# NuMI-L-632

# Nov. 25, 2000

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

## D. Ayres, W. Miller

Version 1.7

**1. Schedule**

-   Time table for start of deliveries

-   Shipping schedules

**2. Surface building**

-   Specifications/description

-   Equipment

-   Storage capacities

**3. Surface loading equipment**

**4. Materials Handling Cage**

**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

**Appendix A. Steel Handling Sequence**

**Appendix B. Scintillator Handling Sequence**

**Appendix C. Scintillator Shipping Schedule**

**Appendix D. Safety Signoff Procedures**

#### 1. Schedule

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

-   **Steel**

```{=html}
<!-- -->
```
-   **1^st^ Strongback and other lifting fixtures May 2001**

-   **Steel Plates SM1 Jun 2001**

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

-   **2^nd^ Strongback Jun 2001**

-   **Coil monitoring electronics Jan 2002**

-   **Coil parts (cable, cooling pipes, power supplies) May 2002**

-   **Steel Plates SM2 Sep 2002**

-   **Scintillator**

-   **First module shipment to surface building Dec 2000**

-   **Module Mapper Mar 2001**

-   **Light Leak test equipment (Soudan Lab) Mar 2001**

-   **First 10 planes modules Feb 2000**

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

-   **First SM2 modules Sep 2002**

-   **Other detector components**

-   **Clear fiber ribbon cables Apr 2001**

-   **MUX boxes Apr 2001**

-   **Pulser system and cables Apr 2001**

-   **Electronics Racks May 2001**

-   **Electronics May 2001**

###### 1.2 Shipping Schedules

-   **Steel Plates**

Steel plates are delivered to the surface building on flatbed trucks
beginning in June 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.
Appendix A describes the steel plate handling procedure.

-   **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. Appendix
B describes the scintillator module handling procedures. Detailed
shipping schedules are given in Appendix C. Appendix D describes the
safety signoff procedures that will be used at Soudan.

###### 2. Surface building

**2.1 Status**

##### Beneficial Occupancy is scheduled for Dec. 4, 2000. About one month of minecrew time is needed to outfit the building and prepare for our first shipments. We will be able to start storing equipment as needed after this date. We will not be able to ship underground until March 2001 when the Soudan Lab Mezzanine is completed.

**2.2 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. Computers in the building will be tied into
underground computing systems. If more computer-office space is needed,
the mezzanine over the office area could be converted into additional
offices.

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

#### 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
>
> Air Compressor 5-7 hp cast iron Shop Vacuum
>
> Assorted air tools
>
> Grinder floor mount \[possibly on hand\]

######### 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

**2.3 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. More room can be made for scintillator
boxes if needed and we will just have a few less piles of steel.

###### 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.

**3.1 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 \$86K,
including the \~\$10k rebate for sale of the boom rig when installation
is complete.

-   [Boom Truck Equipment Costs]{.underline}

######## Boom rig added \$30k

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

-   Large trucks lease \$24k/yr.

-   Utility truck \$21k/yr.

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

> Total cost during installation \$86k

**3.2 Repair of U of Minnesota crane**

The U of Minnesota 15-ton mobile crane needed to have its swing bearing
repaired at a cost of about \$25k (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. Crane repair has been completed and OSHA
inspection is scheduled for December 5, 2000.

###### 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 must make several additions to the cage before its drop
test in the shaft can be completed before the cage is put into service.
Radios and other items must be installed before personnel can ride in
the cage. The materials handling cage will be installed in the shaft in
mid December 2000.

Materials Handing Cage

Steel Bundle Scintillator Box

![](media/image2.wmf){width="6.405555555555556in"
height="7.436111111111111in"}

**4.2 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 was completed and delivered in early Nov.
2000 at a cost of about \$78k. Brackets for holding steel plates,
scintillator boxes and other freight must be built and installed.
Fermilab is helping with all design work.

Due to the long cage changeover time and the DNR tourist season, steel
and scintillator shipping boxes are only hauled underground in the
evening shift.

######## **4.4 Pallets and other dunnage (U of M cage)**

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.

![](media/image3.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-shipping and plane

Scintillator shipping carts, 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. A forklift or hand tugger will be used
to move these carts around. Four are used for storage and movement in
the Soudan Lab. Scintillator storage boxes are always stored on the
carts.

Scintillator plane boxes are moved using one of two plane carts. These
carts are used to move tested modules into the MINOS lab and are light
enough to be pushed by hand. The carts should also be low enough so
modules can be slid directly off the cart onto rollers on the steel
plane. The carts will have one set of wheels in the center of the cart
and two sets of casters on the ends set slightly higher then the wheels.
When pushing on the back end of the cart the front casters come just off
the ground making it easier to steer.

