Doc #: 2100-AD Revision: - Installation of the DESI Zenith Work Platforms. Author(s): Derek Guenther, Miranda Saucedo, Tammie Lavoie

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Doc #: 2100-AD-015-0074 Revision: - Installation of the DESI Zenith

1 Doc #: 2100-AD Revision: - Installation of the DESI Zenith Work Platforms Author(s): Derek Guenther, Miranda Saucedo, Tammie Lavoie

2 Contents Revision History Purpose Applicable To Scope Definitions Training Safety Personnel, Equipment and Materials Required Procedure... 5 Preliminary Steps... 5 Lower Platform Installation... 8 Ladder and Cage Installation Ramp Installation Upper Truss Ring Installation Upper Platform Installation Procedure Review Records References AD Docx Page 2 of 19

3 Revision History Rev Date Approved Sections Affected Reason for Change Remarks and/or Change Details Name -- 2/27/2018 3/16/2018 Initial Release D. Guenther T. Lavoie Approved by: Derek Guenther Name, ME Title SigEM Name, EL Maint SigSci Name, SciOps Tammie Lavoie 19 March 2018 Tammie Lavoie, Safety Manager Date 2100-AD Docx Page 3 of 19

4 1.0 Purpose The purpose of this document is to safely guide all applicable personnel through the installation of the DESI Zenith work platforms. 2.0 Applicable To This procedure is applicable to the Facilities, and Engineering departments, or any additional personnel who will assist in completing these tasks for the Mayall 4 Meter Telescope. This includes members working on the DESI Project. 3.0 Scope This document is a step by step procedure that outlines how to complete the installation of the DESI Zenith work platforms. It is broken down into five sections. 4.0 Definitions The acronyms and definitions referenced in this procedure are listed below. DESI Dark Energy Spectroscopic Instrument ZWP Zenith Work Platforms Truss Clamps Clamps that attach to truss tubes that provide a mounting point for truss spacer tubes and platform rails. 5.0 Training The trainings required for this procedure are listed below. 5.1 Fall Protection 5.2 Lockout/Tagout 5.3 Overhead Crane Operations 5.4 Rigging 5.5 Welding 6.0 Safety The safety documents required for this procedure are listed below. 6.1 Crane Certification(s) 6.2 Cranes SOP (1000-AD ) 6.3 Critical Lift Plan Form(s) 6.4 Daily Briefing Form 6.5 Fall Protection Plan SOP (1000-AD ) 6.6 JHA Form(s) 6.7 Lockout/Tagout SOP (1000-AD ) 6.8 Rescue Plan SOP (1000-AD ) 2100-AD Docx Page 4 of 19

5 6.9 Rigging Certification(s) 7.0 Personnel, Equipment and Materials Required Process # of Personnel Notes P Preliminary Steps 8.1 Lower Platform Installation 8.2 Ladder and Cage Installation 8.3 Ramp Installation 8.4 Upper Truss Installation 8.5 Upper Platform Installation 8 (1) Crane Operator (1) Engineer (3) Maintenance (2) Riggers (1) Welder Equipment/Part/PPE/Tool List Location Notes ᵌ ₄ Plywood 4 Meter/Maint. N/A 2 x 4 x.25 Wall Steel Tubing 4 Meter N/A 5 Ton Overhead Crane 4 Meter N/A 50 Ton Overhead Crane 4 Meter N/A Chain-Fall Come-A-Longs 4 Meter N/A Crane Basket (Man Basket) 4 Meter N/A Eye Protection 4 Meter Face Protection for Welder Fall Protection 4 Meter N/A Genie Boom Lift 4 Meter N/A Handrail Assemblies 4 Meter 2 Hand Protection 4 Meter N/A Hard Hats 4 Meter N/A Man Lift 4 Meter N/A MIG Welder 4 Meter N/A Miscellaneous Carpentry Equipment 4 Meter/Maint. N/A Ramp Ladder 4 Meter With Safety Cage Assembly Safety Shoes N/A Composite or Steel-Toe Slings 4 Meter (2) 5, (1) 6, (1) 20 Taglines 4 Meter Procedure Due to late changes in the vane configuration on the DESI instrument, the following preliminary steps will need to be performed on the structure prior to installation of the upper platform. Preliminary Steps P.1 Obtain 2 of the 2100-ME (UPPER PLATFORM INNER TUBE ASSEMBLY) assemblies. The assemblies can be seen in the Figure 1 below AD Docx Page 5 of 19

3 Weld in the 2100-ME-040-0157 (TUBE PLUG WITH TAP) with the

(Figure 2) (JHA-2). Figure 2: Tube Plug P.

