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Operating Instructions

1. Hydrogen Delivery System Date 10 10 2014 Operating Instructions ded MICE HYDROGEN SYSTEM Operating Instructions R amp D version Author S Watson Document Number MICEH2 TD 120417 Issue 2 Page 1 of 51 Te9files te rl ac uk MDG public _Projects 100 MICE Hydrogen Delivery System S Watson Operations Operating Instructions R amp D doc Hydrogen Delivery System Date 10 10 2014 i l 1 Operating Instructions ncs Science amp Technology Facilities Council Rutherford Appleton Laboratory Rutherford Appleton Laboratory Harwell Oxford DIDCOT OX11 0QX Change Record Issue Change Person 1 Initial issue SW 2 Working issue SW Page 2 of 51 Te9files te rl ac uk MDG public _Projects 100 MICE Hydrogen Delivery System S Watsonl Operations Operating Instructions R amp D doc Hydrogen Delivery System Date 10 10 2014 Operating Instructions Issue 1 Preamble This document is intended to be a record of the manual procedures required to operate the MICE Liquid Hydrogen System This version is explicitly for the R amp D test programme only Step IV operational instructions will evolve from this document The test programme will be deemed successful if liquid hydrogen is detected by the system s level sensor Due to the uncertainty surrounding the hydride bed the final volume of LH2 which will be collected cannot be predicted The specific procedu
2. PV19 interlock override PV19 13 Required for He line purge PV20 interlock override PV20 f 14 Required to open PV20 when VP02B off PV14 keyswitch RV Required for hydride bed charge te PV22 keyswitch PV22 ver 17 Required to open mass spec port Vacuum poisoning switch PUES Shuts PV20 opens PV25 until VG03 1 mbar 18 Page 29 of 51 Te9files te rl ac uk MDG public _Projects 100 MICE Hydrogen Delivery System S Watson Operations Operating Instructions R amp D doc Operating Instructions Issue 1 3 2 Shift work procedures During hydrogen operations there will be a 24 hour shift rota in place The rota incorporates two operators where possible as entry to the MICE Hall will generally be necessary The 24 hour period is broken up into six 4 hour shifts working in a staggered pattern to create overlap between shifts This means no official handover is required between changing shift workers Direct shift worker instructions are provided in the Appendices Section 7 3 3 Interaction with ISIS MCR The ISIS Main Control Room and shift crew do not have any direct association with MICE However due to its proximity to the MICE Hall the MCR should be kept informed of all and any alarms and faults Shift workers should also provide regular progress updates to the MCR The ISIS shift crew may need to enter the MICE Hall at short notice If this occurs during PPS Controlled Acc
3. Gas panel pumping line Gas panel enclosure Figure 6 System layout mezzanine level Te9files te rl ac uk MDG public _Projects 100 MICE Hydrogen Delivery Watson Operations Operating Instructions R amp D doc Page 18 of 51 System S Hydrogen Delivery System Date 10 10 2014 Operating Instructions Issue 1 Stairs to ISIS MCR and MICE Hall roof Stairs to MICE Padlocked gate Hall roof vent area Nee Padlocked gate ATT hall roof n V vent area L1 LR Qema x MICE hall roof Hydrogen stacks Vacuum pump enclosure Figure 7 System layout roof level Page 19 of 51 Te9files te rl ac uk MDG public _Projects 100 MICE Hydrogen Delivery System S Watson Operations Operating_Instructions_R amp D doc 1 5 Piping and instrumentation diagram LL ame rims 19 NOTES H L DRAWING COMPLIES TO BS 5070 3 H ON HALL 200F H H k H H e H Zz H ds Ips l ETE ee H sP m o H pema f H f x H f H A L P E EXTERNAL PUMP M o ENCLOSURE Lu 4l L 2 Og H off f r HEATER CHILLER UNIT LUCATE2 iJ ON SOUTH H ME ZZANINE mo R A E E HL gt Li H N D m
4. o Ensure that the turbo pump is STOPPED and the pressure differential between VG03 and VG06 is less than 100 mbar Open PV20 by pressing Sol ON on the VACUUM screen T mM _ Turbo penning gauge Figure 15 Turbo pump Figure 14 Center 3 controllers and turbo pump 2 7 Heater chiller system If hydrogen is to be used ensure the auxiliary chiller is on by checking the HEATER CHILLER screen If not press Start o The unit set point temperature should be 18 C This can be checked and adjusted if necessary on the front of the unit itself Page 25 of 51 Te9files te rl ac uk MDG public _Projects 100 MICE Hydrogen Delivery System S Watson Operations Operating Instructions R amp D doc Hydrogen Delivery System Date 10 10 2014 Operating Instructions Issue 1 o If the aux chiller is giving an alarm it is likely to be due to low coolant level Contact John Govans x6012 to top up e f hydrogen is to be used check the heater chiller unit is ready to operate by checking the HEATER CHILLER screen If an LH50 ALARM is shown check the screen on the front of the unit itself for the error code and consult the unit manual o If a Code 40 or Code 14 alarm is shown on the unit this indicates low liquid level a relatively common problem The coolant level can be topped up from the filler inlet on the front of the unit Only Julabo Thermal H5 oil should be used
5. 1 2 Control system 1 2 1 Main screen The main screen of the control system allows access to the different sequence screens and various control and data screens Some screens are locked and require a password to access MICE HYDROGEN SYSTEM 1 MAIN MENU 07 86 12 09 17 07 HA PV20 max Differential Pressure 500mbar HA VP02 TURBO Backing Pressure 8mbar alve Test PLC Alog Data Ctrl Data Log Sequences s oar Gee Ed 8 DAC I o ES o EES Figure 1 Control system main screen Page 9 of 51 Te9files te rl ac uk MDG public _Projects 100 MICE Hydrogen Delivery System S Watson Operations Operating Instructions R amp D doc Operating Instructions Issue 1 1 2 2 Sequence screens The sequence screens allow the user to initiate automated sequences as well as providing instructions for any manual intervention and checks required To start a sequence requires a password 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 MICE HYDROGEN SYSTEM 1 HELIUM FILL SEQUENCE 01 02 03 CW04 05 07 08 11 14 17 18 19 20 22 25 Start He Fill Sequence start EN EE E SEES Vac OK HA VGO3 lt 1mb leg to 1 3bar He Fill Line VG05 SP1 ON 1 0bar lt HA PGO2 lt 1 3bar P601 SP1 Off P602 SP1 ON ooler HA PG01 HA PG02 Ctrl HA CVDA 1 0b lt PGO2 lt 1 3 Wd He Full HA LS01 5 Sie Be Close HA PV18 31 HELIUM FILL SEQUENCE COMPLETE ic 16 a mb
6. Date 10 10 2014 Operating Instructions Issue 1 e The entering operator should take the master key PK00 from the LH2 control room key press e The remaining operator should press and hold the release gate button on the PPS control box in the MICE LCR while the entering operator opens the door enters the airlock and then closes the door behind them If the release button is not held until the door is shut again the Search will be dropped e Once inside the airlock the entering operator should insert the door key having removed it from the wall box and insert key PKOO in the personnel key box A personnel key can then be removed and used to open the Yale lock on the inner door The personnel key must be kept with the entering operator at all times e When exiting the Hall the inner door can be opened using the Yale lock lever Once inside the airlock the entering operator should replace the personnel key and door key remove PK00 and contact the remaining operator via the intercom on the wall The exterior door should then be opened using the same procedure as above Intercom Figure 20 PPS key box and access control box 3 1 1 3 Dropped Search procedure The PPS Search can be dropped for the following reasons e Anerroneous Controlled Access attempt e Unauthorised attempt to enter the Hall via any of the entrances e Emergency exit from the Hall If the Search is dropped b
