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Target Testing & Commissioning

Target Testing & Commissioning. Rikard Linander Group Leader Target Operation and Maintenance Deputy Head of Target Division. www.europeanspallationsource.se March 14 2019. Target Organisation, December 2018. Target Op & Maint Group formed in May 2018.

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Target Testing & Commissioning

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  1. Target Testing & Commissioning Rikard Linander Group Leader Target Operation and Maintenance Deputy Head of Target Division www.europeanspallationsource.se March 14 2019

  2. Target Organisation, December 2018 Target Op & Maint Group formed in May 2018. Group members brought on board Aug 2018. Group responsible for planning and coordination of the testing and commissioning phase for Target Station • 38 ESS staff • 28 permanent • 6 limited term • 3 PhD students • 1 matrixed • 45 contractors/consultants • 39 via EIS • 1 via Q • 5 other

  3. Site Admin (2-3 pers) • Time Schedule (Görel Hagermark) • ESH • Document control • Work Permit • Accommodation (Site & Hotel) • Financial control • Procurement inst. hardware/manpower • NCR (Non Conformity Report) Testing & Commissioning integrates closely with Installation (site) organisation • Target Installation Coordinator Tobias Lexholm • Deputy Target Installation Coordinator Sven Jönsson • Over all QC • Installation Inspection • Receival inspection • NDT (X-ray, PT, UT etc.) • Accredited Inspection Body AIB • Accredited Body AB • Final quality documentation ESS Installation Manager Mikael Jakobsson • Available Temporary Services on ESS site • Scaffolding • Laydown Areas • Crane Drivers • Logistics/Transport • Warehouse • Heavy lifting • Temporary Power & Fluids • Concrete Boring/Drilling • Survey/Alignment • Waste • Workshop • Testing & Commissioning • Rikard Linander • Jaime Arriagada • Nils Jönsson Site Operatives Area Coordinator D02, Sven Jönsson Temporary services (2-3 pers) Temporary Service Logistic / Laydown Area Rigging / Lifting • El and I&C installation coordinator • No Name • ESS Framework Agreements • Welders • Fitters • Electrical • I&C • Technicians • ICS Cf. previous presentation by T. Lexholm • Installation Package Leader • No Name • Monolith Systems • WP2-TW, Inner/outer shielding, TMP • WP3-M&R • WP4-Monolith vessel, PBW, Portbl. • Installation Package Leader • Krister Blomberg • Process Systems • WP2-Helium cooling • WP4-Monolith Atmosphere systems • WP5-Fluid systems • Installation Package Leader • Anna Bieliaieva • Target HVAC Systems • WP5- Target HVAC • Installation Package Leader • No Name • Target Cryo Systems • WP3- CMS Cryogenic Moderator System • Installation Package Leader • Mikael Olsson • TSS • WP7- Target Safety Systems • Installation Package Leader • No Name • Instrument Bunker • WP4- NBEX, Light shutter • Installation Package Leader • No Name • Active Cells • WP6- Race scope

  4. Test and commissioning phases • Functional tests, single objects, ColdMain Control Rom / MCR Readings, alarms, controllers • System test, ColdMCRReadings, alarms, controllers, start-stop objects. • Integrated system test, ColdMCR Readings, alarms, controllers- dynamic response, MPS-test, TSS-test • Integrated system test, Hot

  5. Overall TS installation and commissioning periodsFirst to last system 2022 Q1 Q2 Q3 Q4 2019 Q1 Q2 Q3 Q4 2021 Q1 Q2 Q3 Q4 2020 Q1 Q2 Q3 Q4 Installation Functional tests, single objects, Cold System tests, Cold Integrated system test, Cold Integrated system tests, Hot RBOT MAR -22 BOT JUL -22 Delivery to site Start of Installation Hand-over to operation

  6. Tests and commissioning of one specific system Notional plan, example of H2O cooling systems • Cold testing: • With process fluids or similar, but no temperature • Operate pumps, compressors, fans at different regimes in closed circuits, if possible • Auto start-up stand-by units • Check machine vibration levels • Check machine noise levels • Check level logics in tanks • Operation rounds before, during and after each run to find leakages, etc • Check auto data collection OK • "System Test. Cold (MPS partial):" • Testing of components and subsystems, as much as possible, according to proc. & protocols for each system • Reporting: • Reporting of all activities done • Start-up: • Slowly & carefully put each system in operation in a very controlled manner • Do not reach 100% load or operation conditions if not necessary, the idea is to run equipment and opne/close valves, transport fluid in loops, etc. • Tune the systems • Syst Testing Cold (MPS) • Testing of whole systems and subsystems according to procedure & protocols • Reporting: • Reporting of all activities done • Pre-commissioning • Pumps, compressors, fans • If possible TFA from OEM • Check switchgear • Check rotation direction • Check motor function • Check VFD function • Instrumentation • Check range • Calibrate • Automatic valves • Check switchgear, actuators and electric feeding • Check pneumatic feeding • Check fail Safe position (O/C) • Check characteristics curve (if not done at FAT) • Put temporal signs where needed for safe operation at Commissioning • Hand valves • check the movement open/close, set base-line positions • Put temporal signs where needed for safe operation at Commissioning • Dry Commissioning • Where possible, dry commissioning without process fluids • Reporting • Reporting of all activities done • Required Mechanical Completion: • Flushing/blowing of pipes done • Cleaning of tanks done • Hydrotest/Pneumatic test of pressure parts done • Cleaning of installation done • Drying done • Painting finished and in right condition • Tags in place (some temporal tags acceptable) • P&ID checking: • Visual inspection of piping and components; vs drawings (mech/el), data sheets, layouts and isometrics • O&M aspects: • Accessibility of hand valves for operation (handle reachable) • Accessibility of control valves for maintenance • Instruments' displays are visible from ground/platform • Enough space for serving and dismantling • Tube sheet withdrawal possible • Lifting and rigging devices in place • Health & Safety aspects • Fire Fighting System installed and operational • Communications system available • Control Systems • Local PLC for package deliveries operational • DCS in MCR available and operational (at least partially)  • Reporting: • Reporting tool in place and known by Commissioning staff • Reporting procedures and documents acepted by all parties 2022 Q1 Q2 Q3 Q4 2019 Q1 Q2 Q3 Q4 2021 Q1 Q2 Q3 Q4 2020 Q1 Q2 Q3 Q4 Main Control Room SAT complete, ready to operate Primary Water Cooling Systems delivery Installation Documentation (SAT/SFT) Test Readiness Review (TRR) Single objects functional tests “cold” Preparation of system System tests “cold” Integrated system test “cold” Safety Readiness Review (SRR) Integration tests “hot” • Initial Operation • Commercial operation • Operation personnel in charge • Operation at reduced capacity • Gradually increase to reach nominal capacity. • Performance test • Show the plant is capable of delivering agreed perform. • Defined in one or several docs exactly what and how to be tested and expected goals and minimum acceptance criteria. • All instrumentation involved in the performance test must be early identified, their tolerance established, calibration protocols available • An uncertainty calculation must be done by performance engineer (not part of the Commissioning group). • Reporting • Reporting of all activities done 12/3 2/12 RBOT MAR -22 BOT JUL -22 Delivery to site Start of Installation Hand-over to operation

