# NuMI-L-632

# May 9, 2000

## Far Detector Materials Handling Facilities and Procedures (WBS 2.4)

## D. Ayres, W. Miller

Version 1.4

**Outline**

1.  **Schedule**

-   Time table for start of deliveries

-   Shipping schedules

**2.** **Surface building**

**3. Surface loading equipment**

-   Cage-loading truck

4.  **Materials handling cage**

######## Pallets and other dunnage

**5. Equipment in the MINOS Hall**

-   Monorail

-   Steel storage carts

-   Scintillator carts

-   Equipment supplied by WBS 2.1

**6. Soudan 2 Hall facilities**

-   Soudan Hall main floor

-   Soudan Hall mezzanine

**7. MINOS Hall facilities**

-   Workstation area

-   Cranes

-   Storage area

#### 1. Schedule

###### 1.1 Time table for [start]{.underline} of deliveries

-   **Steel**

```{=html}
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-   **1^st^ Strongback and other lifting fixtures Jan 2001**

-   **Steel Plates SM1 Feb 2001**

-   **Steel Collars, Axial rod bolts Feb 2001**

-   **2^nd^ Strongback Feb 2001**

-   **Coil monitoring electronics Feb 2001**

-   **Coil parts (cable, cooling pipes, power supplies) Oct 2001**

-   **Steel Plates SM2 Feb 2002**

-   **Scintillator**

-   **First module shipment Nov 2000**

-   **Module Mapper Nov 2000**

-   **Light Leak test equipment (Soudan Lab) Nov 2000**

-   **First 10 planes modules Dec 2000**

-   **Test equipment (workstations) Feb 2001**

-   **First SM2 modules Jan 2002**

-   **Other detector components**

-   **Clear fiber ribbon cables Jan 2001**

-   **MUX boxes Feb 2001**

-   **Pulser system and cables Feb 2001**

-   **Electronics Racks Feb 2001**

-   **Electronics Mar 2001**

###### 1.2 Shipping Schedules

-   **Steel Plates**

Steel plates are delivered to the surface building on flatbed trucks
beginning in February 2001. The surface building has storage for about 2
months worth of plates (about 55 detector planes). The details of the
shipping schedule have not yet been worked out with the steel supplier.
Our large surface storage facility allows the steel plates to be cut and
delivered in separate shipments for each type of plate if desired.

-   **Scintillator modules**

Due to the different rates of scintillator module production and
installation, we plan to build up a buffer of 3-4 months worth of
scintillator modules (80-110 detector planes). Module factories produce
about 36 modules/week. Each shipping crate holds 2 planes and 5 to 8
crates fit on a truck, depending on the module (crate) width. This works
out to an average of one truck delivery every month, with the empty
crates from the previous shipment going back on the same truck. Detailed
shipping schedules are being worked out now.

###### Surface building

**2.1 Status**

##### Beneficial Occupancy is scheduled for January 2, 2001. About one month of minecrew time is needed to outfit the building and prepare for our first shipments. There is also a small amount of storage space on the surface in a State Park building if storage space is needed before the MINOS surface building is ready.

2.  **Specifications/description**

##### Overall building is 48' wide by 136'. There is a 68' by 48' area for storage of steel plates and scintillator as well as two 17' by 48' truck bays that are all under crane access. The office area is 16' by 48'.

This building is also the receiving station for all UPS, FedEx, and
freight shipments. Materials will be staged here until access is
available at the headframe. Records of all incoming and outgoing
packages will be kept here. Terminals in the building will be tied into
underground computing systems. If more computing space is needed, the
mezzanine over the office area could be converted into additional
offices.

![](media/image1.wmf){width="7.613888888888889in"
height="3.2041666666666666in"}

3.  **Equipment**

> Stationary Tools Power Tools

Bridgeport Mill \[on hand\] Drills-3/8", 1/2", Magbase

> ½ inch floor drill press Skil-saw wormdrive
>
> Welder 200-250 amp wirefeed Sawsall
>
> Oxy-acetylene torch set Jig-saw
>
> Radial arm saw Portaband
>
> Air Compressor 5-7 hp cast iron Shop Vacuum
>
> Assorted air tools
>
> Grinder floor mount \[possibly on hand\]
>
> Band saw, horizontal, metal cutting

######### Vice 6 inch

> Chop saw 12 inch
>
> [Hand Tools]{.underline} [Hand Tools]{.underline}
>
> Mechanics wrench and socket set Framing square
>
> ¾" drive socket set Trouble lights
>
> Track bars Chain hoist 1 ½ ton
>
> Pry bars Cable Puller
>
> Sledge hammers Floor jack
>
> Hand saw Chains
>
> Levels 2 and 4 foot Slings
>
> [Misc. Equipment]{.underline}
