The crane pendant for the main hoist was upgraded to a FLEX EX2 style pendant by Canco Cranes. The installation work was performed by Matt at Canco, supervised by Tom Kauss, David Wang, and Adam Newsome. Installation work was performed in two phases since the initial installation did not provide adequate range and an antenna issue needed to be resolved (I2021-01-14-1, and I2021-02-16-1).

Items installed include:

• New pendant
• New antennae
• New receiver box, mounted on main crane control panel in the crane control room

The old receiver control box will be kept for some time in case there is a need to revert to the previous system for some reason.

The new system was tested by David Wang - including using the pendant at the far end of the target hall where range was previously an issue. Everything is reported to be in working condition. Remote mode is functioning as expected.

In mid-2020 design analysis was completed on the steel plate & pin assemblies (ITA6550) used to connect the ISAC target hall crane hook block to the module lifting yoke assembly ITA0494.  The released design note is Document-184431.  

In November 2020 fabrication was completed on two full plate & pin assemblies (photos attached below).  As per the relevant ASME standards (identified in the design note), each assembly has been identified with serial numbers (#1 and #2).  Material test reports for the steel plate and round bar material used for fabrication are attached in PDF format.  For both materials the tested tensile yield strength (from the MTR) exceeds the value used in design calculations (from Document-184431):  117ksi vs 100ksi for the plate material;  138si vs 103ksi for the round bar material.

On February 8, 2021 both plate and pin assemblies were load tested by David Wang and Frank Song.  The total load applied to each was 31,400 lbs (as per the ISAC target hall crane load cell) which exceeds the 125% of rated capacity (31,250 lbs) required for the test.  The lifts were conducted successfully and no deformations or other damage to the assemblies were observed.  Photos of the load test are also attached.

Both plate & pin assemblies are now certified for use up to their rated capacity.  As specified on drawing ITA6550 and in Document-184431, a monthly visual inspection must be performed to check for structural deformation, cracks, excessive wear, and loose or missing fasteners.  In addition, an annual inspection must be performed to check for structural deformation, cracks, excessive wear, loose or missing fasteners, and missing or illegible markings or safety labels.  A written record of the annual inspection must be documented and kept readily available.

The crane pendant for the auxiliary hoist was upgraded to a FLEX EX2 style pendant by Canco Cranes. The installation work was performed by Canco, supervised by Tom Kauss and David Wang. Installation work was performed in one day (I2021-03-26-1).

Items installed include: new pendant (2 motion, 2 speed)

The existing antenna and receiver box located in the Target Hall were used.

The new system was tested by David Wang. Everything is reported to be in working condition.

An issue was observed in which the target hall crane was not functioning: the N-E-S-W and up/down motions did not work, however the rotation motion did work. These symptoms were similar to what was observed in the past under https://elog.triumf.ca/TIS/RH-ISAC/2039 and https://elog.triumf.ca/TIS/RH-ISAC/1845

The crane control console was not powered (i.e. pressing the ON/OFF buttons when the selector switch was set to remote mode, even when safety conditions were met, did not enable/disable remote functionality). The power supplies were checked and everything appeared to be powered as would be expected, except for items which depended on the main contactor (O-K1) being energized. This contactor needs the PLC to be in an operational state, fault-free. The PLC was checked and the red fault light was flashing. The battery light was not on (i.e. battery was OK).

The program was re-downloaded to the PLC. During an attempt to go online with the PLC, error code 0004h appeared (see attached image for description). This is an unfamiliar error code - typically the aforementioned symptoms arise due to a battery failure and the program being lost. In this case it is uncertain at this time what the cause of this fault is. It will be monitored in the future to determine if it occurs again, and further investigation will be performed.

After re-downloading the program and placing the PLC in RUN mode, the crane was fully restored to its operating state - the main contactor was able to be energized once again. The crane was put into remote mode and a brief functionality test on the motion axes was performed: OK.

Tom Gauss inspected  two target module lifting frames ITA0494-1997-01 and ITA0494-1997-02.. He certified the use of these two frames. Inspection tags have been issued and attached to frames. He has inspection record on them. See attachments.

Tom Kauss inspected target hall crane below hook attachment pins and plates ITA6550-01. He certified the use of these pins and plates. The inspection of these pins and plates was in Target hall crane annual check list. It was issued as a calibration index by Isaac Earle in 2022-Feb-08.  After inspection, The inspection tag  was issued and attached to pin. Tom has an inspection record on this job. See attachments.

Tom Kauss finished target hall overhead crane annual inspection today. The crane works fine. He issued new inspection tag and e-logged the job. 

[edit 2023-01-03] The crane was powered back on this morning - there do not appear to be any faults and it seems that the crane was unaffected by the power outage.

The ISAC target hall overhead crane was powered off for the holidays. Note that this may result in the commonly observed PLC battery failure issue when the crane is powered back on in the new year.

Tom Kauss inspected target hall crane yesterday. The crane works fine. Tom has this inspection record in his file. The inspection tag has been issued.

Tom Kauss  finished TH crane annual inspection yesterday. The crane woks fine. Tom has this inspection record in his file. The crane inspection tag has been issued for 2023.

