The mirror actuation mechanism was observed to be "sticky" during 2023 winter shutdown - it occasionally did not function properly and needed some manual assistance. 

The following items were addressed to resolve the issue: 

• Replacement of the Tyne Myte double acting valve which controls the cylinder (based on troubleshooting tests, it seemed this valve was not functional or intermittently functional)
• Addition of a silencer and in-line flow control on the exhaust of the aforementioned valve - adjusted to allow for smooth operation of the mirror when toggled
• Cleaning of the cylinder's shaft (it had a sticky residue build-up and was notably high friction) - this cylinder should likely be replaced in the near future 
• Replacement of air tubing along the supply line to the valve, and between the valve and cylinder
• Replacement of all fittings (push-connect style) on the valve and cylinders

The mirror actuation was tested after these changes and is behaving normally.

No further repairs required, although it is suggested to change the remainder of the tubing and fittings for the other valves which control different functions on this trolley, and to eventually upgrade the valves themselves to a low profile valve bank. 

The two camera tilt mechanisms on the lift trolley have been upgraded. Upgrades include:

For the individual camera:

• Replaced cylinder
• Replaced fittings for cylinder
• Replaced air tubing from flow control to cylinder
• Visual inspection and fasteners tightened

For the overall platform containing the camera and lighting:

• Replaced cylinder
• Replaced fittings for cylinder
• Replaced valve (5/3 centre closed style)
• Replaced air regulator and set pressure (note: at the time of writing this e-log, it still needs to be fastened in place via its mounting bracket)
• Replaced air tubing
• Visual inspection and fasteners tightened

Outrigger #1 and #2 have had their controls system overhauled as part of the O503 project. The previous controls enclosure and the elements have been replaced with a new aluminum enclosure which contains DIN rail relays, a 5V power supply, and a +-12V Power supply. The new centrepost slave PLC unit handles the control logic of OR1, OR2, the Bridge and is connected to the main PLC in the control room through Ethernet. Both outriggers were tested individually.

Systems Tested:

Vertical Drive - Up, Down, 5V Position (Inches) Potentiometer

Radial Drive - In, Out, Encoder (Inches) 

Shoulder Drive - Home, Out, 5V Position Potentiometer (Deg) 

Elbow Drive - Home, Out, 5V Position Potentiometer (Deg) 

Wrist Drive - Pan Left, Pan Right, Tilt Up, Tilt Down, 5V Position Potentiometer (Deg)

Camera - Zoom In, Zoom Out, Focus Near, Focus Far

Testing Methodology:

We used the control panel which the Outrigger operator will be using during shutdown to confirm that the buttons translate to correct movements of each individual system. Direction control for the motors is done with relay switching of 24V to flip the polarity applied to the motors. +-12V is used for the zoom focus control of the HCZ-6320N camera. Correct movements was observed for both outriggers.

Position feedback was calibrated by adjusting the potentiometer's voltage to 2.5V at the mid point and spanned from 0V at low end to 5V at high end. Correct positions for both outriggers was observed on the HMI screen.

Next Steps

Testing the bridge orbit drive, orbit encoder, centrepost camera, centrepost light, both OR1 and OR2 simultaneously.

The "old" video trolley featuring scissor mechanism and DSLR camera has officially been decommissioned. Going forward, Video Trolley Mk 2 (TRH1089D) will be used.

The original end feet and end caps were removed from the maintenance ladders and replaced by new end caps (TRH1637).

The vault shield door has been closed and seal inflated. The operation was performed with no issue.

The lid down operation took place on Mar. 31, 2023.

The system was energized a few minutes ahead of time.

Starting Master Synchro value: 47388. The master synchro was jogged up prior to starting to approximately 47395.

Upon startup at 10:38 am, the system worked fine and lowered the lid. No stops occurred and the lid lowered smoothly. No abnormal observations made. The lid was completely lowered at 11:05 am.

See attached summary.

During the 2023 shutdown outrigger 1 failed. While performing the HE Probe removal we found that the outrigger could only travel vertically about one inch in each direction.

Upon further inspection we found that the linear bearings had been pulled off the ball screws. And 2/3 of the ball screws had been bent. Additionally one of the linear bearings broke and was missing some of the balls, the parts were later found inside the tank.

The event that caused the failure is unknown, but one guess is that while the outrigger was in the home position the shoulder joint was opened before the elbow joint.

The outrigger was repaired on March 21st, using parts from the old outrigger. After the shutdown the parts should be replaced again with new parts. Additionally it was observed that the linear bearings are quite old so they should be replaced on outrigger 2 also.  See photo for details on which parts where repairs or replaced.

Update 2023-09-01: Both outrigger 1 and 2 had the linear bearings replaced with brand new bearings. Note that the same brand and part number was used (Thomson super-12-OPN ball bushing), however the quality of the new ones seems to have decreased and likely will not last as long as the previous ones. It is recommended that we review if they need to be replaced again in 5-10 years. 