7. are unplugged and the gauge RJ45 port covered with tape If hydrogen is to be used only one resistor in each level sensor array should be energised Contact Phil Warburton for further details 2 2 Cryogenic system Visually check the cryostat cryocooler associated hoses and compressor for any loose fittings or damage The cryocooler compressor pressure shown on a dial on the compressor should be 1 65 MPa when off and up to 2 2 MPa when operating Ensure that the cryocooler is ready to operate by checking that CRYO COOLER PWR ON PRES OK and TEMP OK on the HEATER CHILLER Screen Page 21 of 51 Te9files te rl ac uk MDG public _Projects 100 MICE Hydrogen Delivery System S Watson Operations Operating Instructions R amp D doc Hydrogen Delivery System Date 10 10 2014 Hydrogen Delivery System Date 10 10 2014 Operating Instructions Issue 1 Cryostat Compressor penning gauge cooling water flow meter Figure 9 Cryostat and compressor 2 3 Gas panel enclosure e Ensure all sealed outer panels are in place and undamaged e Visually check air inlet filter hydride bed burst panel and viewing port for any damage e Check that the vacuum poisoning hand valve HV31 is open and padlocked The valve is located at the base of the gas panel enclosure and can be seen aen through the viewing port Figure 10 HV31 vac poison valve 2 4 Ventilation system e Visuall
8. right He PR38 24 Figure 14 Center 3 controllers and turbo pump rrrrrrrrrrrrrrrrrrrrrrrrrrrrererrrrrrrrrrrrrese 25 Figure 15 Turbo pump sssssssessssssseeeeneneeee nnne hh nnne ness nnmnn nnns 25 Figure 16 Heater chiller and auxiliary chiller eeeseeeeeeeeeeeeeeeeeeeee 26 Figure 17 Compressed air supply regulator eeseesseessseeeeeeeee 26 Figure 18 PPS main gate P 27 Figure 19 PPS access control Lasse 28 Figure 20 PPS key box and access control DOX rrrrrarrnnnnnnnnnnnnnnrennnenerenenenenenenenn 28 Figure PD LH2 EEE EE direidi Bare niia nari 29 Figure 21 Traffic light display ssssseenn m 39 Figure 22 Gas detection controller rrrnnnnnnnnnnvnnnnnnnnnnnnnnnnrnnnnnnnnnnnnnnnnrnnnnnnnennr 40 Page 7 of 51 Te9files te rl ac uk MDG public _Projects 100 MICE Hydrogen Delivery System S Watson Operations Operating Instructions R amp D doc Operating Instructions Issue 1 System description 1 1 System design The MICE Liquid Hydrogen LH2 R amp D system is designed to safely store hydrogen gas and deliver it to cryostat whereby a cryocooler will condense it into 22 litres of liquid hydrogen Gaseous hydrogen is stored in a metal hydride bed itself contained within a sealed and ventilated enclosure the gas panel enclosure The hydride alloy absorbs hyd
9. the system should be left in whatever state it currently is and a Hydrogen Expert should be contacted to restore nitrogen flow as soon as possible 5 6 Vacuum failure e n the event of a gradual vacuum failure the control system will react accordingly no operator intervention is required e n the event of a catastrophic vacuum failure all personnel inside the MICE Hall on the MICE roof or in the south wall area should be immediately contacted and evacuate to the MICE LCR o A Hydrogen Expert should be contacted to determine the root cause of the failure and decide on a suitable course of action Page 42 of 51 Te9files te rl ac uk MDG public _Projects 100 MICE Hydrogen Delivery System S Watson Operations Operating Instructions R amp D doc Hydrogen Delivery System Date 10 10 2014 Hydrogen Delivery System Operating Instructions Date 10 10 2014 Issue 1 5 7 Fire in the MICE Hall A fire in the MICE Hall should be treated in the same manner as a fire anywhere The hydrogen system should be left in whatever state it currently is and a Hydrogen Expert contacted immediately Te9files te rl ac uk MDG public _Projects 100 MICE Watson Operations Operating_Instructions_R amp D doc Hydrogen Delivery Page 43 of 51 System S Hydrogen Delivery System Date 10 10 2014 Operating Instructions Issue 1 6 Contact details 6 1 Hydrogen Experts Steve Watson LH2 s
10. If this is exceeded the valve will close e f hydrogen is to be used open the nitrogen supply hand valve HV15 o Check FM5 on the TEMP screen reads 2 l min If not then Completely close the nitrogen supply regulator PR37 inside the hall see Figure 6 Slowly increase PR37 such that FM5 reads approx 2 l min The transfer line jacket flow indicator located within the gas panel should also read approx 2 l min Figure 13 Supply regulators left N2 PR27 right He PR38 Page 24 of 51 Te9files te rl ac uk MDG public _Projects 100 MICE Hydrogen Delivery System S Watson Operations Operating Instructions R amp D doc Hydrogen Delivery System Date 10 10 2014 Operating Instructions Issue 1 2 6 Vacuum system e Ensure the vacuum pump VP01 and VP02B oil levels are within the required range as shown on the indicator e Check the current vacuum level in the cryostat on the Center 3 controller screens If the respective gauges read as follows the cryostat vacuum is OK If not continue with system checks and run a Vac down procedure 4 1 as required o VG03C 1x10 mbar o VG06C 1x10 mbar e Check the turbo pump VP02A status is STOPPED and OK on the VACUUM screen If it is showing ERR press STOP to reset the error If this doesn t work consult the manual e Ensure that the cryostat gate valve PV20 is open on the VACUUM screen If not then
11. ac uk MDG public _Projects 100 MICE Hydrogen Delivery System S Watson Operations Operating Instructions R amp D doc Shift worker instructions MICE LH2 R amp D programme As a shift worker your responsibilities extend to only observation under normal working conditions The system is in an inherently untested state and so should only be interacted with by a Hydrogen Expert or under a Hydrogen Expert s instruction e When starting and finishing your shift o Sign the log book o Ensure the shifter key is handed over to the on shift workers e Check in with ISIS MCR midway through your shift either in person or by phone on x6789 e Use the whiteboard provided to note any of the following o Unexpected system performance changes o Actions taken o Comments or suggestions regarding Operating Instructions o Any other observations e Above all if in doubt contact a Hydrogen Expert EE Shift check it Check Expected value Logged value 1 Max gas detection level lt 12 any channel 2 Nitrogen flow rate FM5 2 litres min 3 Glycol flow rate FM1 4 Nitrogen bottle pack pressure 5 Helium bottle pack pressure lt 2 2 MPa 6 Compressor pressure 7 Glycol level 1 5 bars 8 Aux chiller temperature 30 C Page 50 of 51 Te9files te rl ac uk MDG public _Projects 100 MICE Hydrogen Delivery System S Watson Operations Operating Instructions R amp D doc MICE HYD
12. spare coolant is currently stored next to the unit Do not top up with water Figure 16 Heater chiller and auxiliary chiller 2 8 Services and ancillaries e Compressed air supply to gas panel pneumatic valves is controlled by a hand valve and regulator The hand valve is located at the east end of the south mezzanine see Figure 6 The regulator is directly beneath the mezzanine floor see Figure 5 and should be set to around 5 6 barg or until the control panel reads AIR OK e The cryocooler compressor is plumbed Figure 17 Compressed air supply regulator into a central water supply fed from a pump beneath the MICE hall A flow gauge is located above the compressor ensure that the flow is within the recommended limits indicated If not either adjust the flow using the hand valve next to the gauge or contact J Govans x6012 2 9 Miscellaneous e Prior to any hydrogen operations o Ensure all oxygen cylinders and oxy acetylene sets have been removed from the MICE Hall prior to any hydrogen operations Page 26 of 51 WTe9files te rl ac uKMDG public Projects 100 MICE Hydrogen Delivery System S Watson Operations Operating Instructions R amp D doc Operating Instructions Issue 1 3 Access control and shift work procedures 3 1 Access control There are three working areas with controlled access points see Section 1 4 e MICE Hall o PPS gate e MICE Hall roof o Padlocked gate e Vent are
