The following items from Phase 1 of 2 of Bridge Lift Mechanism Refurbishment (O504) are complete:

• Replacement of pneumatic tubing
• Replacement of hydraulic cylinders for lifting, and procurement of spare

The newly refurbished system has been tested by Dan McDonald (June 16, 2021) and verified as functioning.

Phase 2 of the refurbishment will include replacement of the hydraulic pump and creation of pneumatic/hydraulic drawings. This is expected to be complete by end of 2022.

[Edit 2024-10-16]: Phase 2 has been completed. See e-log 191

 The Blue Shield Door on the B2 level of the RH building has been closed.

The seven copper blockers were removed from the Cyclotron tank by the RH group using the service bridge, lift 
trolley, and attached checklist on 2017-01-30.

The monitor box (NE/SW-5/8/10) and series 200, 400, 500, 600, and 700 shields were installed in the Cyclotron 
tank by the RH group using the service bridge, lift trolley, and attached checklist on 2017-01-31 and 2017-02-
01.

The seven port hole covers were installed in the Cyclotron tank by the RH group using the service bridge, tool 
trolley, and vacuum unit on 2017-01-02.

The two ladders were installed in the Cyclotron tank by the RH group using the service bridge, lift trolley, 
and ladder attachment on 2017-01-02.

=================================================================================================================

The monitor box (NE/SW-5/8/10) and series 200, 400, 500, 600, and 700 shields were removed from the Cyclotron 
tank by the RH group using the service bridge, lift trolley, and attached checklist on 2017-03-07 and 2017-03-
08.

The seven port hole covers were removed and the Cyclotron tank seal was cleaned by the RH group using the 
service bridge, tool trolley, and vacuum unit on 2017-03-09.

The two ladders were removed from the Cyclotron tank by the RH group using the service bridge, lift trolley, 
and ladder attachment on 2017-03-09.

The seven copper blockers were installed in the Cyclotron tank by the RH group using the service bridge, lift 
trolley, and attached checklist on 2017-03-09.

This morning Don Jackson commented to Grant Minor that he believed the tank lid was still not raised high enough to safely operate the Remote Handling bridge and trolleys, despite it having been raised 0.5" yesterday to the point of engaging the limit switches (see e-log from yesterday).  Don said he believed this to be the case as a result of a visual inspection with binoculars from the outside of the tank, as well as from the views achievable with the remote cameras.

Don also believed he had caused further damage to the equipment inside the tank by orbiting with the bridge.

After a teleconference with Klaus Reiniger after lunch (Yuri Bylinski, Dan Louie, Don Jackson, Grant Minor present), the following was confirmed:

• There is a complete set of limit switches at station 1, and duplicate set at station 10 for redundancy.
• Both stations 1 and 10 have an operator upper limit switch, as well as an over-travel limit set slightly higher than the upper limit.
• The lid has traditionally been raised to the point of the upper limit switch tripping, then the lift procedure stops there.
• The wooden stick was traditionally set to just touch the roof beams with the lid at the upper limit.  This means if the stick is contacting the roof beams within 1/32nd inch or so and the upper limit trips, the lid has been raised fully.
• Klaus could only remember one incident of the lid being raised so high before tripping the upper limit that the wooden stick actually bowed under pressure from the roof beams.  In other words, this was not a normal occurrence.
• Klaus also reminded us that the limit switches have some mechanical hysteresis and need to be actuated through their full range of motion to reset them.

Don Jackson indicated that another 1/4" of clearance would be adequate to safely operate the RH equipment in his opinion.

At around 5pm Grant Minor and Ron Kuramoto reset the upper limit switches at both stations 1 and 10 by adjusting the block that both upper limit and over-travel are mounted to, see attached photos.

• A line was scribed in the primer paint to mark the original position of the limit switch mounting block.
• The bolt was loosened, and the block was raised fully to reset the switches, and then set 1/4" higher than the scribed line, measured with a Starrett scale accurate within about 1/64"
• The bolt was re-tightened.

Dan Louie and a shift operator reset the wooden stick 1/4" lower than the roof beams, this was double checked by Grant.

Dan Louie started up the system and confirmed the limit switches were properly reset.  He then raised the lid until the limit switches tripped again, confirmed by checking the illumination of the upper limit lamp (see attached photo).

