# Presentation: 671263

## NuMI Vacuum Pipe WBS 1.1.4

- Outline of this Review
- Engineering Issues (D. Pushka)
- Vacuum Shell
- Cooling
- Upstream/Downstream Ends (Ed Chi)
- Radiation
- Alignment
- Installation
- Costs and Schedule

## Where Are We Supposed to Be?

## Main Changes

- Elimination of Seals
- All Welds for Reliability
- PVC Pipe Around
-                 Cooling Pipe/Vacuum Pipe
- Prevents galvanic action
- Working on Details
- Supervisor Of Welding Process for QA
- Pump-Down Test Before Access Blocked

## Radiation Levels

- Studied as Part of Overall Radiation Safety
- Below Limits
- Formal Memo in Preparation

## Star Density Along Pipe

- Examined Star Density *vs. *Position
- MARS14 Calculation
- Errors from Estimate for Hydrodynamic Flow, *etc*

## Decay Pipe AlignmentV. Bocean, R. Bernstein 

- Scope
- Align** **the decay pipe on the correct ** **line with respect to the designed geometric beam trajectory
- Fermilab alignment task during the construction phase is to check the contractor’s work
- Requirements
- Alignment Phases
- Phase 1: during construction phase
- Phase 2: post construction phase

## Alignment Requirements

- Physics dictates alignment tolerances (see W.Smart’s  detailed
- analysis in Technical Design Report 3.6).
- Two important requirements specified :
- With respect to the ideal beamline, the maximum error of the decay pipe centerline, in both horizontal and vertical planes, must not exceed ± 25 mm (1) at the downstream end. This error should be considered proportionally for the 675 m long pipe.
- With respect to the effective decay pipe aperture, the effective radius, for the entire length of the pipe, must not exceed ± 20 mm (1) from the designed value.

## Alignment Phases

- Two alignment phases:
- During construction phase: alignment support for the decay pipe installation.
- Post construction phase (after the shielding fill): survey the “as built” position and dimensions of
-      the decay pipe.

## During Construction Phase 

**Establish control network throughout the decay tunnel:**
- _Materialized and measured by the contractor’s surveyor._
- Points with x,y,h coordinates no farther than 50 m.
- Constrained on both ends of the decay tunnel (Target Hall and respectively Absorber Hall) on precision points transferred from surface.
- Coordinate errors  mm achievable using classical surveying techniques and instrumentation.
- Fermilab’s task is to check the network for correctness and  level of accuracy achieved. For an objective assessment, the network determination will be performed at least twice as accurately as  the contractor.

## Decay Tunnel and Decay Pipe Networks (draft)

## During Construction Phase 

**Alignment to support the decay pipe installation:**
- From the total error budget of mm, network errors of mm (added in quadrature) will allow to more than  20 mm to be accounted by survey alignment errors, pipe positioning and installation errors, pipe stability errors, pipe deformations from manufacturing or transportation, etc.
- Fermilab’s task is to check the correctness of the installed pipe by measuring multiple interior cross sections, at no more than 10 m intervals, and evaluate the results (i.e. the axis and the residuals of the fitted cylinder) with respect to required alignment tolerances.

## Post Construction Phase 

- Takes place after the shielding fill. Represents the final  survey
- of the “as built” position and dimensions of the decay pipe
- assuming that, after the initial  installation, the pipe will suffer
- deformations and/or displacements caused by casting the
- concrete shielding in place.
**Establish control network throughout the decay pipe:**
- _Materialized and measured by Fermilab._
- The points consist of 0.750.50.5 inch metal stubs having a 0.25 inch precision hole to receive a nest holding a target or retro reflector and welded in at
-       0-120-240 with respect to the circular pipe cross section (similar with those used for the Hadron Hose).

## Post Construction Phase 

- Constrained on both ends of the decay tunnel (Target Hall and respectively Absorber Hall) on precision points transferred from surface.
- Simulations show that point errors ellipses  mm can be obtained rather quickly and with relatively moderate effort using conventional surveying methods and instrumentation (the Geodimeter robotic total station, the precision Gyrotheodolite, and precise leveling).
- The absolute error ellipses for each point and relative error ellipses between points computed at 95% confidence level (2.45 for two-dimensional normal distribution).

