Installation Procedures

Installation Procedure of cart and module equipment at JLAB in Hall-B.

All dates are tentative!

• Survey will happen before we move equipment into the hall.

1. Survey is providing a line on the floor indicating the center of the beam.
2. Survey is providing some marks on the wall indicating beam elevation that we can use to set up the laser.

• Aug. 16

1. Ship BCAL Cart equipment with Roadway as a sealed-divided guaranteed AM delivery from IU for arrival at JLAB before noon on Aug. 21.

• Aug. 21

1. Roadway truck arrives before noon. Equipment is unloaded and placed in a reasonably dry location.

• Aug. 22

1. Hall-B Staff moves crates into Hall-B.
2. Uncrate BCAL module, cart, carriage, light guide boxes and pivot leg.
3. Hall-B Staff lifts PMT shipping crate (estimated at 50 lbs.) and pivot leg (estimated at 140 lbs.) onto platform using straps and then will stash the equipment at the back of the alcove.
4. HBS lifts cart assembly (estimated at 1,700 lbs.) onto platform using straps and Eric will prepare it to receive the carriage assembly.
5. Hall-B Staff assists in building carriage assembly. First a layer of cloth or black plastic is laid down on the carriage (estimated at 770 lbs.). Then the BCAL module (estimated at 1,680 lbs.) is lifted out of its shipping container and placed on the rockers (provided by Regina, see [[1]], [[2]]). The rockers will rotate the module onto its side where it can be picked up and placed on the plastic and secured with the 8 locking clamps. Then the light guide boxes (estimated at 177 lbs. each) are bolted onto either end, but not compressed against the module.

   • Need

   1. 3/4" Box End Wrench (2 or more)
   2. 3/4" Socket with Drive
   3. 7/16" Box End Wrench
   4. 7/16" Socket with Drive
   5. 3/16" Allen Wrench
   6. 1/4" Allen Wrench
6. Hall-B Staff lifts carriage assembly (estimated at 2,804 lbs.) onto platform using straps attached to the carriage steel frame and sets onto the cart and secures. This lifting procedure will use straps attached to the steel frame of the carriage.
7. Cart is rolled into the platform position.

• Aug. 23

1. Hall-B Staff assist with anchoring cart in alcove position. Holes are drilled into the deck plate to bolt cart down or a flange needs to be welded to prevent the cart from spinning. This only needs to happen at the alcove position. According to Doug Tilles, the steel they are using is from a submarine and has to be preheated cherry red to drill or weld to. We will know the platform position and the alcove position and will align the cart to the beam by dropping a plumb bob to the pre-marked deck. We have not decided if we are welding or drilling and tapping.

   • Need

   1. 1/2" Transfer Punch
   2. Hammer
   3. Mag-Based Drill
   4. 1/2" Center Drill
   5. 27/64" Drill
   6. Cutting Oil
   7. 1/2-13 Tap
   8. Tap Handle
   9. Broom, Dustpan & Vacuum

• Aug. 24

1. Sylgard sheets are installed on the end of the module and light guide boxes are pressed up against the ends. We may have to shine a light down the steel tubes at one end to check the seal at the other end.
2. Sylgard cookies are placed on the ends of the PMT - base assemblies, cables are attached. The foam spring is installed and the assembly is slid into the steel tube with the cables being routed through the 3-point locker mechanism.
3. Safety AC crash switches are installed at points of access to disable drive system (there are two).
4. Signal cables are routed along carriage so that they come off behind the pivot point

   • Need

   1. Cable Ties
   2. Wire Cutters
   3. Black Tape, Black Foam, Black Calk
5. PMT's are installed and module is checked for light-tight status

   • Need

   1. XP2020 & 8575 PMT's and Bases
   2. HV & Signal Cables
   3. Cable Ties
   4. Flashlight or Drop Light
6. Horizontal line laser mounted on wall (or forward carriage) needs to be installed and surveyed in to beam height. Laser needs to be visible in all run positions of the module or on some common location on module. There is some concern that the shimming floor will not be flat and the floor may move when the BCAL and cart are put on it. The laser is an independent indicator of elevation.

   • Need

   1. Survey
   2. Laser Level (Class IIA <=1mW, Wavelength: 650nm)
   3. Hammer Drill (if attached to wall)
   4. Concrete Anchors (if attached to wall)
   5. Anchor Setting Tool (if attached to wall)
   6. Broom, Dustpan & Vacuum
7. Various positions along the module in relation to the beam are checked and aligned

   • Need

   1. Plumb Bob
   2. Chalk Line
   3. Tape Measure

• Aug. 25

1. Cart Operation Plan must be followed.
2. The Cart Interlock System is calibrated.
3. The cart is exercised in the platform position by moving the carriage to several positions.
4. The motion control computer is brought up and the drive system is checked out in the alcove position.
5. Final Cart Safety Review can happen now.