Joint repair continues.

Leak Check:

- Local leak check performed around area of T2, M9-Q1. All seals other than T2 Q1 were leak tight. Largest source of leak was the T2 Q1 joint area.

- Leak check done in quadrants around joint, response times were <2 sec of applying helium. Leak detector also responded when He probe was near joint (before actually applying He).

Video and Physical inspection:

- Bottom weld lug bolt found in tension/captive (ie. not free to move). Confirmed static by poking bolt. (Videos of this in RH group folder).

- Top weld lug had > 0.2" of gap.

- East and West pins seen leaning slightly toward North (toward Q1).

Loading Test:

At 13:30 a load test was performed to observe the effects of loading nearby blocks around T2 (see photo). Two 12 x 6 x 3 shield blocks were stacked one on top of the other and vacuum was observed, one then the other. There was no observable effect on the vacuum each time. Bottom weld lug bolt was still frozen when poked.

Blocks were replaced to their original locations once test was complete.

The T2 volume was vented at ~14:15 in preparation for disassembly to be performed on Monday.

Today:

- Removed pins and removed indium through ring. Joint fully open at 14.5 to 15 turns of retraction mechanism.

- Did initial video inspection of T2 and Q1 flanges, some residual indium on knife surfaces, did initial scraping of T2 flange. (see videos on RH group folder)

- One blank off prepared with indium ready for installation.

Will continue tomorrow with Q1 scrape and re inspection.

See inspection notes attached for failed M9T2 double-indium thru-ring TB22148, inspected on Oct 15th 2012.

Ring was approximately 3 mSv/hr on contact and 100 uSv/hr at 0.5 m.

Total dose accumulated during inspection on dosimeter 122 was 0.1 mSv

See attached.

Yesterday:

Installed indium blank off at M9 T2 joint and pumped down at 15:20 to 15:45 overnight. 1ACG7 (T2 vacuum pressure) reads between 6.0E-3mT and 2.0E-2 mT as of 8:15 today.

- Before installing, an attempt was made to set the bellows in a position to correct for some of the misalignment. This was done by closing the joint with no ring and pinning the east flange ear and leaving it for ~1 hour.

- Blank off installation began at 12:30

- A universal joint installation tool was used to install the East pin. This was due to the very small gap available to install the pin on the East side. The east side of the flange was also pried upon in order to close the east side of the joint. As a result the pin leans North once installed. West pin was installed with no issues.

- Installation finished at 14:30 (roughly two hours, not including flange prep work)

- An inspection after installation revealed the lower lug to be in tension an hour after installation of the pins and blank off.

- Spring eye gaps on installation appeared to be 0.05" to 0.06" on the west side and ~0.2" on the east side.

Will be doing inspection and leak check later today.

Today:

Completed leak check of M9 T2 area: joint(s) are He leak tight. Remote He lines checked as well, see attached.

- Indium blank off ring was cut free from the string tethers.

- Removed extra tooling and equipment, West side pin threaded cap installed. East side needs new capping device since the lean of the pin is beyond installation parameters.

- Vacuum pressure still running higher than normal but stable (see previous e log).

- Water leak in the M9 Q2 magnet return header was discovered. Very slow leak (> 10 minutes per drop). See attached photo and videos on RH group drive.

Cleanup continues tomorrow.

Today:

Cleaned up work site and removed extraneous poles and tooling. Radioactive parts stored in lead flask now located on TNF.

- Two pins, an RH bullet bolt and indium ring (tb22148) were put into lead flask for storage, flask now located on TNF.

- Took photos of spring eye gaps and some video inspection, looks roughly the same as yesterday (see photos).

- Installed a dust cover over the east spring pin (see photos).

Looking at placement of indium rings loaded with EPDM and Buna N at joint for radiation exposure. Will install the test rig on Monday & clean up site for covering up.

Today I picked up two 2FT x 4Ft x 0.125" thick strips of stock EPDM and BUNA-N (Nitrile) material from BC Rubber Supply.  A copy of the Packing Slip is attached.  Here is the information from the Sample Sheet:

Nitrile 60 Commercial Grade

Type: Moderate Oil Resistance

Temp. Range: -30 to 190 (does not specify C or F... assuming C)

Ozone Resistance: Poor

Tear Resistance: 240 lbs/in.

