W&M work packages Mike Kordosky, Je ff Nelson, Tricia Vahle NSF mid-scale proposal for APAs planning workshop 11 June, 2019
W&M particle physics • • Neutrino experimental group faculty Machine shop – Mike Kordosky – 2 FT sta ff (Henninger, Bensel) – Je ff Nelson • Henninger is lead tech – $20/hr (costed) – Tricia Vahle – CNC and conventional machining • Current neutrino group includes – Welding – 2 postdocs, searching one right now – Student shop – 4 PhD students (RA’s + add’l MS’s) • Maker’s space – Many undergrads (graduate 35 BSs/ – 3D printing (many materials), year) 3D scanning, laser cutters, • Hadronic experimental group faculty instrumentation lab – Todd Averett – 2 9-mo professional faculty – David Armstrong (Frey & Yang) – Keith Gri ffi oen • Dedicated so fu -wall clean room – Bob McKeown • Chemical workroom – Justin Stevens • 3 additional 12’x24’ neutrino labs • Subatomic theory group (8 faculty) • High Bay [slide]
Small Hall, High Bay Lab • 40 fu x 60 fu crane coverage • 7.5 ton crane – 16 fu hook height • 54 fu wide door – On loading dock (mullions move) • Forkli fu • Single pass ventilation • Chemical storage • Sealed fm oor and walls • Plumbed LN 2 nearby
Some past W&M projects • Je ff Nelson – L2 for MINOS FD installation – L2 for MINOS magnets, coils, DSS & prototyping – MINOS v e and v u WG convener – L2 for MINERvA scintillator planes/towers – Scintillator for CLAS-12 PCAL – MINERvA test beam detector planes – MINERvA inclusives WG convener – TPC coordination for DUNE 35t HV test – ProtoDUNE HV assembly stations & fj xturing • Mike Kordosky – MINERvA prototype commissioner – MINERvA AC, Flux WG convener – Lariat DAQ/trigger – ProtoDUNE cold cameras/lighting – DUNE ND design study & CDR editor • Tricia Vahle – MINOS & NOvA AC – NOvA NDOS installation – NOvA readout acceptance testing & commissioning (FD + ND lead) – Current NOvA co-spokesperson pdf with more projects included in a separate document
Summer 2009 MINERvA team (2/3rds) Fleets of undergrads, professional staff, term staff …
W&M scope of work • APA shipping frames • APA U/V frame boards & hardware – Out fj tting facility – Coordinating with the – Board production Liverpool group (Peter – Cleaning/baking Sutcli ff e et al.) – Gluing tooth boards – Liaison PSL and SURF/ – Cleaning SDSD engineering on design – QC & packaging integration – Shipping to factories – Initial prototype for APA pairing tests at AR (ASAP; CY 2019) – Trial runs at SURF (cage available August ‘20) – – Production for US factories
Shipping frame use cases • Factory packaging and prep for shipment [SBND pix] • Getting to SD – “Truck, ship, truck” or just “truck” • Acceptance testing, long term storage at SDWF (warehouse) • Transport to the head frame, slinging below cage [slide] • Sha fu transport; removal from sha fu ; transport to cavern • Pre-testing and staging in cavern [slide] • Into the SAS and clean room for mating/instrumenting [slide] • Return to the surface, warehouse, disposal/return shipping
Requirements document https://edms.cern.ch/document/2165518/1 3 sections • Overview • Description of the use cases with current installation model • Speci fj cations derived from the use cases Dra fu for comment – posted last week
Current design The image cannot be displayed. Your computer may not have enough memory to open the image, or the image may have been corrupted. Restart your computer, and then open the file again. If the red x still appears, you may have to delete the image and then insert it again.
