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**\*\*\* First DRAFT \*\*\***

***WBS 1.3 RICH Detector***

***Installation Plan***

***By***

***H. Cease et. al.***

**BTeV Document** (number to be assigned)

**March 8, 2004**

# INTRODUCTION

> The present installation scenario is for the RICH detector tank to be
> assembled in the assembly hall partially instrumented. The tank will
> not be instrumented with MAPMTs, or most of the PMTs. The gas
> enclosures for the PMT arrays, the top PMT array fully instrumented,
> front entrance window, liquid radiator vessel, rear exit window,
> mirrors and mirror support structure, and beam pipe are part of the
> tank assembly when rolled into the collision hall in the 2008 summer
> shutdown. When all of the instrument enclosures are in place, an
> initial gas leak check is performed. Once the tank is assembled in the
> assembly hall, it is transported using rollers into the collision
> hall. The RICH tank is installed after the Vertex Magnet and Toroid
> Magnets are installed into the collision hall. At a later date,
> suitable to the installation schedule, the MAPMT enclosures are
> installed along with the PMT beehives and tubes. The RICH is completed
> in the collision hall at the end of the summer 2009 shutdown.

**STEPS IN THE ASSEMBLY HALL (Starting Late 2006 up to the 2008
shutdown)**

> The following steps must be performed before rolling the tank into the
> collision hall:

1.  Shipping the tank frame segments to C-Zero;

    -   *Plates machined summer 2005*

2.  Assembling the tank frame by welding the walls together;

    -   *Frame construction finished Assembly Hall spring 2007*

3.  Attaching the liquid radiator vessel to the tank;

    -   *Fall 2008*

4.  Mounting the front window to the frame;

    -   *Built Fall 2005*

5.  Installing the mirrors and mirror support structure;

    -   *Panel constructed in summer 2006*

    -   *Mirror tiles attached to support structure Fall 2006*

    -   *Mirror support structure is attached to the vessel spring 2007*

6.  Inserting the beam pipe into the tank;

7.  Making the beam pipe to window seals;

    -   *Fabricated summer 2008*

8.  Mounting all of the PMT enclosures completely instrumented;

    -   *Enclosures constructed fall 2007*

9.  Installing the Gas Radiator Passive Expansion Volume;

10. Pre-aligning the mirror tiles;

11. Initial gas leak check of the tank frame, window seals, and
    instrument enclosures.

> **Tank frame segments --**
>
> *Weight \~15,000 lbs*
>
> *Assembled Size \~ 6 meters X, 5 meters Y, 3.5 meters Z*
>
> Large steel plates and structural beams are shipped to the C0 assembly
> building. The pieces need to be small enough to fit through the C-Zero
> exterior entrance door. The entrance door is approximately 12 feet
> wide and 13 feet tall. The frame segments are large and require a
> rigging crew, a technician crew, and a welder to assemble. Survey
> points can be the standard ¼" hole for a fiducial holder.
>
> *Technician man time and rigging time to assemble the tank: 6 man
> months*
>
> *Welder man time to assemble the tank: 2 man months*
>
> *Survey time: 2 weeks*
>
> *Total Calendar time: 4 months*
>
> **Liquid Radiator Vessel --**
>
> *Two Pieces, a lower and upper halves*
>
> *Empty Weight \~ 180 lbs total*
>
> *Assembled Size \~ 2.48 meters X, 2.48 meters Y, 1.6 cm Z*
>
> *Requires plumbing for 4 chambers.*
>
> *Liquid Volume, 5 liters in the Vessel, additional \~5 liters in the
> plumbing.*
>
> The liquid radiator vessel is inserted and mounted to the tank frame
> as a pre-assembled unit. Plumbing lines from the radiator vessel to
> the exterior of the tank are connected. Fiducials located on the
> radiator vessel are transferred to the tank frame prior to the windows
> being installed on the tank frame.
>
> *Technician man time to mount the liquid radiator: 1 man week*
>
> *Survey time: ½ man week*
>
> *Total Calendar time: 1 week*
>
> **Front Window**
>
> *Front Window Weight \~40 lbs carbon fiber*
>
> *Size \~ 2.54 meter X, 2.54 meter Y, 1.3 mm Z*
>
> The front RICH tank wall has a carbon fiber window for particle
> transparency. In order to make the window replaceable, the window is
> mounted with flanges and o-ring seals. Due to the large number of
> attaching nuts and length of the o-rings, an initial gas leak check on
> all seals must be performed.
>
> *Technician time to mount and leak check the front window: 1 man week*
>
> *Total Calendar time: 2 weeks*