13. system check list 2 E The hydrogen side purge sequence is initiated from the He Pur H2 Sq screen Press the START He PURGE H2 SIDE button at the top of the screen The system will ask for a password and request confirmation that the helium bottle pack isolation valve HV16 is open The system will request confirmation that the purge pump VP01 is on if not start it using the Start button provided 1 At this point the helium supply regulator pressure PR38 can checked and reset accordingly See Section 1 3 1 5 Page 32 of 51 Te9files te rl ac uk MDG public _Projects 100 MICE Hydrogen Delivery System S Watson Operations Operating Instructions R amp D doc Hydrogen Delivery System Date 10 10 2014 Operating Instructions Issue 1 The system will request confirmation that the line downstream of PV14 is to be purged o f Yes is selected the system will request that the PV14 override key is activated The system will request confirmation that the line downstream of PV01 potentially including the hydride bed is to be purged o f Yes is selected the system will request that the PV01 override key is activated The remainder of the sequence will complete automatically The system is left pressurised with helium 4 3 Helium fill The helium fill sequence liquefies helium by pressurising the closed cryogenic circuit with warm helium to 1 15 bar allowing the pressure to drop d
14. 00 MICE Hydrogen Delivery System S Watson Operations Operating_Instructions_R amp D doc Hydrogen Delivery System Operating Instructions Date 10 10 2014 Issue 1 1 3 2 Valve list Table 1 Valve list Identifier Valve type Description PV01 Pneumatic valve Hydride bed isolation valve PV02 Pneumatic valve H2 system isolation valve PV03 Pneumatic valve Buffer tank isolation valve CV04 Control valve Buffer tank hydride bed control valve PV05 Pneumatic valve Buffer tank hydride bed relief valve isolation valve RV06 Relief valve Buffer tank hydride bed relief valve 0 3bar differential PV07 Pneumatic valve Buffer tank hydride bed relief valve bypass valve PV08 Pneumatic valve Buffer tank relief line purge valve BD09 Bursting disc Buffer tank bursting disc 0 9bar differential RV10 Relief valve Buffer tank relief valve 0 5bar differential PV11 Pneumatic valve Cryostat relief line purge valve BD12 Bursting disc Cryostat bursting disc 0 9bar differential RV13 Relief valve Cryostat relief valve 0 5bar differential PV14 Pneumatic valve Hydrogen fill line isolation valve HV15 Hand valve Nitrogen bottle pack isolation valve HV16 Hand valve Helium bottle pack isolation valve PV17 Pneumatic valve H2 system vent line isolation valve PV18 Pneumatic valve Helium supply isolation valve PV19 Pneumatic valve H2 system purge pum
15. A traffic light system is situated outside the LH2 control room which provides an indication of the system status en route to the main MICE Hall entrance A key of relevant actions is provided adjacent to the system Figure 22 Traffic light display Table 3 Traffic light display actions Display System status Action Steady areen Gas detection operational PM P OK to enter Hall No gas detected Flashing green Gas detection operational Gas detected See below will also show flashing amber or red No green Do not enter Hall Gas detection not operational Contact Hydrogen Expert Steady amber Hydrogen operations in process hydride OK to enter Hall using bed charge hydrogen fill amp empty Controlled Access procedure PPS in Controlled Entry mode See Section 3 1 1 2 Flashing amber Do not enter Hall Gas alarm 25 50 See Table 4 Steady red Do not enter Hall System fault Contact Hydrogen Expert Flashing r Do not enter Hall dn ed Gas alarm 50 See Table 4 Page 39 of 51 Te9files te rl ac uk MDG public _Projects 100 MICE Hydrogen Delivery System S Watson Operations Operating_Instructions_R amp D doc Hydrogen Delivery System Date 10 10 2014 Operating Instructions Issue 1 5 2 Hydrogen detection The control system displays the status of each detector pair on the Gas Det Alarms Screen as follows e Gas panel enclosure Box 3 e Plen
16. CESS CONTROL AND SHIFT WORK PROCEDURES 27 3 1 Access control 27 3 1 1 Personnel Protection System PPS 27 3 1 2 Keys 29 Page 4 of 51 Te9files te rl ac uk MDG public _Projects 100 MICE Hydrogen Delivery System S Watson Operations Operating Instructions R amp D doc Hydrogen Delivery System Date 10 10 2014 Operating Instructions ener 3 2 Shift work procedures 30 3 3 Interaction with ISIS MCR 30 3 3 1 Evacuation procedure 30 4 OPERATING PROCEDURES 31 4 1 Vac down procedure 31 4 2 Purge procedures 31 4 2 1 Standard helium purge He Purge Sq 31 4 2 2 Helium supply line purge He Line Pur Sq 31 4 2 3 Hydrogen side purge He Pur H2 Sq 32 4 3 Helium fill 33 4 4 Helium empty 34 4 5 Hydride bed charge 34 4 5 1 Bed connection 34 4 5 2 Charging procedure 34 4 6 Hydrogen fill 37 4 7 Hydrogen empty 37 5 FAULT PROCEDURES 39 5 1 Traffic light display 39 5 2 Hydrogen detection 40 5 3 Power failure 42 5 4 Control system failure 42 5 5 Purge gas supply failure 42 5 6 X Vacuum failure 42 5 7 Firein the MICE Hall 43 6 CONTACT DETAILS 44 6 1 Hydrogen Experts 44 6 2 Other contacts 44 Page 5 of 51 Te9files te rl ac uk MDG public _Projects 100 MICE Hydrogen Delivery System S Watson Operations Operating_Instructions_R amp D doc Hydrogen Delivery System Date 10 10 2014 1 l 1 Operating Instructions ncs 7 APPENDICES 45 7 1 System checklists overleaf 45
17. Cryocooler OK Compressor OK Gas panel enclosure Visual checks HV31 open and locked Ventilation system Visual checks Cabinet gate valve shut Fans OK Purge gas supply Bottle pack pressure 100 barg Bottle pack regulator set to 3 barg HV16 open PGO1 1350 1450 mbar Vacuum system Vac pump oil OK Turbo pump OK PV20 open Page 46 of 51 Te9files te rl ac uk MDG public _Projects 100 MICE Hydrogen Delivery System S Watson Operations Operating Instructions R amp D doc Pre sequence check list 2 Applicable to following sequences Hydrogen side purge He Pur H2 Sq Hydrogen fill Hydrogen empty Note This checklist should only be used in conjunction with the system Operating Instructions Control system and instrumentation Control screen OK Air supply OK Penning gauges unplugged Cryogenic system Visual checks Cryocooler OK Compressor OK Gas panel enclosure Visual checks HV31 open and locked Ventilation system Visual checks Cabinet gate valve shut Fans OK Purge gas supply Bottle pack pressure 100 barg Bottle pack regulator set to 3 barg HV16 open PG01 1350 1450 mbar HV15 open FM5 2 l min Vacuum system Vac pump oil OK Turbo pump OK PV20 open Heater chiller Auxiliary chiller OK Heater chiller OK Miscellaneous Oxygen c
18. ROGEN SYSTEM 1 TEMPERATURES amp FLOW HA TS06 HA TS07 ER 4 HA TS03 ER mguugsugggga VENT LINE MICE HYDROGEN SYSTEM 1 HEATER CHILLER CONTROL HA CC01 HA TS01 LER H ATER LH Stat STOP Stat STOP ATO Purge gas regulator panels COMPRESSOR UNIT g Sumitomo Compressor pressure gauge Aux chiller and heater chiller displays Page 51 of 51 Te9files te rl ac uk MDG public _Projects 100 MICE Hydrogen Delivery System S Watson Operations Operating_Instructions_R amp D doc