6 Figure 1: Center Tube Trimming P.2 Cut both ends off at 9 ¾ as shown above (JHA-1). P.3 Weld in the 2100-ME (TUBE PLUG WITH TAP) with the step facing up and the flat surface flush with the tube end (Figure 2) (JHA-2). Figure 2: Tube Plug P.4 Cut the (4) 9-¾ down to 6 long. Cut the open end of the tube off (Figure 3) (JHA-3). Figure 3: ASK DEREK 2100-AD Docx Page 6 of 19

7 P.5 Locate 2 of the 2100-ME (UPPER PLATFORM LONG SIDE TUBE DEFAULT) and 2 of 2100-ME (UPPER PLATFORM LONG SIDE TUBE LEFT) as shown above. Cut 2 ¾ as measured on the tube. Cut all 4 tubes on the end with the counter bored hole in the plug (step facing down) (Figure 4) (JHA-4). Figure 4: Weldment 2100-ME P.6 Weld the (4) 6 long pieces as shown above to the (4) 47-1/4 long pieces cut off in step P4. Some kick rail may need to be added after the platform is installed (JHA-5). P.7 Weld 2100-ME (BRACING TAB) to 2100-ME (SUPPORT LEG) as shown in the following figure (Figure 5) (JHA-6). Figure 5: ASK DEREK P.8 Mount the tabs 2100-ME (BRACING TAB) on the 4 tubes, 2100-ME (SUPPORT LEG), 2 on the left side as shown and 2 on the right side (JHA-7). Measure from the back of the flange to the front of the tab. The following processes must be completed before the installation of the DESI Zenith work platforms can begin. 8.1 Attach all sixteen of the truss clamps 2100-ME (CLAMP RING ASSEMBLY). 8.2 Use yellow safety paint to paint the ramp ladder with the safety cage assembly, and the ramp stair assembly. These two assemblies must be stored in the Pier (JHA-8) AD Docx Page 7 of 19

8 After completing the above, the remaining processes are as follows. Lower Platform Installation 8.3 Move both the 2100-ME (TUBE ASSEMBLY, LONG) and the 2100-ME (TUBE ASSEMBLY, SHORT) C-Floor (JHA-9). These tube assemblies will be located in the Telescope pier. The lower platform tube assemblies have a 4 wide kick plate welded on them. 8.4 Use the Genie boom lift on the Main Floor to pick up one of the TUBE ASSEMBLY, SHORT (JHA-10). 8.5 The kick plate on 2100-ME (TUBE ASSEMBLY, LONG) as seen in Figure 6 is 73 ½ long and the kick plate on 2100-ME (TUBE ASSEMBLY, SHORT) is 63 5/8 long. Figure 6: Kick Plate Lengths 8.6 Load the first TUBE ASSEMBLY, SHORT on to the Genie lift. Move the Genie lift between the North truss tubes to the South truss tubes (JHA-11). 8.7 Loosely attach the first TUBE ASSEMBLY, SHORT between the two truss clamps. The truss clamp can be clocked to match up with the truss tube. 8.8 Once the TUBE ASSEMBLY, SHORT is attached, measure down from the ends of the horizontal tube to the top of the center section (Figure 7). The dimension to the bottom of the tube should be 159½. Note: A second person may be required down on the center section to ensure the tape measure is roughly vertical. Figure 7: Measurement to the Center Section 2100-AD Docx Page 8 of 19

