**1_3 RICH DETECTOR**

**MECHANICAL ENGINEERING, DESIGNER, and DRAFTING**

**BASIS OF ESTIMATE**

March 8, 2004

COLOR CODE

ME and DESIGNER TIME = BLACK

MATERIALS = Green

TECH and SHOP TIME = PURPLE

TYPOs and general comments= RED

General notes:

Survey time should be fnal survey people not necessarily syr.phys.

Fnal.shop time is 0\$

Tooling requires engineering and designer time

1.3.4.5.5 100 hr 200 hr Mirror support structure needs engineering and
designer time

Gas radiator prototype is being constructed now for use on the testbeam

Use of proto vs production vs finalize should be clarified

--see gas radiator wbs line descriptions

> what about shipping prices for parts from Syracuse to Fnal? Many shop
> items are made at Syracuse
>
> what about items that are assembled at FNAL? Syracuse techs or FNAL
> techs?

1.3.1.3.1.2.15 is 2 years delayed? Check date

1.3.2.5.1 pmt module prototype is listed for oct03

1.3.2.5.2.1 listed as oct03

2.  listed as oct03

1.3.5.2.7.1.1 change labor

1.3.5.2.9.1.2 change ME labor

1.3.5.2.14.1.4 fnal tech time --performed here. IFIX is here.

1.3.5.2.15.1.1 add designer labor

1.3.5.3.1.1 proto occurs much after 1.3.5.3.1.3 production

1.3.5.3.1.2.1 change labor

1.3.5.3.1.4.1 add designer labor,material costs and fnal shop/weld
time??

1.3.5.3.2.2 beehive-channel typo

1.3.5.3.2.4.1 add designer labor

1.3.5.3.3.2.1 change Me designer labor

1.3.5.3.3.3.8 techs should leak check, not phys.

1.3.5.3.3.4.1 change labor

> 1.3.5.3.4.2 and .3 (.2 should happen before .3)
>
> 1.3.5.3.5.1.1 two years early?
>
> 1.3.5.3.6.2.1 change labor
>
> 1.3.5.3.6.4.1 changer labor
>
> 1.3.5.3.6.4.2 change labor
>
> 1.3.5.3.7.4.1 change labor
>
> 1.3.5.3.7.4.2 change labor

1.3.5.3.10.1.2 May need to add additional costs for the front window and
also for tooling. A large flat table will be needed. (on the scale of
170 inches square)

1.3.5.3.11.1.1 add designer labor

1.3.5.3.12.3.2 where to put machine shop time for fabbing parts?

1.3.6.4.3.2 and 1.3.6.2.3.2 does this belong in 1.10?

1.3.6.7.4.1.1 Add designer labor

1.3.6.8.5.1 change labor

1.3.7.4.1.1 date is oct06, we are doing this now?

1.3.7.4.2.1 also doing now and needs a lot of ME time and Designer time.

1.3.2.5.4.2Test (QA) - first 25% what about remaining 100%??

1.3.1.3.1.1.1 Finalize Des of modules for production MAPMTS

Design Task

ME,136;

DSGRDR,204

28mar06

> A module consists of 8 mapmts. No mechanical drawings are associated
> with this task.

1.  Acq Parts for mapmt production 100%

> Btev.Syracuse mands, \$18,929 additional \$1893
>
> 25apr06

2.  Fab parts for the mapmt Prod -- first 25%

Syracuse.shop, 64 hrs

25apr06

1.3.1.3.1.2.3 Fab tooling for mapmt Prod

Syracuse.shop, 40 hrs

25apr06

4.  Construct mapmt first 25%

> Syracuse.Tech, 160hrs
>
> 08jun06

1.3.1.3.1.2.8 Fab parts for the mapmt Prod -- remaining 75%

Syracuse.shop, 136 hrs

06sep06

1.3.1.3.1.2.9 Construct mapmt second 25%

Syracuse.Tech, 160hrs

06sep06

1.3.1.3.1.2.12 Construct mapmt third 25%

Syracuse.Tech, 160hrs

19oct06

1.3.1.3.1.2.15 Construct mapmt last 25%

Syracuse.Tech, 160hrs

11dec08

3.  MAPMT Mech Alignment Syst -- FNAL

6-Dec-06

1.  Des alignment scheme & alignment Syst

> Design Task

ME,40

01oct08

> Current design is to use shims between the mapmt enclosure and tank
> frame. The shimming process needs to incorporate a leak tight seal.
> Crude alignment of the mapmt enclosure will occur then the mirror
> array will be positioned relative to the mapmt array.
>
> May require multiple redesigns. Prototype shims are used to position
> the mapmt enclosure on the test beam stand.
>
> The design currently needs one revision from the testbeam stand size
> and shape to the real enclosure size and shape. A second final
> revision will also need to be made.
>
> Shims require 5 drawings, at 4 hours a drawing to make changes and
> produce prints, requires 20 hours drafting time per design change.
> Engineering analysis and follow through requires about 50% the
> drafting time per design change.
>
> 2 design changes
>
> ME time = 20 hrs

Designer time = 40 hrs

2.  Acq parts for Mech alignment System

> Syracuse.Mands \$10516
>
> 28nov08

3.  Fab Parts for alignment Syst

> Syracuse Shop, 40 hrs
>
> 28nov08

5.  PMT mechanics

    2.  Acq parts for Proto Mod

Syracuse.Mands.Base \$10516

15Oct03

Materials:

Prototype stereo-Lithography samples (Fragile)

QTY: 1 \$104

QTY: 25 \$2,345.50

Met-L-Flo

Geneva Il, Lonnie Yingst

Prototype quote #2 Industrial Modern Pattern

Qty : 1 \$800

Tooling: \$1000 (for a cast to make additional qty's)

\$100 each for cast parts made from the model

3.  Fab parts for Proto Mod

Syracuse.Shop 160

15Oct03

1.  Des Proto Module

> PPD.ME 112 hrs
>
> PPD.DSGRDR 168 hrs
>
> 01Oct03

2.  Test & Measure Mech Properties of Protos

PPD.ME 40 hrs

29Oct03

2.  Acq 1^st^ parts for Mod Prod 100%

> Syracuse.mands.additional, \$12093
>
> Syracuse.mands.base, \$2419
>
> 23dec04

Materials:

Prototype stereo-Lithography samples (Fragile)

QTY: 1 \$104

QTY: 25 \$2,345.50

Met-L-Flo

Geneva Il, Lonnie Yingst

Prototype quote #2 Industrial Modern Pattern

Qty : 1 \$800

Tooling: \$1000 (for a cast to make additional qty's)

\$100 each for cast parts made from the model

Production:

Injection mold \$40,000 (Ron Evans Fermi Purchasing)

Price each part \~\$2 depends on plastic type used.