###### 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 3-4 scintillator-shipping
boxes while the modules are being tested and moved to the mezzanine. It
is assumed that the shipping boxes always stay on their cart so they can
be moved into position using a hand tugger.

-   **Mapping table and lifting bay**

####### The module mapper sits under the lifting bay, which is a 16 ft by 32 ft opening. 

####### There is room for one scintillator-shipping box under the lifting bay as well. When the module mapper is actually running, an area 5 ft on all sides must be roped off as a stay-out area (while the radioactive source is out of its shielded enclosure). Only authorized personnel are allowed to run the mapper. 

#### 

#### 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 2,800
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 will be made to accommodate
the crane.

**Layout of Soudan Mezzanine**

![](media/image4.wmf)

**6.3 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 boxes until they are needed at the detector plane workstations. Tested modules will be sorted into the 3 storage positions closest to the lifting bay to minimize crane movement. Once the eight modules needed for a single plane are in a box, the full box will be moved to one of the other 6 storage locations. The boxes will be 29 ft long by 56" wide and about 8" deep and one side of the box will be open to allow modules to be slide out onto the completed steel plane. The storage boxes will be built by the installation task. We plan to accumulate a stockpile of 3-4 months (40-60 planes) worth of scintillator modules during the outfitting and installation startup period. The mezzanine storage areas are approximately 28 ft by 64 ft long and 24 ft by 40 ft. 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 9 storage box stacks.

###### 

###### 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.

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.

**7.2 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.
A 30 ft long by 10 ft wide storage frame from the Soudan Lab will be
moved into this area to supply additional storage space. If needed it
can be enclosed to protect Mux boxes or equipment stored in this area.

**Appendix A. Steel Handling Procedures**

**Bill Miller**

**Nov. 23, 2000**

-   **Materials Handling Studies at Fermilab**

All procedures described in this appendix have been optimized and
tested, as realistically as possible, during the materials handling
prototype studies in the New Muon Lab at Fermilab. These procedures were
thoroughly reviewed by a Fermilab safety committee.

-   **Steel Shipments**

#####  Plates are shipped from Olympic Steel in Mpls., MN. The trucks can carry approximately 13 plates per load. We will keep about a 1 month buffer of steel on the surface at all times and schedule the shipments to keep our stock up. 

#### Bundling Sequence

##### Plates are unloaded using a vacuum lifter or plate clamps 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. Plate clamps are used to rotate 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
tracking plan.

-   **Boom Truck**

The boom truck is used to haul the bundles from the surface building to
the headframe. Three bundles can be loaded onto the truck and 6 bundles
can be hauled underground in one evening shift. This means that the
truck will have to be reloaded once during the evening shift. Extra
bundles are sitting stacked in bundle racks so that the loading time is
short. The boom truck is located in the same spot on the surface for
each load. Blocks are placed on the ground to keep the truck from
sliding when it is holding the load back. One of the 3 bundles is taken
off the truck and lowered onto the skate designed at Fermilab that holds
the back end of the bundle. The front end is hooked to the hoist in the
materials handling cage. As the hoist pulls the bundle into the cage the
truck supplies the horizontal force (2000 lbs) needed to control the
load. Once the load has been totally transferred into the cage the truck
boom releases its cable and prepares for the next bundle.

-   **Materials Handling Cage**

The bundle is secured into the cage using diagonal braces designed for
this purpose by Fermilab. It clamps the load in 2 locations about 8 ft
and 20 ft from the bottom deck. Chains secure the top so that the hoist
does not support the load during the move underground. Safety bars are
placed on the back side of the cage to insure that the load can't shift.
The load is now ready to move underground.

-   **Unloading Underground**

The procedure at the bottom is similar to the top except that the bundle
comes out the back of the cage. Safety stops are removed and a hoist
mounted on the shaft station side of the cage pulls the bundle to the
north so that the load is off the diagonal braces. These are then
lowered out of the way and the bundle is allowed to hang vertically. It
is then grabbed by a hoist located in the entrance hall that pulls the
load towards the south. The bottom corner is lowered onto a steel skate.
The bundle is pulled out until it is now sitting vertically. At this
point the monorail hooks onto the top 2 lifting holes and lifts the
bundle into the air. Once the monorail has the load the cage and
horizontal pull hoists are removed. The cage is secured to go back to
the surface for the next bundle.

-   **Monorail and Steel Storage Cart**

The bundle is moved via the monorail into the MINOS Hall. The steel
storage cart, which moves in an east/west direction, is located so that
a bundle can be lowered into an empty slot. The 2 bolts holding the
bundle together must be removed while the monorail is still holding the
bundle. Once it is in the cart the lifting fixtures can be removed and
the monorail bought back to the shaft and readied for the next load.
Steel plates are now ready to be moved onto the strongback via the
gantry crane and plate clamps.

