Installation, wiring, and commissioning of the high temperature limit switches for the T1 and T2 cooling packages was completed today as part of SAS project SASP0120.  The relay output from the switches was wired in series with the Central Safety System signals for T1 and T2 (cable number 13250 and 12250 respectively) in break-out panel #2 on the Meson Hall south mezzanine.  There were already 3 other circuits wired in series with each signal for various other interlock requirements.

After wiring, commissioning of the switches was performed according to the following procedure:

- With the limit switches in a non-tripped state, it was confirmed that the safety signals were reaching the CSS in the main control room as expected (had to jumper T2 circuit to achieve this as the T2 target is not currently installed)
- The limit switch was tripped by adjusting the set point on the switch, it was confirmed that the signal was lost
- The set point was changed to a non-trip level, and the switch trip cleared, confirmed that the signal in MCR returned
- The enable signal from each cooling package was removed by shutting off the cooling package (for T2 just removed jumper), confirmed that safety signal lost as expected
- Reversed this condition and confirmed that the signal returned
- Checked that the thermocouples are performing properly, and the switches actually trip on high temperature by directly applying heat to the thermocouple area on the cooling package using a heat gun;  the switches tripped as expected when the set-points were exceeded

The results were discussed with John Drozdoff (Safety Systems group leader) who approved the method.

The final task remaining for SASP0120 is to route the PRV outlets to the 1A tunnel active drain using flexible hosing.

 The T1 and T2 expansion tanks were filled on Monday April 8th.  There was no change in the level when inspected today (April 12th).  Visual inspection of the packages also found no leaks.

The T1-MK1 target protect and profile monitor electronics were 'blip' tested by Bill Rawnsley on April 5, 2013.  The response from the profile monitor appeared normal, however the protect monitor response was very weak.  After various debugging it was found that the 9 pin connector on the target on the vacuum side of the vacuum flange had become disconnected from the vacuum flange feed-through.  It is suspected that this happened while changing vacuum flange seals in the hot cell.  The connector was plugged in to the feed-through and reassembled.  The monitor was retested on April 8th and gave a normal response.

The lower air amplifier was started and actuation of the T1 profile monitor tested from the control room:  functioning normally.

Unused cables and hoses, concrete pieces, and various other garbage was removed from the top of the T1 monolith.  Spiro Wrap around the T1 profile monitor cable was replaced as it had degraded.

The T1 target is now ready for beam.

 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.

- 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 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)

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.

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 cooling package water was drained to the BL1A active sump, refilled, cycled, and drained again.  Samples of T2 cooling package active water was given to RPG, tested, and approved for release.

On January 21 at approximately 4pm the full volume of the sump (280L) was released to the city sewer.

 On January 15th, when attempting to move the T2 target from the beam line to the hot cell, the latch mechanism on the flask did not actuate and the target could not be lifted from the beam line.  

On January 16th the flask was placed on blocks (IMG_0818) (while remaining attached to the crane) in the RH hot cell lab for inspection.  The cause of the problem was found to be a damaged and disconnected military style connector (IMG_0824).  Damaged wiring was also found (IMG_0836).

On January 21st the connector and faulty wiring was replaced by Travis Cave, which fixed the problem (IMG_0838).  The new location of the connector is less exposed and should prevent it from getting damaged if the target swings within the flask.  Travis and Don Jackson also used the opportunity to check some wires on the flask that previously were not documented properly.  The flask was returned to its storage position in the lab and is ready for use.

The T2-MK1 target (spare T2 target) was transported from the hot cell to the storage pit today.  

While the flask was being aligned to the storage pit locating pins, the base of the flask bumped the top of one of the alignment pins.  This was caused by a slight misalignment between the flask locating hole and the alignment pin at the moment when the flask was lowered.  This caused the target to swing within the flask and hit the inside wall of the flask.  

While the target was being lowered into the storage pit hole, it was observed that the profile monitor cassette had become loose from the impact and was protruding from its frame.  The target was raised back into the flask and transported back to the hot cell for inspection.

