Leak checked TM3 without source tray in CS this morning. The CS and TM3 vacuum: IG1(top of the TM3 service cap)4.9x E-7Torr, IG2(diagnostic box  primary)1.9XE-6 Torr. IG1S (secondary vessel)7.9X E-7Torr. The leak detector was at 0.0XE-4 torr and 0.0XE-9 atm.cc/sec level during the leak checked. All water lines quick connector fittings, NPT thread fittings, water cap seals, blue insulator seals, bellow, gauges seals, turbo-pumps, all blanket panels,and TM3 to CS vessel seal have been sprayed with helium and leak checked. No leak has been found. The TM3 is leak tight in CS.

CS water cooling and vacuum system have been turned off at 10:00 AM this morning.The TM3 will be disconnected and moved to silo tomorrow morning.

TM#3 with no target and no source tray has been moved from the conditioning station to the north east silo, move went well.

   I have fallen behind on the HV testing that has been completed on TM3. Data can be found on docushare in the TM3 Rev 3 folder files are too large to attach. From the last elog entry the following tests have been completed

July 8 2013 - Long HV conditioning 50kV achieved before sparking caused PS to trip. Was unable to recover to the same voltage

July 9 2013 - Attempted to repeat previous test lost PS at 45kV. Voltage continued to degrade during the day.

July 10 2013 - Max voltage achieve 42.5kV discussed with Friedhelm and decided to run the EINZEL lens at 50% of the BIAS in case this is the source of the sparking

July 10 2013 - Max voltage 40.5kV with EINZEL lens. Communicated with Friedhelm and Lia. It was decided 40kV was good enough. Started developing standard test (see below for testing procedure) for Module so a with and without source tray 

July 12 2013 - Only one spark on route to 40kV. PS tripped after ~10 minutes at 40kV. Near the end of the day there wasn't enough time to repeat test.

July 15 2013 - Test repeated, could not hold 40kV. 39kV held for 1 hour with EINZEL lens off. Sparking was making it difficult to keep on.

July 15 2013 - TM3 was electrically disconnected from the conditioning station. The station ran at 60kV for 1 hour with zero sparks.

July 16 2013 - Test repeated with goal of 39kV intense sparking after 20 minutes caused the PS to trip. Once again the EINZEL lens PS was tripping and eliminated from use to make the test easier. With the failure of this test once again Friedhelm was once again consulted. He advised to stop testing as it appears to be causing damage. There is concern that the module is degrading. Lia has stated this does not affect the source tray and that a source tray will be inserted into TM3 and she accepts responsibility if the module does not hold voltage. 

Standard testing procedure for the bias was as follows. Please note that the EINZEL lens was supposed to follow the BIAS steps at 50%. This procedure was approved by Friedhelm prior to operating. This test was never successfully completed and we will not be able to complete a "apples to apples" test once the source tray is installed.

