Relativistic Heavy Ion Collider (RHIC): sPHENIX Experiment · 2019-08-13 · Required Safety factor...

Relativistic Heavy Ion Collider (RHIC): sPHENIX Experiment No:sP.EAR-2018-007 Date 03/24/18

BROOKHAVEN NATIONAL LABORATORY Rev.: __A______ . PAGE_1_of_7

TITLE: PREPARED BY: _Chris Pontieri ________ Outer HCal Lifting Fixture CHECKED BY: _______________________

ENGINEERING CALCULATION

Introduction The sPHENIX experiment is a collection of state of the art particle detectors used to study the properties of matter at a fundamental level. The detectors include Hadronic Calorimeters, an electromagnetic calorimeter, and high performance detection of momentum and trajectory of the products of charged particle collisions of particles accelerated by the RHIC collider- accelerator. The detectors are arranged in and around a superconducting solenoid magnet. The largest of the detectors, the Outer Hadronic Calorimeter (Outer HCal) is comprised of 32 15 ton, 6 meter long wedge shaped sectors, which in turn are made up of mostly steel plates arranged into a barrel shape, which surrounds and supports the magnet and all of the other detectors. To handle, lift, move and orient the sectors for detector electronics assembly of each of the sectors and connecting the sectors into the barrel, a custom designed lifting fixture is required. This report details the analysis performed to demonstrate the structural integrity of the lifting fixture during these handling operations. .

sPHENIX Outer HCal Lifting Fixture of 7

Purpose: The purpose of the analyses described herein is to assess the mechanical/structural adequacy of the subject sPHENIX tool for use in the installation of the Outer HCal Structural Steel. Part Description: The Outer HCal Lifting Fixture is an assembled fixture that bolts a roller bearing around the throat of the outer HCal trunnion attachment. The fixture is used to remove the HCal structural steel assembly from its shipping sled and place it into static or rotating stands. The same fixture will be used to move sectors from their assembly stations to a storage location, as well as, utilized during the installation process at a future date. The fixture consists of a lower lift plate (205-0100-1017), upper lift plate (205-0100-1016) that enclose a purchased roller bearing (Dynamic Rating 174000N), that is pressed onto a trunnion (205-0100-1018), the lower and upper plates are attached using 2x 1-1/8” Grade 8 bolts. The assembly of the fixture is shown in 205-0100-1022. Analysis: There are 4 components of the Outer HCal Lifting Fixture that need to be analyzed to demonstrate structural adequacy of this lifting tool, plus hardware to assemble the tool:

• Lower lifting plate • Upper lifting plate • Trunnion • Bearing (purchased item)

The weights of these components (plus the weight of the hardware used to assemble the tool are as follows:

• Lower lifting plate 57.8 lbs • Upper lifting plate 74.7 lbs • Trunnion 32.4 lbs • Bearing 5 lbs

Total 169.9 lbs

The entire assembly was analyzed using finite element analyses (FEA) to determine maximum displacements and equivalent stresses in each of the components. (Note: the lifted sector is considered in the analyses, but this report focuses on the lifting fixture. Refer to the separate but related analysis sP.EAR-2018-003 which focuses on the stress and displacements in the sector, for sector structural responses under these same conditions.) Boundary conditions and loading:

a. Lifting Fixture Parameters

• _Lifting fixture length: 2in • _Lifting fixture height: 30in • _Lifting fixture width: 16in • _Lifting fixture weight: 175lb • _Lifting fixture material: Aluminum, 6061 • _Lifting fixture yield strength: 40ksi


• _Lifting fixture ultimate strength: 45ksi

b. Analysis Parameters

• _All contacts are bonded. • _The roller bearing is a purchased part rated for loads greater than a sector, so it is modeled as a solid. • _Boundary conditions: One lifting fixture pick point is fixed, the other is axially free. • _All materials behave linearly. • _Model is defeatured. No Screw holes and no fillets or chamfers smaller than 0.125in.

For the full assembly the maximum equivalent stresses and total displacements were calculated using FEA with the result illustrated in figure 1. Yield Ultimate Aluminum 6061-T6 39000 psi 44000 psi Steel 30000 psi 50000 psi Required Safety factor is 3.0 on yield or 5.0 on ultimate, whichever is smaller. (This creates allowable stress of 8800 psi for the aluminum and 10,000 psi for steel. Results:

• Conclusion:

Based on the above, it is concluded that the lifting fixture is adequate for its intended service.


