DO ENGINEERING NOTE

No 3740220-EN-452

END CALORIMETER TRANSFER BRIDGE MODIFICATION

July 10 1996

HJ Stredde

APproved~

During the assembly of major components into the DO Detector a transfer bridge was required to move the North-End Calorimeter from the clean roomover the cable bridge and onto the north sidewalk of the assembly hall

This experiment is now at the beginning stages of the next phase namely the upgrade of this Detector for future physics research A major piece of this upgrade is the installation of a solenoid magnet into the Central Calorimeter In order to accomplish this the South End Calorimeter has to be removed from the detector and the North End Calorimeter must be moved an additional 2011 from its nominal open position(total 60 movement

The South End Calorimeter will be removed from the detector using the equipment designed for its installation The calorimeter will be staged on the south sidewalk during the installation of the solenoid magnet and the central tracking systems

The North End Calorimeter is moved 60 to give more space between calorimeters during magnet tracker and cable installation work This movement will allow the calorimeter to remain coupled to the cryo system However this movement requires an extension be added to the center beam This extension will support the rear wheels of the calorimeter and in the case of the end calorimeters carry the majority of the weight The extension is to be a modification of the transfer bridge This modification basically has Tl steel blocks added to one end and legs to the sidewalk supports at the other The Tl steel blocks are notched to fit into the center beam porches and are welded to bridge rails This design is the same as that for the instal1ation bridge(3740312-ME-273456) including the welds and weld procedures which are identical in both cases

Since load testing is impractical the critical welds will be non-destructive tested by ultrasonic means The laboratory through the FESS Department has a contract with MQS Inspection Inc The results of this testing will be submitted to the panel for review before the bridge is put into use

It is noted here that MQS did perform an ultrasonic test on the critical welds of the EC-CC installation bridge on Oct 2 1990 That test demonstrated the weld penetrations between the Tl and A-36 materials Copies were given to the committee at that time A copy of the original North End Cap Calorimeter Installation Note is attached for reference

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This experiment is now at the beginning stages of the next phase namely the upgrade of this Detector for future physics research A major piece of this upgrade is the installation of a solenoid magnet into the Central Calorimeter In order to accomplish this the South End Calorimeter has to be removed from the detector and the North End Calorimeter must be moved an additional 2011 from its nominal open position(total 60 movement

The South End Calorimeter will be removed from the detector using the equipment designed for its installation The calorimeter will be staged on the south sidewalk during the installation of the solenoid magnet and the central tracking systems

The North End Calorimeter is moved 60 to give more space between calorimeters during magnet tracker and cable installation work This movement will allow the calorimeter to remain coupled to the cryo system However this movement requires an extension be added to the center beam This extension will support the rear wheels of the calorimeter and in the case of the end calorimeters carry the majority of the weight The extension is to be a modification of the transfer bridge This modification basically has Tl steel blocks added to one end and legs to the sidewalk supports at the other The Tl steel blocks are notched to fit into the center beam porches and are welded to bridge rails This design is the same as that for the instal1ation bridge(3740312-ME-273456) including the welds and weld procedures which are identical in both cases

Since load testing is impractical the critical welds will be non-destructive tested by ultrasonic means The laboratory through the FESS Department has a contract with MQS Inspection Inc The results of this testing will be submitted to the panel for review before the bridge is put into use

It is noted here that MQS did perform an ultrasonic test on the critical welds of the EC-CC installation bridge on Oct 2 1990 That test demonstrated the weld penetrations between the Tl and A-36 materials Copies were given to the committee at that time A copy of the original North End Cap Calorimeter Installation Note is attached for reference

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July 9 1996

TO Richard Andrews Chair DO Mech Safety Review Panel

FROM H J Stredde DO Mech Group

SUBJECT Non-Destructive We1d Inspection

The critical welds of the modified Transfer Bridge were inspected on June 14 at DO by a technician representing STS Consulting Engineers The method of inspection was an ultrasonic review The critical welds were the single bevel groove welds connecting the T-l steel section to the I-Beam webs The result of this inspection is shown on the attached copy of the field report The report indicates that the welds are acceptable with no voids and are full penetration as specified

