list of preparation and assembly …...2005/05/16 · leak proof junctions. beware: pick ups and...

Project

TESLA

Centre National de la Recherche Scientifique (CNRS) – Université Paris Sud XI (UPS)

Institut National de Physique Nucléaire et de Physique des Particules (IN2P3)

Laboratoire de l’Accélérateur Linéaire (LAL) Campus d’Orsay, Bâtiment 200, BP 34, F-91898 Orsay Cedex

France Service Développements et Technologies Mécaniques (SDTM)

TESLA Power

Couplers

First release: 27-10-2004 Last update : 16-05-2005

Réf. : TESLA-COU-TTF3-ASSEM Index : 2 sur

23

LIST OF PREPARATION AND ASSEMBLY OPERATIONS FOR TWO TTF3 COUPLERS ON

THEIR TEST BENCH

Written by Laurent Grandsire For any information contact

Laurent Grandsire Téléphone : (00 33) 1 64 46 84 21

Fax : (00 33) 1 64 46 85 46

E-Mail : [email protected]

TESLA ASSEMBLY OF TTF3 COUPLERS Last release : 16-05-2005 TESLA-COU-TTF3-ASSEM Index : 2 sur 23

Last updates Index Date Modifications 1 27/10/2004 First release 2 16/05/2005 Visual controls

Cleaning procedures Rinsing controls Particle counting onto cold parts Leak tests CuNiSi screws for tuning rod New pictures


Preamble : This paper describe the operations of assembly of TTF3 couplers on its test bench. This document is evolutionary: any relevant remark or result of test can be included in this document. However people (especially technicians dedicated to mounting) are asked to follow the procedures described in this paper. In case of questions or suggestions, people are asked to talk about for approval before assembly. This paper is not about general principles of working in a clean room, things that are developed in an other paper. In the same way, this paper is not about the use of devices located in the clean room area (ionized nitrogen, ultrasonic bath, ultra pure water system, oven, particle counter…), things that are developed in an other paper. It should be remained that the goal of all theses procedures are:

- obtain a good vacuum level (< 10 –9 mbar without RF) in the coupler in order to have a fast conditioning time (let the coupler under clean and dry nitrogen after baking),

- to secure the mounting of couplers onto the niobium cavity at DESY (after RF conditioning at Orsay and dismounting) in order to be sure that cleanliness of cavity is not degraded by the coupler. That implies that cleanliness of cold part is maximal (no dust in cold part that could go onto cavity)

The operations listed in the document are in a logical order. That doesn’t exclude that some operations are processed simultaneously for two different test benches.


Rappel : schematics of TTF3 coupler

Tuning handle

Warm transition

p

W

RF springs

Tuning rod

H

e- pick up

Test stand = cold transition (and

cold pumping) (not on the picture)

Polarisation ring

umping port

indow forPM

Warm part

ollow screw

Cold part


Synoptic of assembly operations : Etape n° : F1 Lavage de deux parties fAntenna tuning, instrumentation, joining to

network, RF conditioning

Starting the pumping (plus optionnal in situ baking)

stag

Assembly of the two warm transitions stag

Tim

e

Cleaning of cold parts and cold transition

stage F1

Assembly of cold part and its closing valve

Leak test stage F3

Assembly of warm part n° 1 onto cold part n° 1

stage FC4

Pré assembly stage F2-a

Baking in oven stage F2-b

Baking in oven of w

Assembly of its pumping group onto warm part n° 1

Leak test stage FC4

Aw

onto

Assembly of ww

Assembly of cold pumping group onto cold part

Leak test stage F3bis

Cleaning of warm parts Stage C1

Stage C2Pré assembly

roides et de la transition froidRF Group

RF

Vacuum Group e FCC6

e FCC7

-a

arm part n° 1stage C3

-b

Baking in oven of warm part n° 2stage C4

ssembly of arm part n° 2 cold part n° 2

stage FCC5-a

arm pumping group onto arm part n° 2 Leak test

stage FCC5-b
Class 10
Class 1000

e Laminar mobile clean room


Stage n° : F1 Cleaning of cold parts and cold transition Duration : 2 h Location : class 1000 Preparation of work Pick up the following parts :

