OPERATIONS GROUP
CYCLOTRON TANK BAKEOUT PROCEDURES
Revision 21 - 22 June 2012 - Peter Yandon - (original: 24 April 1991)
This document is intended to be used as both instructions and as a checklist for bakeout.
The author assumes that anyone using these instructions has a basic knowledge of the location and operation of
the devices mentioned herein.
INDEX
1.0 - RAISING CYCLOTRON TEMPERATURE FOR BAKEOUT
1.01 INITIAL PREPARATION
1.02 CHECK COOLING TOWERS ARE "ON"
1.03 SHUT OFF DEIONIZERS
1.04 CHECK RAW WATER SYSTEM IS OPERATING
1.05 CHECK THAT AL-ALCW SYSTEM IS OPERATING
1.06 SHUT OFF MAIN MAGNET COIL AND BUSS BAR COOLING
1.07 SHUT OFF R.F. TRANSMISSION LINE COOLING
1.08 SHUT OFF R.F. BOOSTER COOLING
1.09 SHUT OFF R.F. DEFLECTOR COOLING
1.10 PREPARE HEAT EXCHANGERS
1.11 ISOLATE DEIONIZERS
1.12 SET INTERLOCKS
1.13 SET AL-ALCW SYSTEM TEMPERATURE
1.14 SET UP TEMPERATURE MONITORING
1.15 SET R.F. THERMOCOUPLE WARNING AND TRIP TEMPERATURES
1.16 TURN HEATERS ON
1.17 MONITOR TEMPERATURES
1.18 MONITOR THREE-WAY VALVE POSITION
1.19 MAINTAIN BAKEOUT TEMPERATURE
1.20 CONTINUE TO MONITOR TEMPERATURES 2.0 - R.F. BOOSTER COOLING SYSTEM
2.1 START UP
2.2 BAKEOUT
2.3 SHUTDOWN / SYSTEM ISOLATION
1.0 - RAISING CYCLOTRON TEMPERATURE FOR BAKEOUT 1.01 - 1.20
* * * Before proceeding, initial checks should be made to see if there are any special instructions
(Blue Book notes etc.) in effect before starting the bakeout. * * *
TURN OFF :
CLOSE and SEAL :
Ensure that the manual switches on the cooling towers (metal boxes) for the variable speed drives are ON,
and the fans are turning. Also check XT Page 2FAN.
1.03 - SHUT OFF DEIONIZERS On SA B2 level, west side of MCC-F, locate the controls for AL-ALCW
SA1-11 DEIONIZER PUMP.
Pump ME-5 (SA1-16) is on and system pressure is 80 psi (adjust valve D-10 appropriately).
Stop the Main Mag. booster pump ME-7 (SA1-17), and set the AL-ALCW system pressure back
down to 80 psi by adjusting discharge valve D-10 on pump ME-5.
Close three supply valves for the Booster upper, lower and coupling loop cooling. See section 2.
Close uppermost supply valve (orange handle, tagged RFD Supply) by NW periscope.
Note : the lower valves (for turbo pumps) and R.F.D. return, must remain open.
The RFD supply valve handle points in a different direction than the others.
Shut off the AL-ALCW water flow through the south heat exchanger, ME-31. Close valve D-17 (red handwheel).
Locate the blue deionizers pump SA1-11 (north of M. Mag. booster pump).
On SA B2 level, locate the RESONATOR COOLING WATER MONITOR unit in rack 10-A west of the B-20 .
On the left side of the Services console, locate the "Al-ALCW Valve Controller" cabinet.
This unit must be powered. If it is not powered, locate P-115 (N. wall outside W. RF room door, near UPS) and check breaker #4.
Select XTPAGE "RFTWV". Open the dialogue box in the lower left corner "[xxxxxx] profile number...."
and select "STOP".
Open the "profile number" dialogue box and select the desired profile number: 1 for 40C, 3 for 60C.
Both profiles will ramp the temperature from the current setpoint to the desired temperature. Select "START".
Set "Proportional Band" to 5%. Set "Integral Time (when RF is OFF)" to 10(S). Set "Derivative Time" to 3 (S).
Start an "XSTRIP" application and load script "BakeoutWatch", and print out XTPAGE "2T" list.
On XT page "2B" and "2T" : set "WARNING temp" to 62 (C) and "TRIP temp" to 63 (C).
