IFR Improvement Phase II (Barrel) Mechanical Engineering Issues

11/15/02 H.J. Krebs

IFR Improvement Phase II(Barrel)

Mechanical Engineering IssuesH. James Krebs

November 15, 2002

11/15/02 H.J. Krebs

Scope of WorkUnder Investigation

• Remove 18 layers of RPCs

• Install 7/8” thick brass in slots previously occupied by layers 3,4,6,7,9,10,12,13,15 & 16 – 10 layers (8.75” thickness)

• Install detectors (technology TBD) in layers 2,5,8,11,14,16,17 & 18 – 8 layers

11/15/02 H.J. Krebs

Modifcation of Detector Loading

Description Weight (tons)

FWD Brass 30

Fwd Steel 28

FWD Belt Chambers 3

FWD Counterweights -24

Barrel Brass 113

Total 150

11/15/02 H.J. Krebs

Present EQ Committee Approval• IFR Improvement Phase I (FWD End Doors)

– Add 1” thick layers of brass in door slots 8,10,12,14 & 16 (30 tons)

– Add 28 tons of steel absorber on fwd end of doors

– Add 3 tons of belt chambers around end door periphery

– Remove one counterweight from each door skid (-24 tons)

• IFR Improvement Phase II (Barrel)– Add 7/8” thick layers of brass in barrel slots 7,9,11,13 &

15 (60 tons)

• EQ Committee approval on 12-18-01

11/15/02 H.J. Krebs

Earthquake Issues for New Scope• Calculate new CGs and determine extent of

loading asymmetries• Differential motion between detector and floor

slab – cannot exceed 8.5”– Re-do isolator analysis

• Strength of floor slab• Strength of X & Z restraint rods and connections

to floor and barrel• Connection of Y restraint to floor• Structural analysis of barrel system

– Redo “Missing Bolts Analysis”

11/15/02 H.J. Krebs

Chamber Removal Issues (General)• At present, the mechanical scope of work does

NOT include removal and replacement of layers 1, 19 and the cylindrical RPC

• RPC extraction and replacement detector installation shall occur on forward end

• Probably committed to whole sextant when starting– Removal of any chamber in a sextant will likely

damage other chambers in that sextant due to the bundling of gas lines and HV cables on backward end

• Rigid installation work platforms will be needed– Modify end door work platforms?

11/15/02 H.J. Krebs

Chamber Removal Issues (General)• Remove fwd end plug for side sextants

BL00,BL05,BL03 & BL02

• End doors open – fwd & bwd

• Extend travel of fwd doors

Layer No.

Side Sextants

Add’l Travel Needed

End Plug Inst. (mm)

Add’l Travel Needed

End Plug Removed (mm)

2 thru 13 0 0

14 26 0

15 121 0

16 216 38

17 315 153

18 467 289

11/15/02 H.J. Krebs

Chamber Removal Issues (General)• Load transfer of calorimeter weight needed

for side sextants– Removal of F-CAL (still under investigation)– Support from upper barrel EQ support beams

• Removal of corner plates– Max of 2 plates removed at any time

• On forward end only

– Continuous position monitoring of detector internals as/after corner plates are removed

• Many dial indicators

• Layer 18 buried behind flux bars which are buried behind corner plates

11/15/02 H.J. Krebs

Layer 18, Layer 19, Corner Blocks

11/15/02 H.J. Krebs

Schedule and Installation Issues• Approximately 2 days lost due to photographers,

film crews and tours• 3 days lost due to PEP survey at end of run• 3 days lost due to PEP survey at start of run• 3 Days lost due to PPS certification• No access to EMC during chamber removal and

installation process• Tooling to install replacement IFR detectors is

probably similar in concept but different than RPC removal tooling

11/15/02 H.J. Krebs

IFR Sextant BL01 (Top)• Work platforms needed• Remove IFR cabling• Disconnect & remove IFR cooling loops• Remove center gap plate• Solenoid

– Disconnect solenoid axial supports– Remove axial support plate

• New fixture needed

– Release upper radial supports

• Remove fwd corner plates at 1:00 & 11:00• Layer 1 replacement will be difficult

– Support plate is cambered

11/15/02 H.J. Krebs

IFR Sextant BL00 (Upr East)• Work platforms needed

• Remove fwd corner plates at 1:00 & 3:00– New fixture needed

• Remove Gap plates – fwd & bwd

• Disconnect and peel back cabling

– SVT

• Remove IFR cabling• Remove piping

– B-CAL N2 vent

– B-CAL chilled water return

– DCH fwd end plate cooling supply & return (not used)

– VESDA line

11/15/02 H.J. Krebs

IFR Sextant BL00 (Cont’d)• Solenoid

– Disconnect solenoid axial supports– Remove axial support plate– Release upper radial supports