1 cold transition with its protection caps

2 cold parts with their leak proof caps, their assembled bellows locking systems (with all screws)

1 cold pumping group :

- 1 CF 35 tube - 2 CF35 valves - 1 CF35 cross - 1 ionic pump (20 l/s) (without magnets) - 1 vacuum gauge - 1 CF35 bend - 1 CF35 T - 1 RGA - 1 adapter (CF/KF35) - 1 plastic cap for KF35

Parts are not assembled at this stage

2 pick-up Visual controls of:

- CF knives - Ceramics - Copper coating

One mounting frame with 2 aluminum bars , big stainless steel round, 2 small stainless steel plates, 6 threaded rods, and its own nuts and washers.

Pick up the following screws and consumables :

2 aluminum seals For cold transition 2 copper CF 16 seals for pick up 10 CF 40 copper seals For pumping group 2 CF 100 Viton seals For storage after baking 12 CHC M4*20 screws + 12 M4 washers + 6 double nuts for pick up 16 stainless steel M6*40 threaded rods+ 16 M6 washers+ 16 M6 CuSiNi nuts for transition 60 stainless steel H M6-35 screws + 120 washers + 60 M6 CuNiSi nuts Pour assembly easiness, pick up an additional 30 H M6*30 stainless steel screws

For pumping group

32 H M8*35 CuNiSi screws + 32 M8 washers for CF100 and ceramic caps

4 Chc stainless steel M8*35 (or longer) For stabilization of supporting frame


3 M8*80 H stainless steel screws + 6 M8 washers + 3 M8 nuts + 6 M12 nuts For assembly of transition onto frame (and for brace)

4 M8*80 H stainless steel screws + 4 M8 nuts + 8 M8 washers For assembly of aluminum bars onto supporting frame

Washers and nuts of threaded rods of frame 17 glass containers At least one container per type of screw 1 container of 5 L of Tickopur R33 Nitrogen (open the bottle before entering the clean room !)

Wipers pour clean room Work

Dismounting of all parts (except the bellows supports !) Write the serial numbers of cold parts and cold transition Clean all the parts (except the pump, gauge, valve, RGA and seals !) by the following procedure:

- put in the tank in a first time ONLY the vacuum parts (cold parts, test transition, tube, cross, bend, T, adapter, caps, pick up)

- fill the bath with ultra pure water and the bottle of Tickopur R33 - wash at 50 °C during 15 minutes - don’t empty the tank, take out the parts and rinse them (see below) - in the same bath, put all the screws - wash at 50 °C during 15 minutes - don’t empty the tank, take out the screws and rinse them (see below) - in the same bath, put the support frame - wash at 50 °C during 15 minutes - take out the frame, rinse it and empty the tank

Rinse with ultra pure water very carefully, beginning with most critical parts (i.e. cold parts and transition parts) with the following procedure:

- control the restivity of draining water (after rinsing the part) and rinse until the value has risen to 14 Mohm.cm

- in all cases, rinse at least 6 times, and at least until the detergent foam has disappeared.

Let all the parts dry one night in class 10 (in a first time blow the parts with ionized and filtered nitrogen). Puts the parts onto clean room wipers or appropriate support (put the CF16 port in the direction of air flow)

Preparation of next stage

Arrange the working area Fill the check list


Stage n° : F2-a et F2-b

F2-a : pre assembly of cold parts F2-b : baking of cold parts in oven (with its pumping group)

Duration : 2 h (F2-a et F2-b in the same session)

Location : class 10 Preparation of work Pick up the following parts : All the parts cleaned at stage F1 (cold parts cleaning)

Pick up the following screws and consumables : All the cleaned screws (stage F1) All the seals (stage F1 )

Alcohol saturated clean room wipers

Work

Visual control of parts :

- CF knives - Ceramics - Copper coating

Put the caps ont o ceramics (with CuNiSi screws) Blow with filtered and ionized nitrogen (P = 4 bars) onto screws (especially the M6*40 rods) and with the control of particle counter Print the particle ticket. The count must be less of 10 particles of 0.3 microns per cubic foot (i.e. per minute). If, after 9 minutes of blowing, there are still too much particles, the parts goes back to cleaning. Blow with filtered and ionized nitrogen (P= 4 bars) on each cold parts :

