1. CMS ZDC Crane Emergency Payload Removal Procedures This document proposes the viability of using a portable hydraulic actuator Hand crane (Davit crane) to implement an alternate method to remove the BARS payloads from the ZDC Crane in the event of severe inoperability of the ZDC Crane system. Paul Debbins May 22, 2014

2. Example Davit crane for Payload Extraction: Beech B1000 1000 lbs (450kg) capacity At Boom length = 1070mm

3. Steel Bars Payload Attachment Points CMS ZDC Crane Emergency Payload Removal HAD Module EM Module 330kg total Lifting Bolt: Bossard 1106856 10mm bolt This feature exists in Steel Bar – used For all previous lifting EM Module lifting eye EM module cannot be fixated From center point due to Presence of lifting lug. Offset Lifting eye provided for Fixation of emergency payload Removal system Lifting Lug 65kg Total

4. CMS ZDC Crane Emergency Payload Removal Lifting 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 fitting Grappling tools insert into thru hole of lifting lug and provide attachment point for manual steering of the Payloads when suspended from hand (davit) crane

5. CMS ZDC Crane Emergency Payload Removal Beech B1000 geometry, clearances to ZDC Crane during operation B1000 Davit crane Boom has 12mm Clearance below ZDC crane carrier Beam. <5mm lift needed To disengage payload From ZDC Crane. 200mm clearance between ZDC Crane Carrier Beam and Payloads Davit crane is capable to Insert into spaces of ZDC Crane and couple to payload 450kg max CAD Model with Basic Crane Dimensions and Movable Joints

6. Line in tunnel floor is origin of Tunnel wall – maximum extents of Davit crane platform Tunnel Floor Monorail Beam – lowest overhead obstacleTunnel wall outline Tunnel Floor CMS ZDC Crane Emergency Payload Removal Tunnel Geometry and Clearances Drawings Referenced: LBL 24C4246 E CERN LHCJ __0013 CERN LHCJ__0014

7. 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 place the 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 Sarco captive 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.

8. 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 in The 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 area To make room for the Davit crane.

9. 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

10. 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.

11. CMS ZDC Crane Emergency Payload Removal Case 2: Payload Fully Raised, Rotation to Maximum Vertical Excursion to overhead cable tray In 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 ~5cm To free the fixation pins which are removed.

12. 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. Maximum position of Davit crane away from TAN

13. Case 2 - continued The Davit crane and suspended payload are then rotated 90 deg. The grappling tools (not shown) allow 4 persons to maintain positive control of the suspended payload from a distance of ~1.5m.

14. 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 are Too narrow for the usual Sarco base platforms. A spare Sarco exists at CERN which can be placed on a narrower platform That 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 Davit Crane. This sarco Will be reserved for This purpose.

15. Case 3: ZDC Crane is fully extended toward Transport Side 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 allow The fixation of the payload to the crane. The operational sequence follows then, the exact steps of Case 2.

16. 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

17. Bracket mounted to the End Plate of the ZDC Crane. Fixation Is with 6 M6 bolts This bracket can be mounted Identically on both sides of the ZDC Crane There exists clearance Between line shaft And lifting point of Payload. Line shaft Can also be removed. Suitable cable winch is Mounted on Bracket Cable Pulley bracket Bolted to frame Case 4: Proposed winch solution

18. Drawing Ref: LBL 24C4236 EM Module payload removal. When positioning the Davit crane for EM module payload removal There 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 faceTan 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.

19. The Davit crane used in this demonstration is a US based model. A suitable European model needs to be identified for use at CERN.