5,500 pieces = \~\$11,000

Total Production cost \~\$56,000

3.  Acq 2^nd^ parts for Mod Prod 100%

> Syracuse.mands.additional, \$42

Syracuse.mands.base, \$10601

24mar05

1.3.2.5.4.1 define Specs & Des PMT Mod

Design Task

ME,96

02dec05

> Design specifications are to make a pmt holder that will hold the pmt
> in the mu-metal beehive and prevent the pmt from falling out of the
> beehive. The module should be stable so that the pmt doesn't move.
> Creep prevention should be considered in the module design. A module
> consists of a single PMT
>
> Prototypes will be used in the test beam, an initial module design is
> complete for a specific 3 inch pmt.
>
> The design currently needs one revision to finalize the test beam
> stand size and shape. A second final revision will also need to be
> made prior to use at C0.
>
> Module require 1 drawings.
>
> 2 design changes, minimum design time 10 hours engineering and 10
> hours drafting.
>
> ME time = 20 hrs

Designer time = 20 hrs

1.3.2.5.4.2 Test (QA) assembled Mod Mechly - first 25% what about
remaining 100%??

Test

ME,56

23dec05

> Test specifications need to be created for glue strengths, module
> construction techniques, strength of pmt holder, debug assembly of the
> module, and creep of the pmt holder.
>
> ME time to create test plans and perform test data analysis
>
> 56 hrs
>
> Tech time to assemble test setups and perform test
>
> 56 hrs

1.  Des Mech alignment Syst

> Design Task

DSGRDR,40;

ME,40

15dec06

> Current design is to use shims between the pmt beehive and the
> enclosure frame. Crude alignment of the pmt beehive and enclosure will
> occur and will be positioned relative to the liquid radiator and
> interaction point.
>
> May require multiple redesigns. Prototype shims are used to position
> the pmt beehive and enclosure on the test beam stand.
>
> The design currently needs one revision to create what is needed for
> the testbeam stand, one for the real enclosure size and shape. A third
> final revision will also need to be made.
>
> Shims require 5 drawings, at 4 hours a drawing to make changes and
> produce prints, requires 20 hours drafting time per design change.
> Engineering analysis and follow through requires about 50% the
> drafting time per design change.
>
> 3 design changes

ME time = 30 hrs

Designer time = 60 hrs

2.  Acq parts for alignment syst Prod

> Syracuse.mands.base \$2629
>
> 02jan07

3.  Fab Parts for alignment Syst

> Syracuse.Shop, 40 hrs
>
> 15dec06

5.  Mirror Array Mechanics

    1.  Des Mirror Mount Proto

> PPD.ME 40 hrs
>
> PPD.DSGRDR 64 hrs
>
> 02Jan04

1.  Mirror-Segment Mech Mounting Construction

> 12sep03

1.  Des mirror mount

Design Task

DSGRDR,120

ME,80

16Nov04

> Current design is to use a 3 point kinematic mirror mount to support a
> 60 cm mirror for the testbeam. 12 drawings are required.

Prototype mounts are used on the test beam stand.

> The design currently needs one revision to create what is needed for
> the 1 meter mirrors for the production design. A second final revision
> will also need to be made.
>
> Mounts require 12 drawings, at 4 hours a drawing to make changes and
> produce prints, requires 48 hours drafting time per design change.
> Engineering analysis and follow through requires about 50% the
> drafting time per design change.
>
> 3 design changes

ME time = 48 hrs

Designer time = 96 hrs

2.  Acq parts for mirror mount

> Syracuse.Mands.additional \$841
>
> Syracuse.Mands.Base, \$3786
>
> 16dec04

3.  Fab Parts for mirror Mount

> Syracuse.shop, 720 Hrs
>
> 16dec04

4.  Fab tooling for mirror mount Assy

> Syracuse.shop, 1 hr
>
> 16dec04

5.  Construct mirror mount

> Syracuse.tech, 400 hrs
>
> 08aug05

1.  Acq Matl for mirror panel

> Syracuse.mands.base \$57,072
>
> 25oct05

Mirror Support Panel

HC 12/02/02

Constructed of Carbon fiber strips and a rohacell foam core.

Material per panel

Carbon fiber 45 Mpsi,

> 12 strips \@24"x176"x 0.062"

16 strips \@24"x80" x 0.062"

400 lbs @ \$100/lb = \$40,000

(Hermans est based on YLA)

Carbon fiber plate ½" thick 2" by 2"

\~100 pieces (400 in\^2) = \$800

(Hermans est based on KCI orders)

Rohacell 51 WF

50% fill , average thickness is 12" x176"x80"

84,500 in\^3 \*\$.15/in\^3 = \$12,672

Epoxy 3M -2216 = \$800

Vacuum bag and tooling = \$2000

Total = \$56,272

Labor per panel

Ribs

> Technician time 4 ribs/day x 2 man =14 man days
>
> Based on lab 3 estimate

Foam

Cutting foam

2 man Days (Hermans Estimate)

> Assembly
>
> 2 man x 10 days per panel = 20 man days
>
> based on lab 3 estimate
>
> Machine shop time to trim ribs and machine mounts for mirrors
>
> 1 month (Herman's estimate)
>
> (ave milling rate \~10 inches per minute -- perimeter of 1 rib is
> \~370 inches --requires 2 passes 1 to score and 1 to cut, also ½ day
> per rib to program the shape)

