EBD existing crane details and future bridge crane upgrade

Alev IbrahimovJune 3 2015

EBD existing crane details

Drawing view from the South side

BEAM

Single crane rail 40’ EBD Housing End

In Electron Beam Dump (EBD) housing there are single rail cranes on the North and the South side. Every rail starts with a short piece and finishes with short piece assumable 20.5’ each . The middle section is a long rail assumable 41’ long. Both cranes have lifting capacity of 10000Lb. The South crane has anchored fixture for crane certification, but the North one doesn’t and it never been certified. Drawing ID 383-930-51 shows single crane rail installation as built. The crane rail is shown as a single section rail 40’ long. The exact length needs to be verified.

EBD existing crane details

The two crane rails are parallel. Distance between rails- 98.5”. Distance from South and North walls to the South and North rail center is 39-1/4”

Drawing view downstream

Single crane rails 98.5” apart

EBD Housing 177”W X 150”H

EBD existing pit area details

EBD pit area details with beam pipe and shielding. Top shield plate is about 79” from the crane rail bottom surface

Drawing view North

Single crane rails 41’ long according to the drawing

SHIELDINGHOIST TRAVEL 40’ according to the drawing

BEAM PIPE EAST WALL

BEAM

EBD existing pit area details

EBD pit area looking downstream (East)

Drawing view downstream

DISTANCE FROM WALLS

SHIELDING

DISTANCE BETWEEN RAILS

BEAM PIPE NORTH

EAST WALL

BEAM

EBD existing cranes rail profile

LIGHT RAIL #34011 (UNIFIED INDUSTRIES)

EBD existing crane rails alignment

Latest input (June 5 2015) from alignment suggesting starting point for the cranes is 693.724m and end point 718.771m. This is 25.047m or about 82’ .Start point is right after PCPM1L and BTN1L (692.72m) and end after the dump face (715.93m).

Actual crane rails are twice longer than drawing shows.

EBD existing crane rails

Parallelism of the two rails for South and North cranes were measured from alignment group in order to explore the option of installing trolley and converting these two single rail cranes to one bridge crane. Without being a crane specialist we can conclude by looking at the measurement results that this upgrade is possible. Alignment group data shown on next slide.

BYD magnets Actual crane rails Shielding East wallWest wall

EBD existing crane rails alignment Results from rails alignment measurement done on May 27 2015

South Rail 2.4207 Average North X (meters)Z (m) X (m) Y (m)

S1A 6.0812 0.0007 -0.0081 dX (m)S1B 11.3830 -0.0012 -0.0006 N1A 0.0015S2A 11.9085 -0.0007 -0.0002 N1B -0.0019S2B 17.8173 0.0022 0.0007 N2A -0.0047S2C 20.5142 -0.0015 -0.0005 N2B 0.0025S3A 21.0751 -0.0001 -0.0018 N2C -0.0002S3B 28.3259 -0.0016 -0.0168 N3A 0.0025

N3B 0.0003North Rail

Z (m) X (m) Y (m)N1A 4.3791 2.4222 -0.0044N1B 11.4739 2.4187 -0.0012N2A 11.8972 2.4160 -0.0030N2B 15.1259 2.4232 -0.0017N2C 20.5932 2.4204 0.0005N3A 21.0704 2.4232 -0.0003N3B 28.4835 2.4209 -0.0039

Notes:

1) Each rail (North and South) is made up of 3 rails. A long ceter rail (number 2) with a short beginning rail (number 1) and short end rail (number 3).

2) Measured 2 points (A and B) on each short rail and 3 points (A, B and C) on each long rail.

3) Measurements where taken on the bottom inside edge of each rail.

4) Average distance between the center of North and South rails is 2.4207 m + 3.25 in (bottom web width) = 2.5032 m.

5) Above coordinate system is based on the center South rail.

EBD existing crane rails

South beam line

North beam line

Shieldingabout 408 tonne combined

Heaviest single objectbetween 5 and 6 tonne (depend of final slug shielding design)

Rail distance from the wallsTop View

EBD upgrade to bridge craneWhy upgrade to a bridge crane:

- Cover the area between both beam lines;- Access area between rails and North/South walls – possibility and how much to be

verified with supplier;- More lifting capacity between rails – number to be verified with supplier;

Considerations:

- Cost of the upgrade;- Time for installation;- Remote control similar to cranes in BSY or manual cranes?;- How much will travel reduction with bridge upgrade ?;- How much will travel reduction in vertical direction ?;- Can we extend travel on the west side and cover BYD magnets?;- Is top plate can be installed with the upgraded crane (distance from rails to top plates

79”);- Do we need construction upgrade?;- Do we need power upgrade?;- Who will update the drawings for the area ?;

EBD upgrade to bridge crane ; continued

Existing crane rails shown in red

EBD upgrade to bridge crane ; continued

EXISTING EBD TUNNEL CROSS SECTION

VIEW FROM WEST TO EAST

EBD crane upgrade to bridge crane ; continued

Crane upgrade requirements:- Single hoist rail;- Capacity – 6t Min;- Dim “A” – 10” Min;- Dim “B” – 160” Min;- Dim “C” – 118” Min

Existing rails

Ceiling

EBD crane upgrade to bridge crane ; continued

Crane upgrade requirementscontinue:- Dim “D” – 920” min;- Dim “E” – 30” Max;

Why upgrade existing EBD crane- Existing crane is built to service beam line which is parallel to the crane rail and

located approximately under the rail;- Existing singe shielding is all inside the South pit. Shielding total weight is about

57 tonne.;- Existing shielding was put in the pit with forklift when there was no East wall in

the housing and noting on the North side;- New dump will have two similar beam lines on the North and south side and very

limited space between them and no forklift access;- New beam lines after the BYD magnets are not parallel to each other and to the

existing crane rails. Existing crane will cover very limited service area;- New shielding is much larger than the existing one – in magnitude more than 7.

Average single shielding plate weight is about 2 tonne. Over 200 shielding components;

- Single lifting object, dump slug with shielding coffin required by RP, is more than 5 tonne;

- In the area covered by the crane there will be much more installed devices than now;

- Installing all shielding's and devices with crane will be much faster and safer than doing this by hand;

- Entire EBD dump area will be modified and crane modification will be part of this process;

Jim Healy; can the upgrade handle this weight?

Jim Healy:Suggest: “Installing shielding and devices by crane will be safer, reduce potential damage, and maintain the project’s aggressive schedule”.

Why upgrade existing EBD crane; continued

Existing rails

Floor level

Housing walls Pit level

New beam lines

New shielding

Heaviest object

Why upgrade existing EBD crane ; continued

Existing cranes coverage area

Upgrade crane coverage area

Back up slides with crane pictures

Back up slides with crane pictures

Back up slides with crane pictures

Back up slides with crane pictures

Back up slides with crane pictures

Back up slides with crane pictures