Muon Detector

Lampshade Panels

Removal and Installation

Procedure

Date: 1/27/97

Prepared by: \_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_

W.  Stokes

Approved by: \_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_

P. Kroon

I. [Introduction]{.underline}: The Phenix detector has two muon
detectors. One called the North Muon Detector and the other the South
Muon Detector. Briefly described, they consist of a central, bullet
shaped feature called the piston core, surrounded by an eight sided,
hollow, conically shaped steel structure which serves as a yoke for flux
return (see fig. 1). The eight sided conical shaped is oriented with two
flats horizontal, two flats vertical, and four flats at 45 angles as can
be seen in fig.1. This structure is constructed having the five upper,
trapezoidal, sections which are removable. These panels, called
lampshade panels, are the one horizontal, two vertical, and two 45
(biased) sections shown in Fig. 1. The three lower sections of the
conically shaped structure are permanently installed and attached to the
floor supports, rear frame, and to one another. To install and service
the equipment that will be mounted inside this cone the lampshade panels
must be removed and reinstalled. Due to factors such as size (12.7\' x
13.1\' ), weight (16,000 lbs.), trapezoidal shape, angle of
installation, and internal clearances to delicate devices (as little as
.78\") the exact, actual, center of gravity (CG) must be located and
reproduced for lifting to maintain mounting orientations. This document
is divided into three sections; 1.) actual CG identification, 2.)
removal procedures, and 3.) installation procedures.

II\. [General Safety Statement]{.underline}: Due to the delicacy of
interior components, value of components, size and shape of panels, and
risk to component and physical harm, rigging safety and all other
applicable safety procedures shall be adhered to. Any individual may
cease operations if they feel unsafe or if they believe unsafe
procedures are being followed.

III\. [Applicable Documents]{.underline}:

A. Engineering Drawings

1\. Muon Detector - North Assembly; LLNL \# 93-101858-OD

2\. Muon Detector - South Assembly; TBD

3\. Lampshade Panels

a\. Horizontal; LLNL \# RAA93-101892 TAB 01

b\. Vertical (east); LLNL \# RAA93-104174 TAB 01

c\. Vertical (west); LLNL \# RAA93-104174 TAB 02

d\. Bias (east and west); LLNL \# RAA93-101890

4\. Lampshade Panels Rigging; BNL \# 002-0504-020

B. Rigging Equipment:

1\. Crane Specification; ACECO, 10T/40T, Tendoned

> 2\. Chain Hoist Specifications; Columbus McKinnon Corp. Series 622, 3
> ton, 12\' chain (or equiv.)
>
> Series 622, 5 ton, 14\' chain (or equiv.)
>
> 3\. Sling: Thimble & Thimble Type, 7 ton capacity min.
>
> 4\. Shackles Specification; Crosby Type S-209 8.5 ton (or equiv.)
>
> 5\. Swivel shackles Specification; McMaster-Carr 30,000 lb. capacity
> P/N 3052T69 (or equiv.)
>
> 6\. Plumb-Bob Specification; BNL Stock \# H-20980 (8 oz., steel)

C. Safety Regulations (but not limited to):

1\. BNL ES&H

a\. 1.5.1; Lockout/Tagout Requirements

> b\. 1.5.3; Interlock Safety for Protection of Personnel

c\. 1.6.0; Material Handling Equipment

d\. 1.16.0; Personal Protective Equipment

2\. BNL SEAPPM

a\. 1.5.1; Lockout/Tagout Requirements

b\. 1.5.3; Interlock Safety

c\. 1.6.0; Material Handling Equipment

d\. 1.16.0; Personal Protective Equipment

3\. RHIC SEAPPM

a\. 1.5.1; Lockout/Tagout Requirements

b\. 1.5.3; Interlock Safety

c\. 1.6.0; Material Handling Equipment

d.  1.16.0; Personal Protective Equipment

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IV. [Locating Actual CG of Panels]{.underline}:

