NUMI

MINOS

MINOS Far Detector Installation & Commissioning

Jeff Nelson

MNHEP DoE Visit

September, 2002

NUMI

MINOS

DoE Review12/02Page 2

Outline

• Plane assembly>Status & experience>Projection methodology>Projected schedule>Issues & costs>Safety

• Detector operation >Live time & data collected

NUMI

MINOS

DoE Review12/02Page 3

The detector in August…

NUMI

MINOS

DoE Review12/02Page 4

Assembly & Commissioning

• SM1 Completed in July

> Met commissioning

milestone on July 26th

• 354 of 484 planes

installed

> 73% completed, 3.9 kton

• 348 planes commissioned

• All commissioned planes

are collecting calibration

& cosmic ray data

NUMI

MINOS

DoE Review12/02Page 5

Installation Schedule

• We have averaged 6.2 planes per week since installation reached full efficiency in Nov. 01

• Currently 4 days behind working schedule> Amall drop off in rate associated

with a few factors including• Workers now have vacation time • Some attrition in staffing

• Plots shows> Current FNAL working schedule> Actual installation schedule> Projected completion schedule

• Differences described in following slides

Plane Installation vs Working Schedule

0%

20%

40%

60%

80%

100%

120%

140%

160%

7/16

/200

1

8/27

/200

1

10/8

/200

1

11/1

9/20

01

12/3

1/20

01

2/11

/200

2

3/25

/200

2

5/6/

2002

6/17

/200

2

7/29

/200

2

9/9/

2002

10/2

1/20

02

12/2

/200

2

1/13

/200

3

2/24

/200

3

4/7/

2003

5/19

/200

3

Working Schedule (100% = 6.4 pln/wk)

Installation Rate

NUMI

MINOS

DoE Review12/02Page 6

Installation Extrapolation Data

• History of MINOS installation hours & plane

installation in 2 week periods

• Some drop in hours work due to crew having

accumulated vacation in their first year of

employment

> About a 10% effect

• Fit shows what a worker

accounts for roughly

0.25 planes/week

> No drop off in efficiency

for reasonable staffing levels

> Some expected a levels below 14 FTE

Installation and Staffing per Pay Period

10

12

14

16

18

20

22

24

26

11/0

4/01

12/0

4/01

01/0

4/02

02/0

4/02

03/0

4/02

04/0

4/02

05/0

4/02

06/0

4/02

07/0

4/02

08/0

4/02

09/0

4/02

10/0

4/02

11/0

4/02

Pay Period (2 Weeks)

FTE

6

8

10

12

14

16

18

Pla

nes

Inst

alle

d

MINOS crew FTE

planes erected

fte/crew

60%

65%

70%

75%

80%

85%

90%

95%

100%

Nov-

01

De

c-0

1

Jan

-02

Feb

-02

Mar-

02

Ap

r-0

2

May-0

2

Jun

-02

Jul-

02

Au

g-0

2

Se

p-0

2

Oct

-02

Nov-

02

pay period

FTE

/Cre

w

[MIN

OS

hou

rs/c

rew

/80

hou

rs]

NUMI

MINOS

DoE Review12/02Page 7

Staff & Future Projections

• Job Market in northern Minnesota> Down turn in iron mining in early 2001 > We were able to hire some very experienced millwrights & operators

for the installation crew> Steel mills are hiring again > We have lost one staff per month

each of the last 4 months• We are starting to replace these

workers to maintain the current efficiency> The projections show what happened

if we replace one of the current losses & all further losses

> This is our current plan• Adding new crew has safety, quality

& efficiency implications during training period> Particularly an issue for materials handling> Costs are about $1k per new employee> We do not take this lightly

NUMI

MINOS

DoE Review12/02Page 8

Costs & Schedule Implications

• The amount of work is the same and there are no changes in efficiency> There are no significant costs for WBS 2.4 associated

with install schedule adjustments

• The only cost implications are to on-project operations costs> 2nd shift charges for DNR hoistman and on-call

electricians> Physicist shift leader travel> Staffing for receiving at surface building> All 3 amounts to $5k per week of slip

