Rail Extensions for Mounting/Removing Detectors

Contents list for the toolboxes on the Detector Service Platforms

• Remove interfering equipment from the service platform ( tables, etc. ).
• Install stop at upstream end of flat wheel track - use 1/2" grade 8 bolts - 3/8" hex key
• install section of angle track at the door - use 1/2" bolts - 3/4" socket
• Install Lexan exit vacuum window cover, under the VDCs.
• Remove DAQ handshake cables which run up along the side of the shield house, up the front of the detector stack. This routing is required to get shortest transit time possible between the two arms. It's only a small number of cables.
• make sure no other cables have been run from the Detector Stack to the walls or under the Boxbeam - all other cables should be run through the articulated cable tray - disconnect or secure any problematic cables
  
• Raise VDC
• make sure there is room above the VDC to raise it - no interferences
  
• install aluminum covers on the top of the VDCs
• disconnect ground strap to box beam from front of VDC assembly - small ratchet and 7/16" socket
• remove bolts at stops at rear of VDC assembly - small ratchet and 7/16" socket
• check to make sure the lifting bolts are installed and secured in place
• adjust the position of the four lifting pillows on the I-beams
• make sure the drain valve on the bottom of the compressor is closed
• attach the hose from the VDC manifold/valves/gauge to the compressor
  
• make sure the regulator output is set to a very low setting - preferrably zero - to avoid any unexpected lifting - in the end something like 40 psi should be sufficient
  
• startup the small air compressor; let run till sufficient pressure is achieved - in the end something like 40 psi on the output should be sufficient
• there are two manual valves on the manifold/valves/gauge - the one inline with the hose lets air into the pillow jacks - the one inline with the open port will let air out of the pillow jacks
  
• carefully begin raising the VDC assembly - pay close attention that the lift is smooth and nothing is snagged - rear end comes up slightly lower than the front end
• raise VDC assembly sufficiently to prevent the bearings from bumping the Thompson rails while the frame is being pulled out, or in
• turn "holding" nuts up till they contact the lifting beams
• when the VDC assembly is secured, release the air from the pillow jacks and remove the air compressor
• the air compressor should be stored with no air pressure in it
• remove any interferring equipment from the service platform ( tables, etc. ).
• remove staircases from platform if required, both large and small.
• bring up a ladder to reach the upper electronics platform when the stack is pulled out ( a short rope to secure the ladder should be in the toolbox ).
• remove any storage cabinets from platform if required.
• grease the rails for the wheels on the detector stack. Wheels are not in perfect alignment, nor are they designed for lateral loading. Friction with the floor will pull the wheels to the side possibly causing failure of the wheel support. GREASE THE RAILS!
• release the chainfall at right rear wheel of detector stack.
• make sure no wires or hoses dangle from the stack such that they will catch the VDC rails/support or exit window - make sure nothing will drag across the exit window
• make sure nothing protruding from the Detector Stack will snag anything along the walls on the way out
  
• hookup the electric winch at the end of the angle track for the right wheels. Use 3/8" chain hook and old nylon sling. Attach them to the end of the winch's cable., Winch should be used to pull the support frame. Do not stand near the cable when the cable is under tension. Whiplash of the cable can result from failure under tension.
• pull stack out.
• Pay close attention to the wheels which ride on the flat plate. They will get pulled to the side, lateral loading. The grease on the rails is intended to allow the wheels to slip and thus minimize the lateral loading.
• Pay close attention to the cables along the stack. Cables can catch on the VDC support frame and the exit window. On the Left Arm pay attention to when the Personnel Safety System (PSS) flexible conduit, at the rear of the stack, passes over the VDC stops. The conduit will need to be lifted up over the stop on the beamline side. The large flexible cable tray can catch the cables along the wall by the door.
• do the work required on the stack