**Mirrors and Support Structure**

> *Mirror tiles weight \~17 lbs per tile without mounts,*
>
> *Mirror tile size, 1 meter square, total of 16 tiles, 8 tiles per
> array*
>
> *Single Mirror Array Size \~ 2 meter X, 4 meter Y, 0.6 meters Z due
> to*
>
> *curvature*
>
> *Support Panel Weight including rear window, \~800 lbs*

*Support Panel Size \~4.4 meters X, 4.4 meters Y, 0.6 meters Z*

> The mirror support panel is a single panel that acts as the support
> structure for the individual mirror tiles and acts as the rear window
> for the tank. The mirror tiles are mounted to the mirror support panel
> using three point mounts. As part of the mirror panel assembly,
> individual mirror tiles are calibrated and adjusted to each other
> prior to the mirror panel installation. The one piece structure is
> then mounted to the back of the RICH tank using a gasket type seal.
> Fiducials are located on the inside surfaces of the support structure
> so that the panel can be aligned with respect to the MAPMT enclosures.
> A second set of fiducials are located on the outside of the structure
> so that it can be position with respect to the tank and the
> interaction point. An initial leak check of the gasket seal must take
> place prior to installing the tank into the collision hall. The
> interface between the mirror array and the rest of the tank should be
> covered with a temporary gas tight barrier. The purpose of the barrier
> is to provide dust protection for the mirrors while the PMT and MAPMT
> arrays are being installed in the collision hall.
>
> *Technician time to mount mirrors and mirror support panel:*
>
> *2 man months*
>
> *Survey time: 1 man week*

##### Total Calendar time: 1 month

> **Beam Pipe**
>
> Installation of the beam pipe involves inserting a custom beryllium
> beam pipe section into the tank frame. The beam pipe is supported by
> the tank frame. After inserting the beam pipe into the tank, the
> window to beam pipe seal is made. The continuity of the Tevatron beam
> pipe must be restored to a vacuum below 10^-7^ torr. Inserting the
> beam pipe into the tank frame and making the seals is estimated to
> take 1 week calendar time.
>
> *Technician time to install the beam pipe: 2 man days*
>
> *Total Calendar time: 1 week*
>
> **Beam Pipe to Window Seals**
>
> A gas seal is required between the beam pipe and the RICH windows.
> This is done by gluing mounting rings to the beam pipe and the rich
> windows, and mounting a light/gas tight bellows between the two
> mounting rings.
>
> *Technician time to install the bellows: 2 man days*
>
> *Total Calendar time: 1 week*
>
> **PMT Enclosures**
>
> *PMT enclosure weight \~few hundred lbs steel frame*
>
> *Top and Bottom Size \~ 4 meter X, 0.2 meter Y, 3 meter Z*
>
> *Side Size \~ 0.2 meter X, 4 meter Y, 3 meter Z*
>
> There are four PMT enclosures, one on the top, bottom and each side.
> The purpose of the enclosure is to provide a light tight and gas tight
> enclosure for the PMT arrays. To ensure a leak tight seal, the
> enclosure side walls are welded to the tank frame. The back plate of
> the PMT enclosure is removable for access to the array
> instrumentation. The enclosures also have to provide a feed thru panel
> for cables and water cooling on one of the sides of the enclosure.
>
> *Technician time to install and leak check all four enclosures:*
>
> *2 man months*
>
> *Welder man time to mount all four enclosures: 1 man month*
>
> *Total Calendar time: 1 and ½ months*

