# Comments from the Beams Division Review of the Kicker Flourinert Cooling System

# June 14, 2002

# Chaired by Maurice Ball

# 

## System Specifications

## Presenter: S. Reeves

1.  ([Reviewer: B. Ducar]{.underline}) From my limited knowledge of
    fluid process systems, the design appeared to be quite thorough and
    well documented. I especially appreciate identification of variables
    to be monitored by ACNET. Some amount of additional effort might be
    required to consolidate (sum) significant status points as a
    \"permit\" to Jensen\'s kicker system.

2.  ([Reviewer: B. Ducar]{.underline}) I have heard that the necessity
    of the back-up pump was questioned. I believe that it should remain
    in the design and note that back-up pumps are included in all or
    most all of the process water systems already planned for NuMI.
    Failure of a single pump could significantly affect operations.

3.  ([Reviewer: B. Ducar]{.underline}) A total of 11 variables are
    indicated for ACNET monitoring. Some thought might be given as to
    which of these, if any, might be monitored by the Beam Permit
    System.

4.  ([Reviewer: D. Pushka]{.underline}) On subject of Pressure gages,
    the bill of materials indicate glycerin filled gauges. These are
    applicable for use where pressure fluxuations would cause the needed
    to vibrate. This should not be the case in thissystem and their use
    is rightly questioned. Apparently, the group mis-interprets glycerin
    filled gauges as being good quality and non-glycerin filled gauges
    as being poor quality. I agree the little non-glycerin filled gauges
    in the stock room are crap, but there are good quality non-glycerin
    filled gauges. Use one.

5.  ([Reviewer: D. Pushka]{.underline}) Use thermowells for the
    temperature instruments. Or just locate the sensor on the pipe wall,
    under the insulation.

6.  ([Reviewer: D. Pushka]{.underline}) Do not design a pressure vessel
    with flat ends. Buy pipe caps and assemble using qualified welders
    so that a MAWP can be calculated.

7.  ([Reviewer: D. Pushka]{.underline}) The specification 1320-ES-296363
    is not a specification as one would attach to a purchase order. It
    is an engineering note and should be labeled as such.

8.  ([Reviewer: D. Pushka]{.underline}) Get the voltage correct in the
    \"specification 1320-ES-296363\". To use a variable speed drive
    (VSD), the motors need to be 3 phase. Hitachi makes some pretty
    affordable 460 VAC drives for 5 HP motors for \$450. I would avoid
    the complexity of attempting feedback control on the pressure by
    using the VSD. Rather, set it to get the right flow thru the load
    resistors and then remove the setting knob.

9.  ([Reviewer: D. Pushka]{.underline}) On the \"specification
    1320-ES-296363\", there is a sentance about having the operation
    point for the system be at or to the left of the \"best efficiency
    point of the pump\" is silly. There is little technical reason for
    doing this on a pump operated at a single frequency, let alone one
    on a VSD.

10. ([Reviewer: D. Pushka]{.underline}) On the Tubing materials, I would
    specify an all welded tubing system except for compression fittings
    at the spools where attachments are made to the load assemblies and
    at the \"skid\" upstairs. A competent contractor should have the
    required automated tube welder or can lease it for the job. If the
    contractor can\'t or is reluctant to, then we don\'t want them on
    our job.

11. ([Reviewer: D. Pushka]{.underline}) List the setpoints for the
    alarms, interlocks.

12. ([Reviewer: D. Pushka]{.underline}) If the heater is needed, can it
    just be heat tracing cable attached to the outside of the tubing?
    This will greatly reduce the energy transfer rate per unit area to
    small values, avoids adding another component into the system (no
    additional leak potential) and can be added later w/o breaking into
    the system.

13. ([Reviewer: R. Reilly]{.underline}) Here are my comments on the
    Fluorinert Cooling System:

    a.  Expansion Tank: FESHM 5031 requires an ASME Code stamped vessel
        or director\'s exemption if the vessel falls within the scope of
        ASME Code Section VIII; see Div. 1 paragraph U-1. Vessels
        outside the scope include: ID not to exceed 6\" with no limit on
        length, or MAWP not to exceed 15 psig. I\'m unhappily surprised
        that there isn\'t something suitable on the market that you
        could get off the shelf. Have you tried suppliers for the dairy
        and food processing industry? You could even make it out of a
        length of 4\" Sch 10S pipe and two pipe caps and a bunch of
        threadolets. Same with the overflow recovery tank. I think I
        have some leftover pipe caps. Do you have a filling port
        somewhere? I suppose it will be at the top of the expansion
        tank. The recovery tank will need a low pressure vent to
        atmosphere or you\'ll dead head it. It would not have to be code
        then, either. Should this tank be upstairs? You could then run a
        line from it to the expansion tank and refill just by opening
        valves.