• Remove any detector support rail extensions. There is a bar for hammering out jammed rail extensions, if required.
• Grease rails for the wheels on the detector stack.
• Hookup the electric winch. Use 3/8" chain hook and old nylon sling. Attach them to the end of the winch's cable.
• Pull stack in.
• Pay close attention to the wheels which ride on the flat plate. They will get pulled to the side, lateral loading. The grease on the rails is intended to allow the wheels to slip and thus minimize the lateral loading.
• Pay close attention to the cables along the stack. Cables can catch on the VDC support frame and the exit window. The large flexible cable tray can catch the cables along the wall by the door.
• Connect and snug-up chainfall at right rear wheel of detector stack. The Left Detector Stack will be pulled back till it contacts the piece of angle welded at the end of the flat track. The Right Detector Stack has a 3" square block of wood with a 3/4" thick piece of aluminum plate against the piece of angle welded at the end of the flat track. The piece of aluminum does not end up in a vertical position, rather it tilts backwards a bit when the stack is pulled back snug against the stop. While this is not the most stable arraingement, changing it would require a calibration run and changes to the software database in the analysis package. Changing the material at the stop would require a little bit of careful thought.
• Install staircases, both large and small, if they were removed.
• Place storage cabinets on platform if they were removed.
• Lower VDCs
• adjust the position of the four lifting pillows on the I-beams
• attach and startup the small air compressor; let run till sufficient pressure is achieved
• carefully begin raising the VDC assembly - pay close attention that the lift is smooth and nothing is snagged
• raise VDC assembly  sufficiently to remove the load on the "holding" nuts
• turn "holding" nuts down low enough to not interfere when the VDC assembly is lowered
• pay attention that the assembly will come down softly and sit correctly on the Thompson rails
• make sure the VDC assembly will not come down on top of the rear stops and get hung up or damage something - VERY bad things can happen
• release the air from the pillow jacks - carefully - pay attention to how and where the VDC assembly is coming down
• remove the air compressor
• the next step is for the Left Arm only
• remove lifting bolts from the lifting beams and the circular plates welded onto the Detector Support Frame - 1 1/8" wrench
• the lifting bolts can remain in place on the Right Arm
• pull VDCs back till they make contact with the stops at the rear of the VDC rails - 500 lbs come-a-long and old nylon sling - use crosswise I-beam for an anchor point
• Install bolts at stops at rear of VDC assembly - do NOT tighten excessively - 7/16" wrench
• connect ground strap to box beam - 7/16" wrench
• rotate bottom S1 counter into correct orientation - small ratchet and socket for hose clamps
• connect DAQ handshake cables which run up along the side of the shield house, up the front of the detector stack. This routing is required to get shortest transit time possible between the two arms. It's only a small number of cables.
• remove exit window cover from under the VDCs
• remove aluminum covers from the top of the VDCs, if they were installed
• remove section of angle track at the door - save the 1/2" bolts - 3/4" socket
• remove stop at end of flat wheel track - save the 1/2" grade 8 bolts - 3/8" hex key
• return equipment to the service platform ( tables, etc. ) if any were removed

Notes on Electron Arm Detector Stack Removal From Shielding House
when stack was on right arm

Electron Detector Stack

• Measured weight : 20,000 lbs. ( S1, S2, Pre-shower Pb-glass, rigging )
• Used special manufacture sling in a choker around the upper cross bar. One end of sling was wrapped around the hook in an extra loop, to shorten it just a little bit more. Used a 10 foot sling in an inverted basket from two hoist rings.

Hadron Detector Stack

• Measured weight : 25,500 lbs. ( S1, SC1, SC2, S2, carbon doors, SC3, SC4, rigging )
• Used a 25 T WLL shackle in the top hole of the lifting fixture. An 8 foot sling looped twice through the hook and shackle, to make it 2 foot long.

• grease gun
• winch
• rail extensions
• VDC transfer frame
• boxes for VDC cable
• jack stands for VDC transfer frame

Vertical Drift Chambers

Scintillator Planes

• S2m
• Measured weight of S2m (Hadron/Left Arm) : 798 lbs
• 14 foot strap in a basket attached to the top. 3 foot strap in a basket to a 1/2 ton chainfall with a 10 foot strap in a basket at the bottom.