- position 1 : blowing on outer and measuring on opposite side

- position 2 : blowing into CF16 port and measuring on the antenna

- position 3 : blowing on the antenna and measuring on the CF16 port

- position 4 : blowing on the antenna and measuring on the antenna

Print the counter ticket In each position of each part, the count must be below 10 particles of 0.3 microns per cubic foot (i.e. per minute) If, after 9 minutes of blowing, there are still too much particles, the parts goes back to cleaning.

position 1 position 2

position 3 position 4

Put on the cold transition the threaded rods (put the caps to avoid dust to fall in the cavity). For same reasons direct the pumping port in the opposite direction of the worker.


Blow with filtered and ionized nitrogen (P = 4 bars) into test transition :

- position 1 : blowing into one port, measuring on the other port

- position 2 : reverse Print the counter ticket In each position of each part, the count must be below 10 particles of 0.3 microns per cubic foot (i.e. per minute) If, after 9 minutes of blowing, there are still too much particles, the parts goes back to cleaning.

Put away one cap, put a saturated wiper on the flange and on the seal Install one cold part and put (without tightening too much at this time) the washers and CuNISi nuts. Put the pick up on the cold part (without tightening too much at this time) Put away the second cap, put the second aluminum seal, install the second cold part, without tightening too much. Tighten all the flanges in order to have helium leak proof junctions.

Beware: pick ups and pumping flange are opposite

Pre assembly of pumping group, that is :

- a tube and a valve - the other valve and the adapter CF/KF

35 - the T and RGA - pump and cross - open the two valves

Tighten all the flanges in order to have helium leak proof junctions.

Dismount the magnet pf gauge and pump ! On picture RGA and T are not assembled!


Put in oven : - the cold piping group - the cold assembly - two ceramic caps (non mounted !)

Close the oven Exit the clean room

cold assembly and caps are not on the picture!

Put first in the oven the parts that will come out last, that is :

- RGA - The valve with

its adapter KF - bend - pump - gauge - tube and valve - thermocouple of

oven - cold assembly - the 2 caps

Start baking at 150 °C

Start the recording of temperature and pressure versus time


Arrange the working area Fill in the check list


Stage n° : F3 Assembly of cold part and its closing valve Leak test

Duration : 2 h Location : class 10 Preparation of work Pick up the following parts : All the parts from stage F1 / F2-a / F2 –b still in oven under vacuum and rest of screws

Pick up the following screws and consumables : Filtered and ionized nitrogen (open the bottle before entering the clean room !)

Work

Break with dry and filtered nitrogen the vacuum in oven and enter the clean room Pull out of the oven the cold assembly, cold pumping group, the 2 ceramic caps.

Don’t wait the opening of oven’s door to enter in the clean room (in order to minimize the duration of expose of parts to air).

Do a visual inspection of parts - knives of CF flanges - ceramics - copper coating

Put 2 CF100 Viton seals, the 2 ceramic caps, screw with CuNiSi screws.

Assemble the CF35 tube and the closing valve on the cold assembly. Close the valve

Blow filterer and ionized nitrogen during the assembly in order to avoid contamination by the moisture of air

Join the valve to the bellow (Viton seal) and call the vacuum group for leak test


Do the leak test in the class 10 as the following:

- start the detector (outside of clean room) - opening of the valve of the detector (outside) - slow opening of the coupler valve (in class 10) - Helium test of all joining - When the leak test is finished: - First close the coupler valve (while pumping) - Close the valve of the detector (outside) - Putt nitrogen in the bellow for disconnection of coupler assembly

Put the cold assembly on its support frame (put 2 nuts as brace) Stabilize the frame with 4 Chc M8*35 stainless steel screw (or longer) underneath

Place the assembly on clean ‘white’ cart. Place on the frame the aluminum bars and the big stainless steel round (with just the threaded rods) Mark off (with clean room adhesive tape) on wich cold part the next warm part will be mounted. (in respect with orientations of the picture) The 2 threaded rods in regard of warm pump should be lowered in respect of the 4 others

windo

windo

pump

Pickup + valve

Pickup + valve

pump




Stage n° : C1 Cleaning of warm parts Duration : 2 h Location : class 1000 Preparation of work Pick up the following parts :

