Painting and relabeling of the modified lower center block (TSH0461) was completed on Monday Nov 24.  The height of the modified block was measured at the four corners using a tape measure and found to be approximately 533mm at all corners.

The block was lowered to the E-Hall and aligned on Tuesday Nov 25.   No cantilever lift was required because the catwalk above the hatch had been removed.  During the block installation one of the crane cables was contacting the concrete on the edge of hatch opening.  Future installations should use a long sling or cable to prevent this.  Photos of the installation are attached.  Beamlines Group assisted with alignment using their laser tracker.  Vertical alignment was achieved using 3x3" metal shims of various thicknesses placed at 4 corners of the block.  North-south, east-west alignment was achieved by installing based on marks drawn on the E-Hall floor by Beamlines group.  After initial placement, measurements were taken with the laser tracker, and the position was adjusted.  The nominal positions of the beam dump according to installation drawing TSH0372 are:

East Face: x=-5926.3mm from EHBT CoP
South Face:  y=2223.6mm from EHBT CoP
Top Face: z=-208.0mm from EHBT CoP

The laser tracker measurements of block position after final placement are as follows:

East Face: x = -5926.2 ~ -5926.9mm
South Face: y = 2220.9 ~ 2224.7mm
Top Face: z = -209.6 ~ 211.6mm

The East face is within 0.6mm of nominal position which is excellent (note that the east-west direction cannot be corrected using the alignment rail track).  The south face position is within 2.7mm.  This is fine because adjustment can be made to the north-south position of the rail track.  The top face of the block is a maximum of 3.6mm below the nominal position which is also fine, as the lower lead shield block can be shimmed up to it's nominal position.  Data from Beamlines Group is attached (note that 19.05mm must be added to each measurement to account for the distance from target base to center).  The location of the measurement points on the top face are as follows.

                 North Side
--------------------------------------------
| 6                  4                  2 |
|                                           |
| 5                  3                  1 |
--------------------------------------------
 

We will aim to have the bottom of the lower lead shield at z = -204.8mm (this leaves nominal 2mm space to be shimmed under the rail track to bring the BD flange center to beam height).  Therefore the following thickness shims should be placed on the top of the lower center block.

Position 1: 5.8mm (suggest 1/8 + 1/16 + 1/32" shim = 5.6mm)
Position 2: 5.9mm (suggest 1/8 + 1/16 + 1/32" shim = 5.6mm)
Position 3: 6.8mm
Position 4: 6.0mm
Position 5: 5.1mm (suggest 1/8 + 1/16" shim = 4.8mm)
Position 6: 4.8mm (suggest 1/8 + 1/16" shim = 4.8mm)

Position 3 and 4 do not need shims, as the outer four corners should be adequate.

During the maintenance period today the E-Hall tunnel was accessed to begin controls tests on the beam dump water system and initial fill of the system.  This work was done by Bill Richert and Dave Morris while I observed.  Before work began I verified that pressure relief valves were installed as per the P&ID (TEL5104 Rev A) - they have been installed but the exhaust ports from the valves have not yet been routed to the active drain.  They first tested the hydrogen venting and measuring system in the E-Hall and all seemed to work properly.  Next, in the tunnel Dave confirmed that he was able to actuate the solenoid valve used for filling the system from EPICS.  Next the pressure sensor used to determine expansion tank level was tested - although not calibrated properly yet they were able to confirm that it is wired correctly and responding as expected.  Upon inspection of the pump it was found that the pump motor was not mounted properly to the support plate below (this should have been done by the supplier before delivery).  Because the pump cannot be run in this state it was decided not to fill the system at this point.  Bill Richert will have the pump properly mounted before the system is filled, possibly during the two day maintenance period next week.

It was reported that the hot cell turntables would not rotate and the access hatch could not be operated. The turntables' elevation motion was working normally, and other cell functions were working.