**Top PMT Array Installation**

*\~1100 pmt tubes,*

*Beehive Weight \~ 3,000 lbs of mumetal tubes*

*Enclosure Weight \~several hundred lbs*

###  Size \~ 4 meter X, 0.2 meter Y, 3 meter Z

> The PMT array is fully instrumented and includes the mu-metal beehive,
> PMT modules and associated electronics and cooling. All cabling to the
> feed thru board is already completed. The array is installed using the
> overhead crane in the assembly hall. Once installed, the PMT assembly
> will be surveyed and adjusted to its correct location with respect to
> the RICH tank and the liquid radiator vessel. All necessary electronic
> cooling and electronic readout connects are made. The back panel to
> the enclosure is then placed onto the enclosure and leak checked. It
> is estimated that installation requires 1/2 week per array and
> surveying requires 1 week of calendar time.

###### Technician time to install, cable and leak check the array: 2 man weeks

> *Survey time: 1 week*
>
> *Total Calendar time: 1 month*
>
> **Gas Radiator, Passive Expansion Volume**
>
> *Expansion Volume Frame Weight \~1000 lbs for ten frames*
>
> *Size \~ 4 meter X, 1 meter Y, 3 mm Z*
>
> The expansion volume is installed on top of the tank by lifting the
> expansion volume frame using the assembly hall overhead crane. The
> expansion volume plumbing is then connected to the tank gas system
> plumbing. The expansion volume has no survey requirements.
>
> *Technician time to install the expansion volume: 2 man weeks*
>
> *Rigging time to install the expansion volume: 1 man week*
>
> *Total Calendar time: 2 weeks*
>
> **Pre-alignment of the Mirror Tiles**
>
> Once the tank is nearly complete, a pre-alignment of the mirror arrays
> can take place. The pre-alignment is performed by viewing by eye an
> image at the focal point of the mirror array.
>
> *Technician time to pre-align mirrors: 2 man weeks*
>
> *Total Calendar time: 1 month*
>
> **Initial Leak Check of the Tank System**
>
> Prior to rolling the tank into the collision hall, the entire tank is
> leak checked. The instrument array enclosures should be gas tight and
> the liquid radiator vessel and plumbing should be liquid tight.
>
> *Technician time to leak check the tank: 2 man weeks*
>
> *Total Calendar time: 1 month*
>
> *TOTAL ASSEMBLY HALL CALENDAR TIME \~ 12 calendar months*

**ROLLING THE TANK INTO THE COLLISION HALL AND FINAL INSTALLATION STEPS
(Summer 2008 Shutdown)**

The RICH tank installation involves the following steps:

1.  The shielding door is opened at the start of a Tevatron shutdown
    period.

2.  The RICH tank assembly is rolled into the collision hall by riggers
    utilizing rollers at C0 and temporary steel plates on the floor.

3.  It may be necessary to remove additional sections of beam pipe to
    allow the tank to roll into position.

4.  The RICH tank assembly will be surveyed and adjusted to its correct
    location with respect to the Tevatron.

> It is estimated that installation requires 1 month and surveying
> requires 1 week of calendar time.

###### Technician time to install : 1 man week

*Survey time: 1 week*

*Total Calendar time: 1 month*

**INSTALLATION STEPS IN THE COLLISION HALL**

> The following steps, not time ordered, are required once the tank has
> been installed into the collision hall.

