A safety walkaround for July 2024 was completed for the B1 and B2 levels by A. Newsome, and for the main shop and back shop by R. Sykes.

Results can be found in the master spreadsheet

Major deficiencies, main shop:

• Unpainted lead bricks need to be picked up. This was requested of mechanical services twice already in July 2024. Follow up next inspection if not removed.
• Nearly half bulbs burnt out - enough to warrant replacement. AN requested of electrical services on 2024-07-17. Follow up next inspection if not replaced.

Major deficiencies, back shop:

• Phone not working. AN created help ticket 2024-7-17. Follow up next inspection.

Minor deficiencies, B1 level:

• 4-5 light bulbs will need to be replaced soon, not urgent yet.

Major deficiencies, B2 level:

• On the outboard support frame, the lifting eye fastener was stripped which prevented the nut from tightening all the way, posing a rigging hazard. The damaged lifting eye was replaced with a working one 2024-07-15.
• Light fixture above bootbox - mounting damaged and hanging precariously. Reported to electrical services 2024-07-15 and informed common users of area.
  Update 2024-07-17 - the issue has been resolved.
• Probes group has rad-waste in the middle of the floor. Reminded them to dispose of it soon.

A safety walkaround was completed for the RH Shop, Back Shop, B1, and B2 levels.

The resulting spreadsheet can be found on DocuShare as Document-242733.

Main deficiencies identified:

• Main Shop:
  
  • Lifting equipment has overdue inspection
  • Light bulbs burnt out
  • Unpainted lead has not been removed
• B1:
  
  • Crane has overdue inspection
  • Lifting equipment has overdue inspection
• B2:
  
  • Crane has overdue inspection
  • Lifting equipment has overdue inspection

Action has been taken on all deficiencies.

A safety walkaround was completed for the RH building B1 and B2 levels.

The resulting spreadsheet can be found on DocuShare as Document-242733.

Main deficiencies identified:

• B2:
  
  • Low on booties stock (more have been ordered)
  • Rad waste from Probes group remains in the middle of the floor (requested RPG to ask them to remove it)

Action has been taken on all deficiencies.

A safety walkaround was completed for the RH building shop and back shop.

The resulting spreadsheet can be found on DocuShare as Document-242733.

Main deficiencies identified:

• Main shop, ground level:
  
  • Lighting still needs to be replaced (this was previously requested of electrical services and they are aware of it)
  • Unpainted lead bricks still need to be picked up (this was previously requested of mechanical services and they are aware of it)
  • Rad waste needs to be picked up (will do soon)

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.           

Lid-up was first attempted yesterday (Jan 28th) by Dan Louie, Arthur Leung, and Maico Dalla Valle.  They experienced problems with Station 9 continually tripping the system and were not successful.

This morning again there were problems raising the lid above ~1 inch due to tripping at station 9.  It was observed that the mechanical counter at Station 9 was increasing about 5 to 6 times faster than the counters at the other stations.  There may be a mechanical problem with the gear reduction for this counter.  However, the mechanical counter is just a readout and does not control any aspect of the lid up.   Comparisons between stations 9 and 10 at the 1 inch trip point are shown below.  Station 10 is representative of the other stations within about 100 counts. 

The lid was lowered fully and the gap between the yoke and the upper structure primary beams was measured by Maico at one spot per station with 1/4" stock and feeler gauges (see attached reference photo from 2012).

Not much could be concluded from the measurements.  The control system is supposed to keep the jacks parallel within about 50 thou, however Stations 1 and 11 appeared to be out by 180 thou.  It is difficult to say without further study whether this larger discrepancy is due to overshoot at each station after the lower limit switches are reached.

