SNS Survey, Alignment, & Metrology (SAM)

1. SNS Survey, Alignment, & Metrology (SAM) Overview & History of Survey, Alignment, & Metrology, (SAM) Microns & Madness! The Role of SAM in the Installation & Alignment of a Beam Line Joseph Error

2. Overview & History of SAM • The alignment of the Spallation Neutron Source, accelerator, instrument lines, etc., represents the culmination of more than 40 years of advancements in the field of precision alignment. These advancements include improvements in instrumentation, skill sets & proven methodology. • Our alignment successes, are among the best ever achieved. • It is our sincere desire, that new projects benefit from our learning curve. Their successes in the field of alignment should hopefully exceed ours.

3. Overview & History of SAM SAM roles and responsibilities are complex, much more than most realize. SAM interfaced with every partner lab & practically every group involved in the construction, installation, & alignment of the SNS Accelerator & Beam-lines. We still do! From the removal of the first scoop of dirt, to the planning of a second target station, SAM played/s an important role.

4. SAM is Concerned With the Whole Pie! Mechanical Engineering Component Fiducialization Parts Inspection Other ORNL Organizations Physics Diagnostics Drawing / Data Integration Instrument Lines R & D Designers Assistance to Other Labs & Organizations Conventional Facilities Electrical Engineering

5. Overview & History of SAM Liaison Through our global survey network, drawing integration, & interfacing with scientists, engineers, etc., SAM is really the liaison that provides a focal point for Physics, Engineering, Conventional Facilities, & others. SAM integrates all of their work into a unified coordinate system. Our task is not to reinvent the wheel, but in addition to alignment, we must make sure that one component cannot occupy the same space as another. It is through this methodology that construction, installation & alignment work is performed correctly the first time.

6. Overview & History of SAM • SAM IS REALLY A VOICE OF REASON, THE FINAL VERIFICATION • They put the project together! • They understand real estate issues! • By integrating the work of all project entities into one coordinate system with a simplified set of drawings, SAM is able to make interference determinations early-on that others simply can’t. • The net result is that costly installation work is performed once & once only.

7. SAM’s DRAWING/DATA INTEGRATION CAN STOP THE TRAIN WRECK BEFORE IT HAPPENS!

8. How well does / did our integration work?Example: SAM Calculated and laid out the locations for over 15,000 bolts holes in support of component stands & other equipment. NOT ONE SINGLE BOLT HOLE HAD TO BE RELOCATED OR REDRILLED!

9. WHO ELSE USES THE SAM DRAWINGS & DATA BASE INFORMATION? • PHYSICS • MECHANICAL ENGINEERING • DIAGNOSTICS • CONVENTIONAL FACILITIES • DESIGNERS • OUTSIDE CONTRACTORS • NEW WORLD-WIDE PROJECTS

10. WHY? • The SAM drawing & data base adheres to a set of standards that ensures that the physics coordinate lattice information is the backbone of the accelerator. Virtually everything has a location relative to the physics lattice. • The same is true on instrument lines although each instrument line is treated as its own individual entity rather than in a global sense. • The SAM drawing & data base was not designed to usurp complex engineering drawings. Instead their purpose is to guarantee that everything related to the individual instrument line will fit.

11. SAM IDENTIFIED THE MISSION THE TIP OF THE ICEBERG! QUALITY PRODUCT / ON-TIME / WITHIN BUDGET / SAFELY Partner Labs Alignment Issues Quality Control Network Issues Conventional Facilities Site Surveyors Floor Deformation Milestones Drawing Integration Adjusting Mechanisms Fiducialization Calibration

12. SAM’s Principles for Alignment are unwavering! All work actually performed, either alignment or work performed in support of others, must preserve the integrity and complex relationship between our global survey network and all other project entities. THIS IS HOW PROJECTS ARE BUILT ON-TIME! THIS IS HOW PROJECTS ARE BUILT WITHIN BUDGET!

