Difference between revisions of "Solenoid Coil Test in Test Lab"

Revision as of 13:03, 28 October 2009

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

Order cryo can - George
- by 15-Nov-2009
Ship jack stands from IUCF - Tom
- by 15-Nov-2009
Modify controls drawings for one chassis/coil and to include all planned instrumentation - Mark S, Slava
- by 15-Nov-2009
Order remaining controls instrumentation - Mark S, Scott
- by 15-Nov-2009
Finish ordering magnet spacer rings and related magnet components - George
- by 15-Nov-2009
Complete design, order, fabrication and repair of magnet and yoke support components - George, Floyd, Kevin
- by 15-Nov-2009
Finish design of cryo can power/control interface and pressure relief systems - Josh, James
- by 15-Nov-2009
Statement of work, PO for IUCF coil repair work - George
- by 30-Nov-2009
Complete coil 1 repair work - Kevin
- by 30-Nov-2009
Order piping components - Tom
- by 30-Nov-2009
Order platform and related components - Tom, George
- by 30-Nov-2009
Arrange for coil storage space - Tom
- by 30-Nov-2009
Get transportainer and rails from IUCF - George, Tom
- by 30-Nov-2009
Start safety review process - George, Elliott
- by 30-Nov-2009

Dec-2009

Arrange for space for coil 2 repair - Tom
- by 15-Dec-2009
Install power supply in Test Lab- Tom
- by 31-Dec-2009
Get 5 G field contours for different magnet currents - George, Floyd
- by 31-Dec-2009

Feb-2010

Complete repairs at IUCF and ship coil to JLab - George, Tom
- by 28-Feb-2009

Apr-2010

Complete coil 2 repairs - George
- by 30-Apr-2010

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.

To Do:
- Look into possibility of locating computer in control room (contact Joe Preble, Mark Drury)- Elliott
- Investigate sensitivity of electronic equipment to B fields - Elliott
- Determine areas to be roped off due to high B field - Floyd, George, Elliott
- Prepare area for installation - Tom

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

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.

To Do:
- Produce overall system diagram - George
- Produce construction/installation sequence - Wayne
- Complete piping design - Tom
  - Design piping to vent N2.
  - Design warm and cold He supply/return systems, LN2 supply system.
  - Determine if any ODH considerations for N2 vent.
- Retrieve rails/transportainer from IUCF - George, Tom
- Install power supply cooling equipment, etc. - Tom
- Arrange for electrical infrastructure installation - Tom, Mark S.

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

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, may need rewiring to ensure always in coil circuit.
- Need switch nearby.
- 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.

Controls system
- Is anything sensitive to B fields?
- Will wire up as per final four-coil system.
- Should use separate chassis for each coil, so we need to modify controls wiring diagrams.
- Own DIN-mount RS232 module, can borrow power supply and ControlNet module from Steve L.
- Steve L has cable and terminators, may need T-taps.
- 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 instrument some thermocouples.
- Must use appropriate wire (phosphor-bronze?) and wire insulation (Formvar?).

Misc tools, tables, chairs, ladders, etc.
- What do we need? Can we beg, borrow, and/or steal?

To Do:
- Design, order, install buttresses in coil 2 - George
- Complete JLab coil repairs - George
- Complete IUCF coil repairs - George
- Understand how to deal with dump resistor in power supply - Mark S
- Order cryo can - George
- Get jack stands from IUCF - George, Tom
- Get transportainer and rails from IUCF - George, Tom
- Order magnet spacer rings - George
- Design and order magnet/yoke support components - George, Floyd
- Design and order piping - Tom
- Design cryo and electrical break system for cryo can - Josh, James
- Arrange for yoke modifications - George
- Modify control wiring diagrams - Mark S, Slava
- Order controls instrumentation - Mark S, Scott and Elliott
- Get heat exchanger from Hall A - Mark S or Tom
- Ensure we have all tools needed - Tom

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

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, James Lagner working on this.
- P&I must include all vessels, valves, instrumentation, etc.
- Need min/max flow rates, delta-T's, strain gauge readings, etc.

To Do:
- Explain overall control strategy to Mark W - George, Mark S
- Create complete P&I diagram for Mark W - George
- 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 - Mark S, Mark W and Elliott
- Design and implement full control and archiving system - Mark W

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

Staging

Notes:
- Will instrument controls racks in F117, then move to Test Lab.
- Will instrument for final 4-coil system.

To Do:
- Rearrange F117 - Mark S
- Verify adequate staging areas available in Test Lab - Tom

Done
- Get and move 3 racks into F117 - Tom, Elliott - done 26-Oct-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:
- Write appropriate documentation - George, Mark S, Tom, Elliott
- Set up all reviews - George and Elliott

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

Construction

Notes:
- Hall D is hiring a new Tech 1 and Tech 2 (Sep 2009).
- What training do we all need?

To Do:
- Get appropriate training - All
- Order controls equipment - Mark S, Elliott and Scott
- Arrange for telephone and networking in test area - Elliott
- Arrange for installation of electrical infrastructure - Tom
- Wire up controls racks - Mark S
- Move controls racks to Test Lab - Mark S, Tom
- Move computer to Test Lab - Mark W and Elliott
- Install all components - Mark S, Tom
- Hook up controls system - Mark S, Mark W and Elliott
- Verify operation of control/archiving system - Mark W, Mark S, George and Elliott

Done

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

To Do:
- Create test plan - George

Done
- Install electronic logbook system - Elliott - done 20-Aug-2009

@@ Line 20: / Line 20: @@
 * Edit if needed, but be very careful.
 * Can print existing pdf file.
-* [http://www.jlab.org/Hall-D/solenoid/Fastrack%20Schedules/Project.html Simple Web Version] of FastTrack schedule
+* [http://www.jlab.org/Hall-D/solenoid/Fastrack%20Schedules/Project.html Simplified web version] of FastTrack schedule

Difference between revisions of "Solenoid Coil Test in Test Lab"

Revision as of 13:03, 28 October 2009

Contents

Meetings

Project Milestones

FastTrack

System Diagrams and Related Documents

Electronic Log

Top To-Do Items

Test Area

Infrastructure

Components

Programming

Staging

Reviews

Construction

Coil Tests

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