ISIS TS1 Project: Shutdown & Commissioning planning

1. ISIS TS1 Project:Shutdown & Commissioning planning Stephen Gallimore Project Manager for the ISIS TS1 Project ICANS XXIII – Chattanooga, TN, USA 15th October 2019

2. Contents • Introduction • Planning & Strategy • Pre-installation testing • Shutdown • Strip-out & installation • Commissioning • Summary

3. Introduction – Project Overview • 9 years • £15M • Sustainability project to secure the operational future of ISIS TS1 Close-up of the target, reflector and moderators (TRaM) CAD render of full target trolley showing TRaM & services trolley

4. Planning & Strategy What do we need to do to be ready for beam? What do we need the beam to do?

5. Planning & Strategy • Overall commissioning strategy document • High level aims • Description of lower level documents • Layout of phases with expecting timings • Work package commissioning plans • Equipment specific • What is being tested and why • Discussion of scheduling and resources • Specific testing plans • Testing procedure • Tolerances of acceptance • Non-conformity & defects • Sign-off

6. Planning & Strategy

7. Pre-installation testing • Site Acceptance Test • Dimensional checks • Sub-set of FATs • Functional operation and mechanical fit • Flow rates & pressure drops • Alignment & adjustability • Basic controls system operations • Sensors reading sensibly • Valve operation Replica reflector and 3D printed moderator heads on the new cantilever frameTS1

8. Pre-installation testing • Regular (maintenance/removal) remote handling • Disconnection and reconnection of services • Putting in a flask • Taking a target in and out of a storage well • Recovery from off-normal scenarios • For example, recovery from a dropped TRaM component A view through the ZnBr remote handling cell window on TS1

9. Pre-installation testing • Procedure practice • Reduce time and dose to workers • Clear thinking in emergencies • Feeds into safety documentation required • Important to have sensible hold points • Sign off equipment as ready • Note any non-conformities & rectifications • Feedback parameters into design calculations • Permission to strip-out existing redundant equipment • Have agreed criteria • Prerequisite to starting shutdown • …once strip-out begins there is no going back!

10. The Long shutdown • 12 months off for TS1 but cycle(s) run on TS2 • Planned to begin Sep 2020 • Rough breakdown of timings: • 3 months strip-out • 3 months install • 3 months pre beam commissioning • 3 months with beam commissioning • First few cycles after start up, there will be disruption

11. The Long shutdown Some of the challenges: • Resources • Remote handling operatives • Shared resources (numbers and dose) • Two parallel working fronts (RHC & TSA) • Work flow bottle-necks • Main hall crane • Waste acceptance processes • Shared resources (?)

12. The Long shutdown Some of the challenges: • Working environment hazards • Trolley movement • Multi-height parallel working • Radiation dose • Ambient conditions • Other large projects during shutdown • Linac tank IV replacement • Riken refurbishment • Instrument projects (various)

13. RHC based strip out A CAD image of the current TRaM design with the reflector cut-away to show internal components

14. RHC based strip out • Most major items have been removed before • Only cantilever frame has never been out • Frame will be cut in half* • Have clear, controlled and well practised procedures from removal and extraction of equipment • Highest dose rate items but very limited chance for exposure • Each item will be put into a shielded storage container *For more information please see the poster: ISIS TS1 Project – Removal of the Target, Reflector and Moderator (TRaM) Support Structure using a Bandsaw within a Remote Handling Cell. By Ross Turnley – 17th Oct @ 16:30

15. TSA based strip out A photo from the construction of the target services trolley (circa 1983) showing the vast array of services’ pipework

16. TSA based strip out • A lot of equipment to remove • Plan to remove highest dose rate items first i.e. filters, IEx columns & water pumps • Have clear waste plan for how to deal with all the different types of waste/waste items • Much work will require RPE as well as PPE • Work to utilise hydraulic cropper for cutting wherever possible • Workers will be exposed to many hazards, so training and preparation are essential

17. Installation • Much equipment design in modular fashion to aid installation • Greater attention paid to remote handling features • Have worked closely with the operators of the equipment in the design phase • Most equipment will have been assembled & tested prior to installation • For RHC installation, aim is to minimise amount of remote handling work required • More care required than for strip-out!

18. Commissioning without beam • Checking of connections and fit into greater system • Full without beam process and control functions: • Flow water through TRaM components • Cool-down and flow cryogens for moderators • Perform drain/vent/maintenance procedures on systems • How to deal with non-conformity and deviations • Installation complete • Hold point - Sign off of equipment and systems • Mechanical • Controls • DSEAR/ATEX

19. Commissioning with beam • Radiation protocol and monitoring • Staged commissioning with increasing power steps • Need to provide expected beam requirements to accelerator team • High enough power to get meaningful heat loads • Keep power as low as possible to minimise activation • Check parameters against designs • Will require some instruments to open shutters • Commissioning complete • Hold point – Hand over to operations

20. Summary • Outline Commissioning plans in existence, detailed commissioning and resource plans to be developed • Schedule is tight: • Late delivery has an impact on pre-install testing • Delays during strip-out & install ‘squeeze’ commissioning • Resources constraints & bottle-necks • TSA strip out likely to lead to highest doses to workers • Must have robust and practiced procedures • Hand-in-hand relationship with safety documentation

21. If you have any questions I would now be happy to take them Thank you for your Attention

22. Back-up slides

23. Pre-installation testing TRaM components: • Alignment • Where possible functional tests; i.e. water flow • Cutting saw final practice cuts Target services area components & systems: • Basic water flow & valve operation testing • Simplified control system • Cold and vacuum testing on cryogenic equipment • ATEX room inspection • Not populating drag-chains prior to installation with electrical cabling