Figure 1: Outer HCAL Lifting Fixture

Upper%Lifting%Plate

Lower%Lifting%Plate

Roller%Bearing%

1%1/8”77%Bolts

Roller%Bearing%Cover

Trunnion

Outer%HCAL%Sector


Figure 2: Outer HCAL Rotating Mechanism

Worm%Wheel%

Shaft

Mating%Worm

Clamp7on%Shaft%Collar Flat%Washer

Steel%Thrust%Ball%Bearing%

Oil%Embedded%Sleeve%Ring

Pillow%Block Machine%Key

Retaining%Ring

3/8”716%%2.25”LG

Worm%Gear%System

Locking%Mechanism

1

1

2

2

3

3

4

4

5

5

6

6

7

7

8

8

A A

B B

C C

D D

SAFETY ENGINEER:

UNLESS OTHERWISE SPECIFIED:ALL DIMENSIONS ARE IN inches [mm]

B

0.0050.015FINISH

THIRD ANGLE PROJECTION

MAX. MIN.

1/25/2018

cpontieriDRAWN BY:

DESIGN APPROVAL:

C. GORTAKOWSKI

A. GORDEEV

D. LYNCH

J. LAJOIE

CHECKED BY:

ENGINEER APPROVAL:

SUPERVISOR APPROVAL:

Q.A. APPROVAL:

DECIMAL TOLERANCESN/AN/A

RUGGIERO

1/23/2018

1/23/2018N/ABB

ANGLES B N/AX.XXX

X.X

INTERPRET IN GENERAL ACCORDANCEWITH ASME Y14.5-2009

X.XX

BREAK EDGES:OF

BROOKHAVEN NATIONAL LABORATORY

1

REV.

205-0100-10161

OUTER HCALUpper Lifting Plate

BROOKHAVEN SCIENCE ASSOCIATES

WEIGHT: N/A

Upton, NY 11973

SHEET

AQ.A. CATEGORY:

1/21/2018

SIZE

DA3

DRAWING NUMBER:

-

SCALE:OUTSTANDING ECN NUMBERS A. FRANZ -

NOTES: 1. Material: ASTM A36 or Equivalent, Material Certification Required. 2. ALL DIMENSIONS ARE IN in[mm}. 3. DIMENSIONS & TOLERANCES IN BRACKETS ARE FOR REFERENCE ONLY. 4. UNTOLERANCED DIMENSIONS ARE BASIC 5. DRAWING MAY BE USED WITH MODEL "Upper Lifting Plate REV 1.stp" VALUES QUERIED FROM 3-D DIGITAL DATA ARE BASIC. 6. SAND BLASTED FINISH ALL SIDES.

PRELIMINARYFOR QUOTATION PURPOSES ONLY

3D VIEW

REVISION HISTORYZONE REV DESCRIPTION DATE APPROVED

1 Initial Release 11/27/2017

R2.00[R50.8]

21.00[533.4]

4.00[101.6]

19.00[482.6]

7.938[201.6]

15.88[403.2]

R1.00[R25.4]

2X

2X P1.188 THRU

2.00B0.01550.8B0.38[ ]

13.0°6.5°

11.500[292.1]

R3.170[R80.5]

5.75[146.1]

L P0.014 C A B

C

B

F 0.030 A B C

1.000[25.4] 2.000

[50.8]

2X 3/8-16 UNC - 2B Z 0.75

3.54[89.9]

L P0.014 A B C

P2.00 THRUL P0.028 A B C

1.00 X 45° Chamfer

A

1.00[25.4]

SECTION A-ASCALE .75

DETAIL BSCALE 1 : 1

A

A

B

1

1

2

2

3

3

4

4

5

5

6

6

7

7

8

8

A A

B B

C C

D D

SAFETY ENGINEER:


B

0.0050.015FINISH


MAX. MIN.