Structural shipping frame welded steel construction
Concept based on SBND experience in UK • DUNE crate concept similar to SBND but with 2 APAs on sides • Protective panels • Coil spring dampening • Structural frame • Instrumentation • Removable side frames • Heat sealed bag • Anchored to a pallet • Tarping • [UK version gets walls]
Shock isolators (coil springs) at 4 locations per APA
Loading onto sha fu based on SURF experience • We will work with SDSD to design a Zimmerman (Zimmer) cart (their scope) – Surface rail system – Factorizes rigging & frame functions – Includes wheels for movement in the dri fu and for on/o ff loading – Include mount points for sha fu guides timbers – Include anchor points for cables to bottom of cage and horizontal tugger – Underground truck provided • Ti is concept makes the slung-load operation consistent with standard SURF practices
Upper connection is base of cage (hoist acts as the upper winch)
Stages in cavern: testing, short-term storage, PSs, pairing PD, ma;ng Hall: in clean Tes;ng in a room clean hut & storage (up to 12 APAs) SAS
In the SAS/clean room • Ti e frame/vertical cart is rolled into the SAS • It is cleaned • PDs installed with protection panels in place • Need to li fu APAs out of the shipping frame and onto the APA assembly frame – pre-li fu to relieve tension, remove springs, move to tower
Shipping frame production model Model for pre-proposal Model for the full proposal • • APA crate production in industry with W&M Pallets produced by crating manufacturer in Port of coordination of the production Norfolk area • – Staged production to match need at factories QA/QC provided by W&M lead technician (8 hr per – Alternative is in-house production frame) – QA/QC provided by W&M lead technician (1 hr per pallet) • Ti e basis of the cost estimate (c.f. DUNE- • Welded central frame produced in fab shop docdb-10683) is benchmarked on a conceptual crate – design, and the cost per crate is derived from Can put 4 per fm at bed – Staged production to match need at factories component costs and production labor estimates in – the UK. (Same vendor as SBND) QA/QC provided by W&M lead technician (8 hr per frame) • Shipping costs for the crates are assumed to be • Side frames made from 80:20; produced on campus included the APA wiring site budgets. – Undergrad e ff ort with GS/PD/PI supervision • Assume to be single usage because APA production • Clear plastic protective panels produced at local water-jet is signi fj cantly ahead of installation. cutter and hardware added at W&M • Cable springs & sensors purchased at W&M Assumes part-;me PI and/or postdoc • Bagging material and heat sealers provided at factories. coordina;on • W&M pays shipping to factories – Pallets and structural frames direct from vendor – Work done by ;me first Mod 1 crates Other parts from W&M crated kits – Included smaller crates and coordination returned to factories • Assume that half of the Mod 1 crates get reused for Mod 2
U/V boards • Procure boards • Board QC • Clean/bake • Epoxy on tooth strips • Cure in fj xtures w/ venting • QC of glued board • Bag cleaned fj nal parts
Geometry boards: (foot & side): 60 min per board Head boards: add 30 or 40 min more for pins • Incoming inspection, cleaning, • U: prep for processing: 10 – 20 head • Tooth strip cutting, handling, – 10 foot – 42 side organizing for production: 10 • Attachment of tooth strips, • V: removal of excess epoxy: 20 – 20 head • Dimensional check, excess – 10 foot – 42 side epoxy removal, spot cleaning: 10 • Ti at’s 144 per APA • Mask solder pads, bag, place in – 21,888 boards total inventory, fj nal inspection, • 4 years of production package for storage or – Average 22 per shi fu shipping: 10 • Plan on infrastructure for ~2x – UG e ff ort bump in summers
Costing model • E ff ort and M&S based on PSL experience (BOE docdb-10689) – Labor includes: incoming inspection, cleaning, prep for processing, pin insertion, tooth strip cutting, solder pad masking, epoxying tooth strips, dimensional checks, excess epoxy removal, spot cleaning, fj nal inspection, and packing for storage/shipping • Ti e board production labor model at W&M assumes: – Half of work completed by undergrads • We assumes happens at 50% e ffi ciency WRT technician in pre-proposal – * evolve to 67% in consistent fj nal model with other sites • 82.0* (85.4*) hours for U (V) boards per APA • Students are costed at $12.50/hour (FICA in summers); 8 students averaged over year – 10hr/wk in term, 40hr/wk summers – Technician e ff ort for remainder • 41.0 (42.7) hours per APA • Lead tech + term technical sta ff within instrumentation shop (2 FTE) • Costed as recharge personal at $20/hour (i.e. fully loaded) – Postdoc and grad student coordination of inventories/QA/tracking/shipping • Professional faculty collaboration possible too • Base grant supported • Purchasing – Postdoc + PIs
Facilities board production • Clean room – 24’ x 36’ lab – 20’ x 20’ class 100,000 clean room • So fu wall, tiled roof – 2 vented workstations; single basin wet lab – Ultrasound cleaner – Space used for cleaning, baking, gluing, curing • Chemical prep room across hall – Outgas any surplus epoxy and clean up materials • Ti ree 24’ x 12’ labs across hall – Shelving on both long walls – Vented workstation; single basin wet lab – Space used for storage, inspection, packaging – Vacuum + inert purge heat sealer (up to 36” capacity)
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