- 2 warm parts and their ceramic caps on it (short type with 4 screws) + 2 caps (long type with central screw) - 2 tuning rods

4 pick ups + 2 windows + 2 diaphragms for windows (Pick up not on the picture)

2 holed screws I54-4D1502 4 RF springs

2 warm pumping groups, i.e. :

- 2 CF 40 crosses - 2 gauges - 2 ionic pumps - 2 valves - 2 adapters CF/KF 40

2 KF40 plastic caps

4 half flanges for locking of warm bellows

Visual control of parts: - knives of CF flanges - ceramics

- copper coating Pick up the following screws and consumables :

2 CF100 copper seals (with broken inner angle) + 2 CF25 copper + 6 CF16 copper + 10 CF40 copper

32 H M8*35 CuNiSi screws + 32 washers M8 (already in the class room because they have been cleaned with cold parts) for CF100

8 H M6-20 stainless steel screws + 8 M6 washers for CF 25 24 M4*20 Chc stainless steel screws +24 M4 washers + 12 double nuts for pick up 12 M4-25 Chc stainless steel screws + 12 M4 washers + 6 double nuts For windows 12 CHc M6*30 stainless steel screws + 12 washers Pour demi brides 60 H M6*35 stainless steel screws + 120 washers + 60 CuNiSi nuts for easiness of assembly add at least 20 H M6*30 stainless steel screws For CF40

2 M8*45 H stainless steel screw + 2 M8 washers (for long type caps) Filtered and ionized nitrogen (open the bottle before entering the clean room !) 1 can of 5 L of detergent Tickopur R33 18 glass containers Clean room wipers

1 special long key (will always stay in the clean room)


Work

Dismount all the parts Write the serial number of warm parts Clean all the parts (except the pump, gauge, valve and seals !) by the following procedure:

- put in the tank in a first time ONLY the vacuum parts (warm parts, tuning rod, copper springs, pick ups, windows, hollowed screws)

- fill the bath with ultra pure water and the bottle of Tickopur R33 - wash at 50 °C during 15 minutes - don’t empty the tank, take out the parts and rinse them (see below) - in the same bath, put all the screws and other parts (caps, diaphragms) - wash at 50 °C during 15 minutes - take out the frame, rinse it and empty the tank

Rinse with ultra pure water very carefully, beginning with most critical parts warm parts) with the following procedure: - control the resistivity of draining water (after rinsing the part) and rinse until the value has risen to 14 Mohm.cm- in all cases, rinse at least 6 times, and at least until the detergent foam has disappeared.

Let all the parts dry one night in class 10 (in a first time blow the parts with ionized and filtered nitrogen). If necessary, put the parts onto clean room wipers.


Arrange the working area Fill in check list


Stage n° : C2 Pre assembly of warm parts Duration : 2 h Location : class 10 Preparation of work Pick up the following parts : All the parts cleaned at stage C1 (cleaning of warm parts)

Pick up the following screws and consumables : Alcohol saturated clean room wiper Seals and screws of stage C1

Work

Do a visual control of parts: - knives of CF flanges - ceramics - copper coating

Set out the two warm parts in a similar way of their position on test frame (in order to avoid mistakes on pumping and windows orientations)

Reminder :windows in the same direction of cold pumping

Mount the windows (do not forget the aluminum diaphragms that are fixed by the heads of the screws) Reminder: both windows are in the same side of test bench ! Mount the pick ups

Mount the RF springs on tuning rods (cut one or two turns, do a twisted knot) (make the test of inserting the rods into warm parts to check that the springs don’t move)

windo

windo

pump

Pickup + valve

Pickup + valve

pump


Insert the holed screws with long key into warm parts, screw them

Make the assembly of valves and their KF/CF 40 adapters Close the valves




Stage n° : C3 and C4 Baking in oven of a warm part and its pumping group

Duration : 1 h each Location : class 10 Preparation of work Pick up the following parts : All the parts from stage C1 and C2 (cleaning and pre assembly of warm parts)

Pick up the following screws and consumables : Alcohol saturated clean room wipers Seals and screws of stages C1 et C2

Work

Choose a warm part, write its serial number. Mark off (with clean room adhesive tape on a cap) on wich cold part the warm part will be mounted (in regard of orientations of the picture) Write the serial number of cold and warm part and their postion in the test frame.

