andy at ip2 infrastructure requirements & experimental construction 1charles folz, bnl

Charles Folz, BNL 1

AnDY at IP2

Infrastructure Requirements&

Experimental Construction

Charles Folz, BNL 2

Expanded Calorimetry• Upgrade of Hcal requires removal of existing modules, replacement of

current base/foundation, and fabrication of azimuthal support • This model shows the design used for Run 12; Run 13/14 will be similar in

design, but incorporate an expanded array:

Charles Folz, BNL 3

New PMT Supports

• After assembly of new array, new aluminum cover panels will be installed and PMT guides will be fabricated in CAD Tech shop – this process was performed this past fall for the Run 12 modifications. The 2 new PMT supports were 5x2 arrays and required custom fitting and are now in service:

Run 12 PMT Support plate

Charles Folz, BNL 4

HCAL Costs

• Hardware & Misc materials purchases apx . $3,650

• BNL Central Shop fabrication costs apx. $11,000

• CAD Techs, Electricians & Rigging to provide remainder of support for assembly, modification and setup

Charles Folz, BNL 5

ECal• All calorimetry required to construct Ecal has been acquired and is

currently on-site at 1002B:

Charles Folz, BNL 6

Ecal Modifications

• Substantial efforts are required to assemble the lead-glass calorimetry in an azimuthal array:

Charles Folz, BNL 7

Azimuthal Array Support & Thomson Rail

• In order to provide structural support around the beam pipe, two semi-circular stainless steel braces will be installed at the center of Ecal. These will be supported by off-the-shelf carbon fiber shapes at the end facing the IR, and by a conventional aluminum fabrication at the opposite end. This design has been checked for strength and modeled….

• In order to allow lateral movement, the array will be supported on rail type linear motion bearings…

Charles Folz, BNL 8

Mechanica Analysis/ProE ModelMaximum deformation of .001058” (Deformation is exaggerated)

Charles Folz, BNL 9

ECal Installation

• Hydraulic lift table has already been acquired and tested

• Miscellaneous hardware, Thomson rail and raw materials purchases estimated to cost $16,000

• Shop fabrication another $6,000• CAD Tech labor is required to install and setup

the lift tables and shims for the array as well as miscellaneous item fabrication

Charles Folz, BNL 10

New Ecal


Ecal Support

Calculations for AnDY CalorimetryEcal cells wt=5.25 lbm , No of Cells in detector: =1632Total weight of Ecal=8568 lbmor.... 4.28 tonsEach lift table will be required support half of this

weight or 2.14 tons The lift tables are rated at 12,000lb each, more than

sufficient to support the calorimeters.No of cells supported by each brace: 40Load on brace: = 40x5.25=210 lbThis load is easily supported by the proposed SS

brace...


Pre-Shower

• Scintillator frame to be field assembled• Consists of three panels of four “quadrants”,

framed in aluminum “track” to accept sandwich panels composed of carbon fiber sheet and scintillator.

• Costs consist mostly of raw materials; estimated (catalog prices) at $28,000

• Custom fabrication and assembly by CAD techs


Single Quadrant Panel Design


Subtotals for CalorimetrySo far we have $81,085 – including contingency of 40%:

Item Material Unit Cost Qty Ext Cost Shop Cost Purchase Item Qty Ext Cost Totals

Hcal Modifications: Enclosure Panels .090"x36"x48" Al Sheet $250.00 6.00 $1,500.00 $0.00 Add'l PMT Guides .375"x24"x48" Al Sheet $575.00 2.00 $1,150.00 $6,000.00 $0.00 Cell Supports $0.00 $5,000.00 $0.00 Misc. hardware $1,000 1 $1,000.00

Hcal SubTotal: $2,650.00 $11,000.00 $1,000.00 $14,650.00

ECal (2 modules of 200 cells): $0.00 $0.00 Enclosure Panels .090"x36"x48" Al Sheet $250.00 8.00 $2,000.00 $0.00 Thomson Rail/Slides $0.00 $1,200 4 $4,800.00 Lift Table bases $0.00 $4,460.00 $0.00 Cable Tray, budget $2,000 1 $2,000.00 Baseplates 1"x24"x24" Al $462 2 $924.00 Misc. hardware $0.00 $1,000 1 $1,000.00

ECal SubTotal: $2,000.00 $4,460.00 $8,724.00 $15,184.00

Preshower $0.00 $0.00 Enclosure Panels .090"x36"x48" Al Sheet $250.00 6.00 $1,500.00 $0.00 8020 Modular Rail & Hardware $0.00 $5,000 1 $5,000.00 Aluminum Channel 2"x1"x60" $25.00 6.00 $150.00 $0.00 Linear Slide Rails $1,170.00 6 $7,020.00 Linear Guide Blocks $352.00 12 $4,224.00 Fiberglass Angle 1"x3/4"x10' $23.00 10.00 $230.00 $0.00 Rigid CF Sheets 1/16"x24"x48" $330.00 12.00 $3,960.00 $0.00 Cable Tray, budget $4,000 1 $4,000.00 Misc. Hardware, adhesives, etc. $0.00 $2,000 1 $2,000.00