9 8.9 Once this dimension is adjusted, tighten the clamp screws and the mounting screws Take the Genie boom lift down to the C-Floor and load a TUBE ASSEMBLY, LONG in the basket. Install this on the northwest side of the telescope as described above (JHA-12) Continue installing the TUBE ASSEMBLIES until they are attached all around the telescope Secure and tie the first 2100-ME (H BEAM) to the Genie boom lift (Figure 8). Lift it up between the truss tubes below the tube assemblies (JHA-13). Figure 8: H Beam 8.13 Insert the open ends of the H Beam onto the posts on the tube assembly on the East and West side of the telescope. Install the eight, ᵌ ₈-16 x 1.00 screws and washers, but do not fully tighten them at this point (JHA-14) Lift the first of four 2100-ME (SIDE BRACE) on the Genie boom lift and install it on one of the posts on the North or South tube assemblies (Figure 9). Install the mounting screws, but do not tighten them all the way down. On the hole that overlaps the tube, one.50 long screw will be required, but 1.00 long screws should be used in the other three holes (JHA-15). Figure 9: Support Leg 8.15 Continue installing the other (3) 2100-ME (SUPPORT LEG) until all of the mounting hardware is loosely installed. Hook a ratchet strap over one of the spider veins, and lift until the tubes are roughly level. Tighten all of the mounting hardware (Figure 10) (JHA-16) AD Docx Page 9 of 19

Figure 10: Plywood Locations 8.16 The 2 center sheets 2100-ME-040-0146 (PLYWOOD #1) are full 48 x 96. Line up the notches in the 2 sheets to form a hole.

10 Figure 10: Plywood Locations 8.16 The 2 center sheets 2100-ME (PLYWOOD #1) are full 48 x 96. Line up the notches in the 2 sheets to form a hole. The (6) outer sheets need to be cut per ME (PLYWOOD #2), 2100-ME (PLYWOOD #3) and 2100-ME (PLYWOOD #4). All sheets need to be painted on all surfaces with a tan latex paint (JHA-17) In order to lift the plywood place a C clamp on the edge of the sheet and hook a shackle through the clamp and the lifting sling (JHA-18). Safety recommends using an alternative to the C clamp on the edge of the plywood. Possibly use a length of metal attached to the plywood with 4-5 screws and have a lifting ring attached to it. Then you can continue to use a shackle and lifting sling. TLL 8.18 Lift the two center sheets (PLYWOOD # 1), one at a time, by the short edge, up from the C-Floor with the 5 ton crane and lower it between the top ring and the prime focus cage. From the Genie boom lift, position each of the sheets with the long dimension running North and South (JHA-19). Measure to the tube assembly and set the sheets at Using the 5 ton crane, lift the two (PLYWOOD #2) sheets, one at a time. Place them on the North and South end of the platform (JHA-20) Bring the other four sheets (PLYWOOD #3 and #4) up with the Genie boom lift and place them on the East and West side (JHA-21) Secure each sheet to the platform using the self-drilling/self-tapping screws in at least four places on each sheet (JHA-22). Ladder and Cage Installation 8.22 Remove the two handrails on the South side of the center section. Remove the center support for the handrails (JHA-23) Install the first 2100-ME (SUPPORT RING SHORT SECTION). Attach it to the upper South truss tube clamps using 4 long SHCS (Figure 11) (JHA-24). Note: In order to install the short tube, the clamp bolts must be loosened AD Docx Page 10 of 19

The top of the tube should be set to 46-1/2 from the bottom of the top ring. This may require minor adjustment to the clamps just adjusted. 8.

11 Figure 11: Set Clamp Height 8.24 Once the SHORT SECTION is installed, measure down from the top ring to the highest point on the truss clamp. The perpendicular distance to the clamp should be set approximately at Install the 2100-ME (SUPPORT RING LONG SECTION) on the East and West side of the SHORT SECTION just installed. The top of the tube should be set to 46-1/2 from the bottom of the top ring. This may require minor adjustment to the clamps just adjusted Continue installing the SUPPORT RING LONG and SHORT SECTION TUBES around the telescope while setting the top of the tubes to 46-1/2 from the top ring Choker the 6 sling to the upper end of 2100-ME (RAMP LADDER W/ SAFETY CAGE) (JHA-25) Lift the RAMP LADDER W/SAFETY CAGE up until the lower end of the ladder is resting on the center section (Figure 12) (JHA-26). Figure 12: Cage Mounting 8.29 Adjust the RAMP LADDER W/SAFETY CAGE until the four bolt holes are lined up with the free end of the bolts that attach the SHORT SECTION to the CLAMP RING ASSEMPLY Install the washers and nuts on the four bolts and lightly tighten the nuts (JHA-27) AD Docx Page 11 of 19

8.31 Move the RAMP LADDER W/ SAFETY CAGE plate about 1 from the edge of the center section. Ensure the ladder is roughly plumb, and transfer-punch the location of the mounting holes (Figure 13).