Put in the oven :

- a pre assembled warm part

- a pre assembled tuning rod

- 1 cross - 1 gauge - 1 valve with adapter

CF/KF - 1 ionic pump - 1 special long key

Remark: the flange of glass window can support the warm part in order to avoid contact between ceramic and mobile cart of oven.

Close the oven and exit the clean room

Start a cycle (at 150 °C) Don’t forget the record of pressure and temperature in regard of time Preparation of next stage



Stage n° : FC4-a / FC4-b and FCC5-a / FCC5-b

Assembly of one warm part onto one cold part Assembly of a pumping group onto warm part

Leak test Duration : 2 sessions of 2 h FC4-a et FC4-b in the same session, FCC5-a et FCC5-b in an other session

Location : class 10

Preparation of work of one session Pick up the following parts :

Complete cold assembly (with puming group) made at stage F3 One warm part, its pumpi,g group, still under vacuum in oven (after baking) screws (cf list of stage C1)

Pick up the following screws and consumables : Seals and screws of stage C1 Filtered and ionized nitrogen (open the bottle before entering the clean room !) Air level (always in class 10)

Work

Break the oven vacuum, enter the clean room. Don’t wait the opening of oven’s door to enter in the clean room (in order to minimize the duration of expose of parts to air). Open the oven, take out the warm part, put in it the special key Do a visual control of parts:

- knives of CF flanges - ceramics - copper coating

Remove the ceramic cap, (the one marked of at stage C3/C4), place the CF100 (remachined) copper seal


Put the warm part (beware of pumping port orientation). Tighten the central screw (check the two parts are well joined by trying to put out the warm part) Don’t firmly tighten the central screw at that point.

Reminder :

Put and tighten the CuNiSi screws of CF100 flange

Tighten the central screw, put out the special key

windo

windo

pump

Pickup + valve

Pickup + valve

pump


Put the slim flange for support of warm bellow and the 2 half flanges afterwards Orientation of flat part: in direction of the other coupler ! Adjust the horizontality.

On the side of CF40, the threaded rod should lower than the other ones in order to install the pumping group.

Blow filterer and ionized nitrogen during the assembly

in order to avoid contamination by the

moisture of air

Place the CF25 seal, insert the tuning rod (bayonet in the internal slot of warm part), turn it of 90 ° (you can use a hexagonal key to push on the small rod into the bellow), try to put the tuning rod out to check it is well connected, place the M6*20 Chc CuNiSi screws.


Place the cap (long version with central screw !) for warm ceramic protection

Make the assembly of warm pumping group - the cross - the pump - the valve (in the same side as the pick

ups !) (with KF connection opposite to the pump !)

- the gauge - the magnets on pump and gauge - the KF40 plastic cap

Beware of orientations (see picture !)


Tighten all the screw in order to have helium tightness of the assembly Re check the horizontality

Join the valve to the bellow (Viton seal) and call the vacuum group for leak test Do the leak test in the class 10 as the following:

- start the detector (outside of clean room) - opening of the valve of the detector (outside) - slow opening of the coupler valve (in class 10) - Helium test of all joining - When the leak test is finished: - First close the coupler valve (while pumping) - Close the valve of the detector (outside)

Putt nitrogen in the bellow for disconnection of coupler assembly Preparation of next stage

Arrange the working area

Put in oven the second warm part (and its pumping group) for the 2nd session (assembly of the 2nd warm part). KF pumping port opposite to the first. Valve on same side as the pick ups. Do a leak test.

Afterwards, exit the assembly of the clean room, put it under mobile laminar clean room, call the vacuum group for Ultra High Vacuum pumping (10 –9 mbar) (and optional in situ baking if necessary).

