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SNS PPU Cryomodule Shipping Plans

SNS PPU Cryomodule Shipping Plans. Ed Daly On behalf of the SNS PPU teams at ORNL and Jlab Special Thanks to Naeem Huque , John Mammosser , Jeff Saunders and Matt Howell. TTC2019, Vancouver. Introduction. (7) SNS PPU Cryomodules will be assembled and shipped from JLab to SNS

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SNS PPU Cryomodule Shipping Plans

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  1. SNS PPU Cryomodule Shipping Plans Ed Daly On behalf of the SNS PPU teams at ORNL and Jlab Special Thanks to NaeemHuque, John Mammosser, Jeff Saunders and Matt Howell TTC2019, Vancouver

  2. Introduction • (7) SNS PPU Cryomodules will be assembled and shipped from JLab to SNS • Cold testing will occur at SNS prior to tunnel installation • “Minor” design changes are being implemented • Shipping system will be adapted to account for minor design changes • Shipping Plan includes component testing and shipping test of first unit SNS MB loaded on Fixture SNS PPU Prototype on tooling

  3. Design Changes (M. Howell) • Implies a number of “minor” design changes that are being analyzed as part of the design effort

  4. Hardware Changes (Mammosser, Saunders) • No HOM couplers; RRR End groups • HV is ASME Code Compliant • End cans - ASME Code Compliant • FPC Inner Conductor wall is 3.5 mm thicker & 1.5 mm shorter

  5. SNS Shipping System (N. Huque) • Shipping Fixture consisted of two frames, separated by 12 helical isolator springs (Aeroflex CB1500-15-C2) • 1 inch thick rubber between CM and cradles on the inner frame • Fixture is designed to reduce shocks by a factor of 6 • Cryomodules held on to the frame by ratchetting straps • Shipping assembly was fitted on a drop-trailer with air-ride suspension • SNS CMs were designed to withstand: • Vertical: +/- 4.0g • Beam-Axis: +/- 5.0g • Transverse +/- 1.5g

  6. Considerations for Shipping Specifications • Current specification is a static-equivalent dynamic loading taken from Barron’s “Cryogenic Systems” • Vertical: +/- 4.0g • Beam-Axis: +/- 5.0g • Transverse +/- 1.5g • Could specify derated set of incident shipping loads • E.g. reduce allowed loads by 50% • Could specify spectrum that define shock and vibration limits separately • Enlist help of shipping experts to refine specifications to better define shock and vibration These design loads apply to shipping, handling and installation Axial motion of LCLS-II FPC bellows - vibration and shock are superimposed (Holzbauer et al.)

  7. Example : Truck Response – Shock and Vibration • Survey combining data from 7 truck-trailer combinations, both spring and air-ride suspensions • Taken from “Shock and Vibration Environments for Large Shipping Containers on Rail Cars and Trucks ”, https://www.osti.gov/servlets/purl/7305222 • Spectra for boat, train and airplane certainly different • Vibration and shock are segregated

  8. SNS Production Shipping Experience (N. Huque) • After successful road tests, SNS cryomodules shipped to ORNL at a rate of one per month • Shocks and vibration data were recorded for all shipments • High shock was recorded while loading the CM into the fixture; procedure was modified to be ‘softer’ • Highest shocks were found to be at the ORNL gate! • One cryomodule, HB01 suffered a beamline vacuum leak during shipment • Not initially reported, and CM functioned with field emission and lower energy • The Shipping Fixture is to be modified (due to changes in End Can design) to transport 7 SNS-PPU cryomodules to ORNL from JLab in 2021

  9. Approach for Shipping Plan • Perform engineering analysis related to design changes (led by Jlab design team) • Identify any sensitive components • Conduct specific component testing focused on FPC inner conductor (led by SNS PPU staff) • In advance of first production shipment • Confirms need for shipping restraint on FPC window • Possibly use shaker table to evaluate lifetime • Develop instrumentation plans based on past experience • Loc/qty of accelerometers, beamline vacuum monitoring, temperature monitoring • Conduct design verification test on first shipment from JLab to ORNL • Consider dummy load tests to verify shipping frame performance

  10. Cryomodule Shipping Lessons (N. Huque) • Install maintenance ports on vacuum vessels • Tuner access ports on LCLS-II CMs have been used for nearly everything but repairing tuners • Conduct shipping road tests prior to starting production shipments • Include shock and vibration spectra separately when creating a shipping specification • Consider sub-component testing of sensitive items (e.g. couplers, tuners, bellows) • Ensure assembly used as testing bed is identical (in sensitive regions at least) to production units • Involve industry at an early stage of shipping scheme development • In addition to paid consultants, some specialized transportation companies may provide advice as part of bidding process • Only employ companies that work with special loads • Variables such as route, speed, road conditions and weather cannot be controlled; a shipping system should be able to handle deviations

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