-   **Personnel Required**

A minimum of 3 minecrew is needed for the work both below ground and
above. This means at least 6 minecrew must work the evening shift to
haul materials.

**Appendix B. Scintillator Handling Sequence**

**Leon Mualem, Bill Miller**

**Oct. 23,2000**

-   **Surface building**

> Scintillator shipping boxes arrive at the surface building via
> dedicated flatbed truck. Approximately every 7 weeks, a truck from the
> Caltech module factory will arrive with 8 long narrow shipping boxes.
> Eight empty boxes will be shipped back to Caltech on the same truck.
> Wide diagonal modules shipping boxes from the University of Minnesota
> factory will arrive every 2 weeks with only 2 crates per shipment.
> Again 2 empty crates will go back on the same truck. The trucks will
> be unloaded using the surface forklift or the 7 ½ ton overhead crane
> in the surface building. Boxes will not be opened on the surface
> unless obvious outside damage to the shipping box can be seen. A
> detailed shipping schedule is available called moduleflow_outA.xls
> (see Appendix C).

-   **Boom truck**

A flatbed truck with a 14,000 lb capacity boom will be used to haul the
scintillator crates to the headframe. Boxes can be loaded with either
the surface building overhead crane or the truck boom. Two boxes turned
on edge can be carried at one time. The boom truck hoist also supplies
the needed horizontal pull needed as the box is pulled into the cage.
Four loaded scintillator-shipping boxes can be hauled underground and 4
empty boxes bought back to the surface in one shift. This means that the
truck must go back down to the surface building to unload the 2 empty
boxes and pickup 2 new full ones. Before each box is pulled into the
cage it is lowered down to the ground. The back end of the box is placed
on a scintillator skate and the front lifting fixture is hooked to the
materials handling cage hoist.

-   **Materials handling cage**

> The materials handling cage is designed to come apart quickly.
> Removing a few bolts and lifting it off the lower deck removes the
> passenger pod. The lower deck has 5 back panels and the door to remove
> and it is ready to take either the steel bundle holding fixtures or
> the scintillator box holder. Fermilab is designing both of these. Once
> the cage is apart it is ready to pull the scintillator box into the
> cage. The boom truck holds the box back as it is pulled in. This
> process takes about 15 min. It takes an additional 15 min to secure
> the load and prepare the cage to go underground. Once the load is at
> the 27^th^ level a combination of permanently mounted hoists and the
> monorail is used to pull the box out of the cage. Once the monorail
> suspends it, it is rotated perpendicular to the monorail and lowered
> onto a scintillator shipping box cart. It is also rotated from an
> edge-down to a bottom-down orientation during this process. It is now
> ready to be pulled into the Soudan Lab using a tugger.
>
> An empty scintillator box is shipped to the surface in the empty cage.
> Total round trip is expected to take between 75 and 90 min. Four
> scintillator boxes should be moved underground in one shift.

-   **Scintillator shipping box cart**

> These carts have yet to be designed but they are simple, very sturdy,
> and can be pulled by a battery-operated tugger. This increases the
> maneuverability of the large 29 ft x 5 ft crates compared to using a
> forklift. A total of up to 4 carts, depending on final design, is
> needed in the Soudan Lab.

-   **Testing sequence**

> The scintillator-shipping box is moved into position next to the
> module mapper. Modules are picked up by the Fermilab vacuum lifter,
> which is attached to the overhead crane, and placed on the mapper. The
> beefier frame on this vacuum lifter is also used as a spreader bar for
> moving the scintillator plane boxes on the mezzanine. While a module
> is being mapped the area is marked as a stay-out zone and only
> authorized personnel are allowed. Once a module has passed all its
> tests and been mapped it is lifted up onto the mezzanine and placed in
> one of the 3 scintillator plane boxes closest to the lifting bay.
> These modules must be stacked in the correct order for direct
> placement on the steel plane. Total time for this test is expected to
> average about 1 hour per module, including crane movement, and require
> one minecrew and one physicist/tester.
>
> Once the first 50-60 planes have been tested this way a decision will
> be made based on the original module map at the factory if this high
> level of testing is needed. If not modules will go through a simpler
> light leak test before sorting into their plane boxes.

-   **Scintillator plane boxes**

Scintillator plane boxes are lightweight 3-sided boxes that hold 1 plane
worth of modules each. There is room for 9 stacks of them on the Soudan
Mezzanine and they can be stacked 5 ft or 6 ft high. The current plan is
to have the minecrew build these. Materials cost about \$250/box and we
need approximately 60 boxes.