> Step to 5000 kV If no sparking after 1 minute

> Step to 10000 kV If no sparking after 1 minute

> Step to 15000 kV If no sparking after 1 minute

> Step to 17500 kV If no sparking after 1 minute

> Step to 20000 kV If no sparking for at least 1 minute after 5 minutes

> Step to 22500 kV If no sparking for at least 1 minute after 5 minutes

> Step to 25000 kV If no sparking for at least 1 minute after 5 minutes

> Step to 27500 kV If no sparking for at least 1 minute after 5 minutes

> Step to 30000 kV If no sparking for at least 1 minute after 5 minutes

> Step to 31000 kV If no sparking for at least 1 minute after 5 minutes

> Step to 32000 kV If no sparking for at least 1 minute after 5 minutes

> Step to 33000 kV If no sparking for at least 1 minute after 5 minutes

> Step to 34000 kV If no sparking for at least 1 minute after 5 minutes

> Step to 35000 kV If no sparking for at least 2 minute after 10 minutes

> Step to 35500 kV If no sparking for at least 2 minute after 10 minutes

> Step to 36000 kV If no sparking for at least 2 minute after 10 minutes

> Step to 36500 kV If no sparking for at least 2 minute after 10 minutes

> Step to 37000 kV If no sparking for at least 2 minute after 10 minutes

> Step to 37500 kV If no sparking for at least 5 minute after 10 minutes

> Step to 38000 kV If no sparking for at least 5 minute after 10 minutes

> Step to 38500 kV If no sparking for at least 5 minute after 10 minutes

> Step to 39000 kV If no sparking for at least 5 minute after 10 minutes

> Step to 39500 kV If no sparking for at least 5 minute after 10 minutes

> Step to 40000 kV Maximum 3 sparks per hour maximum test time 3 hours.

TM#3 and its new source tray have been both moved into the south hot cell.

The water block sealing surfaces on the module-side of TM3 were polished this week by Chad Fisher, using his air-ratchet controlled rotating head tools (single and double-surface polishing tools).

Photos of the polishing tools in-use are attached (from August 16 - 21, 2013)

Scotch-brite pads were used, followed by 2000 grit sandpaper, then white felt with isopropanol, then lint-free dry polishing pads, each on detachable heads that are used with the polishing tool.

The module-side water block surfaces were inspected by Grant Minor on 21 Aug 2013 using a level telescope and camera looking through the hot cell window.  Results can be viewed here, with photos indicating which block is being viewed in sequence.

https://documents.triumf.ca/docushare/dsweb/View/Collection-11251

After a great struggle with the water block jigs, the TM3 source tray was finally advanced fully into the service tray and all water blocks were connected and torqued to spec in the hot cell by Chad Fisher.

Notes and description of problems encountered during the installation:

- The water lines for the optics tray interfered with the module-side water block jig, and had to be bent out of the way to clear while advancing the tray (see attached photos)

- The water block jig on the source tray side was too low relative to the module side, and had to be eventually unbolted completely from it's mounting bracket in order to raise it up into alignment

- A piece of aluminum plate was placed under the jig, and the pneumatic table was raised in order to move the jig upwards

- After many repeated attempts to engage the blocks by pressing the jigs together, it was discovered that some of the blocks had rotational misalignment with their respective counterparts on the module side, preventing the pins from engaging properly

- By looking through the bolt holes on several of the blocks, it was possible to determine which direction they had to be rotated

- Chads polishing tool was used to apply some torque to rotate the source-tray-side water blocks slightly so proper alignment of the pins could be achieved

- See the attached photo which indicates which blocks had to be rotated (blocks 5, 6, 9, 10, and 11)

- The blocks had the bolts installed and were also torqued in the numbered order shown in the attached photo

Next steps are to remove the water block jigs, re-connect the loosened brackets for the remaining water lines (entrance window, optics tray), re-install the containment box and associated VCR connectors, video inspect, and leak check.

While continuing on the TM3 Rev 3 source tray installation, Chad noticed today that one of the steerer wires is broken and has come out of the thermocouple-style connecter block (see attached photos).

From drawing ITA2826 (Rev D02 attached) it is likely that this is for either the "upper" or "right side" steerer plate.

Today Chad finished making all connections to the new source tray, except for:

- steerers - broken wire, must be repaired at a later date

- IMG gauge - bracket required, old bracket thrown out with previous tray by accident, see ITA3301, must be installed at a later date

- entrance window - the window lines on module side were left blanked-off for leak checking, containment box must be removed in the next few days to complete steerer repairs so these lines were not connected to save work from having to be repeated

The containment box was replaced, and TM3 was moved to the CS for pump-down and leak checking (see other e-log).  David reported at 6:15 pm that the turbos were turned on at the CS and the vacuum looked normal (so far).

As stated above, Chad realized today that he had thrown out the old IMG gauge bracket with the previous source tray, and a new one must be manufactured.  The assembly is described by ITA3301.  Three components must be manufactured (ITA3302, ITA3303, and ITA2673).  A stock split-ring clamp for ITA2673 (MDC #716001) was graciously donated by Dimo Yosifov.  Grant Minor submitted a work order to the machine shop today for 2 each of ITA3302 and ITA3303.