Do Not disable, or take off scan, any thermocouple messages, with the exception of the following in the "Scan Management Utility" :
"RFTWV,1" , to prevent the message "3-way valve position nearly CLOSED" from being continuously printed as the Al-ALCW system
is increasing temperature. - ( DIS RFTWV,1 )
"ILRF,718" , to prevent the message "LQ1 Beam Absorber TC TEMP WARNING (RF,506,MUX)" from being continuously printed
when the AL-ALCW temperature is >50 C - ( DIS ILRF,718 )
"RF 260" , to prevent the message "EL260 RF,112,MUXL AL ALCW system temp HIGH exceeds 34" - ( DIS RF,260 )
from being continuously printed when the Al-ALCW temperature exceeds 34 C.
"RF 261" , to prevent the message "EL261 MS,11,MUXL AL ALCW system temp HIGH exceeds 34" - ( DIS RF,261 )
from being continuously printed when the Al-ALCW temperature exceeds 34 C.
It is suggested that XSCAN should be checked for these and other "off scan" items.
There are three 70KW heaters in the AL-ALCW smoothing tank. They are energized by a 480V contactor panel on SA B3 level.
The panel is just west of the smoothing tank near the entrance to the vault basement.
Each heater element can be switched in or out of the circuit via FUSED DISCONNECT SWITCHES immediately to the north of the contactor panel.
To energize the heaters push the BLACK button on the contactor panel. Confirmation of "on" is indicated by
a green light immediately below the RED button.
Note: within a few minutes of turning the heaters on, Service Alarm #33 "ALUMINUM ALCW SUPPLY TEMP HIGH" will come on.
Silence the bell at the Services Console. - (Cannot be reset until after cooldown)
Check the 'BakeoutWatch' "XSTRIP", and print out the XTPAGE "2T" list, every 60 minutes while temperatures are increasing,
and continue until two hours after the desired bakeout temperature has been reached.
When the temperature reaches 58 C. (as set in 1.13), the system will begin to require some cooling in order to maintain a stable temperature.
Check the 'BakeoutWatch' "XSTRIP". Print out XTPAGE "2T" list four hours after temperatures are stabilized.
NOTES :
2.0 - R.F. BOOSTER COOLING SYSTEM 2.1 - 2.3
OVERVIEW
The R.F. booster is cooled by the CU-ALCW system. It is important at all times to prevent condensation
from forming on the booster elements. This can happen anytime the tank is not at vacuum, and can happen at
a molecular level during bakeout due to temperature difference. Therefore the cooling must be shut off for
bakeout. In addition the booster cooling must be on during main R.F. operation as the induced voltages may
reach 10kV if the system is detuned from resonance. Therefore the cooling must be on for any R.F. operation. There are three cooling circuits involved with the R.F. Booster : Upper booster, Lower booster and
Coupling Loop. The valves for these circuits are located in the vault basement, on the inside of the north
cyclotron shielding support wall, in the vicinity of the booster itself. Both the Upper and Lower cooling loops have
flow switches in their return lines. The valves descriptions follow :
A - The Upper and Lower booster supply valves are red handled ball valves located downstream of the red-and-white handled valves off the supply header. *** DO NOT adjust the red-and-white handled valves ***
B - The Upper and Lower booster return valves are blue lever handled gate valves located on the
return header.
C - The booster Coupling loop uses red lever handled ball valves for both the supply and return lines.
These valves are located about six feet upstream of the previously mentioned valves, on the
supply and return headers.
D - The three cooling loops each have an unlabelled drain valve on both the supply and return lines,
on the booster side of the supply and return valves. (Note: Upper/Lower Booster Supply drains are on wrong side of shut-off. Drains should not be a concern for bakeout, anyway.)
All supply and return valves MUST BE OPEN for ANY beam or booster operation.
2.1 - START UP
2.12 - Set the three return valves to full open position (see B and C above)and check for leaks.
2.13 - Set the booster Coupling loop supply valve fully open (see C above)and check for leaks.
2.14 - Set the Upper and Lower booster supply valves fully open (see A above). Check for leaks.
2.2 - BAKEOUT
During bakeout the entire booster cooling water flow must be stopped (see 2,0 Overview).
1.01 - INITIAL PREPARATION
Check CSS Elevating System page for confirmation of "Off 30 minutes"
1.02 - CHECK COOLING TOWERS ARE "ON"
NOTE : Circuit breakers (MCC D, SA B2) for all cells, are now on at all times (except for servicing)
Set "Off / On" switch to OFF.
