dune installation and manpower schedule for single phase ......-repack 2 apas in box-4h • apa...

William Miller

University of Minnesota

28-March, 2018

Dune Installation and Manpower Schedule

for Single Phase Detector

Overview • ProtoDUNE Installation Schedule

- APA

- CPA

• Schedule Assumptions and Overview

- When do we need to start?

• Mechanical Tests at Ash River

• Integration and Testing Facility

• Single Phase Installation and Manpower Schedule

• Summary and Comments

ProtoDUNE

28-March-18 William Miller | Dune Installation Schedule 3

While this is certainly a prototype

and installation times are much

longer, there are design

modifications required in decrease

installation times

• TPC component delivery schedule

- Numerous adjustments were made

to the installation schedule while

waiting for parts

• Safety Approval and

Documentation

- This task took many man-weeks of

effort, safety approval took even

longer

The first drift volume in DUNE

ProtoDUNE APA: ~100 hrs 2-5 FTEs


• Opening up the APA shipping crate, load test on the yoke and mounting the lifting fixture took ~10 hours with 4-5 FTEs plus 3 CERN riggers

- Clearly new design of box and lifting fixture required

• Picking up the APA, rotating it into a vertical position, lowering into the SAS and transferring the load to the Transport beam ~3 hours 3 FTEs plus 4-5 CERN Riggers

~13 hours 3-5 FTEs & Riggers

ProtoDUNE APA-Cleanroom


• Install cable trays and remove protection- ~2 hours 2 FTEs

• Vibration, Inspection and Photogrammetry- ~10 hours 1 FTE

• Install protection- ~1 hour 2 FTEs

• Cold Electronics- ~20 hours 2 FTEs

- ~8 hours 2 FTEs pre-boards and test

- ~8 hours 2 FTEs install & test on APA

- ~4 hours 2 FTEs to dress cables

• PD Installation- ~32 hours 2-4 FTEs

- ~16 hours 2 FTEs Test PD in test box

- ~8 hours 4 FTEs Insert PDs

- ~8 hours 2 FTEs to cable, test and dress

• Remove protection- ~1 hour 2 FTEs

~65 hours 2-4 FTEs

ProtoDUNE APA-Cold Box


This work or similar would happen at the ITF

• Open Cold Box- ~2-3 hours 2 FTEs & 2 CERN crane operators

• Attach transport beam to Cold box beam-1 hour 2 FTEs

• Roll APA into Cold Box and disconnect Beam- 1 hour 2 FTEs

• Feed cables in Feed Through- 1 hour 4 FTEs -2 man-lifts

• Cable to electronics ~3 hours 2 FTEs

• Close Cold Box- ~2-3 hours 2 FTEs & 2 CERN crane operators

~ 11 hours 2-3 FTEs

ProtoDUNE APA- Into cryostat


• Open cold box- ~2-3 hours 2 FTEs & 2 CERN crane operators

• Disconnect cables from electronics and secure cables-~2 hours 4 FTEs

• Connect transport beam to Cold Box- 1 hour 2 FTEs

• Move into cleanroom, replace bad electronics and re-test- 2-8 Hours 2 FTEs

• Attach transport beam to TCO beam- 1 hour 2 FTEs

• Move APA into cryostat- 1 hour 4 FTEs

~9-13 hours 2-4 FTEs

ProtoDUNE- CPA/FC: ~30 hrs


• Unpack, bolt together, add field shaping strips, test and hang single CPA- ~6 hours 3 FTEs

• Unpack second CPA and join with first to make a pair- ~6 hours 3 FTEs

• Lower 2 top field cages, inspect, test and install on CPA pair- ~8 hours 3-4 FTEs plus 3 CERN Crane operators ~ 6 hours

• Lower 2 bottom field cages, inspect, test and install on CPA pair- ~8 hours 3-4 FTEs plus 3 CERN Crane operators ~ 6 hours

• Attach transport beam to TCO beam and move into cryostat- 4 FTEs ~2 hours

First completed CPA-FC assembly

Comparing ProtoDUNE to DUNE


• The times shown for

ProtoDUNE are linear many

because of space constraints

in the 109sq. M cleanroom

• In DUNE we are moving the

PD installation and CE board

installation to the ITF. APA

and CPA are done in parallel.