After the raising of the lid, the wooden stick was confirmed to be contacting the roof beams by Grant Minor.

Dan Louie also confirmed that the master synchro counter had advanced almost exactly 250 counts (proportional to about 250 thousands of an inch).

Mechanical counter readings at each station (where accessible) were taken before and after this 1/4" rise by Dan Wright and Grant Minor:

Grant Minor had dosimeter 208 today, which was signed out at 0.61 mSv and signed in at 0.69 mSv.  Thus elevating system assessments and adjustments resulted in approximately 0.08 mSv dose.

Upper and lower resonator trolleys received mounting plates and brackets to accommodate DC motor controls for updated drive motors.

2C has been successfully removed from the cyclotron and is now currently sitting in the B2 level of the RH building. A tank access was needed to feel the stuck QDL.

2C has been removed from the cyclotron.

2C has been installed into the cyclotron.

Today Remote Handling staff (Maico Dalla Valle, Travis Cave) used the Remote Handling 2C probe removal trolley to remove the probe assembly from inside the Cyclotron.  This is a regular yearly MRO task that is done every shutdown.

This task involves lining up the 2C trolley on the service bridge with the 2C probe assembly remotely with cameras, using a set of alignment markings on the trolley and probe assembly.  Once the trolley is lined up with the probe assembly, a set of solenoids are fired to disengage a corresponding set of four QDLs (quick disconnect latches) at different locations on the probe assembly.  A complete procedure is documented by Remote Handling staff.

The four QDLs are actuated by a set of four solenoid actuators on the 2C removal trolley, numbered 3, 4, 5, and 8.

Traditionally in the past, the QDL actuated by solenoid 8 has  jammed and does not automatically disengage when hit with the solenoid actuator.  A member of Probes or Remote Handling has had to suit up with a respirator, run into the Cyclotron tank, and tap this QDL by hand to free it from it's jammed state.  This has been done every year for quite some time, as long as Don Jackson can remember (around 30 years)!

However, today, Remote Handling staff (Travis and Maico) were able to disengage all four QDLs remotely using the solenoid actuators on the trolley!

A few things were done differently this year compared to previous years, which may have contributed to this success:

a.  The centre post bearing on the service bridge was disassembled, cleaned, and lubricated (see previous e-log from this shutdown)

b.  The "AXIAL A" alignment tab on the 2C removal trolley was intentionally misaligned with the felt pen markings on the 2C assembly (see attached picture that points out this "gap").

c.   The solenoids were fired in the following order: 8 (no success on disengagement), 5 (success), 4 (success), 3 (success), then 8 again (success).

After all four QDLs were disengaged, and the probe assembly was lowered away from its fixture points, it was observed that the assembly moved slightly laterally, indicating a slight stress or misalignment between all four QDL pins and their corresponding receptacles in the Cyclotron tank. The "gap" labelled in the attached picture, shrunk a small amount after this lateral movement.

Don Jackson remarked that in his entire tenure here, he had never witnessed successful remote disengagement of all four QDLs!  This is quite a positive result, as it lowers the expected dose and time required to remove the 2C probe assembly.  This approach to the task should be repeated next year and video documented (unfortunately we were not video recording the successful attempt this year).

Cheers,

Grant Minor, Remote Handling

2C extraction probe has been re-installed in the cyclotron. After some problems on the first install attempt, do to a busted micro-switch that was causing the 24 Volt DC system to short out.

The Cyclotron Elevating System planned maintenance work this year was performed on Jack Station #3, #8, #9, and #10.