> A. Horizontal (LLNL P/N RAA93-101892 TAB 01 and Bias (LLNL P/N
> RAA93-101890) Lampshade Panels:

1\. Ascertain that the work area is safe to enter

> 2\. Identify lampshade to be the correct part specified above.
>
> 3\. Identify the following rigging components to be the correct parts
> specified in Section 3 Article B;

a\. Chain Hoist

b\. Shackles

c\. Swivel shackles

d\. Plumb-Bob

> 4\. Locate the calculated CG of the panel, with a temporary marking
> instrument, using dimensions indicated on BNL engineering drawing \#
> 002-0504-020.
>
> 5\. Install swivel shackles to panel at points A, B, and C as shown on
> BNL engineering drawing \# 002-0504-020.
>
> 6\. Attach the sling and chain hoists to the crane hook.
>
> 7\. Attach the plumb-bob to the crane hook using cord and allowing for
> length adjustment. The location of the plumb-bob must fall directly
> below, and in-line with, the center line of the hook's block.
>
> 8\. Move the crane hook over the previously mounted panel to locate
> the plumb-bob, hanging from the hook, directly above the temporary CG
> cross hair marked in step 3.
>
> NOTE: Once the plumb-bob is positioned directly above the CG cross
> hair DO NOT reposition the crane until step 12.

9.  Attach the sling or chain hoist to the swivel shackle at point A

> and the two chain hoists to the swivel shackles at points B and C
> using shackles as shown on BNL engineering drawing 002-0504-020.
>
> 10\. Adjust chain hoist lengths until chains and sling are snug and
> the plumb-bob settles over the CG cross hairs again.

NOTE: DO NOT move crane to achieve this step.

> 11\. Remove all fasteners attaching the panel to the lampshade
> assembly.
>
> 12\. Slowly lift the panel until the panel's perimeter clears the
> assembly by a minimum distance (\<1\" if possible).
>
> 13.With the panel hanging above its' installed position set the chain
> hoist lengths until the gap around the perimeter of the plate is
> consistent to \<.250\".
>
> NOTE: The crane position may need to be relocated at this step to
> reposition the panel back above its' original installed position due
> to the adjustment of the chain hoist lengths.
>
> 14\. Trial fit the panel back into the installed position.
>
> 15\. Once again, lift the panel to a minimum gap as in step 12.
>
> 16\. Verify perimeter gap to be consistent to \<.250\". If not return
> to step 12.
>
> 17\. Using a permanent marker draw a circled cross hair ( + ) directly
> below the new plumb-bob position. Allow cross hair to dry, center
> punch crosshair intersection, and cover with a coat of clear
> protectant.
>
> 18\. Move panel to a position that is safe for accurately measuring
> distances between swivel shackles and crane hook.

19. Accurately measure and record distances from swivel

> eye to crane hook so that set-up may be reproduced at a later date.

a.  Horizontal Panel:

> Hook to A:\_\_\_\_\_\_\_\_ Hook to B:\_\_\_\_\_\_\_\_
>
> Hook to C:\_\_\_\_\_\_\_\_

b.  Bias Panel (east):

> Hook to A:\_\_\_\_\_\_\_\_ Hook to B:\_\_\_\_\_\_\_\_
>
> Hook to C:\_\_\_\_\_\_\_\_

c.  Bias Panel (west):

> Hook to A:\_\_\_\_\_\_\_\_ Hook to B:\_\_\_\_\_\_\_\_
>
> Hook to C:\_\_\_\_\_\_\_\_
>
> 20\. Store panel and hardware to proceed with the next panel CG
> identification.
>
> B. Vertical Lampshade Panels (East)(LLNL P/N RAA93-104174 TAB 01)
> (west)(LLNL P/N RAA93-104174 TAB 02):

