LBNF/DUNE Joint Project OfficeWork Package: FD-SP

Installation

Group: Installation (UIT)

Doc. Type: ProposalEDMS Document No. Created: Pages:

Modified: Rev. No.:

Prototyping Plan for the Installation of the DUNE Far Detector Single Phase Detector

Submitted by: Author(s) by:W MillerJ Stewart

Approved by:

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Contents

1 INTRODUCTION................................................................................................................3

2 FD-SP INSTALLATION PROTOTYPING GOALS.....................................................................3

3 USING THE NOVA FAR DETECTOR LABORATORY FOR INSTALLATION PROTOTYPING.........4

4 INSTALLATION PROTOTYPING PROGRAM.........................................................................5

4.1 Installation Prototyping Phase 1.........................................................................................................................5

4.2 Installation Prototyping Phase 2.........................................................................................................................8

4.3 Installation Prototyping Phase 3.......................................................................................................................10

4.4 Installation Prototyping Phase 4.......................................................................................................................12

5 PROTODUNE 2 Prototyping……………………………………………………………………………………………………….12

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1 Introduction

The installation of the DUNE SP-Far Detector is a very complicated process involving hundreds of FTE years of effort and contributed equipment from many institutions and different countries. The detector itself will be modeled in 3-D, but it is difficult to model the entire installation process. Also, unless real personnel have attempted each of the tasks it is not possible to determine where difficulties and mechanical conflicts may occur. As the actual installation is performed after most the components are fabricated if any changes become necessary in order to install them a costly and time-consuming process of retrofitting the detector elements would be needed. Minimizing this risk with a thorough prototyping plan is key to preventing rework. As the installation is by definition on the critical path it is vital to ensure that there are no serious difficulties prior to the start of installation. For all of these reasons a complete and through program of prototyping the installation is needed.

In ProtoDUNE-SP phase I each of the installation steps was prototyped using mechanical mock-ups of the final components. This process found many mechanical conflicts and was critical for developing a working set of tooling needed for the installation. This process also developed the initial detailed procedures for installation well in advance of the actual work. Without the knowledge and experience gained by prototyping the installation ProtoDUNE-SP would not have been completed in time for beam.Similarly we propose a complete installation prototyping program where each of the installation steps is tested mechanically using full scale mechanical models of the final detector components and tooling.

2 FD-SP Installation Prototyping GoalsThe goals for the DUNE SP-FD installation prototyping program are as follows:

1. Test each of the detector installation steps with full scale mechanical mockups based on the detector components final design.

a. Verify the component interfaces are accurate and well understood and that the detector can be assembled.

b. Verify the proposed installation tooling is adequate and re-design where needed.

c. Propose design revisions to the detector components where needed.

2. Draft assembly procedure documents for all the installation work.

3. Archive a complete set of component documentation for the mockup tests.

4. Write full set of Hazard analyses for the installation process and identify points where risk mitigation would be beneficial to reduce the risks.

5. Test proposed access equipment (scaffold, scissor lifts, work platforms) and lifting fixtures.

6. Perform assembly time and motion studies including labor estimates which will be used to develop the schedule.

7. Train the installation crew prior to start of work underground.

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Fulfilling these goals requires a staged program for the testing. While the designs of the detector components are being finalized the minimal steps needed to prototype the installation process should be executed with the primary focus of guiding and verifying the interfaces and the component design. After this initial campaign the design of the components can be finalized and the infrastructure for the installation can be revised and optimized. Once the design of the components is final the complete installation process then can be tested, and first realistic time/labor estimates can be determined along with the first draft of the hazard analysis and procedures. At least one revision of the installation equipment is proposed as experiences has shown that numerous small changes and additional tooling will be needed. Finally the installation prototype facility can be used to train the installation crews before the underground area is available. The details of the different installation campaigns will be described in Section 4.