Tom Gauss inspected  two target module lifting frames ITA0494-1997-01 and ITA0494-1997-02 yesterday. He certified the use of these two frames for 2023. Inspection tags have been issued and attached to frames. He has inspection record on them. 

Tom Kauss inspected target hall crane below hook attachment pins and plates ITA6550-01 yesterday. He certified the use of these pins and plates. The inspection of these pins and plates was in Target hall crane annual check list. It was issued as a calibration index by Isaac Earle in 2022-Feb-08.  After inspection, The inspection tag  was issued and attached to pin. Tom has an inspection record on this job

The pail handling tool which is used to move 5 gallon pails around the target hall was inspected by A. Newsome, N. Jorgenson, and E. Lahe. The main tool as well as spare were checked for the following items. The tools are in good, working condition. It is noted that some fasteners on the hook assembly were slightly loose, but have been tightened.

• Inspect structural integrity of long tube - check for bending, warpage, dents, cracks, rust/corrosion
• Inspect structural integrity of hook assembly - check for bending, warpage, dents, cracks, rust/corrosion
• Inspect fasteners - check all fasteners installed as per drawings, fasteners are tight
• Inspect crane interface assembly - check for damage and wear where the tool connects to the crane
• Check alignment - verify the tool connects to the crane and hangs vertically with no major misalignment (this step was not done - alignment is regularly checked during operations, and there was no concern as the tube was straight)

 Note: these tools are being inspected monthly by D. Wang and F. Song.

In an effort to clean up the camera installation on top of the ISAC target hall crane to resolve a fault, the position measuring tape and its associated camera were removed from the target hall crane on July 31, 2023.

Still to do: clean up power bar installation.

 The cleanup of the ISAC Target Hall crane and installation of the new SICK laser which replaced the IBEO laser for the EW crane position was completed on Aug 03 2023.

The clean up tasks which were completed: (Removal of tape viewing camera, Removal of tape, Installation of extension cord, Consolidation of power supplies for the lasers and removal of old laser) 

Currently power bar is still present to act as an extension cable. This will be removed when 2m extension cord is made and put in next target exchange cycle.
   

The installation and testing of new SICK Laser:

1. Calibration points were taken at the 4 corner limits of the crane. North South and East West positions were recorded.

2. Crane was parked at the ladder access position and mounting bracket was machined and installed.

3. A new cable was made and installed for the SICK laser. Continuity test was performed from the control room and crane to ensure pinout of the laser worked with existing serial communication setup in the control room PC.

4. The feedback values from the new SICK laser and old IBEO laser were compared to determine that a calibration offset of 0.06m was needed in the Laser Position Feedback program.

5. Laser Position Feedback program was re-compiled to communicate with 2x SICK lasers with the calibration offset value included in the EW feedback position. (Laser Crane PositionDlg.cpp)

6. Calibration points were taken at the 4 corner limits of the crane again with the new Laser. North South and East West positions were recorded.

There was less than 0.1% variance between the new laser and old laser which is well within the tolerance of the lasers themselves. It can be determined that it was properly calibrated.

It is reported that the crane's hook rotation is not working currently. It was working yesterday (Nov 22). Investigation to follow, and this e-log will be updated.

Edit [2023-11-23]: the issue was a result of a tripped circuit breaker. Perhaps the motor became overloaded. It is advised to monitor the rotation mechanism over the new few operations, and rotate the hook CW and CCW prior to performing any critical operation to confirm it is working.

Tom Kauss finished TH crane annual inspection yesterday. The crane woks fine. Tom has this inspection record in his file. The crane inspection tag has been issued for 2024.

Tom Gauss inspected  two target module lifting frames ITA0494-1997-01 and ITA0494-1997-02 yesterday. He certified the use of these two frames for 2024. Inspection tags have been issued and attached to frames. He has inspection record on them. 

Tom Kauss inspected target hall crane below hook attachment pins and plates ITA6550-01 yesterday. He certified the use of these pins and plates for year 2024. The inspection of these pins and plates was in Target hall crane annual check list. It was issued as a calibration index by Isaac Earle in 2022-Feb-08.  After inspection, The inspection tag  was issued and attached to pin. Tom has an inspection record on this job.

The pail handling tool which is used to move 5 gallon pails around the target hall was inspected by A. Newsome. The main tool was checked, but not the spare as it is currently in a disassembled and unusable state. The tool appears to be in good, working condition. The following items were checked.

• Inspect structural integrity of long tube - check for bending, warpage, dents, cracks, rust/corrosion
• Inspect structural integrity of hook assembly - check for bending, warpage, dents, cracks, rust/corrosion
• Inspect fasteners - check all fasteners installed as per drawings, fasteners are tight (note: one fastener on crane interface subassembly was loose - all fasteners in these subassembly were tightened as a precautionary measure)
• Inspect crane interface assembly - check for damage and wear where the tool connects to the crane
• Check alignment - verify the tool connects to the crane and hangs vertically with no major misalignment (this step was not done - alignment is regularly checked during operations, and there was no concern as the tube was straight)

 Note: these tools are being inspected monthly by D. Wang and F. Song.

Photos can be found in G:\remote handling\Facilities and Projects\ISAC\Pail Handling Tool\Inspections\June 2024

IMPORTANT: the maximum load capacity and lifter tag for the tool are not present. There is a plan in place to affix these two labels in the very near future.