- Post Construction Phase

## Point error ellipses  

-  **XY PLANE STATION 95.000 % CONFIDENCE ELLIPSES (METRES)**
-  ---------------------------------------------------------------
-  FACTOR USED FOR OBTAINING THESE ELLIPSES FROM STANDARD ELLIPSES:
-  **(VARIANCE FACTOR KNOWN)   =   2.4484 ******
-  **STATION   SEMI-MAJOR AXIS   SEMI-MINOR AXIS   AZIMUTH OF SEMI-MAJOR AXIS   AREA OF ELLIPSE**
-  P1            .00478            .00114                90   0   0           .17064D-04
-  P2            .00652            .00227                90   0   0           .46432D-04
-  P3            .00767            .00337                90   0   0           .81245D-04
-  P4            .00848            .00435                90   0   0           .11586D-03
-  P5            .00904            .00513                90   0   0           .14576D-03
-  P6            .00940            .00568                90   0   0           .16757D-03
-  P7            .00957            .00596                90   0   0           .17904D-03
-  P8            .00957            .00596                90   0   0           .17904D-03
-  P9            .00940            .00568                90   0   0           .16757D-03
-  P10           .00904            .00513                90   0   0           .14576D-03
-  P11           .00848            .00435                90   0   0           .11586D-03
-  P12           .00767            .00337                90   0   0           .81245D-04
-  P13           .00652            .00227                90   0   0           .46432D-04
-  P14           .00478            .00114                90   0   0           .17064D-04

- Point error ellipses

## Relative error ellipses between points throughout the decay pipe

**  ****----------------------------------------------**
-  FACTOR USED FOR OBTAINING THESE ELLIPSES FROM STANDARD ELLIPSES:
** ****(VARIANCE FACTOR KNOWN)   =   2.4484 ******
-                                              **AZIMUTH                             STD.DEV.    STD.DEV**
**  ****FROM     TO   SEMI-MAJOR   SEMI-MINOR   MAJOR     DISTANCE    PRECISION  ADJ.DISTANCE ADJ.AZIMUTH**
-    P1       P2       .00478       .00140     90  0  0      50.00000   1:  10452       .00195         2.36
-    P1       P3       .00652       .00263     90  0  0     100.00000   1:  15339       .00266         2.21
-    P1       P4       .00767       .00370     90  0  0     150.00000   1:  19553       .00313         2.08
-    P1       P5       .00848       .00457     90  0  0     200.00000   1:  23582       .00346         1.92
-    P1       P6       .00904       .00519     90  0  0     250.00000   1:  27653       .00369         1.75
-    P1       P7       .00940       .00553     90  0  0     300.00000   1:  31931       .00384         1.55
-    P1       P8       .00957       .00559     90  0  0     350.00000   1:  36582       .00391         1.35
-    P1       P9       .00957       .00537     90  0  0     400.00000   1:  41808       .00391         1.13
-    P1       P10      .00940       .00489     90  0  0     450.00000   1:  47897       .00384          .92
-    P1       P11      .00904       .00418     90  0  0     500.00000   1:  55306       .00369          .70
-    P1       P12      .00848       .00330     90  0  0     550.00000   1:  64853       .00346          .51
-    P1       P13      .00767       .00234     90  0  0     600.00000   1:  78215       .00313          .33
-    P1       P14      .00652       .00149     90  0  0     650.00000   1:  99706       .00266          .19

## Post Construction Phase 

**Determine the “as built” position and dimensions of the**
**decay pipe:**
- Survey cross sections throughout the pipe at 5-10 m station intervals, measuring 8 points per profile.
- evaluate the results of the fitted cylinder through all cross sections with respect to required alignment tolerances
- the cylinder axis with respect to the designed beamline azimuth and the slope
- the residuals to the fitted cylinder surface to the designed effective decay pipe aperture

##             Installation/Vacuum Test

- We Should Check the Vacuum Prior to
-       Constructing Hadron Absorber and Chase
- Need to Work Through Installation                  	Schedule
- No Major Problem Foreseen

## Costs

- Elimination of
-                 Seals
- Addition of
-         Oversight
- 		($22K)
- PVC Cooling
-        Cover
- 		($.A. Healy) -- this will be biggest change

## Costs as of This Morning

## Comments on Costs	

- Unburdened Cost Estimate $115K
- Access Port costed at $56,000
- 		*large over-estimate; needs redo*
- Have BOE from Grozis on Endcaps
- 		*also overestimate, but < $few K*
- For WBS 1.1.4, Cost Will Shrink Some
- TPC will Increase from Cooling =>
- 				WBS 1.1.7