  7. Responsibilities with regard to testing and commissioning • Target sub-project work packages (WP2 through WP7), to provide • All system design, installation and testing documentation • Verification and validation plans • Test plans and instructions • Commissioning plans and instructions • Test and commissioning package leaders • Documentation of performed tests and commissioning activities • Target Operation and Maintenance group • Document templates for test and commissioning plans and instructions • Review and acceptance of test and commissioning plans and instructions • Planning and coordination of tests and commissioning work • Assessment of test and commissioning results  acceptance or rejection • Representing as receiving part at hand-over from installation to commissioning phase (TRR) • Representing as delivering part at hand-over from commissioning to operation phase (SRR) • Target Division organisation • Same staff, currently part of the construction project, will transfer to initial operation • To assume ownership of the systems that have been commissioned and handed over

  8. Testing and commissioning binderEquivalent of the installation binder

  9. Template for testing protocolProvisional content • PURPOSE AND SCOPE • PREREQUISITES • Preparation activities • Data collection and prior verification • Support systems and elements • Filling and initial operation • SYSTEM MAIN EQUIPMENT AND TECHNICAL DATA • Design data • Operational data • PRECAUTIONS • SPECIAL EQUIPMENT AND RESOURCES • TEST INSTRUCTIONS AND ACCEPTANCE CRITERIA • General • Test #1 • Prerequisites • Conducting the test • Test #2 • Prerequisites • Conducting the test • TEST RESULTS AND OBSERVATIONS (punch list, etc) • Test #1 result • Test #2 result

  10. Operation and Maintenance ManualProvisional template • SYSTEM DESCRIPTION • Main functions of the system • Description of the system and sub-systems • COMPLEMENTARY DOCUMENTATION • MAIN EQUIPMENT IDENTIFICATION • PRECAUTIONS • Precautions for the environment • Precautions for the staff • Precautions for the facility • OPERATIONAL PREREQUISITES AND LIMITATIONS • Operational prerequisites • Operational limitations • PRE-OPERATIONAL ACTIVITIES • System filling • System emptying • Other pre-operational activities • SYSTEM START-UP • NORMAL OPERATION • SYSTEM SHUT-DOWN • OPERATION IN THE EVENT OF ANOMALIES AND EMERGENCIES • Alarms • Anomalies and emergencies • OPERATION AND MAINTENANCE • Component #1 • Component #2

  11. Safety culture in commissioning • Target Commissioning Card • Pre- job Breif • Is the scope of work understood? (limitations/boundaries) • What are the expected results? • Do you understand your role? • Are there any parallel activities/other work groups? • What are the hazards? • What are the Environmental/Radiological issues? • Are the procedures clear, understood and agreed? • What will you do if things go wrong? • Has anyone any concerns?

  12. In-kind elements testing & commissioning setup • In-kind elements including testing & commissioning • TIK.2.1 Target Wheel • TIK.2.2 Target He Cooling System • TIK.3.2 Cryogenic Moderator System (LH2) • (TIK.4.5 Monolith Vessel) • TIK.5.2 Intermediate Cooling Systems • TIK.6.1 Active Cells • In-kind elements excluding testing & commissioning • (TIK.3.1 Moderator & Reflector Plug) <part of TIK.3.2 testing> • (TIK.4.2 Proton Beam Instrumentation Plug) • (TIK.4.3 Irradiation Module) • (TIK.4.4 Proton Beam Window) • (TIK.4.9 Tuning Beam Dump) • TIK.5.1 Primary Water Cooling Systems • TIK.5.3 Ventilation & Confinement • Self-perform elements to be commissioned • TIK.3.3 Target Moderator Cryoplant (by the vendor) • (TIK.4.1 Target Monitoring Plug) • (TIK.4.6 Neutron Beam Windows) • TIK.4.7 Monolith Atmosphere System • (TIK.4.8 Monolith Shielding Systems) • TIK.4.10 Neutron Beam Extraction System • TIK.6.2 Internal Casks and Handling Devices • TIK.6.7 Remote Handling Support (Mock-up and Test Stands MUTS) • The integrated system tests (cold and hot) will be executed centrally by TD and ICS, with participation as needed by the in-kind partners.

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