Upon investigation, after going online with the PLC and checking the interlocks for the turntable, it was determined that motion was being prevented because the turntables were in the "critical position" in which they could interfere with the access hatch raising/lowering. However, the access hatch was fully closed, so this logic should not have been actively preventing motion. After inspecting the target access hatch limit switches, it was determined that the upper limit switch's Normally Open contacts were behaving normally, but the Normally Closed ones were not. When the switch was toggled, the NO contacts did not switch over. Thus, the sensor was in an unknown state causing conflicting logic in the PLC (the program thought the access hatch was in an intermediate state between opened and closed, thus preventing motion... and the access hatch could not move because the turntables were in the "critical position"). After testing the switch multiple times, jiggling the wiring/contacts, and rewiring one of the screw terminals, the NO contacts started working normally again. It is suspected that a wire was loose. 

The issue has been resolved and tested - the access hatch logic is functioning regularly and both turntables can fully rotate and elevate.

A fault occurred which presented as "114. Main Hoist Cable Broken (3200PX)". This occurred when a SEG block was suspended approximately 1 m off the ground.

Upon inspection, it was determined that the cable was in fact not broken, but wrapped around itself. There are no guides, and it is possible for the cable to double wrap if loaded in an usual fashion. This condition triggered the "Hoist Rocker Switch 1" sensor, 3200PX. The sensor is not visible or accessible from ground level, and could not be inspected, but it was confirmed that there was no 24 VDC PLC input at 30000EA:I.Data[7].0, as would be expected under normal operating conditions.

To rectify the issue:

• The sensor was bypassed in the control panel by connecting wire 32001 directly to 24 VDC after confirming that there would be no adverse affects from doing this.
• With careful supervision, the load was lowered, while watching the cabling.
• The load was removed from the crane.
• The hoist was then lowered to its extreme lower limit, and the cable unwrapped itself naturally as it was being lowered.
• The sensor bypass was removed.
• The sensor began functioning normally again when the wrapping issue was resolved.
• The hoist was raised and lowered multiple times to confirm the cable wrapping issue was no longer present.

The crane is returned to its normally functioning state. Operators will keep a lookout for any more issues relating to the hoist cable. The crane will be inspected on Sept. 22, 2021.

 December 12, 2024 - Chad Fisher, Albert Kong, Aaron Tam, Austin Hagen

Tests:

Loose piece connection and removal 

• By hand, the two connections were brought together and removed carefully

Observation/notes:

• Copper extensions are fragile and can bend when removing extraction electrode. 
  • This makes this part fairly limited in its capacity to be re-used
  • Copper extensions will need to be tuned before inserting into hotcell for replacement 

Recommendations/follow up items/questions:

• Bigger lead-ins would be appreciated
• What is the exchange frequency?
• the flexible nature of the copper extensions makes re-use limited
• How many connections can we expect from the aluminum fingers?
• Would a closer locating feature specific to the pins help?

December 12, 2024 - Michael Genix, Aaron Tam 

• Guide pins for the extraction electrode contact before the banana plugs
  • As these pins are low tolerance, this will act as the guiding for the plugs
  • Copper extensions have a much smaller diameter than the plugs, so positioning can be less precise in this area 
• Exchange frequency is still TBD
• Pin and plug life is still TBD
• Potentially the copper extensions can be tuned in the hotcell

- On May 4th the EHDT beam pipe section was installed by Mike Vogel of Beamlines Group
- A new Helicoflex seal was used (provided by Vacuum Group)
- 4" RH Clamp was installed by Isaac Earle.  Clamp became stiff in early travel, was backed off, then fully tighetend down to stop-ring (later learned that early stiffness was likely due to lower part of jaw hitting the outside of the flange and it would have been better to jiggle the clamp rather than back off)
- Pump was started on May 4th end of day by Anthony Ip (turbo pump, no ion pump)