1.  MAPMT Array Installation *Spring 2009*;

2.  PMT Array Installation is completed in the assembly hall

3.  Install the Electronic Cooling plumbing system;

4.  Install the Electronic Cooling Slow Control System;

5.  Install Liquid Radiator Plumbing system;

6.  Install Liquid Radiator Slow Control System for the Liquid;

7.  Install Gas Radiator Plumbing system;

8.  Install Gas Radiator Slow Control System for the Gas;

9.  Install the Mirror In-Situ Alignment System;

10. Fill the Liquid Radiator Vessel;

11. Fill the Tank with radiator Gas;

**HPD ARRAY INSTALLATION (OPTIONAL)**

**472 tubes per array, 2 arrays**

*HPD 32 pack Weight \~50 lbs, 32 HPD tubes, electronic cards, support
frame*

*Beehive Weight \~ 700 lbs, 472 mu-metal tubes*

*Enclosure \~1500 lbs of steel framing per enclosure (2.1 m x 1.5 m
x0.025 M)*

###  Size \~ 2.1 meters X, 1.5 meters Y, 0 .6 meters Z

*\~15 packs per enclosure*

*Cables per feedthru*

*Internet data cable 6 per row, max 25 per row*

*4 red high voltage cables per row*

*3 low voltage cables per row*

*Thermistors for slow control*

*2 coolant lines in/out*

*Cables per enclosure (15 feed-thru boards per enclosure)*

*\~70 internet cables*

*60 red high voltage cables*

*45 low voltage cables*

*Thermistors for slow control*

*30 coolant lines in/out*

> The HPD array installation is performed after the straw tube
> installation is complete. The HPD array includes the mu-metal beehive,
> HPD enclosure, exterior magnetic shielding (500 lbs), HPD 32 packs,
> and associated electronic cooling and electronic cables. The HPD packs
> are independent to the assembly structure and can be installed into
> the array when received. Installation of the assembly involves the
> following steps:

1.  The Straw Tube installation is complete.

2.  The shielding door is opened at the start of a Tevatron shutdown
    period.

3.  The HPD Enclosure are rolled into the collision hall as a completely
    instrumented unit by riggers utilizing rollers at C0 and temporary
    steel plates on the floor.

4.  The HPD complete enclosure will be surveyed and adjusted to its
    correct location with respect to the Tevatron, the RICH tank, and
    Mirror array.

5.  All necessary electronic cooling, electronic readout, and gas
    connections are made.

6.  Leak check enclosure.

> Repair of an individual HPD requires the removal the exterior magnetic
> shielding on the HPD enclosure, opening the enclosure, removing the
> HPD row from the structure, removing the necessary electronic and
> cooling connections, then closing the enclosure and replacing the
> exterior magnetic shielding. Repairing of one HPD would require 1 day
> of calendar time.

###### Technician time to install, cable and leak check the instrumented array 

###### (both arrays): 4 man weeks

*Survey time: 1 week*

> *Total Calendar time: 1 month*

**MAPMT ARRAY INSTALLATION (BASELINE)**

### Parts fabricated fall 2005 and assembled together

*4508 tubes per array, 2 arrays*

*Module weight \~ 55lbs, 196 tubes \~ 23 modules per array*

*Gas Enclosure \~1500 lbs per enclosure (2.1 m x 1.5 m x0.025 M)*

###  Size \~ 2.1 meters X, 1.5 meters Y, 0 .6 meters Z

*Cables per feed-thru board*

*5 High-Voltage, 20 MAPMTs per HV*

####  5 Low Voltage, 20 MAPMTs per +/- 5 V

*Data, 10 internet cables*

*Water Cooling, 2 tubes per module*

*Cables per enclosure (23 feed-thrus per enclosure)*

*115 High-Voltage,*

####  115 Low Voltage, 

*Data, \~250 internet cables*

*46 Water Cooling, 2 tubes per module*

> The MAPMT array installation is performed after the straw tube
> installation is complete. The MAPMT array includes the MAPMT
> enclosure, exterior magnetic shielding, MAPMT modules and associated
> electronic cooling and electronic cables. The MAPMT arrays are
> independent to the assembly structure and can be installed when
> received. Installation of the assembly involves the following steps:

1.  The Straw Tube installation is complete

2.  The shielding door is opened at the start of a Tevatron shutdown
    period.

3.  The MAPMT assembly is rolled into the collision hall by riggers
    utilizing rollers at C0 and temporary steel plates on the floor.

4.  The MAPMT assembly will be surveyed and adjusted to its correct
    location with respect to the Tevatron and the RICH tank.