Target Module 3 with no target, and a partially-installed Rev-3 source tray (no steerers connected, no IMG connected, entrance window lines blanked off on module side and not connected to containment box) was transported successfully to the Conditioning Station by Travis Cave and David Wang at around 4pm today.  David attached the vacuum system for start of pump-down to prepare for leak checking.

David Wang started a helium leak check on TM3 at the CS this morning.

David will create an e-log once his check is complete, but here are the preliminary results:

- target oven +/- OK

- mounting support plate OK

- ionizer tube heater +/- OK

- extraction electrode OK

A large leak was found in the heat shield circuit:

- The module pumped down with the leak rate stabilizing at 4.8xE-9 atm.cc/sec
- 60 psi helium was applied to the heat shield fitting on the right side of the Y-shaped connector (see attached sketch, each side of the "Y" is separated by a face to face metal contact only, i.e. no o-ring seal separates supply and return water)
- The maximum leak response was detected in 10 seconds, with base pressure rising from 2.0E-2 torr to 2.8xE-2 torr
- The helium was vented from the line by using an allen wrench to open the valve on the water quick-connect (see attached photo)
- The module continued pumping down, and after some time, the allen wrench was used again to open the valve, but air rushed inside, indicating vacuum was being drawn inside the water line through the leaking interface
- As the module continued to pump, this vacuum vent air rush inside the water line could not be reproduced by opening the valve again with the allen key

The module is currently pumping down at the Conditioning Station. We will leak check the remaining lines tomorrow with whatever base leak-rate we have achieved, and then move TM3 to the Hot Cell for further diagnosis.

TM#3 with no target has been moved from the conditioning station to the south hot cell. The fields observed around the containment box of the module ranged from 0.80 mSv/hr to 1.8mSv/hr..

A huge leak had been found on HS circuit during 60 psi helium pressurize test. Other circuits are free of obvious major leak at present .We will test them again once the TM3 is back to CS. See attachment for details

The heat shield circuit was pressurized with air (15-20 psi) and snoop applied to the water block joint and brazes. Bubbles formed at the joint between the two water blocks indicating that the leak is a c seal problem. Pictures attached but also on docushare Collection-11285.

chad fisher wrote:

The heat shield circuit was pressurized with air (15-20 psi) and snoop applied to the water block joint and brazes. Bubbles formed at the joint between the two water blocks indicating that the leak is a c seal problem. Pictures attached but also on docushare Collection-11285.

 Last night prior to this leak check the Heat Shield was pumped on and helium sprayed on the circuit. The pressure was 0.0 x 10^-4 Torr. The leak was traced to water block. response time was 2 seconds and went from 5.5 x 10^-8 to 1.6 x 10^-6 atm*cc/sec. There was also a response without spraying helium (drift from the nozzle). The results of this testing prompted the testing completed in Chads elog.

Bevan Moss wrote:

chad fisher wrote: The heat shield circuit was pressurized with air (15-20 psi) and snoop applied to the water block joint and brazes. Bubbles formed at the joint between the two water blocks indicating that the leak is a c seal problem. Pictures attached but also on docushare Collection-11285.  Last night prior to this leak check the Heat Shield was pumped on and helium sprayed on the circuit. The pressure was 0.0 x 10^-4 Torr. The leak was traced to water block. response time was 2 seconds and went from 5.5 x 10^-8 to 1.6 x 10^-6 atm*cc/sec. There was also a response without spraying helium (drift from the nozzle). The results of this testing prompted the testing completed in Chads elog.

 Please find attached some schematics which help illustrate the setup for this heat-shield circuit leak check.

