The Bunker Project

1. The Bunker Project Update Zvonko Lazic www.europeanspallationsource.se September 2019

2. The bunker - content • Project overview • Schedule • Production status • Validation processes

3. The Bunker - Overview • Production design phase ended 30.June. ‘19 • Production commences upon ESS approval of the design phase completion. • First components arriving toward the end of ’19. (R6 brackets) • Shielding blocks scheduled to be delivered following ESS integrated installation schedule. • Pilot cast done and inspected.

4. Schedule highlights • Design handover completed June 2019 • Detailed delivery schedule in place July 2019 • Pilot test concrete blocks done August 2019 • Manufacturing start October 2019 • First installation Q1 2020 Credit: Sofie Ossowski

5. Bunker Installation Schedule – updates • Potential delay in port block manufacturing (Target monolith) would possibly delay Bunker installations • Workshops held between NSS, TD, SEC/CF and rigging team to address the issue Result: • Optimized installation sequence with MINIMUN links between LS system and Bunker installation • Gives a schedule that can deal with potential delays in the future better, since it is almost “disconnected” • Optimized Bunker installation (also with minimum links to TD) • Start install walls earlier (earlier access and earlier deliveries) • Continue to build rest of Bunker (except roof) BEFORE insert installations Building Bunker ”without TD” - NSS dates hold ! Credit: Sofie Ossowski

6. Majority of Bunker installed before Insert installation (ex D03 side) 1 5 3 2 4 6 Still room for installations with temp. cranes if needed Credit: Sofie Ossowski

7. First Bunker installations & Instruments The walls are going up first! Prefer to install Bunker wall insert with the wall, please have them Ready for Installation (ie optics aligned in wall insert): • West Wall (D03, 28m): 1 Sep 2020 BEER, BIFROST, MAGIC, C-SPEC, NMX, TREX, MIRACLES, HEIMDAL • North Wall (D03, 15m): 15 Dec 2020 LOKi, TBL, FREIA • South Wall (D01, 28m): 15 Dec 2020 ODIN, DREAM • East Wall (D01, 15m): 15 Jan 2021 ESTIA, SKADI, VESPA Bunker Wall insert envelope frozen and confirmed by supplier 1 June 2020. Wall feed-through cases procured and manufactured by ESS. More info here: https://confluence.esss.lu.se/pages/viewpage.action?pageId=311642808 Credit: Sofie Ossowski

8. Manufacturer’ update Mirrotron Chief engineer QA team QA QA Chief engineer Chief engineer Partner Ltd[pre-form concrete] Csomiép-Enter Ltd[steel structure]

9. Contract award Mirrotron Chief engineer QA team(Dr. Salem Georges) External QA(ISO 9001 accredited) QA(ISO 9001 accredited) Chief engineer Chief engineer Ferrobeton[pre-form concrete] Csomiép-Enter Ltd[steel structure]

10. The bunker – Production (summary) Detailed design completed. Pilot cast done (2 x roof block, and 2 x wall block) ·         Finalizing the model (pending CF interfacing walls scanning) ·         Freeze the model ·         Construction drawings of the shielding blocks to be updated (following the detailed design review) by Vektor, phase by phase. Production of the western wall starting in October Production of the R6 steel structure (and R6 beam shielding) starting in December

11. PILOT shielding blocks Two shielding blocks were selected for the PILOT test Wall block: Ar 62 - weight 1 T - heavy concrete • Roof block: AW101 • weight: 12,6 T • 10 cm borated concrete at the bottom • heavy concrete on the top Bunker Project installation procedureD01/D03 frame Credit: Zoltán Hajdú - Mirrotron

12. PILOT shielding blocks On the 15th July, 2019 blocks were ready for casting in Dunaújváros, Hungary Credit: Zoltán Hajdú - Mirrotron

13. PILOT concrete cast on site On 17th July 2019 two pilot shielding blocks were casted MD8S heavy concrete casting concrete casting is ready Mixer transport tothe factory B4C concrete casting is ready MD8S heavy concrete casting B4C concrete casting Credit: Zoltán Hajdú - Mirrotron

14. MIRROTRON’s Quality assurance system prepared by the Technical University of Budapest On-site inspections: • Shielding block dimension tests, • Testing of fresh concrete, • Sampling and laboratory analysis of additive and magnetite fractions, • Cement sampling for laboratory testing, • Testing of shielding blocks drilled from hardened concrete. Credit: Zoltán Hajdú - Mirrotron

15. Concrete recipes with requirements: Recipes: • MD8S Heavy concrete • B4C Regular concrete Laboratory tests were done in Feb. 2019 for finalising the recipes Credit: Zoltán Hajdú - Mirrotron

16. MIRROTRON’s Quality assurance system prepared by the Technical University of Budapest • Laboratory tests: • Checking of B4C regular concrete and MD8S heavy concrete materials as one structure, • Compressive strength and density of different concrete cubes, according to MSZ EN 12390-3:2009 and MSZ EN 12390-7:2009, • Examination of grain distribution of additives according toMSZ EN 933-1:2012, • Investigation of additive sludge clay content according to MSZ 18288/2-84, Credit: Zoltán Hajdú - Mirrotron

17. Optimization of roof and wall blocks change request CR created by the supplier. Concrete blocks were optimized in order to reduce cost of manufacturing and increase its simplicity. Credit: Dawid Patrzalek