I had the technician also check the welds on the original CC installation bridge This weldment was originally checked by a different company MQS and a copy of that test result is included It is obvious that the report by MQS is more detailed than that of the current company the Lab now uses However the overall results of both tests seem to agree ie no voids and good fusion between members

The attached copy of the STS report needs some clarification The weld joint is identified as TC-U4A This joint designation is shown on the attached copy of Figure 24 section 291 page 13 of AWS D 11 Welding Standard Under remarks the tenn NOT VOLUMETRIC is used This means the weld was reviewed from one side only A both side review is not possible The weld locations are noted as member 1 welds 1 amp 2 which are the newly modified bridge and member 2 welds 1 amp 2 which are those of the CC Installation Bridge (previously checked by MQS) The STS report indicates no type of discontinuity

Further in response to the Panel1s request the original calculations of the transfer bridge were reviewed and revised to correct some errors Additionally calculations have been added to detennine the shear stress on the weld connection between the T-l and I-beam web of the modified structure These calculations are included with this memo

TEST REPORT

MODIFIED BRIDGE

--______ _

FIELD RE P 0 R T _-~r _~~

Construction T e c h n 0 log jgtG r 0 up

NOTE The responsibilities andauthority of STS and STS Field PenlOMellnclude neither the raeponaibitiea northe authority of the middotCompetent Pel8Of1middot for the Pf1)ject site sa defined by OSHA Regulations 29 CFR 1926 SUbpart P

___ of ___

Ffi Project [eYItn) L~b Report No1-)0 50Project NO-=~~~~-_r_-------___ _ DayDate Fri b - 1laquo-9 k

~D81A D - 0Location _-4J~~~(Jn__=-~----------_-_ WealberITomp) SltY1j~ Contractor fshy

Project Competent Pel8Of1 per29 CFR Part 1926 (Subpart P) NAM~________________

FIRM _____________

ADDRESS ____________

PHONE____________

Present on Site eYES eNO

Client _J)O-I Equipment ~ 00 Rental Arrive Job L TOTAL

CHARGEABLETolls $_---- Depart Job j t ~ HOURS 4 hour minimum

Parking $_____ - Total Hours on Job

Mileage -TravelTime

Project Preparation Time ____________

cmiddot

Summary of technical andor engineering services performed including field test data

-----------------------

----------------------

-----------------------

------------------------- ----------------------

-------------=--------------- - ~ryTestResults

Field Representative-fL1LL~=_=~gte--_ ~osition

Company

White-Office White - Field Yellowmiddot lime Card 1196pp75k

STS Consultants Ltd Consulting Engineers

TEST REPORT

MODIFIED BRIDGE

--______ _

FIELD RE P 0 R T _-~r _~~

Construction T e c h n 0 log jgtG r 0 up

NOTE The responsibilities andauthority of STS and STS Field PenlOMellnclude neither the raeponaibitiea northe authority of the middotCompetent Pel8Of1middot for the Pf1)ject site sa defined by OSHA Regulations 29 CFR 1926 SUbpart P

___ of ___

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Project Competent Pel8Of1 per29 CFR Part 1926 (Subpart P) NAM~________________

FIRM _____________

ADDRESS ____________

PHONE____________

Present on Site eYES eNO

Client _J)O-I Equipment ~ 00 Rental Arrive Job L TOTAL

CHARGEABLETolls $_---- Depart Job j t ~ HOURS 4 hour minimum

Parking $_____ - Total Hours on Job

Mileage -TravelTime

Project Preparation Time ____________

cmiddot

Summary of technical andor engineering services performed including field test data

