DUNE PDR: FD2-Installation

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James Stewart (BNL)
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Preliminary Design Review of the DUNE FD2-VD Installation (I&I)

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Tuesday June 14

 8:35 AM  9:30 AM
Installation Process55m
Overview of the FD2 installation
Speaker: James Stewart (BNL)
FD2-VD Installation Process

 

Jen: Slide 16: is there more detail on the cryostat washing procedure and the materials  being used?

Answer: We are going to follow the procedure currently being implemented for cleaning the SBND cryostat so we are planning to adopt the lessons learned from SBND.

 

Jen: Slide 26 - I didn’t see the cable routing for the PDS on the walls - do you have that worked out?

Answer: The plan we are working right now is to route the cables from the wall PDS through the BDE cable trays and are working out how to get the cables from the modules to the BDE trays

 

Jon: Are there any issues with thermal cycling on the spring mounted rods?

Answer: We are designing the spring loading system to take into account the differential contraction due to thermal cycling so we are in good shape there
 

Jen: Slide 58: It says 3 hrs to check the height - is that a rough check or actual survey with metrology? What is the requirement for flatness?

Answer: Flatness requirement is +/-5 mm. I don’t think you need metrology. We are planning for an entire day at the end to check so that may end up with actual surveyors. Correction: The cathode has a thickness of 6 cm and should fit in an 8 cm envelope. So, the allowed deformation is +-1 cm.

 

Fabrice: Once you are finished the installation of the detector you have to come back to finish the cryostat - have you worked out the final steps of cryostat installation

Answer: As the installer of the cryostat hasn’t been finalized yet, we are waiting to work with them the final steps. The TCO will be closed from the outside as specified in the contract, so they will not need to come inside the cryostat. So from I&I we just need to make sure to remove all the installation infrastructure like the walkways and get the clean room out of the way to make sure the cranes can come

 

Jon: Are there any differences with the TCO closing procedures compared to the ProtoDUNES?

Answer: Yes, work continued inside the cryostat during TCO closing and this didn’t work out well, so a lesson learned from PRotoDUNE is to close the TCO before assembling the rest of the cryostat

 

Alberto: Do you have enough time to test cable connections…etc?

Answer: We do have a bit of time and we asked each consortia gave us details on their checkout procedures and the time needed so all of that is built into the schedule. It is integrated into the schedule on a step by step level from the consortia.

 

Alberto: You have 1cm clearance between the CRP and the field cage? What are the mechanical tolerances on the parts? Seems to be quite small.

Answer: After they have been shifted to final position - there is actually 6cm as they are lifting them up and then they are shifted to the final position. That was the clearance they felt they needed.

 

Jen: I also have the same question/concern about the 1cm clearance. It would be helpful to clarify this further

 

Kyle: Same topic - in regards to the top CRP - is there a mechanical connection to the field cage?

Answer: There is a cable for grounding but they are otherwise independent.

 

Jon: The co-ordinated construction of the CRP and the cathode PDS - what are the risks if you encounter delays on one of these systems - this would push back other system quite a bit - will this be addressed?

Answer: The CRP superstructures are not an issue, those are preassmbled. We could evaluate this schedule risk going forward - adding a rework station if the module assembly is delayed for example. We currently don’t have any time for rework/delays or planning in the system

 

Alberto: This is a complicated installation, and to do training underground without having a surface facility to test the procedure and develop the training is a big risk.

Answer: We are still in negotiations to set up a facility at CERN to do some of the procedure prototyping but there is no agreement yet in place. Since it will be European teams doing the assembly and installation, it may be better to have the activities prototyped at CERN.   

 

Kyle: Slide 65 - when we were at Ash River when you pick from two places with two independent cable trays we noticed a lot of back and forth.

