Tevetron Energy Saver Dipole Magnet Incoming … · Web viewTwo similarly made machines utilize the same control scheme and Electronic Control Hardware; this Operating Procedure is

APS-TD / Process Engineering Specification # 5520-OP-333910February 18, 2019

Rev. C

CONDUCTOR INSULATION WRAPPING MACHINE OPERATING PROCEDURE

Tooling Maintenance Identifier(s):TIW1015; TIW1016

Date Organization ExtensionPrepared by:

Luciano ElementiLuciano Elementi

2/18/19 MSD 6767

Reviewed by:

Adam BraceroAdam Bracero

2/18/19 PE 2536

Approved by:

Guram ChlachidzeGuram Chlachidze

2/18/19 MSD 4622

Conductor Insulation Wrapping Machine OPPage 1 of 10


Rev. CRevision Page

Revision Step No.

Revision Description Date

None N/A Initial Release 5-23-13A 3.1.2 Step divided into 2 steps and new step added in between. Updated to ensure cables

are set up correctly1-27-15

3.1.3 Note added3.3.1 Added reference to cruise control potentiometer3.5.1 Added reference to cruise control3.5.2 Step updated3.5.4 Step added to describe disassembly4.2 Step updated6.5 Added a warning about potentially energized cables7.1 Wording updated

B 1.0 Scope broaden to include other uses and similar equipment to allows wider cable sizes

1-14-19

C 3.3.1 Added LOTO when intervening to change the insulation 2-13-19



Rev. CTable of Contents

1.0 Scope

2.0 Equipment/Materials

3.0 Operating Procedure

4.0 Emergency Shut-Down Procedure

5.0 Lock-Out/Tag-Out Procedure

6.0 Special Precautions

7.0 Test Reports



Rev. C1.0 Scope

This document summarizes the process for operation of the insulation wrapping machine for insulation of general-purpose conductor.

Two similarly made machines utilize the same control scheme and Electronic Control Hardware; this Operating Procedure is comprehensive.

One of the machines utilizes a AT-110-FC 5:1 gearbox with an opening of 22 mm, and can be driven by BSM80C-150AA Servo Motor, the second utilizes a AT-140-FC 5:1 gearbox with an opening of 32 mm, and is driven by BSM80C-250AA Servo Motor.

Depending on the equipment used, i.e. TIW1015 or TIW1016, System & Automation would be required to download the appropriate configuration to set the motor’s maximum current, motor protection, and wrapping (overlap) ratio.

2.0 Equipment/Materials

2.1

Figure 1: CAD Rendering of the Wrapping Machine.See Roller Table Assembly (F10001550) andConductor Wrapping Assembly (F10095440)



Rev. C

Figure 2: Wrapping Machine Controller (including HMI display at center)

Figure 3: Wrapping Machine Wrapping Head during Operation



Rev. C

Figure 4: Cable Puller with Pulley(left) and Speed Control (right)



Rev. C3.0 Operating Procedure

Note: Two technicians are required to operate this equipment.

3.1 Preparation

3.1.1 At the first set up, contact Systems & Automation to verify that the appropriate configuration is downloaded.

3.1.2 Ensure that the entire area of the puller (if in use) and the Wrapping Machine Assembly are clear from clutter and that the machine is sufficiently secured to the floor. The speed to which to set the cable puller may be limited, particularly at the beginning of the run. All personnel interacting with the conductor/machinery shall be trained and authorized to the specific operations and procedure and utilize the required PPE and follow the process required operation.

3.1.3 Verify a sufficient stroke is present in all the required mobile parts (for instance the head-swing, and travel when required) paying attention to the encoder wheel.

3.1.4 Cables to the motor, encoder, and cover sensor, shall be properly connected and secured, such that it does not inhibit motion of any moving parts.

Note: If operating with the electrical connection and/or control, ensure the equipment is unplugged while performing this step.

3.1.5 Verify the cable puller is positioned and the cable is securely set-up with proper conductor lead through the Winding machine.

Note: The cable needs to be threaded through the cable machine prior to being able to wrap.

3.1.6 Plug in the power cord of the Wrapping machine to the appropriate outlet. Verify that the wrapping machine is powered ON.

3.1.7 Verify the Tape Roll is ready and that the tape is connected to the conductor and in the correct direction. For instance, Figure 2 the conductor wrapping is shown as clockwise. If the process requires it, the conductor wrapping can be performed in the other direction (counter-clockwise).

3.1.8 Verify the functionality of the cover interlock by depressing the start button with the protective cover open, then again with the protective cover closed.

