Defeated T1 and T2 cooling package vacuum interlocks at 1-C panel on South mezzanine in Meson Hall to allow cooling packages to continue running after beamlines are vented.

Notified operations.

Uncovered T2 monolith and transferred M20BB to hot cell using flask.

Field at 0.5m from beam blocker while being lifted with flask: 21,700μSv/hr (using pole monitor) 

Field above hole after removing M20BB: 9000μSv/hr

 Replaced M20 beam blocker vacuum seal o-rings.  Old o-rings were noticeably harder, but not brittle or cracked.  Applied "Haskel Dry Air Seal" lubricant to air cylinder shafts and "Apiezon M Grease" to vacuum seal o-rings and main shaft.  Took approximately 1 full days work.  Total dose: 0.08mSv.

M9 beam blocker returned to beam line.

T2 target disconnected, picked up using flask, and returned to beam line as training exercise.
Field @ 50cm from T2 target during removal:  ~90,000μSv/hr

Resin can flask with new resin moved from hot cell lab to T1 cooling package area.

Replaced all o-rings and filters on the T1 cooling package.  Replaced resin can.  Refilled package and restarted. 
Can inlet resistivity at 9.8MΩ *cm, outlet at 11.5MΩ*cm after approximately 3.5 hours.

(Collimator A filter and modified filter housing to be installed at a later date)

 Graham Waters has activated the appropriate target ladder position look-up tables for the T1-MK1 target which was installed in the beam line yesterday.

 Diagnostics group completed their "blip" signal response tests on the T1 and T2 profile and protect monitors.  A small amount of leakage was observed on the T2 profile monitor, but was not thought to be a significant concern.  All other results were normal.

 In preparation for extended periods of the T2 volume being vented during the M20 repair, the T2 water package was shut-off, the water lines were disconnected from the target, and the cooling water was removed from the target using compressed air.

 While leak checking components in the M20 front end on May 25th, the top of the T2 monolith was also checked by flooding the top of the monolith with helium while it was covered with plastic sheeting.  There was no response on the Varian leak detector indicating no significant leaks from the flange seals, shaft seals, and seals for upper services on the T2 target, T2 protect monitor, M9BB, M20BB, and M8BB/Col.A

A full rebuild of the upper air amplifier was completed.  New anodized aluminum barrels were installed (replacing the old brass design), as well as new pilot valves, piston seals, bearings, and o-rings.  

The amplifier is operating smoothly with a cycle period of 25.6 seconds, compared to 14.8s before rebuild (based on 8 cycle measurents at 110psi output with beam blockers lowered).  

The lower air amplifier currently has a cycle period of 24.8 seconds under the same conditions (rebuilt in 2010).

 The target water outlet flow transducers on the T1 and T2 cooling packages were serviced (new shaft, paddle wheel, & o-ring) to address a noisy signal.  The service corrected the noisy signal.  Additionally, it appears the worn parts were causing the transducers to read high, as both dropped approximately 1 gallon/minute after the service.  Both transducers would occasionally trip the high flow warning (8.5gpm), and should now no longer do so.

A plot of the water outlet flows before and after the service is attached.  Cyclotron fault report #6086 was returned.

 The following tasks were performed during the 2012 September Shutdown:

- Both targets moved to position 0 in preparation for testing of profile monitors (portable ladder control box was used for controlling ladder motors)
- T2 monitor OK; T1 monitor would not hit 'IN' limit
- The T2 branch of the amplified air system was closed, now the T1 monitor hits the 'IN' limit properly  (conclusion: a known leak in T2 section of amplified air is causing a drop in pressure of the system which prevents the T1 profile monitor from actuating properly)

- Both cooling packages were inspected and photographed (nothing abnormal observed)
- Both cooling packages drained, and water samples delivered to RPG
- Expansion tank level sensors tested at both packages: All OK
- All Hansen quick connect o-rings replaced at T1 package
- 90 micron filter on demin line replaced at T1 (caused ~0.2gpm increase of Q2 flow)
- Both packages refilled and restarted (operating normally)
- Q2 flow on both packages adjusted to ~1.45gpm

