Solenoid Coil Test in Test Lab

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Notes and To-Do lists for the 2009/2010/2011 solenoid coil tests


Meetings


Things To Do


Solenoid and Individual Coil Tests


OSP

  • All OSP docs reside in M:\halld\Solenoid\CoilTest\OSP


Project Milestones

  • Solenoid Test Milestones, 12 GeV milestones to be tracked by project management office.
    • obsolete at this point, given all the additional work required, lack of manpower, and the many delays


FastTrack

  • FastTrack solenoid schedules are in M:/halld/solenoid/FastTrack Schedules.



System Diagrams and Related Documents

  • George put these in M:/halld/solenoid/Controls.


Test Area

  • Notes:
    • Area in the test lab is 20'6" x 25'9", currently filled with coils and coil parts.
    • Bob Bennett is Test Lab "space czar."
    • Wayne is designing overall layout.
    • Will use SRF storage area for large power supply (6' x 5', 5' H, 5000 lbs) and switch (QWeak area unavailable).
    • Must maintain clear areas around racks and power supply, and cannot block pedestrian walkways.
    • Platform is 172" x 160", cryo can will sit on top.
    • Platform must be removed to swap coils, and all connections to it must be broken.
    • Area has two 25T cranes, but need both (and strongback) to lift heaviest pieces (up to 45 tons).
    • Only a few dual-crane lifts needed.
    • Need come-alongs and anchors to move yokes and coils along rails.
    • Some areas will need to be roped off due to high B fields (5 G for pacemakers; other limits 60 G 8-hr body, 600 G 8-hr limb).
    • May need to remove some fences.
    • Magnet forces: 5 kG == 1 Atm, scales as square of B field.
    • When done, may leave infrastructure in place for magnet tests for other halls.
    • Coil center located 1/3 of the way along the long axis of our test area.
    • When saturated low field regions extend fairly uniformly around coil center in all directions. When not saturated low field regions extend out mainly along coil axis.
    • Will be able to use QWeak area for staging, coil repairs (29-Oct-2009).


  • To Do:
    • Determine areas to be roped off due to high B field - Jennifer Williams


  • Done:
    • Enable building access for everyone - Elliott - done 19-Jun-2009 (same requirements as access to Cebaf Center)
    • Look into getting space in adjacent areas - George - done 2-Jul-2009
    • Distribute Floyd's B field map for single coil, no cladding, fine scale - George - done 9-Jul-2009
    • Determine location of all components - Wayne - done 29-Jul-2009
    • Determine how far cranes must be apart for dual-lift - George - done 29-Jul-2009
    • Order yoke strongback - George - done 27-Aug-2009
    • Investigate sensitivity of electronic equipment to B fields - Elliott
      • Seems not to be a problem - 1-Dec-2009


Infrastructure

  • Notes:
    • Platform borrowed from Hall A.
    • Must be moved to replace coils, 4-point lift.
    • Rails and transportainer currently at IU.
    • Have or can borrow all material moving equipment, or will contract out to rigging firm.
    • Have or can borrow all tools needed.
    • Controls racks coming from from computer center.
    • Need 60 W liquid He, Test Lab supply capable of 500 W, but share with Cryo group.
    • Must account for magnetic forces on all structures, perhaps as much as 20-30 Gauss static B field.
    • Electrical cables must be untouchable to 8 feet above floor.
    • Power supply is Danfysik MPS 854 system 8000 w/power input of 480VAC at 91Amps.
    • Power supplies requires 190 liters/min max at max 174psi, minimum differential pressure 43psi.
    • Found electrical switch so don't have to order one.
    • LN2 can relocated to platform so that we can use short U-tubes.
    • Test lab cryo can supply 3 g/s He.
    • Contact for cryogen supply in the Test Lab is Pete Kushnick.


  • To Do:


  • Done
    • Design structures and mechanical components, route cables, etc. - Wayne - done 29-Jul-2009
    • Get three racks from CC - Elliott, Tom - done 26-Oct-2009
    • Determine cryogen supply/return needs - George - done 26-Oct-2009
    • Arrange for cryogen supply/return with Dana Arenius (and Kelly Dixon?)- Tom - done 26-Oct-2009
    • Produce construction/installation sequence - Chuck
    • Retrieve jack stands and rails from IUCF - Chuck
    • Retrieve transportainer from IUCF - Chuck
    • Install power supply cooling equipment, etc. - Tom
    • Arrange for electrical infrastructure installation - Tom


