Mu2e Remote Handling Shield Door, Air Seal, and Transfer Cart Design - - PowerPoint PPT Presentation

Mu2e Remote Handling Shield Door, Air Seal, and Transfer Cart Design Status

Dave Pushka

Mu2e Target, Remote Handling, and Heat & Radiation Shield Review November 16-18, 2015

Items Addressed in this Talk:

• Shield Door between the Remote Handling Room and the PS

enclosure.

• Air Seal between the Remote Handling Room and the PS

enclosure.

– Air Seal is part of the shield door assembly.

• Transport Cart Used to Move the Modules into and out of the

Remote Handling Room and the PS enclosure

Nov 16-18, 2015 Dave Pushka | Shield Door, Air Seal, and Transfer Cart Design 2

Second Draft of Requirements for the Mu2e Remote Handling Room Shield Door and Air Seal

1. Cover an opening 19 feet wide, 13 feet tall, with at least a 6 inch overlap on the top and both sides when closed. 2. Provide shielding equivalent to 2 feet of conventional concrete (150 pound per cubic foot density) 3. Conform to the room and opening geometry as described in Mu2e document 5490v-2 (the In-progress Rev 6 drawings). 4. Open or close Shield Door (not air seal) in less than 10 minutes 5. Air seal to be replaceable within one 8 hour shift (Sealing door time < ½ hour) 6. Provide sealing against airflow between the remote handling room and the PS room when

• closed. Permissible Air leak rate is 130 cfm (this is estimated to be a 1/32 inch wide gap all the way

around the door. Static differential is 0.1 inch water column. Leakage budget for the entire room is 310

• cfm. (note – air seal does not need to be perfect)

7. Air seal on the remote handling room side to facilitate replacement when door is closed. 8. Meet the international building code seismic requirements for the Fermilab site. 9. Locate as much of the moving apparatus on the remote handling room side of the door as is possible.

• 10. Provide loads to the building due to the door to Tom Lackowski, building will be designed to accommodate

the shielding door loads.

• 11. Door will be installed after beneficial occupancy.
• 12. Building dimensions may preclude bringing the entire door in as a single piece. Door may need to be

assembled in place from smaller components.

• 13. Door to accommodate the remote handling cable conveyer system.
• 14. Door to accommodate vacuum pump required space.
• 15. Limit loading to the floor to 1400 psi from the door or from members supporting the door weight.

Nov 16-18, 2015 Dave Pushka | Shield Door, Air Seal, and Transfer Cart Design 3

Shielding Door is a 24 inch thick concrete block shown in Gray. Shielding Door Moves on an aluminum cart, shown in purple. Air Seal included a fixed side (shown in Pink) and a moveable side (moves with the shield door) shown in Blue From the RH room Side

Isometric View of Shield Door and Air Seal Assembly from inside PS room:

Nov 16-18, 2015 Dave Pushka | Shield Door, Air Seal, and Transfer Cart Design 4

Door Weight Sits on Floor When Not being moved Commercial Hydraulic Cylinders are Lift the Concrete when Door is moved Shield Door Moves on Commercially Available Crane Truck Wheels Floor Mounted Rails support the Crane Trucks From RH Room Side

Shield Door Cart (Air Seal Omitted in this Slide for Clarity)

Nov 16-18, 2015 Dave Pushka | Shield Door, Air Seal, and Transfer Cart Design 5

• A single Speed Crane wheel

drive is used to move the door.

• Door Translates at 20 feet per

minute.

• Takes about 1 minute to open or

close.

• Will Use a simple two button

pendant controller to operate.

• Drive Motor to be mounted on

end, near the vacuum pumps.

• A festoon (not yet in the NX

model) will provide power to the door cart.

• Hard Stop to limit transverse

motion in both directions (not shown in NX model yet).

Shield Door Motion

Nov 16-18, 2015 Dave Pushka | Shield Door, Air Seal, and Transfer Cart Design 6

Gear Motor Used to drive the cart (vacuum pumps and everything else hidden in this image):

Shield Door Cart Drive:

Nov 16-18, 2015 Dave Pushka | Shield Door, Air Seal, and Transfer Cart Design 7

Overlap between shield door and the building concrete door jam

Shield Door Overlap and Vacuum Pump Clearance:

Nov 16-18, 2015 Dave Pushka | Shield Door, Air Seal, and Transfer Cart Design 8

• Pink Element is 6 x 6 x

½ “ Aluminum Angle Bolted to the building to provide a smooth, planer surface for the elastomeric seal to press against.