Answer: We learnt from that and so we modified the procedure to address those difficulties

 

FD2 DAQ Installation20m
Speakers: Alec Habig (Univ. of Minnesota Duluth), Alessandro Thea (STFC Rutherford Appleton Laboratory), Giovanna Lehmann (CERN)
FD2-VD DAQ Installation

 

Alberto: Do you have a schedule for having the DAQ ready for the first detector component to be tested?

Answer: The first detector component testing starts Dec 2026 so that is what we are planning for.

 

Jon: Barracks ready step - can you get all your equipment ready in time?

Answer: The barracks ready step - the racks here are not water cooling like in PRotoDUNE but are simpler air cooled racks that will require fiddling.

 

Fabrice/Jon: Do you specify the time that you need additional I&I personnel? Cable management is the responsiblility of who?

Answer: we are planning on DAQ doing all the work - I&I assembles the racks and delivers the computers on racks outside the barracks, but all work on DAQ component installation is the consortia. Cable tray installation aare I&I, cable prep and installation are the DAQ consortia responsible.

 

Alberto: Does DAQ include Slow Control?

Answer: No

 

Jen: Is there a talk on Slow Control?

Answer: Slow control is considered part of infrastructure and is not covered in this review

 

10:40 AM  11:00 AM
FD2 TDE installation20m
Speaker: Dario Autiero (IPNL)
FD2-VD TDE installation

 

Jen: Since the cable routing for the PDS is not defined yet and could interfere with the chimneys..etc - what interfaces have been defined?

Answer: The PD fibers go through the same penetrations as the bottom drift electronics so they are not going through the TDE penetrations. We are still looking into the cable routing for the PDS with BDE cabling and the plan is putting a conduit into the BDE flange.

 

Fabrice: Slide 9: The cart details?

Answer: There are some other details not shown here on and there is a talk on the cart design on day 3 by Charles.

 

 Alberto: Where are these mezannine racks - I have never seen a complete design with all the mezzanine racks and crates on the top of the cryostat to see that there is no interference

Answer: That detail was presented during the TDE reviews. Terry will also give more detail on day 3.

 

11:20 AM  11:40 AM
FD2 Cathode Installation20m
Speaker: Fabien Cavalier (IJCLab)
FD2-VD Cathode Installation

 

Fabrice: What are the risks you are planning to retire from these prototypes ?

Answer: The main uncertainty is on the system which supports the rope. It is not a standard commercial product, but it is not a very complicated design. The details were presented during the CRP PDR.

 

Jon: The tooling that allows bringing the cathode module through the TCO is I&I responsibility

Answer: The lifting tool which lifts the CRP Is consortia responsibility and so is the cart, the rigging and crane..etc. is I&I responsibility.

 

Jen: You mentioned is the largest uncertainty remains with the PDS - what communication do you have with PDS - do you have regular meetings?

Answer: We have regular meetings with PDS as well as special meetings like a 2 hr meeting last week. Their engineer regularly attends cathode meetings as well and we have a good co-ordination with that team

 

Alberto: You are assembling things in supercathode - what is the clearance between supercathodes and what is tolerance and how do you do the electrical connections?

Answer: 10mm between the mesh grids and between the super cathodes you have 14mm. Same as the space between the CRP and SuperCRP. For the moment we have to think about the connection betwwen the super cathode. The discussion with the HV management doesn’t seem to be a big issue. It is not a critical issue.

 

Alberto: If you use a rigid cable you can change the distance between supercathodes -so you need a flexible cable. Can you actually maintain 1cm distance to the field cage after everything is assembled?

Answer: The discussions we are having right now indicate that the distance will probably increase to a few cm. We need to look at the mock up when everything will be raised to study these issues.

Bo: For the electrical connections we will have multiple redundant flexible wires connecting to the field cage which have enough flexibility to keep the cathode connected to the field space

 

Jon: How much motion of the cathode is expected?

Answer: The lateral force is typically small. Even if there is any movement it will not impact performance. It is an equipotential

so lateral displacements have no impact on the field. We also have a detailed simulation of the  Lar liquid flow and it indicates that the motion is negligible after filling.

