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Operation Methods
Date: 07-02-2004
Shaft Alignment and Magnetic Measurement checks.
Prepared By Checked and Approved By Arun Kumar Bangalore BARC, Mumbai Daniel Babu P, BARC, Mumbai
Department of Atomic Energy, India
Dr Vinod Chohan AT/MTM CERN, Switzerland.
Operation Methods are used for testing the LHC Magnets in Cryogenic Conditions inbuilding 2173 (SM18) and are the working documents produced for that purpose only. TheseMethods are step-by-step procedures that may be followed by the Shift Operators of SM 18 forcarrying out different power- tests of the super-conducting magnets.
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Procedure Number Title OP-MM-1 Shaft Alignment and Magnetic Measurement
checks
AIM
1. To find the nominal longitudinal position of the shaft for magnetic measurement. (This is defined by the requirement of symmetry with respect to magnetic field seen at the ends of each aperture by the coils 1 at Lyre end and #12 at the connection end. i.e. position where ∆B1 = B1, #coil 1 - B1, #coi1 12 = 0
2. To check if the magnetic measurements are good and valid.
TEST IN BRIEF
At a current value of 1.5kA, magnetic measurement is performed at various longitudinal shaft positions using the rotating coils in the shafts of the dipole apertures. The measurement is repeated till the field seen by the end coils is symmetric.
Checks are done using various test cases to ensure that the measurements are good and valid.
Pre requisite
1. Measurement shaft must be present for the magnet. 2. Cryogenic system should be ready & magnet temperature should be stable at
around 1.9 K
PREPARATIONS
1. Ensure that the shafts, TRU and mobile rack are connected and powered ON.
2. Ensure that the scanning of the MMP viz: - hardware shafts, TRU and mobile rack are carried out and check that the coil settings for the magnet are configured. (Done by equipment support)
3. Position the shaft of both the apertures to the previous MM position for the bench.
4. Ensure that both the emergency stops (red knobs) in TRU are pulled out so that the
motors are powered. This can be checked by the yellow colour ‘power’ LED on the encoder
5. Check the polarity of the magnet (i.e. whether it is a Right or a Left Magnet) and put the
Polarity Rotary Switch accordingly, carefully following the procedure for assigning rotary switch position.
6. Put the Bench Rotary Switch to the required bench position. (For example E1) carefully
following the procedure for assigning rotary switch position.
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7. Ensure that the required power supply is allocated (by the server) to the test bench
chosen. Server application is running in local sun server for the cluster. 8. Inform the cryogenic system operator about the powering of the magnet to 1500A. Get
his/her OK signal for launching the test from cryogenic point of view.
9. Note down the TT821 temperature in the logbook. It has to be stable around 1.9 K+50mK.
10. Ensure that all the four main quench heater power supplies are fully charged (the
ready/green LED should be glowing).
11. Make sure all cards in main dipole safety matrix are enabled. 12. Ensure that the “Magnet Protection” selector switch in the switch box of quench heater
power supplies is in “HF” position. This will ensure that the main quench heater power supplies will be discharged in to the HF heaters if and when required.
13. Ensure that the “Min. Energy” selector switch in the switch box of quench heater power
supplies is in “0” position. This will ensure that the minimum energy power supply will not be connected to any of the heaters.
14. Set the switch box in the mobile rack of the TRU (Twin Rotating Unit) to “Remote”
position for both the apertures A1 and A2. This will ensure that the switching of the detector coils to “MM” position will be controlled by TEMA.
15. Ensure that the Digital Voltmeter calibrated to read IDCCT current as mV DC (15 kA =
1.5 V) is on. Ensure that it is NOT put to record the maximum current; by pressing the MIN/MAX button once (the MAX indication should NOT glow).
LAUNCHING THE TEST
The test is launched from the server in the SM 18 Control Room executing the Test Master (TEMA) for the cluster concerned. The procedure assumes that TEMA is already running in the corresponding cluster.
1. Ensure that the proper bench is chosen in TEMA and that the magnet name is correct. 2. Select “Standard_MM_Prog_X1.seq” from List of Sequence and then select
“MM_position [email protected]_x1.tst” from List of tests of the Sequence in TEMA. Note: Choose x1 option if you are in bench1 of the cluster. Choose x2 option if you are in bench2 of the cluster.
3. Click Check Application. This will open the following main Lab VIEW windows
namely LF_Web.vi (where the magnet temperature can be read), HFMF ControlStatus
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Panel.vi (HF Data Acquisition) and InstrumentStatus And Control.vi (LF Data Acquisition) in the left display terminal.
4. When the Check Applications button is free, click Run Test.
5. Pay attention to the activities on the screen. The hardware recognition system checks for
all equipments required for the test and then loads the necessary configuration files. The necessary interlocks are checked and arms the HF and LF data acquisitions.
NOTE:
In case of problem in Hardware recognition system call equipment support. In case of PLC faults, refer the document “What to do in case of PLC faults?”