• Considering Closed

Cell LDPE as the seal elastomer

Air Seal (Fixed Portion Attached to the Building Concrete)

Nov 16-18, 2015 Dave Pushka | Shield Door, Air Seal, and Transfer Cart Design 9

• Aluminum Angle (6 x 6

x ½” ) Picture Frame with sheet aluminum skin and aluminum box section stiffeners.

• Picture Frame mates

with the same frame shown on previous slide.

• Mounted to the Shield

Door Cart (which is

• mitted in this image)

Air Seal (Mounted on the shield Door Cart)

Nov 16-18, 2015 Dave Pushka | Shield Door, Air Seal, and Transfer Cart Design 10

• Pink is a 6 x 6 angle

frame bolted to concrete (in green) and fixed in place.

• Light Blue is the

moveable seal frame, also a 6 x 6 aluminum angle.

• Dark Blue is a vertical

adjustment mechanism

• Gray is the shield Door.
• Note Small Space

between Picture Frames

• Space above rail

Door Un-Sealed, Side View

Nov 16-18, 2015 Dave Pushka | Shield Door, Air Seal, and Transfer Cart Design 11

• Light Blue Frame

moves vertically and horizontally on the gray pivot links.

• Moveable seal presses

against vertical surface

• f the fixed seal.
• 0.1 inch w.c. provides

.25 # / linear inch seal compression.

• 4-bar linkage of 2100#

applies 3.75 # / linear inch seal compression at 45 degrees.

Door Sealed:

Nov 16-18, 2015 Dave Pushka | Shield Door, Air Seal, and Transfer Cart Design 12

Green bracket supports two pulleys used to lift moveable portion of seal and allow it to clear rail and fixed seal surface, prior to moving door. Dark blue allows vertical adjustment of assembly to allow moveable seal to sit

• n rail surface when also

bearing against the fixed seal.

Seal Engagement Mechanism (Concrete Shield Hidden in this image:

Nov 16-18, 2015 Dave Pushka | Shield Door, Air Seal, and Transfer Cart Design 13

Wire rope (in dark gray) lifts moveable seal assembly when the door is moved. A simple threaded rod in tension is used to lift the blue member (to which the moveable seal assembly is attached) up and down to get the right contact to the rail on the bottom of the seal assembly. This should be a ‘one-time’ adjustment.

Detail of Adjustment Mechanism:

Nov 16-18, 2015 Dave Pushka | Shield Door, Air Seal, and Transfer Cart Design 14

• Bottom of Moveable

Seal Picture Frame rests on the same rail the door cart rides on.

• This gives a flat,

smooth sealing surface for the bottom of the seal.

• Will need to fill in the

‘corners’ between the fixed seal and the rail with a small horizontal seal

Detail of Bottom Corner of the Air Seal:

Nov 16-18, 2015 Dave Pushka | Shield Door, Air Seal, and Transfer Cart Design 15

Second Draft of Requirements for the Mu2e Remote Handling Transfer Cart:

1. Fit thru an opening 12 feet wide, 11 feet tall (this does not use the entire width or height of the shielding door to allow room for people or other equipment which is as of yet undefined. 2. Move into the Production Solenoid (PS) room or out of the PS room and into the remote handling room (RH) in less than 10 minutes 3. Carry the weight of a target coffin which is 40,000 pounds 4. Carry the weight of the remote handling modules which is 10,000 pounds 5. Total Load on the transfer cart is less than 50,000 pounds. 6. Limit loading to the floor to 1400 psi. 7. Provide a platform for the remote handling module which is located at an elevation of 32 inches above the floor. 8. Locate to within 5 cm of the PS centerline (10 cm error band). 9. Locate to within 5 of the PS End Cap Flange plane (0 to 5 cm error band).

• 10. Ride of the surface of the PS and RH room concrete floors or on rails as deemed best by the

design

• 11. Concrete floor elevation should be assumed to be accurate to only +/- 1 inch
• 12. Concrete floor surface is assumed dry, smooth but not sealed concrete
• 13. Local floor surface deviation from a plane is +/- 5 mm.
• 14. Activation issues favor fabrication of the transport cart from aluminum as much as is
• practical. Studies to quantify are under way.
• 15. Lift the remote handing modules and lower onto the kinematic mounts.

Nov 16-18, 2015 Dave Pushka | Shield Door, Air Seal, and Transfer Cart Design 16

• 10,000 pound capacity
• Pneumatic cylinder to

lift remote handling modules.

• Does not lift casks
• Aluminum construction
• Four Commercial crane

wheels for travel.

• Commercial crane drive
• n two wheels to

provide travel motion.