>
> Steel inspection Rack
>
> Scale for Crane to weight steel sheets
>
> Pallet jacks
>
> Forklift

4.  **Storage capabilities**

######## 750 sq ft. of light storage on mezzanine.

> 3200-4000 sq ft of heavy storage area under overhead crane coverage.

Depending on the amount of miscellaneous dunnage, which is still not
very well defined, there is room for 8 piles of steel plates and 8-14
scintillator shipping crates.

5.  **Bundling sequence**

##### Plates are unloaded using a vacuum lifter when shipments arrive from Olympic Steel. 

The plates are stacked in 8 separate piles and quickly inspected for
major flaws. A more complete inspection is performed before the plates
are bundled. Each plate is given a barcode sticker, to keep track of
which heat batch the steel came from, and entered in the database.
Magnetic measurements, chemical analyses and radioactivity tests done
from each heat sample are included in the database.

Bundles of four plates each (the top or bottom layer of a steel detector
plane) are assembled in the surface building in preparation for moving
the plates underground. The bundling sequence begins with a careful
inspection of the visible top surface of each plate in a bundle. The
plates are arranged in the bundle in the same order and orientation in
which they will be installed. Each plate has all burrs removed with a
grinder and is cleaned. The vacuum lifter rotates the plates from
horizontal to vertical. While in the vertical position, the bottom side
of the each plate is inspected, any remaining burrs are removed and the
plate is cleaned. The plate is now weighted using the in-line scale on
the overhead crane and its weight is recorded in the database. The 4
plates of a bundle are then bolted together. Twelve bundles of steel
plates are moved underground each week to keep up with full-rate plane
installation. These are prepared before the evening shift as we have
limited hoist access during the day shift during most of the year. The
surface building will probably have a bundle rack (not yet designed)
that is accessible to the boom truck, to reduce unnecessary handling.
The installation document gives details of the plate numbering and
bundling sequence.

###### 3. Surface loading equipment

Several different types of equipment are needed to prepare and handle
pallets of miscellaneous materials for the move underground. A forklift
with a narrow enough wheelbase and long enough forks to put pallets into
the cage is essential. The existing Baker-York forklift at Soudan is not
adequate for this task. A new one needs to be leased (about \$7k/year
for 3 years) or found in government surplus. We also need a vehicle to
move pallets up the hill from the surface building to the headframe. The
cage loading truck will be designed with removable steel-bundle-holding
stakes so it can be used to move pallets. A 1-ton pickup truck with snow
plowing capabilities is needed for hauling smaller loads and
transporting materials-handling personnel between the surface building
and the head frame.

1.  **Cage-loading truck**

We plan to use boom-rig mounted on the back of a truck similar to those
used to haul pre-cast concrete. Del Zotto Products, Inc. makes a
boom-rig which could work for about \$27,500. The delivery time is 4-8
weeks and they would buy it back after we have completed construction.
The U of Minnesota will lease us a truck (about \$8k/year for 3 years)
that we can modify for this job. The truck holds only 3 bundles of steel
so it would have to be reloaded at least once per loading shift. Loading
time is estimated to be 30-60 minutes.

A forklift and a utility truck (about \$7k/year each for 3 years) are
also needed. The total cost of this equipment to WBS 2.4 is about \$84K,
including the \~\$10k rebate for sale of the boom rig when installation
is complete.

-   [Boom Truck Option Costs]{.underline}

######## Boom rig added \$27.5k

######## Boom rig rebate -\$10k

-   Large trucks lease \$24k/yr.

-   Utility truck \$21k/yr.

-   [Fork lift \$21k/yr.]{.underline}

> Total cost during installation \$83.5k

1.  **Repair of U of Minnesota crane**

The U of Minnesota 15-ton mobile crane needs to have its swing bearing
repaired at a cost of about \$23k (paid from the WBS 3.3 laboratory
operations budget). This crane is not actually needed for loading steel
plate bundles and scintillator crate if the cage-loading truck is used,
but it would serve as a backup if there were problems with the truck. It
is also very useful for loading and unloading very heavy, odd-sized
items onto the shaft cage.

