Horn-1 module Lower and Upper drives replacement procedure

Vladimir Sidorov20 February 2020

7/31/2020V. Sidorov / Horn-1 module Lower and Upper drives replacement procedure2

NUMI Horn-1 Module drive mechanisms

Upper drivemechanism

Main shaft

Transverseshaft

Lower drivemechanismModule

7/31/2020V. Sidorov / Horn-1 module Lower and Upper drives replacement procedure3

Lower drive mechanismBase plate

Slidingblock

Guiderod

Linearbearing

Link GraphalloybushingAlignment

pin

7/31/2020V. Sidorov / Horn-1 module Lower and Upper drives replacement procedure4

Upper drive mechanism

Motor

Slidingblock

Mainshaft

Gear box

Verticalshaft

Transverseshaft

Link

Baseplate

7/31/2020V. Sidorov / Horn-1 module Lower and Upper drives replacement procedure5

Upper drive condition

Transverseshaft

Main shaft

Link

Lifter drive shaft

7/31/2020V. Sidorov / Target and Horn-1 modules Transverse drives modification and replacement6

NUMI Target Hall Work cellAll steps of the remote handling procedure will be held in the Horm-1 module chase and in the work cell.

T-block storageWork cell

7/31/2020V. Sidorov / Horn-1 module Lower and Upper drives replacement procedure7

Lower and Upper drives exchange procedure1. Open Chase2. Disconnect water, cables and Striplines from Horn-1

Target Chase

Target

Horn-1Chase

T-block

Horn with module

WorkCell

3. Move T-blocks from chase to T-blocks storage and Horn-1 module to Work Cell

Horn-1

V. Sidorov / Horn-1 module Lower and Upper drives replacement procedure

7/31/2020V. Sidorov / Horn-1 module Lower and Upper drives replacement procedure9

4. Close Work Cell door and install top shielding covers5. Disconnect Horn from module and stripline block6. Take off Work cell top shielding covers7. Move Module to the chase8. Move Horn to the morgue9. Install the chase temporary shielding10. Remove the main shaft draw bars, water, instrumentation and gas lines11. Remove the stripline block from the module12. Remove the chase temporary shielding13. Move Module to Work Cell14. Install the work cell top covers15. Disassembly Upper transverse drives and put parts into the storage box

Upper drive mechanisms storage box

7/31/2020V. Sidorov / Horn-1 module Lower and Upper drives replacement procedure11

16. Take off top covers17. Move Module to chase18. Install hatch temporary shielding19. Remove transverse shafts from module with support block

Temporary cover

Mane shaftTransverse shaft

Support block

Base plate

7/31/2020V. Sidorov / Horn-1 module Lower and Upper drives replacement procedure12

20. Remove Upper drive base plate ( this step can be made in the work cell)

21. Attach hoist ring to the main shaft

22. Remove main shaft ( this step can be made when the Module is in the chase)

Transverse drives shafts storage

Cask

Supportframe

Shafts

Cover

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23. Install frames with bottom cask on lifting tables in the Work cell

CaskFrame

Lifting table

7/31/2020V. Sidorov / Horn-1 module Lower and Upper drives replacement procedure15

24. Move module from chase to the Work cell25. Install top covers26. Align bottom cask with the Lower transverse drive

Module

Lower transfer drive Cask

7/31/2020V. Sidorov / Horn-1 module Lower and Upper drives replacement procedure16

27. Remove middle draw rod

28. Attach long thread rod to Low Drive mechanism29. Remove two others draw rods

Draw rod

Long threaded rod ( 108”)

7/31/2020V. Sidorov / Horn-1 module Lower and Upper drives replacement procedure17

30. Lower down Lower drive mechanism into caskand remove long threaded rod

Hammer gently using long rods to disconnect the Lower drive mechanism from module if necessary.

Lower drivemechanism

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31. Lower down lifting tables32. Remove Work cell top covers33. Return module to the chase34. Change lifting fixture

Lower drivemechanismCask

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35. Install and bolting top casks to bottom casks 36. Remove casks from Work cell using T-blocks lifting fixture

Top cask

T-blocksLifting fixture

Lower Drive Mechanisms Casks

Main cask

Small cask

Lower drivemechanism

7/31/2020V. Sidorov / Horn-1 module Lower and Upper drives replacement procedure21

38. Return Module to the work cell39. Install top covers40. Lift up and align lower transverse drives with draw rods holes41. Attach long threaded rod to the middle hole of the Lower drive base plate42. Pull rod till base plate and module contact and secure lower drive mechanism43. Tightening the lower drive mechanism to module by draw rods

37. Place new lower transverse drive assemblies on support frames in the Work cell

7/31/2020V. Sidorov / Horn-1 module Lower and Upper drives replacement procedure22

44. Install new main shaft into the module45. Install new baseplate46.Install the new transverse shaft with support block and spacer

Transverse shaftLink

47. Return Module to the work cell48. Hold transverse shaft by crane and remove spacer49. Slowly move shaft down and connect with link

Main shaft

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50. Assemble and test upper transverse drives

Upper transversedrive

Module

Lower transverse drives

7/31/2020V. Sidorov / Horn-1 module Lower and Upper drives replacement procedure24

51. Return module to chase52. Install instrumentation lines, water lines and draw bars into module

Install stripline block 53. Remove support stands from work cell

54. Place Horn into work cell on the lifting table

Horn-1

7/31/2020V. Sidorov / Horn-1 module Lower and Upper drives replacement procedure25

55. Return module to the Work cell56. Connect Horn to the module57. Connect water and instrumentation lines58. Move module to Chase59. Install T-blocks60. Connect water lines and striplines

7/31/2020V. Sidorov / Horn-1 module Lower and Upper drives replacement procedure26

Horn - module assembly in MI-8

Horn1 module drive mechanisms pre-assembly and Remote Handling Training

Module mock-up design

7/31/2020V. Sidorov / Horn-1 module Lower and Upper drives replacement procedure27

Frame

Support block

Top plate

Bottom plate

7/31/2020V. Sidorov / Horn-1 module Lower and Upper drives replacement procedure28

Horn-1 shafts installation

7/31/2020V. Sidorov / Horn-1 module Lower and Upper drives replacement procedure29

Lower drive mechanism

Upper drivemechanism

Transverseshaft

MainshaftModule

mock-upframe

Module mock-up frame –drive mechanisms assembly

7/31/2020V. Sidorov / Horn-1 module Lower and Upper drives replacement procedure30

The remote handling training will be held in the M-8 facility. The Horn-1 module mock-up frame is installed on the Horn-Module assembly stand for the lower drive mechanism removing and installation practice.

Lower drive mechanism frameHorn-1 module Assembly stand

Module mock-up frame

7/31/2020V. Sidorov / Horn-1 module Lower and Upper drives replacement procedure31

Drive mechanisms parts machining

• Summary:• 1. All replacement parts are made from the stainless steel or anodized aluminum.• 2. More powerful motors and gear boxes will be installed.• 3. Linear ball bearings are replaced with aluminum anodized bushings.• 4. Thrust roller bearings rings are coated with CrNd.• 5. The module mock-up is fabricated for transverse drives pre-assembly.• 6. Lower drive mechanism cask support frame is fabricated.• 7. Drive mechanisms parts storage casks are designed.• 6. The module assembly stand is installed in MI-8 for transverse drives removing

and installation practice.• 7. Special tool is fabricated for remote handling operations.• 8. ALARA Plan , Hazard analysis are required for remote handling operations.

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