2.  Fab Parts for mirror panel Prod

> Fnal.PPD.Shop 448 hrs
>
> 25oct05

3.  Tooling for panel Production

> Syracuse.Mands Base \$2,103
>
> 25oct05

1.  Des Mirror Frame Proto

> PPD.ME 120 hrs
>
> 01oct04

2.  Acq parts for mirror frame Proto

Syracuse.Mands.Base \$5258

12nov04

3.  Fabr Parts for mirror frame Protos

> Syracuse.shop 80hrs
>
> 12nov04

1.  Fab tooling for mirror frame

> Syracuse.shop, 80hrs
>
> 12may06

2.  Acq parts for mirror frame Prod

> Syracuse.Mands base \$15,774
>
> 12may06

3.  Fab parts for mirror panel Prod

> Syracuse.Shop 120 hrs
>
> 12may06

4.  Construct Mirror Panels

> Syracuse.tech 160 hrs
>
> 12jun06

1.  Fab tooling to attach mirror mounts to panels

> Syracuse shop 40 hrs
>
> 26may06

2.  Fab tooling to handle & move mirror mount subAssy

> Syracuse shop 40 hrs

12jun06

3.  Fab tooling to handle & move mirror panel Assy

> Syracuse shop 40 hrs

12jun06

4.  Acq parts to attach mirror mounts to mirror panel

> Syracuse.mands.base \$3,155

26jul08

5.  Fab parts to attach mirror mounts to mirror panel

> Syracuse shop 40 hrs

09aug06

1.  Fab tooling to attach mirror panels to mirr. Frame

> Syracuse.shop 40 hrs
>
> 14sep06

2.  Fab tooling to handle & move mirror frame Assy

> Syracuse.shop 40 hrs

21sep06

3.  Acq parts to attach mirror panels to mirror frame

> Syracuse.base \$3,155

28sep06

4.  Fab tooling to attach mirror panels to mirr. Frame

> Syracuse.shop 40 hrs

26oct06

1.  Fab tooling to attach mirr. Frame to vessel frame

> Syracuse.shop 40 hrs
>
> 22nov06

2.  Acq parts to attach mirror frame to vessel frame

> Syracuse.base \$3,155

01dec06

3.  Fab parts to attach mirr. Frame to vessel frame

> Syracuse.shop 40 hrs
>
> 02jan07

1.  Attach mirror mounts to mirror panel

> FNAL.ppd.tech 160 hrs
>
> 26oct08

1.  Attach mirror panels to mirror frame

FNAL.ppd.tech 40 hrs

09nov06

1.  Attach mirror frame to vessel frame

FNAL.ppd.tech 80 hrs

24jan07

1.  Des alignment Syst Proto (mirror alinment syst Dev)

> PPD.Me 80 hrs
>
> 24aug07

1.  Fab tooling for alignment Syst Assy

> Syracuse.shop 80 hrs
>
> 24sep07

2.  Acq parts for alignment Syst Assy Prod

Syracuse.mands.base \$8413

08oct07

3.  Fab parts for alignment Syst Assy Prod

Syracuse.shop 80 hrs

05nov07

2.  Mirror Monit & Calibration Syst Dev -- FNAL

> 12sep03

2.  Acq Parts for Monit & Calibration Syst Proto

> Syracuse.mands.base \$2629
>
> 22nov05

3.  Fab Parts for Monit & Calibration Syst Proto

Syracuse.shop 80 hrs

22nov05

1.  Des Monit & calibration Syst Proto

Design Task

ME,80

25oct05

> Current design is to use create a support panel for an led array
> inside the radiator vessel.
>
> The design currently needs one revision to create what is needed for
> the prototype.
>
> 1 design changes

ME time = 40 hrs

Designer time = 80 hrs

3.  Mirror Monit & calibration Syst Prod-Syracuse

    2.  acq parts for monit & calibration syst Prod

> Syracuse.mands.base \$5258
>
> 16feb06

3.  fab parts for monit & calibration syst Prod

> Syracuse.shop 80hrs
>
> 16feb06

4.  construct monit & calibration syst

> Syracuse.tech 80 hrs

11may06

4.  Mirror Monit & Calibration Syst

13-Mar-06

1.  Finalize Des of Mirror Monit & calibration Syst

Design Task

ME,32

22nov05

> Current design is to use create a support panel for an led array
> inside the radiator vessel.
>
> The design currently needs one revision to create what is needed for
> the final production model.
>
> 2 design changes

ME time = 40 hrs

Designer time = 80 hrs

1.3.5 Mech,gas,liquid & related systs

2.  Acq gas needed to fill gas radiator

> Syracuse.mands.additional \$1357
>
> 02oct08

1.  Radiator Gas Circulation Syst Dev

    1.  Des Proto radiator gas circulation Syst

Design Task

ME,160

06nov03

> Design for the gas circulation system that will be used on the test
> beam stand is nearly complete. The same design could be used for
> production with a small number of modifications.
>
> A technician will fabricate what is needed for the prototype using the
> process diagram. No plumbing hardware drawings are made.
>
> ME analysis time = 40 hours
>
> Designer time to create PID revisions = 8 hours

1.3.5.1.5.1.2 assess Perfance of Proto gas circulation Syst

Evaluate

ME,40

08mar04

> Ensure that the circulation and filtration systems are performing to
> their specifications.
>
> ME time = 40 hrs

2.  acq matl for proto gas circulation syst

> Syracuse.mands \$84,128
>
> 25jan06

3.  Fab parts for proto gas circulation syst

> Syracuse.shop 160 hrs
>
> 25jan06

4.  assemble Parts for Proto Gas circulation syst

> Syracuse.tech 320 hrs
>
> 14jul06
>
> ESTIMATE FROM FNAL is 1 man month on testbeam system

1.  Radiator Gas Circulation Syst Prod

    1.  Des radiator gas circulation Syst

Design Task

ME,120

3-Oct-05

> Design for the gas circulation system that will be used on the test
> beam stand is nearly complete. The same design could be used that was
> used on the test beam with a small number of modifications.
>
> A production process diagram is needed along with plumbing hardware
> drawings for installation at the collision hall. Analysis of the new
> plumbing hardware system is also performed.
>
> ME analysis time = 40 hours
>
> Designer time to create PID revisions and plumbing hardware layouts =
> 120 hours

1.3.5.1.7.1.2 assess Perfance gas circulation Syst

Evaluate

ME,40

25-Jan-06

> Ensure that the circulation and filtration systems are performing to
> their specifications.