###### 4. Materials handling cage

**4.1 Specifications/description**

The materials-handling cage must be able to hold scintillator boxes (
2.5 tons, 29 ft long by 56-inch wide) and steel plate bundles (6 tons, 8
m by 2 m). It must be readily convertible from a personnel cage to a
materials-handling cage (in one hour or less, 2-3 times/week). DNR and U
of Minnesota officials must approve the cage design before construction
can begin. A drop test in the shaft must be completed before the cage is
put into service. Because of the time needed to convert the cage from
personnel to materials handling use, the materials handling crew would
work a 10 hour shift on these days.

2.  **Additional equipment needed**

Fermilab has already purchased the hoist motor for the top of the cage
and the unloading hoist for pulling the plate bundles north on the
27^th^ level. The unloading hoist for pulling the plate bundles south
will be purchased by the installation task. Fermilab will supply most of
the special lifting fixtures required, except that standard slings,
clamps, clevises, etc. are supplied but the installation task.

**4.3 Costs and schedule**

######## The materials-handling cage is scheduled to be completed in September 2000 at a cost of about \$150k.The schedule and cost estimate will be updated in May 2000.

Due to the long cage change-over time and the DNR tourist season, steel
and scintillator shipping boxes are only hauled underground in the
evening shift. One way to make this more efficient is to have this part
of the crew work 10 hour/days, 4 days/week.

######## **4.4 Pallets and other dunnage**

1.  All loads must have one dimension less than 45"

2.  Loads longer than 15 feet with a cross section less than 3' by 3'
    can stick up through removable roof panel (max. length about 30 ft)

3.  Maximum load is five tons

4.  All pallets must have a minimum of 3 ½ " high skids.

5.  All skids should be spaced to accommodate a 27" wide pallet cart.

6.  A standard "Soudan" pallet measures 40" wide by 44" deep with the
    skids parallel to the 44" dimension.

7.  Soudan personnel must be notified of shipment size and weight prior
    to shipping

8.  No part of any load may project outside of cage outline except
    through roof panel

9\. Max loading: lower deck 650 psf, upper deck 160 psf.

2.  **Cage drawings**

> ![](media/image2.wmf){width="5.527083333333334in"
> height="6.952083333333333in"}

###### 5. Equipment in the MINOS Hall

###### 5.1 Monorail

The monorail will be used to transport steel plates and other heavy
detector components from the shaft station to the storage carts in the
cavern. The monorail will have approximately the following
characteristics:

a)  Seven ton, 210 linear foot length, three curve, 10 percent slope,
    center load rail, side guide roller with two electric trolleys and
    hoists.

b)  The two monorail trolleys are swiveling type with side guide rollers
    capable of a minimum 7.5 foot radius, pushed/pulled by powered
    trucks.

c)  The powered trucks are electric motor driven, two speed (15-45 fpm
    nominal range), with remote hand held push button controls.

    d\) The monorail hoists are electric wire rope, single speed about
    16 fpm, with remote hand held push button controls.

###### 5.2 Steel storage carts 

These 50­ton capacity, 8­m long carts are used to store the steel plates
delivered by the monorail, and to move them under the coverage of the
workstation gantry cranes. There is one for each workstation. Steel
storage carts move via electric truck motors run from a pendant attached
to the cart. Power comes off a retractable spool attached to the back
wall. The cart runs on light-weight rails embedded in the concrete
floor. Each cart can hold up to 8 bundles of plates (4 planes).

###### 5.3 Scintillator carts

These 2­ton capacity, 8.5­m long carts are used to move scintillator
module crates from the shaft station to the Soudan 2 cavern testing and
storage area, and from there to the MINOS assembly workstations. A
forklift will be used to move the cart around.

###### 5.4 Equipment supplied by the Steel and Coils task

The following equipment will be provided to the WBS 2.4 installation
task by the WBS 2.1 steel and coils task:

-   Red shackles for lifting plate bundles on edge (4 sets)

-   Plate loading fixture for putting bundles into cage (2 fixtures)

-   Plate bundling stands, for assembling plate bundles (2 stands)

-   Scintillator box lifting fixtures (2 fixtures each, for 2 types of
    boxes)

-   Steel bundle "skate" (2 skates)

-   Scintillator box "skates" (2 skates)