 

Mary: How about during filling? Will there be issues with connections of the cathode to the field cage due to the fluid pressure?

Answer: The issue is the connection with the HV bus, and that will require some adjustment and adaption during filling. We are planning to test the system during Module 0. The field cage can be adjusted from the outside.

 

Wednesday June 15

 

8:00 AM  8:20 AM
Installation Safety20m
Speaker: Duane Newhart (FNAL)
FD2_ESH_dln1.2.pptx

 

Alberto: Do you interface with the compliance office?

Answer:  Olga is at SURF this week and we are going through the test lift for the APA and we are working with them constantly.

 

Alberto: When you lift a CRP is that considered a critical lift?

Answer: Based on Fermilab guidelines we would consider that a critical lift. We will do our planning in such a way that we turn that into a productiion lift so we don’t need an SOP for every lift.

 

Fabrice: We the main hazard analysis report - do you have a single hazard analysis report or do you have  separate one for FD2?

Answer: The Hazard Report is the umbrella document - it give the overview - for the site specific analysis comes later in our work planning controls document and we will have the site specific plan separately.

 

Fabrice: Do we have site specific hazard analysis for FD2 and the working at height?

Answer: We have a callout in the HAR right now for laser safety - that needs to be beefed up for the higher power laser for the PDS power-over-fibre - from class IV to class I. The 2nd thing to be updated is working with a suspended load that also needs to be added to the HAR.

 

Alberto: Does ES&H delay the installation process? Do you need an ES&H point of contact for each consortia?

Answer: The technical lead in each consortia is my point of contact. But I will also reach out to the individual engineers.

 

8:30 AM  8:50 AM
FD2 BDE Installation20m
Speaker: Cheng-Ju Lin (Lawrence Berkeley National Laboratory)
FD2_Installation_PDF_BDE_06-15-2022.pdf

 

Alberto: What is the clearance between the cables that run the bottom of the cryostat and the field cage?

Answer: We have no interface with the field cage in that regard. The cables in Nick's talk - they are 40mm in diameter and the distance to field cage is 250cm - so it is about 20cm clearance. We are still working on the interface drawings.

 

Jon: What do you use the tripod for?

Answer: Only one is needed the gantry or tripod, we are going to try out the movable gantry then decide if that works we wont need the tripod.

 

Kyle: Slide 15 - for the work-in-progress does this have to do with the bottom CRP?

Answer: We are still having discussions on how to install the last rows of CRPs since we don’t have enough room and some details of how to lift the bottom CRPs are still being worked out

 

Kevin: Under the QC a lot of testing with the channels of the FEMB - shouldn’t we have a good idea of the FEMB working when they get to the warehouse? What happens during installation that damages the channels? Is it planned to have them checked above ground?

Answer: They should be 100% operable when shipped. The major challenge is ESD protection during shipping and handling. They are shipped with ESD protection in the shipping crates. We don’t want to open them up in the warehouse since it is not clean - best to move them in the shipping crates underground and open it up in the clean room and test in the clean room and there is where we have the ability to replace them and all the tools.

 

9:00 AM  9:20 AM
FD2 Wall PD installation20m
Speaker: Nicholas Joniak (BNL)
FD2-VD Wall PD Installation

 

Jen: What is the time to finalize the design and get a cost estimate?

Answer: We will get a response from the CIEMAT group on this question

 

Fabrice: Are you cleared with the cryostat manufacturer on the load issues from the cable trays?

Answer: We are in contact with GTT and cleared that there are no issues with the loading..

 

Kyle: There are 40 BDE bundles and 40 strings of these PD cables along the wall… there are still investigation that still needs to happen as to exact routes that each PD cables takes from each respective module.