- The cause of the amplified air leak was discovered to be a cracked air dryer located in the BL1A service tunnel (photo attached)
- The air dryer was replaced which stopped the leak, resulting in a significant decrease in air amplifier cycle period and an increase in air amplifier output pressure from ~110 to 120psi

- Movement of the T1 ladder caused a spike in beam line vacuum;  After further testing it was concluded that the T1 target was leaking water
- T1-MK2 target was transferred from the beam line to the hot cell; T1-MK1 target was transferred from the storage pit to the beam line
- T1-MK1 profile and protect monitor electronics checked by Bill Rawnsley: Both OK
- Initially a leak was suspected at T1, but it was later discovered that the volume was just pumping down slowly due to water in the beam line from the T1-MK2 leak
- T1 profile monitor was not actuating properly;  It was found to be caused by a short to ground on one of the profile monitor limit switch wires.  The faulty wire was replaced by Probes Group
- T1 and T2 profile monitors tested.  Both actuating properly.
- New target ladder information sheet delivered to ops

- The leak in T1-MK2 was found to be coming from the center of the beam spot on the entry side of the position 3 target (photo attached, but not great quality).  This is a 12mm Be target, and has been running in beam position since initial start-up this spring.

- T1-MK2 target moved from storage pit to hot cell
- Removed unused proximity sensor and associated wiring (stored in tool-port boot box cabinet)
- Tested profile monitor actuation: seems stiff, but moves ok;  start travel @ 30psi, fully in position @ 50psi
- Replaced vacuum flange o-rings: Plug (#202), Feed-through port 1 (#222), Water supply tubes 1 and 2 (#208)
- Replaced all nylon ferrules for water supply tubes
- Leak checked water supply tubes: leak tight
- Replaced rusty nuts on profile monitor lift plate
- Profile monitor limit switch wiring replaced (D. Cameron)
- Heat shrink applied over motor wires (D. Cameron)
- Position micro-switch connectors replaced (D. Cameron)
- All wiring wrapped with protective coil and secured with PEEK zap-straps (D. Cameron)
- All limit and position switches tested: ok
- Profile monitor bellows straightened (noticed rotation of base seems stiff)
- T1-MK2 target moved to storage pit location #3
- T2-MK1 target moved from storage pit to hot cell for re-wiring

 

- T2-MK1 target transported from storage pit to hot cell
- Proximity sensor removed
- Target lift "T" removed, painted, relabeled
- Replaced flange o-rings: Plug (#202), Feed through port 1 (#222), Feed through port 2 (#222), Feed through port 3 (#213), Water supply tubes 1 and 2 (#208)
- Replaced all nylon Swagelok ferrules
- Leak checked water tubes: OK
- All wiring above vacuum flange replaced, secured, inspected  (D. Cameron)
- Damaged lower MS connectors replaced  (D. Cameron)
- Discovered motor wire insulation degrading  (D. Cameron)
- Motor replaced and rewired
- Motor, position micro switches, and profile monitor micro switches tested: ALL OK
- Tested profile monitor actuation: Smooth (IN: start motion @ 5psi, fully actuated @ 20psi)
- Target lift "T" installed
- Feed through port cap #2 replaced with TBP0936 (old cap was makeshift part using weird gunk sealant)
- Upper and lower parts of target photographed
- Target ladder moved to position 0
- Target ready for use.  Will be transferred to storage pit hole #4

* Approximately 50cpm found on 44-2 monitor from wet wipe used to clean blue flanges surrounding hot cell entrance on HC roof
 

Friday Jan 25:
- Both sides of heat exchanger drained, disconnected, and capped
- Heat exchanger transported to warm cell (field from H.E. approximately 15µSv/hr at 0.5m)

Monday Jan 28:
- Both sides of heat exchanger flushed with city water
- Heat exchanger lifted and tilted to drain as much water as possible 

The T2-MK2 target was transported from the beam line to the RH hot cell.  The profile monitor was secured in the 'in' position before lifting the target, as it is better protected in this configuration.  This procedure will be used for all future target moves to reduce the risk of damage to the monitor.

