Aaron and I successfully completed a run through on the procedure to replace the 'Z' motion cable. I will be writing up the procedure for review and we will be performing more run through-s for practice before the actual job.

The North Hot Cell interior walls, floor, and ceiling were re-finished, sealed, and painted by Omni Coating from Feb 6 - 17 under PO #3036471.  This job required 2-3 people for 4-6 hours per day over the 2 week period.  First the existing surfaces were ground and/or sanded to remove existing coatings and protrusions/sharp edges.  This was followed by a coat of primer to highlight uneven surfaces and improve adhesion of following fillers and coatings.  Metal shims between the cell walls and roof were cut away where they protruded into the cell.  Loose steel cylinders between SHC and NHC spaces were fixed in place using epoxy filler. Epoxy or polyurethane fillers were used to fill all gaps, cracks, holes, etc, as detailed below.  Foam backer rod and polyurethane filler were used to seal all large wall-to-wall and ceiling-to-wall gaps.  An approximate 2cm radius rounded corner was formed at all wall-to-wall and floor-to-wall corners using polyurethane sealant.  The interior of the tool-port, personnel access hatch, as well as the north roof hatch were also re-finished with the same procedure.  After all sealing and finishing work the surfaces were coated with "Mill White"  Macropoxy 646 Fast Cure Epoxy Paint as per manufacturer instructions.  Note:  this paint is recommended by the manufacturer for nuclear applications and has been tested for decontaminability:  99% water wash; 95% overall as per ASTM D4256/ANSI N 5.12 as well as for radiation tolerance:  Passed ASTM D4082 / ANSI 5.12 with a 525 micron thick coating.

The following products were used as described (data sheets attached):

Sanitile 120 Universal Acrylic Primer - 50-75 micron dry film thickness coat applied over all existing ceiling, walls, and floor surfaces after preparation by sanding

Sika Duochem 8107 Epoxy Paste - Used for filling voids and cracks in concrete surfaces

Sikaflex 291 Polyurethane Elastomeric Adhesive and Sealant - used for caulking joints and cracks in the concrete walls and aluminum panel wall and for creating radiused corners in wall-to-wall and wall-to-floor corners

Macropoxy 646 Fast Cure Epoxy Paint - 4 coats applied on all surfaces using rollers or brushes to create a total thickness of 525 microns as per data sheet

Aaron and I completed assembling (re-assembling) the clean spare on Tuesday, February 14th to assist in determining a procedure for replacement of the 'Z' motion cable on the south hot cell manipulators.

The anchor point in the slave end of the clean manipulator could not be found as the manipulator stand is too low and does not allow full extension of the slave end.

Did some poking around on the in-situ manipulator in the south cell and was able to find the anchor point viewing it with the in cell camera (see blurry attached photo).

Was able to then find reference to the "cable clamp" in the parts list and drawing for the slave end. Also, confirmed there is not a procedure in the manual for a CABLE 'Z' motion system as we have, only a tape driven system. The procedure should however be very similar safe this mystery anchor point I discovered today and how readily this anchor point can be worked in.

TCS:TK2 , Water has been refilled to 28.5" level. It was 15.1". Fall protection equipment  are used during the job.

 The North Hot Cell shielding window gaskets have been changed and the window has been filled with new oil.  Although there was no noticeable oil leaks before starting the job, the gaskets had not been changed since initial installation approximately 15 years ago, so they were done now as part of construction of the new  cell.  The work took place between January 26 – Feb 8, 2017 following the attached PDF “Full procedure for NHC shielding window gasket change” which references “Gasket change procedure from Hot Cell Services” (also attached).

To drain the window a 1/2”polyethylene hose was attached to the drain line using  a Swagelok fitting and routed into a 55 gallon drum.  A vent valve on the expansion tank was opened to allow air to enter  the window.  It took approximately 5 hours to drain the window using this method.  Approximately 50 US gallons were drained from the window, agreeing with the amount specified on Hot Cell Services drawing #96173-100 (attached).

After draining, the window was purged with helium then pressurized to approximately 13” WC with helium.  A pressure drop of 0.6” WC was observed over a 2 hour period.  While pressurized, a Varian G8601-60001 leak detector was  used to sniff for helium around the perimeter of the gaskets on both the hot and cold  sides – no helium leaks detected.  A small leak was found on the pressure gauge used to monitor helium pressure.

The cold side cover panel assembly was  then removed  following the HCS procedure.  From HCS Drawing #96173-100, the weight  of the cold side glass cover panel was estimated to be  approximately 50lbs.  The guide  pins used were McMaster-Carr PN# 93460A385.  The trim frame could be easily removed, however the glass panel was stuck to the window housing.  A putty knife and isopropyl alcohol were used to cut through the gasket to separate the window from the housing.  The alcohol did not damage the paint of the housing – acetone was also tested on a small area and did not cause damage  to the paint.  Two suction cup handles were used to transport the glass panel, and it was easily lifted by two people.  Various methods were attempted to remove old gasket material and gasket adhesive  from the trim frame and housing surfaces – the most successful was using a razor blade scraper to remove the majority of the material, followed by an acetone wipe to remove the remainder of the stuck-on gasket adhesive.  The panel was reinstalled with new gaskets following the attached  procedures - no issues encountered.  After torqueing the trim frame bolts the window was leak checked as before.  A drop of 0.8” WC was observed over two hours, and no helium could be detected around  the perimeter of the new cold side gasket.