Fill in the check list


Stage n° : F3bis Assembly of cold pumping group onto cold part Leak test

Duration : 2 h Location : class 10 Preparation of work Pick up the following parts : All the parts from stage F1 / F2-a / F2 –b and the screws

Pick up the following consumables: Filtered and ionized nitrogen

Travail

Do a visual control of parts : - Knives of CF flanges

Put in place the cold pumping group By order of assembly :

- Bend, gauge on cross and pump - This assembly onto coupler closing

valve (slightly down facing in order to do easily the electrical connection of gauge (beware of vertical position of pump in order to be able to put on it the magnets afterwards)

- T and RGA on the bend (beware of position of T in order to be able to put on it the magnets afterwards)

- Close the valve - The valve on the T - Plastic cap on KF40

Souffler de l’azote filtré et ionisé durant le montage sur les parties sous vide pour éviter une contamination par l’humidité de l’air

Join the valve to the bellow (Viton seal) and call the vacuum group for leak test Do the leak test in the class 10 as the following:

- start the detector (outside of clean room) - opening of the valve of the detector (outside) - slow opening of the pumping group valve (in class 10) (the coupler valve still closed) - Helium test of all joining - When the leak test is finished: - First close the pumping group valve (while pumping) - Close the valve of the detector (outside) - Put nitrogen in the bellow for disconnection of coupler assembly

Préparation de l’étape suivante



Stage n° : FCC6 Vacuum in system

in situ baking (optional) Duration : Location : mobile laminar clean room Preparation of work Pick up the following parts :

Assembled test bench Electrical connector of RGA and ionic pumps 2 dry and clean turbo molecular pumping system

Pick up the following screws and consumables : Work

In a general manner, start the pumps before opening the valves, so that dust can not flow in the coupler direction (especially on cold parts) Place the 2 turbo pumps (1 for cold parts, the other is for the two warm parts) After the vacuum level has reached a value close to turbo molecular system limit, start the ionic pumps, close the valves of pre vacuum and check the rate of pressure decreasing (and RGA spectrum) If pressure decreasing don’t allow to go to 10 –9 mbar easily, stop the ionic pumps, bake the whole system in situ (at 150 °C) (limitt due to aluminum seals) with a pumping by turbo pumps. After baking, close the pre vacuum valves and re start the ionic pumps.

Disconnect the bellows that goes tu turbo pumps in order to make easier the mounting of next stage


Call mechanical group for mounting of warm transitions. Fill in check list


Stage n° : FCC7 Assembly of the two warm transitions Duration : 2 h Location : mobile laminar clean room Preparation of work Pick up the following parts :

Complete assembly, under vacuum, turbo pumps disconnected 2 copper transitions (blow them with clean air if necessary) (write the serial numbers) Do a visual control to check there are no points or corrosion

4 half flanges

2 polarization rings

(write the serial numbers of thee packaging)

2 tuning mechanisms in plastic (with stainless steel flange)

There are 2 types of this: this is not a problem

2 covers with coil Pick up the following screws and consumables :

Aluminum film transparent plastic protections of ceramics 8 stainless steel H M4*10 screws + 28 M4 washers + 20 M4 nuts For half flanges 32 CHc M3*8 stainless steel screws For polarization ring 8 M4*10 CHc stainless steel screws For tuning mechanism 16 M4*8 Z stainless steel screws (cruciform) For hood

Air level


Work

Place an aluminum ribbon on warm part stainless steel collar Put away the stainless steel cap of the ceramic Place on the ceramic one protection made of transparencies (to protect the surface of ceramic).

Place the warm copper transition Write the serial number and position on the test bench

Fix the half flanges underneath (don’t tighten too much at this time) (U face upward)

Put away the transparent protection

Place the polarization ring and its screws (without tightening too much at this moment) . (protuberant part downward) Write the serial number (on packaging) and position on the test bench

Tighten the screws of half flanges, internal and external screws of the polarization ring (in that order)

Recheck horizontality

Place the tuning mechanism (insert under the electrical contact of coil under one screw head) Place the cover and tight it firmly on the transition Place the knob (pressure screw on the side) (don’t turn the knob ! let the RF group do that !)

Unscrew and put away the cold bellow support

Do all the same operation on the 2nd coupler

Don’t connect to RF network at this moment ! Preparation of next stage

Arrange the working area Call RF Group so they make antenna tuning, instrumentation, Rf network connection and conditionning

Fill in the check list

list of preparation and assembly …...2005/05/16 · leak proof junctions. beware: pick ups and...

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