19. Rupture disks BS amp B LPS Check valves Swagelok SS 16C VCR 1 Pipework designed and manufactured by AS Scientific GA drawing C0 16800 Explosion relief panel design and manufactured by RAL 1 3 1 3 Vacuum system Backing pump Leybold TRIVAC D65B Page 13 of 51 Te9files te rl ac uk MDG public _Projects 100 MICE Hydrogen Delivery System S Watson Operations Operating Instructions R amp D doc Hydrogen Delivery System Date 10 10 2014 Hydrogen Delivery System Date 10 10 2014 Operating Instructions Issue 1 e Roughing pump Leybold TRIVAC D25B e Turbo pump Leybold TURBOVAC SL300 e Gate valve VAT Series 48 2 e Vacuum pipework Manufactured by AS Scientific 1 3 1 4 Ventilation system e Ventilation fans CFC CMV 450 e Plenum Designed by RAL BPG polypropylene construction e Bottle cabinet Designed by RAL BPG polypropylene construction e Ductwork Designed by RAL BPG polypropylene construction GA drawing TD 1055 0896 e Dampers Greenbox GCD ABS and PVC construction e Flame arrestors Elmac DFC 1 3 1 5 Purge gas supply e Regulator panels Designed and manufactured by Swagelok GA drawing 50995 e Supply regulators GCE Druva LMD 500 1 3 1 6 Heater chiller e Heater chiller Julabo LH50 e Aux chiller Tool Temp TT5000 1 3 1 7 Miscellaneous e UPS Riello Multi Plus 20kVA Page 14 of 51 Te9files te rl ac uk MDG public _Projects 1
20. Shift worker instructions MICE LH2 R amp D programme 50 Page 6 of 51 Te9files te rl ac uk MDG public _Projects 100 MICE Hydrogen Delivery System S Watson Operations Operating Instructions R amp D doc Hydrogen Delivery System Date 10 10 2014 Operating Instructions nerd Figures Figure 1 Control system main SCreen arannnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnennnnnenennnsennnne 9 Figure 2 Control system sequence screen example ssssssseeessss 10 Figure 3 Control system data screen example sesseeeee 11 Figure 4 Control system control screen example sssseeeeee 12 Figure 5 System layout ground level rararrrnnnnnrnnnnnnannnrnnnnnrrnnnnnnennnnnnnnnnnnnnenener 17 Figure 6 System layout mezzanine level ssssssmme 18 Figure 7 System layout roof level rennnnnnnnnnnnnnvrnnnnnnnnnrnnnnnrnnnnnnnnnnnnnnnnnnnnnnnnnnnnr 19 Figure 8 Control screen m 21 Figure 9 Cryostat and compressor rnrnnnnnnnnnnnnannnnnnnnnnnannrnnnnnrnnnnnnnennnnnnnnnnnnnnnneenne 22 Figure 10 HV31 vac poison VAIVE ia sccatctencad cerateeatibencndcteadnentadsvchicrestesancieescomstenans 22 Figure 11 Ductwork gate valve and fan control boxes seeeeeeeeeeeeeeese 23 Figure 12 Purge gas regulator pelfigl i5 ieri ee mettede 23 Figure 13 Supply regulators left N2 PR27
21. a o Padlocked gate 3 1 1 Personnel Protection System PPS Access to the MICE Hall is controlled using the PPS System This system is uses a system of electromagnetic gates and personnel keys to control entry to the Hall but allow uninhibited emergency evacuation A search procedure ensures that the Hall is evacuated prior to hydrogen operations and any unauthorised attempts at entry will drop the search notifying the MICE LCR 3 1 1 1 PPS Search procedure The MICE Hall mezzanines DSA and trench areas are searched by trained personnel resulting in the PPS search being enabled Note Hydrogen Experts are not necessarily trained in the PPS Search procedure The _ MICE Operations Manager MOM should be contacted if Figure 18 PPS main gate an unscheduled PPS Search is required Once the Search is enabled the Hall can only be accessed using the Controlled Access procedure in Section 3 1 1 2 3 1 1 2 Controlled Access procedure The Controlled Access procedure allows operators to access the MICE Hall via the PPS gate without dropping the search Two operators must be present to access the hall using this method one operator must remain in the MICE LCR to control the exterior electromagnetic lock Page 27 of 51 Te9files te rl ac uk MDG public _Projects 100 MICE Hydrogen Delivery System S Watsonl Operations Operating Instructions R amp D doc Hydrogen Delivery System Date 10 10 2014 Hydrogen Delivery System
22. and the regulator PR40 on the regulator panel o Open both hydrogen bottle valves BV39 fully o Open both pre regulator hand valves HV24 and check that the regulator upstream pressure is as expected o Open both post regulator hand valves HV 41 o Slowly open the regulator PR40 until the downstream pressure is 1 5 bara e Continue the control sequence by pressing OK The sequence will open PV14 and begin to charge the hydride bed e The regulator upstream pressure should be checked every 30 minutes Once the bottle pressure stabilises or 8 hours is shown on the control screen counter press Ch on the sequence screen e The system will request that the user closes the hydrogen bottle valves but leave all other valves open Press Bottle Closed to continue the sequence e A Hydrogen side purge He Pur H2 Sq 4 2 3 with PV14 open and PV01 closed will automatically be initiated It is likely that a hydrogen detector alarm in the vac pump enclosure will sound during this sequence see Section 5 2 for instructions e Once the purge has been completed the hydrogen bottles can be removed using the same process described in Stage 1 above Page 36 of 51 Te9files te rl ac uk MDG public _Projects 100 MICE Hydrogen Delivery System S Watson Operations Operating Instructions R amp D doc Hydrogen Delivery System Date 10 10 2014 Operating Instructions Issue 1 4 6 Hydrogen fill The hyd
23. ar mbar mbar 0 Lev EBA voor ESE e oem rom J EG Figure 2 Control system sequence screen example Te9files te rl ac uk MDG public _Projects 100 Page 10 of 51 MICE Hydrogen Delivery System S Watson Operations Operating_Instructions_R amp D doc Hydrogen Delivery System Date 10 10 2014 Hydrogen Delivery System Date 10 10 2014 Operating Instructions Issue 1 1 2 3 Data screens The data screens display sensor readings and graph them against time Pressing will pause the graph and allow the user to scroll left to view the previous 24 hours Data files are logged automatically every 24 hours pressing the 5l button will interrupt the graph and download an intermediate data file to the logger There are 4 data screens vacuum level temperature and heater chiller There are an additional 2 dedicated sensor readout screens for level and temperature MICE HYDROGEN SYSTEM 1 TEMP amp PRESSURE LOG 07 40 07 50 00 08 10 08 20 08 30 08 40 gt mjes m Se E EH HA CV04 as ee fih ii a Figure 3 Control system data screen example Page 11 of 51 Te9files te rl ac uk MDG public _Projects 100 MICE Hydrogen Delivery System S Watson Operations Operating_Instructions_R amp D doc Hydrogen Delivery System Date 10 10 2014 Operating Instructions Issue 1 1 2 4 Control screens The control screens allow for manual control of various LH2 system compone
24. barg consider changing pack before operating the system o Both regulator panels incorporate changeover valves so if two bottle packs are connected this feature can be used If only one pack is connected and the empty pack Figure 12 Purge gas regulator panel needs to be physically replaced contact Stewart Greenall x1309 Page 23 of 51 Te9files te rl ac uk MDG public _Projects 100 MICE Hydrogen Delivery System S Watson Operations Operating Instructions R amp D doc Hydrogen Delivery System Date 10 10 2014 Operating Instructions Issue 1 o If the helium bottle pack is changed a Helium supply line purge He Line Pur Sq sequence must be run prior to any other operations e Set both nitrogen and helium bottle pack regulators PR35 amp PR36 to around 3 barg e Open the helium bottle pack isolation valve HV16 o Check PG01 on the CRYO HEATER screen reads 1350 1450 mbar If not then Activate the PV02 VT keyswitch Close all system valves using the VT and VT2 screens Completely close the helium supply regulator PR38 inside the hall see Figure 6 Use the VTT screen to momentarily open PV17 to reduce the pressure to atmospheric Ensure it is shut again before proceeding Open PV18 and PV02 are open by checking the VTT screen Slowly increase PR38 such that PG01 reads 1450 mbar Note that PV18 is interlocked to a PG01 reading of 1500 mbar
