CMS ZDC Crane Emergency Payload Removal Procedures

This document proposes the viability of using a portable hydraulic actuatorHand crane (Davit crane) to implement an alternate method to remove the BARS payloads from the ZDC Crane in the event of severe inoperability of theZDC Crane system.

Paul DebbinsMay 22, 2014

Example Davit crane for Payload Extraction:Beech B1000

1000 lbs (450kg) capacityAt Boom length = 1070mm

Steel Bars Payload Attachment Points

CMS ZDC Crane Emergency Payload Removal

HAD Module

EM Module

330kg total

Lifting Bolt: Bossard 110685610mm boltThis feature exists in Steel Bar – used For all previous lifting

EM Module lifting eye

EM module cannot be fixatedFrom center point due to Presence of lifting lug. OffsetLifting eye provided for Fixation of emergency payloadRemoval system

Lifting Lug

65kg Total

CMS ZDC Crane Emergency Payload RemovalLifting Lug and Hand “Grappling” Tool

Lifting Lug

Grappling Tool

Lifting lugs are fitted with 12,5mm thru hole. Grappling tool is ~1,25m steel tubing with 12mm pin fittingGrappling tools insert into thru hole of lifting lug and provide attachment point for manual steering of the Payloads when suspended from hand (davit) crane

CMS ZDC Crane Emergency Payload RemovalBeech B1000 geometry, clearances to ZDC Crane duringoperation

B1000 Davit craneBoom has 12mm Clearance below ZDC crane carrierBeam. <5mm lift neededTo disengage payloadFrom ZDC Crane.

200mm clearance betweenZDC Crane Carrier Beam andPayloads

Davit crane is capable to Insert into spaces of ZDCCrane and couple to payload

450kg max

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Line in tunnel floor is origin ofTunnel wall – maximum extents ofDavit crane platform

Tunnel Floor

Monorail Beam – lowest overhead obstacleTunnel wall outline

Tunnel Floor

CMS ZDC Crane Emergency Payload RemovalTunnel Geometry and Clearances

Drawings Referenced: LBL 24C4246 ECERN LHCJ __0013CERN LHCJ__0014

CMS ZDC Crane Emergency Payload Removal

Case studies of Removal in Different stages of ZDC Crane Position

4 positions of ZDC Crane are considered

Case 1: ZDC Crane Positioned over TAN slot – Payload can be in any vertical lift position.The Davit crane is used to lower the payload back into the TAN slot.

Case 2: ZDC Crane is positioned at Maximum Height excursion.The Davit crane is used to remove the payload from the ZDC Crane and placethe payload into a Special Sarco reserved for this purpose. This is NOT the usual Sarco used in normal ZDC Crane operation.

Case 3: ZDC Crane is positioned centered over Sarco – Payload is raised (not penetrating Sarco)This condition is the maximum extension of the system toward the transport side tunnel wall. The Davit crane is used in the same manner as Case 2.

Case 4: ZDC Crane is positioned centered over Sarco – Payload is partially lowered into Sarco.In this case the Davit crane cannot be used as the lowered payload holds the Sarcocaptive in place which obstructs the placement of the Davit Crane. A cable winch is used in this case to lower the Payload into the Sarco directly.

Case 1: Payload raised partially or fully – still centered over TAN Slot

These show the geometric placement of the Davit to make initial fixing to the Payload inThe fully raised (worst case) position. Adequate clearances exist to tunnel features.

Prior to the placement of the Davit crane – the normal Sarco is removed from the areaTo make room for the Davit crane.

Case 1: Next steps

The Davit crane is raised slightly to lift the payload off from the fixation pins. The fixation pins are Removed and the payload is then progressively lowered back into the TAN slot

Case 1: final steps

The payload is fully lowered into the TAN and the Davit crane is disconnected from the payload. The HAD section and EM section are each done separately in similar manner.

CMS ZDC Crane Emergency Payload Removal

Case 2: Payload Fully Raised, Rotation to Maximum Vertical Excursion to overhead cable trayIn this condition there exist 50mm clearance of ZDC crane to cable tray on + side TAN, 120mm clearance on – side TAN

The Davit crane is fixed to the payload as in Case 1. Again adequate clearances exist to attach the Crane to the payload and to the space and services of the tunnel. The Davit crane lift the Payload ~5cmTo free the fixation pins which are removed.

Case 2: extraction of Payload away from ZDC Crane

The payload is lowered slightly to allow the Lifting Bridge fixtures to clear. It is also possible to unbolt the lifting Bridge components to remove them after the payload is suspended from the Davit crane.

The Davit crane and payload are moved straight back from the TAN toward the transport side tunnel wall.

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Case 2 - continued

The Davit crane and suspended payload are then rotated 90 deg. The grappling tools (not shown) allow4 persons to maintain positive control of the suspended payload from a distance of ~1.5m.

Case 2 – Final steps

The Davit crane cannot fully lower the payload to the floor. The distance between the floor legs of the Davit crane areToo narrow for the usual Sarco base platforms. A spare Sarco exists at CERN which can be placed on a narrower platformThat will fit between the legs of the Davit crane. The Davit crane is then positioned to span the special sarco and The payload is lowered into the Sarco and disconnected.

Special Sarco To fit with the DavitCrane. This sarco Will be reserved for This purpose.

Case 3: ZDC Crane is fully extended toward TransportSide of tunnel. This case is the minimum clearance for the Davit crane against the Transport side tunnel wall.

With the davit crane placed at the furthest limit to the Transport side tunnel wall, there is enough clearance to allowThe fixation of the payload to the crane. The operational sequence follows then, the exact steps of Case 2.

Case 4: Payload is partially inserted into receiving Sarco

In this case the receiving sarco cannot be removed to allow placement and use of Davit Crane. A hand operated cable winch is affixed to the side of the crane and with the use of a pulley bolted to the ZDC crane top most beam the payload is lowered directly into the Sarco

Bracket mounted to the End Plate of the ZDC Crane. FixationIs with 6 M6 bolts

This bracket can be mountedIdentically on both sides of the ZDC Crane

There exists clearanceBetween line shaft And lifting point of Payload. Line shaft Can also be removed.

Suitable cable winch is Mounted on Bracket

Cable

Pulley bracketBolted to frame

Case 4: Proposed winch solution

Drawing Ref: LBL 24C4236

EM Module payload removal.

When positioning the Davit crane for EM module payload removalThere exists adequate clearance between the Davit crane leg and The front floor jack of the TAN

384mm clearance of Davit Crane leg to Tan front face Tan Jack floor plate occupies space 300mm Back from TAN face

The EM module payload is removed in the same fashion as the HAD module for All cases.

The Davit crane used in this demonstration is a US based model.

A suitable European model needs to be identified for use at CERN.