APA Ground Meshes Dr. Lucien Cremaldi L. Cremaldi Universiy of - PowerPoint PPT Presentation

APA Ground Meshes Dr. Lucien Cremaldi L. Cremaldi Universiy of Mississippi Dr. Don Summer APA Construction and Proposal Workshop Dr. David Sanders Fermilab, June 11, 2019 Dr. Gavin Davies (NOvA+nearDUNE) M

APA Ground Meshes Material Type Mesh Wire mm Aperture Open Weight Kg mm Area % m^2 Proposed SS 304 20x20 0.089 (3.5 mil) 1.17 84.87 0.10 Scheduling 8/1/2020 2021 2022 2023 2024 total APA 23 33 33 33 30 152 Meshes 460 660 660 660 600 3040 NSF MidScale pre-Proposal UK Vendor: US Vendors: Locker Wire Weavers Ltd. 1) Unique Wire Weaving, Hillside, NJ 1200 off part: 294-10320 @ £146.50 each 2) GKD-USA, INC. Cambridge, MD 1800 off part: 294-10314 @ £146.50 each 3) Edward J. Darby & Son, Inc. Philadelphia,PA Delivery schedule: Approx: 20-22 weeks 4) Banker Wire & Iron Works, Milwaukee, W from order (mesh will take approx. this 5) McNichols, Tampa FL long to weave) Terms: To be agreed. $190.45 per mesh 2

https://edms.cern.ch/ui/#!master/navigator/document?P:100233194:100324720:subDocs Dimensions 996mm x 1131 mm ( 39.2” x 45.6” ) 10mm x 20mm x 1.5mm tubing 3/4 “x 3/8” x 1/16” 8. TENSIONING head 1 3 3 3 4 2 3 3 3 5 mounting bracket

Assembly at Locker Wire (UK) SS frames are welded. Mesh tensioned and resistance welded. Locker Process: Tubing for frame cut and drilled outside and shipped to Locker. • Wire mesh purchased outside and shipped to Locker. • Frames welded in house. • Screens stretched and welded to frame. 2 welds on top + 1 weld on side. • Frames inspected and cleaned. (QC Manchester) • 4

welds 5

Seam Weld Stainless Steel Mesh with and PG2 Hand Piece Attachment $6-8K ?? Sunstone AC 5 KVA Welder https://sunstonewelders.com/videos/100914-ss-mesh-welds-with-ac5-kva-and-pg2/ https://sunstonewelders.com/product/5-kva-ac-spot-welder/ https://sunstonewelders.com/product/pistol-grip-single-probe-hand-piece-pg2-with-roll-spot/ 6

$16/m 7

$800/100ft $25/sqm https://www.twpinc.com/tcpdf/pdf/create.php?prod_id=3613 8

Packing & Shipping (unit=20 meshes) $30/box $300/pallet 9

Mesh Production A. Fabricate meshes in the US. Waiting for a quote from Unique Wire Weaving, Hillside, NJ. Still working on pricing, large inquiries like these take some time to get wire pricing for. I will follow up with it. Bill Bard, Unique Wire My estimate: 4m tubing (material) $60 - $100 tubing machining & welding (frame) $80 - $150 1 hr labor 1 m 2 mesh material $20 - $100 Stretch & weld mesh $80 - $150 1 hr labor $240 - $500/mesh B. Purchase 600 meshes/yr from Banker Wire (UK) at $190/mesh and ship to the US. Estimating $500 shipping per APA (20meshes) adds +$25 to mesh cost. Must be negotiated with Banker Wire(UK). $225/mesh C. Hybrid plan- 50% US meshes + 50% UK meshes. May be safest? 10

Mesh Schedule Schedule 8/1/2020 8/2021 2022 2023 2024 2025 total APA 23 33 33 33 30 152 Meshes Setup/Stockpiling 460 660 660 660 600 3040 Scenario-1 160 60/mo 60/mo 60/mo 60/mo Scenario-2 400 55/mo 55/mo 55/mo 55/mo Mesh QC • Insure outer dimension and hole ±1/2mm pattern correct – jig stands. • Frame flatness test. ±5mm • Mesh flatness test. ±1mm • Mesh tension test. < 1mm deflection ½ kG • Screen inspection. No loose ends • Wipe test of screen and tubing. Little or no residue • Anti-static cleaning vacuum or dry air • Label and bag (plastic). 11

Facilities Research wing 12

Facilities Clean Room Past Projects Clean Room • Babar CsI ECAL • CMS HCAL/Pixels • Pierre Auger Tank Liners • MICE Aerogel Ckov + Targets Lewis Hall Basement Floor Shop S t o r a g e C l e a n R o o m 1 0 0 0 0 0 L a b 350 sqft L a b 13

5 yr Budjet Package Unit cost Units Comment Total Grounding mesh $3,809 152 APAs (UK quote) $578,968 (20 meshes) (fasteners) (???) Ship to wiring centers* $240/APA 152 APAs motor freight $36,480 Technical Labor $78.85/hr 260 hours jigs + $20,500 (0.03 FTE/y) maintenance Student Labor (AY) $15/hr 1520 hours QC $22,800 (1/2 hr per mesh) (2 mo summer) Materials & Supplies* $200 QC rigs materials $1000 (clean tent) $1000 $5/APA 152 APAs QC $1520 $50/APA 152 APAs packing/skid $7600 Equipment $1000 1 anti-static vac $1000 system * new costs 14

Personnel Project Leader(s): Lucien Cremaldi/Don Summers uncosted Deputy Leader: David Sanders scientist uncosted Technical: Scot Watkins machinist <0.05 FTE + uncosted Undergrads: 1 or 2 Grad student 1 base grant request Final Comments/Risks • US Mesh more expensive than Asian markets. US fabrication costs unclear. Should we be producing prototypes? • Banker Wire (UK) may be the best option? • Best to charge Fedex Freight directly to winding centers. • Risk – Having a two mesh producers may be a safer road. • Risk - NSF or DOE base funding not straightforward. 15