facility preparedness: current facility and cleanroom

A Partnership of: US/DOEIndia/DAEItaly/INFNUK/UKRI-STFCFrance/CEA, CNRS/IN2P3Poland/WUST

S. K. Suhane/ RRCATPIP-II Technical Workshop02/12/2020

Facility Preparedness: Current facility and Cleanroom upgrade / Tooling and HPR

Movement of Cavity in the Cleanroom

2/12/2020 S. K. Suhane | Technical Workshop | PIP-II2

Assembly and Vacuum Testing

HPR and Cleanroom Processing

HPR of cavity(3 Pass)Area ‘3’

Drying in the HPR station (Class 100)

Area ‘3’

Shift to HPR station for second

HPR

Shift inside class 100 cleanroom and assemble top flange, MC

&FP flange Area ‘4’

HPR of cavity(3 Pass)Area ‘3’

Shift inside class 100 cleanroom and

assemble End flange with vacuum

valve and burst disk

Area ‘4’

External HPR of cavity &

hardware

Shift to VTS Facility

Leak TestArea ‘4’

Vacuum Pump Down

Area ‘4’

Leak Test OK

Yes

No


HPR set up for HB650 cavity

HPR Set up detailsStructure support 304 SS Sq. Pipes

Wetted parts 316 S.S.

Nozzle material Hardended S.S.

Type of pump Reciprocating piston

Final Filter 0.05 micron

Cavity rotation Timing belt drive

Enclosure Polycarbonate

Cleanliness Class 100 (ISO-5)

Jacketed cavity rinsing • Wand adjustment• Mounting bracket

Bare Cavity HPR Jacketed Cavity HPR

External HPR Arrangement

Nozzle tip Filter Trigger Gun

Nozzle Holder

Nozzle Tip


High Pressure Rinsing Process

HPR Parameters

Jet pressure 80-100 bar

Pump Flow rate 8-10 LPM

Wand Rotation 2-5 RPM

Cavity verticaltravel

5-20 mm/min

Nozzles type 40° fan jet

Nozzlearrangement

Two oppositelyplaced nozzles

HPR duration (3+1+3) passes ofHPR after light EP,total duration of 7hours.

Q.C. in HPR processOnline monitoring of UPW parameters

Flushing of piping is done before every HPR cycle

HPR structure, fixtures, clean enclosure walls are thoroughly cleaned with

IPA using lint free cloth regularly

Water from rinsed cavity is collected and sent for microbial analysis

Wand filter cartridge is changed every year

Polisher unit is run in recirculation mode to maintain purity of UPW

Collection of water from rinsed cavity for particulate analysis (Planned in

new HPR set up)


Tooling for Cavity Handling in Cleanroom

S.S. cart with swivel castorsfor movement of cavity inthe cleanroom

Fixture with toggle clampsfor holding the cavity cage

Cleanroom compatible cart for cavity lifting and swivelling

Loading of cavity on HPR set up Holding fixture for jacketedcavity


Cleanroom Preparation of CavityCavity Assembly Process All tools and hardware cleaned with

ultrasonic cleaning before taking them insidethe cleanroom

Flanges and fasteners are rinsed withultrapure water and after drying, cleanedwith nitrogen using ionizing blow-off gun.

Particle count measured during each step ofcavity assembly

Torque wrench used for bolt tightening Aluminum seal and copper gasket carefully

checked and cleaned with IPA then purgedwith nitrogen blow-off gun

High purity nitrogen gas (99.9995 %) is usedfor purging

All movements and operations insidecleanroom are performed slowly andcautiously

Thorough cleaning of cleanroom walls, floorand furniture regularly Cleanroom assembly of Cavity


Cavity Vacuum Pumping

Cavity Pumping set up Pumping cart comprises of a combination of SIP

and TMP pum backed by a scroll pump, RGA, along with valves , gauges and associated fittings

All the flanges are CF type and sealed using copper gasket

Vacuum pumping is done slowly for evacuating the cavity. (Pump down rate 10 torr/min)

A by-pass line containing fine control leak valve is used in the pumping line for slow evacuation of cavity