 Annual Jack Inspection: The annual elevation system inspection has been completed (Jan 31,2023).

At station 1, Highfield gear Jack 13R needs a coupler seal replacement. It is ok for this shutdown, but should be replaced before next shutdown.

During the lift, station 7, Right Highfield was running a little rough - should also be checked before next shutdown. 

All motor and gearbox temperatures recorded during lift were consistent to temperatures recorded in the past. 

The full service to two jacks are not being completed this year. 

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.

The lid up operation took place on Jan. 30, 2023.

The system was not energized well ahead of time to allow to "warm up", as is usually done.

Starting Master Synchro value: 62

The Master Synchro was jogged to a value around 2 prior to starting, to allow it to lag behind the jacks.

When first starting: after a few attempts to raise, it was determined that the master synchro value needed to lag behind the other synchros more than initial suspected. This was changed, and the system operated smoothly for a short time.

During lid travel, station 5 and station 11 both caused trips and needed to be manually jogged to match the rest of the stations. The system was restarted, and more trips occurred. Stations 7 and 10 were adjusted as well. Eventually, after adjusting a few stations, the lid travel smoothed out and no more issues were observed for the remainder of the operation.

The system was stopped at approx. 3 inches of travel (synchro count 5255) to inspect the seal, etc. Everything OK.

No major issues with any jacks. No overheating observed.

Jack 11 showed occasional noise spikes on readback (this happened in 2021 and 2022 as well - suggest replacing this station's synchro next).

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

Ending Master Synchro value: 47388

The attached spreadsheets show all synchro values before and after the operation, as well as jack station infrared heat measurements.

Start time: 9:23 am
End time: 10:53 am (includes gap measurement, etc. - actual lid travel finish was a bit earlier)
Total time to raise was approx. 1.5 hr.

Doses:
Adam Newsome: 0.005 mSv
Maico Dalla Valle: 0.121 mSv
Eric Lahe: 0.056 mSv
Ryan Anderson: 0.017mSv
Kevin Lucow: 0.060 mSv
Ed Parton: 0.007 mSv
Jason Zhang: 0.025 mSv
Nadia Jorgenson: 0.005 mSv
Arthur Leung: 0 mSv
Dan Louie: N/A

[edited 2023-09-8 to fix typo - Adam Newsome]

The vault crane annual inspection was completed by Tom Kauss.

The wired pendant was replaced with a remote pendant by Tom Kauss.

Under work permit C2022-10-04-1, the motor contactors for jack motors 1 through 12 were replaced. The contactors showed signs of corrosion.

The LE1/LE2 Probe Frame was mounted on the Upper Resonator Trolley in the mockup with the intention of confirming functionality and making some updates to the probe installation/removal procedure document.

The following updates were made to the LE1/LE2 Probe Frame and the Upper Resonator Trolley:

• Additional holes drilled and grommets installed in the trolley's valve bank mounting plate to support all of the air cylinders on the Probe Frame
  
• All old brass fittings replaced with quick-connect style fittings
• All air tubing replaced with new polyurethane tubing
• Flow control valves installed
  

The air cylinder functionality was tested in the mockup and working as expected. In the future, a full mockup procedure will be performed in order to confirm camera views as well as finish updating the procedure document.

 The vault shield door has been closed and seal inflated. The operation was performed with no issue.

 We removed the left bushing that is around the air cylinder on the festooning rail, right outside the cyclotron. It was cracked. Will need to replace next year when the vault door opens again.

The rope and pulley system that is used to raise the festooning rail across the vault shield door has been re-routed. It now makes use of all three pulleys and is easier to raise and lower without interference. 

All of the old brass air fittings on the Tool Trolley have now been swapped over to push-connect style fittings. As these are plastic fittings, it is recommended to inspect them after ~5 years for degradation.

The lid down operation took place on Apr. 27, 2022.

The system was not energized well ahead of time to allow to "warm up", as is usually done.

Starting Master Synchro value: 47387

Upon startup, the system worked fine and lowered the lid.

After some time, jack station 12 became out of sync with the master synchro. It needed to be manually jogged to adjust its synchronicity. After it was adjusted, the entire operation went smoothly and the system did not automatically stop again.

No major issues with any jacks. No overheating observed.

An issue was observed in which radial motion on the Video Trolley Mk 1 did not respond to commands. After troubleshooting, it was determined that this was due to the "OP LIMIT" interlock - the "OP LIMIT" pushbutton on the console was illuminated in red, and needed to be continuously held down in order to operate the radial in/out motion buttons.

It was determined that the root cause of the issue was a failed radial limit switch which was likely damaged during trolley transport. The limit switch was replaced, and functionality was restored.