XPP Supports PDR Aug 27, 2008WBS 1.2.2.1 & 1.2.2.2 p. 1
XPP SUPPORTSXPP SUPPORTSPreliminary Design ReviewPreliminary Design Review
(WBS 1.2.2.1 & 1.2.2.2)(WBS 1.2.2.1 & 1.2.2.2)J LangtonJ Langton
Jim Jim DefeverDefever
AUG 27, 2008AUG 27, 2008
XPP Supports PDR Aug 27, 2008WBS 1.2.2.1 & 1.2.2.2 p. 2
Outline
ObjectiveScopeInstrument ConfigurationGeneral Operations Plan / RequirementsEngineering Requirements Overall Hardware Configuration Value EngineeringSurface Plate & Pedestals (WBS 1.2.2.1)Component Position Absolute StabilityStrongbackLinear Motion & StopsBeamline Mover (WBS 1.2.2.1)Seismic RestraintDown-Beam Support (WBS 1.2.2.1)Hutch 2 Support (WBS 1.2.2.2)Radiation Spot ShieldingSchedule Status / ForecastBudgetSummary
XPP Supports PDR Aug 27, 2008WBS 1.2.2.1 & 1.2.2.2 p. 3
Objective
Report status of engineering, design, schedule and budget of XPP WBS elements 1.2.2.1 & 1.2.2.2 (optics / diagnostics supports systems)Approval to proceed with final engineering and design of WBS 1.2.2.1 / 1.2.2.2
XPP Supports PDR Aug 27, 2008WBS 1.2.2.1 & 1.2.2.2 p. 4
Scope
This review covers all the hardware required to support XPP X-ray diagnostic and optic hardware, and associated equipment, from the floor up to the interface datum(s) with DCO WBS 1.5.WBS 1.2.2.1 and 1.2.2.2 PDRs.
XPP Supports PDR Aug 27, 2008WBS 1.2.2.1 & 1.2.2.2 p. 5
Instrument ConfigurationXPP Beamline Schematic – MIE’s
XPP Supports PDR Aug 27, 2008WBS 1.2.2.1 & 1.2.2.2 p. 6
General Operations Plans / Requirements
The design service life of the XPP hardware is 10 years.Operational hutch temperature is 68 +/-1 degree F. Extreme hutch temperature is 68 +/-20 degree F.
XPP hardware will accommodate extreme temperature / tolerance without permanent damage. All hardware will return to nominal position when hutch temperature returns to operational specifications.
No extraordinary hutch humidity is anticipated.All XPP systems shall be designed, constructed and installed to support experiment reconfiguration in 8 hours or less.
Includes relocating hardware from “position 1” to “position 2”, or visa-versa,
All tasks to reconfigure the XPP hardware will be within the competency of a typical SLAC mechanical technician.
No specialized expert capabilities, such as alignment engineers,will be required to reconfigure XPP.
XPP Supports PDR Aug 27, 2008WBS 1.2.2.1 & 1.2.2.2 p. 7
General Operations Plans / Requirements
With XPP translating hardware in position 1 (straight ahead or “white beam”)
access into hutch 3 will be permitted contingent on meeting all PPS requirements including closing a photon shutter up-beam of hutch 3.
With XPP translating hardware in position 2 (offset or “pink beam”)
Without monochromator: access is permitted into hutch contingent on meeting all PPS requirements with x-ray passing through hutch.
Local shielding most likely required at vac valves.With monochromator: access into hutch 3 will be permitted contingent meeting all PPS requirements including closing a photon shutter at the up-beam end of the main optics-diagnostics suite.
X-ray beam will be permitted to pass through hutch 3 while access is permitted, allowing prescribed PPS conditions are met.Local shielding, as determined by radiation physics simulations, or other measures, will be required.
XPP Supports PDR Aug 27, 2008WBS 1.2.2.1 & 1.2.2.2 p. 8
Engineering RequirementsRequirements established-agreed per ESD SP-391-000-84.
All translating beamline elements must be under “positive control” at all times.All elements will have fixed (immovable) hard stops defining motion extentsPositive action required to initiate motion NOT to stop motion.Human intervention will not be required to confine elements within their intended range of motion.