1\. Ascertain that the work area is safe to enter

> 2\. Identify lampshade to be the correct part as specified above.
>
> 3\. Identify the following rigging components to be the correct parts
> specified in Section 3 Article B;

a\. Chain Hoist

b\. Shackles

c\. Swivel shackles

d\. Plumb-Bob

> 4\. Locate the calculated CG of the panel, with a temporary marking
> instrument, using dimensions indicated on BNL engineering drawing \#
> 002-0504-020.
>
> 5\. Install swivel shackles to panel at points A and B (east panel)
> and points A and C (west panel) as shown on BNL engineering drawing \#
> 002-0504-020.
>
> 6\. Attach the sling and chain hoist to the crane hook.
>
> 7\. Attach the plumb-bob to the crane hook using cord and allowing for
> length adjustment. The location of the plumb-bob must fall directly
> below, and in-line with, the center line of the hook's block.
>
> 8\. Move the crane hook over the previously mounted panel to locate
> the plumb-bob, hanging from the hook, directly above the temporary CG
> cross hair marked in step 3.
>
> NOTE: Once the plumb-bob is positioned directly above the CG cross
> hair DO NOT reposition the crane until step 12.
>
> 9\. Attach the sling or chain hoist to the panel shackle at point A
> and chain hoist to the swivel shackle at point B (east panel) or at
> point C (west panel) using shackles as shown on BNL engineering
> drawing 002-0504-020.
>
> 10\. Adjust chain hoist lengths until the sling and chain hoist are
> snug and the plumb-bob settles over the CG cross hairs again.

NOTE: DO NOT move crane to achieve this step.

> 11\. Remove all fasteners attaching the panel to the lampshade
> assembly.
>
> 12\. Slowly lift the panel until the panel's perimeter clears the
> assembly by a minimum distance (\<1\" if possible).
>
> 13.With the panel hanging above its' installed position set the chain
> hoist lengths until the gap around the perimeter of the plate is
> consistent to \<.250\".
>
> NOTE: The crane position may need to be relocated at this step to
> reposition the panel back above its' original installed position due
> to the adjustment of the chain hoist lengths.
>
> 14\. Trial fit the panel back into the installed position.
>
> 15\. Once again, lift the panel to a minimum gap as in step 12.
>
> 16\. Verify perimeter gap to be consistent to \<.250\". If not return
> to step 12.
>
> 17\. Using a permanent marker draw a circled cross hair ( + ) directly
> below the new plumb-bob position. Allow cross hair to dry, center
> punch crosshair intersection, and cover with a coat of clear
> protectant.
>
> 18\. Move panel to a position that is safe for accurately measuring
> distances between swivel shackles and crane hook.

19. Accurately measure and record distances from swivel eye to crane
    hook so that slings may be purchased to replace chain hoists.

20. Vertical Panel (east):

> Hook to A:\_\_\_\_\_\_\_\_ Hook to C:\_\_\_\_\_\_\_\_

b.  Vertical Panel (west):

> Hook to B:\_\_\_\_\_\_\_\_ Hook to B:\_\_\_\_\_\_\_\_
>
> 20\. Store panel and hardware to proceed with the next panel CG
> identification.

V. Panel Removal

> A. Horizontal (LLNL P/N RAA93-101892 TAB 01) and Bias (LLNL P/N
> RAA93-101890) Lampshade Panels:

1\. Ascertain that the work area is safe to enter

2.  Identify lampshade to be the correct part as specified above.

> 3\. Identify the following rigging components to be the correct parts
> specified in Section 3 Article B;

a\. Chain Hoist

b\. Shackles

c\. Swivel shackles

d\. Plumb-Bob

> 4\. Install swivel shackles to panel at points A, B, and C as shown on
> BNL engineering drawing \# 002-0504-020.

5\. Attach sling and chain hoists to crane hook.