Grant Minor, Dan, Maico, and Arthur met in the Main Control Room at around 1:30pm to assess.  Dan commented that Station 9 was continually lagging in the system and causing the ~1 inch trip.   The decision was made to drive the whole system to the ~1inch trip point and then jog Station 9 manually to bring it back into the "go" band of tolerance, and continue on this way until the "sticky" portion of travel was overcome.  In Grant's opinion, the transmission system at each station (motor, reducers, jacks, and upper bearing) sits dormant in one position for a full year each year and settles in a single position.  Some asymmetry in the static and dynamic friction from station to station is expected after such a long idle period.  Additionally, the lubrication at station 9 has not been serviced since 1996 (18 years).  Grant also felt that jogging the system in small increments to bring it back into the tolerance band should not damage the jacks, motors, or reducers provided they were carefully monitored for abnormal noises or overheating.

The sequence of events following the 1:30pm meeting is outlined below:

- The system tripped as expected around 1 inch.

- Station 9 was jogged upwards 20 thou, measured with the dial indicator.  Station 9 counter increased from 9255 to 9429.

- The entire system was run upwards by about another inch with several more trips, some from Station 9 and some from other stations.  Dan reset the system after each trip.

- At around 2 inches, Station 9 was jogged again.  Maico reset the dial indicator and attempted to jog manually but the dial did not move.  This might have been due to the lag at Station 9 creating some amount of backlash before the load was taken again.  He reset the dial again and this time measured a jog of 25 thou.  Dan asked us to back off by 20 thou, then he reset the system and we continued to raise.

- The system was raised to about 3" in small increments with several more trips, each time reset by Dan.  Station 9 was jogged 3 more times during this period by 10 thou each time, at approx. counter readings 16 362, 16 802, and 17 134.

- The system then ran properly for quite some time and tripped at around 6 inches.  We stopped to inspect the tank seal, which was OK.

- The system was reset by Dan and run again to about 10 inches, at which point station 1 tripped.  Station 9 counter read 60 775, Station 11 counter read 10 829 (again a factor of 6 discrepancy).

- Dan requested a jog of 10 thou at Station 1, and then we continued to run.  The system ran with only a couple of trips up to about 1 foot from the upper limit.

- At around 1 foot from the upper limit, Station 7 started to cause tripping.  It was jogged 10 thou and we continued all the way to the upper limit.

(Total travel is approximately 48 inches or 4 feet).

During the course of the work, it was observed that the motor at station 9 was getting hot early (around 2 to 3 inches of travel), but the motors at other stations (e.g. Station 11, Station 1) reached about the same temperature to touch after the system was running properly.

Report by Grant Minor, P.Eng.

Dan Louie's e-mail comments from 30 Jan 2013 are attached.

- Grant

Due to concerns raised regarding the state of the lubrication of the power screws at Station 9, the lubrication was visually inspected by me and Ron Kuramoto on February 4th.

Photos are attached.

The power screws for these stations were serviced and re-lubricated on the following dates:

Station 9 - 1996

Station 10 - 2001

Station 11 - 1997

Station 6 - 2011

There did not appear to be any major visual differences in the lubrication between any of these stations.  The grease at Station 9 appeared to coat the power screw uniformly through its range of travel, and there were no major signs of drying, hardening, or separation of the constituents relative to the other stations inspected.

There is a slight apparent difference in the opacity of the grease between Station 9 and Station 6 in the photos attached, but this may be due to the lighting and camera flash at the angle taken.

There did not appear to be any flecks of metal, contaminants, or other signs of abnormal wear in the grease.

The mechanical properties of the grease at Station 9 vs. virgin grease would have to be assessed by a tribologist in a laboratory setting from samples.

Samples of the grease were not collected at this time, but could possibly be collected in the future when Station 9 is removed for service.

Attached is a compiled record showing the years of service of the jacks, upper bearing, and gear reducers, prepared by Grant Minor on December 17 2012.

Attached is a scan of a handwritten record from 1994 showing yoke-to-upper-structure gap measurements from 1994, both L and R sides, with tank under vacuum and vented.

The measurements appear to be made with a 0.25" shim and 0.01" pieces of shim stock as they are only in increments of 10 thou.

The 1994 gap appears to vary from 0.25" to 0.33" (80 thou max variation) under vacuum, and from 0.29" to 0.33" vented (40 thou max variation).