13. INSTRUMENT-LINE THE METAPHORICAL FOOT! • Each individual 3-dimensional instrument line (or the accelerator beam line) representes a metaphorical foot. • Buildings, components, equipment, etc., are the metaphorical shoe that fits that foot (not the other way around). • If the project were to succeed, then every part of SNS & partner labs had to understand and accept that basic concept. • Easy sell for the accelerator and construction people. • Hard sell for target / instrument people!

14. In summary.. If the mission is to build a quality product, on time, within budget, and safely, every project skill set has an important and significant role. Few technical groups however, interface with so many entities as Survey, Alignment & Metrology Group (SAM). SAM’s successes are really project successes. When SAM succeeds, everyone benefits and the project saves time, money, and headaches.

16. The Business of Measuring & Alignment! “Microns & Madness”

17. Instrument-Line Support from a SAM Perspective • For Alignment people, Instrument Line support starts with asking some basic questions: • With regard to alignment accuracy…. • What is achievable? • What is not achievable? • What alignment tolerances are really needed? • Achievable at what cost? • Where? • On a construction site? • Under laboratory conditions? • On a computer generated model? • In conjunction with other work in progress that is not conducive to precision alignment?

18. What is Achievable? Laboratory Conditions? (Controlled Environment)

19. What is Achievable? Less Than Laboratory Conditions?

20. What Is Achievable?Construction Conditions?

21. So We Ask the Question: What Is Really Achievable in the World of Modern Accelerator or Beamline Alignment? or…What alignment people world-wide refer to as ”Microns & Madness”

22. Microns & Madness • Questions need to be answered prior to performing alignment regardless of the alignment tolerance band. • Relative to what? • At what confidence level? • Under what conditions / environment? • At what cost? • Timeframe?

23. Microns & Madness! • Uncertainty / Tolerances? • Thermal expansion? • Forklift / cranes, machinery working in the area? • Mechanical adjustment capability? • Floor Stability? • Alignment within error budget?

24. Microns & MadnessSummary So, with respect to precision alignment, what is really achievable on an instrument line? There really is no simple answer. Alignment quality is a by-product of many factors. The quality of aligned components can also change as conditions change. Speaking in more generic terms however, component-to-component alignment of ±0.002 inches [±50 μm] is usually achievable with a high degree of confidence, and ±0.005 inch [±125 μm] over the length of the beam line.

26. THE ROLE OF SAM IN THE INSTALLATION & ALIGNMENT OF INSTRUMENT LINE Few technical professionals are really aware of the significant role modern survey & alignment plays in the construction of an accelerator. (long before any alignment work!) From ground-breaking to beam operation and beyond, SAM is integrally involved. What is even less clear is the significant SAM contribution to the construction, modifications & operation of instrument lines. This presentation deals with the involvement of SAM in the construction and commissioning of an instrument line. A chronological step-by-step history is shown on the following pages.

27. THE ROLE OF SAM Modern SAM is much more than alignment. SAM provides a wealth of information (data, drawings, elevations) for designers, engineers, instrument scientists, & others. At each phase of the project, SAM has a role. SAM is part of an overall team concept where numerous technical & professional groups work together to construct an on-time, on-budget, fully functioning instrument line, & do so safely!

28. THE ROLE OF SAM • Collaborate with instrument engineer and receive initial instrument footprint drawings. • Assess the existing area. This may involve scanning or mapping of the beam line area. 28

29. Design a preliminary network based on the previous assessments. Install monuments and create an operational 3-Dimensional coordinate network. Networks evolve as the instrument construction advances. THE ROLE OF SAMIn the beginning…

30. THE ROLE OF SAM • Analyze our measured data & provide input back to instrument engineers & designers. • In-turn, we receive updated drawing from design engineers consisting of their layout that may have been modified as a result of the SAM “as-measured” data / drawing input. • Transform / integrate design drawings to SAM instrument beam line network.

31. THE ROLE OF SAM • SAM coordinate information supports a multitude of activities including cave layouts, PIP outlines, centerlines, elevations, stud holes, bracket mounts, tray locations, etc. • SAM calculates all coordinate information relative to 3-dimensional beam position, (an absolute value not subject to construction variations).