Preshower SubTotal: $5,840.00 $0.00 $22,244.00 $28,084.00

Project Sub-Total: $57,918.00

Contingency: 40.00% 23,167.20$

Project Total: $81,085.20


Phobos Dipole

This magnet will require:• Opening of the aperture; new upper half support

posts from Central Shops• Updated power supply from CAD• Cooling water system – using tower planned for

installation to support CeC• Installation by CAD Techs,Electricians & Riggers


Power Supply• Explored the option to use power supply from Phobos installation; this

unit was determined to be unreliable and is no longer available• A new power supply can be assembled from components available to

CAD Power Supply Group at minimal cost given sufficient lead time.• Working part-time, a replacement power supply can be assembled in

approximately 4 months .• It is anticipated that parts purchases should be minimal• From Wuzheng Meng’s field calculations, we have the following:• “The required ampere-turns per pole, both for PHOBOS and for AnDY

are the same: 172800 Ampere-turn (per pole).”• “If we look into the conductors (on the drawing), there are 96 turns

(single) conductor per pole. Since PHOBOS was powered in pairs, then we can say that the current from the power supply was 3600 A; and the total ampere-turn per pole was 3600 A x 48 = 172800 A-T per pole.”

• “In AnDY case (with expanded gap size), I used the same number of the ampere-turns to get the field map with the peak field around ~1.3 Tesla. Now, I am using 3600 A as the operating current to calculate the inductance of the magnet.”


Dipole Installation

• It was requested to expand the dipole aperture by a factor of two, from the existing gap of 15.7 cm to 31.4 cm

• In order to accomplish this, the existing corner posts will be replaced with new posts fabricated at BNL Central Shops from 8” Sch 8o steel pipe with flat steel base plates.

• Material cost estimated at $400 and labor would be approximately $400/pc for a total of $2,000

• Reassembly will follow the same method as original, Survey to obtain as-constructed dimensions.

• Support will provided by conventional jacks


Dipole Installation - Continued

• Dipole to be physically installed Summer-Fall 2012• Installation of CeC required cooling tower will be

leveraged to provide for cooling water• A 3MW tower from (PTR) is available and planned for

installation on the pre-existing footings remaining from Brahms installation

• Installation of piping and wiring is outlined in the following budget sheet….


Dipole Budget for 2013-141755 hrs per FTE

$0.00 $0.00 $0.00 $0.00 $0.00 $142.82 $120.45 $142.82 43.15% 52.45% 17.55% 17.55%

Total Total Total withPlant PE Assigned Central Labor Cost Material 21.12%

Description Physicist Engineer Job Shop Design Tech Engineering Labor Shops w/Indirect Job Shop <$25,000 >$25,000 > $600,000 w/ Indirect Total Contingency$0 0.00 0.00$0 0.00 0.00

Dipole Power Supply $0 0.00 0.00 $11,672Power supply, design & spec 40 80 24 $0 0.00 0.00Power Supply Recondition 40 320 $0 0.00 0.00Install tray & cable 40 80 40 80 $9,636 0.00 9,636.12Terminations, setup & test 40 40 80 $0 0.00 0.00Job #5 $0 0.00 0.00

$0 0.00 0.00$0 0.00 0.00

Dipole Cooling System - use existing 3MW PTR Tower $0 0.00 0.00 $134,869Rigging 24 96 $11,563 0.00 11,563.34Build new sub-frame 24 32 $3,854 $5,000 7,622.74 11,477.18Installation (mech - pumps, piping etc) 80 80 240 $28,908 $5,000 7,622.74 36,531.09Installation cabling, tray, etc 80 80 240 $28,908 $5,000 7,622.74 36,531.09Clean/restore exisitng piping 40 80 $0 $10,000 15,245.48 15,245.48Job #6 $0 0.00 0.00Job #7 $0 0.00 0.00Job #8 $0 0.00 0.00Job #9 $0 0.00 0.00

$0 0.00 0.00$0 0.00 0.00

Install Dipole $0 0.00 0.00 $3,460Extend support posts 20 $2,856 0.00 2,856.38Install in place 40 120 $0 0.00 0.00Job #3 $0 0.00 0.00Job #4 $0 0.00 0.00

$0 0.00 0.00$0 0.00 0.00

Total Hours 80 488 80 64 760 0 688 20 2,180Total FTE 0.05 0.28 0.05 0.04 0.43 0.00 0.39 0.01 1.24

Costs -$ -$ -$ -$ -$ -$ 82,871$ 2,856$ $85,727 $0 $25,000 $0 $0 $38,113.69 $150,000

Subtotal $123,840.67

Contingency @ 21.12% $26,159.33

TOTAL BUDGET $150,000.00

Labor Rates with Indirect Overhead

Labor Hours Materials (Direct)

Wrap Burden Rates Percentages


Preliminary Layout of 1002 IR


Summary

• Preliminary design work to bring the AnDY experiment to useful function has been completed

• Detailed design work remains, specifically in the area of calorimetry

• Hcal azimuthal arrangement is proven design – in service• CAD labor should be sufficient to assemble the necessary

components (including power supply) from off-the shelf and custom made parts outlined previously

• Calorimetry budget is estimated at $81,000• Dipole installation is estimated at $150,000• Close coordination will be necessary to allow completion of

AnDY while not impeding CeC progress

andy at ip2 infrastructure requirements & experimental construction 1charles folz, bnl

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