Our 2013 measurements, made with a 0.25" piece of stock and a feeler gauge, varied from 0.265" at Station 1 to 0.445" at Station 11, (180 thou max variation, see Jan 28 e-log).

I have not yet found any other records of this measurement but I will keep searching.  The gaps may have varied by as much as 180 thou for many years.

I recommend checking the clearance at all stations and jogging individual stations such that the gaps are within a 40 thou band prior to the next lift.

The dimension between the yokes and the Cyclotron upper structure primary beams was set to .25" nominal at all jack stations today.

At each station:

1. The jacks were jogged manually upwards until the yokes hard-stopped on a piece of .25" nominal shim stock (see attached reference photo, measured accurate within .005").
2. The dial indicator was set and zeroed, and the station was backed off by .005" to 0.010" in order to remove the .25" reference stock (except at station 4 where the dial indicator mount was damaged).
3. After the adjustment, the mechanical counter was decoupled from the output shaft of the jack (without affecting the synchro) and set to "00100".

This work was performed by Maico Dalla Valle and Daniel Wright in co-ordination with Dan Louie.

The defective mechanical counters at stations 5 and 9 were replaced, with a brand new counter at one station and a used repaired counter at the other station.

The yokes at all jacking stations should now be .250" +/- .015" from the upper structure.

There was a brief access period to the Cyclotron vault during April 9 to 12, 2013 due to other Cyclotron issues.

This time was utilized to perform the following Elevating System tasks:

- Drilling of 2 (two) holes for concrete anchors (DBI Sala Product 2100085) for self-retracting lifelines (see TRIUMF purchase order TR197399)

- Installation of 2 (two) ceiling-hung self-retracting lifeline units, one above the climb-up access point to the bearing, and the other above the recently installed outboard safety platform (see TRH1217)

- Complete service of the upper bearing assembly at Station 9 (dis-assembly of bearing races, cleaning off old grease, inspection of races and guide tube, application of new grease, re-assembly of races)

- Tear down of safety handrails for some minor modifications (see upcoming Rev B to TRH1217 and sub-components)

 All work was completed on Wednesday April 10th by Dan Wright and Maico Dalla Valle.

Maico Dalla Valle and Grant Minor, supported by Dan Louie and Arthur Leung, entered the Cyclotron Vault on January 15th, 2014 to check the indexing of the jacking stations.  520MeV work permit 2014-01-15-4 was filled out for this work.

Yoke gaps at all stations were found to be within .005" to .010" of the .25" shim stock, and all mechanical counters were found to read zero.  This is consistent with the recalibration done on March 19th, 2013.

The system is properly indexed mechanically, and ready for lid-up.

Grant

Yesterday Grant Minor (me), Maico Dalla Valle, Dan Louie, and Arthur Leung worked with Operations to perform the Cyclotron Lid-Up task for the 2014 winter maintenance.

Work Permit 2014-01-22-2 was issued for this job.

In general, the lid up operation was rough at the beginning.  The system began to trip-out within about 500 counts on the mechanical counter, just when the jacks started taking the load, then continued to trip within the first ~ 3 inches of travel.  Multiple station jogs, complete lowerings, and complete raisings were required to get beyond the rough spot. 

I tried as best as possible to record the mechanical counters for each trip event, as well as confirm the master synchro count and culprit station with Arthur.  The data I collected is summarized below:

Start of Operation: All stations were indexed with yoke gaps within .005" and .010" of the .250" nominal shim stock (see previous e-logs).  Mechanical counters were all set to 100 counts (each count is approximately .001").

1. First lid up attempt tripped at less than 1" of travel.  Station 9 was found to be lagging adjacent stations.  It as jogged in local mode as shown:

2. Lid was raised again and stalled.  Station 11 was found to be lagging and was jogged:

3. Lid was raised again and stalled.  The decision was made to lower completely and raise again.  All station counters were recorded before lowering:

4. Lid stalled on the way down.  Station 9 was found to be lagging and was jogged:

5. Lid was lowered completely and then raised again.  It tripped at Station 9.  It was examined and found not to be lagging a great deal.