Stable relative optical–diag element position (IE: elements with respect to other).Goal: < 5 micron (+/- 2.5)Assumed sources of deviation:
thermal gradients within supportsloads across bellows due to remote commanded component motionsDynamic response to cyclic input loads
Stable absolute optic-diag suite position (IE: elements as a unit in global space)Goal: < 15 micron (+/-7.5) with 2 (+/-1) deg F variationAssumed sources of deviation:
Gross bulk thermal variationDynamic response to cyclic input loadsUnintended redundant loads
Slits to serve as position datum for optic-diag suiteAssumes use of invar component fine align supports
High repeatability of translation hardware (IE: moving between positions 1 and 2)Goal:
XPP Supports PDR Aug 27, 2008WBS 1.2.2.1 & 1.2.2.2 p. 9
Overall Hardware ConfigurationPrimary emphasis on the “Long Table” supports for diagnostics and optics immediately up beam of sample.
Most difficult overall~4.3 meters of beamline required to move 0.6 M horizontally (positions 1 and 2)Beamline Component design ~1700 Lbs (10 Lbf/in)
Design elements directly exportable to the “short table” down beam of sample and to WBS 1.2.2.2 (hutch 2) elements.The design of the support systems, with the exception of the seismic restraint is NOT an issue of stress, or component failure. Issue is deflection, stability, money and time only.
XPP Supports PDR Aug 27, 2008WBS 1.2.2.1 & 1.2.2.2 p. 10
Overall Hardware ConfigurationIntegrated design driven by engineering requirements.“Surface plate” configuration criteria met:
1) Easy to accomplish “positive control”.2) Meets all the physics-engineering stability
requirements simultaneously.3) Low thermal expansion (bulk).4) Large thermal time constant.5) Reduced thermal gradient deflections.6) Rail alignment is easy (system position in the
tunnel is not a component of rail relative alignment).
7) Applicable to slit positions as datum. Slits fixed in 6 DOF
8) Ease of fabrication.9) Seismic restraint is easy, can be accomplished
without constraining overall system.10) Surface plate and pedestal system is per federal
spec.11) Provides datum for future system diagnostic-
metrology if desired/needed.12) System full up assembly, trouble shooting-
solving easily accomplished before moving components to hutch.
13) Configuration is easily modified to all three DCO locations....and to CXI-XCS if they want it.
14) Configuration is easily modified should we experience changes in the next couple of months....we are way out in front of most others.
15) Configuration is the baseline for P3 and budget.
Surface Plate
(4X) Linear translation hardware
Seismic restraint
(2X)Component support strongback
Translation mover
XPP Supports PDR Aug 27, 2008WBS 1.2.2.1 & 1.2.2.2 p. 11
Value Engineering
CONFIGURATION OPTION LEG S'BACK 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15STL STL N N N N N N N N N N N N N N NSTL GRANITE N N N N Y N N N N N N N N N N
GRANITE STL N N Y Y N N N N N N YN N N N NGRANITE GRANITE N Y Y Y Y N N N N N YN N N N N
STL STL YN N N N YN N YN N N N N N N N NSTL GRANITE YN N N N Y N YN N N N N N N N N
GRANITE STL YN Y Y Y YN N YN N N N YN N N YN NGRANITE GRANITE YN Y Y Y Y N YN N N N YN N N N N
STL STL Y N N N Y N Y N YN N N N N N NSTL GRANITE Y N N N Y N Y N YN N N N N N N
GRANITE STL Y Y Y Y Y N Y N N N YN N N YN NGRANITE GRANITE Y Y Y Y Y N Y N N N YN N N N N
GRANITE STL YN N Y Y N Y N Y Y Y Y Y Y Y Y
GRANITE GRANITE YN Y Y Y Y Y N N Y Y Y Y N N N
GRANITE STL Y Y Y Y Y Y Y Y Y Y Y Y Y Y YN
GRANITE GRANITE YN Y Y Y Y Y Y N Y Y NY Y N N
XPP Supports PDR Aug 27, 2008WBS 1.2.2.1 & 1.2.2.2 p. 12
Surface Plate & Pedestals
Parameters defined by Federal Specification GGG-P-463c covering issues such as:
Material and gradeFlatnessThickness (based on load and flatness)Support pedestal locationsWorkmanship, QA and testing
Surface plate dimensions: 156” L X 48” W x 21.5” TSurface plate wt.~15,300 Lb
Total wt. of installation ~18900 Lb2x 890 Lb strongback1750 Lb “payload” (= ~10 Lb / in)
Supported on 3 granite pedestals / Sunnex precision leveling pads
Spherical spacer & flat shims (for floor elev.) in stack
XPP Supports PDR Aug 27, 2008WBS 1.2.2.1 & 1.2.2.2 p. 13
Surface Plate & Pedestals
Spherical Spacer
Leveling Pad
Shimming
Granite Pedestal
(4x) Vendor installed linear bearing rails
Surface plate hutch location tols:X-Y-Z: 0.5 mm (+/-0.25 mm)Roll:
XPP Supports PDR Aug 27, 2008WBS 1.2.2.1 & 1.2.2.2 p. 14
Component Position Absolute Stability
Issue: gross temperature variation in hutch affects component absolute vertical position Goal: < 15 micron (+/- 7.5)Hutch temperature tol = +/-1 deg F per LCLS room data sheetsTime constant of surface plate is ~30 days per fed spec.
