SNS PPU CRYOMODULE PDR Cryomodule Assembly Plan Kurt
SNS PPU CRYOMODULE PDR Cryomodule Assembly Plan Kurt Macha Mark Wiseman Wednesday, February 27, 2019
Outline • Four major assembly steps 1. 2. 3. 4. Clean Room Assembly (earlier talk by K. Wilson) Cold Mass Assembly Thermal Shield/Space Frame Assembly Cryomodule Final assembly • Will go through each of the assemblies showing a combination of old photos and CAD images • Current assembly plan is based on the original SNS CM build plan • Will highlight planned changes from the original plan with new tooling requirements 2
Cavity string transfer to cryomodule assembly • Maintain and monitor the cavity vacuum via an ion pump Warm to cold beam-pipe bellows will be included in the clean room assembly 3
Cold mass assembly • Cryogenic piping and leak testing -2 K circuit -5 K FPC -4 K piping to HX • Tuner installation • Liquid level & Heaters -Wiring & 2 k heat stationing • Diodes -Mounting & 2 k heat stationing • Primary magnetic shielding • Install coupler bellows & leak test • 2 k insulation 4
2 K circuit welding • Where possible orbital welding may be used -Increased quality of welds -Saves production time -Reduces risk of leaks 5
Spaceframe/ thermal shield assembly Transfer the cavity string into the spaceframe and remove the lollipop tooling 6
Preparation for string transfer to spaceframe • Install the shield into the spaceframe • Assemble the spaceframe/ shield onto the rail tooling -Support in proper locations and observe deflections for alignment concerns -Leak test thermal shield -Insulate the 50 k shield • Axial restraint rods get inserted loosely • Slide the spaceframe over the cavity string assembly Spaceframe tooling -Use caution around the couplers, the interferences will need attention -Ensure the coupler ceramic windows are protected -Protect the coupler bellows 7
Transfer of the string load to the spaceframe • Install the axial and radial nitronic rods -Carefully tension the nitronic rods to ensure minimal beam -line movement during load transfer • Remove the lollipops -Track the beamline movement with dial indicators • Install the lower spaceframe ring ties 8
Cavity string alignment • Align the cavity string -One arm alignment arms mounted on the cavity flange and leveled using a precision level -Target at the and of the arm will have a target that can be sighted for adjustment into position Alignment Arm 9
Routing and heat stationing of instrumentation • Heat stationing of instrumentation -The RF cables require routing from the 50 k shield out of the insulation -Diode wiring will be routed -Heater and liquid level wiring will be staged at the ends for further routing • Instrumentation verification check -TDR checks for the RF cables -Diodes will receive meter verification to ensure no shorts 10
Final spaceframe assembly • Install the bottom thermal shield panels and MLI patches • Run and weld the coupler exhaust connections -Inspect and leak test connections • Install the outer magnetic shield onto the spaceframe -Test fit spaceframe lockdowns -Ensure proper clearances around the couplers 11
Vacuum vessel / end can assembly • Install the vacuum vessel onto carriage assemblies and stage next to the spaceframe Vacuum Vessel Tooling Portable Rail Cart 12
Spaceframe insertion into the vacuum vessel • Roll the spaceframe into the vacuum vessel 13
Alignment of the spaceframe into the vacuum vessel • Align the spaceframe in the center of the vacuum vessel Center BL Flange To Vacuum Vessel Flange -Investigating differential screws for fine adjustment • Install and secure all lockdowns • Final welding and leak test of the 5 K coupler circuit • Fiducialize the vacuum vessel to reference beam center • Crane the vacuum vessel assembly to a new work center, install saddles and set the assembly on concrete blocks 14
End can installation • Secure each end can to the vacuum vessel -New tooling will hold and Supply End Can adjust the end cans to the vacuum vessel until secured -Bayonets will be properly positioned allowing the bellows, rotatable flange and interface block to give compliance • The vacuum vessel end plates will remain off to allow installation of 2 k, 4 k and shield piping. • After the piping is welded and leak tested, the end cap thermal, Mu shielding and MLI will be installed. • Install the top-hats Return End Can 15
Beamline assembly • Install the end can plates to seal the ends of the vacuum vessel • Extra precautions to ensure reduced particulate. -Slow pump and slow backfills will be done using improved equipment and procedures • Install the final beam line sections using portable clean room work spaces 16
Vacuum vessel final • Final wiring and instrumentation check • Test run stepper motors • Install the JT actuators and test • Final Alignment verification • Close all vacuum vessel ports -Vacuum vessel evacuation and leak test • Pressure test the inner circuits as part of the final leak test (Leak detector on insulating vacuum) 17
Kurt Macha Conclusion Mark Wiseman • New tooling will be needed for end can installation • Most procedures are in place from the original build -Main difference is the end can installation and end sections of the vacuum vessel • The alignment of the spaceframe is more critical due to no beamline adjustment at the ends 18
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