ifr improvement phase ii (barrel) mechanical engineering issues
DESCRIPTION
IFR Improvement Phase II (Barrel) Mechanical Engineering Issues. H. James Krebs November 15, 2002. Scope of Work Under 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) - PowerPoint PPT PresentationTRANSCRIPT
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 $407K M&S
11/15/02 H.J. Krebs
Brass Engineering Issues• Prefer to install brass after reinstallation of
all corner plates
• Handling fixtures and installation tooling needed
11/15/02 H.J. Krebs
Engineering Responsibilities• Jim Krebs (SLAC)
– Project Management
– Brass design including installation and handling fixtures
– Installation platforms
– Miscellaneous handling fixtures• Corner plates
• Solenoid support arms
• Richard Boyce (SLAC)– RPC removal fixtures
– Replacement chamber handling and installation fixtures
11/15/02 H.J. Krebs
Engineering Responsibilities• Les Dittert (Contract)
– Earthquake design and analysis
• Knut Skarpaas VII (Contract)– Calorimeter load transfer– Calorimeter support arm handling fixture
• Nancy Yu (SLAC)– Finite element analysis
11/15/02 H.J. Krebs
11/15/02 H.J. Krebs
11/15/02 H.J. Krebs
EDIA Cost EstimateType Man Years K$/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!