The field on the target while lifting was approximately 5mSv/hr at 2m.  A field of 12mSv/hr was measured directly above the T2 target hole on the monolith.  A shield plug was installed into the hole which reduced the field to 500µSv/hr.

A section of the "montior" cable was found to have damaged insulation (photo attached).  Fortunately this cable terminates at the cooling package, so only a short section needs to be replaced.

- The new tube array was picked up from Kaltech on Feb 8th (observed vessel holding 60psi on hydro test at their shop)
- Vacuum leak checked at TRIUMF: would not pump down
- Applied 20psi air, and found leaks on both tube sheets using Snoop

- Dropped off tube array at Kaltech on Feb 13th for repairs
- To fix the welds on the manifold side it was necessary to cut open the manifold, then weld on a cap after re-doing the welds
- Calculations were performed to determine the stress on the welds of the new cap.  The weld was found to have a factor of safety of 27.4 (notes attached in PDF format)

- Repaired tube array was pressurized to 65psi with air at Kaltech and placed in a water bath: no bubbles.  Also checked welds with Snoop: no leaks
- Transported tube array to TRIUMF on Feb 20th
- Helium leak checked assembly, no leaks

- Old heat exchanger assembly was disassembled: old o-rings were stiff, but not cracking
- Small active metal chunks and flakes were found in the tube side outlet manifold (~1mSv/hr on contact)
- The old tube array was measured to be 8µSv/hr at 0.5m, and 500µSv/hr on contact at specific locations, which indicates that active chunks of metal may be stuck at certain places in some tubes
- Shell side of old tube array had  brownish/orange buildup, tube side appeared fairly clean (see photo below)

- The new tube assembly was inserted into the H.E. shell (required some filing on baffle welds)
- The welds between the baffle strips and large tube sheet were found to interfere with the flange on the shell as shown below (this was an oversight on the drawings, not machine shop error)

- The tube sheet face was skimmed on the lathe by Maico and Dan Wright to remove the interfering weld material
- Repeated the vacuum leak check after machining: no leaks
- The modified tube array fit properly within the shell as shown below

- All parts were cleaned using Windex, followed by methanol, with special attention to sealing surfaces
- The heat exchanger was reassembled using new o-rings, new fasteners, and NeverSeez compound on all fasteners
- A static water test at city supply pressure (~70psi) was performed on the vessel, and a leak was found coming from the tube stub seal (#319 o-ring)
- An o-ring calculation was performed which indicated that the current configuration only compressed the o-ring 15.4%
- 1.50" OD, 1.080" ID shims were machined from 6061 aluminum at 0.017", 0.022", and 0.029" thicknesses as shown
- The addition of a 0.029" shim was calculated to increase the o-ring compression to 27.7%

- The 0.029" thick shim was installed as shown below

- The vessel was filled with water and pressurized to city supply pressure (~70psi): no leaks
- The pressure was increased to 150psi (1.5X the working pressure) using a Reed hydrostatic test pump supplied by Beamlines Group
- No water leaks were observed
- The vessel was valved off while under pressure downstream of the pump hose
- The following pressure drop was observed over the course of a weekend:
     Mar 1st @ 2:35pm:  151psi
     Mar 1st @ 4:30pm:  142psi
     Mar 1st @ 5:30pm:  139psi
     Mar 4th @ 9:00am:  70psi

- This indicates a slow leak either through an o-ring seal on the vessel, the valve used for pressure testing, or one of the fittings used for pressure testing
- The vessel was drained and pressurized with air to house pressure (~100psi)
- Snoop was applied around all o-ring seals: no leaks found
- The leak check with Snoop indicates that the leak must have been through a valve, on a pipe fitting, or of too low a rate to be of any concern

- The heat exchanger was tipped on its side to allow the shell side to be fully filled with water
- After filling with city water, a ball valve and solenoid valve were installed on the shell side ports to prevent water leaking during transport (see photo below)