- Vacuum level at low 10E-6 Torr by morning May 5th.  Leak check was performed by Anthony.
- Small leak found at top of 4" seal. No other leaks in system.
- Baseline leak rate ~4*10E-8 Torr*L/s.  Reaching plateau of 1*10E-7Torr*L/s when flooded with helium
- Leak is suspected to be caused by beginning torquign clamp then backing off as mentioned above

- Beamline vented and seal removed (will be reinstalled after water hose swap, before RH test)

- The hoist rings were removed from the upper lead shield
- Two standard lock-blocks were installed over the E-Linac beam dump according to TSH0372
- 5/8" of shims were required on the north end of both blocks to make them level.  Aluminum shims were used (1/2" + 1/8")
- The service stand plug was also installed using a cable sling and chain-fall pulley setup prepared by Neil Wong (tight fit with surrounding shielding, but the install went smoothly)
- No change in EHDT vacuum (approximately 3.0E-8 Torr)
- The modified block TSH0487 is now required.  Installation will continue once it is ready.

Upon powering on the crane today and attempting to use the main hoist, the following faults were present:

1. Main Hoist East Drum North Motor Drive Fault (700VFD)
2. Main Hoist West Drum South Motor Drive Fault (900VFD)
3. Main Hoist East Drum North Motor Drive Not Ready (700VFD)

Note that the auxiliary hoists functioned as normal.

Upon power cycling the crane to reset, the faults disappeared, and the main hoist functioned normally again. The root cause of the issue is unknown. It is suspected to be related to either prolonged inactivity, improper safety reset sequence, or the battery being removed from the pendant. This issue will be monitored for re-occurrence.

Testing was performed on the ceramic water breaks to be used on the beam dump water hose assemblies.  The ceramic breaks are a custom MDC product with the following description:  3kV ceramic break, 1" OD tube 0.083" wall thickness, 2" length, 304SS tube stub each end, 250psi water rating (see TRIUMF PO#  TR199315).

A load was applied perpendicular to the part, 12" away from the center of the ceramic, and increased incrementally until failure.  Two parts were tested, which failed at 125lbf and 170lbf. Equivalent to 125ft*lb and 170ft*lb when converted to torque.  Test data, photos of the failed specimens, and a more detailed description of the test setup are attached.

The purpose of the tests was to gain an understanding of how fragile the ceramic parts are.  The results show that the ceramic breaks should be able to withstand the expected loads caused by the flexible hoses being pulled as the RH water blocks are installed or removed remotely using pole tools, however this operation should still be done cautiously.  The ceramic breaks are at risk of failure if a torque of over 100ft*lb is applied, such as if someone were to stand on the ceramic breaks or the attached hose.

I received a call today from Jim Adamson at Kaltech regarding modifications to shielding block TSH0225.

They had finished removing 19mm from the bottom of the block, as well as removing 10mm of material from the side plates (TSH0246).  He was wondering whether it was also necessary to remove material from the back plate (TSH0253) and weld the back plate to the 6" plate (TSH0252).  I instructed him that it is not necessary to machine and weld the back plate.  This decision is based on weld strength calculations I performed last week which showed that the existing welds are much stronger than what is required to take the load applied when lifting the block (FOS >> 10)

It was observed today that the crane's west light was not functioning.

There was an issue with a 20 A circuit breaker used to control motor assist functions for the telemanipulators (specifically, the rightmost CB in the panel for the right (East) manipulator set). This circuit breaker was moved to the panel for the left (West) manipulator set in the rightmost position, and then subsequently replaced with a new one, which is functioning correctly. It is suspected that the former CB which was not working was calibrated towards the low end from the factory, based on discussions with the manufacturer and extensive testing of multiple scenarios.

The bridge motion was slowed due to encoder homing issue. It is likely that the problem which occurred yesterday caused an velocity fault (mismatch between encoder speed and commanded speed), which unlatches the homing status for the bridge motion axis.

When the bridge was in the southmost position (bumper pressed against wall), the position readback was: 0.353 m, encoder count = 5164003.