3 Using the NOvA far Detector Laboratory for Installation Prototyping

The NOvA Far Detector Lab located at Ash River is owned and operated by the University of Minnesota via grants from the DOE and Fermilab. The NOvA detector measure 50 ft wide and 50 ft tall (15x15 m) roughly matching the dimensions of the DUNE Far Detector modules. Because of this the NOvA far detector assembly area adjacent to the operating detector is a logical place for the DUNE far detector installation prototyping effort. The 16m wide and 16.75m tall area available at Ash River for the DUNE installation tests is shown in Figure 1. This space is sufficient to both test the component assembly and also the deployment of the detector elements inside the cryostat. At Ash River an experienced crew of technicians and riggers are needed for support of the NOvA operations and are available for working on the DUNE installation during normal NOvA operating periods All of this crew has had multiple months of fabricating experience at CERN building ProtoDUNE. Also, a 75’ x 100’ loading dock and ramp access, two 10-ton cranes, a machine shop and wide assortment of tools are also available to support the installation testing. The combination of the local infrastructure and an existing crew knowledgeable on ProtoDUNE-SP installation makes the Ash River site the logical location for the installation testing.

While the University has jurisdiction over the safety program at Ash River, Fermilab’s Safety Program is also followed in a joint effort to insure a safe working environment. One of the key attributes of the ProtoDUNE work was compiling sets of documentation from component design, to hazard analysis, the final assembly procedures for approval by CERN HSE (Health Safety and Environment). For Ash River and DUNE this is all part of the Operational Readiness Clearance (ORC) process. Documentation for both the trail assembly process at Ash River and for DUNE will be stored on EDMS at CERN.

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NOvA Assembly area at Ash Riverwith APA Assembly Tower

DUNE Trial Assembly

Figure 1 Left: Photograph of the NOvA assembly area at Ash River. Right a 3-D model of the test installation setup.

4 Installation Prototyping ProgramWhile many of the DUNE-SP TPC components are similar to the components used in ProtoDUNE-SP the installation process is very different. The DUNE-PS TPC is constructed by hanging two 6m APA to form a 12m tall structure and extending the cathode planes from 6 to 12m. This requires connecting the two APA together underground and then cabling both the electronics at the bottom of the detector and at the top. In order to do this, different handling techniques need to be developed and a safe reliable means of working at 14m height has to be designed. Also, the detector needs to be assembled in 9 months requiring a much faster assembly process than what was used at ProtoDUNE-SP. The development of the installation equipment and processes are divided into four phases: Phase-I developing the APA assembly tooling and procedure, Phase-II initial prototyping of the installation process inside the cryostat and cleanroom, Phase-III refining the installation process and testing work on the cryostat roof, and finally Phase-IV training the installation crew. The details of the work for each Phase are given below:

4.1 Installation Prototyping Phase 1The first phase of the installation prototype focuses on the development of the APA assembly and cabling process including the handling and transport of the APA. These are the steps that are needed to verify the APA final design and related interfaces to the installation process. The installation infrastructure for this phase is the minimum needed to support the development of the APA assembly process and is meant to define the requirements and specifications for the final installation infrastructure. Also at this time the first cathode plane assembly tooling can be built and tested using the same infrastructure.

16.5m

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The goals of the Phase-I testing campaign are:

Installation prototype Phase-I Goals

APA transport and rigging test

Develop the process of handling the APA transport boxes and how the APA are removed from the boxes and placed on the installation infrastructure. Design the tooling needed to remove the APA from the transport boxes. Understand the interfaces between the APA and the installation equipment.

APA test assembly Test the assembly of an Upper and Lower APA. This requires design and construction of an assembly tower capable of holding the APA assembly fixtures. Developing the process of rigging the APA and mounting it on the fixture. Testing how the linkage can be inserted and verifying the interfaces between the top and bottom APA. The interface to the conduits inside the APA side tubes and the linkage and the assembly fixture must be verified.

APA cabling test Develop the process of inserting the cables for the bottom APA through the APA side tubes. Verify that there is adequate space in the conduit to allow the cabling to take place. Develop the method to hold the 13m long cable bundles in place. Develop the process of bundling the cables into the cable trays at the top of the APA.

Prototype the APA assembly and cabling tower

Develop the initial design of the APA assembly tower and access equipment. Draft the specifications for the APA assembly tower. Understand the space/access needs for the assembly work. Test the construction to estimate the time needed. Get initial cost estimates.

CPA assembly test The CPA design has been modified to construct 12m tall panels and to take into account the lessons learned from ProtoDUNE-SP. The fixture to hold the CPA units during assembly will be tested and the interface to the installation support structure defined. The assembly process will be tested and the planned times revised.