ME time = 40 hrs

7.  Radiator Gas Monit Syst

    1.  des proto PRODUCTION radiator gas monit syst

> Syracuse.srtech 40 hrs
>
> 03oct05

1.3.5.1.8.2 acq parts for proto PRODUCTION gas monit syst

syracuse.mands.base \$5258

31oct05

1.3.5.1.8.3 fab parts for proto PRODUCTION gas monit syst

> Syracuse.shop 80 hrs
>
> 31oct05

1.3.5.1.8.4 assemble parts for proto PRODUCTION gas monit syst

> Syracuse.tech 160 hrs

30nov05

1.  Des radiator gas Monit Syst

Design Task

ME,56

3-Oct-05

> For the gas system with 20 I/O channels, assuming it is added to an
> existing control system:
>
> Wiring effort including drawings, pulling cables, terminations, 3
> man-days. Sensor calibration, say two hours for each pressure
> transmitter, one for each temperature sensors. If there are high
> precision or very sensitive instruments it would take twice as long.
> Conversely non-critical temperature sensors have no calibration time.
> This assumes that common industrial instruments are involved.
>
> Effort to draw graphics, enter database, setup historical collection,
> 2 man-days.
>
> Effort to configure controls depends on how much automation. The last
> time we talked the only automatic control involved the pressure
> control. The circulation may be started and stopped through the
> control system. Estimate 2 man-days.
>
> Total engineering and technician time 10 man-days. It would not hurt
> to add a couple of days contingency to the total.

ME time = 40 hrs

Tech time = 30 hrs

Designer time = 20 hrs

2.  assess Perfance of gas Monit Syst

Evaluate

ME,24

31-Oct-05

> Confirm that all I/O is working properly and that all alarm features
> and setpoints are working.

ME = 24 hrs

1.3.5.2 LIQUID RADIATOR SYST

2.  acq liquid needed

> Syracuse.mands.base \$5,109
>
> Syracuse.mands.additional, \$7,663
>
> 02oct07

1.  Liquid Radiator Vessel Des Development

> PPD.ME 120 hrs
>
> 02oct07

2.  Assess Mech properties of Liquid rdiator vessel Proto

> PPD.ME 160 hrs
>
> 27mar08

1.  Define quartz window specs&geometry

> PPD.ME 120 hrs
>
> 05sept07

2.  Assess that quartz windows conform to specs

> PPD.ME 8 hrs
>
> 03oct07

2.  acq parts for liquid radiator vessel

> Syracuse.mands.base \$15,774
>
> 30dec04

Materials:

Plastic 48" x 96" sheet, PVC, (AIN) = \$250 per vessel

Adhesive = \$100 per vessel

Carbon fiber backing 0.059" x48" x96"

\$100/ lb, 0.08 lb/in\^3 = \$2200 carbon per vessel

Tooling (vacuum bag, release paper) = \$1000 per vessel

Total: =\$3550 per vessel

3.  fab parts for liquid radiator vessel

> Syracuse.mands.shop 400 hrs
>
> 01feb05
>
> Machining time for plastic vessel:= 80 hrs (Fermi Shop est)
>
> Machining time for carbon fiber parts
>
> Machining time for carbon fiber tooling

4.  assemble liquid radiator vessel

> Syracuse.tech 800 hrs
>
> 03oct07
>
> FNAL.PPD.Tech assy time, carbon layup and Assembly of vessel = 120 hrs
> (D. Butler Lab 3) (1 vessel 2 required)
>
> = 240 hrs Total
>
> Requires quartz butt joints, See Delphi Rich for similar joints

2.  acq quartz windows

> Syracuse.mands.base \$20,243
>
> 31oct07

Materials:

Quartz

Behm Quartz 1-800-543-7875 \$2.60/in\^2

National Scientific Company \$2.25/in\^2

9200 in\^2 \* \$2.40 ave per in\^2 = \$22,000 Total (2 vessels)

6.  Liquid Vessel

1.3.5.2.7.1.1 finalize the liquid radiator vessel Des

Design Task

ME,45 dsgrdr, 90

30dec04

> A prototype Vessel will be used on the test beam stand. A production
> version design will be created based on the knowledge of the
> prototype. Then a finalized revision will be made.
>
> The vessel design requires 10 drawings, at 4 hours a drawing to make
> changes and produce prints, requires 40 hours drafting time per design
> change. Engineering analysis and follow through requires about 50% the
> drafting time per design change.
>
> 3 design changes

ME time = 60 hrs

Designer time = 120 hrs

> Footnote:

1)  Design still needs input for liquid fittings and attaching frame to
    RICH tank

2)  Stud spacing in vessel is determined by minimizing the stress in the
    quartz due to liquid head pressure.

    1.  Quartz Window Prod & Test

1.3.5.2.7.2.1.1 define Quartz Window Specs & Des

Design Task

ME,80 ppd.tech 40

03oct07

> Analysis is performed to ensure that the liquid pressure does not
> induce large stresses in the quartz. Also analysis and procedures are
> required to create butt joints between quartz windows and also between
> the quartz and the vessel. Testing for glue joints will also be
> performed.
>
> 3 designs , prototype, production, finalized

ME time = 80 hrs

Tech time = 40 hrs

2.  Acq parts for liquid radiator circulation system proto

> Syracuse.mands.base \$10516

Feb05

3.  fab parts for liquid radiator circulation syst proto

> Syracuse.shop 160 hrs
>
> Feb05

4.  assemble liquid radiator circulation and control syst proto

> Syracuse.tech 160 hrs
>
> Jun05

1.  des liquid radiator circulation syst

> PPD.DSGRDR 240 hrs
>
> PPD.ME 160 hrs
>
> 30Dec04

See Delphi Rich for similar system, Mr. Bosteels

2.  test liquid radiator circulation and control syst proto

> PPD.ME 320 hrs
>
> 15feb05
>
> see comments about gas system testing ME=100 hrs

2.  acq parts for liquid radiator circulation syst Proto

> Syracuse.mands.additional \$1,315
>
> Syracuse.mands.base \$5,258

01feb05

Prototype liquid system is used on the testbeam stand

Materials:

UV sterilizer?