Answer: We know the general location of the trays but the details of the exact location and routing are still being worked out

 

Top CRP Installation20m
Speaker: Dominique Duchesneau (LAPP, CNRS-IN2P3)
FD2-VD Top CRP Installation

 

Alberto: A critical point is when people are going to crawl over the CRP to attach the cables - can you clarify the hanging status of the CRP at that point - there are cables and the linking part in the final location but when you are connecting the cab les you are 30 cm lower than the final system - are you still hanging from the hoist, where are the suspension cables and links? Is that allowed by safety?

Answer:  The CRP superstructure will be attached to the four cables and still hanging from the hoist. The platform will be rigidly

 attached to the top of the cryostat. We are still investigating working on the suspended CRPs when they are connected to the winches- we think we can address the safety standards needed.

 

Eric: What are the requirements are on the alignments and surveys and how the final adjustments are made after installations?

Answer: We are talking about metrology inside the superstructure - there is a requirement there, then after we have attached the CRPs on the superstructures (slide 5) we may have a change of postion, we realigh all the six pieces w.r.t the superstructure. It will not stay horizontal for sure after cooldown - we expect few cm deformations. We have 4 suspensions for each superstructure going out of the liquid and we will be able to adjust the height of the superstructure after cooldown and it will be done for each superstructure within a few mm. We cannot do metrology of course after lifting and cool down, but we will use the level sensors to adjust.

 

Eric: What about the connection to the cathode - what happens when you adjust the CRP separately after filling will you then end up inadvertantly tilting the cathode? What about with the bottom CRP?

Answer: The tension of the cables between the superstructure and the supercathode and we will maintain the parallelism with the cathode. We need to guarantee that the horizontality  of the bottom CRPs. We cant adjust any of the cables going down to the cathode - those are fixed.

 

Fabrice: Have you completed the structural analysis of the suspended structure on slide 4?

Answer: We did the analysis with the loading of the CRP and the catwalks and the cathode

 

Fabrice: Slide 6 - a number of construction steps are very uncomfortable - on the knees, on the back.

Answer: We are designing the cable fixtures to enable one-to-one cabling and limiting the time in uncomfortable positions.

 

10:30 AM  10:50 AM
FD2 CathodePD Installation20m
Speaker: Ryan Rivera (FNAL)
FD2-VD Cathode PD Installation

 

Jen: Slide 9 - is there someone keeping track of who needs space in the clean room and when they need it?

Answer: Jim Stewart and I&I is tracking that very closely. We are going back and forth with the cathode team. We would like 6 tables and 3 walls but the plan is still for 3 tables and 3 walls - we are working this out.

 

Jen:  Slide 14 - the interface with the HV system - we saw in the HV review that they are ready to adapt to whatever PDS needs for cable routing.

Answer: We met last week with the cathode team and we have a baseline plan for the cable routing. The main issue is the HV discharge study - if the conclusions from that study change, we may have to rework the fibre routing and PDS placement but so far the study results have been stable for a few months.

Answer: End of August for making the decision on the patch panel

 

Alberto: Slide 7 - those fibres long along the suspension cables of the cathode - are they attached to the cables? How do you go there to add bindings?

Answer: The favorite concept is to laterally bind them but no vertical load on the suspension cable. We will need access to the points to binding them.

 

Alberto: Are you going to test the unrolling of cables above the CRP during installation? Pulling the pull cord and unrolling cord is a delicate point.

Answer: We don’t unroll, everything is fixed. There is no relative motion for the pull cable until the CRPs are in the final position. Assuming we can do the 2 bend pull cord there is no intervention after CRPs are lifted.

 

Fabrice: What is the level of statistics needed to get confidence that the optical connectors will work?

