Transcript LST Installation Readiness Review Mechanical Installation Preparation H. James Krebs May 5, 2004 May 5, 2004 H.J.

LST Installation Readiness
Review
Mechanical Installation Preparation
H. James Krebs
May 5, 2004
May 5, 2004
H.J. Krebs
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Mechanical Installation Preparation
• IR-12 is the location of most mechanical
preparation work during 2004 & 2005
• Why IR-12?
– IR-12 Hall is very similar to IR-2 Hall
• Same floor plan
• Identical 50/10 ton crane combination
– We need space
• IR-12 was empty
• IR-2 is presently occupied with BaBar related items
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IR-2
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IR-12 - Before
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IR-12 Today
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IR-12 Activities
• Pre-installation preparation of brass plates
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Radius corners
Drill & tap threaded holes for slide swivel shackles
Camber plates as needed
Stage plates for assembly
• BaBar model
– Build a fairly crude but full scale mock-up of the
forward end of BaBar including:
• Barrel assembly simulating corner blocks removed
• FWD end doors
• FWD PEP pier
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Full Scale BaBar Model
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12” Thick (Z) Sextant Prototype
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Sextant Iron Cable Channel
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IR-12 Activities
• Purpose of Model
– Construct elevator platform
• Test function
• Check for interferences with end doors, beamline and PEP
pier
• Load test
• Modify as necessary for corrections or improvements
– Brass installation preparation
• Test installation hardware
• Practice brass plate installation
• Brass push test
– LST detector installation preparation
• Test installation hardware
• Practice LST detector installation
– A full length XZ gap (layer 8) model is being constructed for this
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IR-12 Activities
• Steel handling fixtures
– Train technical support staff
– Check centers of gravity
– Determine appropriate rigging
– Load test
– Function test, if possible
– Modify as needed
– Perform a field job hazards analysis
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Elevator Platform
• Due to SLAC internal problems, the
purchase req for the elevator platform was
issued two months later than planned.
– Expect upper elevator components beginning
of June
– Expect lower elevator components mid June
– Still enough time to erect, test and modify
these platforms
• Very little schedule float remains on these items
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RPC Pulling Clamps
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Brass Handling Fixtures
• Brass positioners
– Purpose
• Adjusts the orientation of the brass absorber plates to align
with openings in the flux return steel. The positioners for the
lower sextant are different than those for the upper sextant.
– Needed 2004
– Responsible person
• Allen Constable
– Status
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Design and drawings are complete
Fabrication of upper positioners complete
Fabrication of lower positioners in process
Need to function test using BaBar mock up
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Upper Brass Positioners
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Upper Brass Positioners
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Brass Handling Fixtures
• Brass plate pushers
– Purpose
• To push the brass absorber plates into the gaps in
the steel flux return.
– Needed 2004, 2005
– Responsible person
• Jim Krebs
– Status
• Design and drawings are complete
• Fabrication is nearing completion
• Need to function test using full length XZ gap mock
up
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Brass Plate Pushers
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24” Brass Plate Pusher
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Brass Pull Test
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Brass Pull Test (315.3 lb Plate)
Description
lb Force to
Overcome
Static
Friction
µs
Brass plate sliding on painted steel plate
>100
>.31
Brass plate sliding on 1” wide stn stl bars
58
.18
Brass plate sliding on dry lubricated 1” wide stn stl bars
39
.12
Brass plate with chrome plated binder head screws
sliding on painted steel plate
60
.20
Brass plate sliding on dry lubricated 1” wide stn stl bars
with 1” of sag dragging on painted steel plate
47
.15
Brass plate with teflon pads sliding on painted steel pl.