Distiller to remove water vapor? or c4f10??

Reservoir tank to hold entire system volume

Heat exchanger to maintain stable bath temperature

Insulated plumbing lines to maintain temp. from xchanger to vessel

1 particulate Filter \$1000

2 Pressure gages and 2 pressure transmitters minimum \$1000

Circulation pump \$3600

6 temperature sensors minimum \$600

4 throttling valves to balance flows between chambers

4 drain valves, one for each chamber

4 flow meters to monitor flow in each chamber and calibrates flow

> transmitters \$600

4 flow transmitters, one for each chamber \$4000

3.  Fab parts for liquid radiator circulation syst Proto

> Syracuse.shop 160 hrs

01feb05

4.  assemble liquid radiator circulation syst

> Syracuse.tech 480 hrs

24may05

1.  Radiator Liquid Circulation Syst Prod

    1.  Des liquid radiator circulation Syst

Design Task

DSGRDR,200

ME,120

30-Dec-04

> Time includes analysis and creation of a system that maintains a clean
> liquid and the desired temperature and pressure ranges.
>
> Task includes the process diagram and plumbing hardware layouts
>
> Task includes the design for the prototype used at the test beam, the
> production version and the final version.
>
> ME time = 120 hrs
>
> Designer time = 200 hrs
>
> Footnotes:

1)  Requires 4 separate systems to prevent excessive liquid head
    pressure from forming on the quartz plates.

2)  Pumps are located on a skid near the RICH tank inside the collision
    hall. Pumps are on the floor to prevent large overhead head
    pressures on the quartz plates. Also to maintain bath temp vs vessel
    temp

1.3.5.2.11.1.2 test liquid rad. circulation & control Syst Proto

Test

ME,40

1-Feb-05

Time includes system startup analysis and monitoring time includes gas
system?

2.  acq parts for liquid radiator monit system

> Syracuse.mands.base \$5258

01mar05

3.  fab parts for liq rad monitor

> syracus.shop 80 hrs
>
> 01mar05

1.  Des liquid radiator monit syste (R&D)

PPD.ME 40 hrs

01feb05

2.  assess liq rad monitor syste

> PPD.ME 40 hrs
>
> 29mar05

2.  acq parts for liquid radiator monit syst

> Syracuse.mands.base \$5258

29mar05

3.  fab parts for liquid radiator monit syst

> Syracuse.shop 80 hrs

29mar05

4.  assemble parts for liquid radiator monit syst

> Syracuse.tech 160 hrs

24may05

CHANGE TO FNAL TECH TIME

1.  Radiator Liquid Monit Syst Prod

1.3.5.2.15.1.1 Des liquid radiator Monit Syst

Design Task

ME,80

1-Feb-05

> For the gas system with 20 I/O channels, assuming it is added to an
> existing control system:
>
> Wiring effort including drawings, pulling cables, terminations, 3
> man-days. Sensor calibration, say two hours for each pressure
> transmitter, one for each temperature sensors. If there are high
> precision or very sensitive instruments it would take twice as long.
> Conversely non-critical temperature sensors have no calibration time.
> This assumes that common industrial instruments are involved.
>
> Effort to draw graphics, enter database, setup historical collection,
> 2 man-days.
>
> Effort to configure controls depends on how much automation. The last
> time we talked the only automatic control involved the pressure
> control. The circulation may be started and stopped through the
> control system. Estimate 2 man-days.
>
> Total engineering and technician time 10 man-days. It would not hurt
> to add a couple of days contingency to the total.
>
> Three revisions are required, one for the test beam prototype, one for
> the production design, and one for the final version.

ME time = 120 hrs

Tech time = 90 hrs

Designer time = 60 hrs

1.3.5.2.15.1.2 assess liquid radiator Monit Syst Perfance

Evaluate

ME,72

29-Mar-05

> Confirm that all I/O is working properly and that all alarm features
> and setpoints are working.

ME = 24 hrs

2.  RICH vessel

    1.  des superstruct Proto

> PPD.ME 320 hrs
>
> 31jan08
>
> change to me 180 hrs designer 180 hrs

2.  acq parts for superstruct prod

> syracus.mands.base \$4,732
>
> 28apr05
>
> Tank Superstructure fabrication
>
> Constructed of 1 inch thick steel plates

Material

15,000 lbs of steel @ \$0.30/lb = \$4500

(Herman's estimate)

Labor

Machining 500 hours @ \$55/hr (FNAL Shop Est.) = \$27,500

Welding 500 linear feet ¼" fillet weld \~400 hrs = \$22,000

(Herman's Estimate)

3.  fab parts for superstruct prod

> syracus.shop 500 hrs

28apr05

4.  fab tooling for superstruct prod

> syracus.shop 80hrs

18oct05

5.  construct superstruct

> syracus.tech 240 hrs

06apr06

4.  SuperStruct Prod FNAL

1.3.5.3.1.4.1 Finalize the superStruct Des

Design Task

ME,120

28-Apr-05

Multiply time by 3.5, this task will re redesigned several times

Also needs a large amount of drafting time, for redesigns.

> The tank frame is designed after all of the other enclosure designs
> are complete. The tank frame interfaces with the sensor enclosures,
> the windows, the liquid radiator, must have outlets for the gas
> expansion volume, plumbing ports, features for transferring fiducials
> used during assembly and installation, tank frame feet and rollers,
> include a leak tight gas seal to all features, and include features
> that other detector subsystems need like supporting the beampipe
> installation rails for the straw tube chambers. As enclosures become
> finalized the tank frame is also updated to match the requirements of
> each attached subsystem. Installation procedures of each subsystem
> also need to be analyzed.
>
> The vessel design requires 20 drawings including weldments, at 4 hours
> a drawing to make changes and produce prints, requires 80 hours
> drafting time per design change. Engineering analysis and follow
> through requires about 50% the drafting time per design change.
>
> 4 major design changes

ME time = 160 hrs

Designer time = 320 hrs

2.  Test (QA) assembled superStruct Mechly

> ME,40
>
> 26sep06
>
> Load tested to ensure frame stability during temperature cycles and
> loading of subsystems.

