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.

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).

 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.

 The beam dump and upper lead shield flexible hose assemblies have been replaced with smaller diameter versions to allow for easier remote handling.  The new beam dump hoses are TEL5501 (Rev A) & TEL5502 (Rev A).  The new upper lead hoses are TEL5503 (Rev B) and TEL5504 (Rev B).  All Swagelok joints were installed 1-1/4 turns past finger tight as per Swagelok instructions.  The new Swagelok connections have not been leak tested yet.  This will be done after the remote handling test of the vacuum seal and water block which is scheduled to begin on May 27th.

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 Dec 2 the cables from the BD service stand area to the junction box were traced to establish which sensors correspond to which cable number in the junction box.

The beam dump thermocouple probe cable numbers are as follows (as labeled on the beam dump and the TC block upper half):
TC#1: T44,  TC#2: T55,  TC#3: T11,  TC#4:  T22,  TC#5: T66,  TC#6: T77
 

The service stand water sensor cable numbers are as follows:
Inside Tray, East Side: 44
Inside Tray, West Side: 22
Under Tray, East Side: 33
Under Tray, West Side: 11

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.

A spare pendant for the overhead crane was procured from COH. The pendant's functionality is the same as the original one's. The pendant was tested today by Adam Newsome - all functions behave as expected.

Important - to change to the spare pendant in the case of failure of the original one, insert a battery into it, and transfer over the small black transmitter card shown in the attached picture. The pendant will not pair with the receiver without this card. There is nothing else that needs to be set up for it to work.

The spare pendant is kept in a labeled box on top of the electrical cabinets located in the crane control room (L1 floor).

Today while operating the crane with load, the crane stopped moving. Upon investigating, all safety signals appeared to be OK. Fault messages regarding drive faults for various VFDs were present, which seemed to stem from an ethernet adapter card fault (see attached photo). It is unknown how this occurred, but suspected that it was due to a brief blip in network communications or the external drive power supply control signal. It is worth noting that the diesel generator tests took place today, and there could have been some affect from a power surge because of this.

The crane was power-cycled using the main disconnect, and safety system reset. The faults disappeared. The crane was operational again.

If this issue occurs again, it should be investigated more thoroughly. It would be worth checking if there were any generator tests or other things which could cause some sort of power surge.

Wednesday, March 05, 2025, 13:00

Implemented and tested travel zone restrictions for the 1000kg crane to prevent collision with the manipulator arms. West operator station is currently occupied so testing was done and confirmed functional for the East operator station.

Movement of the crane is restricted and limited to only moving out of the zone in the following coordinates. Referencing the X and Y position to calibrate the encoder will bypass the zone restriction interlocks.

East Operator Station restriction Zones:

3048mm < X < 4601mm

1550mm < Y < 1680mm

Restrict +X When: 

3048mm < X < Mid point (3824mm)

1550mm < Y < 1680mm

Restrict -X When:

Mid point (3824mm) < X < 4601mm

1550mm < Y < 1680mm

Restrict +Y When:

3048mm < X < 4601mm

1550mm < Y < 1680mm

-Y is not restricted because it is always a safe operation.

West Operator Station restriction Zones:

(TO BE ADDED LATER)

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

Tests:

Gas lines removal: 

• Starting with the most exterior connection, VCR connection loosened off with open ended conventional wrench
• Once loose, the nut can be un threaded with manipulator finger (rolling nut technique) 
• Once gas line unhooked, gasket removed by bringing female end outside the service tray footprint and jiggling until the gasket was removed
  • Also possible to use a pick if needed
• The same procedure was conducted for the interior VCR connection

Gas lines installation: 

• Starting with the inner most connection
• Gasket placed on 3D printed tool and clipped into position on VCR male end
• At first an M10 bolt was inserted into the elbow below VCR connection, but without rotational authority, the makeshift handle is not worth using
• Griping the elbow with one manipulator and rolling the nut onto the threads with the other proved successful
• Nut was tightened using conventional open ended 19mm wrench

Observations/Notes:

• Service Tray was not in a fully connected position, so even less space will be afforded.
  • This may affect the ability to get 2 manipulators on the same connection
• Piston modules were missing some limit wires on the side. These constrain movement horizontally and will either need to be removed as part of the procedure or, make the procedure more difficult
• Mass markers and various other connectors not installed, and these could slightly restrict movement as well
• Service tray pin was restricting the movement of the left manipulator during install
• Lighting was inadequate under the piston 

Recommendations/follow up items/questions:

• All metal Parker VGR style gaskets to replace plastic retainer versions
  • This is so that the degraded plastic doesn't break off and end up in the gas lines (upside down connections)
• A modified wrench with flats for handles and with more length would make the above procedures easier 
• Along with raising and lower the service tray, the service tray pin being oriented towards the beam entry direction, would make life easier 
• Still need to test gasket install on "other" Piston gas line connection
  • Chad will redesign some new gasket tools to be tested
    • side load and axial load gaskets, low and high clearance, aluminum construction 
• Lighting positioned to flood the service tray area will be needed
• labeling the gas lines with a more permanent solution will be needed
• Once the high voltage feed-through parts have come in, we can re-test and see if the piston module can be lowered to aid in target removal situations
• Aaron will test Parker style seals to see if they can be removed as easily once brought up to specified torque 

------------------------------------------------------------------------------------------------------------------------------------------------------------------

 December 16, 2024

• Upon inspecting the piston modules on AETE in TISA, we became aware of how the wires are arranged for the limit switches, it may be a good idea to look into how these wires are handled when using the piston module jig.

Today RH (CF and AK) agreed upon using the following style of gaskets for the ARIEL front ends:

• All metal rings to be used to avoid plastic retaining rings deteriorating due to radiation and leaving bits stuck in the nuts
• Parker style (4 VGR-SS and 8 VGR-SS) gaskets for all VCR joints, except
• For the piston module and hanging water line VCR joints (found in the 'back', these should use SwageLok side-load gaskets (SS-4-VCR-2-ZC-VS and SS-8-VCR-2-ZC-VS)
  • The primary reasons for which are clearance issues to fit normal loading VCR tools in these joints.

Dec 10, 2024

Testing completed:
 - Used hydraulic scissor jack cart to test raising/lowering service tray onto front-end, with only manipulators, placement of jack table done by hand because it isn't freely moving on the plane of the lift table.
 - Removal and insertion of the center post pin with indirect view to FE.
 - Application and removal of VCR gaskets on HVFT water connection array with 3D printed tool, only for 1/2" size (service tray side of VCR joints).
 - Checking whether the VCR joints can be done up with the service tray 'lifted' (not fully connected but the screws on the HVFT bracket are slid onto their slots)


Observation/notes:
 - Lift table slope creates some difficulty bringing the service tray up.
 - Effective misalignment of service tray changes with the degree in which it is 'brought up' because the ribbon connectors start to compress and exert load, tipping the service tray. There isn't a 'CG' that we can place the table under which will balance the service tray throughout the attachment operation.
 - Service tray is large and will not be fully supported by the base jig without custom jig on top.
 - Using a clamped piece of 2x4 wood on the jack cart worked to increase the supported region during testing, something similar with the base jig may work.
 - The service tray needs to be brought up such that the HVFT is ~1" from being fully engaged before the screws on the bracket can be upturned and start to engage. Likely the bus bar connectors will have started engaging before this is achieved (bus bar connectors roughly 2" in depth), this can create complications because the loading on the base jig will be really uneven at that point.
 - The pin for the center post can be easier to handle if we added a handle or an extender. A makeshift handle was made using tape and scrap U-channel nearby.
 - We managed to remove and attach the pin with the HTV table facing East using a remote camera view, but in practice it would be ideal if we could rotate the front end with service tray supported by some jig between orientations where the HVFT and center post are more easily accessed. This will require the ribbons and the alignment cylinders on the HVFT to transmit some force onto the lift table to overcome any friction the base jig may have on the lift table during rotation.
 - With the brackets on the HVFT on, we were able to start and even tighten the VCR joint closest to the corner bracket (using low clearance wrench, no photo).
 - Difficult to get at all brackets on HVFT and do up, will need cameras irrespective of the orientation, did not do up the bracket yet so we don't know how careful we need to be when inching each up and establishing the HVFT connection.
 - Difficult to get at and rotate screws on HVFT bracket, with torque tool due to proximity with HVFT structure, a longer bit on the torque tool will be beneficial. Note, using an Allen key with the manipulator gripper is difficult because of the same issue.
 - VCR wrenches slippery without catching features, will add pin for better grip
 - If 'fence' on HVFT for water lines is taken off it is quite easy to loose track of where the lines are supposed to return to, should have markings/labels for where the water lines need to return.
 - HTV side ribbons bend inward instead of outward.