Components

  • Platform
    • Entire platform and supports will be moved when changing coils.
    • Must account for magnetic forces.
    • Ladder needs to be shortened and straightened.
    • Must include cable trays and strain relief, especially for power connections.
  • Rails
    • Currently in transportainer at IU, George will have a look when he goes out there.
  • Cryo, U-tubes, can and heat exchanger
    • Bids in for cryo can, no contract or delivery date yet.
    • Heat exchanger from Hall A.
    • By moving LN2 can will not need to order U-tubes.
    • Will use Anaconda and borrowed short U-tubes.
  • Piping
    • Not clear where N2 vent will be routed.
    • Must incorporate drip pan under N2 vent due to icing.
    • May be ODH considerations.
  • Electrical power
    • Need to work out where outlets are needed.
  • Power supply
    • Resides in Physics Storage bldg.
    • Uses 3-phase 480 V.
    • 10V supply, 3000 A.
    • Integral dump resistor, must bypass reversing switch when wiring to magnet.
    • Need switch nearby.(c** Look into possibility of locating computer in control room
    • Cables not water-cooled. 1.5" diameter cables, 1" copper.
  • Coils, rings and yokes
    • Buttresses are needed in coil 2.
    • Yoke modifications are needed.
    • Coil repairs will continue through summer 2009.
    • All must be leak-tested again.
    • Spacer rings designed in identical quadrants, two pieces per quadrant.
    • Need to design yoke jack stands.
    • Need to replace PVC-coated controls wiring in all four coils.
  • Controls system
    • Is anything sensitive to B fields?
    • Will wire up as per final four-coil system.
    • Own DIN-mount RS232 module, can borrow power supply and ControlNet module from Steve L.
      • Not needed, will use Point I/O system for RS232 and Ethernet/IP communications adapter.
    • Steve L has 75-Ohm quad-shield RG-6 cable and terminators for ControlNet wiring.
    • Must be careful not to use 50-Ohm components in ControlNet system.
    • Not clear where computer will be located.
    • Should use high-quality color-coded terminal blocks.
    • Should use color-coded wiring, different color schemes for different systems.
    • We will not instrument any thermocouples, but added some Si diodes.
    • Must use appropriate wire (phosphor-bronze?) and wire insulation (Formvar?).
    • Do we need a redundant PLC system?
      • Decision is yes since cost is relatively low and impact high.
    • Need a backup computer for coil test.
    • Decided to use one A-B chassis for two coils.
  • Misc tools, tables, chairs, ladders, etc.
    • What do we need? Can we beg, borrow, and/or steal?


  • To Do:
    • Reinforce coil 2 windings and replace wiring - George
    • Complete IUCF coil 3 shield and wire replacement - George
    • Replace wire in coil 4 - George


  • Done
    • Verify we can borrow heat exchanger from Hall A - Mark S - done 2-Jul-2009
    • Determine if sensible to use one PLC chassis per coil - Mark S and Elliott - done 16-Jul-2009, yes!
    • Verify all cryo transfer lines and U-tubes are available on site - Mark S - done 29-Jul-2009
      • Situation changed 28-Aug-2009, may not be able to use Hall C U-tubes!
    • Complete coil 2 stress analysis - George, Floyd - done 20-Aug-2009
    • Borrow short U-tubes and Anaconda - Tom - done 26-Oct-2009
    • Design and order magnet/yoke support components - George - done 29-Oct-2009
    • Order magnet spacer rings - George - done 29-Oct-2009
    • Arrange for yoke modifications - George - done 29-Oct-2009
    • Verify copper/PVC wire will work at LN2 temperatures - Scot - done 1-Nov-2009
      • Will replace all PVC-coated wire in all coils
    • Create complete P&I diagram for Mark W - James, George - done 9-Dec-2009
    • Modify control wiring diagrams - Mark S, Scot, Slava - done 9-Dec-2009
    • Order A-B equipment - Elliott - done 14-Dec-2009
    • Order other controls instrumentation - Scot - done 17-Dec-2009
    • Modify power supply dump resistor wiring - Mark S. - done 7-Jan-2010
      • Not needed, just need to bypass polarity reversing switch
    • Order cryo can - George - done 7-Jan-2010
    • Complete coil 1 repairs and wire replacement - George
    • Design cryo/electrical interface to cryo can - Josh, James
    • Design pressure relief system for cryostat testing - Josh
    • Design and order vent and other piping - Tom
    • Get heat exchanger from Hall A - Tom
    • Ensure we have all tools needed - Tom
    • Get backup controls computer - Elliott


Programming

  • Notes:
    • Mark W will do all programming.
    • Can borrow lots of code from Steve Lassiter and co.
    • Single computer will perform all control and monitoring tasks.
    • Hall D P&I diagram will be the basis for control system design.
    • P&I must include all vessels, valves, instrumentation, etc.
    • Need min/max flow rates, delta-T's, strain gauge readings, etc.
    • Have about one man-week of Steve Lassiter's time for consultation.
    • IMPORTANT - power must be off to carbon composite resistors in He vessel when under vacuum or they will burn out!
    • May use EWEB module to server controls data to web.