Gas Cerenkov

• Electron(Right) Arm
• Measured weight (with top and bottom mounting braces) : 1431 lbs
• 10 foot strap in an inverted basket attached to the top. 3 foot strap in a basket to a 1 ton chainfall with an 8 foot strap in an inverted basket at the bottom. Inverted basket ends should be attached to the threaded rod the roller assemblies are mounted on. Use 1/2" shackles.
• Rather than choke the ends around the U-channel I have been putting the shackles on the threaded rod connecting the roller assemblies to the U-channel. With the new storage stands for the detectors I cannot get a sling around the U-channel while it is resting on the storage stand.
• Hadron(Left) Arm
• Measured weight (05-15-01)(with all mounting braces): 1197 lbs
• Measured weight (05-15-01)(with Rutgers extension box): 1354 lbs
• When using the Rutgers extension box a 2 inch square tube needs to be added to the rails for the counter.  The counter needs to be moved downstream by 2 inches to clear the VDCs.
• Extrapolated weight of Rutgers gas volume extension box: 157 lbs
• Pull the stack out till the bottom rail, number 4, is at least even with the center split of the two halves of the bayonet box cover on the platform.
• 10 foot strap in an inverted basket attached to the top. 3 foot strap in a basket to a 1 ton chainfall with an 8 foot strap in an inverted basket at the bottom. Inverted basket ends should be attached to the threaded rod the roller assemblies are mounted on. Use 1/2" shackles.
• Rather than choke the ends around the U-channel I have been putting the shackles on the threaded rod connecting the roller assemblies to the U-channel. With the new storage stands for the detectors I cannot get a sling around the U-channel while it is resting on storage stand.

Carbon Blocks

• Weight ( measured ) of aluminum frame and carbon blocks : 6,000 lbs
• Weight of removal frame for doors is 131 lbs ( measured )
• Weight of lightest set of doors is 113 lbs ( measured ) each
• Weight of next set of doors is 183 lbs ( measured ) each
• 1.8g/cc =>
• Removal of carbon doors requires pulling the detector stack out of the shielding hut as far as the stack can be pulled, to the reasonable limit allowed by the cable trays. This will provide enough clearance between the crane trolley and the shield house doors.

The Dillon dynomometers should be used for the removal procedure. Installation probably will not require their use, but their use may be prudent. The dynomometers are the Dillon model ED-2000. Use 4, one on each sling.
Use 5/16 inch shackles on each of the four coners of the lifting frame Use 1 inch master link on crane hook for the top slings. Attach two dynomometers to the 1 inch master link using 5/8 inch shackles. Attach the 3 foot slings to the dynomometers with 1/2 inch shackles. Attach the 3 foot slings to the 5/16 inch shackles on the lifting frame using 1/2 inch shackles. Put one end of the 3 - 5 foot slings directly on the crane hook. Attach the dynomometers to the slings with 1/2 inch shackles. Attach the 1/2 ton chainfalls directly to the dynomometers. Attach lower hook of chainfalls directly to 5/16 inch shackles on the lifting frame, by the bottom end of the door.
• Materials required
• Lifting frame, welded angle construction, manufacturered by Rutgers
• 7 of 1/4-20 screws. To fasten lifting frame to carbon block edge
• Wrench to turn screws. Some holes are a little roughed up.
• 7 of 1/4-20 nuts. Nuts go on screws first. Screws too long for lighter doors.
• 7 of 1/4 washers. Insert between lifting frame and screws, holes are oversized
• Brass rods. To be inserted in bearing race after door removal. Prevents ball bearings from falling out.
• 4 of 5/16 inch shackles, to fit holes on lifting frame
• 6 of 1/2 inch shackles
• 2 of 5/8 inch shackles
• 1 of 1inch master link
• 2 of 3 foot slings, for legs of bridle at the top of the door
• 2 of slings 3 to 5 feet long, for chainfall legs of bridle
• 2 of 1/2 ton chain falls
• 4 of Dillon ED-2000 dynomometers (with readout unit)