25. bottle valves once connected e Open both hand valves on the hydrogen bottle regulator panel HV24 and HV41 and fully open the regulator PR40 Again do not open the hydrogen bottle valves Stage 4 Pre purges e A Standard helium purge He Purge Sq 4 2 1 should be run e A Hydrogen side purge He Pur H2 Sq 4 2 3 with PV14 open and PV01 closed should be run e A Hydrogen side purge He Pur H2 Sq 4 2 3 with PV01 open and PV14 closed should be run Stage 5 Charging sequence e The bed charge sequence is initiated from the Bed Charge Sq screen e Press the Start button at the top of the screen Page 35 of 51 Te9files te rl ac uk MDG public _Projects 100 MICE Hydrogen Delivery System S Watson Operations Operating Instructions R amp D doc Hydrogen Delivery System Date 10 10 2014 Hydrogen Delivery System Date 10 10 2014 Operating Instructions Issue 1 e The system will ask for a password and will check that the nitrogen flow is sufficient FM05 e The heater chiller will be set to absorb mode with an enforced 5 minute pause e The system will request confirmation that the purge pump VP01 is on if not start it using the Start button provided e PV19 opens and the hydride bed and connecting pipework is evacuated e The system will request that the user opens the hydrogen bottle valves and respective hand valves o Close all hand valves HV24 and HV41
26. d alert the MCR to the alarm recommending evacuation of the building if necessary See Section 3 3 1 for the evacuation procedure Page 40 of 51 WTe9files te rl ac uKMDG public Projects 00 MICE Hydrogen Delivery System S Watsonl Operations Operating Instructions R amp D doc 10 10 2014 m o g 5 fio 2 a LL B 9 e o T 42 o O JE gt N c od a D c c o 5 gt 5 p Q O uwnuajd UONENDEAS JEPISUOJ UONENUSA Vee Y 900H OH HON SISI wozu YSL JE HON SISI WJOJUI YS JE ME Se9Je 0 SS922e IdluOld sease 0j ss929e jIgiuoJd MOIN SISI uuojui sseooe j9ujsei EUONUSJUIUN eJnso pue uogen2e e Jopisuo uueje anw jeuonueju dund OL 88 OL GOGH XH HON SISI wozu YSL JE JOU uinnoeA seale 0 SS929P JIGIUOld Jo jeuonugjui JI eDpnf Buleo UONENIEAS JAPISUOX UONENIEAS JepisuoD IleH 301N 694 6 VOOH XH HON SISI wozu YSL JE HON SISI WOU YSH JE sease 0 Ss922e IdluOld sease 0j ss929e IQIUOI HOIN SIS uuojur SS8908 HON SISI UUOJUI sseooe j9ujsei EUONUSJUIUN ysa EUONUSJUIUN eui uue e anw JEUONUSJU uueje ojnuJ jeuonuo u UONENUSA ORG Z OGH OH Jou jou iir Jo euonusjul Ji eDpnf Jo jeuonugjui JI eDpnf eunso puo uonenoe e Jepisuoj eued sec 9 cCOQH OH HON SISI wozu YSL JE HON SISI uuojul YS JE sease 0 SS922e IdluOld sease 0j ss929e IQIYOI s sjouueua Xoq u 19S 0S lt poy 0S SZ MOJI A 19 ouo5 Jonuo9 J
27. drogen bottle valve PR40 Pressure regulator Pressure regulator to control hydrogen bottle pressure HV41 Hand valve Hydrogen hand valve for System A RV42 Relief valve Hydride bed coolant circuit relief valve Page 16 of 51 Te9files te rl ac uk MDG public _Projects 100 MICE Hydrogen Delivery System S Watson Operations Operating Instructions R amp D doc Hydrogen Delivery System Operating Instructions Date 10 10 2014 Issue 1 1 4 System layout diagram Stairs to ISIS MCR and MICE Hall roof LH2 Control Screen Room Air supply regulator location LH2 control racks south wall south shield wall LH2 Control south wall H2 bottle cabinet Test cryostat PPS Gate MICE Hall MICE Local Control Room MLCR Stairs to south mezzanine Cryocooler compressor Figure 5 System layout ground level Te9files te rl ac uk MDG public _Projects 100 MICE Watson Operations Operating_Instructions_R amp D doc Page 17 of 51 Hydrogen Delivery System S Hydrogen Delivery System Operating Instructions Date 10 10 2014 Issue 1 Stairs to ISIS MCR and MICE Hall roof Stairs to MICE Hall roof Turbo pump location Air supply hand south shield wal IL I i Purge gas regulator location Transfer line Heater chiller
28. e VACUUM screen e When VG06 is less than 1 mbar start the turbo pump VP02A by pressing the relevant Start button on the VACUUM screen e When VG03B and VGO6B drop below 1x10 mbar the respective Penning gauges will switch on e When VG03C reads less than 1x10 mbar the system is ready for cryogenic operation 4 2 Purge procedures 4 2 1 Standard helium purge He Purge Sq A standard helium purge clears the buffer tank absorber pots and delivery pipework of contaminants e Fill out Pre system check list 1 e The helium purge sequence is initiated from the He Purge Sq screen e Press the START He PURGE button at the top of the screen e The system will ask for a password and request confirmation that the helium bottle pack isolation valve HV16 is open e The system will request confirmation that the purge pump VP01 is on if not start it using the Start button provided e The remainder of the sequence will complete automatically The system is left pressurised with helium 4 2 2 Helium supply line purge He Line Pur Sq A helium supply line purge clears the pipework from the helium bottle pack of contaminants This sequence does not purge the buffer tank or absorber Note this sequence requires manual operation of a bottle hand valve Two operators with walkie talkies is recommended Page 31 of 51 Te9files te rl ac uk MDG public _Projects 100 MICE Hydrogen Delivery System S Wa
29. e hydrogen empty sequence is initiated from the H2 Empty Sq screen e Press the Start button at the top of the screen e The system will ask for a password and will check that the nitrogen flow is sufficient FM05 e The hydride bed relief valve bypass valve PV07 is opened and the heater chiller is set to absorb mode Page 37 of 51 Te9files te rl ac uk MDG public _Projects 100 MICE Hydrogen Delivery System S Watson Operations Operating_Instructions_R amp D doc Hydrogen Delivery System Date 10 10 2014 Operating Instructions Issue 1 e The system will begin a heater control loop to boil off liquid hydrogen and return gas to the hydride bed e Once the absorber temperature TS03 reaches 30K the heaters switch off e Once TS03 reaches 100K and the buffer tank pressure is 0 1 bara the hydride bed isolated valve PV01 is closed e A Standard helium purge He Purge Sq 4 2 1 will automatically be initiated Page 38 of 51 Te9files te rl ac uk MDG public _Projects 100 MICE Hydrogen Delivery System S Watson Operations Operating Instructions R amp D doc Hydrogen Delivery System Date 10 10 2014 Operating Instructions Issue 1 5 Fault procedures All fault procedures require the input of Hydrogen Experts and no action should be taken by non experts other than to contact a Hydrogen Expert and inform the ISIS MCR 5 1 Traffic light display