  • To Do:


  • Done
    • Install new memory in controls computer - Elliott and Mark W - done 6-Jul-2009
    • Borrow code from Steve Lassiter - Mark W - done 9-Jul-2009
    • Purchase new software licenses - Elliott - done 16-Jul-2009 none needed thanks to Steve Lassiter
    • Install all software on controls computer - Mark W - done 16-Jul-2009
    • Renew software update/maintenance contract - Elliott - done 27-Aug-2009
    • Update all software to latest version - Mark W - done 9-Sep-2009
    • Set up in test rack in ARC 101 - Mark W - done 15-Sep-2009
    • Explain overall control strategy to Mark W - George, Mark S, Scot - done 9-Dec-2009
    • Determine min/max flow rates, delta-T's, strain gauge values, etc. - George
    • Determine what needs to be archived and how often - George
    • Set up controls hardware in F117 - Armen, Scot, Mark S, Mark W and Elliott
    • Design and implement full control and archiving system - Mark W
      • Work with Steve Lassiter as appropriate.


Staging

  • Notes:
    • Will instrument controls racks in F117, then move to Test Lab.
    • Armen (Electronics group) will help with wiring in F117.
    • Will instrument for final 4-coil system.


  • To Do:


  • Done
    • Get and move 3 racks into F117 - Tom, Elliott - done 26-Oct-2009
    • Verify adequate staging areas available in Test Lab - Tom - done 29-Oct-2009
    • Rearrange F117 - Scot, Mark S - done 17-Dec-2009


Reviews

  • Notes:
    • Bob May and Paul Collins are contacts with EHS&Q for safety documentation and reviews
    • Need cryo, electrical, mechanical, and operations reviews.
    • Suresh Chandra responsible for structural review new platform and related components; will use outside consultant.
    • There will be a magnet review in Nov 2009.


  • To Do:


  • Done
    • Mini-review of PLC vendor choice (Report from Omar Garza and Jonathan Creel) - done 15-Jun-2009
    • Write thank-you letter to Jonathan Creel and Omar Garza for participating in PLC vendor review - Elliott - done 24-Jun-2009
    • Contact EH&S group concerning documentation and reviews - Elliott - done 29-Jun-2009
    • Write appropriate documentation - George, Mark S, Tom, Elliott
    • Set up all reviews - George, Elliott


Construction

  • Notes:
    • What training do we all need?


  • To Do:


  • Done
    • Get appropriate training - All
    • Arrange for telephone and networking in test area - Elliott
    • Move controls racks to Test Lab - Mark S, Tom
    • Move computer to Test Lab - Mark W and Elliott
    • Install all components - Mark S, Tom, Scot
    • Hook up controls system - Mark S, Scot, Mark W and Elliott
    • Verify operation of control/archiving system - Mark W, Mark S, Scot, George and Elliott


Coil Tests

  • Notes:
    • Purpose:
      • Verify correct operation of all coils.
      • Measure coil strains up to full current (1600 A).
    • Will take about six weeks per coil to install, cool down and test.
    • Only about 1 day of actual measurements per coil.
    • Nitrogen usage for the 300-80 K cooldown is ~18 to 21 g/s
    • 300-80 K cooldown: ~7 to 11 days
    • 80-4 K cooldown: ~2 to 4 days
  • Done
    • Install electronic logbook system - Elliott - done 20-Aug-2009


  • Connection for Coil 3
    • Chan 21: Pickup 1
    • Chan 23: Pickup 2
    • Chan 25: Pickup 3
    • Chan 27: Pickup 4
    • Chan 13: Coil D1
    • Chan 11: Coil D2
    • Chan 15: Coil A
    • Chan 7: Coil BC
    • Chan 5: Field Probe O2
    • Chan 31: Field Probe O3 (conditioned, delay)
    • Chan 19: MPS current
    • Chan 1: MPS voltage
  • Connection for Coil 2
    • Chan 21: Pickup 1
    • Chan 23: Pickup 2
    • Chan 25: Pickup 3
    • Chan 27: Pickup 4
    • Chan 7: Coil C
    • Chan 13: Coil D
    • Chan 9: Coil A
    • Chan 15: Coil B
    • Chan 5: Field Probe O2
    • Chan 31: Field Probe O3 (conditioned, delay)
    • Chan 19: MPS current
    • Chan 1: MPS voltage
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