Cavity is sealed at ultimate vacuum of 2xE-7 mbar

Bypass Line Leak Valve RGA


screen capture of RGA analog spectrum

Ultrapure Water Generation Plant

Parameter Value

Resistivity ≥ 18 MΩ-cm

TOC < 30 ppbTotal Bacteria Count < 1 cfu/100ml

Flow Rate 800 LPHFinal Storage Tank 2500 litreGasket PTFE

• Ultrapure water generation plant installed close to new mini cleanroom facility

• Storage tank made of virgin PP fitted with 0.22 micron PTFE vent filter

• Pump MOC: SS316

• Piping made of electropolished Stainless Steel grade 316

• Online Conductivity, Resistivity meter and TOC monitor

• Sample collection port for microbial analysis


Cavity Processing Facility Building

1

PLATFORM

D2

A

D4 D4 D4

D2

D2 D2

Large CleanroomAir conditioned envelope in PEB for housing Large Cleanroom

EP Set up CBP M/cUPW Plant

Mini Cleanroom


AHU for Large Cleanroom

AHU for Mini Cleanroom

New Mini Cleanroom

Personnel Entry

Cavity Entry

US Cleaner

SQUARE PIPE100x100

Air Lock(ANTE ROOM)

CHANNEL-100

1195CHANNEL-100 1195 1103

803

100

DO

OR

SIZ

E 10

00m

mIN

T O

PE 8

36m

mD

OO

R S

IZE

1500

mm

INT

OPE

130

2mm

975 975 975 975132

1195CORNER-100

1195 1103

165

935100

DOOR SIZE 1000mmINT OPE 836mm

CHANNEL-100

1195

975 975 975 975100

DO

OR

SIZ

E 15

00m

mIN

T O

PE 1

302m

m

975

CHANNEL-50

CH

ANN

EL-50

975

975

1005

140

666

CORNER-100

1195

1800

1202D2LH

Gowning Area

ANTE ROOM

76

0

DYN

AM

IC PA

SS B

OX-1

WALL M

OUNTED

INTER

NAL S

IZE:-6

00

X60

0X6

00

EXTERNAL S

IZE:-7

60

X67

0X1

05

0

670

AIR SHOWER

CH

ANN

EL-50

CH

ANN

EL-5

0

839

CHANNEL-50

DO

OR

SIZ

E 10

00m

mIN

T O

PE 8

57m

m

100 975 962

CH

ANN

EL-50

ISO Class-4 ISO Class-6 ISO Class-8


3.8

m

9.6 m

New Mini CleanroomFeatures of New Mini Cleanroom Required for High Pressure Rinsing, Drying,

Assembly and Evacuation of SCRF cavities Located in the vicinity of EP facility Floor area ~ 36 m2 , Room height - 4 m Cleanliness : ISO class 4 to class8 Temperature 20°C ± 2°C, RH 55% ± 5%. Flooring: Raised floor with perforated panels Air shower for entering ISO class 4 area Dynamic Pass Box for tool/component entry Portable particle counter with measuring range

range from 0.1 to 5.0 micron S.S. tubing for high purity gases and vacuum line Fire and smoke detectors Dedicated cleanroom garment laundry facility

Mini Cleanroom under construction

Expected to be operational byEarly next year


Proposed HPR set up in New Mini Cleanroom

The existing HPR set up will berelocated to the new cleanroom withcertain modifications in the structure

New cleanroom has raised floor in theISO 4 area. Base structure of HPRhas been modified for installation onthe raised floor.

Suitable opening shall be made in theraised floor for installing HPRstructure

Vertical frame has been suitablystiffened to support both the bare aswell as dressed cavity.

The existing high pressurereciprocating pump will be replacedwith a new diaphragm type pump.

PP/PVDF pipeline for ultrapure waterdistribution from the UPW plant will beinstalled

