BL4N 35-deg bender magnet "No. 1" has been installed onto the magnet stand with "stand leg" configuration in the Proton Hall Extension loading bay area.  The magnet fit as expected, and with the support legs resting on the ball transfers the magnet position could be easily adjusted by turning one of the adjuster leg fasteners (with the others loose).  After experimenting with position adjustment, the fasteners were torqued to 70ft*lbs.

The engineering analysis (Document #138415) as well as drawings TBP1804, 1805, 1806, 1811, and 1820 are in the process of being updated to reflect all as-built changes.

Assembly of two complete bender stands was completed on Friday June 2nd as well as installation of new hardware on the dipole magnets for support, adjustment, and seismic restraint.  All parts were installed according to drawing TBP1804.

One of the frames was assembled with the caster wheel configuration.  This frame was pushed from the proton hall B2 level to its final installation location in the ARIEL tunnel.  The frame was a tight fit around the first corner around BPM 26 but it could still pass by without having to remove any items including the electrical boxes on the right side of the tunnel (when facing towards ARIEL).  Part of the grouting for the BPM 26 support stand and the next three stands after that was ground away to allow more clearance for the frame.  The nut/bolt on the frame casters on one side were swapped which also provides an additional ~1/8" clearance.  After these modifications the stand was pushed out past this area and then back to its installation spot confirming that there is now ample clearance.

The other frame was assembled in the configuration with stand legs.  This frame has been moved to the proton hall extension loading bay to be used for magnet field testing.

Both dipole magnets have been assembled with the new adjuster blocks and support legs.  For the magnet labeled “No.01” the original support legs were removed, cleaned in the ultrasonic cleaner, and then reassembled with way oil  The support leg support pads (TBP1822) were replaced with new parts, but all other parts were reused.  For the other magnet, labeled “No.03”, new support legs were fabricated because it was supported differently in its previous location and did not have these parts.  The fasteners attaching the adjuster blocks and support legs to the magnets were torqued to the recommended torque for each fastener based on the fastener grade and size.

Various minor changes to the design were made since the release of drawings, primarily to improve ease of manufacture.  As-built drawings will be released after the magnets have been installed on the stands in case additional changes arise.

Adjustment blocks were installed on the second dipole bender today (labeled "No. 03" "C15-III-57/15").  The mounting holes on the magnet were not aligned properly, so modification was required for two of the blocks.  The counterbored holes on TBP1809 were slotted 0.10" vertically, and on TBP1808, 0.06" horizontal slotting was required.  A stress analysis was performed to confirm that the blocks are still strong enough to withstand the seismic loads (PDF attached).

 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.

On March 29, 2017, a 9 tonne steel shield block was transferred from the ARIEL Target Pit and placed into a 
wood container on the Target Hall B1 level with the overhead crane main hoist in Local Mode without incident. 
Afterwards, the overhead crane was switched into Test Mode (which is the same as Remote Mode but without the 
Target Hall interlocked) and an attempt was made to transfer the shield block from the wood container on the B1 
level to a wood container in the Target Pit remotely with the main hoist. At 11:51:09, after lifting the shield 
block ~1 m above the B1 level, a "136. Main Hoist West Drum South Motor Drive Fault (900 VFD)" alarm pop-up was 
shown on the overhead crane HMI in the crane control room which disabled the controls on the remote console. 
The reset button on the remote console was pressed and the remote lifting operation was resumed briefly until 
the same fault occurred at 11:51:42 and the reset button was pushed once again. While attempting to lower the 
shield block back down to the ground this fault-reset sequence reoccurred at 11:57:25, 11:58:16, 11:58:28, 
11:58:43, 11:59:27, and 12:00:27, at which point the remote crane operation was aborted and the shield block 
was lowered down to the Target Pit floor with the main hoist in Local Mode, without incident. The Test Mode 
faults did not appear to depend upon the speed/acceleration of the lift, nor did they appear to be spaced apart 
by a fixed time interval. Upon closer inspection of the alarm history screen in the HMI (shown below) and the 
exported alarm log (attached below), almost every time the fault #136 occurred, the following three additional 
faults were logged simultaneously in the alarm history (but were not displayed as a pop-up on the main HMI 
screen):
"103. Main Hoist East Drum North Motor Drive Fault (700 VFD)" 
"104. Main Hoist East Drum South Motor Drive Fault (800 VFD)" 
"135. Main Hoist West Drum North Motor Drive Fault (1000 VFD)" 