Need 3 APA stations. Cables

will be done underground.

• ProtoDUNE

- APA: 98 Hours

- CPA: 30 CPA

• DUNE-12m 3 APA & 2 CPA

• ITF-APA ~30h

- Unpack-Hang Vertical-4h

- Install PDs and Test-8h

- Install CEs and Test-8h

- Cold box-In and Out-4h

- Repack 2 APAs in Box-4h

• APA Underground-Vic Est. ~24h

- 24 hours (3 ten hr shifts) to unpack, rotate into position, bolt together, cable and test

• CPA Underground-Vic’s Est.

- 8 hours (1 ten hr. shifts) to unpack, rotate 6 CPA pieces, bolt together, add Top and Bottom Field cages, make all electrical connections

Installation Schedule Overview


Beneficial Occupancy of the first Cryostat in the end of December 2022

The Basic Logistic Concept


• ~ 1 week buffer of TPC components underground and ~1 month at ITF

• Access underground controlled by SDSTA, slung loads take ~66 min, regular cage loads ~17 minutes. Personnel trips max 30 people ~15 minutes

Schedule Assumptions


• Lessons learned from

ProtoDUNE point out there are

numerous design modifications

required to reduce installation

time for SP DUNE detector

• The weekly installation

schedule assumes:

- We can install three APAs pairs

(2 vertically stacked)

- Two 12m CPA/FC assembly

- Move them into the cryostat,

deploy Field Cages and run

APAs cables into feed-thru


• Working two 10 hour shifts/4 days per week. Friday would be schedule contingency

• 2 APAs install/day so there is not time to install PD and CE underground, cables must be installed underground

• Shipping box design must be light weight, reusable, meet cage design criterial and able to make cage rotation

• ~ 1 week buffer of TPC components underground and ~1 month at ITF

• Access underground controlled by SDSTA

Installation Assumptions

What happens before B.O.?


• Design-Complete installation concept so engineered design can begin for TCP components and ITF concept

• Mechanical tests at Ash River to confirm that modifications will work

• Test pre-production APA, CE & PD at CERN in cold box

• Commission Integration and Testing Facility

• Begin testing of first TPC components

FY18 FY19 FY20 FY21 FY22

Q3 Q4 Q1 Q2 Q3 Q4 Q1 Q2 Q3 Q4 Q1 Q2 Q3 Q4 Q1 Q2 Q3 Q4

Design

Mechanical

Pre-Production

Commission ITF

Testing ITF

DUNE Trial Assembly at Ash R


• NOvA Far detector assembly

area is 16.75m deep from

the loading bay with a hook

height of 6.1m on the crane

• The open loading bay area

is 21m x 21m if needed

• Two 10-ton overhead

cranes, tools, fork lifts, small

machine shop, etc. available

• Experienced crew that

helped build ProtoDUNE

staffed at Ash River


Dune

Assembly

Prototype

Area

17m

Glue machine will be removed

If needed NOvA access scissor lifts can be removed to

increase width ~20m


Dune

Assembly

Prototype

Area

16.75m


View looking North from NOvA assembly area to loading dock

Schedule for ITF: Pre-B.O.


ITF Cold Test Assumptions


• We need to cold test 6

APAs/week during the full speed

assembly of the Far Detector

• This requires ~6 cold boxes with

a cryogenic system

• It takes ~1 week to install, PD,

CE and about ~1 week for the

cold test

• This number can be reduced if a

large number of the APAs are

tested longer before assembly

begins and there is enough

space for a storage buffer

Building would need to be about 10-12,000 sq. ft. with an overhead

crane with 8m hook clearance

Need to better define tasks/tests to estimate FTE requirements

Underground Installation Schedule• Current installation schedule

is based on a top down

estimate to fit between the

beneficial occupancy's of the

first and second caverns.