Recommendations/follow up items/questions + answers as appropriate:
 - Consider adding grabbing features and an extender attachment for the center post pin: (Dec 16, 2024) Michael agreed to cut the tab and cross-pin the center post pin to match the HTV water connector pins.
 - Can we change the screws used on the HVFT bracket to be longer so it can engaging before the bus bars? (Dec 16, 2024) Michael will look into.
 - Can we add a lip to the HVFT top brackets to keep the screws in place and not fall out during tightening? (Dec 16, 2024) Michael will look into.
 - Consider more items that may help simplify the brackets on the HVFT
 - Is it possible to re-orient the center post holes to be toward the HVFT instead of aligned with the HTV platform axis, this may avoid the need for re-orienting the FE when raising/lowering the service tray. (Dec 16, 2024) Michael will look into.
 - Need to capture effect of bus bars connection in future testing. (Dec 16, 2024) Albert will design and send something to the shop to work with Phoenix's mock up.
 - Need to repeat service tray testing with base jig.
 - Check if ribbons are bending in the right direction. (Dec 16, 2024) Yes.
 - Perform full service tray coupling with actual machined brackets to inform coupling operation (3D printed brackets currently not strong enough and deflect unrealistically).(Dec 16, 2024) received spares from Michael.
 - Need modification to wrench to prevent slippage. (Dec 16, 2024) Albert and Aaron working on this (will simply add cross-pin)
 - VCR gasket tool for smaller size VCR's to be made.(Dec 16, 2024) Chad to do.
 - Real deal VCR gasket tools to be made out of soft metal to prevent scratching sealing surfaces in operation
 - If not possible to do with base jig, possibly a suspended plate with turnbuckles instead will be sufficient to support the service tray during attachment/removal operations. (Dec 16, 2024) Discussed with Michael the possibility of changing the HVFT 'cables' to threaded rod to also facilitate ejection of the service tray on the HVFT side (necessary to disconnect bus bar connections).

 

Removal and replacement testing of the stainless VCR lines extending from the HVFT to the piston modules and FE plate is documented in this ELOG.

Exchange of the FE plate water connector lines is documented in a ELOG #79. Exchange of VCR gaskets in the permanent joints is given in ELOG #83.

Photos provided in PDF, download and open to view all, ELOG preview not guaranteed to show all.

Feb 13:

• Connecting VCR joints between PEEK seal water lines at FE plate to welded pipe section from HVFT was tested:
  • Between the two joints, the one that is routed more internally was tested, there are more lines in the way of access to this joint so it is likely the more difficult of the two joints to service.
  • The gas line routed from the back of the FE is routed next to this joint and interferes with servicing slightly.
  • Retaining bracket on HVFT was kept on for the HVFT side of the line to simulate exchanging the VCR gasket only.
  • It is very easy to drop the gasket during this operation, and in a very hard to reach location, would be good to come up with a solution to prevent this or minimize the chance of the gasket dropping into hard to reach crevasses, better if dropped onto lift table.
  • Need to wedge something at the welded tube section to prop up the male VCR side of the joint for access for VCR exchange, large handled wrench worked best during testing.
  • Recommend end-mount gasket to minimize risk of losing, end loaded gaskets are more secure than side loaded ones.
  • Multi-pin bundle was not present during testing, in practice it will likely further obstruct the joint and increase the risk of dropping a VCR gasket, recommend unpinning FE side of the bundle and getting it out of the way in the real operation.
  • Due to the way that the lines are welded, they tend to be misaligned unless 'turned' by the manipulator into orientation, a camera mounted on the base jig, a dedicated stand, or even on the table would be good to get an alternate view and ensure that the threads are aligned during servicing. This creates side load onto the threads and makes 'hand tightening' with the manipulator fingers difficult to do.
  • By hand, the welded tube section looks like it could be removed without issue, assuming the VCR joints are undone, the FE plate side was tested separately.
  • A design change suggestion that was discussed was the addition of some kind of retainer or other feature on the line routing trays on the FE to hold the male side of the VCR joint and help simplify the gasket exchange operation.
  • Ultimately, however, we were able to successfully exchange the gasket in this line.
• The long gas lines between the HTV and the service tray was tested by hand:
  • the electrical connectors on the FE plate (mass markers) were not present during testing, but we believe it should not have affected the outcome.
  • the line(s) were successfully 'fished out' by hand, we believe it can go through the FE plate opening both ways (from the back or through the front) without too much issue.
  • the gas line brackets on the FE plate needs to be taken off in order to exchange the top gas line
  • the critical operation for the gas line will be removing the screws from the bracket, if it is dropped there is a high risk of it dropping into the FE carriage mechanisms and be difficult to retrieve
  • a catch tray is strongly recommended to prevent this
  • a hand tool to grab onto the sealing faces of the gas line is recommended (see previous observations in ELOG 72)
• Most other lines between the HVFT and the service tray look like they could be pulled out and returned without having to remove other lines, but we will check for sure when we revisit testing these lines.
  • Note: one slightly concerning line is the one routed in along the lowest layer, obstructed by all other lines above.