1/25/2018

C. PontieriDRAWN BY:

DESIGN APPROVAL:

C. GORTAKOWSKI

A. GORDEEV

D. LYNCH

J. LAJOIE

CHECKED BY:

ENGINEER APPROVAL:


Q.A. APPROVAL:


RUGGIERO

1/23/2018

1/23/2018N/ABB

ANGLES B N/AX.XXX

X.X


X.XX

BREAK EDGES:OF


1

REV.

205-0100-10171

OUTER HCALLower Lifting Plate


WEIGHT: 54.845 lbmass

Upton, NY 11973

SHEET

AQ.A. CATEGORY:

1/21/2018

SIZE

DA3

DRAWING NUMBER:

-


PRELIMINARYFOR QUOTATION PURPOSES ONLY

3D VIEW


1 Initial Release 11/27/2017

2.00[50.8]( )

1.00[25.4]

2.188[55.6]

11.500[292.1] 2X 1 1/8-7 UNC - 2B Z 3.0

7.63[193.7]

1.807[45.9]

4.00[101.6]

7.938[201.6]

7.875[200.0]

3.938[100.0]

R2.622[R66.6]

4X 3/8-16 UNC - 2B Z 0.75

0.47[11.9]

1.063[27.0]

1.00[25.4]

13.875[352.4]

0.394[10.0]

1.211[30.8]

3.150[80.0]

R 2.62[66.6]( )R

0.14 X 45° Chamfer

15.88[403.2]

TYP. 0.13B0.010 X 45.00° Chamfer

2.00[50.8]

A

C

B

L P0.014 A B C

L P0.014 C A B

NOTES: 1. Material: ASTM A36 or Equivalent, Material Certification Required. 2. ALL DIMENSIONS ARE IN in[mm}. 3. DIMENSIONS & TOLERANCES IN BRACKETS ARE FOR REFERENCE ONLY. 4. UNTOLERANCED DIMENSIONS ARE BASIC 5. DRAWING MAY BE USED WITH MODEL "Lower Lifting Plate REV 1.stp" VALUES QUERIED FROM 3-D DIGITAL DATA ARE BASIC. 6. SAND BLASTED FINISH ALL SIDES.

F 0.020 A B C

1

1

2

2

3

3

4

4

5

5

6

6

7

7

8

8

A A

B B

C C

D D

A3Q.A. CATEGORY:

- DSCALE:

DRAWN BY:

DESIGN APPROVAL:


ENGINEER APPROVAL:

C. Pontieri

CHECKED BY:

J. LAJOIE

D. LYNCH

A. GORDEEV 1/23/2018

1/23/2018

SIZE

OUTER HCAL1/21/2018

-


DRAWING NUMBER:

Trunnion


OF

21

BREAK EDGES:WEIGHT: SHEET

205-0100-1018REV.

MIN.

Q.A. APPROVAL:

SAFETY ENGINEER:

N/AN/A

BN/AB

X.X X.XX

X.XXX N/AANGLES B

DECIMAL TOLERANCES

WITH ASME Y14.5-2009INTERPRET IN GENERAL ACCORDANCE


MAX.FINISH

B

ALL DIMENSIONS ARE IN inches [mm]UNLESS OTHERWISE SPECIFIED:

Upton, NY 11973

32.367 lbmass 1

1/25/2018RUGGIERO

C. GORTAKOWSKI

0.015 0.005OUTSTANDING ECN NUMBERS A. FRANZ -

3D VIEW


1 RELEASED FOR REVIEW 1/25/2018 RR

2 ADDED NOTE 7 / 1.571 WAS 1.567 3/28/2018 RR

4.000[101.60]

4.000[101.60]

3.000[76.20]

6.000[152.40]

3.000[76.20]

6.000[152.40]

4X P0.781B0.005 THRU[4X P19.84B0.13 THRU]

4X 0.750B0.015 X 45.00° Chamfer[4X 19.05B0.38 X 45.00° Chamfer]

P2.750[P69.85]( )

(60°)

3/8-16 UNC - 2B Z 0.75Equally Spaced on P2.750 BC

3/8-16 UNC - 2B Z 19.05Equally Spaced on P2.750 BC[ ]

P4.567[P116.00]

8.00[203.20]( )

8.000[203.20]

8.000[203.20]

1.571P - 0.0010.000+

39.90 - 0.030.00+[P ]

