1. sLHC Engineering Upgrade FCAL Remove-Install step by step procedure. Mircea Cadabeschi-University of Toronto March 01, 2010 1

2. Step by step procedure 2

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5. Estimate tooling cost 5

6. Install the first minivan to the front of the EC -Lower the minivan on the rails by crane. -Time for installing 4 hours by 2 people.. -No shield necessary. 6 The extension tube is attached to the extension support, rotated 90 degree Rotary table

7. Move back the first minivan -Two people move back the minivan 3m. -Time of moving 4 hours by 2 people. -No shield necessary. 7

8. Insert the second minivan -Install the minivan by crane. -The minivan has a shield attached. -Time for insertion 4 hours by 2 people. -No shield necessary. 8 Two THK rails are attached to the second minivan.

9. Set up the extension tube on minivans. -Move the second minivan close to the first. -Rotate the extension tube and install it in the right position. -Connect the second minivan with the first. -Time to set up, 16 hours. -No shield necessary. 9 Shield attached to the minivan

10. Attach the extension tube to the con forward -Move the EC close to the assembly and set the position. -Adjust the height of the extension tube to match the FCAL. -Insert the extension tube inside the con forward. -Time: 16 hours, by 4 people. 10

11. Install the structure to the back of the EC -Lower the structure (already assembled outside of the cavern) on the rails, by crane. -Time for installing 4 hours by 2 people. -No shield necessary. 11

12. Set-up the structure -Move the structure and set it up in position. Set-up the position of the mandrel. -Attached the mandrel flange to the bulkhead. Connect the mandrel with the extension tube. -Remove the 48 bulkhead bolts. -Lift the FCAL (by turnbuckles) to clear the EC. -Time for installing 24 hours by 4 people. -No shield necessary. The mandrel square flange work as a shield. 12

13. Remove the FCAL -Move the FCAL on THK rails 500mm. -Time: 8 hours by 4 people. -Cut the 112 connectors wires. -Special tool is necessary to cut the wires. -Protective gear are necessary for the people who cut the wires. -Time: 4 hour by 2 people. 13

14. Wires to be cut 14

15. To remove the old FCAL will use a new cradle made from two halves, which will have a double purpose, as a cradle and a shield. I called it sarcophagus, because the FCAL will stay inside the cradle all the time. 15

16. Remove the FCAL 16 - Move the FCAL 1500mm to clear the scissor table. - Time: 4 hours by 4 people. - No shielding is necessary.

17. Remove the FCAL -Lift the sarcophagus to touch the FCAL. -Release the turnbuckles to change the FCAL load on sarcophagus. -Time: 8 hours by 2 people. -No shielding is necessary. 17

18. Remove the FCAL -By crane, lower the top half of sarcophagus which will engage the bottom half. -Time 4 hours by 2 people. -No shielding is necessary. 18

19. Remove the FCAL -Move the extension tube, to clear the con forward. -By crane, lift the FCAL just to clear the table and move it backward for the con forward to clear the EC. -Time: 4 hours by 2 people. -No shielding necessary. 19

20. Remove the FCAL -Lift slowly the FCAL and clear the area. -Time: 4 hours by 2 people. -No shielding necessary. 20

21. The summing boards -112 connectors for the FCAL to be disconnect. 28 boards, 4 connectors per board 21

22. The summing boards connectors. The diameter for the bulkhead. 22

23. Removing the old connectors -The shield lowered by crane. -Rotating the flange, position the window in front of each summing board, allowing to disconnect the old connectors. -Time 24 hours by 1 person. shield Rotating flange window 23

24. FCAL on Cradle - The existing cradle can be used with the crane to insert the new FCAL. FCAL Cradle 24

25. -The Installation of the new FCAL will be made in reverse order. -The new FCAL will install with the existing cradle. -To connect the new connectors some tooling is necessary!!!??? -A lifting table possible to be design (using mechanical jacking screws), in stead of buying a scissor table. -The time to remove the old FCAL and install the new one, about 6 weeks on each side. 25