Answer: We wanted to avoid connectors but we are doing VE to understand the reliability

 

11:00 AM  11:20 AM
FD2 HV Supply and Field cage Installation20m
Speaker: Bo Yu (Brookhaven National Lab)
HV Supply and Field Cage Installation

 

Dddd

 

11:40 AM  12:00 PM
FD2 Bottom CRP installation20m
Speaker: Matthew Worcester
FD2-VD Bottom CRP Installation

 

Eric: Slide 18 - t has 3 bars because you have to come from the bottom and then you have to move the truss out of the way - you need to have the lift this up and remove the truss and lower it to the floor? Are you assuming the installation truss is perfectly flat?

Answer: At the location we actually level the truss then we do that then we lower the CRP on to it.

 

Eric: The assumption is even after filling the floor of the cryostat remains flat?

Answer: The understanding is that the membrane cryostat is less than 2mm deformation and our leveling requirement is 5mm relative to the cathode.

 

Eric: Is the slack in the cables when you lift? What happens to the slack when you lower?

Answer: Once the truss is out nobody will be under there - there will be strain relief applied at the patch panel.

 

Thursday June 16

8:00 AM  8:30 AM
I&I Schedule and Person-power30m
Speaker: William Miller (University of Minnesota)
Installation Schedule and Labor

 

Jen: I didn’t hear anything about installation of RTDs and other temperature monitoring?

Answer: That is in the schedule in the first stage -

 

Fabrice: Slide 4 - the consortia also comes with support - but this is not captured here?

Answer: Yes what is shown on the slide is the I&I technician effort - in the same spreadsheet we do capture the consortia effort. I&I is all on project, some small part of the consortia effort is also on project but most of it is not.

 

Fabrice: How do you label LOE? Based on your analysis of what you need? What is the different in the logic between the activity based and the LOE?

Answer: The issue is we have those people there all the time - it takes a couple of hours to get people underground at the start at the end of the shift - so that is why we put this down as a LOE - we need all these people there all the time at a constant level - which is why there is some discrepancy between LOE and activity levels

 

Alberto: Are all these numbers in P6 - I&I and consortia?

Answer: We asked the consortia to put in the LOE in P6 - the consortia LOE is in the consortia part not I&I

 

Alberto: What is the 60% contingency on?

Answer: It is on the I&I effort and based on the NOvA experience where they kept it at 50% throughout the project, we don’t expect it to be decreased by much.

  

8:30 AM  9:00 AM
FD2 Installation Hardware overview30m
Installation Hardware

 

Jen: Do you have a list of all the fasteners you need for the detector components? Lessons learned from MicroBooNE is that we ended up with a bunch of detector components but no fastners to connected to them that we had to go out at the last minute to buy.

Answer: We do not have a spreadsheet that list all the parts - we do require that the final drawings have all the parts listed. We will not be able to generate a full parts list before the final drawings.

 

Alberto: In your slide that you showed the mezannine racks - you mentioned the slow control - do you also include the racks for slow control which is now the responsibility of I&I?

Answer: Installation is not reponsible for slow control - integration is so that is a question for them

 

Alberto: You showed the metallic superstructures for the CRPs - who is providing the cat walks?

Answer: I&I is responsible for the catwalks

 

Alberto: Who is responsible for the installation platform for CRP?

Answer: the consortia

 

9:00 AM  9:15 AM
Cryostat Ventilation15m
Speaker: Manhong Zhao (BNL)
Cryostat_Ventilation

 

 

Kyle asked about air quality (temp, humidity). 

Answer: air conditioning is outside scope, but some simulations have been run with point heat sources to represent people.

 

9:15 AM  9:30 AM

FD2 TCO beam Design15m
Speaker: Nicholas Joniak (BNL)
TCO Hoist Beam design

Q: Is it correct that the plan is to not use this to lift installation equipment that are rather heavy (e.g. scissor lifts and mobile cranes).

Answer:

 

9:30 AM  10:00 AM

FD2 Cleanroom design and layout15m
Speaker: Nicholas Joniak (BNL)
FD2-VD cleanroom Design and Layout

 

Jen asked when the decision on whether to reduce the size of the clean-room entrance opening would be made.  The answer is it is under study, but will be made soon.

