LST Mechanical Design
Review
2004 IR-2 Installation Schedule
H.J. Krebs
October 22, 2003
October 22, 2003
H.J. Krebs
1
2004 Installation
• Scope of work is located on top & bottom
sextants
– Remove 18 layers of RPCs
– Install 6 layers of 7/8” thick brass absorber in
layers 5,7,9,11,13 & 15 – 11.5 tons/sextant
– Install LST detectors in layers
1,2,3,4,6,8,10,12,14,16,17 & 18
– An investigation will be performed at
commencement of this down to determine if
the layer 19 RPC can be retained at some
functioning level
October 22, 2003
H.J. Krebs
2
2004 Installation
• Schedules do not include any time for:
– Post and pre-run PEP survey work
• In the past, this has been 2.5 to 3 work days
– PPS certification
• In the past, this has been 4 days
– Tours and photography sessions
• In 2002, we lost two days to this
• If tours or photography sessions are important, they may
occur between midnight and 07:00
– LST commissioning
• 15 work days for bottom sextant
• 2 work days for top sextant
– Replacement of any LST detectors that have
problems after installation
October 22, 2003
H.J. Krebs
3
2004 Installation
• Flux return steel
– Side gap plates
• Have removed many times
• Very confident in schedule for these tasks
– Center gap plates
• Have never removed before
• Very confident in schedule for these tasks
– Corner plates
• Have never removed before
• Schedule times for these tasks are an educated guess
• Test removal of two corner block bolts in summer 2003
– Somewhat easy to remove
– Bolt threads appear to be in excellent condition
• An unbolting/bolting sequence needs to be developed
– Assume torquing these bolts 3 times during reinstallation
– Helicoils
• Have had trouble with these in the past
• Assume a problem with 1% of helicoils
– Means replacing two helicoils in 2004
– There is no time included in the schedule for helicoil replacement
» Probably a few hours per helicoil replacement
October 22, 2003
H.J. Krebs
4
2004 Installation
• Steel position
– Shall be monitored to assure that the barrel assembly
is stable
– Some early thoughts on this
• Dial indicators at strategic locations
• Survey targets added at strategic locations
– i.e., on mid corner blocks to see if structure is becoming egg
shaped
• Take periodic measurements
–
–
–
–
–
–
October 22, 2003
At beginning for reference
After bolts are loosened on each corner plate
At the beginning of each day
At the beginning of second shift
At the end of each day
At end for final reference
H.J. Krebs
5
2004 Installation
• RPC removal
– RPCs are “ripped” out
• HV & gas line still connected on BWD end
• Time may be lost cleaning the steel gaps of this debris
– Bottom RPCs must be ripped loose, then cut, then
pulled, then cut, etc.
• Not enough space in Z to extract in one piece
– RPCs range in weight from approximately 150
pounds for layer 1 to 250 pounds for layer 18
– 3600 sq ft of RPCs will be removed
– Cover FWD beamline and detector face for protection
October 22, 2003
H.J. Krebs
6
2004 Installation
• Where do items go during the installation process?
– Flux return steel to IR-12
– Flux return bolts
• There are approximately 232 bolts 1-1/2”-6UNC x 14” lg.
• Need to keep track of these
• Need to protect threads
– Platforms and walkways along service road to Building 611
– Main shield wall blocks along the Loop Road
– RPCs thrown out in the IR-2 parking lot
• Where do items come from during the installation
process?