47
.15
Brass plate with nylon binder head screws sliding on
painted steel plate
63
.20
Brass plate with stn stl hex head screws sliding on
painted steel plate
47
.15
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Steel Handling Fixtures
• Side Gap Plate Fixture
– Purpose
• Remove and reinstall the side gap plates on the FWD and
BWD ends to enable removal of RPCs, installation of brass
absorber plates and LSTs, and access to RPC electronics
– Needed 2004, 2005
– Responsible person
• Jim Krebs
– Status
• Fabrication complete
• CG tested in unloaded and loaded conditions (have used
many times in the past)
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Side Gap Plate Fixture
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Side Gap Plate Fixture
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Steel Handling Fixtures
• Center Gap Plate Fixture
– Purpose
• Remove and reinstall the upper and lower center gap plates
on the FWD end to enable removal of RPCs and installation
of brass absorber plates and LSTs
– Needed 2004
– Responsible person
• Jim Krebs
– Status
• Fabrication complete
• CG tested in unloaded condition
• Rigging procedure and job hazards analysis written and
reviewed
• Load tested to 168% of design load
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Center Gap Plate Fixture
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Center Gap Plate Fixture
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Center Gap Plate Load Test
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Center Gap Plate Load Test
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Center Gap Plate Load Test
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Steel handling Fixtures
• Solenoid Support Arm Fixture
– Purpose
• Remove and reinstall the upper and lower solenoid support
arms on the FWD end used to react axial loads. This will
enable removal of the upper and lower FWD corner blocks.
– Needed
• 2004, 2005
– Responsible person
• Jim Krebs
– Status
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Design and drawings complete
Fabrication complete
CG tested in unloaded condition
Rigging procedure and job hazards analysis written and
reviewed
• Load tested to 236% of design load
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Solenoid Support Arm Fixture
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Solenoid Support Arm Fixture
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Solenoid Supt Arm Load Test
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Steel Handling Fixtures
• Corner Block Adaptors
– Purpose
• Moves corner block rigging connection in Z direction to more
convenient location. There are two basic adaptors
corresponding to the mid & lower corner blocks and right and
left hand units to correspond with east and west.
– Needed
• 2004 (lower), 2005 (mid & lower)
– Responsible person
• Jim Krebs
– Status
• Design and drawings complete for lower adaptor
• Fabrication complete
• Load tested to 139%
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Lower Corner Block Adaptor
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Lower Corner Block Adaptor
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Steel Handling Fixtures
• Adaptor Installation Fixture
– Purpose
• Used to install and remove the adaptors on the mid & lower
corner blocks.
– Needed
• 2004, 2005
– Responsible person
• Jim Krebs
– Status
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Design and drawings complete
Fabrication complete
CG tested in unloaded and loaded conditions
Rigging procedure and job hazards analysis written and
reviewed
• Load testing believed to be unnecessary
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Adaptor Installation Fixture
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Steel Handling Fixtures
• FWD Lower Corner Block Fixture
– Purpose
• Supports the FWD lower corner block dead load from crane
during removal and reinstallation process.
– Needed
• 2004, 2005
– Responsible person
• Jim Krebs
– Status
•
•
•
•
Design and drawings complete
Fabrication complete
CG tested in unloaded condition
Rigging procedures and job hazards analysis have been
written and reviewed
• Load tested to 129% of design load
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FWD Lower Corner Block Fixture
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FWD Lower Corner Block fixture
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Lwr Crnr Blk Fixture Load Test
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Steel handling Fixtures
• BWD Lower Corner Block Fixture
– Purpose
• Supports the BWD lower corner block dead load
from crane during removal and reinstallation
process.
– Needed
• 2004, 2005?
– Responsible person
• Richard Boyce
– Status
• Design is in process
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Steel handling Fixtures
• FWD Upper Corner Block Fixture
– Purpose
• Supports the FWD upper corner block dead load from crane
during removal and reinstallation process.
– Needed
• 2004, 2005
– Responsible person
• Jim Krebs
– Status
•
•
•
•
Design and drawings complete
Fabrication complete
CG tested in unloaded condition
Rigging procedures and job hazards analysis have been
written and reviewed
• Load tested to 132% of design load
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FWD Upper Corner Block Fixture
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FWD Upper Corner Block Fixture
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FWD Upr Crnr Blk Load Test
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Steel Handling Fixtures
• Corner Block Bolt Storage Bins
– Purpose
• Stores corner block bolts and organizes bolts to reinstall
them in their original locations. Six storage bins will be
fabricated.