Verify that once ON, the machine is turned off with the opening of the protective cover.

Do not proceed if the interlock is not working: the machine requires maintenance by the Systems & Automation group.

3.1.9 Prior to running the machine, the protective cover must be closed.



Rev. C3.2 Operation

3.2.1 Press the Start Push Button and ensure that the green ‘following’ light stays lit on.

3.2.2 Begin pulling the cable through the machine verifying the wrapping process and quality. If adjustment (for instance it is noticed the presence of conspicuous bubbles in the Kapton, the overlapping is irregular, etc.) is required, contact Systems & Automation for maintenance.

3.2.3 The assigned technician should monitor the wrapping of the insulation throughout the process to verify the insulation is applied in accordance to the project requirement.

3.3 Replacement of insulation tape (for changing of insulation tape)

3.3.1 Open the cover; ensure that the ready light goes off at the same time.This is to test the working condition of the safety interlock and the operation of tape replacement by the operator.

Systems & Automation can configure the cover safety interlock (if required by the process) to be interconnected with other processing machinery, for instance the cable puller.

Note: For safety this operation requires LOTO of the machine.

If the plug is readily accessible, unplug the machine before proceeding. Whenever the tape head cover is open, unplug and maintain control of the plug.

3.3.2 Cutting and splicing of insulation tape should be done when the insulation tape is finished, or almost finished. It is recommended to slow down the process to allow operator intervention at the appropriate time.

3.3.3 Clearly cut the tape near the conductor ensuring that the arm is already in a position where access to the removal of the insulating spool is easy and where the splicing of the insulation can happen seamlessly.

3.3.4 To gain access to the tape: the cotter pin should be removed first, followed by the outer washer, the compression spring, the inner washer, and then the outer plastic guard disk.

3.3.5 Once the tape is replaced, components should be installed in reverse order as described in the previous step. The cotter pin is to be placed in the corresponding hole of the tape axle to maintain the assigned tension to the insulating tape.

3.4 Shut down and Break in Operation

3.4.1 To achieve a coordinated stop, the pulling of the material through the Wrapping Machine needs to be gradually stopped first (or a misalignment of the insulation to the conductor will occur).

Communication between the technicians performing the wrapping operation in tandem is essential.



Rev. C3.4.2 Come to a complete stop with the feed through of the conductor, ensuring no tension

is present. Press the Stop button and/or the Emergency shut down button.

Note: The Emergency shut down button is designed to remains latched until the operator physically resets it.

3.4.3 The Emergency shut down button is designed to ONLY stop the Wrapping Machine.

Process operation may require the Emergency shut down button to be inter-connected to multiple devices (and from multiple areas); for instance, with the cable puller. This can be performed by Systems & Automation. Under normal conditions shutdown should be as dictated above.

4.0 Emergency Shut-Down Procedure

4.1 Stop the Wrapping Machine (and depending on the process designed operation other ancillary equipment) by depressing the emergency stop button on its controls.

Note: Opening the protective cover disables the Wrapping Machine. This does not constitute a coordinated stop.

Under normal conditions shutdown should be as dictated under “Shut down and End of Operation”.

5.0 Lock-Out/Tag-Out Procedure

5.1 No Lock Out/Tag-Out Procedures is required for this equipment since it is a plug-in device.

6.0 Special Precautions

6.1 There are hazards associated with the rotating arm of the Wrapping Machine. Any interaction with the rotating parts shall happen only when the machine is off. For instance, the emergency stop is depressed and the (interlocked) protective cover is open.

Interaction within the electronic controls shall happen only by qualified personnel and possibly with the machine in its lockout state (unplugged).

6.2 During the process the cable will be under tension. The speed of the process is considerably slow and the cable (typically) robust enough to withstand the tension. No dangerous elastic energy is generally accumulated during the process.

6.3 There is a possible hazard due to trip and pinch points. The operator must keep his or her hands clear of the table mechanisms during operation. Operator must also ensure that others stay at a safe distance from the area of operation.

6.4 It is possible that after cleaning the surface of the conductor, the edges will be sharp. The conductor itself shall be handled with gloves.

6.5 Unplug the machine before disconnecting any cables. The cables to the motor are potentially energized anytime the machine is plugged in.



Rev. C

7.0 Test Reports

7.1 Quality assurance reports shall be generated in accordance to the pertinent traveler.


Documents

Tevetron Energy Saver Dipole Magnet Incoming … · Web viewTwo similarly made machines utilize the same control scheme and Electronic Control Hardware; this Operating Procedure is