1. Philippe Goudket ASTeC, STFC Daresbury Laboratory TTC –TOPICAL WORKSHOP SRF CLEANROOM ASSEMBLY

2. Shrikant Pattalwar CM workshop ESS Nov 15-16 2014 2 Facilities at Daresbury Laboratory * Tower cleanroom * ETC cleanroom * New cleanroom facilities Experience with DICC cryomodule assembly * Cold and warm coupler assembly * Higher order mode coupler cleaning and assembly * Problems!

3. HPR Tower Cleanroom Facility ISO 5 ISO 4 3 x 6 m Components access People access ~7 m 12 m Cryomodule 0.8 x 3.5m dimensions (approx) N2/He N2/He/RF feedthroughs ISO 5 ISO 5* ISO 6 BCP ALICE-type cryomodule ISO 4 booth Sink DI water Philippe Goudket TTC SRF/Cleanrooms workshop Nov 12-14 2014

4. Existing SRF Facilities UPW Facility:  >18 M  /cm HPR:  Fully automated  1350 psi HP water supply  Rinse nozzle wand 2RPM max  Linear rail 60 inches/min max  Motions are slow  No pinch points BCP Facility:  A full sized walk-in laminar flow booth  Fully automated  Acid mixture - HF (49%), HNO 3 (65%), H 3 PO 4 (85%), 1:1:1 mixture Philippe Goudket TTC SRF/Cleanrooms workshop Nov 12-14 2014 Cleanroom:  ISO 4 (5.7 m x 2.8 m)  ISO 5 (8.5 m x 3.5 m)  ISO 6 (2.8 m x 2.8 m)

5. ETC Floor Plan Exhibition Area Vacuum Laboratory Precision Machining Centre CMM CAM Meeting Room Reception Magnet Test ISO 3,4,5 Cleanroom PM Build Area UHV Cleaning Ovens 23 m 30 m 40 m 15 m 21 m 92 m 30 Tonne Crane coverage Large Systems Assembly Area ISO 4 Soft wall Clean Room Philippe Goudket TTC SRF/Cleanrooms workshop Nov 12-14 2014

6. Relocation to old workshop area Philippe Goudket TTC SRF/Cleanrooms workshop Nov 12-14 2014 BCP Water Changing Room Tool Room ISO 4 Cleanroom

7. ETC Build Area & Clean Rooms 30T Crane Magnet Test Room ISO 4 Cleanroom Particle counter Soft Wall ISO 4 Cleanrooms Large ISO 4 Cleanroom Assembly Hall 30 Tonne Crane

8. DICC Cryomodule Overview

9. DICC Cleanroom Procedure 9 This was achieved by: Bagging or taping over as much of the cavity string and cold coupler as was possible (illustration of that on Figure 1 and Figure 2), as well as any hard to clean areas such as recessed bolt holes. Ideally, only smooth, flat metal surfaces remained near the working area. Particle counts of the area were taken before deciding the cavity string was ready for the coupler. Bagging the coupler tip after the coupler was particle counted in a separate area from the cavity string. The bag was placed in such a way that it did not touch the coupler surface and could be removed with minimal risk of contamination. The bag was kept on the coupler as long as possible into the installation process in an effort to keep the tip clean. Bagging the scissor jack. Despite best efforts, the scissor jack released more particles than was allowable when operated (more than 10 particles per cubic foot per minute). By bagging the jack, the particles generated were kept inside the bag. The bag was only removed once the coupler was installed and the flange sealed. Slow movements of the cleanroom personnel at all times, in particular after the flange was opened. Despite best efforts, some dust inevitably remained in the cleanroom. In order to avoid lifting it up with displaced air, movements of the operators was to be kept as slow and efficient as possible. Practice runs while monitoring the particle counters are useful to determine the amount of disturbance caused. In practice, it was generally found that the levels could be kept within the allowable parameters. If there was a particle spike, as seen by constant monitoring of the counters, the personnel would step back and resume work only once the levels were down to the baseline levels of the cleanroom (no particles detected) Particle counting near the critical location of the operation. In Figure 2 we see that the particle counter’s collection cup is located at the level of the flange and as close as was possible to it. Care was also taken to ensure that gloves were clean – this was achieved both by changing gloves regularly (eg. after any operation that could generate particles, or touching an item that wasn’t known to be clean, or prior to any critical step of the procedure) but also being careful of what was touched to avoid carrying dust from one surface to another. Two pairs of gloves were worn (visible on Figure 2), the outer pair being replaced often. Care was taken to touch only the outer gloves with the inner pair to ensure no transfer. Operation to ISO 4 standards. Cleanroom at rest to perform at ISO 3 or better. Bagging/taping over any source or trap of particles. Placing particle counter heads close to the critical areas of the operation. Pre-clean 6bar nitrogen blasting of any area near the operation. Process continues until resulting particle counts are to ISO 4 standard. Prior to removing flanges, using a vacuum cleaner to remove as many trapped particles as possible (NOT done when interior volume can be affected ) For the cold coupler, the tip was bagged without contact of the copper tip. The bag was only removed just prior to insertion in the beampipe. Bagging the scissor jack that lifted the cold couplers into place. Despite extensive cleaning, they still produced particles. Keeping gloves clean. Two layers were worn. The outer layer was changed after any possible contamination or just prior to any critical step. Slow movement of personnel in the cleanroom at all times. Pausing operation to allow a particle count spike to recover. Practice runs of complex or risky procedures, in order to reduce to a minimum all unnecessary movements. Philippe Goudket TTC SRF/Cleanrooms workshop Nov 12-14 2014

10. DICC HOM and Coupler Assembly 10 Cold coupler assembly ½ HOM sliding alignment fixture Warm coupler assembly Philippe Goudket TTC SRF/Cleanrooms workshop Nov 12-14 2014

11. HOM Particle Counts 11 Philippe Goudket TTC SRF/Cleanrooms workshop Nov 12-14 2014

12. DICC HOM assembly particulate contamination Shrikant Pattalwar CM workshop ESS Nov 15-16 2014 12 Particulates, probably Cu from the gasket, <100  m

13. Outlook 13 Philippe Goudket TTC SRF/Cleanrooms workshop Nov 12-14 2014 Preparation and vertical testing of industrial collaboration cavities Looking at ways of expanding and completing the new development Thank you for your attention