RHIC 56 MHz
HOM DamperFundamental Damper
Fundamental Power CouplerPick-ups
S. Bellavia
January 19th, 2010
Higher Order Mode (HOM) Damper
Higher Order Mode (HOM) Damper
HOM Thermal-Electric PerformanceSolid Model Assembly in Pro-E, Finite Element Model built in ANSYS 13.0
HOM Thermal-Electric Performance (cont.)Boundary Conditions:
• Surface RF Currents
• Dielectric (Joule) Heating of Sapphire
• Heat Leak from Ambient
HOM Thermal-Electric Performance (cont.)
Dielectric Heating of HOM Sapphire Break
Dielectric Heating of Sapphire Break (cont.)
HOM Thermal Performance (cont.)
Internal Components
HOM Thermal Performance (cont.)
Assembly with Heat-Stationed Cable
50K Heat StationFrom Heat Shield
HOM Cable
Joule Heating vs. Thermal Conductivity
OFHC Copper vs. 304 Stainless Steel
Thermal Conductivity of Cu vs SS
0.001
0.01
0.1
1
10
100
1000
0 50 100 150 200 250 300 350
Temperature (K)
Th
erm
al C
on
du
ctiv
ity
(W/c
m-K
)
Copper
SS 304
Electrical Resistivity of Cu vs. SS
1.0E-10
1.0E-09
1.0E-08
1.0E-07
1.0E-06
1 10 100 1000
Temperature (K)
Ele
ctr
ica
l Re
sis
itiv
ity
(o
hm
-m)
SS304
Cu
Cable Joule Heating Due to RF Current
Coaxial Cable Choices
Model for Calculations
FEA Model(s)
SS Conductors, Heat Station with Effect of Contact Resistance
These regions made 100X more thermally resistive than PTFE to simulate contact resistance
FEA Results
50K to Outer Shield
For 250 SS Cable - FEA performed on many types and sizes
FEA Results Summary
Coaxial Cable Comparison
0.000
0.200
0.400
0.600
0.800
1.000
1.200
.250 SS - SS .141 SS - SS .085 Cu Ctr, SSouter
.141 Cu Ctr, SSouter
.141 Cu - Cu
Cable
Hea
t (W
atts
)
Heat into cold end
Heat into Heat Station
HOM Cable-Connector Assembly
HOM Cable-Connector (cont.)
HOM Hex Seal
10 x 5/16-24 SS Bolts, Torqued to 113.1 in-lbs results in 1809.6 lbf (80% of yield)
Bolt Circle = x 3.700 = 11.62 inches
Linear Sealing Load = 10 x 1809.6 / 11.62 = 1557 lbf/inch
HOM Final Design / Fabrication / Procurement
• Full set of drawings being checked
• SOW and Specification to be released this week, followed by Purchase order / RFQ
• Parallel Effort to build “in-house” (BNL will manage piece-part fabrication)
- Quotation for brazing Sapphire break received
- Quotation for Custom Sapphire tubes received
- Awaiting Quotation for Stock Size Sapphire Tube
HOM Design / Fabrication
HOM Design / Fabrication (cont.)
HOM Filter Assembly
HOM Procurement
HOM Procurement (cont.)
HOM Procurement (cont.)Sapphire for Filter Components
HOM Schedule
• Jan 21 – Release of Drawings (numerical rev’s for quotation)• Jan 21 – Signature / release of SOW and Specifications• Jan 21 – Purchase order for building entire HOM assembly
– Phase 1 – Prototype / First Article (20 +2 weeks – June ‘11)
– Phase 2 – 6 follow-on HOM’s (36 +2 weeks – Oct ‘11)
• Feb 7 – P.O. for brazing of Sapphire-Niobium break• supply vendor with sapphire tubes and machined niobium parts (12 weeks –
April ‘11 )• purchase and receive brazed assemblies (16 weeks – May ‘11)• arrange machining of niobium components (12 weeks – April ’11)• send out machined parts and brazed assemblies for pre-cleaning, welding
and final cleaning, (most likely to AES). (32 weeks – Sep ’11)• Receive Final HOM’s (36 weeks – Oct ’11)
• Feb 21 – P.O. for Brazing of Filter Assembly
HOM Costs
• Sapphire tubes $ 15K
• Niobium (raw material) $ 10K
• Niobium machining $ 50K
• Brazed Break $ 20K
• Brazed Filter Assy $ 10K
• Welded Assemblies$200K
• Cleaned Assemblies $ 50K
• Total$355K
• First Article$150K
• 6 Final HOM’s $425K
• Total$575K
Done “In-house” by BNL Done by Outside Vendor
Fundamental Damper
Fundamental Damper (cont.)
Fundamental Damper (cont.)
Fundamental Damper Motion System
Fundamental Damper Motion System Costs
Motion System
• Feb ‘11 – Thermal / Structural Analysis• May ’11 – Detailed Design / Drawings
Fundamental Damper Schedule / Costs
Total Cost = $125K = 400 shop hours
Fundamental Power Coupler
FPC
Fundamental Power Coupler (cont.)
Fundamental Power Coupler (cont.)
Fundamental Power CouplerConnector
7/16 DIN Type N
Fundamental Power CouplerWeldable, UHV Compatible Connector / Window
Fundamental Power CouplerWeldable, UHV Compatible Connector / Window
Fundamental Power CouplerWeldable, UHV Compatible Connector / Window
Fundamental Power CouplerWeldable, UHV Compatible Connector / Window
Fundamental Power CouplerWeldable, UHV Compatible Connector / Window
• Total Cost = $95,600
Fundamental Power Coupler Schedule / Cost
• Mar ‘11 – Thermal / Structural Analysis• June ’11 – Detailed Design / Drawings
• Total Cost = $2,100
Pick-Ups Schedule / Cost