-   **Scintillator plane box carts**

These carts can be had pushed by hand into the MINOS lab. The carts
should be low enough so modules can be slid directly off the cart onto
rollers on the steel plane. The carts will have one set of fixed wheels
in the center of the cart and two sets of casters on the ends set
slightly higher then the wheels. When pushing on the back end of the
cart the front casters come just off the ground making it easier to
steer.

-   **Roller method of moving scintillator modules**

From experience at the module factories, the most efficient method of
moving modules with 2 people is to use roller strips (different length
bars with roller balls on top). Strips are laid down on the steel plane
and used to roll each module from a scintillator plane box into
position. A complete set of roller strips needed for 1 strongback will
be purchased before beneficial occupancy. A second set for the other
strongback will be ordered if this method proves easier than the
gantry-crane method, described below.

-   **Gantry-crane vacuum-lifter method of moving modules**

> A vacuum lifter attached to the gantry crane may be used for placing
> modules on the strongback, if this method works easier than the roller
> method. It takes 2-3 people to use the gantry crane method. It may be
> that a combination of both module-moving methods will prove most
> efficient. A single vacuum lifter, available from Argonne, will be
> used to try out this method in parallel with the roller method. If an
> additional lifter is needed for the second strongback, it will be
> ordered later.
>
> Appendix C. Scintillator Shipping Schedule

(This section is being updated to agree with the new outfitting
schedule. )

##### **Appendix D.**

##### **Soudan Installation Safety Signoff Procedures**

## Earl Peterson

# **November 20, 2000**

Far detector installation procedures and equipment will be required to
meet Soudan Laboratory safety standards. An approval process similar to
the Fermilab Operational Readiness Clearance procedure will be used to
certify that procedures and equipment are safe before routine use
begins.

All procedures and equipment are subject to University of Minnesota
safety regulations, and the facility is subject to routine inspection by
University code officials. In addition, all operations which take place
in and around the Soudan mine shaft are subject to State Park safety
regulations. Although Fermilab has no formal responsibility for the
safety of operations at Soudan, the MINOS detector installation staff
will require that equipment and procedures meet the same basic safety
standards as on-site Fermilab experiments. In order to guarantee that
far detector installation procedures and equipment meet all safety
requirements, each system will be subject to a formal inspection before
it is placed into operation, and to routine inspections thereafter. The
documentation of these procedures is now under way. A draft description
of the safety approval process is reproduced below.

[Draft Installation Signoff Procedures for MINOS Far
Detector]{.underline}

**1. Electrical**

a.  **Electronic devices:**

All non-commercial PC boards must be approved by FNAL before shipment to
Soudan. The Soudan Laboratory safety officer or his designee will check
the units as they arrive (for exposed A/C and grounding) and energize
them as appropriate. They will then be tagged as ready to either test or
install. The designee might be the physicist/engineer responsible for
the unit.

> **b. High-current devices**:

A licensed electrician must do junction box wiring. High-current devices
(magnet coil power supplies are an example) should not be activated
before the Safety Officer and an engineer from Fermilab (Bob Trendler or
designee) have written an operations procedure and powered the units.
This may involve utilizing a test load. The magnet coil turn-on should
follow a similar plan. These units should be protected by LOTO
(lock-out/tag-out) procedures during maintenance, and should be operated
only by personnel certified to do so by the Safety Officer. Fermilab
power technician training or equivalent should provide this
certification.

1.  **Mechanical**

#### Cranes, Monorail and Steel carts

### The outfitting contract provides for operator training by the equipment suppliers. Jerry Meier will participate in the training, and he is himself certified to train.

1)  A written procedure will be abstracted from the training
    documentation furnished by the suppliers.

2)  Jerry Meier will train and authorize crew bosses to use the
    equipment. Only authorized personnel can operate this equipment.

#### 

#### Materials Handling Cage

1)  A signoff committee will be formed to assess and document
    procedures. The (tentative) membership will include Jerry Meier,
    Bill Miller, Jim Beaty, and Anthony Zavodnik and Alan Kosir from the
    DNR. Jim Kilmer from Fermilab will act as a member (if present) or
    consultant.

2)  The committee will review the videotapes from the New Muon Lab tests
    and develop a written procedure based on the Fermilab ORC
    documentation.

3)  Jerry Meier will insure that mine crew members are familiar with,
    and follow the procedure.

    a.  **Strongback use and plane deployment**

```{=html}
<!-- -->
```
1)  A signoff committee will be formed to assess and document
    procedures. The (tentative) membership will include Jerry Meier,
    Bill Miller and Jim Beaty. Jim Kilmer from Fermilab will act as a
    member (if present) and as a consultant

2)  The committee will review the videotapes from the New Muon Lab tests
    and develop a written procedure based on the Fermilab ORC
    documentation.

3)  Jerry Meier will insure that mine crew members are familiar with,
    and follow the procedure.