30. equinN UOHne201 peuinbaj uondy 10 99 9q suonoe uonoojep uaboupAp ip 91981 Page 41 of 51 Delivery System S Hydrogen MICE Te9files te rl ac uk MDG public _Projects 100 Watson Operations Operating_Instructions_R amp D doc Operating Instructions Issue 1 5 3 Power failure e n the event of a power outage the system is passively safe The control system and ventilation fans will operate for 2 hours on the system UPS If the power outage occurs during a sequence the cryocooler heater chiller vacuum pumps and purge pump will lose power and trip off e If hydrogen is in use all personnel inside the MICE Hall on the MICE roof or in the south wall area should be immediately contacted and evacuate to the MICE LCR o A Hydrogen Expert should be contacted to determine whether it is safe to manually switch the system back on once the power supply has been restored 5 4 Control system failure e Inthe event of a PLC failure touch screen malfunction or loss of control due to manual intervention the system is passively safe e If hydrogen is in use all personnel inside the MICE Hall on the MICE roof or in the south wall area should be immediately contacted and evacuate to the MICE LCR o A Hydrogen Expert should be contacted to determine the root cause of the failure and decide on a suitable course of action 5 5 Purge gas supply failure e In the event of a nitrogen supply failure
31. es g L 1 E eos ii g Gand P onus f op d moe GAS PANEL d web Fa EE NE IE Em Are FNCI SURF MN Ced Ts REP 17 19 ir ee di D sr ren ss cont ant COOLANT CARC DEV co acit oe con o OUT ME BASELINE P amp ID SYSTEM A MICE HYDROGEN SYSTEM vere am Al 0 TD 1085 100 01 Page 20 of 51 Te9Qfiles te rl ac uk MDG public _Projects 100 MICE Hydrogen Delivery System S Watson Operations Operating_Instructions_R amp D doc Operating Instructions Issue 1 2 System checks System checks should be carried out prior to the initiation of any automated sequences Where checks depend on whether hydrogen is to be used this applies only to hydrogen external to the hydride bed Check lists can found in Section 7 these should be printed off and filled in where appropriate 2 1 Control system and instrumentation Ensure the control panel is plugged in and responding Ensure air supply to pneumatic valves is on by checking any of the automated sequence screens in the control panel and looking for a green button marked AIR OK If the button is red and displaying AIR OFF see Section 2 8 for instructions for how to Switch on the air supply Zero the flow total readout if required Ei on the TEMP screen igure 8 Control screen If hydrogen is to be used and the system vacuum is stable and less than 1x10 5 mbar ensure both Penning gauges VG03C and VG06C
32. ess mode the ISIS crew member will contact the LH2 control room for access If this happens the MICE operator must not restrict access to the Hall unless there is a clear safety risk 3 3 1 Evacuation procedure If a consensus is reached between MICE LH2 experts and the ISIS MCR that the risk of an unforeseen and catastrophic hydrogen incident is heightened and developing evacuation must be considered In this scenario the nearest fire alarm should be activated The alarm should only be silenced once a Hydrogen Expert has determined that the risk level has dropped It must be stressed that the decision to sound the fire alarm must include input from the ISIS MCR Some ISIS MCR personnel may remain in the MCR as it is an essential site communications hub This will be at their own discretion The RAL site Alarm Investigation Team AIT should be contacted and liaise with the MICE team to clarify the situation Security should be asked to inform the Site Emergency Controller Page 30 of 51 Te9files te rl ac uk MDG public _Projects 100 MICE Hydrogen Delivery System S Watson Operations Operating Instructions R amp D doc Hydrogen Delivery System Date 10 10 2014 Operating Instructions Issue 1 4 Operating procedures 4 1 Vac down procedure The vac down procedure creates a high vacuum in the insulating volume in the cryostat e Start the backing pump VP02B by pressing the relevant Start button on th
33. main MICE Hall door Page 34 of 51 Te9files te rl ac uk MDG public _Projects 100 MICE Hydrogen Delivery System S Watson Operations Operating Instructions R amp D doc Operating Instructions Issue 1 e Ensure the hand valve is tightly closed before moving a bottle Check that the route to the charging station via the main door is clear of obstacles and that the charging station front panel has been removed ready to receive the bottles e The bottles should be carefully secured on to a four wheeled bottle trolley and moved into the Hall The bottles should be brought to the charging station via the ramp beneath the south mezzanine e Each bottle should be positioned on one of the racks within the charging station fastened with the chain and rotated such that the valve connection faces the regulator Do not connect the bottles Stage 2 System preparation e The MICE Hall should be placed under controlled access using the PPS search procedure see Section 3 1 This will prohibit access to the Hall via the equipment door and control access via the main door e Manually confirm that the ventilation system is operating as expected see Section 2 4 Stage 3 Bottle connection e Connect the pigtail bottle connection to the bottle valve Note POL adaptors for hydrogen bottles are left hand thread e Once both bottles are secured and connected replace the charging station front panel Do not open the hydrogen
34. nts They are used in commissioning and troubleshooting The control screens operate outwith the predefined sequences and so are password protected There are 3 control screens cryo heater vacuum and heater chiller inc cryocooler controls There are also 4 valve test screens with which each individual valve setting can be controlled MICE HYDROGEN SYSTEM 1 VACUUM CONTROL CRYOSTAT H2 SYSTEM PUMP LINE VAC PUMP LINE VAC 2022 2023 V v Em EE mbar mbar Figure 4 Control system control screen example Page 12 of 51 Te9files te rl ac uk MDG public _Projects 100 MICE Hydrogen Delivery System S Watson Operations Operating_Instructions_R amp D doc Operating Instructions Issue 1 1 3 Components list 1 3 1 Hardware 1 3 1 1 Cryostat Cryostat designed and manufactured by AS Scientific GA drawing C0 14907 Transfer line designed and manufactured by AS Scientific GA drawing C0 14922 Cryocooler Sumitomo SRDK 415D Cryocooler compressor Sumitomo CSW 71D 1 3 1 2 Gas panel Gas panel enclosure designed and manufactured by AS Scientific GA drawing C0 15114 Hydride bed Treibacher Auerstore MHS30000IHS Buffer tank designed and manufactured by AS Scientific GA drawing C0 14908 Pneumatic valves MARS 83 series Control valve MARS 88 series Pneumatic actuators Automax Super Nova SO63 S10 amp SO85 S10 Relief valves Leser DZ E F 80
35. p isolation valve PV20 Pneumatic valve Cryostat gate valve PV22 Pneumatic valve Mass spectrometer port RV23 Relief valve Hydride bed relief valve 30bar differential HV24 Hand valve Hydrogen bottle isolation valve PV25 Pneumatic valve Vacuum poisoning isolation valve NR26 Non return valve Back flow protection for nitrogen purge line NR27 Non return valve Pressure surge protection for buffer tank bursting disc NR28 Non return valve Pressure surge protection for cryostat bursting disc PR29 Pressure regulator Pressure regulator to control hydride bed pressure NR30 Non return valve Hydride bed return valve HV31 Hand valve Vacuum poisoning hand valve lockable NR32 Non return valve Cryostat leak arrestor valve Te9files te rl ac uk MDG public _Projects 100 Page 15 of 51 MICE Hydrogen Delivery System S Watson Operations Operating_Instructions_R amp D doc Hydrogen Delivery System Date 10 10 2014 Operating Instructions Issue 1 BV33 Bottle valve Nitrogen bottle pack valve BV34 Bottle valve Helium bottle pack valve PR35 Pressure regulator Pressure regulator to control nitrogen bottle pressure PR36 Pressure regulator Pressure regulator to control helium bottle pressure PR37 Pressure regulator Pressure regulator to control nitrogen pressure to system A PR38 Pressure regulator Pressure regulator to control helium pressure to system A BV39 Bottle valve Hy