Start date: January 10, 2017
End date: January 23, 2017

Lockout procedure
 - Performed electrical lockout of Cyclotron Elevating System

Jack Station #10
 - Disconnected power from electric motor
 - Noted initial station counter reading and yoke gap
 - Removed limit switch
 - Removed complete spare set #14 from station (2x Duff-Norton screw jacks, 2x Highfield gear reducers, and 1x electric 
motor)
 - Installed complete original set #10 onto station (2x screw jacks, 2x Highfield gear reducers, and 1x electric motor)
 - Installed limit switch
 - Set yoke gap and station counter reading according to initial values
 - Reconnected power to electric motor


Jack Station #9
 - Noted initial station counter reading and yoke gap
 - Removed 2x screw jacks from original set #9 for early inspection
 - Lifted 2x screw jacks to RH active shop
 - Broke-out worm-screw from screw jack #9R
 - Inspected worm-screw and worm-gear surfaces: observed discoloured grease, similar to that found while servicing this 
screw 
jack in 
September 
2015
 - Decided not to reinstall screw jacks from original set #9 so that they can be serviced again after shutdown
 - Installed 2x screw jacks from spare set #14
 - Set yoke gap and station counter reading according to initial values

Jack Station #8
 - Disconnected power from electric motor
 - Noted initial station counter reading and yoke gap
 - Removed complete original set #8 from station (2x screw jacks, 2x Highfield gear reducers, and 1x electric motor)
 - Installed complete spare set #13 onto station (2x Duff-Norton screw jacks, 2x Highfield gear reducers, and 1x electric 
motor)
 - Set yoke gap and station counter reading according to initial values
 - Reconnected power to electric motor
 - Lifted complete original set #8 to RH active shop for inspection and servicing
 - Inspected and serviced upper bearing: ok

Jack Station #3
 - Unable to remove screw jacks from original set #3 for inspection and servicing since there no remaining spare screw 
jacks 
available
 - Decided to postpone removal of complete original set #3 until January 2018
 - Inspected and serviced upper bearing: ok

Pre lid-up preparations
 - Tested Jack Station #8 and #10 to verify correct motor phasing
 - Indexed all jack stations to 0.25"

The Cyclotron Elevating System Shut Down  work done this year was done on Station #9 and Station #10.

 Work done on Station #9

                       - note the readings on the Station counter and the gap clearance on the Yoke.

                       - Remove all the spares from Station #9 Elevating system (Spares are made up of two Jacks, two Highfield gear reducers,and one electric motor)

                       - Reinstall the complete serviced original Station into Station #9.

                       - Set the noted gap on the Yoke and the same readings on the Station counter.

                      - Station #9  Jacks were found to have some discoloration on the worm and worm gear. Next shut down they will be taken out and inspected and reinstalled.

Work done on Station #10

                        - Note the readings on the Station counter and the gap clearance on the Yoke.

                        - Remove the complete Station #10 Elevating system.

                        - Install the complete Spare Elevation system(Station#14) into Station #10.

                        - Set the noted gap on the Yoke and the same reading on the Station counter.

                        - The complete original Station #10 is taken to the Remote Handing Active Machine shop where each component will be inspected and serviced.(This Station will be ready to be reinstalled during next years Shut Down)

 Electric Motors have been reconnected on Station #9 and #10. We have not been able to test them until all the Interlocks have been satisfied. This may happen on Monday February 1st. 

The Cyclotron Elevating System Shut Down  work done this year was done on Station #4 and Station #9.

 Work done on Station #4

                       - note the readings on the Station counter and the gap clearance on the Yoke.

                       - Remove all the spares from Station #4 Elevating system (Spares are made up of two Jacks, two Highfield gear reducers,and one electric motor)

                       - Reinstall the complete serviced original Station into Station #4.

                       - Set the noted gap on the Yoke and the same readings on the Station counter.

Work done on Station #9

                        - Note the readings on the Station counter and the gap clearance on the Yoke.

                        - Remove the complete Station #9 Elevating system.

                        - Install the complete Spare Elevation system in Station #9.

                        - Set the noted gap on the Yoke and the same reading on the Station counter.

                        - The complete original Station #9 is taken to the Remote Handing Active Machine shop where each component will be inspected and serviced.(This Station will be ready to be reinstalled during next years Shut Down)

 Electric Motors have been reconnected on Station #9 and #4. We have not been able to test then until all the Interlocks have been satisfied. This may happen on Monday January 26th.

The Upper Bearing are needed to be serviced on Station #5 and #10. We wound like to do this work this Shut Down.This work can be done after the Cyclotron lid has come back down after service and maintenance has been done inside the Cyclotron.

