Dune Installation and Manpower Schedule for Single Phase Detector - - PowerPoint PPT Presentation

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Dune Installation and Manpower Schedule for Single Phase Detector - - PowerPoint PPT Presentation

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Dune Installation and Manpower Schedule for Single Phase Detector William Miller University of Minnesota 28-March, 2018 Overview ProtoDUNE Installation Schedule - APA - CPA Schedule Assumptions and Overview - When do we need to start?

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SLIDE 1

William Miller University of Minnesota 28-March, 2018

Dune Installation and Manpower Schedule for Single Phase Detector

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SLIDE 2

Overview

  • ProtoDUNE Installation Schedule
  • APA
  • CPA
  • Schedule Assumptions and Overview
  • When do we need to start?
  • Mechanical Tests at Ash River
  • Integration and Testing Facility
  • Single Phase Installation and Manpower Schedule
  • Summary and Comments
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SLIDE 3

ProtoDUNE

28-March-18 William Miller | Dune Installation Schedule 3

While this is certainly a prototype and installation times are much longer, there are design modifications required in decrease installation times

  • TPC component delivery schedule
  • Numerous adjustments were made

to the installation schedule while waiting for parts

  • Safety Approval and

Documentation

  • This task took many man-weeks of

effort, safety approval took even longer

The first drift volume in DUNE

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SLIDE 4

ProtoDUNE APA: ~100 hrs 2-5 FTEs

28-March-18 William Miller | Dune Installation Schedule 4

  • Opening up the APA shipping

crate, load test on the yoke and mounting the lifting fixture took ~10 hours with 4-5 FTEs plus 3 CERN riggers

  • Clearly new design of box and

lifting fixture required

  • Picking up the APA, rotating it

into a vertical position, lowering into the SAS and transferring the load to the Transport beam ~3 hours 3 FTEs plus 4-5 CERN Riggers ~13 hours 3-5 FTEs & Riggers

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SLIDE 5

ProtoDUNE APA-Cleanroom

28-March-18 William Miller | Dune Installation Schedule 5

  • Install cable trays and remove protection- ~2

hours 2 FTEs

  • Vibration, Inspection and Photogrammetry- ~10

hours 1 FTE

  • Install protection- ~1 hour 2 FTEs
  • Cold Electronics- ~20 hours 2 FTEs
  • ~8 hours 2 FTEs pre-boards and test
  • ~8 hours 2 FTEs install & test on APA
  • ~4 hours 2 FTEs to dress cables
  • PD Installation- ~32 hours 2-4 FTEs
  • ~16 hours 2 FTEs Test PD in test box
  • ~8 hours 4 FTEs Insert PDs
  • ~8 hours 2 FTEs to cable, test and dress
  • Remove protection- ~1 hour 2 FTEs

~65 hours 2-4 FTEs

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SLIDE 6

ProtoDUNE APA-Cold Box

28-March-18 William Miller | Dune Installation Schedule 6

This work or similar would happen at the ITF

  • Open Cold Box- ~2-3 hours 2 FTEs

& 2 CERN crane operators

  • Attach transport beam to Cold box

beam-1 hour 2 FTEs

  • Roll APA into Cold Box and

disconnect Beam- 1 hour 2 FTEs

  • Feed cables in Feed Through- 1

hour 4 FTEs -2 man-lifts

  • Cable to electronics ~3 hours 2

FTEs

  • Close Cold Box- ~2-3 hours 2 FTEs

& 2 CERN crane operators ~ 11 hours 2-3 FTEs

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SLIDE 7

ProtoDUNE APA- Into cryostat

28-March-18 William Miller | Dune Installation Schedule 7

  • Open cold box- ~2-3 hours 2

FTEs & 2 CERN crane operators

  • Disconnect cables from

electronics and secure cables- ~2 hours 4 FTEs

  • Connect transport beam to Cold

Box- 1 hour 2 FTEs

  • Move into cleanroom, replace

bad electronics and re-test- 2-8 Hours 2 FTEs

  • Attach transport beam to TCO

beam- 1 hour 2 FTEs

  • Move APA into cryostat- 1 hour

4 FTEs ~9-13 hours 2-4 FTEs

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SLIDE 8

ProtoDUNE- CPA/FC: ~30 hrs

28-March-18 William Miller | Dune Installation Schedule 8

  • Unpack, bolt together, add field

shaping strips, test and hang single CPA- ~6 hours 3 FTEs

  • Unpack second CPA and join with

first to make a pair- ~6 hours 3 FTEs

  • Lower 2 top field cages, inspect,

test and install on CPA pair- ~8 hours 3-4 FTEs plus 3 CERN Crane

  • perators ~ 6 hours
  • Lower 2 bottom field cages,

inspect, test and install on CPA pair- ~8 hours 3-4 FTEs plus 3 CERN Crane operators ~ 6 hours

  • Attach transport beam to TCO

beam and move into cryostat- 4 FTEs ~2 hours

First completed CPA-FC assembly

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SLIDE 9

Comparing ProtoDUNE to DUNE

28-March-18 William Miller | Dune Installation Schedule 9

  • The times shown for

ProtoDUNE are linear many because of space constraints in the 109sq. M cleanroom

  • In DUNE we are moving the

PD installation and CE board installation to the ITF. APA and CPA are done in parallel. Need 3 APA stations. Cables will be done underground.