1.04 - CHECK THAT RAW WATER SYSTEM IS OPERATING
Pumps SA1-4 and SA1-5 on and Raw Water Supply pressures are at least 50 psi.
1.05 - CHECK THAT AL-ALCW SYSTEM IS OPERATING
Ensure that the "submarine" level is correct.
1.06 - SHUT OFF MAIN MAGNET COIL AND BUSS BAR COOLING
Close Main Mag. coil cooling supply valves, two blue valves in SW corner of Vault, labeled "Main Magnet Cooling Supply Valve #1" (& #2),
and again set the AL-ALCW system pressure back down to 80 psi.
*** added 09 October 2009 - Close the "Main Magnet Buss Bar Cooling" supply valve. Red handle on 1" piping at ceiling level just downstream of the Chain Valve. (note: Ladder may be required)
1.07 - SHUT OFF R.F. TRANSMISSION LINE COOLING
The AL-ALCW cooling water to the transmission line must be shut off to prevent heat damage to the internal polyflow cooling lines.
1.08 - SHUT OFF R.F. BOOSTER COOLING
1.09 - SHUT OFF R.F. DEFLECTOR COOLING
1.10 - PREPARE HEAT EXCHANGERS
Shut off the Raw water flow to the north heat exchanger, ME-30. Close valve H-18 (red handwheel).
1.11 - ISOLATE DEIONIZERS
Close the supply valve (green handle), downstream of the DEMCO pneumatic valve, on
the output of the pump.
This valve requires many more turns than a typical valve would.
1.12 - SET INTERLOCKS
1.13 - SET AL-ALCW SYSTEM TEMPERATURE
1.14 - SET UP TEMPERATURE MONITORING
1.15 - SET R.F. THERMOCOUPLE WARNING AND TRIP TEMPERATURES
1.16 - TURN HEATERS ON
* * * DO NOT OPERATE THESE DISCONNECTS WHEN THE CIRCUITS ARE ENERGIZED. * * *
They are not normal switches! They are only disconnects and as such are not designed to switch a load.
Switching these disconnects except in a de-energized state, will result in extensive damage to the
disconnects and may result in severe bodily injury ! Normally all three heaters are connected (disconnects ON).
To de-energize the heaters push the RED button on the contactor panel.
1.17 - MONITOR TEMPERATURES
Ensure that the temperature is rising in all octants (ie. no airlocks).
The temperature should rise at a rate of about 7 C per hour, therefore raising the temperature from 32 to 60 C should take
about 4 hours.
1.18 - MONITOR THREE-WAY VALVE POSITION
From the 'BakeoutWatch' "XSTRIP", XTPAGE "RFTWV" or visually from the S.A.B. camera, watch for the three-way valve to begin opening.
1.19 - MAINTAIN BAKEOUT TEMPERATURE
This is indicated by the opening of the three-way valve. When this valve opens to greater than 20%,
start the AL-ALCW water flow through the south heat exchanger ME-31, by opening valve D-17 (red handwheel) as
required to maintain the three-way valve position at about 30% (20-40% OK).
For the first adjustment of valve D-17, turn the handwheel one full turn. Further adjustments should
be in increments of 1/6 of a turn only.
Wait at least one minute between adjustments.
Continue adjustments until stability is achieved.
1.20 - CONTINUE TO MONITOR TEMPERATURES
Continue printing XTPAGE "2T" list once per shift for 48 hours then only once per day thereafter until cooldown commences.
Run " Bakeout Alarms " program either from " SCAN " \Utilities\Bakeout Alarms or type " BAKEOUT " on DEV cluster.
If the heaters trip off and cannot be re-energized immediately, close heat exchanger valve D-17.
When heaters are re-energized, return to step 1.17.
Error Messages generated if RF 947 & 948 are not disabled and temperature (nn) exceeds 34 deg C :
- (SCAN_RF) EL947 RF,112,MUXL AL ALCW system temp HIGH exceeds 34(RAWDATA=nn)
- (SCAN_RF) EL948 MS,11,MUXL AL ALCW system temp HIGH exceeds 34(RAWDATA=nn)
2.10 - Ensure that the water lines are intact.
2.11 - Check and close the six drain valves. (see D above)