• Rides on surface

mounted Rails, which may be stainless or carbon steel

Transfer Cart:

Nov 16-18, 2015 Dave Pushka | Shield Door, Air Seal, and Transfer Cart Design 17

• A single Speed Crane wheel

drive is used to move the cart.

• Cart Translates at 15 feet per

minute; takes about 90 seconds to move.

• Hard stop will provide

transverse location alignment with PS.

• Will Use a simple two button

pendant controller to operate.

• Drive Motor to be mounted on

Remote Handling Room end.

• Multiple means exist to provide

power to drive.

• Contactors / controls mounted

in Remote Handling room.

Transfer Cart Motion

Nov 16-18, 2015 Dave Pushka | Shield Door, Air Seal, and Transfer Cart Design 18

• Based on the method

used to lift boats in a boat lift.

• Uses an Air Cylinder as

the actuator

• Other actuators are possible

including gear drive electric motors, hydraulics, commercial linear actuators, ball screws, etc.

• Air cylinder chosen only because

the modules are using air cylinders and air is presumed to be available.

• Connection between

wire rope and the air cylinder via a guided block.

• Cylinder Pmax = 250

psig

Module Weight 10000pounds Air Cylinder Capacity @ 100 psig 2827pounds MCM 6211K432 Air Cylinder stroke 30in Number of support points 4 number of 'parts' of wire at each support point 2 total number of 'parts' 8 load per 'part' of wire rope 1250pounds pulley capacity, each 1800pounds MCM 3175T45 5/16 inch wire rope capacity 2100pounds MCM 3441T66 Load on cylinder: 2500pounds Maximum Module Vertical Travel: 15inches

Module Lift Mechanism

Nov 16-18, 2015 Dave Pushka | Shield Door, Air Seal, and Transfer Cart Design 19

Technical Risks for Shield Door, Air Seal and Transport Cart

Risk Mitigation Shield Door Motion Using commercial crane hardware consistent with past experience in radioactive areas. Active components on RH room side of door. Wheels replaceable with Door in any position Air Leakage exceeding Leakage Budget Designed Air Seal from the ground up, not as an afterthought with duct tape and Herculite. Transport Cart Motion Using commercial crane hardware consistent with past experience in radioactive areas. Design allows the addition of a second method to retract cart into RH room, if found necessary in evaluating the FMEA. Transport Cart Lifting of Module Used simplest lifting mechanism possible. Based on commercial method used to lift boats. Unified lift explicit in the design.

Nov 16-18, 2015 Ryan Schultz | Contamination Control, Schedule & Conclusions 20

Transport Cart, Shield Door, and Air Seal Failure Mode Effect Analysis (FMEA):

Nov 16-18, 2015 Dave Pushka | Shield Door, Air Seal, and Transfer Cart Design 21

• Component orientated (each component is reviewed for

possible failure states).

• Use failure rates for electrical equipment from FESHM 4240

(ODH) Tables 1 and 3.

• Use failure rates for human error from FESHM 4240 table 3

(may be conservative due to continuous radiation safety

• versight of activities).
• Refer to references in FESHM 4240; Some come from NRC

and are applicable to equipment in radiation areas.

• Including only single level failures.
• FMEA for shield door, air seal and transport cart are a work in

progress, being completed with the design effort.

• Rails for the door and

the transfer cart cross at 90 degrees.

• Commercially

manufactured ‘points’ not yet found to be available

• Flanges on the wheels

require a gap in the cross rails.

• A gap on the rail in the

direction of travel is bad.

Rails for the two Carts:

Nov 16-18, 2015 Dave Pushka | Shield Door, Air Seal, and Transfer Cart Design 22

• Four Small custom

crosses solve the problem.

• Manually turned 90

degrees

• Set for the Transfer

Cart Move:

• Set for the Door Move:
• Can include ‘detents’ to

cause the pivoting section to ‘snap’ in at 90 degrees.

• Assume would be

manipulated from behind the shield door.

Solution for the Crossing of the Rails for the two Carts:

Nov 16-18, 2015 Dave Pushka | Shield Door, Air Seal, and Transfer Cart Design 23

• Solve Cable Chain

Interferences with Air Seal and Shield Door Structure:

• Work with Radiation Safety

to:

– Address 7Be control measures – Evaluate suitable air seal elastomers – Unsure if the commercial polyethylene sill plate seal material is HDPE or LDPE – Evaluate Wheel Wipe for

7Be control

– Address Air Seal Change procedure.

Remaining Work on Door and Air Seal:

Nov 16-18, 2015 Dave Pushka | Shield Door, Air Seal, and Transfer Cart Design 24

• Finish FMEA for equipment.