  • ProtoDUNE
  • APA: 98 Hours
  • CPA: 30 CPA
  • DUNE-12m 3 APA & 2 CPA
  • ITF-APA ~30h
  • Unpack-Hang Vertical-4h
  • Install PDs and Test-8h
  • Install CEs and Test-8h
  • Cold box-In and Out-4h
  • Repack 2 APAs in Box-4h
  • APA Underground-Vic Est. ~24h
  • 24 hours (3 ten hr shifts) to unpack,

rotate into position, bolt together, cable and test

  • CPA Underground-Vic’s Est.
  • 8 hours (1 ten hr. shifts) to unpack,

rotate 6 CPA pieces, bolt together, add Top and Bottom Field cages, make all electrical connections

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SLIDE 10

Installation Schedule Overview

28-March-18 William Miller | Dune Installation Schedule 10

Beneficial Occupancy of the first Cryostat in the end of December 2022

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SLIDE 11

The Basic Logistic Concept

28-March-18 William Miller | Dune Installation Schedule 11

  • ~ 1 week buffer of TPC components underground and ~1

month at ITF

  • Access underground controlled by SDSTA, slung loads take

~66 min, regular cage loads ~17 minutes. Personnel trips max 30 people ~15 minutes

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SLIDE 12

Schedule Assumptions

28-March-18 William Miller | Dune Installation Schedule 12

  • Lessons learned from

ProtoDUNE point out there are numerous design modifications required to reduce installation time for SP DUNE detector

  • The weekly installation

schedule assumes:

  • We can install three APAs pairs

(2 vertically stacked)

  • Two 12m CPA/FC assembly
  • Move them into the cryostat,

deploy Field Cages and run APAs cables into feed-thru

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SLIDE 13

28-March-18 William Miller | Dune Installation Schedule 13

  • Working two 10 hour shifts/4

days per week. Friday would be schedule contingency

  • 2 APAs install/day so there is not

time to install PD and CE underground, cables must be installed underground

  • Shipping box design must be

light weight, reusable, meet cage design criterial and able to make cage rotation

  • ~ 1 week buffer of TPC

components underground and ~1 month at ITF

  • Access underground controlled

by SDSTA

Installation Assumptions

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SLIDE 14

What happens before B.O.?

28-March-18 William Miller | Dune Installation Schedule 14

  • Design-Complete installation concept so engineered design can

begin for TCP components and ITF concept

  • Mechanical tests at Ash River to confirm that modifications will

work

  • Test pre-production APA, CE & PD at CERN in cold box
  • Commission Integration and Testing Facility
  • Begin testing of first TPC components

FY18 FY19 FY20 FY21 FY22 Q3 Q4 Q1 Q2 Q3 Q4 Q1 Q2 Q3 Q4 Q1 Q2 Q3 Q4 Q1 Q2 Q3 Q4 Design Mechanical Pre-Production Commission ITF Testing ITF

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SLIDE 15

DUNE Trial Assembly at Ash R

28-March-18 William Miller | Dune Installation Schedule 15

  • NOvA Far detector assembly

area is 16.75m deep from the loading bay with a hook height of 6.1m on the crane

  • The open loading bay area

is 21m x 21m if needed

  • Two 10-ton overhead

cranes, tools, fork lifts, small machine shop, etc. available

  • Experienced crew that

helped build ProtoDUNE staffed at Ash River

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SLIDE 16

28-March-18 William Miller | Dune Installation Schedule 16

Dune Assembly Prototype Area 17m

Glue machine will be removed If needed NOvA access scissor lifts can be removed to increase width ~20m

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SLIDE 17

28-March-18 William Miller | Dune Installation Schedule 17

Dune Assembly Prototype Area

16.75m

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SLIDE 18

28-March-18 William Miller | Dune Installation Schedule 18

View looking North from NOvA assembly area to loading dock

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SLIDE 19

Schedule for ITF: Pre-B.O.

28-March-18 William Miller | Dune Installation Schedule 19

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SLIDE 20

ITF Cold Test Assumptions

28-March-18 William Miller | Dune Installation Schedule 20

  • We need to cold test 6

APAs/week during the full speed assembly of the Far Detector

  • This requires ~6 cold boxes with

a cryogenic system

  • It takes ~1 week to install, PD,

CE and about ~1 week for the cold test

  • This number can be reduced if a

large number of the APAs are tested longer before assembly begins and there is enough space for a storage buffer

Building would need to be about 10-12,000 sq. ft. with an overhead crane with 8m hook clearance Need to better define tasks/tests to estimate FTE requirements

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SLIDE 21

Underground Installation Schedule

  • Current installation schedule

is based on a top down estimate to fit between the beneficial occupancy's of the first and second caverns.