Elongation: 500%

Tensile Strength: 1700 psi

EPDM AB-563 Premium Grade

Type: Excellent thermal & Chemical Resistance

Temp Range: -40 to 250 F

Ozone Resistance: Excellent

Tear Resistance: 145 lbs/in

Elongation: 500%

Tensile Strength: 890 psi

Sample preparation notes:

- Rectangular cross-section rings of this material were cut by hand using a compass-type rotating blade cutting tool on a work bench.  The process of cutting the rings to get the cross section as even as possible all around was finicky and required several attempts.

- The rubber rings cut from the stock material were nominally 8.040" OD X 7.66" ID x 0.125" thick, but this varied likely within +/- 0.020" each on the OD and ID due to the lack of precision in the cutting process.

- In the end, the final rubber rings cut were adequate to fit in the 8" double-sided aluminum carrier ring seal grooves without falling out.  For the future, a rule die would be best for cutting the samples and one should be made to prepare the next planned set of test samples.

- The strips were cleaned with Methanol.

- Two 8" double-sided aluminum carrier rings were cleaned and prepared, one packed with EPDM and one packed with BUNA-N (Nitrile). 

- Break-away sample coupons for analysis of the neutron flux received by the 6061-T6 aluminum carrier ring material were notched into the carrier ring fins with a bandsaw and deburred.  Two coupons nomially 0.25" x 0.25" x 0.125" thk were prepared for each ring.  These coupons will be broken off for analysis upon retrieval of these test samples.

- A make-shift lifting yoke to allow us to lower the rings to their resting place over the M9/T2 flange was prepared with and aluminum strip and bail wire (see attached photos).

Our plan for Monday Oct 22nd is to lower the two test samples on their lifting yoke and bail and rest them above the M9/T2 flange before covering up the area with blocks. 

The date and time of insertion will be recorded and samples will live there and receive operating dose from the beam and T2 target until the next time the M9 T2 area is uncovered and we can retrieve them for analysis and testing. 

The reason the 8" aluminum double-rings are used is because we plan to build a vacuum leak test jig using the standard 8" spring-loaded knife edge flanges typical of the designs at the M9T2 and M20T2 joints. 

The irradiated samples will be tested in this jig and compared to samples prepared using the virgin (non-irradiated) material  A test plan will be written to encompass the exact set of mechanical tests the samples will undergo to compare them to the virgin baseline.

Today;

Restoring shielding at M9 T2 area and cleaning up RH setup.

- RH workbench, pole tray and bridges removed from work site.

- 18' x 6' by 3' bridging block removed (at 14:25) to reveal the T2 monument. No apparent change in vacuum, will monitor as shielding is restored.

- Magnet power tests completed by beamlines group, no issues reported.

- Rubber testing ring installed between M9 Q1 and T2, see photo.

- Spring eye gaps appear to be the same as on Friday (after 48h), see photos and video.

Work continues re covering the M9 T2 site tomorrow.

Shielding around m9 t2 restored as of 11:45, vacuum levels still the same since 19 October.

- Work permit returned.

- A dose record of the job is attached as a spread sheet. Total dose for all workers is 1.89 mSv for the job.

- A Small gap in shielding near T1 filled in by plant group in addition to the shielding restoration (neutron radiation).

Started work on removing M9 Q1 Q2 magnets; area clean up and preparation, removing shielding above Q1 and Q2 and remote handling setup over magnet (moving blocks).

1. Covered T2 cooling package and top of monolith with plastic sheeting.

- In addition covered 1A triplet shielding as well.

- Installed 1AS1 18' shield block after sheeting was laid down.

2. Discovered 1A Q14 indium ring thermocouple (TW# B1-378) & thermocouple coil circuit #1 (TW# B1-379) had cable insulation damage. Damage was down to bare wire.

- Wires located under east side of cooling package. See photo.

- Wires repaired with black electrical tape.

3. Vacuum started on T2 volume @ 10:47, roughing pump only.

- @ 11:15 vacuum pressure leveled off at 1.5 T (1ACG4 reading). 11:15.

- @ 13:30 the roughing pump blower package was turned on.

- @14:45 vacuum level steady at 250 mT (1ACG4 reading) .

4. Uncovered and partially set up over T2 M9, Q1 Q2.

- This setup is similar to 2011 and 2012 setups.

- 1A Q12 and 13 were uncovered during setup and a visual check for water leaks was done. None were found.

- Setup uses two 12' x 6' x 4' blocks with 18' x 6' x 4' resting on top, spanning the joint; See photo.

- Will continue with set up next day.

Completed remote handling/shielding setup over T2 M9, see photos for setup.