-   Feed-wire welding machines (2 machines plus spare parts)

-   Strongbacks (2 strongbacks, complete with rollers and swivel hoist
    rings)

-   Strongback spreader bar (1 spreader)

-   Plate clamps (3 sets of 4 clamps each)

-   Plate clamp spreader bars (3 spreaders)

###### 6. Soudan 2 Hall facilities

###### 6.1 Soudan Hall main floor

**Specifications/description**

The existing Soudan 2 staff shop, containing general-purpose machine
tools (lathe, milling machine, drill press, band saw), will be upgraded
for MINOS installation work. The existing supplies of hand tools and
mechanical parts will be maintained for MINOS use.

**Storage area**

A small amount of area is available to hold several
scintillator-shipping boxes while the modules are being tested and moved
to the mezzanine.

**Mapping and testing table**

####### Need details from scintillator task

#### 6.2 Soudan Hall mezzanine

**Specifications/description**

The mezzanine located in the Soudan 2 cavern provides floor space to
store tested scintillator modules and for other storage and work
activities. Its elevation has been set to allow use of existing
stairways for egress, via the counting house stairs on the north end and
the cleanroom stairs on the south end. Scintillator module handling
requires a bridge crane equipped with a vacuum lifter to move modules
from the floor to the mezzanine and to store and retrieve boxes. The
crane covers the entire mezzanine in order to maximize use of floor
space.

The mezzanine will be constructed from custom-made structural steel
components. The machine shop and other existing work areas will be
relocated under the new mezzanine deck to maximize materials handling
and storage space. The mezzanine floor area is approximately 2,400
square feet and is about 13 feet above the Soudan 2 Hall floor level. A
lifting bay area is provided for raising and lowering scintillator boxes
between the mezzanine and the floor level.

The work area under the mezzanine will be provided with lights and
sprinkler coverage as part of the outfitting task. Modifications to the
location of the overhead sprinkler system may be necessary to
accommodate the crane.

![](media/image3.wmf){width="7.497916666666667in"
height="3.626388888888889in"}

3.  **Soudan Mezzanine Crane**

This 7.5-ton crane will be used to raise and lower scintillator boxes
between the Soudan 2 cavern floor and the mezzanine, and to move boxes
to and from work and storage areas on the mezzanine. The crane has
approximately the following characteristics:

a)  7.5-ton, 150 linear foot length, I-beam type, with one variable
    electric trolley and hoist.

b)  Electric motor driven bridge, variable speed (15--45 fpm nominal
    range), with remote hand held push button control.

c)  7.5-ton capacity hoist, electric wire rope, variable speed 10-45
    fpm, with remote hand held push button control.

###### 6.4 Storage areas

**Scintillator storage**

##### Tested modules are placed in storage racks until they are needed at the detector plane workstations. At that time the eight modules needed for a single plane are placed in an installation crate (only about three of these creates are needed). The installation crates are designed to hold one complete plane of modules each. The crates will be 29 ft long by 56" wide and about 8" deep. Both the storage racks and installation crates will be built by the installation task. We plan to accumulate a stockpile of 3-4 months worth of scintillator modules during the installation startup period. The mezzanine storage area is approximately 28 ft by 64 ft long. The U of M code officials have requested that scintillator module storage be arranged with at least 2-ft walkways between stacks. This allows sprinkler-water coverage for fire control between stacks. We have room for 8 storage racks, each at least 5-ft high.

**Miscellaneous storage area**

The mezzanine has an additional area, approximately 30 ft x 16 ft, which
is too small for scintillator crates. This will be used to store
miscellaneous materials like cables, MUX boxes, etc.

###### 

###### 7. MINOS Hall facilities

###### 7.1 MINOS Workstation area

The assembly area of the MINOS cavern is approximately 52 feet wide
(clear) and 44 feet high (clear) at the peak. It provides space for two
strongbacks, scintillator modules and other detector plane components
needed during the plane assembly process. It also has space for steel
plate storage, a forklift and access aisle, and assembly work areas.
Each workstation has a complete set of tools and equipment for plane