0.938[23.81]

1.000[25.40]

2.551[64.79]

3.722[94.53]

6.137[155.87]

4.563[115.90]

0.875[22.22]

0.479B0.00312.17B0.08[ ]

0.060[1.52]

1.350[34.29]P

Full Radius

0.662[16.82]

3.536P - 0.0020.000+

89.81 - 0.050.00+[P ]

2.235[56.76]

R0.125[R3.18]

3X R0.063[R1.59]

0.060B0.015 X 45° Chamfer[1.52B0.38 X 45° Chamfer]

NOTES: 1. Material: ASTM A36 or Equivalent, Material Certification Required. 2. ALL DIMENSIONS ARE IN in[mm}. 3. DIMENSIONS & TOLERANCES IN BRACKETS ARE FOR REFERENCE ONLY. 4. UNTOLERANCED DIMENSIONS ARE BASIC 5. DRAWING MAY BE USED WITH MODEL "Trunnion REV 2.stp" VALUES QUERIED FROM 3-D DIGITAL DATA ARE BASIC. 6. SAND BLASTED FINISH ALL SIDES. 7. INSPECTION MEASUREMENTS SHALL BE MADE AT 72deg F +/- 8deg.

A

B

L P 0.014 A B

F 0.010 A B

L P 0.014 A B

3.995 - 0.0020.000+

101.47 - 0.050.00+[ ]

P

0.125B0.015 X 45° Chamfer[3.18B0.381 X 45° Chamfer]

2

SECTION A-ASCALE 1.5

A

A

1

1

2

2

3

3

4

4

A A

B B

C C

D D

SAFETY ENGINEER:


B

0.0050.015FINISH


MAX. MIN.

1/25/2018

C. PontieriDRAWN BY:

DESIGN APPROVAL:

C. GORTAKOWSKI

A. GORDEEV

D. LYNCH

J. LAJOIE

CHECKED BY:

ENGINEER APPROVAL:


Q.A. APPROVAL:


RUGGIERO

1/23/2018

1/23/2018N/ABB

ANGLES B N/AX.XXX

X.X


X.XX

BREAK EDGES:OF


1

REV.

205-0100-10191

OUTER HCALTrunnion Cap


WEIGHT: 0.625 lbmass

Upton, NY 11973

SHEET

2Q.A. CATEGORY:

1/21/2018

SIZE

CA3

DRAWING NUMBER:

-


3D VIEW


1 RELEASED FOR REVIEW 1/25/2018 RR

2

ADDED NOTE 7ADDED 0.250 LOCKING HOLES

6.000 OD WAS 4.567 OD1.146 WAS 0.521

ADDED 3.453 C'BORE

3/28/2018

DLRRRRRRRR

6X P0.397B0.005 THRUX P0.582B0.015 Z 0.198B0.015Equally Spaced on P2.750 BC

NOTES: 1. Material: ASTM A36 or Equivalent, Material Certification Required. 2. ALL DIMENSIONS ARE IN in[mm}. 3. DIMENSIONS & TOLERANCES IN BRACKETS ARE FOR REFERENCE ONLY. 4. UNTOLERANCED DIMENSIONS ARE BASIC 5. DRAWING MAY BE USED WITH MODEL "Trunnion Cap REV 2.stp" VALUES QUERIED FROM 3-D DIGITAL DATA ARE BASIC. 6. SAND BLASTED FINISH ALL SIDES. 7. INSPECTION MEASUREMENTS SHALL BE MADE AT 72deg F +/- 8deg.

F 0.010 A B

(60°)

L P0.014 A B

1.65°

11.25°

32X P0.125B0.005 THRUEqually Spaced on P5.250 BC

A

0.521[13.23]

1.576 - 0.0000.005+

40.03 - 0.000.13+[ ]

P

0.125 X 45° Chamfer

0.834[21.17]

32X P0.250B0.005 Z 0.750B0.015

EQUALLY SPACED IN P6.000

P6.000[P152.40]

B

3.453[87.70]P 4.567

[116.00]P

L P0.014 B A

L P0.014 A B

1.146[29.11]

2

2

2

Relativistic Heavy Ion Collider (RHIC): sPHENIX Experiment · 2019-08-13 · Required Safety factor...

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