-----------------------

----------------------

-----------------------

------------------------- ----------------------

-------------=--------------- - ~ryTestResults

Field Representative-fL1LL~=_=~gte--_ ~osition

Company

White-Office White - Field Yellowmiddot lime Card 1196pp75k

STS Consultants Ltd Consulting Engineers

--______ _

FIELD RE P 0 R T _-~r _~~

Construction T e c h n 0 log jgtG r 0 up

NOTE The responsibilities andauthority of STS and STS Field PenlOMellnclude neither the raeponaibitiea northe authority of the middotCompetent Pel8Of1middot for the Pf1)ject site sa defined by OSHA Regulations 29 CFR 1926 SUbpart P

___ of ___

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Project Competent Pel8Of1 per29 CFR Part 1926 (Subpart P) NAM~________________

FIRM _____________

ADDRESS ____________

PHONE____________

Present on Site eYES eNO

Client _J)O-I Equipment ~ 00 Rental Arrive Job L TOTAL

CHARGEABLETolls $_---- Depart Job j t ~ HOURS 4 hour minimum

Parking $_____ - Total Hours on Job

Mileage -TravelTime

Project Preparation Time ____________

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Summary of technical andor engineering services performed including field test data

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Company

White-Office White - Field Yellowmiddot lime Card 1196pp75k

STS Consultants Ltd Consulting Engineers

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Design of Welded ConnectionsI3

~ Single-bevelgroove weld (4) Tolerances

Butt joint (B) AsDelaiIed AsFrt Up

L (see 292) (see 33)

R-+116-O +14-1116

RJ n a-+10~- 0 0 +10~-5deg

I

j T1 L

Base Metal Thickness Groove Preparation Gas

(U bull unlimited) Permitted Shielding

Welding Joint Root Groove Welding for

Process Designation T1 T2 Opening Angle Positions FCAW Notes

R-14 a45 0 All - BrN SMAW B-U4a U - a30 0 BrNR-38 All

R-3I16 a 30 0 All Required ABrN GMAW B-U4a-GF U - R14 a45 Q All Not req ABrN FCAW

R38 a30 0 F Not req ABrN

TolerancesSingle-bevel-groove-weld (4) n As Fit Up As DetailedT-joint (T) I (see 33)(see 292) Corner joint (C) 10_ NOTEJ NOTE V bull +114-116R-+1116-o

a- +10 ~ 5 0 +10~middot5deg T1 ~ J

F-

- [JJ X- R

T2

Base Metal Thickness Gas

Permitted Groove Preparation

Shielding(U bull unlimited) Welding for Process

Joint WeldingGrooveRoot T1 T2 FCAW NotesDesignation Angle PositionsOpening

All JQVR14 a=45deg -USMAW TCmiddotU4a U

JQVFVOHa30degR-38 -a 30 0 RequiredAll AJQV

GMAW R316

AJQVF Not req a30degR38TC-U4a-GF U UFCAW

All Notreq AJQVR14 a45deg

a- 30 0

R-3I8 JQVFSAW TC-U4a-S U -U a45degR14

Note A Not prequalifled for gas metal arc welding using short circuiting trsnsfer Refer to Appendix A

Note Br Dynamic load application limits these jOints to the horizontal position (see 9125) Note C Backgouge root to sound metal before welding second side Note J If fillet welds are used In statically loaded structures to retnforce groove welds In comer and T-jolnts they shall be equal to

114 T1 but need not exceed 38 in Groove welds in comer and T -joInts of dynamically loaded structures shall be reinforced with fillet welds equal to 14 T1 but not more than 38 In

Note N The orientation of the two members in the joints may vary from 135deg to 180deg provided that the basic joint configuration (grpove angle root face root opening) remain the same and that the design weld size is maintained

Note Q For comer and T-joints the member orientation may be changed provided the groove angle is maintained B8 specified Note V For comer joints the outside groove preparetlon may be In either or both members provided the basic groove conflgurstion

Is not changed and adequate edge distance is maintained to support tha welding operatiOns without excessive edge melting

Figure 24 (continued) - Prequalified Complete Joint Penetration Groove Welded Joints (see 291)

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