assembly. In some cases tools can be shared so this plan gives us a
spare of everything.

Two steel plates are placed in the concrete floor near each strongback
to support the large pressures caused by the Hillman rollers during the
lifting of strongbacks. These 0.5" thick steel plates are flush with the
concrete floor, and are approximately 3' by 16'. They are to be
installed during the final phase of cavern construction. Welding and
conventional power are supplied to these areas via raceways embedded in
the slab by the cavern construction contractor.

Heavy-duty motorized rolling carts on the east side of the assembly area
provide steel plate storage. The detector plane assembly areas occupy
the middle and the west side of the assembly area. The forklift and
access aisle separates the plate storage and assembly areas. During
detector fabrication, steel plates are placed on the carts by the
monorail system and removed from the carts by the gantry crane, which
moves them to the strongback. Both the carts and the gantry cranes run
on rails that are set into the concrete cavern floor.

2.  **Gantry Cranes**

Two 2-ton rolling gantry cranes are used in the assembly area to move
steel plates and scintillator modules from storage carts to the
strongbacks. CNA is providing the specification for these cranes and
their electrical power and rails, which are to be installed as part of
the outfitting construction task. The cranes themselves may be
constructed under a contract that is separate from that for the main
outfitting task. The gantry cranes have approximately the following
characteristics:

a)  Two ton, 30'--0" span single girder, double leg gantry crane, Class
    C, with a single electric trolley and hoist.

b)  The gantry bridges are electric motor driven, variable speed 15-45
    fpm nominal range, with remote hand held push button controls.

    c\) The gantry trolleys are electric motor driven, variable speed
    10-35 fpm nominal range, with remote hand held push button controls.

**7.3 Lifting fixtures and equipment**

A strongback is used at each assembly workstation as a rigid flat
support upon which the eight steel plates of an octagon plane are
assembled and plug welded. After the scintillator modules are mounted on
the steel plane, the strongback and detector plane assembly is raised
into the vertical orientation by the 30­ton bridge crane and set on the
detector support rails where it is supported by the steel plane
\"ears.\"

> Other equipment includes:
>
> 1\. Slings, spreader bars, plate clamps, clevises, etc.
>
> 2\. Hand tools, grinders, drills, air tools, etc.
>
> 3\. Welder, air scrubber, welding screens, etc.

###### 

###### 7.4 Overhead cranes

#### Main bridge crane

A bridge crane will serve the entire MINOS cavern except for the
triangular area at the north end. Two bridges use the same crane rails:
the large-capacity bridge with a 25-ton hoist (for detector-plane
handling) and a smaller capacity, custom designed, bridge for detector
access by maintenance personnel (described in the next section).

The large-capacity bridge crane, which lifts and transports completed
planes from the assembly area to the supermodules, has the following
characteristics:

a)  Top running, double girder, overhead traveling crane with one 25-ton
    capacity hoist, motor-driven, variable speed to about 11 fpm.

b)  Motor-driven, variable-speed bridge, with a maximum travel rate of
    about 130 fpm.

c)  Motor-driven, variable-speed trolleys, with about 75-fpm maximum
    travel rate,

d)  The crane should include remote hand held radio controls.

e)  The crane should have programmable lift capabilities.

f)  The crane should have a two-bridge collision warning system.

**Personnel access bridge**

The detector access bridge and frame is used only for personnel access
to the top of the detector. The crane bridge has the following
characteristics:

a)  Capable of supporting the detector access frame.

b)  Variable-speed bridge with a maximum travel rate of about 130 fpm.

c)  Two bridge collision warning system.

###### 7.5 Additional storage areas

The south end of the main MINOS cavern has space allocated for temporary
storage. This clear area is 45 feet wide (clear) and 44 feet high
(clear) at the peak, and includes space for walkways and egress. The
clear area reserved for a possible future detector is 10 meters in
length. Electrical power and lighting should be provided on the walkways
(the continuation of the detector support structure around the end of
this area) and conduits for eventual quiet power installation installed.