 

Alberto asked about whether there was enough room for more carts for cathode sections as was suggested yesterday. The answer is that full carts will be moved into the cryostat, so no more space is needed in the clean room.  Alberto followed up asking if this meant there would be a schedule impact from this (speed-up).  Answer: no, the extra carts would give more opportunity for PD system installation/testing.

 

Kyle: Regarding superstructure assemblies, how do they arrive and move through the cleanroom?

A: Arrive in sub modules and assembled on fixtures in the cryostat.

 

10:15 AM  10:30 AM
Chimney Installation Cart15m
Speaker: Charles Maupin (South Dakota Science And Technology Authority)
Chimney Installation Cart

 

Fabrice : Is the cart rolling on a temporary top floor? Does this top floor has penetrations to insert the chimney? And is the top floor the responsibility of I&I?

 

10:30 AM  10:45 AM
FD2 Cryostat Floor Design15m
Speaker: Justin Freitag (FNAL)
FD2-VD Cryostat Floor Design

 

Fabrice: Slide 5 any concern that there is space for people to fall off the edge?

Answer: Good point - we will work with Duane if there is an effective method to keep people from going over the edge.

 

Fabrice: What about the gaps - are there any?

Answer: We did check delections and they are small and we don’t expect any gaps

 

10:45 AM  11:00 AM
FD2 Roof Cable trays and GAr Purge lines15m
Speaker: Justin Freitag (FNAL)
FD2-VD Roof Cable Trays and GAr Purge Lines

 

Alberto: Did you discuss with the top electronics team the Gar purging? What happens during running if you need to change the TDE CE and need to repurge the chimney again?

Answer: This discussion is about the Ar purge not the nitrogen for the TDE. We would use a flexible pipe to flow nitrogen to go to the TDE chimney, it is only a few PSI. This is something we will deal with once things are plates. We didn’t include the nitrogen system included in this talk.

 

Alberto: It would be good to get a drawing with the micro TCO crates sitting on the top to see that there is no interfaces.

Answer: Something we are working with Jack on. We have an initial placement but we need to iterate with Dario.

 

Fabrice: I couldn’t tell from the pictures how you secure the cable trays and pipes to the Ibeams?

Answer: Preliminary we will just have the piping sitting on the structure and we are envisioning and stand-off to support the cable try. Still a work in progress - maybe the pipe sits there and for some other connection we have a flexible bellows.

 

11:00 AM  11:15 AM
FD2 Installation Interfaces15m
Speaker: James Stewart (BNL)
Installation Interfaces

 

Fabrice: About the physical interface between subsystems and the cold membrane - is it your responsibility to collect those interfaces and present them to GTT or the consortia?

Answer: All those interfaces are I&I scope - we need to complete the drawings

 

Fabrice: What is the sign off process on these interfaces - you have 3 parties involved: consortia, I&I and GTT/CERN?

Answer: I would think the approval process needs to include all 3 and it goes through system engineering

 

Alberto: Do we have a fully integrated 3-D model for FD2?

Answer: Yes - that is the responsibility of integration - from installation point of view we are able to get the STEP files from CERN and build the model. The uploading takes a long time though - about a week or so for example. For the most part accessing what is officially approved is not a problem.

 

Alberto: You mentioned the survey - it is important that there are well defined survey points. What do you survey when the CRPs are 12 meters high? - that is not so clear.

Answer: We have not worked through some of those issues

 

11:15 AM  11:30 AM
FD2 Installation QC Plan15m
Installation QC Plan

 

11:30 AM  11:40 AM
FD2 Rack Layout - Fiber plant - power infrastructure10m
Speaker: Theresa Shaw (FNAL)
Installation Rack layout - fiber plant - Power Infrastructure

 

Jon: Will the cabling and installation be done by experts?

Answer: All work done by certified electricians and trained technicians

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