> 6\. Attach plumb-bob to crane hook in line with the centerline of the
> hook block.
>
> 7\. Set chain hoist lengths as described in Section IV, Article A,
> Paragraph 19.
>
> 8\. Attach sling or chain hoist to swivel shackle at point A and chain
> hoists to swivel shackles at points B and C with shackles as shown on
> BNL engineering drawing \# 002-0504-020.
>
> 9\. Adjust crane hook position to locate plumb-bob directly over the
> prelocated panel CG and raise hook until all straps are taught. Check,
> by hand, to ascertain that tension in all straps is equal.
>
> 10\. Detach panel from the cone assembly by removing all fasteners.

11\. Slowly lift panel to clear the cone assembly.

> NOTE: If panel does not lift evenly from the assembly discontinue lift
> until the cause of unevenness is determined.
>
> D. Vertical Lampshade Panels (East)(LLNL P/N RAA93-104174 TAB 01) and
> (west)(LLNL P/N RAA93-104174 TAB 02):

1\. Ascertain that the work area is safe to enter

> 2\. Identify lampshade to be the correct part as specified above.
>
> 3\. Identify the following rigging components to be the correct parts
> specified in Section 3 Article B;

a\. Chain Hoist

b\. Shackles

c\. Swivel shackles

d\. Plumb-Bob

> 4\. Install swivel shackles to panel at points A and B (east panel) or
> points A and C (west panel) as shown on BNL engineering drawing \#
> 002-0504-020.

5\. Attach sling and chain hoist to crane hook.

> 6\. Attach plumb-bob to crane hook in line with the centerline of the
> hook block.
>
> 7\. Set chain hoist lengths as described in Section IV, Article B,
> Paragraph 19.
>
> 8\. Attach sling or chain hoist to swivel shackle at point A and chain
> hoist to swivel shackle at point B (east panel) or point C (west
> panel) with shackles as shown on BNL engineering drawing \#
> 002-0504-020.
>
> 9\. Adjust crane hook position to locate plumb-bob directly over the
> prelocated panel CG and raise hook until all straps are taught. Check,
> by hand, to ascertain that tension in all straps is equal.
>
> 10\. Detach panel from the cone assembly by removing all fasteners.

11\. Slowly lift panel to clear the cone assembly.

> NOTE: If panel does not lift evenly from the assembly discontinue lift
> until the cause of unevenness is determined.

VI\. Panel Installation

> A. Horizontal (P/N RAA93-101892 TAB 01) and Bias (LLNL P/N
> RAA93-101890) Lampshade Panels:

1\. Ascertain that the work area is safe to enter

> 2\. If any rigging hardware/equipment has been removed from the panel
> since the panel removal sequence proceed with steps a through h. If
> not, go directly to step 3.
>
> a\. Identify lampshade to be the correct part as described above.
>
> b\. Identify the following rigging components to be the correct parts
> specified in Section 3 Article B;

a\. Chain Hoist

b\. Shackles

c\. Swivel shackles

d\. Plumb-Bob

> c\. Install swivel shackles to panel at points A, B and C as shown on
> BNL engineering drawing \# 002-0504-020.
>
> d\. Attach sling and chain hoists to crane hook.
>
> e\. Attach plumb-bob to crane hook in line with centerline of hook
> block.
>
> f\. Attach sling or chain hoist to swivel shackle at point A and chain
> hoists to swivel shackles at points B and C, with shackles as shown on
> BNL engineering drawing \# 002-0504-020.
>
> g\. Set chain hoist lengths as described in Section IV, Article A,
> Paragraph 19.
>
> 3\. Lift panel to a position hovering above its installation position.
>
> 4\. Slowly lower the panel to a position approximately 1\" above its
> mating panel.
>
> 5\. Check alignment with the mating panel and reposition if necessary.
>
> 6\. Lower panel into is final resting position while still maintaining
> sling tension.

7\. Install all fasteners snugly.

8\. Remove rigging hardware.

9\. Torque all screws to specification.