5.  All necessary electronic cooling, electronic readout, and gas
    connections are made.

6.  Leak check enclosure

> Repair of an individual module requires the removal the exterior
> magnetic shielding (500lbs) on the MAPMT enclosure, opening the MAPMT
> enclosure, removing the Module from the structure, making the
> necessary electronic and cooling connections, then closing the MAPMT
> enclosure and replacing the exterior magnetic shielding. Repair of a
> module would require 1 day of calendar time.

###### Technician time to install, cable and leak check the instrumented array 

###### (both arrays): 4 man weeks

*Survey time: 1 week*

*Total Calendar time: 1 month*

**PMT ARRAY INSTALLATION**

**5000 total tubes, At least 4 arrays**

*Beehive Weight \~ 12,000 lbs, 5000 mu-metal tubes*

*Gas Enclosure \~ several hundred lbs per enclosure*

###  Size \~ 4 X meters, 0 .3 Y meters, 3 Z meters

*Electronic Cards*

> *Bases*

*Front end boards*

*Data combiner boards*

*Cables per 256 tubes*

*64 channels for a hybrid board,*

*\` 256 for a mult-iplexer 3"x 10", near middle of array*

*High-Voltage, ??*

####  Low Voltage, ??

*Data, ??*

*Water Cooling each base and hybrid and multi-plexer*

> The PMT array installation is performed at a convenient time in the
> installation schedule and is not affected by the installation of other
> components. The PMT array includes the mu-metal beehive, PMT
> enclosure, exterior magnetic shielding, PMT modules and associated
> electronic cooling and electronic cables. The PMT modules are
> independent to the assembly structure and can be installed when
> received. Installation of the assembly involves the following steps:

1.  The labyrinth door is opened at the start of a Tevatron shutdown
    period.

2.  The PMT assembly is rolled into the collision hall by riggers
    utilizing rollers at C0 and temporary steel plates on the floor.

3.  The PMT assembly will be surveyed and adjusted to its correct
    location with respect to the Tevatron, the RICH tank, and the liquid
    radiator vessel.

4.  All necessary electronic cooling, electronic readout, and gas purge
    connections are made.

5.  Leak check enclosure

> It is estimated that installation requires 1 week per array and
> surveying requires 1 week of calendar time.

###### Technician time to install, cable and leak check the instrumented array 

###### (three remaining arrays): 4 man weeks

*Survey time: 1 week*

> *Total Calendar time: 1 ½ months*

## ELECTRONIC COOLING SYSTEM

> The electronic cooling system for each of the instrumented arrays
> consists of:

1.  The plumbing system and associated instrumentation;

2.  The monitoring system;

3.  The control software including alarm function.

###### Technician time to install the plumbing hardware system:

######  XX man weeks, XX% of the time in the Assembly hall

*Engineering time to qualify the plumbing hardware:*

> *XX man weeks, XX% of the time in the Assembly hall*

###### Technician time to install the monitoring system: 

> XX man weeks, XX% of the time in the Assembly hall

*Engineering time to qualify the monitoring system:*

> *XX man weeks, XX% of the time in the Assembly hall*

###### Technician time to install the control software system: 

> *XX man weeks, XX% of the time in the Assembly hall*

*Engineering time to qualify the control software system:*

####### XX man weeks, XX% of the time in the Assembly hall

*Total Assembly hall calendar time, XX weeks*

*Total Collision Hall calendar time XX weeks*

## MIRROR IN-SITU CALIBRATION SYSTEM

> The mirror calibration system consists of:

1.  The LED arrays;

2.  The monitoring system;

3.  The control software including alarm function.

###### Technician time to install the LED arrays and get them cabled:

######  XX man weeks, XX% of the time in the Assembly hall

###### Engineering time to qualify the LED arrays and get them cabled:

> *XX man weeks, XX% of the time in the Assembly hall*

###### Technician time to install the monitoring system: 

> *XX man weeks, XX% of the time in the Assembly hall*

*Engineering time to qualify the monitoring system:*

> *XX man weeks, XX% of the time in the Assembly hall*

###### Technician time to install the control software system: 

> *XX man weeks, XX% of the time in the Assembly hall*

*Engineering time to qualify the control software system:*

####### XX man weeks, XX% of the time in the Assembly hall

*Total Assembly hall calendar time, XX weeks*

*Total Collision Hall calendar time XX weeks*

## LIQUID RADIATOR SYSTEM

> The slow control system consists of:

1.  The plumbing system and associated instrumentation;

2.  The monitoring system;

3.  The control software including alarm function.

###### Technician time to install the plumbing hardware system:

######  XX man weeks, XX% of the time in the Assembly hall

*Engineering time to qualify the plumbing hardware:*

> *XX man weeks, XX% of the time in the Assembly hall*

###### Technician time to install the monitoring system: 

> XX man weeks, XX% of the time in the Assembly hall

*Engineering time to qualify the monitoring system:*

> *XX man weeks, XX% of the time in the Assembly hall*

###### Technician time to install the control software system: 

> *XX man weeks, XX% of the time in the Assembly hall*

*Engineering time to qualify the control software system:*

####### XX man weeks, XX% of the time in the Assembly hall

*Total Assembly hall calendar time, XX weeks*

*Total Collision Hall calendar time XX weeks*

## FILLING THE LIQUID RADIATOR VESSEL WITH C5F12 LIQUID

> Filling the liquid radiator vessel requires that the following tasks
> are complete:

1.  The vessel has been installed into the RICH tank;

2.  The vessel has been leak checked;

3.  The liquid radiator re-circulation system is complete and has been
    tested.

> The process of filling the liquid radiator vessel and confirming the
> re-circulation system is operating properly is estimated at 1 month of
> calendar time.

###### Technician time to perform the fill: 

> *XX man weeks, XX% of the time in the Assembly hall*

*Engineering time to qualify the fill:*

> *XX man weeks, XX% of the time in the Assembly hall*

*Total Assembly hall calendar time, XX weeks*

> *Total Collision Hall calendar time XX weeks*

## GAS RADIATOR SYSTEM

> The slow control system consists of:

1.  The plumbing system and associated instrumentation;

2.  The monitoring system;

3.  The control software including alarm function.

###### Technician time to install the plumbing hardware system:

######  XX man weeks, XX% of the time in the Assembly hall

*Engineering time to qualify the plumbing hardware:*

> *XX man weeks, XX% of the time in the Assembly hall*

###### Technician time to install the monitoring system: 

> *XX man weeks, XX% of the time in the Assembly hall*

*Engineering time to qualify the monitoring system:*

> *XX man weeks, XX% of the time in the Assembly hall*

###### Technician time to install the control software system: 

> *XX man weeks, XX% of the time in the Assembly hall*

*Engineering time to qualify the control software system:*

> *XX man weeks, XX% of the time in the Assembly hall*

*Total Assembly hall calendar time, XX weeks*

*Total Collision Hall calendar time XX weeks*

## FILLING THE RICH TANK WITH C4F10 GAS

> Filling the RICH radiator tank requires that the following tasks are
> complete:

1.  The tank has been installed in the collision hall;

2.  The tank has been leak checked;

3.  The temporary gas barrier for the mirrors has been removed;

4.  All of the mirrors have been installed and are position with respect
    to each other, the MAPMT array, and the Tevatron;

5.  The gas radiator re-circulation system is complete and has been
    tested.

> The process of filling the RICH tank and confirming the re-circulation
> system will be performed carefully.

###### Technician time to perform the fill: 

> *XX man weeks, XX% of the time in the Assembly hall*

*Engineering time to qualify the fill:*

> *XX man weeks, XX% of the time in the Assembly hall*

*Total Assembly hall calendar time, XX weeks*

> *Total Collision Hall calendar time XX weeks*

*TOTAL ASSEMBLY HALL TIME \~ XX calendar months*

*-assumes Hexads and PMTs are installed in parallel*

> *-assumes Liquid Radiator and Gas Radiator systems are installed and
> debugged in parallel*