1. IBBelle: Status Commissioning at MPP Transport to KEK
Installation at KEK
Commissioning plans at KEK

2. IBBelle Commissioning at MPP
Install and debug software: PLC EPICS:
Check complete setup (with CERN expert)
Basic functionality tests (SCADA instructions and expert commands).
Pressurize complete system with N2 and check for tightness.
Fill with liquid CO2, run without insulation (cannot reach design temperature)
Complete foam insulation
Operate at design temperature
Safety inspection => June 29/30
Long term tests => July and later at KEK
Response to change of operation conditions (load on/off…)
Exercise maintenance and emergency scenarios.

3. Long Term Operation (almost) continuous operation for 1 month 12.7.16
CO2 temperature
Compressor speed
Accu temperature
CO2 flow
Heater power
False alarm during 0 power operation
Installation of weighing scale
Off, Zaragoza
CO2 temperatures of -30°C (sometimes -32°C and -35°C)
Heater power in JB: 0W – 3000W
CO2 flow 12g/s and 16g/s
Very stable operation, only 1 (false) alarm
=> Stable -30°C and 3000W heater power

4. Dry Out Test for dry out: Tset = -30°C, flow: 12 g/s
Increase heater power: 2500W => 2950W
2900W
2950W
2750W
2800W
Flow increased to 16 g/s
2500W
Heater surface temperature
Dry out
Dry out can be controlled by increasing CO2 flow
Gas temperature at outlet of heater is not very sensitive to dry out!

5. Arrival at Tokyo and KEK
IBBelle after unloading from container
IBBelle being lowered into B1
left Munich
vessel left Hamburg
arrival at Tokyo port
unloading at port
arrival at KEK
Customs formalities in Japan went fine
(donation, no duty and tax paid)

6. Location Enough service space? CO2 line
1 m additional clearance requested
UNIT A
Pump removal
UNIT B (optional)
Cannot move Unit A further in the centre, not enough space to lower done Unit B by crane

7. IBBelle in B1
A unit is now at B unit position (shifted to the wall). Space for B unit to the left
Electrical power, cooling water and pressurized air are connected (October 28)

8. Status at KEK By Shuji-san
400V 3-phase transformer: delivered, connected tested
Compressed air (6.6 bar): connected (hose, fixed connection planned)
Water pipe connection (25°C, 3 bar): connected (fixed connection planned)
Anchor: done
CO2 bottles and cart: delivered (not yet used)
Scale for weighing CO2 bottle: delivered ?
Tools and furniture: delivered
O2/CO2 monitor with alarm: one set delivered
Network: connected
R404a filling: confirmed by Sanei-Giken, sheduled for November 28
Connection tubes for CO2: request made to Suzuki-Shokan, to be finished November 28
Vacuum for flex lines: 10-7 bar, from vacuum group (or sharing helium pump)
By Shuji-san

9. Junction Box and Manifolds
Junction Box and Manifolds are installed
Junction box electrically connected

10. Commissioning at KEK Commissioning plan:
Put IBBelle in place, anchor in floor
Service connection (electricity, water, air, network)
Power up, check software
Basic functionality tests (valves, sensors..)
Pressure & Leak test
Produce and install support for JB and Manifolds
Install JB and Manifolds
Complete connections to transfer line, JB & manifold
Fill wit R404A (company) and CO2
Commission with internal heater
Connect to transfer lines and JB
Commission with JB; parameter optimization
Prepare for cold tests of flexlines (December?)
Training of KEK operation team
October (MPP)
Nov, (KEK & company)
November 28-Dec 2 (MPP)
Technical support by S. Horn, R. Sedlmeyer, S. Vogt and A. Wunderl

11. Problems encountered I
After power on the PLC went into an error state
Memory lost after 2 months without power
(however, backup batteries should operate for 9 months!)
In principle no problem, just reconfigure PLC using Schneider software ‘Unity Pro’
However, on our laptop we have Unity Pro V11, the CERN software was compiled with V7
Some external libraries were not compatible with V11
(we never encountered this at MPP, since we did only partial compilations, which do not need the libraries)
CERN team needed ~1 day to install the libraries
Backup batteries were replace, O(1h) power loss ok
Software up to date and working. Nevertheless we will bring a 2nd laptop with a backup.

12. Problems encountered II
After filling with 2.5 bar of CO2 (gas). Clear indication of a leak in pump unit (other parts ok).
Defect seals of the burst disks were identified.
Apparently burst disk seals do not stand vacuum (at least for several hours).
However, vacuum needs to be applied for filling wit CO2.
Burst disks will be replaced by a modified type which uses an additional O-ring. This is presently tested at MPP
Standard seal
O-ring

13. Conclusions
Shipment, customs, installation at KEK went according to schedule
First part of commissioning was ok, only minor problems
Second part planned for November 28 ff: filling and cooling
Thanks to the KEK team for organisation and support