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Cryomodule Assembly Facility (CAF) @ Fermilab Cleanroom

The Cryomodule Assembly Facility (CAF) at Fermilab is a state-of-the-art cleanroom facility for the preparation and assembly of cavity strings. It features a Class 1000 (ISO6) ante cleanroom area, Class 100 (ISO5) sluice area, and a Class 10 (ISO4) assembly cleanroom area. The facility meets Fermilab's performance and cleanliness standards and is equipped with the necessary infrastructure for vacuum and gas manifold, UHV cleaning, and rail for cavity string assembly.

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Cryomodule Assembly Facility (CAF) @ Fermilab Cleanroom

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  1. Cryomodule Assembly Facility (CAF) @ Fermilab Cleanroom Tug Arkan

  2. CAF-MP9

  3. CAF-MP9 Clean Room • Cavity String Assembly Clean Room • A ~250 square-meter clean room: • Class 1000 (ISO6) ante clean room area (12 m x 8 m) • Preparation of the dressed cavities for transportation into the assembly clean room. • Class 100 (ISO5) sluice area • Parts and Fixtures final preparation to enter the Class 10 assembly area. • Class 100 (ISO5) area (20 m x 4 m) • Parts and Fixtures preparation for assembly. • Class 10 (ISO4) assembly clean room area (20 m x 4 m) • Where the cavities vacuum is vented to interconnect them with bellows. Class 100 Class 10 Class 1000 Rail

  4. Cleanroom Infrastructure Vacuum / Gas Manifold UHV cleaning area Class 1000 cleanroom for the dressed/qualified cavity preparation to enter the cleanroom

  5. Cleanroom Specs • Fermilab wrote the performance specs • Designed and built by a vendor: • Pre-design meeting, October 2006 • Design review (hired a consultant to help) , 1 week • Design completed, November 2006 • Construction started: January 12, 2007 • Acceptance of cleanroom by Fermilab: April 28, 2007 • 11 change orders were done throughout the fabrication • FE-209E standards were followed. Recent cleanroom purchase, we specified ISO 14644-1 standards

  6. During Construction

  7. Acceptance / Certification • The clean room classes are specified in an operational state. Empty clean room particle counts can be expected to increase up to an order of magnitude in the operational state. It is Fermilab’s intention to simulate normal operations in the clean room during certification by bringing in the requisite number of personnel (four or five), properly gowned (full jumpsuit, boots, hood, mask and gloves), and having these individuals actually carry out typical mechanical assembly and disassembly tasks as similar as possible to the activities designed to be carried out in the new clean room. Does Luwa have any comments, questions or suggestions regarding this approach? (vendor did not agree) • Will Luwa provide their protocol for clean room construction to start up? Luwa shall provide janitorial personnel for clean rooms preparation for testing and certification. • Luwa stated that their company is NEBB (National Environmental Balancing Bureau) certified. It is our understanding that Luwa has NEBB certified personnel and it is imperative that certification will be done by only NEBB certified personnel. Is this Luwa’s intention? • It is stated in the proposal that Luwa will use 5 ft. x 5 ft. grid for FS 209E testing and certification. It is Fermilab’s desire that Luwa used 4 ft. x 4 ft. grid for this test. • Will Luwa record the actual particle count for each sample volume taken at each sample location? • It is stated in the proposal (page 24) that Luwa will use an optical particle counter that detects particles at least 0.3 micron and larger. Fermilab desires that Luwa uses a particle counter that will measure 0.3 micron and larger particles for the airborne particle count. The statement “at-least” is not acceptable. If Luwa wishes to use a particle counter with detection limit less than 0.3 microns; that is acceptable. • The clean room shall meet airborne particle count requirements for both 0.3 and 0.5 microns particles.

  8. Maintenance • Weekly cleaning: (~10 hrs per week) • Tacky roll map the walls and the ceiling • Windows cleaning (Tekopur TX160 (1 cup to 2 gallons of water): cleanroom detergent, in a squirt bottle, not spray) • Vacuum and mop the floor (micro mops, stainless steel buckets) • Empty waste baskets • Every 3 months: • Remove the raised floor panels and clean underneath (rails, epoxy coated air plenum sub-floor)

  9. Equipment • Particle Counters: Met One 3313 (3), 4313 (1), calibrated annually • Blow guns: Richmond AFC Airflow Controller manufactured by Simco. Change filters every 3 months • Nitrogen in-line and point of use filters: Mott Defender series sintered all metal (0.03 micron)

  10. Consumables • Inner scrubs: Washed every 2~3 days • Street clothes are removed every morning • Street shoes are not allowed in the cleanroom (safety toe cleanroom shoes) • Cleanroom gowns (overall, hoodie with mouth cover, boot covers): Change everyday during actual assembly, change once every 5 days during regular • Cleaned and maintained by a professional service • Shoe covers, hair net, face mask, nitrile gloves (certi clean, Class 10, individually packaged) • Cleanroom wipes (Alpha Sorb Class 10, sealed border wipes, TX1050) • Cleanroom hand lotion

  11. Rail for Cavity String Assembly Rail length: 3.65 m, 12 rails aligned to each other to 0.1 mm

  12. Parts / Fixture / Hardware Preparation • Assembly hardware: • Wash in the ultrasonic bath • Blow clean with ionized nitrogen under the Class 10 hood • Bag and transport in the Class 1000 ante clean room • Blow clean with ionized nitrogen while monitoring the particulates count in the sluice area • Transport into the Class 10 assembly Class 10 / ISO4 Hood US cleaner

  13. 1.3 GHz Cavity Support Posts Fixture Cavity is supported through the alignment ring on the beampipe flange at the field probe end Cavity is supported through the alignment ring on the beam pipe flange at the coupler end

  14. Cavity Alignment in the clean room X-Y Alignment Fixture: Cavities beam line flanges are aligned to ~0.5mm for the interconnect bellows assembly in the clean room Rotational Alignment Fixture: Coupler position: parallel to earth with respect to the cavity helium vessel lugs

  15. String Assembly • Gate Valve to Cavity Assembly: • Sub-assembly of the right angle valve • Installation to the support post and vacuum hose assembly • Leak check • Alignment to the cavity beam line flange • Particulate free flange assembly (PFFA) procedures • Assemble the gate valve to the cavity

  16. String Assembly (cont.) • Cavity to Cavity Assembly with the interconnect bellows: • Assemble vacuum hose to the cavity. Pump down and Leak check. Backfill • Align the interconnect bellows to the cavity field probe end beam line flange • Assemble with PFFA • Align the bellows to the other cavity coupler end beam line flange • Assemble with PFFA

  17. Adjustable Table Fixture This fixture is used to align the flanges of the parts that will be assembled

  18. Miscellaneous Fixtures Interconnecting Bellows Holder Fixture Gate Valve Holder & Alignment Fixture

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