1. S1 Global Module Cavity String Assembly Workflow Tug Arkan January 15, 2010

2. 2 Assembly Team FNAL: –Brian Smith –Marco Battistoni DESY: –Manuela Schmoekel –Patrick Schilling KEK: –Okada-San (auxiliary support help, minor infrastructure modification, ultrasonic cleaning etc.) Tug Arkan (FNAL) Eiji Kako (KEK)

3. 3 Current status As of Thursday January 14: –2 FNAL and 2 DESY dressed cavities are staged on the clean room fixtures in the Class 1000 area – The cavity exterior surfaces were wiped clean (by KEK colleagues) to Class 1000 cleanliness level –The cavities are rough aligned (rotational & X-Y)

4. 4 Cavity String Layout Gate Valve sub-assembly (Step 1) –Right angle valve + zero length reducer flange –Transition piece DESY Z109 to Z108 cavity assembly (Step 2) FNAL ACC-011 to Step 2 assembly (Step 3) FNAL AES-004 to Step 3 assembly (Step 4) Step 1 to Step 4 assembly (Step 5) String Assembly Complete

5. 5 Tentative Schedule: Friday Jan 15 (today) Move the gate valve and four cavities into Class 10 area –Wipe clean, blow with ionized air/nitrogen & monitor the particle count –Workflow: Move gate valve into Class 10 Move cavities (one by one) into Class 10: –pump down –leak check –leave under vacuum –move the cavity to position –Align –Check the resistance of the HOM connectors (multi-meter needed) Gate valve transition piece will be received today from the company: –KEK group cleans and preps this part to enter the Class 1000 area. This part is needed for assembly on Saturday Jan 15 morning.

6. 6 Step 1 Assembly: (on the workbench in Class 10 area) –Right Angle valve + zero length reducer flange assembly –Clean the interior surfaces of the gate valve (ionized nitrogen blow, monitor the particle count) –Move Transition piece into Class 10 –Assemble the Gate valve sub-assembly –Leak Check, Backfill the cavity –Stage the sub-assembly on the support post Continue to move the cavities into Class 10 Receive the parts sent by DESY: –Already cleaned and bagged in Class 10 at DESY Tentative Schedule: Saturday Jan 16

7. 7 Step 2 Assembly: –Assemble backfill lines, backfill the Z109 and Z108 cavities –Remove the blind flange from Z109 cavity (position #4) and assemble the new flange/valve assembly sent by DESY –Assemble Z109 cavity to Z108 (position #3) cavity with interconnecting bellows (standard size, sent by DESY) Tentative Schedule: Sunday Jan 17

8. 8 Step 3 Assembly: –Assemble backfill line, backfill the ACC-011 cavity. (Step 2 assembly is already backfilled) –Assemble ACC-011 cavity (position #2) to Step 2 assembly with interconnecting bellows (long size, sent by FNAL) Tentative Schedule: Monday Jan 18

9. 9 Tentative Schedule: Tuesday Jan 19 Step 4 Assembly: –Assemble backfill line, backfill the AES-004 cavity. (Step 3 assembly is already backfilled) –Assemble AES-004 cavity (position #1) to Step 3 assembly with interconnecting bellows (standard size, sent by FNAL)

10. 10 Step 5 Assembly: –Backfill Step 1 assembly (Step 4 assembly is already backfilled) –Assemble Step 1 to Step 4 assembly Adjust coupler to coupler position Pump down the string, leave active pumping overnight Tentative Schedule: Wednesday Jan 20

11. 11 Tentative Schedule: Thursday Jan 21 Leak Check the string: –Ensure that the bellows squirm protections are installed –Bag the bellows, fill with helium for fine leak check –Conduct leak check Backfill the string with Argon (overnight): –0.5 liter per minute flow, a cavity beamline volume is approx 25 liters –~50 minutes per cavity to backfill to atmosphere –~ 200 minutes to backfill the string

12. 12 Tentative Schedule: Friday Jan 21 Spare day for unforeseen assembly schedule delays

13. 13 Proposed Daily Work Hours DESY & FNAL group meet in the mornings at 7.30 am in front of the STF clean room Gown up and enter the clean room by 8 am Assembly from 8-10 am Break at 10 am for 15 minutes Lunch break at 12 pm for 1 hour Assembly from 1.30 pm to 3.30 pm Break at 3.30 pm for 15 minutes Assembly from 4 pm to 6 pm