6. Confirm that the HF and LF Data acquisitions are fully armed. (Refer diagram1.) This
can be confirmed by reading the latest status on the message windows of HFMF ControlStatus Panel.vi (HF) and InstrumentStatus And Control.vi (LF) respectively.
7. In the local sun server where MMP application runs normally, launch MMP.
8. In MODE menu, choose HARDWARE. Then in FILE menu, choose LOAD, then
“MBB_main_dipole.hmd” to load the hardware configuration
Note: Make sure that the power program and the Magnetic measurement Program (MMP) is not running for this cluster. Otherwise a conflict will arise when starting MMP in local.
9. Reply ‘YES’ to establish the client/server connection. 10. Run AUTO TEST. (This will check multiplexer, VME, amplifier, motors, and power supply. In case of errors the communication for these peripherals as well as healthiness of these devices have to be individually checked). 11. In MODE menu choose RUN. 12. Click on the Magnet Icon. Choose LOAD MAGNET SETTINGS :
“MBB_main_dipole_flat_x1.mst” to load the measurement configuration. Click “SAVE and RETURN”.
Note: If magnet name, shaft numbers are not correct call equipment support. 13. Click in the MASTER box to configure the Power Converter: Current Mode should be constant. Click CONFIGURE and enter the following settings.
Current: 1500 Number of measurements: 1
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Time between measurements: 0 Time before first measurement: 0 Time after last measurement: 0 Total Time: 0 SAVE and RETURN twice.
14. Click MEASUREMENT PARAMETERS
Run Type – Manual Power Supply – Constant Aperture Configuration - // SAVE and RETURN.
15. In the MODE menu, choose MEASUREMENT then START – wait for the results. 16. Check that Magnetic Measurements are working correctly (Refer MMP checks
procedure).
The aim of the test is to adjust the shaft positions until the field measured in the first sector (0001, CFB end) is equal to the field measured in the last sector (2223, MRB end).
ALIGNMENT METHOD
• In the Harmonics column, select TABLE, and de-select NORMALISATION. (If NORMALISATION is not de-selected, there will not be any difference between S0001 (normal) and S2223 (normal).
• Choose aperture 1 (0 in the menu) • Select Sectors 0001 and note the first value in the ABSOLUTE/NORMAL
column. • Select sectors 2223 and note the first value in the ABSOLUTE/NORMAL
column. • Move the shaft in aperture 1 in the corresponding direction (according to the
following table) • Repeat the above four steps for aperture 2 also. • RETURN from the results window, and repeat the measurement. • Continue this process until the two end coil values for both apertures are equal.
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Display window showing measurement results.
17. Reduce current to zero and switch off power converter. Power converter is accessed from PS_ Main Panel.vi. For this in Remote mode in MMP window, click Master icon. Set the target current to 50 Amp. Then click “execute ramp” power converter goes to stand by mode. Switch of the power converter by clicking “OFF” button. Quit MMP application.
18. In case of a quench during this test, note down the name of the file created in the
message windows of HFMF ControlStatus Panel.vi (HF) and InstrumentStatus And Control.vi (LF) and analyze the results of the file . Inform the test co-coordinator.
19. Check if the measurements are as expected. For this in “display mode” of the MMP
application, check all the test cases mentioned in MM checks procedure.
20. Create labels and mark the MM position obtained in the TRU. QLOC position is 630mm more than the MM position towards the CFB end
21. Enter the test in the Test Sequence (SMTMS).
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Table for MM Shaft alignment at 1.5kA
Difference between 0001
and 2223
Displacement in mm
Difference between 0001
and 2223
Displacement in mm
1 54 0.48 260.98 53 0.46 250.96 52 0.44 240.94 51 0.42 230.92 49 0.4 22
0.9 48 0.38 200.88 47 0.36 190.86 46 0.34 180.84 45 0.32 170.82 44 0.3 16
0.8 43 0.28 150.78 42 0.26 140.76 41 0.24 130.74 40 0.22 120.72 39 0.2 11
0.7 38 0.18 100.68 37 0.16 90.66 35 0.14 80.64 34 0.12 60.62 33 0.1 5
0.6 32 0.08 40.58 31 0.06 30.56 30 0.04 20.54 29 0.02 10.52 28
0.5 27 IF 2223>0001 displacement is negative i.e. away from CFB IF 2223<0001 displacement is positive i.e. towards CFB
CONCLUSIONS
The test is successful if all the validity checks are complied with and a symmetric longitudinal MM position is obtained.
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Checklist for “MM checks and shaft alignment”
PREPARATIONS
1 Shafts, TRU and mobile rack are scanned into the hardware recognition system.
O Yes O No
2 Shafts of both apertures of the mobile rack are in MM position and motors are powered.
O Yes O No
3 Power Converter Rotary Switch is in the proper bench position. O Yes O No 4 Polarity Rotary Switch for is in the correct polarity position.
