Mechanical Engineering Improvements for IFR Phase II: Barrel Redesign and Issues

1. IFR Improvement Phase II(Barrel)Mechanical Engineering Issues H. James Krebs November 15, 2002 H.J. Krebs

2. 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 H.J. Krebs

3. Modifcation of Detector Loading H.J. Krebs

4. 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 H.J. Krebs

5. 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” H.J. Krebs

6. 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? H.J. Krebs

7. 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 H.J. Krebs

8. 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 H.J. Krebs

9. Layer 18, Layer 19, Corner Blocks H.J. Krebs

10. 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 H.J. Krebs

11. 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 H.J. Krebs

12. 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 H.J. Krebs

13. 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 H.J. Krebs

14. Load Transfer H.J. Krebs

15. 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 H.J. Krebs

16. 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 H.J. Krebs

17. 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 H.J. Krebs

18. 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 H.J. Krebs

19. IFR Sextants BL02 & BL03 • Similar to sextants BL00 & BL05 • Disconnect solenoid hall probe • Not necessary to remove belt chambers on fwd west end door H.J. Krebs

20. Brass H.J. Krebs

21. Alternate Materials • Interaction Lengths • Fe ~17cm • Cu ~15cm • Pb ~17.1cm • U ~10.5cm • W ~9.6cm • Pt ~8.9cm H.J. Krebs

22. Brass Design Option • Layers 3,4,6,7,9,10 equals 62 tons • Would not require EQ Committee approval • Savings of $407K M&S H.J. Krebs

23. Brass Engineering Issues • Prefer to install brass after reinstallation of all corner plates • Handling fixtures and installation tooling needed H.J. Krebs

24. 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 H.J. Krebs

25. 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 H.J. Krebs

26. H.J. Krebs

27. H.J. Krebs

28. EDIA Cost Estimate H.J. Krebs

29. Fabrication and Shop Labor • Fab & Testing • Shop Labor H.J. Krebs

30. Installation Labor H.J. Krebs

31. M&S Costs H.J. Krebs

32. Total Costs - Mechanical H.J. Krebs

33. 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! H.J. Krebs