32. THE ROLE OF SAM • SAM continues to provide support for the various labor crafts including marking penetrations, “as-building” new construction, & updating drawings to support future construction. • On-going activities include engineering support / planning for actual component alignment, fiducialization, & quality control.

33. THE ROLE OF SAM • Components requiring precise positioning are fiducialized to provide a means of locating them accurately within the instrument line. • Fiducialization is often the most misunderstood process that SAM performs yet it is among the most valuable. • Components requiring periodic realignment require permanent fiducials.

34. THE ROLE OF SAM • SAM Engineers and Technicians work together to provide the instrument line with the best alignment & data analysis achievable. • As construction progresses, the instrument network is updated and expanded. This expanded update also provides the design engineer with any deformation or other unknown feature that may impact installation or operation.

35. THE ROLE OF SAM • Next, SAM receives component structure drawings consisting of items such as embed plates, stands, rails & boxes, etc. • SAM generates necessary coordinate information to support layout / installation.

36. THE ROLE OF SAM • SAM personnel lay out component locations. • If grouting is part of the process, then SAM will re-verify location. • If welding is involved, components are aligned and monitored throughout the welding process.

37. THE ROLE OF SAM • Instrument line component drawings usually contain the necessary information to begin aligning guides, support stands, choppers, slits, detectors & specialized equipment, etc. • Sometimes additional input from engineers / scientists may also necessary.

38. THE ROLE OF SAM • Components are fiducialized. • Fiducialization data is sent to the SAM engineer for analysis & transformation into beam line drawing. New coordinates are generated to support alignment.

39. THE ROLE OF SAM • Chopper stands are generally positioned in the beam line using the appropriate gauge chopper. • Choppers are aligned on the chopper alignment stand.

40. THE ROLE OF SAM • Installation of guides, choppers & other beam line equipment is in full swing. • Drawings for devices such as a detector vessel, get-lost tube, beam dump, slits, shutters, sample positioner are received & added to SAM model.

41. THE ROLE OF SAM • Detector vessel installation can be time consuming & labor intensive depending on size and complexity. • Large detector vessels may obscure existing SAM network monuments. This may requires additional monuments and network observations.

42. THE ROLE OF SAM • Detector vessels may require both external and internal fiducialization to position the tank & components. • Inside-the-tank networks must be made part of a larger overall beam line network. This is indeed a challenging task.

43. THE ROLE OF SAM • With the majority of components now installed, SAM often aids the control group with indexing motion devices such as translation stages, sample positioning devices, slits, etc. • SAM provides accurate absolute positions, relative to the instrument beam line or other requested features.

44. THE ROLE OF SAMIt’s not over yet! • Detector mounts may be positioned or the “as-built” positions mapped. • From SAM’s perspective, the instrument is about ready to take beam although there is still work to do. • SAM continues to provide data and analysis related to equipment locations, additional shielding, modified components, “tune-up” positions, setting cameras, providing references, positional verification & indexing.

45. THE ROLE OF SAMCommissioning • SAM archives all alignment data for each instrument. This information is often requested well after installation is complete. • During instrument tune-up, beam-based analysis might suggest to the Instrument Scientist that components position may need to be changed. SAM also supports this activity.

46. THE ROLE OF SAMBecoming Operational • SAM is often one of the first groups summoned in the event of unexpected beam performance. Eliminating mechanical / alignment issues is an initial step in solving operational issues. • In congested areas, aligned components may accidentally get bumped. SAM can verify discrepancies and realign if necessary.

47. THE ROLE OF SAMSummary • SAM’s state-of-the-art alignment & alignment methodology benefits the project in a number of ways. • Cost Savings • SAM provides a second set of eyes to view & evaluate design drawings. In our world, if we can’t fit the model to our network & instrument line drawing, then there is no point proceeding any further until this issue is resolved. • The survey network is really the “back-bone” that ties together the work of so many. • SAM accurately “puts the puzzle together.” • Continue to monitor factors affecting alignment where possible! (floor deformation)

48. QUESTIONS?