In order to achieve the Phase-I goals the following equipment is needed (more details are found in the accompanying spreadsheet):

Equipment needed for Phase-I Responsible GroupTwo mockup APA side tubes APATwo APA frames APAAPA assembly fixture APAAPA rigging tools APACE cables and cable trays CETrolleys InstallationPD cable mockups PDAPA assembly tower InstallationScissor lift for 12m Installation

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Scaffolding for the assembly tower

Installation

Revised HV Panel and FC module HVCathode assembly tooling HV

In addition to the hardware the consortia will deliver complete drawings and part lists. The prototype APA assembly tower is designed by the APA group, but procured through the University of Minnesota. The design of the tower is shown in Figure 2. The concept is to build a steel frame which holds the APA assembly fixture and then install a scaffolding on the inside to allow access to the sides of the APA over the full 12m height. On the side away from the tower the face of the APA can be accessed using a scissor lift. Initial equipment to insert the CE cables in the APA side tubes will be purchased and the specifications developed for the final tooling.

Figure 2: Prototype APA assembly cabling tower

The deliverables from the Phase-I test are:

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1. Verification that the upper and lower APA can be assembled and the design of the linkage is viable or recommendations for re-design.

2. Draft Procedures for the assembly of two APA into a doublet.3. Draft hazard analysis for the assembly process.4. First time estimate for the APA assembly step.5. Interface documentation between the APA assembly fixture and the installation tower.6. Verification that the lower CE readout electronics cables can be installed using the

conduit. 7. Initial interface drawings between the APA and CE cabling.8. Definition of the 25m CE cable support to the APA frame9. Draft procedures for the cable installation10. Proposal for the cable bundling in the cable trays on the APA.11. Initial interface drawings between the APA, Cable trays, and trolleys.12. Initial time estimate for the cable installation step.13. Cable harness drawings14. Hazard analysis for the cable insertion15. Initial design of the frame to hold the CPA assembly fixture16. First test of the 12m cathode assembly tool17. Input to the preliminary design of the installation infrastructure

4.2 Installation Prototyping Phase 2

It is expected that a great deal will be learned from the initial assembly tests that will alter the plans for the later tests. The experience gained during the initial tests will guide the preliminary design process for the installation infrastructure and may lead to significant revisions to the prototype tower design. The infrastructure at Ash River will also be expanded to allow testing of the switchyard and DSS systems along with a test deployment of the detector components. The goals for the phase-II test are below:

Installation prototype Phase 2 Goals

Revise the APA assembly and cabling prototype tower

The assembly tower will be modified in accordance to the lessons learned from the Phase-I test.

Test the transport and switchyard concept

The motion of the 12m tall APA on the rail system to be used for DUNE Will be tested. The rail connections will be refined to allow rapid safe connections. The motorized and passive trolleys will be tested and the designs revised based on the operation under realistic conditions.

Verify the detector deployment process and tooling

A prototype model of the DSS inside the cryostat will be constructed. Test deployments of the first and last rows of the detector will be performed. This will verify the interfaces between the detector components, the cryostat, and the installation tooling. Revisions to the tooling and detector elements will be proposed.

Perform QA on detector Verify that TPC alignment is correct and that all components hang

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deployment vertically.

Perform time and motion studies for the installation

Once the deployment has successfully been completed numerous times then the first realistic time and motion studies can be performed.

Develop installation procedures and hazard evaluations

Draft procedures for the installation process will be developed as part of the test installation. Initial hazard evaluations will be developed prior to the start of the prototype work.

The equipment needed for the phase-II tests are summarized below (more details are found in the accompanying spreadsheet):

Equipment needed for Phase 2 Responsible GroupModified assembly tower-Add Platform

Installation

Modified APA assembly fixture APAModified APA rigging tools APARevised CE cables and cable trays CEMotorized and passive Trolleys InstallationDSS support tower InstallationDSS Prototype InstallationRevised HV assembly fixture HVHV deployment Tooling HVDSS installation tooling InstallationRevised HV Panel and FC module HVTop and bot. HV ground planes HVFC latches HV

The concept of the Phase 2 setup is shown in Figure 3 and Figure. A prototype of the switchyard is between the assembly tower from Phase 1 and the detector deployment area. This includes the DUNE cleanroom work platform attached to the tower for better access. Part of the phase-II testing will be to develop the tooling and procedures to remove the switchyard at the end of the installation.