Shut down work for 2012.Replaced serviced Jacking Station #6. Tapered alignment pins were damaged. They were skimmed and checked and installed. Station #4 was removed and the spare Station was put in its place.Station # 4 Upper Bearing was inspected and serviced.Station #4 had a problem with the Jack on the right side.The coupling hub than joins the Jack to the High Field was installed backwards.(Not sure how long the hub has been like this maybe 15-20 years?). The coupling and hub had to be cut/split apart to get them off of the Jacks shaft. A new coupling and hub was machined and installed. Anew shaft seal was installed next to the new coupling hub. All the old grease was removed from the Jack. The Jack was inspected and then new grease was replaced. The left Jack was also serviced. It was taken apart and the old grease was removed. The Jack was inspected. The shaft seal on the other side of the coupling hub was replaced. New grease was replaced. The two High Fields had the oil drained. They were inspected and new oil was replaced. #4 Stations motor has four mounting bolt holes and two tapered pin holes for alignment. The one tapered pin hole in the front right side of the motor had a small hairline crack. The paint was removed in the area where the crack was so it could be welded.(The motor base is made of Cast Iron). The crack was  welded with 309L SS welding rod. After welding the tapered pin hole was checked with the tapered pin.(It was OK). The #4 motor was bolted to the service area work bench. An Electrician hooked the motor up for testing. The motor was greased  and then  it was  started.  It ran nice and smooth.           

The lid up operation took place on Jan. 28, 2025 under work permit C2025-01-28-1

The system was energized approximately 1.5 hr ahead of time during motor direction checks. Motor direction was correct for both stations.   

Starting master synchro value: 2

The master synchro was not jogged prior to starting. It was noted prior to starting that station 12 would likely cause issue as it was near the borderline of the tolerance window for its synchro count.

Upon starting, station 12 faulted almost immediately. It was manually jogged to match the other stations' synchro counts. The system was restarted. This occurred twice until 12 became synchronized with the others. 

The system was stopped at around 1" opening (master count 1958) to allow the tank seal to have time to fall out of place (approx. 5 minutes).

The system tripped unexpectedly at master count 3400 because one station drifted slightly out of tolerance. It was resumed again with no adjustment, no issues.

The system was stopped at approx. 3" of travel (master count 4230) to inspect the seal, etc. Everything OK.

During lid travel:

• No abnormalities were noticed with any synchro feedback via the DAQ - they all appear to be in good working condition.
• No jack stations exhibited any abnormal behaviour
• Stations 2, 11, and 12 ran warmer than the others - this should be considered in the future for replacement planning (see attached spreadsheet)
• Total motor current draw from all motors operating simultaneously (nominal condition) was noted to be 280A

The system stopped when the lid was fully raised at a master synchro count of 47397.

When finished, the limit switches toggled as expected, and the gap was measured at 46.5" (correct value).
 

Start time: 11:15 am
End time: 11:57 am (travel finish)

The lid down operation took place on March 21, 2025 [slightly ahead of schedule].

The system was energized a few minutes ahead of time.

Starting master synchro value: 47428. The master synchro was jogged up prior to starting.

Upon startup at 9:56 am, the system worked fine and lowered the lid. No stoppage occurred. No abnormal observations made. During lowering, operators in the DCR monitored the tulips to ensure alignment. The lid was lowered at 10:23 am.

Overall, as mentioned in the previous year's e-log, the lowering process was very smooth and required relatively few motor/brake toggles during travel (this is just based on memory and visual observations, not actual data).

See attached summary.

A third lid down operation took place over May 6-7, 2024.

The system was energized a few minutes ahead of time.

Starting master synchro value: 47387 (after it was jogged up slightly prior to starting).

Upon startup on May 6 at 14:42, the system worked fine and lowered the lid. The lowering was paused at 15:28 (master synchro value of 17593).

Jack 6 exhibited issues similar to previous lid up (see e-log 166). It was likely due to an issue with a motor contactor. Electricians were contacted but could not work on the issue until the following day so the lowering was paused.

At 07:30 on May 7, electrician Randy Boehm determined that a cable connector on the motor contactor was loosened. After tightening the cable, jogging motor 6 was tested - OK.

Lid down commenced again at 08:10. Master synchro: 1915.

The lowering was stopped at approximately 1" gap as per standard procedure for Operations to perform checks. The lowering was stopped again multiple times to check resonator latching - OK.

