Preparation of larger parts in a Clean room Class 10000 (ISO7)
Preparation of smaller parts in a baldaquin annex Assembly in a
clean-room Class 100 (ISO5) Using assembly tooling specifically
designed for the task Following a predefined sequence According to
written procedures With qualified staff Governed by a QA plan
HIE-ISOLDE Cryomodule Assembly2
Slide 3
Consists of: The clean room as shown by Karl A set of rails
anchored into the floor of the clean-room Horizontal and Co-planar
within 0.5 mm An assembly frame comprising: The fixed frame
structure surveyed vertical to within 0.5 mm anchored into the
floor An internal horizontal rectangular motorized frame that moves
vertically And that can elevate over 4m, equipment weighing up to 3
tonnes Two rolling trollies One multipurpose trolley MPT for
general transport of equipment One specifically to handle the
solenoid and the cavities CST A chevre hand operated For loading
equipment onto the two trollies at the Clean-room entrance door
HIE-ISOLDE Cryomodule Assembly3 Rails Rolling trolley
(Solenoid/Cavity type) Assembly Frame fixed Loading area Class
10000 Area Class 100 Area Internal motorized frame The Tooling set
is designed to offer an intrinsic precision, to largely offload
this burden from the assembly staff and allow them to concentrate
more fully on the assembly steps in hand
Slide 4
4 Jean-Alexandre BOUSQUET Graeme BARLOW Lloyd WILLIAMS Derived
from: The Assembly Breakdown Structure The decision to assemble
vertically Schematic views of the tooling, more details later
Slide 5
5 Get v-vessel box from storage Attach rail wheels, put onto
rails Unwrap, roll into 10000 area Clean inside and outside Into
100 area under frame Measure position and adjust Lifted with
motorized frame, lowered on blocks Flange blanks removed Cleaned
inside and outside Ancillaries added Top dust cover added Lifted
with motorized frame, blocks removed lowered onto rails Wheeled to
10000 area Get v-vessel top plate Remove top dust cover Attach and
seal v-vessel top plate to v-vessel box Do leak test on VV Remove
v-vessel top plate Wrap top plate remove to storage Replace top
dust cover on v-vessel box Wrap v-vessel box Take outside, remove
rail wheels Remove v-vessel box to storage
Slide 6
6 Unwrap, panel 1 Take it into 10000 area Cleaned Into 100 area
under frame Lower the motorized frame Hook onto motorized frame
Clean to class 100 Repeat for panels 2, 3, and 4
Slide 7
7 Repeat for the bottom panel 5 Assemble the panels together to
form a box Connect the 60 - 75 K cryo-circuits Leak test the
complete 60 - 75 K cryo-circuit Measure the size and shape of the
box Tighten all fixing bolts
Slide 8
HIE-ISOLDE Cryomodule Assembly8 Get vacuum vessel box from
storage Attach the rail wheels Put onto rails Unwrap, roll into
10000 area Clean Roll into 100 area Locate under the suspended
thermal shield Measure position and adjust
Slide 9
HIE-ISOLDE Cryomodule Assembly9 Lower the thermal shield box
into the v vessel box Fix the thermal shield box to the v vessel
box Measure position and adjust Replace dust cover on v vessel Roll
the assembly to 10000 area Wrap Take outside Remove rail wheels
Take to storage
Slide 10
HIE-ISOLDE Cryomodule Assembly10 Assemble the Chimney assembly
in Baldquin Clean to class 100 Wrap Transport to Clean room Unwrap
install on MPT Roll under motorized frame and position Measure
position and adjust
Slide 11
HIE-ISOLDE Cryomodule Assembly11 Wrap the chimney assembly
Lower the motorized frame Attach the Chimney to the motorized frame
Elevate the chimney Remove MPT to 10000 area Bring the platform
elevator into the clean-room Elevate personnel Attach chimney to
fixed frame Measure position and adjust Detach chimney from
motorised frame Lower personnel Lower motorized frame Remove
platform elevator outside Allow clean-room time to recover
Slide 12
HIE-ISOLDE Cryomodule Assembly12 Get top plate from storage
Unwrap top plate and place it in 10000 area on the MPT Clean the
top plate to 10000 level
Slide 13
HIE-ISOLDE Cryomodule Assembly13 Roll the top plate into class
100 area under the fixed frame Measure position and adjust Clean
top plate to class 100 level Lower motorized frame Attach top plate
to motorized frame Elevate top plate Roll MPT out to 10000