The deliverables from the Phase 2 test are:

1. Testing and verification of the revised cabling and assembly tower for the installation preliminary design including the elevated work platform.

2. Tests of the switchyard concept for moving the 12m tall APA in the cleanroom. Proposal for revisions to the switchyard and DSS design to facilitate the motion.

3. Test motion of the CPA from the assembly area to the cryostat.4. Validation of the DSS preliminary design 5. Propose revisions to the TPC component designs to enable the assembly, if required.

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6. Validation of the TPC mechanical design by validating that the components can be assembled.

7. Initial installation tooling list.8. Draft procedures for the TPC installation and deployment9. Draft hazard evaluations.10. Initial time and motion studies for the TPC assembly inside the cryostat.11. Initial procedures for the TOC closing and final assembly steps.

Figure 3: 3D model of the Phase 2 configuration of the DSS steel support structure

4.3 Installation Prototyping Phase 3

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The third phase of the installation prototyping is dedicated to testing the proposed revisions to the installation equipment, detailed studies of the DSS, and prototyping the work on the roof of the cryostat. The DSS prototype infrastructure is expanded to include one row of DSS support feedthroughs. This will allow both testing the feedthrough installation and the DSS installation in general. It will also test the lateral support system in the DSS so the motions of the rails during the installation process can be better understood. A false roof is also installed over the Phase-II setup which allows testing the CE cable deployment through the cryostat roof. This step is especially important to prototype as the individuals inside the cryostat are working from a 12m tall lift and the APA wires will be exposed. Careful planning here is important to insure no damage can occur.

Installation prototype Phase 3 Goals

Validate the DSS final design. Test the lateral support system for the DSS and understand the motion during APA installation. Test the DSS feedthrough installation.

Test the final CE cabling deployment.

Develop the procedure for feeding the detector cables through the cryostat roof. Propose any protective covers/tooling needed to protect the APA.

Time and motion study for the CE cabling

Develop the procedures for the cabling and estimate the time and labor requirements.

APA Shipping test Test the APA packaging and shipping for the first units from UK and US

A summary of the equipment needed for the Phase 3 test is as follows:

Equipment needed for Phase-III Responsible GroupModified DSS support structure InstallationMockup of the cryostat roof InstallationCE feedthrough CECE tee CERevised Trolleys InstallationFinal APA shipping box APAFinal Installation tooling Installation

The deliverables from the Phase 3 test are:

1. Validation of the CE cabling procedure.2. Validation of the CE cable tray and feedthrough design.3. Final time and motion studies and updated schedule for the installation.4. Draft procedures for the CE cabling through the cryostat.5. DSS installation procedures.6. DSS survey procedures.

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7. Validation of the APA packaging and shipping process.

4.4 Installation Prototyping Phase IV

The infrastructure used to develop the installation procedures and tooling is used in this phase to train the lead workers for the installation itself. This work is performed just prior to the start of the detector setup period. Once the lead workers for the core crew are trained they will start work at SURF to set up the detector installation. As the core installation team are hired several installation campaigns will take place at Ash River to prepare the workers for the detector installation. The goal of this period is to ensure that all the workers know how to handle the detector components prior to starting to work on live elements. As a single APA doublet costs about $500k this preparation with mockups if warranted.

5. ProtoDUNE 2 Trial Assembly

Early in 2021 we are scheduled to install 3 new APAs and a complete new HV field cage system at CERN for ProtoDUNE. We have left the original ProtoDUNE trial assembly steel structure in place so these tests can be performed. Before work at CERN an entirely new deployment system must be designed and tested for both the Endwall and the Field Cages. Preliminary tests of the new Field cage and ground plane design will be completed at Ash River in 2019.

A summary of the equipment needed for the ProtoDUNE 2 test is as follows:

Equipment needed for Phase-III Responsible GroupModified deployment system InstallationMockup of the DSS InstallationEnd Wall and Field Cages HV

The deliverables from the ProtoDUNE 2 Trial Assembly test are:

1. Validation of the HV installation procedures.2. Validation of the TPC deployment3. Document and test all new lifting fixtures4. Final time and motion studies and updated schedule for the installation.5. Draft procedures for decommissioning ProtoDUNE in the cryostat at CERN6. Draft procedures for new installation procedures and documentation required for

approval

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