More Remaining Work On Door and Air Seal to Address:

Nov 16-18, 2015 Dave Pushka | Shield Door, Air Seal, and Transfer Cart Design 25

• Complete calculations to

confirm member and connection sizing calculations.

• Create Hard Stop to prevent

potential for pinch hazard between door and building.

• Verify VSD not needed for

cart to ease against hard stops.

• Develop a back-up seal

clamping device.

• Develop seal install procedure
• Prepare detail fabrication

drawings

• Perform technical review of

each object with technicians, rad techs, and other stake holders as per the FEM

• Prepare cost estimates
• Prototype testing of air seal
• Develop details of the

concrete shielding block to allow assembly from multiple pre-cast sections and clear transfer cart rail.

More Remaining Work On Transfer Cart to Address:

Nov 16-18, 2015 Dave Pushka | Shield Door, Air Seal, and Transfer Cart Design 26

• Complete calculations to

confirm member and connection sizing calculations.

• Prototype testing of the

transfer cart lift mechanism

• Model Hard Stop in PS room

for transverse transfer cart movement.

• Verify VSD not needed for

cart to ease against hard stops.

• Develop interface between

transfer cart and modules

• Develop interface between

transfer cart and cask(s).

• Prepare detail fabrication

drawings

• Perform technical review of

each object with technicians, rad techs, and other stake holders as per the FEM

• Prepare cost estimates
• Evaluate Rail Wiping fixture

for 7Be control.

Back-Up Slides: Back-Up Slides

Nov 16-18, 2015 Dave Pushka | Shield Door, Air Seal, and Transfer Cart Design 27

Shield Door and Air Seal EPC Risk Assessment:

Engineering Risk Assessment

Project:Mu2e Target Hall Shield Door Lead Engineer:Dave Pushka Department:AD/ Targets Date:June 8, 2015

Engineering Risk Element High Chapter A B C D E F G Risk Subtotal Assessment 1 Requirements and Specifications 2 1 3 ≥10 6 Standard Risk 3 Requirements and Specification Review 2 1 3 3 3 ≥16 12 Standard Risk 4 System Design 2 1 2 3 3 2 ≥19 13 Standard Risk 5 Engineering Design Review 2 1 2 3 3 2 ≥19 13 Standard Risk 6 Procurement and Implementation 1 3 3 3 2 ≥16 12 Standard Risk 7 Testing and Validation 2 3 3 2 ≥13 10 Standard Risk 8 Release to Operations 3 ≥4 3 Standard Risk 9 Final Documentation 1 3 ≥7 4 Standard Risk Project Risk Element High H I J K L M N O Risk Subtotal Assessment 2 2 2 1 2 2 1 2 ≥25 14 Standard Risk Engineering Risk Elements Project Risk Elements A Technology H Schedule B Environmental Impact I Interfaces C Vendor Issues J Experience / Capability D Resource Availability K Regulatory Requirements E Safety L Project Funding F Quality Requirements M Project Reporting Requirements G Manufacturing Complexity N Public Impact O Project Cost

Nov 16-18, 2015 Dave Pushka | Shield Door, Air Seal, and Transfer Cart Design 28

Transfer Cart EPC Risk Assessment:

Nov 16-18, 2015 Dave Pushka | Shield Door, Air Seal, and Transfer Cart Design 29

Engineering Risk Assessment

Project:Mu2e Remote Handling Transfer Cart Lead Engineer:Dave Pushka Department:AD/ Target Date:June 8, 2015

Engineering Risk Element High Chapter A B C D E F G Risk Subtotal Assessment 1 Requirements and Specifications 1 1 3 ≥10 5 Standard Risk 3 Requirements and Specification Review 1 1 2 2 3 ≥16 9 Standard Risk 4 System Design 1 1 2 2 3 2 ≥19 11 Standard Risk 5 Engineering Design Review 1 1 2 2 3 2 ≥19 11 Standard Risk 6 Procurement and Implementation 1 2 2 3 2 ≥16 10 Standard Risk 7 Testing and Validation 1 2 3 2 ≥13 8 Standard Risk 8 Release to Operations 3 ≥4 3 Standard Risk 9 Final Documentation 1 3 ≥7 4 Standard Risk Project Risk Element High H I J K L M N O Risk Subtotal Assessment 2 3 2 1 2 2 1 2 ≥25 15 Standard Risk Engineering Risk Elements Project Risk Elements A Technology H Schedule B Environmental Impact I Interfaces C Vendor Issues J Experience / Capability D Resource Availability K Regulatory Requirements E Safety L Project Funding F Quality Requirements M Project Reporting Requirements G Manufacturing Complexity N Public Impact O Project Cost