area
Slide 14
HIE-ISOLDE Cryomodule Assembly14 Get LTT from storage Unwrap
LTT and place it in 10000 area on the MPT Clean the LTT to 10000
level Roll the LTT into class 100 area under the fixed frame
Measure position and adjust Clean LTT to class 100 level Lower
motorized frame Clamp top plate to LTT and seal Detach top plate
from motorized frame Elevate the motorized frame Roll out MPT with
top plate on LTT to 10000 area
Slide 15
HIE-ISOLDE Cryomodule Assembly15 Get equipment for top plate
from storage Unwrap equipment and place it in 10000 area Clean the
Equipment to 10000 level (small components will be treated in the
baldaquin) Remove blind flange from top plate, attach and seal
equipment in its place Carry out leak test Repeat for all equipment
to be attached to the top plate** When all equipment is installed
and leak tight: Clean complete top plate to class 10000 level Roll
the top plate under the fixed frame Measure position and adjust
Clean the top plate to class 100 level Lower the motorized frame
Attach the top plate Wrap the upper part of the top plate Elevate
the top plate Remove MPT to the 10000 area ** Note that leak tests
may be done on a group of components Grouping TBD
Slide 16
HIE-ISOLDE Cryomodule Assembly16 Get equipment from storage
Clean in the baldaquin and wrap Take to 10000 area and put on the
MPT Unwrap Roll equipment to 100 area Clean the Equipment to
class100 level Attach the equipment to the frame position adjusters
Measure position and adjust
Slide 17
HIE-ISOLDE Cryomodule Assembly17 Get Helium vessel from storage
Unwrap and place it on the MPT in 10000 area Clean the he vessel to
class10000 level Get Thermal shield upper plate from storage Unwrap
and place it over the helium vessel and on to the MPT in 10000 area
Clean the thermal shield upper plate Assemble the thermalization
collars Measure position of this assembly adjust and fix
Slide 18
HIE-ISOLDE Cryomodule Assembly18 Roll the MPT into class 100
area under the fixed frame Measure position and adjust Clean the
helium vessel and thermal shield upper part to class 100 level
Lower motorized frame to bring the top plate down over the helium
vessel neck Attach the top plate flange to the helium vessel flange
Measure position and adjust Seal the top plate flange to the helium
vessel flange Detach the helium vessel from the MPT Elevate the
motorized frame Remove the MPT to 10000 area
Slide 19
HIE-ISOLDE Cryomodule Assembly19 Bring the platform elevator
into the clean room Elevate personnel Elevate the helium vessel to
insert the chimney into the helium vessel neck Connect the
cryogenic instrumentation cabling to the feedthroughs on the
chimney top flange Attach the Chimney flange to the top plate
flange and seal Detach chimney from fixed frame Lower the chimney
together with the top plate and helium vessel Lower personnel Do
electrical checks on cryogenic instrumentation Leak test the helium
vessel top plate and chimney assembly Remove platform elevator
outside the clean-room Allow the clean room to recover its air
quality
Slide 20
HIE-ISOLDE Cryomodule Assembly20 Insert the current leads from
the top Feed their extension cabling through the chimney, down
through the helium vessel and out through its lower flange Insert
the 4.5K bayonets into the helium vessel and engage the feeder into
the distribution manifold Connect the helium feeder down pipe for
the solenoid to the distribution manifold Attach the cable
retention spiders to the helium feeder pipe Attach the upper flange
of the solenoid down pipe to the helium vessel flange hand
tight.
Slide 21
HIE-ISOLDE Cryomodule Assembly21 Assemble the end plates with
their upper fixing system in the baldaquin, clean and wrap. Take
the end plate assemblies into the clean room unwrap and attach to
the load spreader bars. Measure and adjust their lower extremities
into one horizontal plane
Slide 22
HIE-ISOLDE Cryomodule Assembly22 Get the support frame from
storage Load it onto the MPT in the 10000 area unwrap and clean
Level the support frame on the MPT Roll the support frame into the
100 area into position under the motorized frame Measure and adjust
position of support frame Clean support frame to class 100 level.