 Today Chad entered the south hot cell on work permit 2013-08-29-3 to repair the leaking heat shield line. The heat shield line was removed from the module and the surfaces cleaned. New C seals and spring were inserted and the line re-attached. During this time Chad also installed the new vacuum gauge. Grant took video of this work and Keith some pictures. The video and pictures can be found on the M: drive (groups) in the RH folder. The total time taken was ~ 25 minutes. The line was then pumped on and the block was sprayed with helium. The pressure and leak rate started at 0.0 x 10^-4 Torr and 4.0 x 10^-8 atm*cc/Sec. When the helium tank was opened there was an immediate response with the leak rate climbing to 2.7 x 10^-7 atm*cc/Sec. It then stabilized at 2.0 x 10^-7 atm*cc/Sec and was sprayed with helium. Response time was ~2 seconds the leak rate climbed to ~2.3 x 10^-5 atm*cc/Sec the pressure also increased to ~3.0 x 10^-3. The leak detector cart was left attached for another 1.5 hours but still was not able to stabilize in the 10^-9atm*cc/Sec range. 

Bevan Moss wrote:

Today Chad entered the south hot cell on work permit 2013-08-29-3 to repair the leaking heat shield line. The heat shield line was removed from the module and the surfaces cleaned. New C seals and spring were inserted and the line re-attached. During this time Chad also installed the new vacuum gauge. Grant took video of this work and Keith some pictures. The video and pictures can be found on the M: drive (groups) in the RH folder. The total time taken was ~ 25 minutes. The line was then pumped on and the block was sprayed with helium. The pressure and leak rate started at 0.0 x 10^-4 Torr and 4.0 x 10^-8 atm*cc/Sec. When the helium tank was opened there was an immediate response with the leak rate climbing to 2.7 x 10^-7 atm*cc/Sec. It then stabilized at 2.0 x 10^-7 atm*cc/Sec and was sprayed with helium. Response time was ~2 seconds the leak rate climbed to ~2.3 x 10^-5 atm*cc/Sec the pressure also increased to ~3.0 x 10^-3. The leak detector cart was left attached for another 1.5 hours but still was not able to stabilize in the 10^-9atm*cc/Sec range.

 Also of note is that Chad received a full days dose and that when the plastic was surveyed there were ~150 counts found on it.

Bevan Moss wrote:

Bevan Moss wrote:  Today Chad entered the south hot cell on work permit 2013-08-29-3 to repair the leaking heat shield line. The heat shield line was removed from the module and the surfaces cleaned. New C seals and spring were inserted and the line re-attached. During this time Chad also installed the new vacuum gauge. Grant took video of this work and Keith some pictures. The video and pictures can be found on the M: drive (groups) in the RH folder. The total time taken was ~ 25 minutes. The line was then pumped on and the block was sprayed with helium. The pressure and leak rate started at 0.0 x 10^-4 Torr and 4.0 x 10^-8 atm*cc/Sec. When the helium tank was opened there was an immediate response with the leak rate climbing to 2.7 x 10^-7 atm*cc/Sec. It then stabilized at 2.0 x 10^-7 atm*cc/Sec and was sprayed with helium. Response time was ~2 seconds the leak rate climbed to ~2.3 x 10^-5 atm*cc/Sec the pressure also increased to ~3.0 x 10^-3. The leak detector cart was left attached for another 1.5 hours but still was not able to stabilize in the 10^-9atm*cc/Sec range.   Also of note is that Chad received a full days dose and that when the plastic was surveyed there were ~150 counts found on it.

Today Chad entered hot cell again and removed the HS module side and Junction Block Wiring Harness (module side). In addition to this he blanked off the module side HS line. It took Chad 16 minutes to perform these tasks and he received a dose of 0.20 mSv bringing his total to 0.84 over the last 2 days. After exiting the hot cell Chad completed a leak check on the module side. The line pumped down to the limits of the leak testing cart 0.0x10^-4 Torr and 0.0x10^-9 atm*cc/sec and there was no response. A video of Chad in the hot cell can be found in:

M:\remote handling\Photos\2013\2013_tm3_source_tray_refurb

This afternoon was spent surveying the anteroom and receiving teaching from Chad as to how to be a hot cell operator. There was little in the way of contamination ~150 counts near the HC door and ~50 counts on the surrounding floor. The wiring harness has a field of 900 uSv/hr but is suspected most of that is coming from the aluminum steerer bracket.