(in) (mm)surface plate leg 9.3 236.2 granite 4.40E-06 1.04height adjust 3.765 95.6 4140 6.80E-06 0.65surface plate 21.5 546.1 granite 4.40E-06 2.40s'back / rails / brgs 4.553 115.6 4140 6.80E-06 0.79adjust support 16 406.4 304 sst 9.60E-06 3.90
total (w/ granite) 55.118 1400.0 8.78total (w/o granite) 5.34
sub invar for sst 16 406.4 invar 7.20E-07 0.29total (w/ granite) 55.118 1400.0 5.17
total (w/o granite) 55.118 1400.0 1.73
dh(micron)component
height material(baseline)
cte(1/deg F)
XPP Supports PDR Aug 27, 2008WBS 1.2.2.1 & 1.2.2.2 p. 15
StrongbackProvides interface to DCO scope instrument specific precision alignment supports.
Surfaces provided at 10”and 16” below beam centerline
Will be a fabricated steel component
Bolted joints
Linear bearings and rails mounted belowDeterministic supports
IE: non-singular stiffness matrixCompliant to thermal excursions in X,Y and ZMinimize-eliminate redundant loads
XPP Supports PDR Aug 27, 2008WBS 1.2.2.1 & 1.2.2.2 p. 16
Strongback
Requirement: component position relative stability (thermal gradient)Issue: Air current in hutch results in heat flow into / out of strongback and subsequent thermal gradient.Goal: < 5 micron (+/- 2.5)Hutch temp tol. = +/-1 deg FMax thermal gradient 0.25 - 0.4 deg F okay.
XPP Supports PDR Aug 27, 2008WBS 1.2.2.1 & 1.2.2.2 p. 17
StrongbackRequirement: component position relative stability (torsion)Issue: Remotely adjustable components moved and offset loads in bellows induces torsion in strongback Goal: < 2 micron (+/- 1)15 Lbf offset load per bellows (significantly higher than vendor info).Assume completely open s’back (no top plate)Assume reaction loads carried to s’back at supports (only counteracting moment from redundant at s’back support)
15 Lbf15 Lbf
30 Lbf
XPP Supports PDR Aug 27, 2008WBS 1.2.2.1 & 1.2.2.2 p. 18
Linear Motion and StopsLinear motion via THK LM bearing-rail systems.
Utilize maximum preload / negative clearance bearing set .10K lb load rated bearing units
For each strongback:One set fixes “Z” position
adjacent to slit.
One set of crossed rails-bearings provides for dimensional tolerances, thermal expansion, etc.
Total force to translate is
XPP Supports PDR Aug 27, 2008WBS 1.2.2.1 & 1.2.2.2 p. 19
Linear Motion and Stops
Stops are fixed, adjustableStop clamps are “self latching”
Do need to be manually torqued
Stop clamps work in conjunction with beamline mover to eliminate pinch hazard.
Clamp Toggle
Clamp Detent
Hard Stop SwivelAdjustable Hard Stop
Stop Clamp
XPP Supports PDR Aug 27, 2008WBS 1.2.2.1 & 1.2.2.2 p. 20
Beamline Mover
Provides positive control of beamline translation.
Action required to start motionAction halted – motion halted
In conjunction with stop clamps eliminates pinch hazard.Eliminates “hard dock” on stops.
Compliant s’back attachment
Load beam
Lead screw slide
Hand wheel
XPP Supports PDR Aug 27, 2008WBS 1.2.2.1 & 1.2.2.2 p. 21
Seismic Restraint
Designed to meet revised SLAC seismic requirements for experimental equipment
1.5*W (V) + 0.7*W (H)or
.06*W (V) + 0.7*W (H)
System does not constrain surface plate.Non-grouted anchorage using mechanical under-cut anchorsDirectly exported to other support system assemblies
perimeter frame
6x anchorage
Shimmed gaps ateach anchorage
XPP Supports PDR Aug 27, 2008WBS 1.2.2.1 & 1.2.2.2 p. 22
Seismic Restraint
Surface plates will overturn at
XPP Supports PDR Aug 27, 2008WBS 1.2.2.1 & 1.2.2.2 p. 23
WBS 1.2.2.1 Downbeam Support
All elements identical to upbeam installation except for overall Z length.