1.3.5.3.1.4.3 leak check

fnal.tech 80 hrs

10oct06

> Superstructure should be leak checked and tested mechanically to
> ensure all joints are solid.
>
> Tech time = 80 hrs

1.  MAPMT plane suppt structs (channels)

    1.  Des of beehive proto (channel)

> PPD.ME 80 hrs
>
> 01Oct03

2.  acq parts for channel prod

> Syracuse.mands.base \$31,548
>
> 09may06

3.  fab parts &tooling for channel assy

> Syracuse.shop 80 hrs
>
> 09may06

4.  construct channel

> Syracuse.tech 800 hrs
>
> 29sep06

4.  MAPMT Beehive Prod FNAL

1.3.5.3.2.4.1 finalize channel Des

Design Task

ME,40

25apr06

> Current design is a 4x49 pack that is wired and assembled onto a
> support frame. A version of this is used on the testbeam stand.
>
> A single support bar requires 10 drawings to create the support, at 4
> hours a drawing to make changes and produce prints, requires 40 hours
> drafting time per design change. Engineering analysis and follow
> through requires about 50% the drafting time per design change.
>
> 2 design change
>
> ME time = 40 hrs
>
> Designer time = 80 hrs

2.  MAPMT Enclosure Prod

    1.  Finalize Des of enclosure Protos

> PPD.ME 160 Hrs
>
> 30Nov04
>
> ME 60 hrs designer 120

2.  Des external MagnShielding

> PPD.ME 80 hrs
>
> 01Feb05

2.  acq feedthrus for cables and cooling

> Syracuse.mands.base \$5,258

27oct06

3.  acq magnetic shielding

> Syracuse.mands.additional\$5,258
>
> Syracuse.mands.base \$21,032

27oct06

4.  fab tooling for enclosure assy

> Syracuse.shop 80 hrs

27oct06

5.  fab parts for mapmt enclosure

> Syracuse.shop 160 hrs

27oct06

6.  construct enclosure (2)

> Syracuse.tech 400 hrs

20apr07

1.3.5.3.3.4.1 Finalize Des of enclosure for Prod

Design Task

ME,80

09may06

> Requires 8 drawings for the enclosure, at 4 hrs a drawing to make
> changes and produce prints, requires 32 hours for the beehive tooling
> changes. Engineering analysis and follow through requires about 50%
> the drafting time per design change.
>
> The prototype design is used in the test beam. The production and
> final revisions are required.
>
> 2 revisions
>
> ME time = 32 hrs

Designer time = 64 hrs

2.  Fab tooling for assy procedure (modules into beehive)

> Syracuse.shop 160 hrs

24jul07

1.3.5.3.4.2.2 fab tooling for assy procedure (beehive onto vessel or
enclosure)

Syracuse.shop 160 hrs

24apr09

3.  per assy procedure (beehive into vessel or enclosure)

> Syracuse.tech 480 hrs
>
> Syracuse.grads 320 hrs
>
> 103aug09

2.  fab tooling for assy procedure (mapmt enclosure onto vessel)

> Syracuse.shop 160 hrs
>
> 28nov08

1.3.5.3.4.3.3 perf assy procedure (mapmt enclosure onto vessel)

Syracuse.tech 320 hrs

Syracuse.grads 320 hrs

30jan09

1.  Assy of modules into MAPMT Beehive

1.3.5.3.5.1.1 define Assy procedure of modules onto MAPMT
beehives/support bars

Procedure

ME,160

30mar07

> Writing a procedure for inserting a MAPMT module into the beehive is
> created. The procedure includes writing trailers for the location and
> details of the MAPMT module. An initial set of documentation is
> written, then revised based on feedback from the test beam prototyping
> experiences.

ME time = 80 hrs.

2.  Assy of MAPMT Beehive/support bars onto RICH Vessel SuperStruct

1.3.5.3.5.2.1 define Assy procedure of beehives/support bars onto RICH
vessel

Procedure

ME,160

30mar07

> Writing a procedure for inserting the beehive into the enclosure is
> created. The procedure includes writing trailers for the location and
> details of the MAPMT modules and beehive location information. An
> initial set of documentation is written, then revised based on
> feedback from the test beam prototyping experiences.

ME time = 80 hrs.

2.  perf assy procedure assy mapmt beehive onto rich vessel (enclosure)

> fnal.ppd.tech 320 hrs
>
> 30jan09

3.  Assy of MAPMT Enclosure onto RICH Vessel SuperStruct

1.3.5.3.5.3.1 define Assy procedure of MAPMT enclosure onto vessel

Procedure

ME,160

27mar09

> Writing a procedure for installing a complete instrumented enclosure
> onto the tank frame in the collision hall is created. The procedure
> includes writing trailers for the location and details of the MAPMT
> modules and beehive location information. An initial set of
> documentation is written, then revised based on feedback from the test
> beam prototyping experiences.

ME time = 80 hrs.