36. res to reach this point are as follows e Hall search and shift crew training Section 3 e Hydride bed charge Section 4 5 e Purge of H2 fill lines Section 4 2 3 e Purge of buffer tank Section 4 2 1 e Hydrogen fill sequence Section 4 6 e Hydrogen empty sequence Section 4 7 e Purge of buffer tank Section 4 2 1 The programme is expected to take 23 days a 24 hour shift rota incorporating 17 days float has been finalised Please note that this document is necessarily a work in progress please consult Steve Watson or Phil Warburton with any queries or comments see Section 6 1 for contact details Page 3 of 51 Te9files te rl ac uk MDG public _Projects 100 MICE Hydrogen Delivery System S Watson Operations Operating Instructions R amp D doc Hydrogen Delivery System Date 10 10 2014 Operating Instructions ener Contents SYSTEM DESCRIPTION 8 1 4 System design 8 1 2 Control system 9 1 2 1 Main screen 9 1 2 2 Sequence screens 10 1 2 3 Data screens 11 1 2 4 Control screens 12 1 3 Components list 13 1 3 1 Hardware 13 1 3 2 Valve list 15 1 4 System layout diagram 17 1 5 Piping and instrumentation diagram 20 2 SYSTEM CHECKS 21 2 1 Control system and instrumentation 21 2 2 Cryogenic system 21 2 3 Gas panel enclosure 22 2 4 Ventilation system 22 2 5 Purge gas supply 23 2 6 Vacuum system 25 2 7 Heater chiller system 25 2 8 Services and ancillaries 26 2 9 Miscellaneous 26 3 AC
37. rogen fill sequence liquefies hydrogen by pressurising the closed cryogenic circuit with warm hydrogen to 1 15 bar allowing the pressure to drop due to cooling by 0 1 bar then pressurising again e Fill out Pre system check list 2 e Runthe Vac down procedure 4 1 if necessary e Run a Standard helium purge He Purge Sq 4 2 1 if necessary e The hydrogen fill sequence is initiated from the H2 Fill Sq screen e Press the Start button at the top of the screen e The system will ask for a password and will check that the nitrogen flow is sufficient FM 05 e The heater chiller setpoint will be set to evolve mode and hydrogen will begin to be liberated from the hydride bed e The system will begin the cooldown and liquefaction of hydrogen Once cold the absorber fills at approximately 1 5 L day a complete fill will take approx 15 days e The user can interrupt the sequence by pressing the FULL button at any time This will cause the heater chiller to be set to absorb mode and will reroute the path from absorber to hydride bed through a relief valve e If the user does not interrupt the sequence the hydrogen level will eventually reach the recondensing heat exchanger at which point no more hydrogen can be liquefied 4 7 Hydrogen empty The hydrogen empty sequence operates the absorber pot heaters to boil off any liquid and return the gas to the hydride bed e Fill out Pre system check list 2 e Th
38. rogen in an exothermic reaction requiring cooling to continue the reaction Heating of the bed creates an opposite endothermic reaction to evolve hydrogen A precision heater chiller unit provides the relevant temperature control Evolving gas passes through a regulator and control valve and then into a 1000 litre buffer tank also within the gas panel enclosure From here the gas is transported outside the enclosure via a nitrogen jacketed transfer line to a vacuum jacketed test cryostat A closed cycle cryocooler cools a copper heater exchanger on which the hydrogen gas condenses to a liquid The liquid collects in a 22 litre pot representative of the eventual absorber pot which will reside with the MICE focus coil Gas delivery is managed in the gas panel using pneumatically actuated ball valves Each system operation is controlled using a pre defined automated sequence The control system uses an Omron PLC and a bespoke GUI The system is designed to DSEAR regulations with intrinsic safety being the chosen ATEX protection method The gas panel enclosure ventilation system vacuum pipework and vacuum pump enclosure are all designated as Zone 2 Page 8 of 51 Te9files te rl ac uk MDG public _Projects 100 MICE Hydrogen Delivery System S Watson Operations Operating Instructions R amp D doc Hydrogen Delivery System Date 10 10 2014 Hydrogen Delivery System Date 10 10 2014 Issue 1 Operating Instructions
39. s e Fill out Pre system check list 1 e The helium empty sequence is initiated from the He Empty Sq screen e Press the Start button at the top of the screen e The system will ask for a password e The system will begin a heater control loop to boil off liquid helium and release the gas into the vent lines e Once the absorber temperature TS03 reaches 70K the heaters switch off e The user can end the sequence by pressing the Empty button This will close the vent line isolation valve PV17 4 5 Hydride bed charge 4 5 1 Bed connection The bed connection procedure is a one off procedure for opening the hydride bed hand valve for the first time e The hydride bed is stored pressurised with argon gas to prevent air leakage into the unit e A Hydrogen side purge He Pur H2 Sq 4 2 3 should be initiated with the user answering YES to Step 7 This will purge the line upstream of the hydride bed isolation valve PV01 of air The sequence finishes by pressurising the system to 1 1 bar helium and isolating the hydride bed e The hydride bed hand valve can now be opened 4 5 2 Charging procedure The charging procedure is a complex operation with manual and automatic elements Anti static clothing must be worn during this procedure and only non sparking tools should be used e Fill out Pre system check list 3 Stage 1 Bottle positioning e Two hydrogen bottles are stored in a standard bottle rack outside the
40. tson Operations Operating Instructions R amp D doc Hydrogen Delivery System Date 10 10 2014 Operating Instructions Issue 1 Fill out Pre system check list 1 The helium supply line purge sequence is initiated from the He Line Pur Sq screen Press the START He LINE PURGE button at the top of the screen The system will ask for a password and request confirmation that the helium bottle valve BV34 is closed the helium bottle pack isolation valve HV16 is open and the PV18 override key has been activated The system will request confirmation that the purge pump VP01 is on if not start it using the Start button provided The line is pumped down The system will request that BV34 is opened This must be done manually on the helium bottle pack itself The line is pressurised The system will then make two further requests for BV34 to be closed and opened ultimately leaving the system pressurised with helium 4 2 3 Hydrogen side purge He Pur H2 Sq A hydrogen side purge gives the user the option of clearing either the pipework downstream of the hydrogen fill line isolation valve PV14 or the hydride bed isolation valve PV01 of contaminants the sequence will not allow both options to be selected as this would create the risk of an open hand valve on the hydrogen bottle regulator panel admitting air into the hydride bed This sequence does not purge the buffer tank or absorber Fill out Pre