The hot side cover panel assembly was changed using the same method as for the cold side.  The glass panel was estimated to be 150lbs.  A small amount of oil (< 0.5 L) remained behind the hot side glass panel after draining which spilled out after removal of the glass. Four suction cup handles were used, and four people were required to remove and reinstall the panel.  After installation the leak check was repeated with a drop of 0.3” WC observed over two hours, and no helium detectable around the perimeter of the hot side gasket.

The replacement gaskets were ordered from Hot Cell Services under PO# 3033973 matching the material and sizes specified on  HCS drawing #96173-100.

The window was filled with Drakeol 10B LT MIN OIL NF, Product  code: PEN1550-00-C-DR, PO #3034657.  The window was filled by lifting the drum onto the walkway leading  to the target hall entrance, and siphoning the oil out of the drum with a 1/2” polyethylene tube connected to the drain fitting, and an air vent open on the expansion tank.  Oil was added until the expansion tank was approximately 80% full.

After filling was complete, the cold side housing was repainted using Macropoxy 646 epoxy paint, 4019 Flint Gray.  When the inside of the NHC is next accessible the hot side trim frame bolts will be re-painted to protect the bare metal exposed from removing and reinstalling them.

Note that a quote for $74,313 ($56,823 USD) (PDF attached) was received from Hot Cell Services for them to do this job.  We were able to  successfully complete this ourselves with approximately $4500 required for the gaskets, $200 for other materials, and roughly 8 FTE days of work.

Target module window  cooling lines at TCS has been modified to use spare 2 channel in TCS: WFB1. The old cooling lines used a spare channel in TCS WFB2(HVC channel) are removed and capped. After change, TCS window cooling lines will be interlocked with heaters. The test run on new lines are good. No leak  on all fittings, and signals on flow and temperature are good.   Control people will be noticed on this change for their following up job.

 Lead gasket IRH1633 was installed today according to assembly drawing IRH1618 Rev B.

ITW has been cleaned up today.  All station are vacuum cleaned. I wiped all HV cover and HV area including conductors and insulators. The black foams which are used to wrap around TP back up line are degrading now. I removed most of these foams. Also, Some obsolete  water lines  are moved our of station. All waste are bagged . they will be surveyed and  stored(or disposed) according to radio-active level.

Update 2017 winter shut down target hall schedule. See attachments

TM2 has been connected in ITE. The SST window water lines in ITE can not be connected properly to TM2. The water line connector on TM2 window is 90 degree CCW installed in direction comparing to TM4.This caused the problem. Solution: Two piece of flexible lines and extra male QC adapters have been used to fix this issue.  HV cover and HV fence in ITE work  with TM2. Other connections are good as well.

The move is successful.

On Thursday, January 26th UCx#18 and Ta#50 were inspected and packaged into spent target pails, move to storage vault.

Ta#50 has been was removed from TM4 on Wednesday, January 25th.

On Tuesday, January 24th UCx#18 was removed from TM2 and Ta febiad dummy installed. I encountered the same issue mounting the new target as last time. Was able to determine that the issue is the routing of the waterlines to the right-hand (as viewed from the operator) high current tube heater. The lines interfer the the target mounting plate (bottom right hand corner).

The move is smooth. Yasmine and Travis did the move.

I connected TCS vacuum system to TM2. The station is under roughing now. All turbo pumps will be started soon.

I did electrical check before and after Fefiad target installation on TM2. The RU (coil) Is till short to 60KV as before. Other result are good. After Febiad target is installed, Tm2 HS line is leak checked. On leak detector, base leak rate pumping down is much slow  than before.  The base pressure still could be pumped down to 0.0XE-4 torr.  After a long time wait, Chad and I leak checked at 2.2XE-8 atm.cc/sec base leak rate. Chad sprayed lots helium around the fittings and target. No any response has been found on LD. At this leak rate, the target and HS line is leak tight.  The Tm2 has been moved to THC so a heium pressure check will be fulfilled on HS line at TCS to confirm this leak check result.  

TM2 HS line is pressurized with 70 psi helium at TCS. LD base leak rate: 0.0 X E-9 atm.cc/sec. Base pressure 0.0XE-4 torr. 5 minutes test time. The leak rate slowly climed to 3.3XE-9 atm.cc/sec and stabled there( 3minutes). base pressure no change. The leak is too small to be concern. We will run this target as this condition.

Updated target hall schedule for 2017 winter shut down. See attachments 1,2

Update schedule after Febiad beam schedule changed to ITE. See attachments 3,4

 The final panels of the partition wall were installed today as per drawing IRH1609.  Sealing, finishing, and painting of the NHC walls and floor can now commence.

ITE and TM4 2017 winter shut down leak check are finished. All ITE primary, secondary vacuum vessel and TM4 water lines are good. No any leak has been found.