12 8.31 Move the RAMP LADDER W/ SAFETY CAGE plate about 1 from the edge of the center section. Ensure the ladder is roughly plumb, and transfer-punch the location of the mounting holes (Figure 13). Figure 13: Ladder Lower End Location 8.32 With the RAMP LADDER W/ SAFETY CAGE still suspended from the 5 ton dome crane, remove the nuts and washers that are holding the upper end of the cage. Lift the ladder up about 3 and trolley the crane out to move the ladder away from the truss tubes (JHA-28) Drill and tap the holes for ᵌ ₈-16 screws using a magnetic base drill (JHA-29) Trolley the crane to move the RAMP LADDER W/ SAFETY CAGE back over the center section. Install the washers and nuts on the upper cage ring. Leave the nuts loose until the lower mounting bolts are installed (JHA-30) Install and tighten the ladder mounting bolts (JHA-31) Tighten the upper mounting nuts. Ramp Installation 8.37 Install non-slip tape on the top of the steps Open the center hatch on the Main Floor (JHA-32) Lower the hook on the 5 ton dome crane to the Ground Floor (JHA-33) Place the 2100-ME (RAMP STAIR) on two dollies. Roll the assembly under the hatch on the Ground Floor (JHA-34) Choker a 6 sling around the upper end channel on the assembly. Lift the assembly vertically to the Main Floor. Place the back of the assembly on two dollies (JHA-35) Loosely assemble two of the 2100-ME (RAMP STAIR HAND RAIL). The two rail assemblies will be mirror images of each other. Bolt them on either side of the stair ramp assembly using ½-13 SHCS (JHA-36) Once the ½-13 mounting bolts are tightened, tighten all of the set screws in the Hollaender rail system (JHA-37) Remove the RAMP STAIR upper end CAP on the upper end of the ramp (Figure 14) AD Docx Page 12 of 19

Figure 14: Ramp Stair Upper End Cap 8.45 Choker the 6 sling on the upper end of the assembly just below the first hand rail. Attach two taglines to either end of the assembly.

46 Position the RAMP STAIR assembly on the South side of the telescope, over the Cassegrain ramp with the upper end on the edge of the center section.

13 Figure 14: Ramp Stair Upper End Cap 8.45 Choker the 6 sling on the upper end of the assembly just below the first hand rail. Attach two taglines to either end of the assembly. Lift the RAMP STAIR using the 5 ton dome crane (JHA-38) Position the RAMP STAIR assembly on the South side of the telescope, over the Cassegrain ramp with the upper end on the edge of the center section. Center the upper end over the RAMP LADDER W/ SAFETY CAGE and install the upper end cap (Figure 15). Figure 15: Ramp Stair Position 8.47 The lower end of the RAMP STAIR may have to be on top of the Cass ramp entry platform to clear the Cass ramp handrails. Note: The 2100-ME (RAMP STAIR BOTTOM SUPPORT) may have to be modified to sit on the existing Cassegrain ramp. Upper Truss Ring Installation 8.48 Starting on the South East side of the telescope, next to the already installed SUPPORT RING SHORT SECTION install the 2100-ME (SUPPORT RING LONG SECTION) as seen in Figure AD Docx Page 13 of 19

