ZDC Remote Handling System

March 10, 2011Project Status and Forward Planning

Technical Implementation Group Meeting

Paul DebbinsUniversity of Iowa

Model Crane Installed on (-) TAN

Crane installation and testing underground at Pt5

- Provided a method to validate all geometric considerations

- Provided practice in assembly and handling of system underground * Generate a sequence of assembly/operation steps with associated times and positions for CERN Transport and RadioProtection groups.

Crane in Standby condition, parking position when not in use

Position shown is past full movement

Crane in stages of operational movement, withAttached representative payload

Payload

Hard Clearances

Vertical to ceiling services

R(-)

L(+)

Min. Payload - TAN (transport side)

Min. Actuator – TAN (QRL side)

Actuator spindle protectiontube clearance to tunnelwall services – plenty, incl.anti-runout device extra lengthof tube. No collision with QRLplatform.

No collisons to hard artifacts of Tunnel and TAN.

Measured clearances in excellent agreement with Virtual Models – confidence in the manual survey and its translation in to CAD

L(+) side vertical clearance was most critical. Model validates several cm availablespace to expand vertical clearances in system – esp. min vertical space to BRAN

Soft Clearances

1. Interference with rotary jack interconnect input drive axle. Discussed with E. Bravin. Simple to move gas hose.

2. No interference of crane with cable trays on either side.

3. ZDC cabling is to be re-done, to use single multi-contact connectors for all signals, HV, and Laser. This substantially reduces the time spent (un)cabling during operations (ALARA). Eliminates the good probability of mis-cabling, and

reroutes the cables into clean pathways clear of crane and human movements in the area.

1Rotary Jack input drive coupling axle

BRAN Vert. Clearance

Vertical clearance to BRAN: crane carrier beamFully raised, 625mm clearance, 615mm verticalCarrier travel to lowest pos + 10mm clearance Above beam => “0” clearance to BRAN survey ball

Model testing allows to provide for 20mm additionalClearance. Crane Design modified to provide Additional BRAN overhead clearance.

Survey balls are removable and also provide Useful fixation points for attachment to crane forBRAN lifting. Discussed this option with E. Bravin BRAN survey points

BRAN group must provide engineering to design and implement a fixture attaching the BRAN to the crane for BRAN removal. This is NOT a Univ. of Iowa responsibility.

BRAN mounting in slot is also in need of remedy – BRANS are placed in different locations in the slot. 1 BRAN is keyed intoLocating holes in TAN, the other is ‘free – floating’. Both units need to be keyed at consistent locations, with proper clearancesTo adjacent elements (ZDC) when mounted in TAN

Crane Model Testing - - - > Allows final commitment to geometry With increased Vertical Clearances

Some Structure Design modifications – DONE

Modified designs sent to welding fabricators for Comments/mods to suit their best practices - DONE

Final Geometry allows exact commitmentTo actuator specifications

- Actuator specs sent to supplier to generate a current order then Referred to KU and ordered.

~ 1 week

Crane Production Readiness

Crane model ported toSimulation / Analysis environmentTo allow Force determination and FEA analysis of complete model 50% complete

Generate Mechanical Study of Safety

Order Steel Structure Fabrication~ 2 Weeks

Additional preparation for testing

Sarcophagus Design - DONE- Need to send to KU for production- 1 Sarco needed for testing

Construction of Testing Platform

Where? Pt5? Pawel, CMS TC

How ? Design concepts exist- Need to discuss and refine

“BARS” payload (S.Steel abosrber)- Design DONE- Send to A.L Perrot for referral to CERN shops for fabrication

Above Ground Testing of System

- Begin July 2011

Payload

Sarco

Platform

Crane