2.  perf assy procedure

> fnal.ppd.tech 160 hrs
>
> 03aug09

5.  PMT plane suppt structs (beehives)

    1.  Des PMT beehive protos

> PPD.ME 400 Hrs
>
> 03oct05
>
> change to ME 100 hrs, designer 200 hrs ( a dozen or so prints
> required)

2.  test mech properties of PMT beehive Proto

> PPD.ME 72 hrs
>
> 30nov05

2.  acq parts for pmt beehives

> Syracuse.mands.base \$122,778
>
> Syracuse.mands.additional \$5,419

01mar06

4.  fab parts for pmt beehives

> Syracuse.shop 640 hrs

01mar06

5.  assemble pmt beehives

> Syracuse.tech 400 hrs

29jun07

4.  PMT Beehive Prod FNAL

1.3.5.3.6.4.1 finalize PMT beehive Des

Design Task

ME,80

6-Jul-07

> Requires 7 drawings for tooling to create the beehive and 2 drawings
> for the beehive construction, at 4 hrs a drawing to make changes and
> produce prints, requires 36 hours for the beehive tooling changes.
> Engineering analysis and follow through requires about 50% the
> drafting time per design change.
>
> The prototype design is used in the test beam. The production and
> final revisions are required.
>
> 2 revisions
>
> ME time = 36 hrs

Designer time = 72 hrs

2.  test Mech properties of PMT beehives

> Test

ME,72

03aug07

> Testing includes glue strength, outgases, chemical compatibility tests
> and load testing of the beehive structure. It also includes testing
> the assembly procedure.

ME time =20 hrs

Tech time = 40 hrs

6.  PMT Enclosure Prod

    2.  acq parts for pmt enclosure proto

> Syracuse.mands.base \$2629
>
> 17jul07

3.  fab parts for pmt enclosure proto

> Syracuse.shop 80 hrs
>
> 17jul07

1.  Define spec and des PMT enclosures

> PPD.ME 120 Hrs
>
> 06jul07

2.  test mech properties of PMT enclosure Protos

> PPD.ME 40 hrs
>
> 29oct07

2.  #1 acq parts for pmt enclosures

> Syracuse.mands.additional \$2629
>
> Syracuse.mands.base \$5258

03aug07

3.  #2 acq parts for pmt enclosures

> Syracuse.mands.base \$5258

30jan08

4.  fab parts for pmt enclosures

> Syracuse.shop 640 hrs

03aug07

5.  assemble pmt enclosures

> Syracuse.tech 320 hrs
>
> Syracuse.mands.base \$5258

18jul08

1.  finalize Des of PMT enclosures

Design Task

ME,320

06jul07

ME time is higher than other tasks.

Designer time is required.

> Requires 8 drawings for the enclosure, at 4 hrs a drawing to make
> changes and produce prints, requires 32 hours for the beehive tooling
> changes. Engineering analysis and follow through requires about 50%
> the drafting time per design change.
>
> The prototype design is used in the test beam. The production and
> final revisions are required.
>
> Additional engineering analysis for the magnetic shielding is included
> in this task.
>
> 2 revisions
>
> ME time = 80 hrs conservative 160 hrs

Designer time = 64 hrs conservative 80 hrs

2.  test Mech properties of PMT enclosures

Test

ME,40

27jul07

> Testing includes strength, outgases, chemical compatibility tests and
> load testing of the beehive structure. It also includes testing the
> assembly procedure and intial leak checking.

ME time =20 hrs

Tech time = 40 hrs

2.  fab tools to assemble mods into pmt beehives

> Syracuse.shop 160 hrs
>
> 29nov06

3.  assemble mods into pmt beehives

> Syracuse.tech 1500 hrs
>
> Syracuse grads 800 hrs
>
> 26mar07

2.  fab tooling to assemble pmt beehives onto rich vessel

> Syracuse.shop 160 hrs
>
> 30oct06

3.  assemble pmt beehives onto rich vessel

> Syracuse.tech 640 hrs
>
> Syracuse.grads 640 hrs
>
> 29nov06

1.3.5.3.8.3.2 fab tooling to assemble pmt enclosures onto vessel

> Syracuse.shop 320 hrs

29dec08

1.3.5.3.8.3.3 assemble pmt enclosures onto vessel

> Syracuse.tech 320 hrs
>
> Syracuse.grads 320 hrs

26feb09

1.  define Assy procedure of Mods into PMT beehives

> Procedure

ME,160

02oct06

> Writing a procedure for inserting a PMT module into the beehive is
> created. The procedure includes writing trailers for the location and
> details of the PMT module and associated electronic harware. An
> initial set of documentation is written, then revised based on
> feedback from the test beam prototyping experiences.

ME time = 80 hrs.

1.  define Assy procedure of PMT beehives onto vessel

> Procedure

ME,80

02oct06

> Writing a procedure for inserting the beehive onto the vessel is
> created. The procedure includes writing trailers for the location and
> details of the PMT modules and beehive location information. An
> initial set of documentation is written, then revised based on
> feedback from the test beam prototyping experiences.

ME time = 80 hrs.

2.  assemble PMT beehives onto vessel

> fnal.ppd.tech 160 hrs

29nov06

1.  define Assy Proc.of the PMT beehives ENCLOSURE onto vess.

> Procedure

ME,160

02oct06

> Writing a procedure for installing a complete instrumented enclosure
> onto the tank frame in the collision hall is created. The procedure
> includes writing trailers for the location and details of the PMT
> modules and beehive location information. An initial set of
> documentation is written, then revised based on feedback from the test
> beam prototyping experiences.

ME time = 80 hrs.

2.  assemble PMT beehives ENCLOSURE onto vess.

> Fnal.ppd.tech,160

26feb09

1.3.5.3.10 entrance &exit windows

2.  acq parts for entrance and exit windows

> Syracuse.mands.base \$21,032
>
> Syracuse.mands.additional \$10516
>
> 03mar05
>
> Rear Window
>
> HC 12/02/02
>
> Constructed of .016 inch thick carbon fiber skins using 45 mpsi fiber,
> 1.5 inch thick rohacell core, approximately 160 inches square

Material

Carbon fiber 45 mpsi, \~65 lbs fiber @\$120/lb = \$7800

(YLA verbal estimate) The vendor can ship +/- 10% or the total order

Rohacell grade 51WF 38,400 inch\^3 @\$0.15/in\^3 = \$5,760

(estimate from previous order)

Vacuum bag and tooling = \$5000

(Herman's Estimate)

Total = \$18,560

Labor

Technician days... 2 man months

> (Herman's Estimate)

3.  fab parts for entrance and exit windows

> Syracuse.shop 480 hrs

03mar05

4.  acq parts for entrance and exit windows

> Syracuse.tech 320 hrs

24jun05

1.3.5.3.11.1.1 Finalize Des of entrance & exit windows

Design Task

ME,160

2-Nov-04

Needs designer time to create fabrication prints. Includes window frames

What about a prototype design time?