6. System was reset and lid was raised further.  It continued to trip.  Station 9 was examined and not found to be out.

7. Lid was lowered completely and then raised again.  It tripped again, and Station 9 was found to be out.  It was jogged with some intentional overshoot.

8. Lid was raised again and tripped.  The decision was made to lower lid completely.  Some counter values were recorded when the lid had reached the lower limit, for comparison to the starting reference.

9. Lid was raised again and traveled more smoothly until tripping at around 850 counts.  6 counter values were recorded.  Station 9 was found to be lagging and was jogged:

10. Lid was raised again and tripped.  Station 9 was found to be lagging and was jogged:

11. Lid was raised again and tripped.  Station 9 was found to lag very slightly (but within the normal variation band), and was jogged:

12. Lid was raised further and tripped again.  Four of the counters recorded and the group broke for lunch (approximately 1 hr).  The lid was left at this position over lunch.

13. After lunch, the lid was raised up to about 1090 counts with 4 trips.  Counters were read as below:

14.  Lid was raised but tripped almost immediately.  Decision was made to lower again.  Counters at bottom limit were read again:

15. Lid was raised with 3 trips.  Station 9 was found to be lagging and was jogged:

16. Lid was lowered completely, then raised.  It went up fairly smoothly and tripped out at about 1350 counts.  All counters were recorded:

17.  A few more attempts were made to raise the lid with a few more trips.  The system traveled in longer bursts and more smoothly between trips.  Counters were recorded and stations 9 and 11 were jogged:

18. System was reset and lid was raised again with a few more trips close together.  The decision was made to lower the lid completely and raise again.  Master synchro was recorded at 2285 before lowering.

19. Lid was lowered completely and raised fairly smoothly up to a master count of 2363 before tripping out on stations 1 & 9.

20. A few attempts were made to lower the lid slightly (not all the way) and then raise again.  This did not seem to reduce the frequency of trips.  The system tripped out around 2820 and all counters were recorded before taking a short break to allow the contactors to cool down:

21. After the break, there was a raise and lower cycle within about 3600 counts that I was not present for.  When I had returned the system was still rising in small bursts and tripping out on station 9 mostly.  Over a span of 5 trips, Station 9 was jogged 5 times by between 20 and 50 counts, with 20-count overshoot.

22. The master synchro passed 3600 counts and then the system tripped.  Stations 9 and 10 were recorded and Station 9 was jogged:

23.  The master passed 3800 counts, and then they system went up smoothly for the first time by about 1500 counts before stopping. Some counters were recorded:

24.  Lid was raised again and stopped around 6350.  The group paused to check the tank seal and all counters were recorded:

25. The lid was raised further with 2 trips at station 9.  Stations 9 and 10 were checked and station 9 was jogged:

26. Lid was raised again with 2 trips initially and then smooth travel up to a Master count of 9600.  After 3 more trips and resets, I began recording just the station trips and master counts at each trip.  No jogs were required during this period.

27. Jacks 1 & 5 tripped at 10,200 counts on the master.

28. Jacks 1 & 9 tripped at 11,500 counts on the master.

29. Jack 9 tripped at 13,400 counts on the master.  Several trips occurred immediately after this.  Counter readings were taken and station 1 was jogged:

30. Lid was raised again with trips at station 1, 5, 7 & 9.  Master synchro count was 15,600.

31. Lid was raised again with trip at stations 1 & 7.  Master synchro count was 18,800.

32. Lid was raised again with trips at stations 5, 7, and 9.  Master synchro count was 21,650.

33. Lid was raised again with trips at stations 1, 3, 5, 7, 9, 11.  Master synchro count was 23,360.

34. Lid was raised again with trips at stations 1, 5, 7, 9. Master synchro count was 23,700.

35. Lid was raised again with trip at station 9.  Master synchro count was 25,420.

36. Lid was raised again with trip at station 7. Master synchro count was 27,700.

37. Lid was raised again with trip at station 5.  Master count was 27,700.

38. Lid was raised again with trip at station 7. Master count was 30,300.

39. Lid was raised again with trip at stations 1 & 3. Master count was 33,650.

40. Lid was raised with trip at station 7.  Master count was 37,400.

41.  A moaning / groaning noise was heard from the structure around 38,000 counts.  This noise was also observed during the 2013 lid-up.