> B. Vertical Lampshade Panels (East)(LLNL P/N RAA93-104174 TAB 01) and
> (west) (LLNL P/N RAA93 104174 TAB 02):

1\. Ascertain that the work area is safe to enter

> 2\. If any rigging hardware/equipment has been removed from the panel
> since the panel removal sequence proceed with steps a through h. If
> not, go directly to step 3.
>
> a\. Identify lampshade to be the correct part as specified above.
>
> b\. Identify the following rigging components to be the correct parts
> specified in Section 3 Article B;

a\. Chain Hoist

b\. Shackles

c\. Swivel shackles

d\. Plumb-Bob

> c\. Install swivel shackles to panel at points A and B (east panel) or
> points A and C (west panel) as shown on BNL engineering drawing \#
> 002-0504-020.
>
> d\. Attach sling and chain hoist assembly to crane hook.
>
> e\. Attach plumb-bob to crane hook in line with centerline of hook
> block.
>
> f\. Attach sling or chain hoist to swivel shackle at point A and chain
> hoist to swivel shackle at point B (east panel) or point C (west
> panel) with shackles as shown.
>
> g\. Set chain hoist lengths as described in Section IV, Article B,
> Paragraph 19.
>
> on BNL engineering drawing \# 002-0504-020.
>
> 3\. Lift panel to a position hovering above its installation position.
>
> 4\. Slowly lower the panel to a position approximately 1\" above its
> mating panel.
>
> 5\. Check alignment with the mating panel and reposition if necessary.
>
> 6\. Lower panel into is final resting position while still maintaining
> sling tension.

7\. Install all fasteners snugly.

8\. Remove rigging hardware.

9\. Torque all screws to specification.

> NOTE: IF ANY PANEL HAS ANY MODIFICATION MADE TO IT THE PANEL MUST
> UNDERGO ACTUAL CG POSITION DETERMINATION AGAIN.

HORIZONTAL PANEL RIGGING

SLING LOAD

VECTOR CALCULATIONS

**[GEOMETRY H1:]{.underline}** H

A

b c

C B

L1 a

CG

[Given]{.underline}: B = 90°, Length a = 51.0", Length c = 33.0", Load c
= 4316.0 lb.

[Calculations]{.underline}:

Length b = v a2 + c2 = 60.75"

TAN C = c / a = 0.647 = TAN 32.91°

Sling Load b = Load c / SIN C = 7943.7 lb.

**[GEOMETRY H2:]{.underline}** H

A

b c

C B

CG a L2

[Given]{.underline}: C = 90°, Length a = 51.0", Length b = 104.0", Load
b = 7368.0 lb.

[Calculations]{.underline}:

Length c = v a2 + b2 = 115.8"

TAN B = b / a = 2.039 =TAN 63.88°

Sling Load c = Load b / SIN B = 8206.0 lb.

HORIZONTAL PANEL

LIFT POINTS

WEIGHT DISTRIBUTION

16,000 lb.

51.0" 43.53"

94.53

L3 L1+ L2

> Reaction Load L3 = 16,000 lb. ( 43.53" ) / 94.53" = 7367.8 lb.
>
> Reaction Load L1+L2 = 16,000 lb. - 7367.8 lb. = 8632.2 lb.
>
> Reaction Loads L1 and L2 = 8632.2 lb. / 2 = 4316.1 lb.

BIAS PANELS RIGGING

SLING LOAD

VECTOR CALCULATIONS

**[GEOMETRY B1:]{.underline}** H

A

b c

C B

L1 a

> CG

[Given]{.underline}: B = 90°, Length a = 52.0", Length c = 31.9", Load c
= 3937.9 lb.

[Calculations]{.underline}:

Length b = v a2 + c2 = 131.96"

TAN C = c / a = 0.613 = TAN 31.53°

Sling Load b = Load c / SIN C = 8441.0 lb.

**[GEOMETRY B2:]{.underline}** H

A

b c

C B

a L2

CG

[Given]{.underline}: C = 90°, Length a = 85.4", Length b = 116.4", Load
b = 3183.8 lb.