XPP Supports PDR Aug 27, 2008WBS 1.2.2.1 & 1.2.2.2 p. 24
WBS 1.2.2.2 Hutch 2 Support
Modifications restricted to addressing fixed location (no s’back – rail system) and H2 / SXR stay clear constraints.
XPP Supports PDR Aug 27, 2008WBS 1.2.2.1 & 1.2.2.2 p. 25
ESH Hazards and Mitigations
Fabrication:No special hazardous processes or materials.
Installation:Heavy weight components - rigging.
Mitigated using LCLS developed procedures of work authorization,contractor qualification, etc.
Operations:Radiation: (see next slide)Seismic: restraint system designed per latest SLAC requirements,anchorages to be reviewed-approved by CE P.E. and seismic safety committee gives final approval.Pinch Hazards: stop clamp / beamline mover system eliminates pinch hazards. Covers to be installed to eliminate any additional hazards from stop / clamp / rail system on table. (also protectssystem from lubricant contamination).
Decommissioning – disposal:Not special hazardous processes or materialsActivation ?
XPP Supports PDR Aug 27, 2008WBS 1.2.2.1 & 1.2.2.2 p. 26
Rad Spot Shielding
XPP instrument baseline design presented to RP 6-22-08Hutch 3 shielding issues addressed in RP notes
RP-08-05: Dose rate in NEH hutchesRP-08-04: Dose rate in NEH due to Brem….RP-07-11: Shielding design for NEHLimited spot shielding thicknesses req’d per RP notes.Maturity of designs, self shielding accounting, etc, not clear.
Present requirements believed to be:Hutch 2 components spot shielded
Design considers ¼” stl box supported from seismic restraint.
Hutch 3 local shielding at vacuum valves only.Thick wall (.25 in) vac chambers recently suggested.
XPP Supports PDR Aug 27, 2008WBS 1.2.2.1 & 1.2.2.2 p. 27
Schedule Status / Forecast
This review covers:PDR - Long Table, (1.2.2.1, XPP1221115)……..…………July 22 PDR - Short Table (1.2.2.1, XPP1221135). …..…………..Aug 12PDR Optics Support Table (1.2.2.2, XPP1222115)……..July 31Seismic reviews***
Long and short tables, hutch 3 (1.2.2.1, XPP1221200)..…Aug 27 Optics table, hutch 2 (1.2.2.2, XPP1222175)….….………..Aug 28
Will pursue CF approval of anchor system and present detailed analysis to Seismic committee
Specific RP analysis and requirements pending.
***further review approval req’d from CE p.e. and seismic SOC.
XPP Supports PDR Aug 27, 2008WBS 1.2.2.1 & 1.2.2.2 p. 28
Schedule Status / Forecast
Next Review sequence:FDR, 1.2.2.1, scheduled Nov 18FDR, 1.2.2.2, scheduled Oct 9
All reviews for 1.2.2.1 & 1.2.2.2 have schedule float >150 d.
To do prior to FDR’s: Final analysis of system dynamics.Finalize interface to DCO (ICD in draft review).Improved (or final) vacuum system configuration.Preliminary / final cable management design.Preliminary / final rail / stop cover designShielding requirements and design approval needs to be completed.Final joint(s) design / tolerance study.
XPP Supports PDR Aug 27, 2008WBS 1.2.2.1 & 1.2.2.2 p. 29
Budget
ITEM BOE RequoteSurface plate system $34.2K $30.1KRails / bearings $13.0K $14.0KSeismic restraint $10.4KStrongback $35.3KShielding $7.5KDelievery $4.5K
No element or component of the design exceeds the expectations or requirements of the baseline –BOE’sSome elements were simplified.
XPP Supports PDR Aug 27, 2008WBS 1.2.2.1 & 1.2.2.2 p. 30
Summary
All physics and engineering requirements, for XPP support systems, that have been defined have been met.The XPP support system Designs are >80% engineering / design complete.
All element designs are well advancedRadiation Physics simulations and requirements for shielding, with respect to the XPP specific design, is not complete.
Expectations and conceptual designs are based on RP requirements released to date.
Designs are consistent with the concepts used for XPP P3 schedule and budget.
Re-quotes that have been completed are consistantwith the CD2 prep’d BOE.Work to date on schedule.
