# Presentation: 712588

## MERIT Hg System Design

**V.B. Graves**
**P.T. Spampinato**
**T.A. Gabriel**
**MERIT Review Meeting**
**Brookhaven National Laboratory**
**Dec 12, 2005**

## Outline

**Requirements & layout**
**Hg delivery system description**
**Syringe pump**
**Primary/secondary containment**
**Beam windows**
**Optical diagnostics**
**Sensor & controls**
**Installation**
**Cost & schedule**

## Reqmts and Operating Conditions:

**1-cm diameter jet at 20 m/s delivered every 30 minutes**
**Q=1.6liter/s, Re~10****6**
**>1-sec steady state jet during the magnet peak field**
**Baseline Hg environment is 1-atm air, also considering running in rough vacuum**
**Full-beam interaction length is 30-cm**
**Beam line is 120-cm (47.2”) above the tunnel floor**
**Up to 100 pulses for the CERN test, >500 operating cycles for system testing**
**The pump equipment operates in a range of 6000 Gauss to 300 Gauss (*****1 Tesla = 10******4****** Gauss)***

*Target system must deliver a stable, unconstrained jet of Hg into a 15 Tesla field*

## Experiment Layout

**Hg target is a self-contained module inserted into the magnet bore**
**Two containment barriers between the Hg and the tunnel environment**

## MERIT Side View

## Geometry of the Interaction Region

**Horizontal proton beam**
**Magnet axis to beam is 67 milliradians**
**Jet to beam is 33 milliradians**
***Recent change: Jet now starts above beam***
**The jet centerline crosses the beam center at Z=0 (center of the solenoid)**
**7 milliradian**** horizontal beam kick**

## Hg Delivery System

**Capacity 23liters Hg (~760 lbs)**
**Provides 1cm dia, 20m/s jet for up to 12 sec**
**Secondary containment box approximately 1m x 1m x 1.5m**
**Estimated weight 2T with Hg**

## Hg Syringe Performance

**Hg flow rate 1.6liter/s (24.9gpm)**
**Piston velocity 3.0cm/s (1.2in/sec)**
**Up to 103 bar (1500 psi) Hg pressure in cylinder**
**Hg cylinder force 525kN (118kip)**

## Syringe Procurement

**Awarded to Airline Hydraulics (HQ Bensalem, PA)**
**Complete system design based on specified requirements**
**Piston pump (inside secondary containment)**
**One 10-inch Hg Pump Cylinder**
**Two 6-inch Drive Cylinders with integrated position sensors**
**Tie beam**
**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**
**Expected delivery Feb/Mar 2006**

## 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**
**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**

## Secondary Containment

**SS304L/316L 1/2" bottom plate, 1/4" sides**
**Flexible sleeve (non-metallic, combustibility issue)**
**SS304L/316L cylindrical sleeve (13ga, 0.089")**
**Passive filtration**
**Filtered inlet and outlet, normally capped**
**Final sizing to be completed once models from syringe vendor received**

## Secondary Containment Ports

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

## Beam Windows

**Currently have a simple, flexible beam window concept fabricated from titanium alloy**
**Welded attachments provide more usable space for beam**
**Single windows for primary containment, double windows for secondary**
**Pressurize or evacuate secondary windows, monitor to detect failure**

## Optical Viewports

**100mm-dia, 6mm-thick sapphire disks**
**Face seals**
**Mechanical fasteners**
**One set of windows configured for reflector assemblies**

## Optical Components

**BNL to provide splitters, prisms, lenses, bracket, mounting hardware & adjustment mechanisms**

## Z=0 Section Cut

## Common Baseplate

**Supports both magnet and Hg system**
**O/A length 3.15m (124")**
**Rollers used to grossly align solenoid to beam**
**Provides lateral movement of solenoid for alignment to beam once rollers removed**

## Installation Sequence

**Transport Hg System**

**Remove Rollers**

**Transport Baseplate, Install Magnet**

**Remove Rollers, Level Magnet**

**Roll Hg System into Magnet**

**Add Rollers**

## LabView-Based Control System

**Remote control over long distance limited choices**
**Analog I/O modules need to be close to equipment and power supplies**
**LabView controller on laptop computer was chosen**
**National Instruments recommends CompactPCI I/O modules**
**Communicates to laptop via EtherNet cable**
**Custom operator interface will be develop**
**Should allow straightforward integration with other control systems**

## Instrumentation & Sensors

| Controlled Components |  |  |  |
| --- | --- | --- | --- |
| Hydraulic pump | Proportional control valve* | Heater foil |  |
| Analog Sensor Inputs |  |  |  |
| Hg discharge pressure | Hg level | Hg sump thermocouple | Secondary containment thermocouple |
| Cylinder 1 position* | Cylinder 2 position | Hg vapor 1 | Hg vapor 2 |
| Hydraulic fluid high pressure | Hydraulic fluid low pressure | Beam window 1 pressure* | Beam window 2 pressure* |
| Digital Sensor Inputs |  |  |  |
| Hydraulic filter dirty switch | Hydraulic low level switch | Conductivity probe |  |

*** Critical for system operation or safety**

## Items to be Fabricated

**Common Baseplate - $22K**
**(includes magnet**
**support beam)**

**Target**
**Transporter - $5K**

**Target Cart - $3K**

**Primary Containment - $12K**

**Secondary Containment - $14K**

## Hg System Costs

**Syringe ~$80K**
**Remaining BNL procurement estimates**
**Fabricated item cost estimates from ORNL fabrication expert (hopefully conservative)**
**Common baseplate ($22K)**
**Target transporter ($5K)**
**Target cart ($3K)**
**Primary containment ($12K)**
**Secondary containment ($14K)**
**Miscellaneous equipment incl. jacks, Hilman rollers ($3K)**
**Total $60K**
**Additional ORNL funding needed for "toolbox" that will travel with equipment to MIT/CERN (includes PPE/safety equipment, etc), also covers costs for some modifications to Hg system uncovered during ORNL testing**
**Requested $10K**
**Crating / shipping costs to transport system to/from MIT**
**Requested $10K**

## Schedule – Major Milestones

**    **_**Highlights**_
**Solenoid Tests at MIT Jan ’06**
**Target Tests at ORNL May-Aug ’06**
**Integrated Tests at MIT Sep-Oct ’06**
**Retest, if needed Nov ’06**
**Beam Tests at CERN Apr ’07**
**Retest, if needed Jun ‘07**

## Conclusions

**Final design details of Hg system must be completed**
**Nozzle details (position, orientation, length, etc.)**
**Some changes may be required based on Princeton Hg testing**
**Fabrication drawings must be completed soon so procurement process can begin**
**Baseplate design complete, drawings to be ready by end of year**
**Secondary containment drawings can be finalized now that syringe dimensions are known**

## Backup Slides

## Experiment at CERN

## Containment Schematic

## Hg Syringe System

## Stray Field Plot

## Flow Simulation Using AFT Fathom

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

## 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)**
**No MHD effects included**
**Changed system design pressure to 1500 psi (100 bar)**

## 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**

## Normal Syringe Operations

**Slowly extend cylinder to fill Hg cylinder from sump**
**Slowly retract cylinder to starting position & pre-fill Hg supply piping, wait for trigger**
**Some time after trigger is received, ramp cylinder to full speed**
**Steady-state jet for 1sec**
**Ramp cylinder to zero velocity**
**Sudden stop can cause flow separation & Hg hammer**

## Current Toolbox List