Straw Tube Wire Chambers

• SC1
• Measured weight of SC1 (no power cables attached) : 708 lbs
• Rigging is similar to SC2.
• There is sufficient room when the detector is up by the Detector Stack to allow removal/installation of the cover for the strawtubes.
• SC2
• Measured weight of SC2 (no power cables attached) : 763 lbs
• One 10 foot sling in an inverted basket on the top of chamber. 1/2" shackles around bolts on top rollers.
• 4' sling in a basket to 1/2 ton chainfall. Two 8' slings in a choke on the bottom come up to the chainfall. The choke is done so the bite is at the bottom of the detector frame. This keeps the chain of the chainfall as far away from the tubes as I can get them. The wire chambers are not built symmetrically. The left side, as the beam sees it, is a little heavier than the right side. Offset the slings on the bottom of the chamber to compensate for this. Something like 4 to 6 inches of offset is sufficient.
• This setup just barely keeps the chain of the chainfall from hitting the strawtubes. It may be prudent to tie the chains to the 8 foot slings to prevent them from damaging the tubes.
• It has proven very unwise to attempt to install or remove the cover for SC2 when it is up by the Detector Stack. Although it is very dangerous for the straw tubes, I recommend removing/installing the cover when it is down by the floor. Use a LOT of EXTRA care when rigging SC2, moving it, and removing the rigging without the cover in place.
• SC3
• Measured weight of SC3 : 795 lbs
• Use a 10 foot sling in an inverted basket hitch on the upper end of the detector. Connect each end of sling to an eyebolt in the mounting hole at each corner. Use a 1/2 inch shackle to connect each end to the eyebolts. Bring the center of the sling up to the crane hook.
• Use a 40 inch sling in a basket hitch to connect the 1/2 ton chain hoist to the crane. Use a 16 foot sling in an inverted basket hitch on the lower end of the detector. Connect each end of sling to an eyebolt in the mounting hole at each corner. Use a 1/2 inch shackle to connect each end to the eyebolts. Bring the center of the sling up to the chain hoist.
• In this configuration the chain hoist will need to have only about 6 inches of chain played out in order to have the detector hang at 45 degrees.
• Use the long rail extensions to mount the detector on the support frame.
• Use a portable support on the lower rail extension, to prevent excessive deflection of the lower rail extension
• Pull the detector stack out of the shielding house as far as is possible, to facilitate installation/removal. Open the shield house door, on the side of the removal/installation, as far as is possible.
• SC4
• Measured weight of SC4 : 910 lbs
• 434 lbs ( measured ) lifting top end of chamber
• 476 lbs ( implied by 434 lbs measurement ) lifting bottom end of chamber
• Holes on frame for hoist rings are 60 inches apart and 13 feet 8 inches apart.
• Small spreader bars are attached directly to the hoist rings with the 1/2 inch shackles
• Small bar at the top of the chamber is attached directly to the ring of the larger speader bar
• Small bar at the bottom of the chamber is attached to the larger bar with a 1 ton chainfall
• Middle support ring of larger spreader bar is positioned in the 21st hole. 25th hole is the center hole.
• 1 3/4 inch shackle is used to attach the middle support ring of the larger spreader bar to the crane hook.

Detector Space Frame Assemblies

• Estimated weight of Electron assembly is 13000 lbs.
• Estimated weight of Hadron assembly is 12000 lbs.
• Estimates are from Critical Lift Plans submitted for lifting the assemblies.

Delay Spool Assemblies

• measured weight of each spool is 44.8 lbs.
• estimated weight of aluminum center rod is 10.5 lbs.
• estimated weight of steel bracket is 99 lbs.
• estimated weight of one assembly is 335 lbs.

Portable Staircase for Detector stack

• Measured weight : 479 lbs
• Use one 8 foot sling. Pass under the second step down from the top platform, pass under across the width of it. Bring ends up the sides to the hook. It should hang level.
• With an 8 foot sling it should not be necessary to remove hand rail from side of service platform to provide clearance.

Detector Support Platform (from Hall B surplus)

• Measured weight : 4.0 tons

Detector Support Platform (from ODU surplus)

• Measured weight of bottom section : 1546 lbs
• Measured weight of top section : (used three slings and dynamometers) 352+328+190 = 870 lbs

Lead Glass Array for Hadron Arm ( Pion Rejector ) ( Second Version )

• Measured weight of empty support frame :
• Measured weight of complete assembly : 10 foot strap to Dillon dynamometer with an 8 foot strap to the shackle. One on each of the three pick points. Looking down on the detector, the dynamometer on the bottom pick point read 2058 lbs, the dynamometer on the top left pick point read 2174 lbs, the dynamometer on the top right pick point read 2111 lbs. Measured 1-3-01.
• 1 inch shackles on each of the three pick points. A 24 foot sling is looped between the upper two shackles to make a 6 foot inverted basket. A 3 foot sling in a basket with a 3 ton chainfall to the bottom shackle. The 3 ton chainfall seemed a little hard to adjust; it may be overloading the chainfall?
• On 02/25/10 we pulled the stack out so the center of the front wheel on the "V" rail was 43 inches from the end of the "V" rail. This gave us enough clearance, with the doors opened so the inside surface was even with the edge of the balcony, to remove the Pion Rejector
  