End time: 08:37

Ending master synchro value: 59

Jogged master synchro value to 2, adjusted station 12 to match.

Notes: It was observed that at lid down Jack 12 did not have any gap. Jack 12 was jogged to match synchro values with the master synchro but still exhibited a 0.125” gap instead of the ideal 0.25” gap. It is recommended to keep an eye on Jack #12 during the next operation and check the motor contactors for loose fittings. In the before and after photos of the motor contactor it looks like the fitting on the bottom right corner of the motor contactor could have either come loose from the vibrations or the screw was sheared off. Further investigation is required.

See attached summary.

The Hinged section of the festoon rail at Cyclotron has a piston to keep rail in the up position for shutdown work (Bridge and Trolley in tank work).

A plastic liner for the piston has fallen apart and needs to be replace.

A spare one has been temporarily put into  place until another one has been machined and reinstalled.

See previous e-log for phase 1: e-log 134

Phase 2 of the bridge lift mechanism refurbishment was completed. The scope of work for this phase includes replacement of the hydraulic pump (including dump valve) and associated controls hardware, plus some portion of the hydraulic tubing which interfaces with the pump itself. Work was completed by Hyseco under work permit C2024-10-02-2.

The pump was integrated such that existing operator control functionality was maintained, except for one difference: with the new system, the pump does not run all the time when the operator turns the "pump on" switch on. Rather, the pump is turned on during the action of raising/lowering. This was deemed acceptable by operators.

During installation, flow rates were adjusted by Hyseco techs to achieve the desired performance in terms of raising and lowering speed. It has been noted that raised appears to be slightly more smooth and even than previously. Lowering behaves similarly to previous. Furthermore, the new pump is much quieter.

Due to the relative simplicity of this system, a full commissioning report was not created, but the following commissioning tests were performed multiple times between 2024-10-14 and 2024-10-15:

• Turn pump enable on
• Raise bridge to maximum upper limit and confirm it stops automatically
• Lower bridge to rest on centre post support stand
• Dump to fully disengage cylinders

These tests were successfully completed and witnessed by A. Newsome, T. Cave, R. Sykes, J. Zhang, N. Jorgenson, M. Dalla Valle, and the Hyseco techs. Therefore, the system is considered commissioned and operational. Some minor wiring cleanup remains to be done and the system will be tested again multiple times prior to shutdown. A maintenance manual will be requested from the vendor.

The old pump will be kept for ~3 years as a spare.

Update 2024-10-21 [AN]:

For reasons unknown, the system is no longer functioning. There are two issues, which may be related or may not be:

1. Previously during the aforementioned testing the hydraulic pump motor was powered via 120 VAC wall outlet. Now it is being powered from our Carrier (ultimately from the blue power supply box in B2 level). There are large line losses associated with this. We measure approximately 35 VAC drop at the input to the pump when attempting to run the system. Because of this, the 24V supply located in the pump's control box used for enabling the motor and for the relays is dropping out, which turns the pump off immediately and causes chattering. When this 24VDC supply is separately powered from wall outlet, it does not drop out, but still the large line loss voltage issue remains for the pump motor. Based on an estimate of around 100 ft long wiring, the line losses measured suggest an inrush current of approximately 50A. This seems relatively high given the pump's FLA of 10A. This should be investigated further. Perhaps it is related to the second issue listed below, or perhaps the motor should be switched to 240 VAC, or perhaps the wiring should be changed from 14 AWG to 10 AWG to reduce losses.

2. When pressing the "down" button, the system moves up. There is no way to move down aside from dumping. Even when disconnecting the control signals entirely from the valves and manually pushing them in, both valves cause upward motion. Suspect an issue with hydraulic line plumbing or the valves themselves.

Hyseco engineer will be contacted and further troubleshooting will take place this week. This log will be updated accordingly.

Update 2024-10-29 [NJ]

The issue of the system moving up when pressing down is resolved. Hyseco engineer returned to repair. It was determined the the relief valves by nature have some leakage and because the flow control valves were so tight more fluid was travelling through the leakage than the control valve. The relief valve was moved to be before the flow control valve, which seemed to resolve the issue.  Additionally one of the pressure gauges was replaced.