Solenoid Coil Test in Test Lab

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


Meetings


Project Milestones


Top To-Do Items

Note: Installation in Test Lab can begin once local coil repairs are complete, starting around 1-Nov-2009.


Aug-2009

  • Order controls instrumentation - Mark S
    • by 31-Aug-2009
  • Get overall system diagram, P&I, controls strategy to Mark Wissmann - George, Mark S
    • by 31-Aug-2009
  • Order magnet spacer rings and related magnet components - George
    • by 31-Aug-2009
  • Order cryo can and related components - George
    • by 31-Aug-2009
  • Order yoke strongback - George
    • by 31-Aug-2009

Sep-2009

  • Modify controls drawings for one chassis/coil and to include existing thermocouples - Mark S, Chuck
    • by 10-Sep-2009
  • Arrange for space for coil 2 repair - George, Tom
    • by 15-Sep-2009
  • PO for IUCF coil repair work - George
    • by 15-Sep-2009
  • Order electrical equipment - Mark S
    • by 15-Sep-2009
  • Arrange for mods to existing cryo transfer line - George, Mark S
    • by 15-Sep-2009
  • Install power supply in Test Lab- Tom
    • by 15-Sep-2009
  • Arrange for electrical infrastructure installation - Mark S or Tom
    • by 15-Sep-2009
  • Complete piping design - Wayne
    • by 15-Sep-2009
  • Order piping components - Mark S
    • by 30-Sep-2009
  • Get transportainer and rails from IUCF - George, Elliott
    • by 30-Sep-2009
  • Get 5 G field contours for different magnet currents - Floyd
    • by 30-Sep-2009
  • Platform structural safety review - George
    • by 30-Sep-1009

Oct-2009

  • Order platform and related components - George
    • by 10-Oct-2009
  • Complete coil 1 repair work - Kevin
    • by 31-Oct-2009
  • Complete repairs at IUCF - George
    • by 31-Oct-2009

Nov-2009

  • Organize safety reviews - George, Elliott
    • by 15-Nov-2009

Dec-2009

  • Complete coil 2 repairs
    • by 31-Dec-2009

Jan-2010

Feb-2010

  • Complete safety reviews - George, Elliott
    • by 1-Feb-2010
  • Start coil tests
    • By 1-Feb-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
    • Order yoke strongback - George
    • Determine areas to be roped off due to high B field - George, Elliott
    • Prepare area for installation - Mark S, 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


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 Randy H or 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.
    • Need support for heat exchanger.
    • Electrical cables must be untouchable to 8 feet above floor.


  • To Do:
    • Produce overall system diagram - George
    • Produce construction/installation sequence - Wayne
    • Complete piping design - Wayne
      • 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, Elliott, Tom
    • Get three racks from CC - Mark S and Elliott
    • Determine cryogen supply/return needs - George
    • Arrange for cryogen supply/return with Dana Arenius (and Kelly Dixon?)- George and Elliott
    • Order electrical switch and cables - Mark S
    • Arrange for electrical infrastructure installation - Mark S
    • Get heat exchanger support - Mark S


  • Done
    • Design structures and mechanical components, route cables, etc. - Wayne - done 29-Jul-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 can and heat exchanger
    • RFQ out for cryo can, no delivery date yet.
    • Heat exchanger from Hall A.
  • 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 Phsyics 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.
    • Are 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.
  • 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 all thermocouples.
  • 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 and IUCF coil repairs - George
    • Understand how to deal with dump resistor in power supply - Mark S
    • Order cryo can - George
    • Get transportainer and rails from IUCF - George, Elliott
    • Order magnet spacer rings - George
    • Order remaining piping - Mark S
    • Design cryo and electrical break system for cryo can - George and Mark S
    • Arrange for yoke modifications - George
    • Modify control wiring diagrams - Chuck
    • Get heat exchanger from Hall A - Mark S
    • Ensure we have all tools needed - Mark S, Tom, Elliott


  • 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
    • Complete coil 2 stress analysis - George, Floyd - done 20-Aug-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.


  • To Do:
    • Explain overall control strategy to Mark W - George, Mark S
    • Determine what needs to be archived and how often - George
    • Set up controls hardware in lab - 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


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
    • Get and move 3 racks into F117 - Mark S, Elliott
    • Verify adequate staging areas available in Test Lab - Tom, Elliott


  • Done


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 DOE (I think) magnet review on Oct 2009.


  • To Do:
    • Write appropriate documentation - George, Mark S, Tom, Wayne and 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:
    • Do we have enough manpower?
    • What training do we all need?


  • To Do:
    • Get appropriate training - All
    • Order controls equipment - Mark S and Elliott
    • Arrange for telephone and networking in test area - Elliott
    • Arrange for installation of electrical infrastructure - Mark S
    • 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 one month per coil to install, cool down and test.
    • Only about 1 day of actual measurements per coil.
    • Will take a few days to cool down or warm up a coil.


  • To Do:
    • Create test plan - George


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