• When installed, only seven of the top eight bolts could be inserted in their holes. One hole was too far out to allow insertion of the bolt.
• When removing the assembly I started by removing six of the top seven bolts. The seventh bolt was pinned in its hole, so I left it in. I figured it was good to have at least one bolt in to keep the frame from shifting off the posts. I did not leave the nut on the one remaining bolt on the top end. I thought this would allow the top end of the frame to lift up when the rigging was finally adjusted correctly. It would save me having to climb up and down the Detector Support Frame when making the final adjustments in the rigging. Then I placed a laser plumb bob on the crane hook (see JLAB-TN-05-062). Next the slings and chainfall were connected to the frame. The crane hook was raised and positioned to put tension on the rigging. Two bolts were loosened on each side of the bottom. The washers were removed from the nut side and the nut was put back on, just enough keep the nut on. This would hopefully leave enough free length on the bolt to allow adjusting the rigging without having to worry about the frame slipping off the posts. One more bolt was loosened on each side of the bottom. I adjusted the crane and rigging till I felt it was close to being able to hold the frame correctly. One remaining bolt was loosened on the bottom. I thought that by loosening bolts gradually I would see the frame shift if the rigging was not adjusted correctly. The remaining bolt was loosened gradually. Bolts on the bottom that were not pinned when the nut was loosened had the washers on the nut end removed and the nut put back on just enough to make sure the nut was on sufficiently to hold but give some length of bolt to work with. So, with eight loose bolts on the bottom and one loose one on the top it was ready to make the final adjustments. The top corner with the bolt still in it seemed to be pinned. At this point it became clear two people would be required to do the adjustments. A ladder was placed at the back of the Support Frame so the second person (Ed) could work the bolts on the bottom while the second person (me) sat on top of the Support Frame to move the top end. While the rigging was close to being correct, some skewing of the load is inevitable and some minimal amount of force is required to work the load so the bolts can be removed. It is critical to make sure the load is actually supported by the rigging, and not a jammed bolt, before too many bolts are removed. With some patience we were finally able to remove all the bolts. The frame was, in the end, hanging only by the rigging and just a fraction of an inch above the posts. The frame was then removed with the crane.
• When the detector is flat on the floor of the hall a level lift can be achieved using a 10 foot sling in an inverted basket across the top two pick points and an 8 foot sling in a basket hitch to the bottom pick point. (Done by Scot 08-12-09)
  

Aerogel Diffusion Box - A1

• Measured weight of Aerogel Diffusion Box (with original supports) : 608 lbs
• Two 10 foot slings choked to the points the top support meets the diffusion box
• One 6 foot sling in a basket at the point the bottom support meets the diffusion box.
• One 3 foot sling from the hook to a 1/2 ton chainfall. Other end of the chainfall holds the ends of the 6 foot sling on the bottom end of the diffusion box.
• To get the diffusion box to fit under SC1 we had to loosen the bolts holding the top and bottom mounts to the diffusion box. The bolts are undersized. This allowed the diffusion box to drop substantially and clear SC1.
• Use thinner rail extensions. Bracing flag should be flipped. Use lower extension on the top and upper extension on the bottom, so the flags point in the wrong direction. If stack parked next to the box covering the bayonets we can use a 12 ton, 1 1/2 x 6, 10" high bottle jack to brace up the lower rail extension.
• This lift works fine.

Aerogel Diffusion Box - A2

• Measured weight of Aerogel Diffusion Box (with supports) : 688 lbs
• Mounting is adjusted in Z by loosening four bolts in slotted holes on the top and bottom cross braces.
• One 8 foot sling on the top. 3 foot strap to 1/2 ton chainfall with an 8 foot strap in a basket on the bottom. If stack parked next to the box covering the bayonets we can use a 20 ton, 2 x 12, 16" high bottle jack (or a 24 ton, 2-1/2 x 12, 17" high bottle jack) to brace up the lower rail extension.
• This lift works fine.

Big Bite

• Calculated weight of the wire chamber transport frame : top 130 lbs : bottom 320 lbs