(Right or Left) O Yes O No
5 Switch box for both apertures of the mobile rack are set to “Remote” position.
O Yes O No
6 “Magnet Protection” selector switch on the switch box of the main quench heater power supplies is in “HF” position.
O Yes O No
7 Min. Energy selector switch on the switch box of main quench heater power supplies is in “0” position.
O Yes O No
8 All the four main quench heater power supplies are charged. O Yes O No 9 All the cards in safety matrix are enabled. O Yes O No 10 Required power supply is allocated (by the server) to the test
bench. O Yes O No
11 Voltmeter for reading the IDCCT current is in mV range and set to hold the maximum value.
O Yes O No
WHILE LAUNCHING THE TEST
1 Active bench and magnet name are properly chosen in TEMA. O Yes O No 2 Both HF and LF acquisitions are armed. O Yes O No 3 Test type is “mc – mm position search at 1.9K” O Yes O No
AFTER TEST
1 Data validity checked and MM position found. O Yes O No 2 Entered in the Test Sequence. O Yes O No 3 Current is ramped to zero and power converter is switched OFF O Yes O No
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What To Do In Case Of PLC Faults ?
1. In case any of the conditions necessary for launching a selected test are not satisfied, then a window with the message “Faults present in PLC” will appear.
2. Press “Ok”. Another window with message “Do you still want to load HF and LF
data acquisitions?”.
3. Press “no” and then acknowledge the message “Faults present in PLC”.
4. Now, click “Check Faults” in the “TM_Main_Panel.vi” to get a list of conditions not satisfied in the PLC for the test chosen presently, each of which is shown in red.
5. Now press “Check Faults” in the “PS_MainPanel” and then press “Read and Reset”
to clear any memorized fault s which might have come during earlier tests. (To access PS_MainPanel go to Remote mode and click Master icon.)
How To Check Whether The HF And LF Data Acquisition Systems Are Armed Properly ?
Diagram 1
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MMP Checks Procedure. Essential checks necessary for ensuring good and valid magnetic measurements at 1.5kA and 1.9K. These checks have to be done in both apertures during the longitudinal positioning of the shafts at.1.5 kA.
Checks Observation when it is wrong.
Action to take if not correct
Consequences if not detected.
Comments
1 Magnet name Orange color in display
Call equip.support in stand by.
Data not exported. See *
2 Shaft number h02XXXXX No color Call equip.support in stand by.
Wrong measurements See *
3 Read current is 0 Orange color in display Call equip.support in stand by.
Data not exported and Wrong measurements
See *
4 Over-range in sectors 0001, 2345, 2021,2223
Orange color in display Call equip.support in stand by.
Field integral not available. See *
5 b11 not correct in sectors 0001, 2345, 2021,2223
Orange color in display Call equip.support in stand by.
Field integral not available. See *
6 End field polarity not correct.
Orange color in display Call equip.support in stand by.
Field integral not available. See *
7 More than 2 Over-ranges in one aperture
Orange color in display Call equip.support in stand by.
Field integral not available. See *
8 More than 2 b11 not correct in one aperture.
Orange color in display Call equip.support in stand by.
Field integral not available. See *
9 Rms in rotation speed higher than 3 %
Red color in display Stop the measurements.
No further MM before repair.
Danger for the shafts Wrong measurements
Check of the system by Mechanic Team.
*These are serious errors to be fixed before doing any further magnetic measurements.
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Case 1: Wrong magnet name
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Case 2: Check of the head shaft number h0xx.
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Case 3 : Read current is zero.
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Case 4 : Over-range in the sector 2021(CMP signal)
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Case 4 : Over-range in the sector 0001 (abs signal).
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Case 5: b11 is not correct in the sector 0001.
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Case 6: End field polarity is not correct for sector 0001.
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Case 7 : Over-range in one sector (cmp signal)
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Case 8: b11 is not correct for a sector (end region excluded).
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Case 9 : Rms of rotation speed is higher than 3%
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Annex 4 – Table of troubleshooting This table indicates what to do in the case of mistakes or loss of the cryo-ok during measurements. Cases: - wrong temperature or unstable temperature during the measurements - quench forgotten before the measurements - quench happening or loss of the cryo-OK during the measurements - pre-cycle added or mistake in the cycle before the cleansing cycle - wrong ramp rate during the measurements - overshoot in current - systematic over-range.
Experiment
Temperature Error
Quench forgotten
Quench or loss of cryo
OK
Pre-cycle error
Ramp rate error
Overshoot Over-range
Load line r n r b n r
Ramp r n r b r v r
Machine cycle r r r r r r r Degaussing r n r b n r r r : measurements must be repeated b : measurements can be recovered with repeating the pre-cycle (note on the protocol). v : measurements can be recovered with re-starting the cycle at the present ramp rate (including the pre-cycle).
: measurements can be recovered with repeating the measurement on the plateau where the over-rang occurs. n : Measurement is not sensitive.