Attach lower extremities of the end plates to the support frame
Detach support frame from MPT Measure and adjust position of
support frame Elevate the assembly with the motorized frame Wrap
the MPT and remove it to storage
Slide 23
HIE-ISOLDE Cryomodule Assembly23 Get the equipment from storage
Clean it in the baldaquin and wrap Take the diagonal tie rods into
the clean room and attach them Measure and adjust the position of
the support frame Take the support frame cooling tubes and attach
them to the helium vessel and the support frame Measure and adjust
the position of the support frame Frame cooling tubesDiagonal tie
rods
Slide 24
HIE-ISOLDE Cryomodule Assembly24 Get the solenoid and cavity
trolley from storage put it on the rails Drive it into the 10000
area unwrap and clean it Clean the solenoid in the baldaquin and
wrap Bring the solenoid into the 10000 area install on the trolley
and unwrap Compress to full extent the 2 bellows on the solenoid
down tube Roll the trolley under the fixed frame Measure position
and adjust Lower the motorized frame to engage and connect the
helium fill tube
Slide 25
HIE-ISOLDE Cryomodule Assembly25 Complete the power supply
electrical connections Complete the instrumentation connections Do
full electrical checks on current leads cabling and solenoid
Slide 26
HIE-ISOLDE Cryomodule Assembly26 With the trolley lift the
solenoid to give clearance Insert the solenoid cross-bars (omegas)
Centre the solenoid cross-bars with respect to the support frame
Align the solenoid cross-bars horizontally and vertically Lower the
solenoid into place on its cross bars Verify the correct
positioning of the solenoid Release the two bellows on the down
tube Seal the 2 flanged interfaces to complete the solenoid
cryogenic connection Do a leak test on the helium vessel and
solenoid Insert the remaining 10 cavity cross-bars Align them all
vertically and horizontally with respect to the solenoid Check good
centring in the support frame Fix them in place Attach
thermalizations
Slide 27
Successive installation of the cavities onto the trolley in the
10000 area HIE-ISOLDE Cryomodule Assembly27
Slide 28
First cavity in place HIE-ISOLDE Cryomodule Assembly28
Slide 29
Arrival of the second cavity HIE-ISOLDE Cryomodule
Assembly29
Slide 30
Second cavity in place HIE-ISOLDE Cryomodule Assembly30
Slide 31
Third cavity in place HIE-ISOLDE Cryomodule Assembly31
Slide 32
Fourth cavity in place HIE-ISOLDE Cryomodule Assembly32
Slide 33
Fifth cavity in place HIE-ISOLDE Cryomodule Assembly33
Slide 34
HIE-ISOLDE Cryomodule Assembly34 Remove blind flanges from the
helium vessel cavity ports Flange hand tight the 5 flexible bellows
to the helium vessel Compress the bellows completely Turn all
cavities through 40 degrees acl from top Check position and
verticality of all the cavities on the trolley Clean the cavities
and trolley Roll the trolley under the fixed frame Measure position
and adjust
Slide 35
HIE-ISOLDE Cryomodule Assembly35 Lower the support frame to
pass over all the cavities Rotate the first cavity in the series*
clw from top by 40 degrees Release this cavity from the trolley
Lift the frame to pick up the cavity Complete the helium fill tube
connection Release bellows and flange hand tight to cavity Measure
position and adjust Repeat sequence for the 4 remaining cavities
*The series is defined to keep the frame ~balanced see next
frame
Slide 36
HIE-ISOLDE Cryomodule Assembly36
Slide 37
HIE-ISOLDE Cryomodule Assembly37
Slide 38
HIE-ISOLDE Cryomodule Assembly38
Slide 39
HIE-ISOLDE Cryomodule Assembly39
Slide 40
HIE-ISOLDE Cryomodule Assembly40
Slide 41
HIE-ISOLDE Cryomodule Assembly41
Slide 42
HIE-ISOLDE Cryomodule Assembly42
Slide 43
HIE-ISOLDE Cryomodule Assembly43 FLANGE A Connectors 5 x 37
pins 4 x 25 pins 8 88888 8 8 8 8 8 8 8 8 8 8 8 8 8 8888 8 8 8 8 4
> 24 pins> 32 pins > 16 pins> 32 pins 32 16 88 32 20 16
T-sensors 4.5-300K 250 W heater T-sensors 50-300K Temperature wires
mA/mV Heaters wires 5A/230V n Connector with n used pins Version 18
Feb. 2014 24 > 20 pins > 16 pins 32 No written procedures
exist today for the installation of the instrumentation cabling and
feedthroughs
Slide 44
Pressure and leak test on 4.5K cryogenic vessel? Pressure and
leak test on 60-75K cryogenic vessel? Geometry of suspended
assembly Electrical checks RF checks HIE-ISOLDE Cryomodule
Assembly44
Slide 45
HIE-ISOLDE Cryomodule Assembly45 Get vacuum vessel from storage
Attach wheels, put onto rails Unwrap, roll into 10000 area Cleaned
outside Roll into 100 area under fixed frame Measure position and
adjust Top dust cover removed from v vessel Cavity aperture
protections opened and secured open
Slide 46
HIE-ISOLDE Cryomodule Assembly46 Lower the suspended assembly
into the vacuum vessel Settle the top plate onto the vacuum vessel
seals Detach top plate from motorized frame Elevate motorized frame
Add clamps and seal Do global leak test on complete cryo circuit
Roll into 10000 area Roll outside crane lift place on blocks remove
rail wheels Call delivery to test area