[Calculations]{.underline}:

Length c = v a2 + b2 = 144.37"

TAN B = b / a = 1.363 = TAN 53.73°

Sling Load c = Load b / SIN B = 3949.0 lb.

**[GEOMETRY B3:]{.underline}** H

A

b c

C B

a L2

> CG

[Given]{.underline}: C = 90°, Length a = 50.3", Length b = 124.4", Load
b = 8878.3 lb.

[Calculations]{.underline}:

Length c = v a2 + b2 = 144.37"

TAN B = b / a = 2.473 = TAN 67.98°

Sling Load c = Load b / SIN B = 9576.9 lb.

BIAS PANELS

LIFT POINTS

WEIGHT DISTRIBUTION

16,000 lb.

[L3 CALCULATION]{.underline} 44.36" 49.95"

94.31"

L3 L1+ L2

> Reaction Load L3 = 16,000 lb. ( 49.95" ) / 94.31" = 8474.6 lb.\*

16,000 lb.

[L2 CALCULATION]{.underline} 15.1" 64.4"

79.5"

L1+L3 L2

> Reaction Load L2 = 16,000 lb. ( 15.1" ) / 79.5" = 3039.0 lb.\*

16,000 lb.

[L1 CALCULATION]{.underline} 45.85" 14.08"

59.93"

L1 L2+ L3

> Reaction Load L3 = 16,000 lb. ( 14.08" ) / 59.93" = 3759.0 lb\*

\*Adjustments due to rounding errors;

8474.6 lb. + 3039.0 lb. + 3759.0 lb. = 15,276.6 lb. .......... 16,000
lb. - 15,276.6 lb. = 727.4 lb.

727.4 lb. / 15,276.6 lb. = .045 .......... This represents a 4.5% error
in calculations due to rounding.

Since 8474.6 lb. is 55.5% of 15,276.6 lb., add 55.5% of 727.4 lb. to
8474.6 lb. to correct rounding error.

8474.6 lb. + ( 0.555 ( 727.4 )) = 8878.3 lb. = L3

Since 3039.0 lb. is 19.9% of 15,276.6 lb., add 19.9% of 727.4 lb. to
3039.0 lb. to correct rounding error.

3039.0 lb. + ( 0.199 ( 727.4 )) = 3183.8 lb. = L2

Since 3759.0 lb. is 24.6% of 15,276.6 lb., add 24.6% of 727.4 lb. to
3759.0 lb. to correct rounding error.

3759.0 lb. + ( 0.246 ( 727.4 )) = 3937.9 lb. = L1

VERTICAL PANELS RIGGING

SLING LOAD

VECTOR CALCULATIONS

**[GEOMETRY V1:]{.underline}** H

A

b c

C B

L1 a

CG

[Given]{.underline}: B = 90°, Length a = 64.0", Length c = 115.4", Load
c = 7382.0 lb.

[Calculations]{.underline}:

Length b = v a2 + c2 = 131.96"

TAN C = c / a = 1.803 = TAN 60.99°

Sling Load b = Load c / SIN C = 8441.0 lb.

**[GEOMETRY V2:]{.underline}** H

A

b c

C B

a L2

CG

[Given]{.underline}: C = 90°, Length a = 54.0", Length b = 55.0", Load b
= 8618.0 lb.

[Calculations]{.underline}:

Length c = v a2 + b2 = 77.08"

TAN B = b / a = 1.018 = TAN 45.53°

Sling Load c = Load b / SIN B = 12,076.5 lb.

VERTICAL PANELS

LIFT POINTS

WEIGHT DISTRIBUTION

16,000 lb.

63.17" 54.11"

117.28"

L1 L2

> Reaction Load L1 = 16,000 lb. ( 54.11" ) / 117.28" = 7382.0 lb.
>
> Reaction Load L2 = 16,000 lb. - 7382.0 lb. = 8618.0 lb.