FDR Station 3 lift fixture, laser screens and brackets T. Brown and L. Morris with analysis support from A. Brooks December 3, 2007

1.Are the requirements well defined? 1.Does the design meet the requirements? 2.Do the drawings define the design adequately to be used as the sole basis for fabrication and acceptance of the support fixture? 3.Does the analysis adequately underpin the design and have they been checked? 4.Has safety been adequately addressed in the design of the support fixture? 5.Can the support fixture be fabricated and installed within the budget and schedule identified in the project baseline? 6.Have all relevant chits from previous design reviews been adequately addressed? Charge

Scope This review covers the Station 3 lift fixture, laser mounts and screens. The support fixtures for the MC’s and VV have already been covered in an earlier FDR. The local alignment fixtures used to provide added positional adjustments of the MCHP will be shown.

Requirements Provide a lift structure that will allow safe movement of the MCHP over the VV Provide stable mounting brackets for the laser Provide stable laser path tracing support frames

Assembly components making up Station 3 Laser screens Laser support brackets Fixed left MCHP support Moveable right MCHP support VV support Lifting fixture frame weldment Items in red are included in this review

Structure only Left side base grout plates Fixed left MCHP support Moveable right MCHP support VV support Weight of structure: 4970 lbs Cost range: $18,350 or $3.69/lb $25,880 or $5.21/lb $26,496 or $5.33/lb $32,144 or $6.47/lb $20,478 or $4.12/lb (includes $2k shipping) MCHP and VV support structure

Lifting fixture frame weldment Lift fixture mounting bracket weldment Sissco lift system Lifting fixture frame weldment

The lifting fixture frame weldment was arranged to span the MCHP CG with attachments made to existing support holes on the MC feet A single lift fixture can be used on both the MCHP left and right side. The plan is to procure only one.

Lifting fixture frame weldment drawing se

The weldment is joined using fillet welds except at beam cap interfaces where two sided “J” grooves are used.

Laser support brackets Inboard horizontal laser Outboard horizontal laser End vertical laser

Reworked Screen New Screens New left side base / grout plates New and reworked laser screens

Floor mounted tracks and screen drawing se

Left Side Right Side Strap Length 29” max travel 120” constant length wire rope

Left Side Right Side Fraction of load carried by each sling MCHP CG Lift pt 3 Lift pt 1Lift pt 2 Lift pt 3 Fig 1 Fraction of load carried by each sling

Lift pt 1Lift pt 2 Lift pt 3 MCHP CG Position of hook on left side at Step 247 The position show is the lift position on the left side at Step 247 Weight Calculations

FEA Assumptions:  Linear analysis  The lift support frame was fully constrained at the bottom pads  Material properties ASTM A36, Fy = 36 ksi, Ftu = 58 ksi Allowable stress: at 2/3 yield is 22 ksi at 1/3 ultimate is 19.3 ksi  The total weight of the lift is 24,000 lbs Station 3 rigging analysis

The maximum load condition occurs on the left side at Step 247 at lift point 1 Peak stress is 16.8 ksi (multi pass) 18,000 lbs 4,560 lbs 1,680 lbs

The maximum load condition occurs on the left side at Step 247 at lift point 1 Peak stress is 16.1 ksi (multi pass) 18,000 lbs 4,560 lbs 1,680 lbs 16.1 ksi

 12 ksi With added rib the local peak stress drops from 16.8 to 16.2 ksi and moves to the opposite side ksi

18,000 lb load at inner lift point in the direction of the lift at Step 247 Peak deflection is.0018” (multi pass)

Assume 24,000 lb load at lift point 1 in the direction of the CG Peak stress is 35.7 ksi (multi pass) 25.3 ksi 35.7 ksi 24,000 lbs

Assume 24,000 lb load at lift point 1 in the direction of the CG with an added stiffener Peak stress is now 22.7 ksi (multi pass)

Assuming 24,000 lb load at lift point 2 in the direction of the CG Peak stress is 19.3 ksi (multi pass) moves to the lower section of the web

24,000 lb load at lift point 3 in the direction of the CG Peak stress is 17.7 ksi (multi pass)

Fixture Reaction Loads 1-8 bolt, SAE J429 Grade B8 Bolt Ftu = 150 ksi Fy = 130 ksi Tension allowable (based on 1/3 ult) = 27,551 lbs Fixture Reaction Loads 1-8 bolt, SAE J429 Grade B8 Bolt Ftu = 150 ksi Fy = 130 ksi Tension allowable (based on 1/3 ult) = 27,551 lbs

Lifting shackle link calculation

Station 2 style adjuster plates mounted to the support base Local alignment fixtures are used for positional adjustments (similar to Station 2)

Baseline procurement cost estimate Weight of structure: 4970 lbs Cost range: $18,350 or $3.69/lb $25,880 or $5.21/lb $26,496 or $5.33/lb $32,144 or $6.47/lb $20,478 or $4.12/lb (includes $2k shipping) (MC and VV supports) (5) 17,396 4,750 22,855 Remaining Remaining purchase New cost inputs: Uncertainty range - 10% / +15% Items purchased

Estimate for outstanding procurements 22,855 Left from original budget $ 5,023 Over original budget Note: if all procurements come in at the $3.69/lb cost of the first procurement then the hardware cost would come in $1948 under budget.

1.Are the requirements well defined? Requirement are specified 1.Does the design meet the requirements? Yes 2.Do the drawings define the design adequately to be used as the sole basis for fabrication and acceptance of the support fixture? Drawings have been prepared and are ready to be issued for approval 1.Does the analysis adequately underpin the design and have they been checked? Analysis and calculations have been completed 2.Has safety been adequately addressed in the design of the support fixture? Analysis shows structural margins are satisfied and techniques are defined to allow assembly adjustments to be performed without working under the load. 3.Can the support fixture be fabricated and installed within the budget and schedule identified in the project baseline? Cost and schedule estimates have been made and reviewed. 4.Have all relevant chits from previous design reviews been adequately addressed? This is new information; no chits are outstanding. Charge