• Remove forward end plug• Disconnect fwd east door drive and move door

additional 289mm– Remove belt chambers

• Transfer calorimeter load – east side• Layer 1 replacement will be difficult

– Support plate is cambered

11/15/02 H.J. Krebs

Load Transfer

11/15/02 H.J. Krebs

IFR Sextant BL05 (Lwr East)• Remove fwd corner plates at 3:00 & 5:00

– New fixture needed

• Remove gap plates – fwd & bwd• Disconnect and peel back cabling

– F-CAL– B-CAL

• Remove IFR cabling• Remove piping

– B-CAL N2 vent - F-CAL Source return– B-CAL H2O supply - F-CAL fluorinert supply– F-CAL N2 Supply - F-CAL fluorinert return– F-CAL Source Supply

11/15/02 H.J. Krebs

IFR Sextant BL05 (Cont’d)• Solenoid

– Disconnect solenoid axial supports– Remove axial support plate– Release upper radial supports

• Remove forward end plug• Disconnect fwd east door drive and move door

additional 289mm– Remove belt chambers

• Transfer calorimeter load – east side

11/15/02 H.J. Krebs

IFR Sextant BL04 (Bottom)• Remove fwd corner plates at 5:00 & 7:00• Remove gap plates – fwd & bwd• Remove center gap plate

– New fixture needed?

• Remove IFR cabling• Disconnect and remove IFR cooling loops• Solenoid

– Disconnect solenoid axial supports

– Remove axial support plate

– Release upper radial supports

11/15/02 H.J. Krebs

IFR Sextant BL04 (Cont’d)• Chamber removal easier if fwd PEP raft

support pedestal is removed

• Not enough Z clearance for chambers to be nominal 3740mm in length– Interference with PEP concrete pier– Maximum clearance is 3570mm

• Good news – layer 18 remains intact at 3340mm

• Layers 1 thru 17 limit to 3550mm and position to forward end

11/15/02 H.J. Krebs

IFR Sextants BL02 & BL03• Similar to sextants BL00 & BL05

• Disconnect solenoid hall probe

• Not necessary to remove belt chambers on fwd west end door

11/15/02 H.J. Krebs

BrassLyr No. Weight/Sex (lbs) Total Weight (lbs) Cost (K$)

3 3103 18617 74

4 3200 19201 77

6 3393 20361 81

7 3489 20936 84

9 3683 22095 88

10 3780 22680 91

12 4002 24013 96

13 4112 24670 99

15 4364 26186 105

16 4509 27053 108

Total 37635 225810 903

11/15/02 H.J. Krebs

Alternate Materials

• Interaction Lengths– Fe ~17cm

– Cu ~15cm

– Pb ~17.1cm

– U ~10.5cm

– W ~9.6cm

– Pt ~8.9cm

11/15/02 H.J. Krebs

Brass Design Option

• Layers 3,4,6,7,9,10 equals 62 tons– Would not require EQ Committee approval– Savings of $407K M&S

11/15/02 H.J. Krebs

Brass Engineering Issues• Prefer to install brass after reinstallation of

all corner plates

• Handling fixtures and installation tooling needed

11/15/02 H.J. Krebs

Engineering Responsibilities• Jim Krebs (SLAC)

– Project Management

– Brass design including installation and handling fixtures

– Installation platforms

– Miscellaneous handling fixtures• Corner plates

• Solenoid support arms

• Richard Boyce (SLAC)– RPC removal fixtures

– Replacement chamber handling and installation fixtures

11/15/02 H.J. Krebs

Engineering Responsibilities• Les Dittert (Contract)

– Earthquake design and analysis

• Knut Skarpaas VII (Contract)– Calorimeter load transfer– Calorimeter support arm handling fixture

• Nancy Yu (SLAC)– Finite element analysis

11/15/02 H.J. Krebs

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EDIA Cost EstimateType Man Years K$/MYr Total (K$)

Engineer 7 175 1,225

Designer 4 106 424

Eng Ass. 1 130 130

Total 1,779

11/15/02 H.J. Krebs

Fabrication and Shop Labor• Fab & Testing

• Shop Labor

Type Man Years K$/MYr Total (K$)

Tech Support 4 90 360

Total 360

Type Total (K$)

Heavy Fab 50

Alignment 10

Rigging 10

Total 70

11/15/02 H.J. Krebs

Installation LaborType Man Years K$/Myr Total (K$)

Tech Support

5.33 90 480

Eng Ass. 1.33 130 173

Total 653

11/15/02 H.J. Krebs

M&S Costs

Type Total (K$)

Tooling & Supplies 50

Brass 903

Total 953

11/15/02 H.J. Krebs

Total Costs - MechanicalType Amount (K$)

EDIA 1,779

Fab & Testing 360

Shop Labor 70

Installation Labor 653

Total (FY2002 $) 2,862

11/15/02 H.J. Krebs

Schedule

• Early drafts from ~1.5 yrs ago:– Top sextant only: ~1.5 months– East diagonals: ~3.3 months (no endcap removal

might cut this by a month)

– These were very preliminary schedules that need update!