The bridge was moved to the "zero position" as indicated on the remote display - the tick was aligned with the zero.

The encoder was homed at this position. The home position readback was: 0.356 m, encoder count = 5164447. Note that this position is in alignment with the measuring tape zero mark, not pressed up against the wall.

The bridge was run to its full extreme positions in either direction to confirm proper slowdown and stopping behaviour. It appears to be functioning normally again.

Beam dump waterblocks #1 (BD Inlet) and #3 (Upper Pb Inlet) were removed as per the attached procedure on June 1-2.  The following was noted:

- The RH pole tool (TRH1244) and water tool wrench (TRH1243) fit easily over all four water block nuts and was easy to use

- The rubber nut thread tool was sometimes difficult to located in the hole on the water block (WB) lower half body, could be done after a few attempts, perhaps tool locating feature can be improved

- The rubber nut thread tool worked well, but a new one should be made as it is starting to degrade and drop pieces of rubber

- The WB upper halves must be lifted carefully with the pole tool supported well to prevent them from swinging in the east direction due to water hose stiffness

- The gasket/retainer assembly on the WB lower half is likely to become dislodged when removing the WB upper half.

- A tool must be developed for picking up the old gasket w/o damaging the WB lower half gland (could simply be a plastic hook attachement)

- A tool must be developed for placing a new gasket on the lower gland (concept in progress by Keith Ng)

- Installation of the upper water blocks (#3 and #4) may require assistance with a hook tool to get the upper WB in the correct orientation.  The lower water blocks (#1 and #2) should not

See attached procedure for full details and photographs.  More photos and videos of the procedure are stored on Isaac Earle's hard drive.

- On Thurdsay June 4th the EHDT beamline section was vented by Vacuum Group so that they could install a new pump
- After pumping down again a leak was found at the BD front flange seal around the top of the seal
- The RH clamp and Helicoflex seal were removed and an o-ring seal was installed with a band clamp
- The EHDT section was pumped down and leak check performed - no leaks

- While the EHDT section was vented both flanges were measured and found to be in spec (see attached PDF)
- The clamp jaws were also checked and were in spec (see PDF)
- Seal was inspected: delta fully crushed at bottom, but a visible ridge remained around the top

- A meeting was held on June 5, with Grant Minor, Isaac Earle, Keith Ng, and Bill Paley in attendance.  Meeting minutes copied below:

Meeting Summary:
- We suspect the leak is caused by inadequate seal compression
- The leaks on this installation may be because of the new batch of seals which are thinner (by ~0.006") and have a less pronounced delta  (all the successful installations on 2A are using the old batch of seals)
- It is possible that the recent bench tests performed with the new batch of seals also had very small leaks that were not detectable with the "Star Wars" leak detector
- The clamp must be modified to achieve the manufacturer seal compression spec (currently 0.020" short)
- We will not pursue testing of clamp closure beyond the point where the jaws are concentric (0.685" stop-ring)

Actions:
- As a temporary measure a seal from the old batch will be installed at the e-dump next Monday (Keith, Isaac, Bill)
- Modified clamp jaws, to achieve design seal compression, will be designed/ordered (Keith), and bench tested (Keith, Isaac/Bill)
- We will pursue purchase of a new leak detector for the lab.  If leak checking is required before then we will borrow a modern detector from Vacuum Group  (Isaac)
- If the old batch seal installation at the beam dump is leak tight, we will still switch to a new seal and modified clamp jaws once development is complete and an opportunity to swap presents itself (Isaac)

- Vacuum has been pumping steadily on the EHDT section since June 8, reaching 3.2E-8 Torr at 8am today (June 12)
- Leak check performed this morning by Anthony Ip: no leaks
- Vacuum vented and re-pumped, leak check repeated: no leaks
- Reached 5.0E-7 Torr by 9:20am

Installation of shielding over the beam dump will begin next Tuesday.