On March 31, 2017, the overhead crane main hoist was operated once again in Test Mode; however, no load was 
connected to the hook block to determine if the faults that occurred two days earlier could depend on the load. 
The main hoist hook block was remotely lowered ~3 m below the upper 'home' position, and then remotely raised 
as high as possible to function test the upper limit switch in remote mode; at 14:21:05 immediately after 
initiating the 'hoist up' motion, the same four faults occurred simultaneously. This incident shows that these 
specific faults do not depend on what load is connected to the hook block. Note: the crane position data from 
March 31 is attached below, however the times shown are 1 hour fast due a DST adjustment error.

Follow up with the crane supplier, COH, is required to obtain a index and troubleshooting guide for these (and 
all other) fault codes.

2017-04-06 update: Sylvain Raymond of COH has been assigned to resolve these crane faults by Maxime Dubé-Blanchet 
of COH.

On Tuesday, February 14th I finished modifying Jason's boxes for the remote crane tests by adding shelves to mount cameras... Apart from given the edges a quick sanding (so no one gets slivers)...which I will try and do tomorrow.

 In August 2014 gasket corrosion tests were prepared by placing a 1" Swagelok VCR gasket in a 500mL beaker with de-ionized water and a 1"x3/4"x1/8" piece of 6061 aluminum.  Tests were prepared for a silver plated 316L SS gasket (Swagelok PN: SS-16-VCR-2), a silver plated nickel gasket (PN: NI-16-VCR-2), and a TRIUMF made 0.060" thick 6061 Al gasket.  The top of the beakers were sealed, and they were left to sit until March 2016.

The Nickel and SS gaskets show no noticeable corrosion.  The aluminum gasket became dull in colour, with some corrosion visible on the surface.  See attached photos of each gasket.  The gaskets have been bagged and stored with beam dump spare parts in the NW corner of the RH Meson Hall hot cell lab.

Two small (approx. 5 cm across) puddles of green fluid were discovered on the floor, directly below the crane trolley.  The hook block was lowered and inspected.  No fluid found on hook block.
The plant group (Neil Wong) was notified and asked to schedule an inspection when the maintenance crew is on site to inspect the ISAC target hall crane.

The crane bridge and trolley were moved to another position on Friday evening and parked over the weekend.  The floor directly below the crane trolley was inspected on Monday morning.  Three very small (1-3cm diameter) puddles of green fluid were found.

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.

The location of the already installed blocks including the TSH0392 protruding lift bails were remeasured, and it was found that modification of the Standard Lock-Block Flat Top block was not required.  A Standard Lock-Block Flat Top block was installed in the place of TSH0487 in drawing TSH0372, and the remainder of the blocks on top were installed.  It was a tight fit for the lower two Half Height Lock-Blocks, but future removal of the BD shielding and SS plug should still be possible.  Drawing TSH0372 will be updated to reflect as-built status.

- 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.

- 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.

A leak test was performed on the beam dump water system on June 9 in the afternoon.

- Pipe segments tested: The entire HAW system except for the expansion tank, air separator and HAW pump
- Test medium: air
- Test pressure and duration: 60 minutes at 50psi with no loss in pressure
- Swagelok joints and VCR joints around the beam dump which had been opened since last test were sprayed with Snoop: no bubbles

 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
 

- 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)

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.

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.)