41. ue to cooling by 0 1 bar then pressurising again Fill out Pre system check list 1 Run the Vac down procedure 4 1 if necessary Run a Standard helium purge He Purge Sq 4 2 1 if necessary The helium fill sequence is initiated from the He Fill Sg screen Press the Start button at the top of the screen The system will ask for a password and request confirmation that the helium bottle pack isolation valve HV16 is open The system will request confirmation that the helium supply regulator is set to the correct value The system will begin the cooldown and liquefaction of helium Once cold the absorber fills at approximately 0 5 L day a complete fill will take approx 45 days The user can interrupt the sequence by pressing the FULL button at any time This will close the helium supply valve but keep the cryocooler operating If the user does not interrupt the sequence the helium level will eventually reach the recondensing heat exchanger at which point no more helium can be liquefied Page 33 of 51 Te9files te rl ac uk MDG public _Projects 100 MICE Hydrogen Delivery System S Watson Operations Operating Instructions R amp D doc Hydrogen Delivery System Date 10 10 2014 Hydrogen Delivery System Date 10 10 2014 Operating Instructions Issue 1 4 4 Helium empty The helium empty sequence operates the absorber pot heaters to boil off any liquid and release the gas into the vent line
42. um Box 4 e Ventilation line Box 7 e MICE Hall ceiling Box 9 e Vac pump enclosure Box 10 These correspond to channels on the gas detection controller see Table 4 Figure 23 Gas detection controller Each detector has three alarm modes for 25 50 and 100 of Lower Explosive Limit of hydrogen A trip on any detector will sound an alarm within the LH2 control room while a trip in the gas panel enclosure or Hall will sound an additional alarm on the front of the gas panel and a trip in the vac pump enclosure will sound an additional alarm outside the enclosure building The status of the traffic light system will also change see Section 5 1 It should be noted that the detectors in the ventilation line HC HD03 are of a different design as they do not operate in air As such they will also detect helium e n the event of any hydrogen detector alarm all personnel inside the MICE Hall on the MICE roof or in the south wall area should be immediately contacted and evacuate to the MICE LCR A Hydrogen Expert should view the Gas Det Alarms screen to determine the source of the alarm e Specific actions required for individual detector alarms are given in Table 4 Hydrogen detection actions o Prohibit access to areas at risk means to collect and control all keys giving access the following areas MICE Hall MICE Hall roof South wall area hydrogen vent lines o Inform ISIS MCR means to dial x6789 an
43. y a mistake made during a Controlled Access attempt and the remaining operator is sure of this the Controlled Access can go ahead as planned Once the entering operator has exited the Hall PKOO should be locked in Page 28 of 51 Te9files te rl ac uk MDG public _Projects 100 MICE Hydrogen Delivery System S Watson Operations Operating Instructions R amp D doc Hydrogen Delivery System Date 10 10 2014 Operating Instructions Issue 1 the LH2 keypress and no further Controlled Access is permitted until the Search has been enabled again If the Search is dropped for any other reason PK00 should be locked in the LH2 keypress and no Controlled Access permitted until the Search has been enabled again 3 1 2 Keys Access to the MICE Hall roof and vent area are restricted with padlocks Padlock keys are held in the LH2 keypress situated on the wall of the LH2 control room Keys for keyswitches and various lockable valves are also held in the keypress Where applicable spares are held by Stewart Greenall 3 1 2 1 Keyswitches Certain system valves have keyswitches located on the LH2 control rack to override interlocks and enable manual operation Figure 21 LH2 keypress Table 2 Keyswitches Keyswitch Action required when Key tag number H2 operation permit PV01 Required in H2 filllempty and hydride bed 11 charge PV02 Manual control enable 12 Required to manually operate valves
44. y check all panels are in place including the hydrogen bottle cabinet front panel and operating hatch and all ductwork is undamaged e If hydrogen bottles are to be used ensure the manually actuated gate valve in the bottle cabinet ventilation ductwork is open It is located on the south mezzanine behind the shield wall see Figure 6 e f hydrogen bottles are not to be used ensure the gate valve is closed e Ensure all the ventilation fans are operating as required Page 22 of 51 Te9files te rl ac uk MDG public _Projects 100 MICE Hydrogen Delivery System S Watson Operations Operating Instructions R amp D doc Hydrogen Delivery System Date 10 10 2014 Operating Instructions Issue 1 o On the GAS DET ALARMS screen the following boxes should be green 02 00 02 01 02 02 Gas panel fan A 02 03 02 04 02 05 Gas panel fan B 02 10 02 11 Vac pump enclosure fan A 02 12 02 13 Vac pump enclosure fan B o If the gas panel fans are not on they can be switched on by pressing the green RUN button on each respective control box found in the LH2 control room o If the vac pump enclosure fans are not on contact Phil Warburton lan Mullacrane or Dave Matthewson x6210 95 LL Figure 11 Ductwork gate valve and fan control boxes 2 5 Purge gas supply e Check helium and nitrogen bottle pack pressures The packs are found outside the MICE Hall equipment door If either is below 100
45. ylinders and oxy acetylene sets removed L Page 47 of 51 Te9files te rl ac uk MDG public _Projects 100 MICE Hydrogen Delivery System S Watson Operations Operating Instructions R amp D doc Pre sequence check list 3 Applicable to following sequences Hydride bed charge Note This checklist should only be used in conjunction with the system Operating Instructions Control system and instrumentation Control screen OK Air supply OK Penning gauges unplugged Gas panel enclosure Visual checks Ventilation system Visual checks Cabinet gate valve open Fans OK Purge gas supply Bottle pack pressure gt 100 barg Bottle pack regulator set to 3 barg HV16 open PGO1 1350 1450 mbar HV15 open FM5 2 l min Vacuum system Vac pump oil OK Heater chiller Auxiliary chiller OK Heater chiller OK Miscellaneous Oxygen cylinders and oxy acetylene sets removed Page 48 of 51 Te9files te rl ac uk MDG public _Projects 100 MICE Hydrogen Delivery System S Watson Operations Operating Instructions R amp D doc Pre sequence check list 4 Applicable to following sequences Vac down procedure Note This checklist should only be used in conjunction with the system Operating Instructions Control system and instrumentation Control screen OK Air supply OK Vacuum system Vac pump oil OK Turbo pump OK PV20 open Page 49 of 51 Te9files te rl
46. ystem manager x6331 office x1188 mobile 1 15 R66 RAL Phil Warburton LH2 control engineer x3882 office B1 DL Mike Courthold LH2 cryogenic engineer x6462 office 07770 652507 mobile 1 11 R65 RAL 6 2 Other contacts ISIS Main Control Room x6789 Andy Nichols MICE project manager x5251 Vicky Bayliss MICE cryogenics engineer x7017 Tom Bradshaw Cryogenics Group Leader x6149 lan Mullacrane MICE electrical infrastructure x3403 John Govans ISIS services manager chillers compressors water supply x6012 Stewart Greenall MICE Hall manager x1309 Page 44 of 51 Te9files te rl ac uk MDG public _Projects 100 MICE Hydrogen Delivery System S Watson Operations Operating Instructions R amp D doc Hydrogen Delivery System Date 10 10 2014 Operating Instructions ded 7 Appendices 7 1 System checklists overleaf Page 45 of 51 Te9files te rl ac uk MDG public _Projects 100 MICE Hydrogen Delivery System S Watson Operations Operating Instructions R amp D doc Pre sequence check list 1 Applicable to following sequences Standard helium purge He Purge Sq Helium supply line purge He Line Pur Sq Helium fill Helium empty Note This checklist should only be used in conjunction with the system Operating Instructions Control system and instrumentation Control screen OK Air supply OK Cryogenic system Visual checks

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