**
**Recommend deflector thickness of 2mm**
**FS = 3.5**

## Accommodating Tilt Changes

**Hg delivery system can accommodate some amount of decreasing tilt angle and keep beam in windows**
**30mrad upstream**
**33mrad downstream**

## Beam Window Fabrication Issues

**Do not have definitive answer to question of weldability between Ti6Al4V and SS304L/316L**
**If reliable process is found, it likely will require some development by fabricator to establish welding parameters**
**Material samples and added cost**
**Can windows be SS316L/304L?**

## Secondary Containment

**SS304L/316L 1/2" bottom plate, 1/4" front, sheet metal sides & back (7ga, 0.179")**
**May add stiffeners to sides & back**
**Flexible sleeve (non-metallic, combustibility issue)**
**SS304L/316L cylindrical sleeve (13ga, 0.089")**
**Passive filtration**
**Filtered inlet and outlet, both will be have shutoff gates**

## Secondary Containment Double Beam Windows

**Similar in construction to Hg plenum**
**SS pipe with Ti6Al4V caps**
**All Ti if necessary, but attachment to secondary containment still an issue**
**Flexible tubing back to hydraulic system**
**Pressurize and monitor to detect failure**
**Can also vacuum monitor, but pump and larger tubing required**
**Will test at ORNL, determine final method**

## Secondary Containment Access Ports

**Optical diagnostics**
**Instrumentation**
**Hydraulics**
**Hg drain & fill (without opening secondary)**
**Hg extraction (in event of major leak in primary containment)**

## Secondary Containment Monitoring and Filtering

**Two Hg vapor monitors for secondary volume**
**Passive filtration with shutoff, can connect to active filtration system**
**Will have single cartridge rather than respirators**
**Third vapor monitor for passive filter exhaust and/or tunnel monitoring**
**Investigating whether monitors can be moved away from experiment**

## Baseplates

**Purpose – provide mobility, alignment, and structural support for experiment components**
**Experiment requires magnet tilt of 66mrad (3.8****°)**
**Two baseplates**
**Target transporter**
**Common baseplate**

## Target Transporter

**Transports Hg system inside tunnel using Hilman rollers**
**O/A length 62" (1.6m)**
**Rails for Hg system cart wheels**
**Jack bolts prevent rolling**
**Swivel hoist rings for lifting & cart tie-down**
**Material: AL6061-T6**

## MERIT Side View

## Common Baseplate

**Shares design with transporter baseplate**
**O/A length 124" (3.15m)**
**Rollers used to grossly align solenoid to beam**
**Provides lateral movement of solenoid for alignment to beam once rollers removed**

## Design Constraints & Requirements

**Total supported weight**
**Magnet: 9000 lbs**
**Hg System with 23liter Hg: 4000 lbs**
**Baseplate: 1000 lbs**
**Movement requires lateral force of 700 lbs (****μ****s**** = 0.05 per Hilman)**
**Maximum width of 1.3m (51") to meet CERN facility constraints**
**Fabrication material to be non-magnetic (chose AL 6061-T6)**
**Must have lifting & leveling provisions**
**Currently not anchored to floor – is there a need?**

## Common Baseplate Structure

**4-inch AL channel frame, I-beam internal supports**
**Hilman roller support plates**
**Welded leveling jack gusset plates**
**Side-load swivel hoist rings for lifting**
**Removable jack stand gussets**

## Magnet Lateral Alignment

**Gross adjustment provided by Hilman rollers**
**Low-friction surface plate sits between magnet support plate and baseplate**
**Weld studs with nuts hold final position**
**Jackbolts provide lateral moving force**
**Lateral adjustment range ****±25mm**

## Common Baseplate Structural Analysis – 3 Rollers

**Condition: loaded baseplate carried by 3 Hilman rollers**
**Min FOS = 0.65 in extremely localized area due to modeling issues, general FOS>3**

## Common Baseplate Structural Analysis – 4 Lift Jacks

**Condition: loaded baseplate supported by 4 hydraulic jacks**
**Min FOS>4**

## Common Baseplate Structural Analysis – 4 Leveling Jacks

**Condition: loaded baseplate supported by 4 leveling jacks**
**Min FOS=1.8 in localized areas**

## Some Final Design Details

**Some dimensions of Hg delivery system can't be finalized until syringe design is complete**
**Will need magnet as-built height on its base**

## Remaining Design Work

**Finalize procured component details for drawings**
**Drawing check**
**Sensor / instrumentation wiring diagram**
**Generate fabrication vendor list**
**Write procurement specification**

## Design Issues

**Nozzle configuration – plenum vs non-plenum**
**Nozzle details – length, exit features**
**Final dimensions for syringe system, magnet height**