18. Upstream supports change request CR created by ESS. Upstream supports were not included in original SoW, as they were requested to be integrated after the Bunker tender package was released. Additional cost of 44 kEUR. Credit: Dawid Patrzalek

19. Additional thread under R6 box beams change request CR created by ESS. Target division requested integration of 78 threads under R6 box beams for lifting purposes. Change request does not affect deadlines and cost. Credit: Dawid Patrzalek

20. Requirements for cooling pipes in corner blocks change request CR will be created by ESS. • Final requirements for casting water cooling pipes in corner blocks were not established on time. Finalizing requirements work is still ongoing, with potentially high risk for the project – corner blocks must be cast till the end of this year (around 3.5 months left) and requirements are not finalized and not delivered to the supplier yet. • Additional cost for the project not evaluated yet. Credit: Dawid Patrzalek

21. Feedthroughs redesign change request Change requests created by ESS. • Many instrument teams requested minor redesign changes. Cost and deadlines were not affected. • Manufacturing of concrete blocks has started, thus if additional change will be requested, it might have potentially high risk (cost and time-wise) for the project. The supplier has a right to reject a CR (e.g. if delivery deadlines would be affected). Credit: Dawid Patrzalek

22. Pilot cast checks • Inspection of the pilot cast blocks was performed at end of the Aug. • Our main concern was dimensional stability of cured blocks. • The blocks were cast with very good tolerances (>6m block, had +/- 2mm deviations, with one exception, measured -5mm (allowed deviation is +/- 5mm). • There were shortcomings on top surface finish (quality). • And on locating features of the roof block. • The inspection report has been compiled, list of corrective actions agreed on. • The manufacturer will action all corrective actions and submit report of the ‘corrected pilot’.

23. Why do we test the bunker construction material? • To determine quantitatively which elements are present in the material. • The more of the strongly activating, long half-life elements are present, the stronger the lasting activation of the bunker wall will be. • This activation affects how we work in the bunker and how much time after beam shutdown passes before we can enter the bunker. The tests are currently performed under strong support of the SULF (Sample and User Lab Facilities)team and use of the ESS user laboratories. • Examples for elements that are undesired even on the %-level: • Na, K, Sc, Cr, Fe, Co, Eu, Zn, Rb, W… Credit: Monika Hartl

24. How are we testing? Measurements to determine composition of the construction material:  • The method for elements heavier than sodium is X-ray fluorescence (XRF) which can be performed best on a fine powdered, pressed sample (done at the SNS or ISIS user labs) • The method for elements lighter than sodium is Inductively Coupled Plasma Optical Emission Spectroscopy (ICP-OES) which is available at Lund University for a fee. The samples need to be dissolved (“liquid”) before performing measurements. Sample preparation: • XRF: Pulverizing the sample: 20 minutes in a ball mill or 2 days for manual grinding. • ICP-OES: Dissolving the sample in concentrated NaOH in an autoclave at 190 ˚C over night. Neutralizing the solution before sending it to Lund University. Credit: Monika Hartl

25. XRF (Sep. 2019 in user lab at SNS) – preliminary results Credit: Monika Hartl

26. Activation and dose rates from bunker walls and roof are needed for bunker access and operation • Dose rates from the roof are at the level of 10s mSv/h after 3 days decay. • Dose rate from a roof block removed and placed on the bunker floor are at the level of 1 mSv/h or less at 1 m from the block, 1 day after shutdown • Dose rates from a realistic irradiation condition of the wall, i.e., with a beamline in place, going through the bunker, are comparable to the dose rates for the roof, for the short sector wall, and lower for the long sector wall. • Results are in ESS-0416081 Credit: Luca Zanini

27. Roof activation long sector from CSPEC beamlineGamma dose rate (10 years irradiation, 3 day cooling) Only activation of roof and wall has been calculated (i.e. not components in the bunker) Dose rate levels are at the level of 10s of mSv/h, which is acceptable as in most cases work is done remotely 3 days cooling Credit: Luca Zanini

28. Dose rate from extracted roof block laying on bunker roof after - 1 day cooling Credit: Luca Zanini

29. Updated calculations are in progresswith updated material specification • For walls and roof (heavy concrete): • Material composition for heavy concrete is available from manufacturer • Additional amount of Co and Ni impurities will be provided • The first 10 cm of regular concrete + 40 kg/m3 B4C to reduce activation of roof • Alternatively, optional heavy concrete wall with first meter of heavy concrete + 10 Kg/m3 of B4C • For straight wall (regular concrete): • Material composition for regular concrete (side walls) is not complete and composition of aggregates under study. • Detailed material composition will be provided. It is of interest the possible presence of elements resulting in gamma emission with half life > 12 h such as Na, K, Sc, Cr, Fe, Co, Zn, Rb Credit: Luca Zanini

30. The bunker – Installation Installation manager for this project – Dawid P. NSS installation manager – Antonio B. Antonio has developed set procedures and requirements for initiating and conducting the installation effort (addressed in his session). Dawid is preparing required documentation, installation sequences and instructions.

31. The Bunker - outlook • Outlook • Production process is progressing well. • QA systems are in place, at manufacturers' site, as well as at ESS. • Production schedule, delivery schedule, are being updated following updates of the NSS integration/installation plans.

32. The Bunker OverviewQ/A • End of presentation • Q/A