A 1/8" SS tube was routed from the Swagelok fitting on the front of the lower lead shield to the service stand water catch tray as shown in the attached photos.

The tube was routed to fit in the cut-out and chamfered corner gaps of block TSH0387 in the de-rated EHDT shielding assembly TSH0293.

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 December 2 the upper half of the RH water blocks were installed (4 total) using a 0.030" thick 6061-T6 Al shim torqued to 60ft*lbs as was tested in Document-114260.

Bypass loops for testing the cooling system piping were installed as shown in the attached photo.

On November 28th the lower lead shield was installed with 3/8" shimming at the front end, and 11/32" shimming at the rear end.  The south and east faces were aligned as flush as possible with the lower center block.  The beam dump insert was then placed on the rails in the lower lead shield.

Laser tracker measurements were performed by Michael Vogel, and he reported that the beam dump was 1.7mm high at the rear, and 0.8mm high at the front.

The lower lead shield was lifted, and 1/32" shimming was removed from the front, and 3/32" from the rear.  The block was then placed precisely using the laser tracker with targets on the beam dump insert.

After placing the lower lead shield, Michael aligned the beam dump by shimming and adjusting the rail track, and was able to get all fiducial points within 0.2mm of the nominal position.

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.

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)

Tuesday, November 04, 2014, 16:58

This is a test.