Add 160 hrs designer time

1.  Beam Pipe Enclosure Design

> Ppd.me 80 hrs
>
> PPD.dsgrdr 120 hrs
>
> 02oct07
>
> Numbers are high -- about 4 drawings at 3-4 hrs a piece.
>
> ME 20 hrs, designer 40 hrs

4.  evaluate Mech prop of beam pipe enclosure Prototype

> ppd.me 40 hrs
>
> 20jun08

4.  Beam-Pipe Enclosure Prod FNAL

    2.  acq parts for beam pipe enclosure

> Syracuse.mands.base \$2629
>
> 02jan08
>
> material is enough for both the front end rear windows

Materials:

Polyurethane bellows McMast Carr #9741K47 cost = \$49.29

Adhesive

Carbon fiber cuffs for the bellows \~ .25" thick cost = \$100

> Vendor KCI, phone \# 760-945-4470

Total = \$149.29

Labor

Machining time (estimate) 16 hours @\$55/hr = \$880

Tech assembly time 16 hours

Drafting time 16 hours

> Mechanical Engineering time 8 hours

3.  assemble beam pipe enclosure

> Syracuse.tech 80 hrs

27mar08

1.  Finalize beam pipe enclosure Des

> Design Task

ME,80

02oct07

> Requires 4 drawings for the beam pipe to window seal, at 4 hrs a
> drawing to make changes and produce prints, requires 16 hours for the
> beehive tooling changes. Engineering analysis and follow through
> requires about 50% the drafting time per design change.
>
> A prototype stand was created. Production and final revisions are
> required.
>
> 2 revisions
>
> ME time = 16 hrs

Designer time = 32 hrs

2.  evaluate Mech properties of beam pipe enclosure

> Evaluate

ME,40

20jun08

> Mechanically test glue joints, permeation, leak checking, and strength
> of the beam pipe to window joint.
>
> ME time = 20 hrs
>
> Tech time = 40 hrs

1.  Des MAPMT cooling proto

> Ppd.me 80 hrs
>
> 12dec03

1.3.6.7.3.2 MAPMT Electronics Cooling Syst Prod (2)

2.  assemble mapmt electronics cooling syst

> Syracuse.tech 240 hrs
>
> 22 mar06

3.  const mapmt electronics cooling syst monitor

> Syracuse.srtech 160 hrs

14jul06

4.  acq parts for mapmt electronics cooling syst

> Syracuse.mands.base \$10,516

25jan06

1.  Finalize the cooling Syst Des and Monitoring

Design Task

ME,40

3-Oct-05

> Design for the electronic cooling system that will be used on the test
> beam. The same design could be used that was used on the test beam
> with a small number of modifications.
>
> A production process diagram is needed along with plumbing hardware
> drawings for installation at the collision hall. Analysis of the new
> plumbing hardware system is also performed.
>
> ME analysis time = 40 hours

Designer time to create PID revisions and plumbing hardware layouts =
120 hours

2.  define cooling Syst Test procedure

Procedure

ME,40

25-Jan-06

> Ensure that the cooling capacity is as stated in the specifications.
> Thermal calculations are compared to measurements.

ME time = 40 hrs

1.3.6.8 PMT electonics cooling syst

1.3.6.8.3.1.1 des pmt cooling PMT proto

> ppd.me 80 hrs
>
> 15dec03

1.  define cooling syst test procedure

> ppd.me 40 hrs
>
> 03oct05

5.  PMT Cooling Syst Prod -- FNAL

    1.  Finalize the cooling Syst Des and Monitoring

> Design Task

ME,40

03oct05

> For the gas system with 20 I/O channels, assuming it is added to an
> existing control system:
>
> Wiring effort including drawings, pulling cables, terminations, 3
> man-days. Sensor calibration, say two hours for each pressure
> transmitter, one for each temperature sensors. If there are high
> precision or very sensitive instruments it would take twice as long.
> Conversely non-critical temperature sensors have no calibration time.
> This assumes that common industrial instruments are involved.
>
> Effort to draw graphics, enter database, setup historical collection,
> 2 man-days.
>
> Effort to configure controls depends on how much automation. The last
> time we talked the only automatic control involved the pressure
> control. The circulation may be started and stopped through the
> control system. Estimate 2 man-days.
>
> Total engineering and technician time 10 man-days. It would not hurt
> to add a couple of days contingency to the total.
>
> Three revisions are required, one for the prototype used on the test
> beam stand, one for the production and one for the final design
> revision.

ME time = 120 hrs

Tech time = 90 hrs

Designer time = 60 hrs

2.  PMT electronics Cooling Syst Test (2)

    1.  define cooling Syst Test procedure

> Procedure

ME,40

22-Mar-06

> A procedure to measure the effective cooling capacity of the cooling
> system will be created.
>
> ME time = 40 hrs

1.  Des gas syst & monit (mapmt beamtest gas syst)

> Ppd.me 80 hrs
>
> 21may04

1.  des beam test box & associated infrastruct

> ppd.me 96 hrs
>
> 01oct07

1.  des liquid circulation syst & monit

> ppd.me 80 hrs
>
> 01oct04

4.  Lev 2 Subproj Mgmt Assistance Construct phase

1-Oct-04

1.  help Coord Mech tasks

ME,400

1-Oct-04

> Could be 15% total engineering time of the project
>
> General follow through of purchase orders, quality control, attending
> meetings, scheduling tasks. Attending collaboration meetings and RICH
> mechanical meetings are expected to take 10% of a man year each year.

ME Time = 800 hrs

1.3.9.5.4.1 Personel Time

ME,224

1-Oct-04

consultants

1.  Oversee Mech Systs ES&H

> Evaluate
>
> ME,48

2.  Oversee Mech Systs ES&H

> Evaluate
>
> ME,48

3.  Oversee Mech Systs ES&H

Evaluate

ME,48

Creates Safety documentation

\# of documents required = 2

ME time =50 hrs.