    b.  Tubing quality: I had leakage of Fluorinert when I used ordinary
        stainless tubing and Swagelok fittings on the top of my TeV
        kicker pulsers, and the fittings galled when I overtightened
        them trying to stop the leaks. This was with just 6\" of head
        pressure. I ended up doing an overkill, getting polished tubing
        and welding the fittings. I think I would not have had this
        problem if I had used polished tubing to begin with. I have some
        of the failed ones if you want to look them over.

    c.  Pipe Threads in Ball Valves: I think it is perfectly reasonable
        to use NPT to compression unions and weld them into the valves
        if it saves a lot of money.

    d.  Flow Meters: You show a flow indicator. Do you need a flow
        meter?

14. ([Reviewer: R. Reilly]{.underline}) I think the system looks good.
    You might consider putting it all on a skid like Ross does with his
    RAW systems.

15. ([Reviewer: J. Riordan]{.underline}) There are about a dozen sensors
    that measure process parameters for the system. The designer should
    consider the cost of the cable, connectors, and the cost of the
    labor required to pull and terminate the cables.

16. ([Reviewer: J. Riordan]{.underline}) The Powers 535 is not capable
    of powering all the process parameter sensors. Therefore, an
    instrumentation chassis or some module will have to be built.

17. ([Reviewer: J. Riordan]{.underline}) The Powers 535 can handle a
    remote temperature set point if desired.

18. ([Reviewer: J. Riordan]{.underline}) A temperature sensor on the
    return line for the CHW after the heat exchanger or a temperature
    sensor on the Fluorinert line before the heat exchanger would help
    monitor the heat exchanger performance.

19. ([Reviewer: J. Riordan]{.underline}) A strainer with a low micron
    rating in addition to or in place of the 5 micron filter on the CHW
    should be considered. This would maximize the interval between
    filter change outs and minimize maintenance time.

20. ([Reviewer: J. Riordan]{.underline}) I would recommend measuring the
    temperature of the Fluorinert with RTDs that can be epoxied to the
    pipe under the insulation. Since the temperature control (+/- 3 F)
    range is not incredibly narrow, the better accuracy of a RTD in a
    thermowell is not required. Also, the thermowells would be
    additional, unnecessary leak paths.

21. ([Reviewer: J. Riordan]{.underline}) Pressure is an important
    parameter for the system. Consider using pressure gages with
    compression fittings to minimize the threaded joints and the
    potential leak paths. Also, Noshok pressure transmitters are high
    quality and have been used successfully at the laboratory --
    non-threaded connections might be available.

22. ([Reviewer: K. Williams]{.underline}) The excess use of gauges and
    valves in the filter line is to be commended. Often, filter lines
    are equipped with isolation valves at each end only. And, although
    having pressure gauges between each filter is very good practice
    from a diagnostic point of view, they are sometimes excluded due to
    cost. Changing a single filter can easily dump 1/4 to 1/2 gallon of
    fluid. A series of filters in a row, unisolated by valves, can dump
    more, even if only one filter in the series is opened. If it is
    necessary to open and check each of the filters, wastes go up. At
    \$400 per gallon, Fluorinert is a very costly fluid. The losses
    experienced on the very first access of the filters for service and
    maintenance can more than pay for the minimal added expense of the
    two extra valves and gages in the filter line.

23. ([Reviewer: K. Williams]{.underline}) Somewhat cheaper, reliable
    glycerin gauges are available. This cost may be reduced by 20 to 30%
    if buying in quantity, from a total of \$1500 to say \$1100 or
    \$1200. The caution here is, you get what you pay for. In the LCW
    group's extensive experience, cheap gauges such as those stocked by
    the Fermilab stockroom, unfilled and smaller in size, do not have
    the quality, reliability or service life to support their use. Also,
    one vendor, Swagelok, has introduced a new line of gauges that are
    connected via tube stubs and compression fittings instead of 1/4"
    NPT threaded joints. Although I do not have current pricing, they
    may be a good way to compromise between the need for information,
    and the concern of NPT joints leaking Fluorinert.