- Rad levels at 16' above Q2 were 1.2 mSv/h. Shielding was built up to 20' level, same as the opposite side to minimize exposure.

Local and remote leak checks on M9 T2 area were done today to confirm leak; Leak was still present at T2 M9 joint. M9 Q1 and Q2 power supply leads were disconnected (C. Yee). Next task is to find the ground fault on the Q1 magnet.

Indium one piece blank off plate (TB22267) for blanking off assembly (TB22265) was submitted into shop today.

Removed 8" rubber test rings from M9 T2 joint. Rings moved to RH warm cell. Radiation levels were 70 µSv on contact 1.7 µSv @ 1/2 m.

Bagging bunker was setup west of the T2 M9 work area, see photos.

Began disconnecting M9 Q1 Q2 services: Electrical and thermal switch connectors disconnected from service stand, water service lines for Q1 and Q2 remain to be disconnected.

Beam lines group purged M9 Q1 Q2 magnets and water lines in preparation of disconnecting water services to those magnets, done in morning.

- Note: Q15 protueus paddle wheel was replaced after finding it was worn

Water connections at service stand partially disconnected.

- Q2 water lines disconnected, 1 Q1 water line is disconnected but stuck on hansen fitting. with continue on Monday.

- Photo showing stuck fitting shown below (fitting on the right).

Today, re-arranged electrical wiring on Q1 Q2 magnet away from Q2 indium joint. Cable bundles were bundled as neatly as possible.

- One of the klixon thermal switch wires broke off while the cable bundles were being organized. See photo.

Completed disconnecting water services from services stand to Q2.

- Supply connector (the connector that did not come off last week) came off with some effort, return connector came off with no effort.

- Appears to be a slow leak from the male hansen fitting supply side; leaking @ one drop every 11 sec. Also observed a very slow leak (> 2 min) on Q1 return side on magnet stand.

Determined M9 Q2 service stand supply connector was slowly leaking.

- Ball valve to the supply was leaking through allowing trace amounts of water through.

- System was bled again and pressure relieved, leak appears to have stopped.

Inspected M9 Q1 joint bottom bellows bolt lug and spring eye gaps.

- Bottom bolt is in tension, tried to move with tool and did not move.

- Observed spring eye gaps: 1/32" or less on West spring eye, 0.200" on East spring eye.

Cleaned up RH setup in preparation for moving bridge setup tomorrow.

CUALCW system water loss was not from 1A triplet. Q15 Q16 held static pressure at 90 psi since 9 am until 17:00. Holding with very minimal change in pressure. Q14 reading 64 psi as of 17:00. D. Preddy informs all other systems leak tight.

M9 Q1 joint disassembled, blank off and pins removed.

- M9 Q2 joint pin drive retracted but was not removed. Pin drive did not contain the roll pin that aids extraction of the drive.

M9 Q2 15" pin drive was removed and disconnected.

- Pin drive retention screw had to be completely removed to be able to remove pin drive completely.

- Had to make tools to remove pin drive and retention screw, see photos.

- Retention screw removed with 3/4" hex socket with .010" shim inside to cause interference with 3/4 hex bar. Hex socket was then jammed on to screw to retain it. Part was then unscrewed and carried away with socket. 80 µSv on contact, 10 µSv @ 1/2 m, no removable contamination.

- Pin drive removed with double hook tool, left on stand next to steel blocks at magnet elevation.

- 93 turns to fully retract pin drive, 4 turns to completely remove retention screw.

- Q2 joint was pried open with a screwdriver wedged between B1 flange and indium ring. See photo for final result.

Removed Q2 15" indium seal ring, discovered seal contained rubber on both sides instead of indium.

- Some kind of oil residue seen at the bottom of the sealing ring and inside of the Q2 vacuum box. (Note: Oil residue was from downstream vacuum roughing pumps. They were connected when T2 M9 joint was leaking. Oil got into the vacuum pump back streamed into the beam line.)

- Probing of rubber seal showed it was still soft at the top and bottom while brittle on the sides near the beam plane (Small pieces broke away when pressure was applied).

- Ring measured 11 µSv on contact, 0.7 µSv @ 1/2 meter, no removable contamination.

Removed a stainless remote handle-able bolt from Q1 cover plate for assaying.

- Bolt removed from South East corner of top cover plate. See photo for location of removed bolt.

- Removed bolt measured 600 µSv on contact, 11 µSv @ 1/2 m, no removable contamination. Bolt placed in a marked lead vial for storage.

- Replaced with identical remote handling bolt in same location.