The following work was performed on May 27 & 28, 2015:

- The beam dump 10kW Remote Handling setup was arranged as shown in the attached procedure

- The EHDT split ring clamp was found to be installed too far downstream and the pole tool could not be installed properly;  the position was adjusted

- The cuff of the previously installed used seal was found to be damaged because it was not located properly on the EHDT side flange at the bottom when the clamp was closed.  Thorough inspection (visual from top, camera for bottom) must be used in the future to prevent this from happening again

- Flange gap was measured with the beam dump in far upstream and downstream positions:  .190" and .762" 

- Seal width is 0.255", and cuff width is 0.475", giving 0.297" clearance for installation, and .065" bellows compression when closed 

- EHDT beam pipe was adjusted approximately 0.125" downstream to give more bellows compression with seal installed and the BD advanced upstream 

- New flange gaps: 0.083" and 0.649;  New instillation clearance: 0.174"; New bellows compression: 0.172" 

- Two trial seal installations were performed according to the attached procedure (no major issues encountered)

- A new helicoflex seal was used for the final installation (also according to the procedure).  One of the clamp jaws did not seat properly around the flanges at beginning of travel; this was overcome by backing up 1/4 turn and adjusting the clamp angle to get the jaws seated properly.  After this the clamp closed normally.

- A helium leak check was performed by Anothony Ip from Vacuum Group:  No leaks found!

See attached procedure for full details and photographs (updated document uploaded June 2 to include comments from Ron K.)

 On Monday June 8 the following work was performed by Isaac Earle and Keith Ng:

- EHDT beamline vented
- Band clamp and o-ring seal removed
- Flanges cleaned with methanol and Kimwipe
- Flanges inspected visually: clean and scratch free
- New seal prepared as per TEL5568 from old 1997 batch of seals (as decided at Friday June 5 meeting)
- Seal cleaned with methanol and Kimwipe
- Seal installed remotely following procedure attached to Ariel E-Log #18 (install went smoothly, no catching of clamp jaws)
   Rocking the clamp back and forth while tightening seemed to be a good technique to avoid jaws catching on outside of flanges
   Clamp began getting stiff with around 5/8" of gap remaining to stop ring.  It gradually got stiffer as travel progressed until reaching hardstop
- Inspected visulally close up: all appeared normal
- Vacuum pumped at 10:15am, Leak check performed around 11:30am - Leak tight

- Will leave the BD under vacuum for a few days, then attempt to vent, repump, and repeat leak check (which caused failure before)
- RH bridges removed to allow water lines in north-west corner to be reinstalled
 

 As there likely won't be an opportunity to properly document the design of the beam dump insert and cooled lead shielding in design notes, a list of design reviews, released on Docushare is provided below.  These provide a reasonable overview of the design process for each item.  In addition the attached PDF of scanned notes provides detailed information on the lead shielding design.  Further notes, ANSYS documents, meeting minutes, concept reviews, etc, can be be found on Isaac Earle's hard drive.  Released drawings for each completed design are available on the PDM Works Vault.

DR-P0104-35 (Document-110856):   Design Review for the e-Linac 100kW Tuning Dump Pb Shielding

DR.P0104-23  (Document-104081):   E-Linac 100kW Tuning Dump Water Cooling Package Concept Design Review

DR-P0104-41:   Design Review for the Tuning Dump Local Shielding (10kW De-Rated)

DR.P0104-24 (Document-104082):   E-Linac 100kW Beam Dump Insert Design Review

DR.P0104-32  (Document-109104):   E-Linac 100kW Beam Dump Shielding Design Review

 Hardness testing was performed on 1 sample each of parts TBP1822 and TBP1823 (part of the 35-deg magnet stand assembly TBP1804),  They were found to be 60-60.5 Rc and 60-61 Rc respectively which is within spec.  The alloy used to fabricate these parts was AISI #8620. The testing was performed by Precision Heat Treat in Surrey who also performed the heat treatment at an earlier date.