While lowering the target into the hot cell, the profile monitor cassette was protruding so much from its frame that it hit the target support ring on the hot cell turn table.  This caused the profile monitor cassette to come completely out of its frame and fall onto the hot cell table.  The cassette was damaged from the fall and appears to be unusable.  Probes Group is in the process of assembling a new cassette, which should be ready within the next few days.  They have requested that the damaged cassette be given to them so they can salvage parts (the cassette has not seen beam and should not be active).

The target was inspected and photographed and then transported to storage pit hole #4.  It is possible that the profile monitor frame was also damaged.

This mistake can be avoided in the future by working much more carefully and slowly when locating the flask on alignment pins and by completely removing all flask swing before lowering the flask.

 The BL1A tunnel was accessed to drain and sample T2 cooling package water.  A puddle of water was noticed in the South TNF area around the drain by the boot-box.  No water was found in the BL1A tunnel.  Photos attached.

- 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
 

 The BL1A air amplifier has been shut down by closing the air supply valve on the device. The air amplifier supplies high pressure air (110psi) to the following devices: M9BB, M20BB, T1 Profile Monitor, T2 Profile Monitor, T2 Collimator, Septum Polarity Switch

- 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

 

 On Wednesday November 21 at approximately 9am the level of the Remote Handling active sump was inspected and found to be at approximately the 7000L level.  The high level alarm sounds at approximately 5800L.  The high level alarm had been silenced by somebody, and RH staff had not been notified.  It is unknown when the high level alarm was reached.  The total sump volume is 7200L (which if exceeded will cause active water to spill on the lab floor).  The sump was previously inspected about 3 weeks prior, and the level was observed to be well below the high level sensor.  The recent increase in volume was from the RCR lab in the MHESA basement.

The sump contents were sampled and approved for release by RPG.  Sump contents were released on November 22nd using the procedure written in Document #64834.

A sign was put up next to the high level alarm silence button indicating that RH staff must be contacted if the alarm is silenced.

The high level sensor was tested and found to be working properly.

 Repair of the west side manipulator in the west hot cell was completed today.  Part of the repair was done by entering the hot cell using double tank suits and supplied air.  The repair was then completed on the master side of the manipulator.  The manipulator is now operating smoothly.

Two sales representatives from Central Research Labs visited TRIUMF today as they were already in Vancouver on other business.  I showed them the RH Lab manipulators and received  hourly and daily service charge estimates if repair of the east hot cell (junk cell) manipulators requires one of their experts to come in.

 During the recent shutdown for the T2/M9 joint repair Graham Waters replaced the corrupted application code on the controller RAM disk.  The T1 target position control is now functioning properly.  T2 target position control is still not operational due to an electronics problem within the motor driver.   The T2 ladder position may still be moved using the portable control box.  The T2 target ladder was moved to position 3 (10cm Be) today in preparation for the upcoming running period.

The target ladder was detached, old delta seals removed, sealing surfaces cleaned using scotchbrite pad and a dremel tool, and delta seals were installed on the lower face of the upper slide plate.  The target was leak checked and found to have no significant leaks (no response from 2s helium spray at previous leak location on upper slide plate).

The profile and protect monitor electronics were checked by Bill Rawnsley and appear to be functioning normally.

The T1-MK2 target is now ready for use in the beam line.

  After removal of the leaky target cassette at position 3, plugs were installed on the target ladder and a leak check was performed.  With the target pumped down to approximately 10 mTorr, and helium detector gauge baseline of 9 on the 10X scale, a response of up to 25 on the 500X scale was observed when leak checking the right side delta seal on the lower face of the upper slide plate using a standard 1s spray of helium at 3 psi.  The flange screws were tightened and the leak check repeated.  Under the same conditions there was a response of up to 60 on the 100X scale - There was still a leak, but not as severe as before.  The screws were tightened further, and the target leak checked again, with no change.

At time of installation a response of  up to 10 on the 100X scale was found at the same location.  This target was found to be water leak tight and was used in  the beam line for ~4 months.  It is possible that the seal is still water leak tight.

The seal must be replaced or a static water test performed to show that the target is water leak tight.  Seal replacement will take approximately 2-3 days.