• Now projecting a 6 week change in completion date

NUMI

MINOS

DoE Review12/02Page 9

Safety at Soudan

• Major activities>Continued monthly & annual outside inspections of

equipment and facilities>Materials handling procedure review >Field mapping, signage, & training

• Monthly joint safety meetings continued throughout the period>Back safety >Annual fire safety refresher>Annual operators certification >Cryogenic safety>Site safety update>Rescue team exercises

NUMI

MINOS

DoE Review12/02Page 10

Safety at Soudan

• We have had 4 safety reports at Soudan since the last review>1 lost days incident

• Most serious was a herniated disk while moving steel plates at the assembly workstation

>5 safety reports • 3 near misses

• 2 no list time accident

• Incident rates for project>A reportable incidence rate of 3.1

@ (per 200,000 hours worked, for crew + physicist)

>A lost time incidence rate of 2.5 @

>A lost days incidence rate of 0.5 @

NUMI

MINOS

DoE Review12/02Page 11

Detector operations

• Since the summer we have been collecting data for calibration and cosmic rays

• We have also been working to increase the live time

• Addressing potential hardware impediments>HV monitoring improved and

hardware swaps>Optimizing automatic recovery

hardware/software

• Have made good progress since early spring in increasing live time

0%

10%

20%

30%

40%

50%

60%

70%

80%

Feb-0

2

Mar-

02

Apr-

02

May-0

2

Jun-0

2

Jul-02

Aug-0

2

Sep-0

2

Oct-

02

Nov-0

2

Dec-0

2

Liv

eti

me

-0.20.40.60.81.01.21.41.61.8

Kto

n-m

onth

s (fi

d)

Livetime Exposure

NUMI

MINOS

DoE Review12/02Page 12

Slides in Hand

NUMI

MINOS

DoE Review12/02Page 13

Physicists & Installation

• A total of 900 physicist weeks or 18 physicist years at Soudan on installation tasks

• No safety incidents involving physicists at Soudan!

0

2

4

6

8

10

12

14

16

18

20

A-0

1M

-01

J-01

J-01

A-0

1S

-01

O-0

1N

-01

D-0

1J-

02F

-02

M-0

2A

-02

M-0

2J-

02J-

02A

-02

S-0

2O

-02

N-0

2D

-02

J-03

F-0

3M

-03

A-0

3M

-03

J-03

J-03

A-0

3

Shifters + expertPSL + L2

Monthly averages

Today

NUMI

MINOS

DoE Review12/02Page 14

Laboratory Staff Organization

Lab SupervisorBill Miller

Asst Lab SupervisorSafety OfficerJerry Meier

Crew BossWork station 1Brian Anderson

Crew BossMaterials HandlingSurface Building

Jack Zorman

Materials HandlerSurface Building

WelderDave Bjorgo

Materials HandlerSurface Building

Marvin Jonas

WelderWork Station 1

Dan Marolt

Steel/Scin. AssemblerWork Station 1

Jim Berg

Steel/Scin. AssemblerWork Station 1

Fred Povhe

WelderWork Station 2Tom Poderzay

Steel/Scin. AssemblerWork Station 2

SurveyorDan Harp

Administrative AideEileen Amos

Electronics TechDave Saranen

Steel/Scin. AssemblerWork Station 2

SurveyorBrian LaFrenier

Steel/Scin. AssemblerModule SorterDon Carlson

Day Shift Organization Chart

CDMS ConstructionSupervisorJim Beaty

JanitorNancy Jamnick

Lead Crew BossLab MaintenanceWork Station 2

Curt Lerol

Lab SupervisorBill Miller

Asst Lab SupervisorSafety OfficerJerry Meier

Lead Crew BossAfternoon ShiftBruce Farkas

Materials HandlingSurface Building

Equipment OperatorMike Novack

Materials HandlerSurface Building

Equipment OperatorRyan Martin

Materials HandlerSurface BuildingRandy Johnson

Crew BossWelder

Doug Wiermaa

Materials HandlerPlane Assembler

Gregg Benson

Materials HandlerPlane Assembler

Mike Raj

Plane AssemblerWelder

George Brown

Materials HandlerPlane Assembler

Mike Muhvich

Afternoon Shift Organization Chart