50 Install the second 2100-ME-040-0212 (SUPPORT RING LONG SECTION) on the West side of the Telescope (JHA-39). 8.

14 8.49 Measure from the top of the tube to the bottom of the top ring. The perpendicular distance should be set to 46-½. Once both of the ends are set to that distance, tighten the four attaching bolts and the four clamp bolts (Figure 16). Figure 16: Tube Location 8.50 Install the second 2100-ME (SUPPORT RING LONG SECTION) on the West side of the Telescope (JHA-39) Install the next two support ring short sections on the East and West side of the telescope (JHA-40) Install the final two support ring long sections on the Northeast and Northwest side of the telescope (JHA-41) Install the final SUPPORT RING SHORT SECTION to complete the Truss SUPPORT RING (JHA-42). Upper Platform Installation 8.54 Arrange the parts shown on Figure 17 below for 2100-ME (UPPER PLATFORM ASSEMBLY, ZENITH WORK PLATFORMS WITH VANE SPACE). Loosely bolt the ends of the assemblies together with ½-13 socket head cap screws (JHA-43). Figure 17: First and Second Frames 8.55 Place the 2100-ME (CENTER SUPPORT TUBE) on the frame and install the 2 ball lock pins (JHA-44). Using a square set the bar at 90 at both ends. Once the frame is squared up the corner bolts can be tightened AD Docx Page 14 of 19

8.56 Build the second frame per the above Figure. 8.57 Build the 3 rd frame per Figure 18 and the above procedure. Figure 18: Third Frame 8.58 Build the 4 th frame per the Figure below (Figure 19).

15 8.56 Build the second frame per the above Figure Build the 3 rd frame per Figure 18 and the above procedure. Figure 18: Third Frame 8.58 Build the 4 th frame per the Figure below (Figure 19). Figure 19: Final Frame 8.59 Choker two 5 slings at the points shown in Figure 11. Attach the 2 slings to a comealong. The come-a-long will be used to control the angle of the assembly. Choker a 20 sling to a point shown in the figure below (Figure 20) (JHA-45). Figure 20: Lifting Upper Platforms 2100-AD Docx Page 15 of 19

8.60 Hook the sling and the come-along on the 5 ton crane hook. Lift the assembly with the crane.

Lift the assembly up and over the top ring. Lower it down between the top ring and the primary focus cage (JHA-47). 8.

Figure 21: Platform Attaching Screws 8.63 Install the upper platform support leg against the support angle with the ball lock pin (Figure 22).

16 8.60 Hook the sling and the come-along on the 5 ton crane hook. Lift the assembly with the crane. Adjust the come-along so the side with the two 5 slings is about 2 higher than the 20 sling attachment point (JHA-46) Attach a tagline near the 20 sling. Lift the assembly up and over the top ring. Lower it down between the top ring and the primary focus cage (JHA-47) Attach the outer edge of the platform to the angle on the support ring short section using two ⁵ ₁₆ x ᵌ ₄ screws and washers (Figure 21). The rigging can now be removed (JHA-48). Figure 21: Platform Attaching Screws 8.63 Install the upper platform support leg against the support angle with the ball lock pin (Figure 22). Plumb the leg and attach the lower end to the plywood using ᵌ ₈ x 1 lag screws (JHA-49). Figure 22: Upper Platform Support Leg 8.64 Rig the second upper platform assembly as done above. Lift with the 5 ton dome crane and lower the assembly down on the South side of the telescope. Attach the outer edge to the support ring short section as show in Figure 21 (JHA-50) Attach the upper platform support leg (Figure 22) (JHA-51) Install the remaining two upper platform assemblies as shown above (JHA-52) Install 2100-ME (#1), 2100-ME (#2) and 2100-ME (#3 Trap Door Only) the precut and painted plywood floor panels (Figure 23). Secure the small corner pieces with self-drilling/tapping screws (JHA-53). Figure 23: Plywood Floor 2100-AD Docx Page 16 of 19

Use ᵌ ₄ long hex head cap screws (JHA-54). Figure 24: Ladder Installation 8.69 Roughly plumb the ladder and attach the bottom plate to the plywood with two ᵌ ₈ x 1 lag screws (JHA-55). 8.70 Lay the upper platform door beside the trapdoor hole in the open position (Figure 25).