  • Time and motion studies from

the ProtoDUNE point to many potential engineered solutions that can help reduce both the manpower and schedule, but schedule is extremely aggressive

  • Shipping box design is critical
  • DUNE crew does all the

rigging, box moving &

  • pening and moving TPC

components in the cryostat

  • The different consortia do all

the cabling, testing and commissioning

  • First estimate is roughly 20

FTE DUNE crew, 30 FTE consortortia

  • Small ramp-up and ramp-

down installation

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SLIDE 22

Underground Installation Phases

28-March-18 William Miller | Dune Installation Schedule 22

There are five major phases of the installation

  • 2.1.3 Design

This is the design effort needed between the review of the TDR and the start of the production

  • f the SP-TC infrastructure

necessary for detector installation.

  • 2.1.4 Production of Common

Equipment

Production of the equipment which may be used for the second detector. It represents the costs that do not scale with the number of detectors. (Non- recurring costs)

  • 2.1.5 Production of Detector#1

infrastructure

Production of the equipment which will scale with the number of detectors.

  • 2.1.6 Integration and Test

Facility

Operation of the ITF including logistics to receive, test, store and repackage goods including trucking and handling of return goods

  • 2.1.7 Installation Underground

Underground installation

  • peration and oversight
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SLIDE 23

2.1.3 Design

28-March-18 William Miller | Dune Installation Schedule 23

  • Some of the design phase needs

to begin in Q3/Q4 2018

  • To move the installation process

design ahead enough to design the trial assembly structure at Ash River for FY19

  • Early design phase and scope of

the ITF to begin building facility in FY19

  • Design work that involves CF

information required

  • Design work in FY19/FY20 would

include cold box and cryogenic for ITF, APA fixtures for rotation and cabling. Shipping box designs, etc. Information required for the final design phase of the TPC

  • FY21/22 Final design work
  • Underground Installation
  • Surface logistics & Testing
  • Common Integration Facility

Infrastructure

  • Common Underground

Infrastructure

  • Detector Support System
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SLIDE 24

2.1.4 Prod. of Common Equip

28-March-18 William Miller | Dune Installation Schedule 24

  • Common Cleanroom

Infrastructure

  • Cleanroom
  • Gantry Crane
  • Cleanroom Rigging equipment
  • Scissor Lifts
  • Alamak/work platforms
  • Common Integration Facility

Infrastructure

  • Office/Lunch Area
  • Forklift
  • Shop/tool area
  • Pallet jacks
  • Common Underground

Infrastructure

  • CUC cable trays
  • Underground storage
  • Data room and Work Area
  • Forklift
  • Carts, pallet jacks,

conveyances

  • Diagnostic equipment
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SLIDE 25

2.1.5 Production of Det#1 Infra

28-March-18 William Miller | Dune Installation Schedule 25

These are all items required to begin building Detector #1

  • Install Cryogenic Piping
  • Clean Cryostat-Install Floor
  • Cryostat Roof
  • Cable Trays
  • Racks
  • Rack Cooling
  • AC Power
  • Crossing Tubes & Flanges
  • Detector Support System
  • DSS components
  • Survey
  • Trollies
  • Switchyard
  • TCO Beam
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SLIDE 26

2.1.7 Underground Installation

28-March-18 William Miller | Dune Installation Schedule 26

  • Installation starts May 2023 with

End Wall #1

  • A month long startup period of ½

speed construction APA-CPA-FC 1-2

  • APA-CPA-FC 3-48 take 6

months

  • APA-CPA-FC 49-50 take 1

month

  • 1 month for End Wall#2
  • 1 month to install instrumentation

and final testing

  • 2 months to Close TCO
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SLIDE 27

This is a first rough DRAFT!

28-March-18 William Miller | Dune Installation Schedule 27

I have been swamped working on making ProtoDUNE happen and have not devoted the time an effort this really requires. I am hoping for feedback, need more help

  • I have not tried to go thru all

the steps in detail from Vic’s installation sequence and tried to optimize manpower levels, se have gone thru 5 different scenarios in the last 4 months

  • I have used manpower cost

estimates from Fermilab and School of Mines

  • We have started a first pass
  • f M&S costs for some of the

tools and equipment needed but nothing has been

  • ptimized.
  • I have assigned no cost to

consortia effort

  • There is no M&S for
  • peration cost of disposables
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SLIDE 28

Next Steps

28-March-18 William Miller | Dune Installation Schedule 28

  • The WBS outline still needs

some organizational help

  • It is critical over the next few

weeks/months to confirm that any requirements we have that impact the CF design as the final design is starting now. As the process moves forward it will be close to impossible to make any changes.

  • Start the process of writing a

more detailed set of step by step procedures so a reasonable BOE can be written for both manpower and M&S.

  • Work directly with the different

consortia to define changes required from the current ProtoDUNE design to maximize efficiency in installation and quality for longevity or operation

  • We need to increase the

engineer detector effort as ProtoDUNE comes to a completion to answer critical questions like cable routing, electrical connections, mechanical stability

  • Do a time and motion study on

paper to check for conflicts in gantry crane usage, staging etc.