T R I U M F

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.

Print the WP file " BAKE_OUT.wpd " , ("T:\WPWIN\DOCUMENT\BAKE_OUT.wpd) -

 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. * * *

1.01 - INITIAL PREPARATION

TURN OFF :

CLOSE and SEAL :


1.02 - CHECK COOLING TOWERS ARE "ON"

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.
NOTE : Circuit breakers (MCC D, SA B2) for all cells, are now on at all times (except for servicing)

1.03 - SHUT OFF DEIONIZERS

On SA B2 level, west side of MCC-F, locate the controls for AL-ALCW SA1-11 DEIONIZER PUMP.
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

Pump ME-5 (SA1-16) is on and system pressure is 80 psi (adjust valve D-10 appropriately).
Ensure that the "submarine" level is correct.

1.06 - SHUT OFF MAIN MAGNET COIL AND BUSS BAR COOLING

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 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

Close three supply valves for the Booster upper, lower and coupling loop cooling. See section 2.

1.09 - SHUT OFF R.F. DEFLECTOR COOLING

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.

1.10 - PREPARE HEAT EXCHANGERS

Shut off the AL-ALCW water flow through the south heat exchanger, ME-31. Close valve D-17 (red handwheel).
Shut off the Raw water flow to the north heat exchanger, ME-30. Close valve H-18 (red handwheel).

1.11 - ISOLATE DEIONIZERS

Locate the blue deionizers pump SA1-11 (north of M. Mag. booster pump).
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

On SA B2 level, locate the RESONATOR COOLING WATER MONITOR unit in rack 10-A west of the B-20 .

1.13 - SET AL-ALCW SYSTEM TEMPERATURE

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).

1.14 - SET UP TEMPERATURE MONITORING

Start an "XSTRIP" application and load script "BakeoutWatch", and print out XTPAGE "2T" list.

1.15 - SET R.F. THERMOCOUPLE WARNING AND TRIP TEMPERATURES

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.

1.16 - TURN HEATERS ON

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.
* * * 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 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.
To de-energize the heaters push the RED button on the contactor panel.

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)

1.17 - MONITOR TEMPERATURES

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.
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

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.
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

Check the 'BakeoutWatch' "XSTRIP". Print out XTPAGE "2T" list four hours after temperatures are stabilized.
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.

NOTES :
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)


2.0 - 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

2.10 - Ensure that the water lines are intact.

2.11 - Check and close the six drain valves. (see D above)

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).

To do so, close the three supply valves only (see A and C above).


2.3 - SHUTDOWN / SYSTEM ISOLATION

To stop the water flow in any or all of the cooling loops, close the Supply Valve Only!

To shutdown or isolate any of the three cooling loops (ie. checking for leaks, opening the cooling lines etc.) an additional step (3) is required in comparison to most other water cooling systems.

1, Close the supply valve

2, Close the return valve.

3, OPEN AN ASSOCIATED DRAIN VALVE (thus reducing the pressure on the cooling loop to zero).
For the Upper & Lower Booster, open the drain on the Return line. If the supply side needs to be drained, contact RF personnel for instruction.

DO NOT close a return valve before closing the associated supply valve.

DO NOT close a return valve without immediately opening an associated drain valve.



NOTE: The supply and return valves are "tagged" but not labelled, and the drain valves are not marked in any way.