17 8.68 Lift the ladder assembly up above the top ring and lower it down through the trap door hole in the upper platform. Place the ladder against the handrails and against the center support assembly (Figure 24). Mark the mounting hole locations and drill and tap for ⁵ ₁₆-₁₈ screws. Use ᵌ ₄ long hex head cap screws (JHA-54). Figure 24: Ladder Installation 8.69 Roughly plumb the ladder and attach the bottom plate to the plywood with two ᵌ ₈ x 1 lag screws (JHA-55) Lay the upper platform door beside the trapdoor hole in the open position (Figure 25). Shim the door panel up with ⅟₄ thick plywood in order to install the hinge in the correct position. Install the hinge with twelve flathead wood screws (JHA-56). ( Is it possible to have the trap door close automatically after you enter through it?(spring closed?) I don t want the door to be left open where someone could accidently step through the opening.)tll Figure 25: Trapdoor 8.71 Once the hinge is installed, apply black and yellow striped safety tape around the trapdoor. In addition, the door itself should be labeled as a trapdoor. (Could also paint it RED)TLL 8.72 Assemble one fourth of the handrails per the upper platform rail assembly. Note: The dimensions on the drawing only need to be approximate. Once the rails are 2100-AD Docx Page 17 of 19

18 mounted, the dimensions will be adjusted. Lift the rail assembly up to the East side of the upper platform Place the center two mounts about ᵌ ₄ from the kick rail. Roughly center the handrail in the North and South direction. Screw the mounts down using the ᵌ ₈ x 1 lag screws (JHA-57) Loosen the set screws on the two vertical tubes and rotate the end tubes out to where the mounts are about ᵌ ₄ from the kick rails. Screw the outer mounts down. Tighten all of the set screws on the rail (JHA-58) Assemble the remaining handrails and lift them up to the upper platform as described above. Mount them to the plywood as described above (JHA-59). 9.0 Procedure Review This procedure must be reviewed by employees under the following terms: 9.1 Initially 9.2 When there is a change in the job process(es) 9.3 When there is a change in a worker s status, or job title 9.4 When governing authorities (such as OSHA) make changes 9.5 Every three years, at a minimum 10.0 Records The records that must be kept on file by the supervisor are listed below. Training records must be available and maintained for a minimum of five years Daily Briefing Form Signature Page(s) 10.2 JHA Signature Page(s) 10.3 Personnel Training Records: Fall Protection Lockout/Tagout Overhead Crane Rigging Welding 11.0 References DOCUMENT NUMBER 2100-ME ME ME ME DOCUMENT TITLE CLAMP RING TUBE ASSEMBLY, LONG TUBE ASSEMBLY, SHORT H BEAM ASSEMBLY 2100-ME SUPPORT LEG 2100-ME PLYWOOD # ME PLYWOOD # AD Docx Page 18 of 19

19 2100-ME PLYWOOD # ME PLYWOOD # ME UPPER PLATFORM 2100-ME ME ME ME ME ME ME ME ME ME ME ME ME ME ME ME ME ME ME ME ME ME ME ME ME ME UPPER PLATFORM INNER TUBE TUBE PLUG WITH TAP CENTER SUPPORT UPPER PLATFORM LONG SIDE TUBE UPPER PLATFORM SHORT SIDE TUBE UPPER PLATFORM OUTER TUBE CENTER SUPPORT TUBE UPPER PLATFORM W/ TRAP DOOR RAMP LADDER W/ SAFETY CAGE SUPPORT RING SHORT SECTION SUPPORT RING LONG SECTION RAMP STAIR RAMP STAIR HAND RAIL RAMP STAIR BOTTOM SUPPORT UPPER PLATFORM W/ VANE SPACE UPPER PLATFORM INNER TUBE UPPER PLATFORM LONG SIDE TUBE UPPER PLATFORM SHORT SIDE TUBE BRACING TAB 2100-AD Docx Page 19 of 19

Doc #: 2100-AD Revision: - Declination Work Platform Installation. Author(s): Derek Guenther, Miranda Saucedo

Doc #: 2100-AD Revision: - Declination Work Platform Installation. Author(s): Derek Guenther, Miranda Saucedo Doc #: 2100-AD-015-0082 Revision: - Declination Work Platform Installation Author(s): Derek Guenther, Miranda Saucedo Contents Revision History... 3 1.0 Purpose... 4 2.0 Applicable To... 4 3.0 Scope...