The new EX4N housing assembly drawing TEC0071 (unfinished) was installed and connected to the EX4 tank side port flange over a 3 day period from Feb29 – Mar 2, 2016. This was a hands on installation spread amongst 5 people with the total accumulated dose was 2.97 mSv.  See W/P C2016-02-29-5
 

Attached are;

- Rad field survey map.
- Updated installation procedure (rev4) with additional notes/comments during the installation  Revisions in Red.  Competed steps in Green. 
- Photo of the EX4N housing assembly.

Recent photos, are on Dimo's S drive :S\dyosifov\Extraction 4\Photos 2016

All copper blocker removed from the cyclotron and first radiation survey done. Shields start tomorrow.

Over 50% of the shields are in some 700's left and the monitor box covers.

Day one of RH in tank work for the cyclotron (shields and blockers stuff like that) many pictures were taken.

All shields, ladders and pothole covers are in. One rad survey left to do.

Final Radiation Survey done. All in tank work completed bridge removed from the tank.

Lid up procedure Started at  12:00pm. Initial numbers. # 1-47,2-49,3-45,4-47,5-47,6-47,7-49,8-45,9-50,10-50,11-51,12-49. After a number of unsuccessful attempts at jogging the system and trouble shooting it was decided to suspend operations record numbers  and resume on Feb 2nd. Final numbers for Feb 1st #1-1289,2-1297,3-1288,4-1295,5-1283,6-1298,7-1287,8-1289,9-1290,10-1296,11-1287,12-1296.

Feb 2nd commence lid up operations at 11:30 am .When Maico Dalla Valle and my self arrived Dan Louie and Arther Leung had attempted to trouble shoot elevating issues and lowered the lid in hopes that raising would be smoother . The counter numbers on our arrival where as follows station   # 1-2856,2-2858,3-2848,4-2857,5-2855,6-2861,7-2856,8-2857,9-2852,10-2862,11-2860,12-2859. After Discussion between Grant Minor, Dan Louie and all involved it was decided to lower the lid re gap the yokes and reset counters to base numbers ensuring they correlated with master synchro. lowered lid numbers #1-55,2-59,3-55,4-57,5-57,6-54,7-50,8-54,9-59,10-59,11-58,12-59.

At this point we re gapped to .250" with counters at #1-119,2-177,3-123,4-144,5-137,6-120,7-123,8-111,9-127,10-148,11-128,12-117. After comparison with Dan L and the Master Synchro, stations #2,3,4,5,10 where jogged to better match the average on the counters and synchro these stations where put at 120 on the station counters. Once this was completed we started final lid up operations stopping at 5" to check tank seal, once it was confirmed the seal was not sticking we continued uninterrupted  to final lid up position. #1-16947,2-47366,3-47351,4-47365,5-47362,6-47365,7-17495,8-47358,9-47360,10-47366,11-47362,12-47363. Counters #1 #7 appear to be failing, they will be changed out and indexed to match as needed.

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.

 All cyclotron in tank work has been completed.

The following outlets were installed by Electrical Services Group in order to facilitate upgrading power supplies for Cyclotron Remote Handling, as per Work Request 5289:

• 2x 15 Amp outlets
• 2x 20 Amp outlets

The four breakers for these outlets are located in the panel adjacent to the main entry door to the electrical lab. The outlets are located in behind the control console.

The pendant used for controlling the orbital motion of the bridge mockup was upgraded. Features of the new pendant include:

• One cable to controller (formerly two cables required)
• Ergonomic and robust form factor of pendant
• Easily modifiable button/contact setup, with spare button space
• Extended cable to reach anywhere in the room

Pictures attached show before and after.

Measurements of the cyclotron magnet face gap were taken on March 15, 2013 at two locations around the tank with the cyclotron lid in the fully raised position (the lid had been raised until the upper limit switches caused the control system to stop travelling).  The purpose of the measurements is to establish an independent means of verifying correct lid height before beginning in-tank remote handling activities at the start of a shutdown period.