42. Lid was raised with trip at station 7. Master count was 39,722.

43. Lid was raised with trip at station 1.  Master count was 41,600.

44. Lid was raised with trip at station 9.  Master count was 42,857.

45.  All counters were read and selected stations were jogged:

46. Lid was raised but tripped at station1.  Station one count was found to be behind and was jogged from 42,804 to 42,880.

47. Lid was raised until limit switches were contacted.  All final counter readings were recorded:

***

Photos of the limit switches and the reference "stick" relative to the roof beam are attached.  The stick appears to be between 1/16" and 1/8" clear of the roof beams.

The Cyclotron Lid Down was successfully completed today on Work Permit C2014-03-03-6.

The system only tripped twice on the way down.  Both trips were at Station 9, at the following Master Syncro readings: 43194, 39198.

Oil was observed on the Jack #1 platform, but it was determined that it was coming from the crane when it's parked in the beam-on position, and not actually from the elevating system.

The final counter readings after the lower limit was reached were recorded:

The Master Syncro was recorded at 28.  All station yoke gaps were very loose on the .25" shim, which makes sense, as they are about 70 thou lower than the starting position before lid-up this year (100 counts at each station).

The system was NOT re-indexed.  The decision was made to wait until lid-up next year to re-index.  The lit should be raised until the Master is at about 100 counts, then the yoke gaps checked and adjusted as required.

Regards,

Grant

The cyclotron lid was raised on June 27th, 2014.  Start time was 1:05pm end time was 2:17pm (good!) Dan McDonald collected and recorded numbers from the mechanical counters for the lid up sequence, I am entering the data into the e-Log on his behalf.

Below are the mechanical counter values from the start and finish of the lid-up job:

There were 5 local jogs made to the jacks during the lid up process: 

Cyclotron lid down was successfully completed on July 2 2014. Lid went partially down before jack nine had to be jogged to catch up to system. After thirty min of continual system trips Maico Dalla Valle and I Jogged all stations to 42745. Still encountering continual system trips Gord Roy and Dan Louie removed and reset all relays in system, lid proceeded to lower with out problem. Final jack position recording done at 19:45.

5 x TRH1217 Upper Bearing Service Platform assemblies were installed between January 6th and January 13th at Stations 8, 10, 3, 4, and 5 (see attached photos).

The assembly went very smoothly.  Dan McDonald and Maico Dalla Valle worked together to install the platforms and wore harnesses and lanyards while working on top of the vault crane at each station (see attached photo).

Some notes were observed during assembly:

- There were not enough McMaster Carr 3949T1 3/4" Zinc Plated High Strength Snaps.  Assembly drawing TRH1217 Rev C only calls out 2 of these snaps, but this is incorrect, as 6 snaps are required per assembly.

- The ultra-coated 3/8-16 UNC bolts and nuts ( ref McMaster p/n 91257A634) were found to be very difficult to fasten.  In the future, zinc plated or mild-steel hardware should be used.

Both of the above items must be revised on TRH1217 towards Rev D.

Horizontal DBI Sala lifelines are now installed as well between Stations 8, 9, and 10, and between Stations 4 and 5, to permit access to the stations that do not have a direct ascent up the Cyclotron magnet structure.

All platforms and handrails are now installed on stations 8, 9, and 10 and stations 3, 4, and 5.  This permits full jack and gear reducer service at stations 9 and 4 (as adjacent stations are required for chainfall installation), as well as upper bearing service at all stations with platforms.

Still remaining is the work to drill the holes required for the ceiling mounted Self-Retracting Lifeline units that permit the first ascent and setup of the guardrails at each station.

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.