24. ([Reviewer: K. Williams]{.underline}) Although the CHW lines are
    piped through the length of the MI-60 gallery in stainless steel,
    from the point where the Fluorinert skids will tap into them could
    be a cheaper material. Carbon steel, or even hard piped copper could
    be used. This could substantially reduce the costs of piping
    materials.

25. ([Reviewer: K. Williams]{.underline}) In the review meeting, I had
    spoken up about the temperature control valve placement before the
    heat exchanger. Upon further study, its placement in the CHW supply
    line to the heat exchanger looks fine to me. There are two schools
    of thought here, the first, that placing it after the exchanger
    helps ensure the exchanger stays flooded, the second, that placement
    after the unit submits the unit to undue pressure load. In this use,
    the lines returning from the exchanger to the CHW system are long,
    and above the exchanger, and it should easily remain fully flooded
    after initial fill.

## System P&ID

## Presenter: S. Reeves

1.  ([Reviewer: D. Pushka]{.underline}) The P&ID drawings and the layout
    drawings are not signed off. They should be signed off and formal
    revisions made when the design changes.

2.  ([Reviewer: D. Pushka]{.underline}) On the P&ID, since this is a
    cooling system, include the temperatures in the legend. Also show
    the heat loads.

3.  ([Reviewer: D. Pushka]{.underline}) On the P&ID, there are a heck of
    a lot of bits of instrumentation, everyone is a possible leak source
    due to the threaded connections. Reduce the number to the bare
    minimum needed and epoxy them in.

4.  ([Reviewer: D. Pushka]{.underline}) P&ID should indicate the chilled
    water flow.

5.  ([Reviewer: D. Pushka]{.underline}) P&ID should indicate carbon
    steel piping for the chilled water.

6.  ([Reviewer: D. Pushka]{.underline}) P&ID should move the 7 gallon
    overflow tank to upstairs and get it out of the tunnel. Reduce the
    set pressure of the relief valve accordingly.

7.  ([Reviewer: D. Pushka]{.underline}) P&ID shows 31 ball valves in
    fluorinert service. Are all of these really needed? Every one is a
    potential leak. Consider using the bellows sealed Nupro valves as
    the isolation for the pressure gauges.

8.  ([Reviewer: D. Pushka]{.underline}) P&ID should indicate a set
    presure on the relief valve.

## Cost Estimate

1.  ([Reviewer: B. Ducar]{.underline}) A comment relative to fixed price
    vs T&M. There are clear yet different advantages to these two
    methods of getting work done. Supervision by the Task Manager is
    especially critical to getting T&M work performed efficiently. As
    Childress has pointed out, choice of T&M can minimize EDIA. Another
    consideration is that shorter and unpredicted shutdowns are more
    amenable to T&M. Generalities aside, the choice is nonetheless quite
    subjective.

2.  ([Reviewer: D. Pushka]{.underline}) Since the cost estimate
    currently exceeds the budget, the system needs to be slimmed down
    (remove hot spare pump, reduce instrumentation, etc.) to get the
    cost in line with the budget.

3.  ([Reviewer: D. Pushka]{.underline}) Remove all spare parts from the
    cost estimate. Spares are to be paid for out of the operation
    budget, not the plant line budget.

4.  ([Reviewer: D. Pushka]{.underline}) Complete the piping layout
    drawings and plan on executing this work as a fixed price contract.
    This adds drafting costs at about \$30 per hour but saves pipe
    fitter costs for a two man crew of \$120 per hour. Which is more
    economical, paying a draftsman to work out the routing details to
    avoid interferences or paying a piping crew to do the same? Using
    the formar also allows the routing to be documented and to be shared
    with others who have devices in the tunnel.

5.  ([Reviewer: K. Williams]{.underline}) In my experience, this project
    is at the dividing line between which method, T & M or fixed-price,
    would be best. If all necessary drawings, specifications, bids and
    permits can be acquired in time that this project can be part and
    parcel of a larger package, and that the timeline of the project
    does not suffer, I think the fixed price bids method would be
    prudent. If, however, there is not a suitable larger package this
    can ride on, and / or the deadlines cannot be met, T&M may be the
    wisest choice. Although I have heard much criticism concerning T&M
    crews not having motivation, in my extensive experience, the current
    crews at Fermilab can and do provide competent and sufficiently
    expedient work for many small or miscellaneous projects, enough so
    to offset some of the extra time, work, and hassles of running a bid
    package through the system.