The height of the lid at the time of measurement was confirmed to be adequate for the bridge to perform a full orbit without any interference between the bridge or cable tray and devices on the lid.

Measurement locations were labelled using permanent marker.  A plumb-bob was used to ensure the measurement location on the upper and lower faces were aligned vertically.  The measurements were performed using a tape measure hung from the upper magnet face and read at the lower magnet face as shown.

Location #1: RH bridge entry/exit point (~50° position), Measured gap: 46-1/2" +/- 1/16"

Location #2: East side of jack station #1 (~215° position), Measured gap: 46-9/16" +/- 1/16"

Photographs of the upper limit switches on jack stations #1 and #10 were taken as shown below:

At this lid height, the reference stick on the top of the cyclotron lid was found to be touching the concrete ceiling, but was not bowed.  See photo below.

 The distance between the cyclotron tank lid and the RH bridge was then measured using a meter stick attached to the lift trolley.  The trolley was moved into the tank, and the stick raised until it contacted the tank lid.  This position was recorded, the stick was lowered, the trolley was removed from the tank, then the stick raised again to the recorded position.  A piece of aluminum angle was used to translate the measurement from the center of the trolley to the edge of the bridge as shown below:

Total Distance from RH Bridge Rail to Cyclotron Tank Lid: 15-7/16" + 6-5/16" = 21-3/4" +/- 1/8"

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: 

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.

Lid was raised today (2nd time during 2015 shutdown) for additional inflector work.

Dan and Maico report that the lid went up smoothly and no jogs were required.  The operation took about 30 minutes.

- Grant

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

Remote Handing is ready for January, 8 2018 Cyclotron lid up. Elevating system service has been completed.

A Cyclotron Lid raise was attempted on Monday, January 8 at 12:00, however this attempt was aborted after lifting the lid several millimeters due the motor
brake on Station #9 that would not release properly. After troubleshooting the elevating system for several hours, motor brake wires were disconnected from
the motor terminal block at the station and pulled through the vertical conduit down the B2 level below the Cyclotron for further inspection. The inspection
showed severe damage to the wire insulation and conductor over an 18" interval, which corresponded to the position directly across the mid-plane of the
cyclotron. New wires were spliced to the existing wires at the bottom of the vertical conduit section, which were run through the conduit and reconnected to
the motor terminal block.

The motor drive wires on Station #9 were also removed for inspection, which revealed major damage to the wire insulation over the same 18" interval;
however, the conductor remained intact and was covered in electrical tape and re-run through the conduit vertical and reconnected to the terminal block. The
elevating system was then tested and the motor brake on Station #9 released as expected.

The Cyclotron Lid was successfully raised on Monday, January 8 at 20:00. The initial station readings are shown below:

00075 - Master
00045 - Station #1
00044 - Station #2
00042 - Station #3
00045 - Station #4
00044 - Station #5 
00044 - Station #6
00045 - Station #7
00044 - Station #8
00044 - Station #9
00047 - Station #10
00048 - Station #11
00045 - Station #12

The final lid-up station readings are shown below:

47422 - Master
- Station #1
- Station #2
- Station #3
- Station #4
- Station #5 
- Station #6
- Station #7
- Station #8
- Station #9
- Station #10
- Station #11
- Station #12


The Cyclotron Lid was lowered on Tuesday, February 20, between 11:30 and 12:00. The final station readings are shown below:

00081 - Master
00086 - Station #1
00089 - Station #2
00054 - Station #3
00016 - Station #4
00087 - Station #5
00087 - Station #6
00085 - Station #7
00083 - Station #8
00086 - Station #9
00087 - Station #10
00089 - Station #11
00088 - Station #12

While lowering the lid, the following observations were made:

- The left High Field gear reducer on Station #1 made noise intermittently during the middle of the lid lowering operation
- The right High Field gear reducer on Station #2 made noise intermittently during the end of the lid lowering operation
- The right High Field gear reducer on Station #11 made noise intermittently during the beginning of the lid lowering operation