–
–
–
–
–
Steel handling fixtures from IR-12
Elevator platforms from IR-12
Brass absorber plates from IR-12
LST detectors from SLD Collider Hall
Electronics and gas system from SLD Collider Hall
October 22, 2003
H.J. Krebs
7
2004 Installation
• Schedules are based on:
– Mechanical installation assumes two 8-hour shifts per
day, six days per week (3rd,6th and last week one 10hour shift) – very taxing
– LST installation assumes one 10-hour shift per day,
six days per week
• Mechanical installation team will provide support to LST team
during this period and will also work one 10-hour shift per
day, six days per week
– Wireway installation, cabling and gas hookup will be
performed on owl shift
– Installation schedules denote IFR/LST work only
• Work by other systems must be performed during owl shift
October 22, 2003
H.J. Krebs
8
Hall Crew Actual Work Time (Two 8-hour Shifts)
Days
Actual Work Time
0.05
39 minutes
0.1
1 hour 18 minutes
0.15
1 hour 57 minutes
0.2
2 hours 36 minutes
0.25
3 hours 15 minutes
0.3
3 hours 54 minutes
0.35
4 hours 33 minutes
0.4
5 hours 12 minutes
0.45
5 hours 51 minutes
0.5
6 hours 30 minutes
0.55
7 hours 9 minutes
0.6
7 hours 48 minutes
0.65
8 hours 27 minutes
0.7
9 hours 6 minutes
0.75
9 hours 45 minutes
0.8
10 hours 24 minutes
0.85
11 hours 3 minutes
0.9
11 hours 42 minutes
0.95
12 hours 21 minutes
1
13 hours
October 22, 2003
H.J. Krebs
9
Hall Crew Actual Work Time (One 10-hour Shift)
Days
Actual Work Time
0.05
23 minutes
0.1
47 minutes
0.15
1 hour 10 minutes
0.2
1 hour 33 minutes
0.25
1 hour 56 minutes
0.3
2 hours 20 minutes
0.35
2 hours 43 minutes
0.4
3 hours 6 minutes
0.45
3 hours 29 minutes
0.5
3 hours 53 minutes
0.55
4 hours 16 minutes
0.6
4 hours 39 minutes
0.65
5 hours 2 minutes
0.7
5 hours 26 minutes
0.75
5 hours 49 minutes
0.8
6 hours 12 minutes
0.85
6 hours 36 minutes
0.9
6 hours 59 minutes
0.95
7 hours 22 minutes
1
7 hours 45 hours
October 22, 2003
H.J. Krebs
10
2004 Installation Schedule
October 22, 2003
H.J. Krebs
11
Open FWD and BWD End Doors
October 22, 2003
H.J. Krebs
12
Install EQ Braces & Remove IFR Cooling Loops
Earthquaqe blocks are installed with
shims.
October 22, 2003
H.J. Krebs
Earthquaqe blocks
13
2004 Installation Schedule
October 22, 2003
H.J. Krebs
14
Install Beam Line Protection, Remove Solenoid Support Arms
Beam pipe protection
can interfere with the
man lift.
October 22, 2003
H.J. Krebs
15
2004 Installation Schedule
October 22, 2003
H.J. Krebs
16
Remove Gap Plates, Upper Corner Blocks & Upper Flux Bar
October 22, 2003
H.J. Krebs
17
Remove Lower Corner Blocks & Lower Flux Bar
Install Elevator Platform, Begin Brass Absorber and LST Installation
October 22, 2003
H.J. Krebs
18
2004 Installation Schedule
October 22, 2003
H.J. Krebs
19
2004 Installation
October 22, 2003
H.J. Krebs
20
2004 Installation Schedule
October 22, 2003
H.J. Krebs
21
2004 Installation Schedule
October 22, 2003
H.J. Krebs
22
2004 Installation Schedule
October 22, 2003
H.J. Krebs
23
2004 Installation Schedule
October 22, 2003
H.J. Krebs
24
2004 Critical Path
October 22, 2003
H.J. Krebs
25
2004 Critical Path
October 22, 2003
H.J. Krebs
26
2004 Critical Path
October 22, 2003
H.J. Krebs
27
2004 Critical Path
October 22, 2003
H.J. Krebs
28
2004 Critical Path
October 22, 2003
H.J. Krebs
29
Conclusions and Comments
• 10 weeks of scheduled work time is needed to replace RPCs with 6
layers of brass absorber and 12 layers of LST detectors in both the
top and bottom sextants if NOTHING goes wrong
– Additional 4 days of PPS certification almost a certainty
– Some time lost for tours and/or photography is a probability
– No time allotted to replace LSTs that are not functioning properly after
installation – overly optimistic
– 17 days allotted for commissioning of lower sextant LSTs but only 2
days are allotted for commissioning of upper sextant LSTs
– Many tasks have NEVER been performed previously – could be a long
learning curve
– Will lose 1:1 on schedule time for any of the above
• There may be some schedule optimization possible – but not much.
From the critical path it is determined that the schedule is:
– Driven by crane usage – 1 crane
– Driven by LST installation – 1 installation team
– Most everyone is working in the same place – FWD end of barrel
October 22, 2003
H.J. Krebs
30
Conclusions and Comments
• Our mechanical installation team is aging
– Have some young replacements but not as experienced
• A mechanical breakdown of the crane would have an
adverse schedule effect
• An agreement must be worked out to deal with the
VESDA system during this installation period
– Have experienced significant schedule delays in the past by us
setting off the fire alarms
• A two month down would result in a reduced scope of
work
– Only one sextant could have the brass absorber/LST
replacement, or
– Remove RPCs and replace with brass in both sextants but NO
LST installation (just an opinion), or
– Some other option
• Our goal is to be ready as early as possible to take
advantage of any potential schedule advancement.
October 22, 2003
H.J. Krebs
31