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 se185-316

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

Reworked Screen

New Screens

New left side base / grout

plates

New and reworked laser screens

Floor mounted tracks and screen drawing se185-301

Left SideStrap Length

200

205

210

215

220

225

230

235

240

1 51 101 151 201

Step Number

Str

ap L

eng

th (

in)

Strap 1Strap 2Strap 3

19.4

9.8 10.4

Right SideStrap Lengths

210

215

220

225

230

235

240

0 50 100 150 200 250

Step Number

Str

ap

Len

gth

(in

) Strap 1Strap 2Strap 3

23.5

14.19.5

Left Side

Right Side

Strap Length

29” max travel

120” constant length wire

rope

Right SideFraction of Load Carried By each Sling During Assembly

0

0.1

0.2

0.3

0.4

0.5

0.6

0 50 100 150 200 250 300

Step#

Lo

ad

Fra

cti

on

Sling1

Sling2

Sling3

Left SideFraction of Load Carried By each Sling During Assembly

0

0.1

0.2

0.3

0.4

0.5

0.6

0.7

0.8

0 50 100 150 200 250 300

Step#

Lo

ad F

ract

ion

Sling1

Sling2

Sling3

Left Side Right Side

Fraction of load carried by each sling

MCHP CG

Lift pt 3Lift 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 lbs1,680 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.

16.2 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