- The heat exchanger was bagged and transported back to the T2 cooling package
- Testing of the heat exchanger will be done when the T2 target is reinstalled and the CuALCW system is back up (in approximately 2 weeks time)

- T2-MK2 target moved from beamline to hot cell (Feb 4th)
- Steel target support shield installed as well as ~3 layers of lead blankets.  Even with this extra shielding fields in the working area were as high as 800µSv/hr.
- Target flushed with water, then with air overnight to dry
- Target pumped out using cold trap (required 4 iterations to removed all water)
- Target lift "T" removed, painted, labelled 
- Unused proximity sensor removed and stored in tool port boot box cabinet
- Replaced o-rings for feed through ports #1, 2, and 3, as well as plug port
- Removed unused electrical feedthrough at port #3 and replaced with plug
- Replaced all nylon Swagelok ferrules on water supply lines
- Leak checked upper water supply lines, found Hansen fitting teflon tape needed replacing, then was leak tight

- Target wiring inspected by Dave Cameron, determined all wiring requires replacement including motor wires
- Removed target ladder drive motor, found motor coupling had degraded and was crumbling
- Ordered new aluminum flexible coupling (McMaster PN: 6208K511)
- Installed new coupling and replacement motor (See attached photo)

- Disassembled profile monitor upper cable housing, and inspected the o-ring under part SKRH1001B.  The condition of the o-ring was good. Bent pins found on Deutsche connector
- Deutsche connector was found to be installed with 2 o-rings in a single o-ring groove, neither was the correct size
- Reassembled profile monitor assembly using new Deutsche connector installed with nut side up for easier future removal.  New SKRH1001B part was used with polished o-ring surfaces.  New o-rings used with Apiezon M grease

- Re-wiring completed by Dave Cameron (March 12th) (See attached photos)

- Checked motor functionality, position microswitches, monitor microswitches:  All OK
- Actuated profile monitor: smooth travel, no bellows twist, fully engaged @ 20psi
- Installed lift "T", threads on support pillar B10106 required chasing
- Photographed target ladder and above vacuum flange
- Confirmed suspicion that part B10105 is undersized and was installed with an undocumented spacer between it and part D10390
- Added this spacer to Solidworks model of target (3/4" OD, 0.505" ID, 5/8" height)

- Leak checked water supply bellows and target cassettes: OK (scanned PDF of results attached)
- Target ladder left in position 0
- Profile monitor raised and secured in position for transport
- Target moved to storage pit location #5  (no standoffs on pit hole flange) (~1.8mSv/hr at 3-4m from target)  (March 15th)

- The old T2 heat exchanger tube array was moved to the storage pit while the blocks were off (placed between hole locations 12 & 13)

 The following work was performed on the T1-MK1 target:

- Unused proximity sensor removed
- Lift flange removed, painted, relabeled
- Seals changed for feedthrough #1, #2, plug port, and both water supply feedthroughs
- Seals (2) changed for feedthorugh #3 which required desoldering protect monitor connector and machining o-ring support tube
- Replaced nylon ferrules for water supply swagelok fittings
- Leak checked upper water supply tubes: all OK

- Target rewired by David Cameron (motor wires OK, micro switch wires were re-terminated, but not replaced)

- Installed lift flange
- Checked potentiometer, motor, micro switches, profile monitor limit switches: all OK
- Checked profile monitor actuation: smooth motion, travel starts at 10psi, fully actuated at 35psi
- Leak checked target ladder: results OK, see notes attached
- Noticed protect monitor wire conduit had dropped down from vacuum flange.  It is secure in current position and connector would have to be de-soldered to lift it, so decided to leave as-is.

- Target ladder moved to position zero
- Profile monitor raised to 'IN' position and secured for transport
- Target transported from the hot cell to the beam line

Note that after the target was installed in the beam line and vacuum was pumped down it required ~55psi to actuate the profile monitor.  Approximately 20psi more than when not under vacuum.

The T2 P1 pressure transducer (Omega PX315-100GI) and T2 Q1 Proteus flow meter (0150SSTF3) have been replaced with new units to address issues with noisy signals.