• Time and motion studies from

the ProtoDUNE point to many

potential engineered

solutions that can help reduce

both the manpower and

schedule, but schedule is

extremely aggressive

• Shipping box design is critical

• DUNE crew does all the

rigging, box moving &

opening and moving TPC

components in the cryostat

• The different consortia do all

the cabling, testing and

commissioning

• First estimate is roughly 20

FTE DUNE crew, 30 FTE

consortortia

• Small ramp-up and ramp-

down installation

Underground Installation Phases


There are five major phases of the installation

• 2.1.3 Design

This is the design effort needed between the review of the TDR and the start of the production of the SP-TC infrastructure necessary for detector installation.

• 2.1.4 Production of Common Equipment

Production of the equipment which may be used for the second detector. It represents the costs that do not scale with the number of detectors. (Non-recurring costs)

• 2.1.5 Production of Detector#1 infrastructure

Production of the equipment which will scale with the number of detectors.

• 2.1.6 Integration and Test Facility

Operation of the ITF including logistics to receive, test, store and repackage goods including trucking and handling of return goods

• 2.1.7 Installation Underground

Underground installation operation and oversight

2.1.3 Design


• Some of the design phase needs to begin in Q3/Q4 2018

- To move the installation process design ahead enough to design the trial assembly structure at Ash River for FY19

- Early design phase and scope of the ITF to begin building facility in FY19

- Design work that involves CF information required

• Design work in FY19/FY20 would include cold box and cryogenic for ITF, APA fixtures for rotation and cabling. Shipping box designs, etc. Information required for the final design phase of the TPC

• FY21/22 Final design work

- Underground Installation

- Surface logistics & Testing

- Common Integration Facility

Infrastructure

- Common Underground

Infrastructure

- Detector Support System

2.1.4 Prod. of Common Equip


• Common Cleanroom Infrastructure

- Cleanroom

- Gantry Crane

- Cleanroom Rigging equipment

- Scissor Lifts

- Alamak/work platforms

• Common Integration Facility Infrastructure

- Office/Lunch Area

- Forklift

- Shop/tool area

- Pallet jacks

• Common Underground

Infrastructure

- CUC cable trays

- Underground storage

- Data room and Work Area

- Forklift

- Carts, pallet jacks,

conveyances

- Diagnostic equipment

2.1.5 Production of Det#1 Infra


These are all items required to

begin building Detector #1

• Install Cryogenic Piping

• Clean Cryostat-Install Floor

• Cryostat Roof

- Cable Trays

- Racks

- Rack Cooling

- AC Power

- Crossing Tubes & Flanges

• Detector Support System

- DSS components

- Survey

- Trollies

- Switchyard

- TCO Beam

2.1.7 Underground Installation


• Installation starts May 2023 with

End Wall #1

• A month long startup period of ½

speed construction APA-CPA-FC

1-2

• APA-CPA-FC 3-48 take 6

months

• APA-CPA-FC 49-50 take 1

month

• 1 month for End Wall#2

• 1 month to install instrumentation

and final testing

• 2 months to Close TCO

This is a first rough DRAFT!


I have been swamped working on making ProtoDUNE happen and have not devoted the time an effort this really requires.

I am hoping for feedback, need more help

• I have not tried to go thru all the steps in detail from Vic’s installation sequence and tried to optimize manpower levels, se have gone thru 5 different scenarios in the last 4 months

• I have used manpower cost estimates from Fermilab and School of Mines

• We have started a first pass of M&S costs for some of the tools and equipment needed but nothing has been optimized.

• I have assigned no cost to consortia effort

• There is no M&S for operation cost of disposables

Next Steps


• The WBS outline still needs

some organizational help

• It is critical over the next few

weeks/months to confirm that

any requirements we have that

impact the CF design as the

final design is starting now.

As the process moves forward

it will be close to impossible to

make any changes.

• Start the process of writing a

more detailed set of step by step

procedures so a reasonable

BOE can be written for both

manpower and M&S.

• Work directly with the different

consortia to define changes

required from the current

ProtoDUNE design to

maximize efficiency in

installation and quality for

longevity or operation

• We need to increase the

engineer detector effort as

ProtoDUNE comes to a

completion to answer critical

questions like cable routing,

electrical connections,

mechanical stability

• Do a time and motion study on

paper to check for conflicts in

gantry crane usage, staging etc.

dune installation and manpower schedule for single phase ......-repack 2 apas in box-4h • apa...

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