– Comments
• A written torquing sequence and torquing procedure is in
process
– Needed
• 2004, 2005
– Responsible person
• Jim Krebs
– Status
• Design and drawings complete
• Fabrication complete
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Corner Block Bolt Storage Bins
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Corner Block Bolt Storage Bins
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Steel Handling Fixtures
• Corner Block Receptacle & Lift Eye
– Purpose
• Supports corner block vertically to release C-Hook and to lift
corner block and load on truck using conventional rigging.
– Needed
• 2004, 2005
– Responsible person
• Jim Krebs
– Status
• Design and drawings are complete
• Fabrication Complete
• Lift eye load tested to 139% of design load
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Corner Block Receptacle - Lower
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Corner Block Receptacle - Mid
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Corner Block Receptacle - Upper
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Corner Block Receptacle
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Corner Block lift Eye
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Corner Block Lift Eyes
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Corner Block Lift Eye Load Test
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Steel Handling Fixtures
• Flux Bar Handling Fixture
– Purpose
• Used to remove and reinstall the flux bars that are located
behind the corner blocks. The flux bars must be removed to
access layer 18.
– Needed
• 2004 (top & bottom), 2005 (sides)
– Responsible person
• Jim Krebs
– Status
• Design and drawings are complete
• Fabrication is complete
• CG tested in unloaded conditionRigging procedure and job
hazards analysis have been written and reviewed
• Load tested to 132% of design load
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Steel Handling Fixtures
• Flux Bar Handling Fixture (Cont’d)
– Issue
• There are no accessible threaded holes on the flux
bar to enable bolting up of rigging equipment
– Solution
• The corner block bolts protrude through the flux
bar. When these bolts are removed, the clearance
holes may be tapped in the field. The metric size
of these holes matches the tap drill size of a
1-13/16UN special thread.
– Status
• Special taps are in house
• Special bolts have been designed and fabricated
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Flux Bar Tapping Tests
• Test material used was a left over sample of the BaBar
flux return steel 100mm in thickness.
• The tests were performed using the crudest of tools and
incompetent personnel (me)
• Test1
– Hole was initially tapped using a 1.75-12UN tap and then the
threads chased with a 1.812-12UN tap. This process was very
easy.
• Test 2
– Hole tapped only with 1.812UN tap. This was sightly more
difficult but still fairly easy.
• Comments
– A special tap handle will need to be designed and fabricated –
fairly easy.
– Effort will be needed to control cutting fuid and metal chips
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Flux Bar Tapping Test
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Flux Bar Fixture
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Flux Bar Fixture Unloaded CG Test
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Flux Bar Fixture Load Test
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Steel Handling Fixtures
• FWD End Plug Spreader Bar
– Purpose
• This spreader bar will be used in 2005 to remove
the FWD end plug form the FWD end doors. It is
also used in 2004 in conjunction with fixtures to
remove and reinstall the FWD lower center gap
plate and the FWD lower flux bar.
– Responsible person
• Jim Krebs
– Status
• Design and drawings are complete
• Fabrication is complete
• Load tested to 131% of end plug load
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FWD End Plug Spreader Bar
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End Plug Spreader Load Test
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IFR Background Shield Wall
• A non-LST item but is installed by the same crew
during the down
• Wall is in final stages of assembly
– Only two lift eyes need to be installed
• Main support structure components are
fabricated and in-house
• Earthquake restraints are fabricated and inhouse
• The shield “snout” is fully assembled
• The ceiling bracket installation beam is in the
final stage of fabrication
• One ceiling bracket needs a minor modification
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IFR Background Shield Wall
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Shield Wall “Snout”
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Shield Wall Structural Supports
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Shield Wall Earthquake Restraints
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Comments
• The full scale model will be a valuable tool for installation
preparation
– Earthquake bracing is being fabricated
– EQ committee approval received mid April
– Construction of model shall be complete by end of May
• All support personnel will be trained using actual hardware
• Elevator platform will be tested to assure fit function and safe
operation
• Brass absorber will be prepared and staged for installation
• Brass installation hardware is in final stages of fabrication
• Only one steel handling fixture remains to be fabricated
– BWD lower corner block fixture
• All major mechanical installation components are either in house or
on order
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Potential Risks
• The elevator platform may not arrive in
time to adequately test and make any
necessary modifications
– We believe we there is adequate time
– We can “wing it” on the lower sextant
– Absolutely need the elevator platform for the
upper sextant
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