We will resume testing by attempting to replace the gas lines with the manipulator

------------------------------------------------

Feb 20:

Gas lines:

• The ideal order of operation for exchanging these lines would be:
  • rotate the FE such that HVFT faces window, undo bracket and release the HVFT side of the gas lines
  • rotate FE back so HTV faces window, place protective cover/grabber on seal face as necessary, undo small screws for lines onto bracket, undo bracket screw and remove lines with bracket from FE plate
  • fish out line to be replaced from HTV side, insert replacement, if line catches cable tray at any point, rotating on the axis of the line can help free the line
  • insert new lines through the opening (likely good idea to have protective cover/holder for the seal faces at this point), mount onto bracket without screws, mount bracket onto plate with screw, put screws for lines on bracket
  • remove protective cover on new lines.
  • the above order minimizes the # of times the FE has to be rotated on the turntable.
• When removing the gas line bracket screw by hand at the start of the testing session, as the screw was side-loaded by forces from the braided hose, the helicoil insert on the tapped hole spun out. This is a critical failure mode as if it were to happen during operation, it may necessitate the replacement of the part with the helicoil installed. This is often not possible within the hot cell so the whole FE assembly would instead be exchanged. To prevent this failure mode, we strongly recommend switching from helicoils to key inserts, which have drastically reduced possibility of spinning out because of how they are installed.
• Using a smaller sized Allen key lets us line up the bracket by passing it through the unused hole (see picture).
• We successfully pulled out the two gas lines up through the opening on the FE plate and reinserted them into place, ready to be mounted onto the bracket and reinstalled.
  • Again, the caveat being we don't have any of the mass marker cables and connectors (barrel, multi-pin connectors) on the FE plate that would likely interfere with the gas lines.
  • There is a tendency for the lines to 'wedge' and 'catch' on cutouts on cable trays, but this can be remedied with proper views and by simply loosening and rotating the lines if it feels like they've caught onto something.
• We will fix the key insert in the coming week and finish up hot cell testing of the gas line (just need to return the lines onto the bracket and re attach the bracket onto the plate).

Besides the above, we also confirmed that there is interference between tubes at the upper VCR array with 4 joints (see picture). 

------------------------------------------------

Mar 06:

• The helicoil that spun out was replaced
• We are confident from prior testing that we can take off the gas lines from the bracket and take off the bracket from the FE plate and fish the faulty gas line from it's routing path
• Something to allow us to distinguish the upper from bottom line would be good if only replacing a single gas line, used tape during testing
• Attempted to reattach gas lines to the bracket
  • great difficulty, need 1 manipulator to hold the gas line, another to hold the bracket, and a third to operate the allen key and insert the shoulder screw
  • likely possible but will take many attempts
  • note that it was possible to pick up the small shoulder screw with the T-handle allen key
  • one shoulder screw lost during testing and could not be retrieved, this is a likely failure mode during operation
• recommend full exchange of gas lines on bracket -> the preferred approach
  • two manipulators recommended for routing the gas lines back in when attached to the bracket
  • there is a possibility for the gas line to catch In an awkward spot behind some HV shielding (see picture)
  • smaller sized allen key used to 'pin' and roughly locate the unbolted alignment hole of the bracket, recommend checking that the used allen key fits into the threaded hole before using
  • operation order is: feed lines mostly in, roughly position to allow allen key pinning, pin with allen key, bring the bracket closer to the alignment holes, use allen key with fastening screw to bring the bracket together with the FE plate as a final operation
  • generally cramped work area, in the final step for tightening, needed to remove manipulator from pinning allen key
  • during the test, the bracket feature that is meant to align with the slot on the FE plate was not aligned fully as the bracket screw was tightened but at the very end it snapped into alignment
  • The replaced helicoil did not feel particularly smooth, possibly the underlying thread was damaged
  • The retaining tab for the gas line makes the operation difficult, would be a good idea to remove if possible
  • If the helicoil in the unused threaded hole on the FE plate is unused it is recommended to remove it to prevent it from being accidentally unwound and interfereing with future bracket exchange operations
  • without close up cameras, difficult to see when screws start and when the pinning allen key is in place

We successfully performed a removal and replacement of a power busbar stabuli connector on the front end plate where the HTV connects to:

• The middle-lower connector was tested as the others are more straightforward to work with.
• It may be a good idea to use a 3D printed jig to wedge into the connectors without damaging the flexures/pins.
• A longer hex bit on the hot cell torque tool would greatly help this operation.
• Even without special tooling the bottom connector returned and mated back onto the locating features relatively easily with just the manipulators.
• Longer hex bits purchased, 3D printed too left for future.
• Screws and washers are effectively captive in the connectors which helps