Triplex Diaphragm Pump

Support Structure for new HPR setup

Aerosol particle counter


Integrated Large Cleanroom Facility

ED1

D3

SLIDE

D3 D3

D3

CLASSISO-7

D3

D3

D3

D3

D2

SD1 SD1

SD2 SD2

CLASSISO-7

CLASSISO-8

CLASSISO-8

CLASSISO-7

CLASSISO-6

CLASSISO-7

CLASSISO-4

CLASSISO-4

CLASSISO-4

CLASSISO-4

CLASSISO-7

CLASSISO-6

CLASSISO-7

CLA

SSIS

O-7

CLASSISO-7

CLASSISO-4

CLASSISO-6

CLASSISO-7

ED1

D2

D2

D2

D2

D2

D2 D2

SLIDE

D3

D3

D3

CLASSISO-5

HAND HPR AREA

VACCART

HPRPUMP

Dimensions of Cleanrooms:Total Area of cleanrooms: 600 m2

Area of ISO class 4 rooms: 140 m2

HPR Room Height: 4 m

Raised Floor Height: 0.5 m

Final Assembly

HPR

String Assembly

HandHPR

Cavity Receiving

Ante-Room Cavity Tuning

ISO Class-4

ISO Class-5

ISO Class-6

ISO Class-7

High Vacuum Furnace

Legends:


Personnel Entry

Cavity Entry

Air Shower

Gowning Area

Salient Features of cleanrooms

Cleanrooms installed in a Pre-Engineered building having separate HVAC system for conditioning of the circulating air

Cleanroom design and construction as per ISO 14644 Perforated raised flooring in ISO 4 and 5 areas to maintain uniform unidirectional flow of air Supply air from ceiling mounted filter units and return air through side walls/ under the raised floor ISO class 4 areas have ceiling with physical filter coverage of 87-99 % with ACPH of 410 – 470 Room air pressure ranging from 6 Pa in Dynamic Air lock to 40 Pa in HPR area (ISO class 4) Static dissipative floor, wall and door materials to prevent charge buildup and resultant particle

attraction Two sets of floor mounted rails installed underneath the raised floor in string assembly area ISO class 4 rooms constructed using double walls at 250 mm inter-spacing for return air 60 mm thick double skin wall panels with 1 mm thick Stainless Steel 304 sheet on both sides and

PUF as infill are used in ISO class 4 walls Outer most walls constructed using 100 mm thick double skin wall panel with 1.6 mm thick

anodized aluminum sheet on both faces with inbuilt return air risers and PUF as infill


Salient Features of cleanrooms

HVAC system type: Ducted with positive plenum concept

Ducting from AHU to Cleanroom plenum are made of anodized aluminum

Individual filters connected to the plenum through flexible ducting

Filter type: ULPA-HEPA filter bank for ISO 4 and 5 Areas ; HEPA filters for ISO 6, 7, 8 Areas

HEPA and ULPA filters in SS box casing with full face gasket sealing

Personnel entry to cleanrooms through Air shower

Dynamic pass box for entry of tools and fittings

Sequential type particle monitoring system with 32 channel manifold. Particle size range of the monitor :

0.1 – 5.0 µm

Electropolished Stainless steel tubing with manifold for high purity gases and vacuum line

Analog Addressable Fire Alarm System with Dry-Sprinkler type Fire Suppression System

Cleanroom validation by a certified third party agency


Current Status

• Contract for design and construction has been awarded

• Site survey and measurement has been done by the contractor

• Cleanroom and HVAC design has been completed by the contractor

• Construction drawings have been completed

• Design documents and drawings have been reviewed by RRCAT

• Procurement of cleanroom systems, components and equipment by the contractor is

under progress

• Rails under raised floor for string assembly area are installed


HPR set up for large cleanroom A new HPR facility for HB 650 cavity is planned in the

integrated cleanroom. It will have a structure similar tothe new HPR stand in FNAL

The HPR structure will be installed on the raised floor ofcleanroom

Base support has been modified to suit the height ofraised floor.

Suitable opening shall be made in the raised floor forinstalling the structure

The facility can be used to rinse bare as well as jacketedcavity by adjusting the wand position

The cavity frame holding fixture on the HPR structure ismade common for both bare as well jacketed cavity

Components and sub-systems required for the new HPRset up are under procurement

Structure assembly is under fabrication For loading of cavity on the new HPR structure, suitable

cleanroom compatible lifting cart with wider legs openingis under procurement

Linear Actuator for Cavity Translation Cavity Loading Cart

Geared motor for wand rotation

Support Structures in fabrication


Conclusion and Future Plans

• Presently Cavity EP and HPR facility are at different locations.• New mini cleanroom for HPR and cavity assembly under construction in

the close proximity of EP facility.• HPR facility will be set up in the mini cleanroom• An integrated cleanroom facility for HPR, cavity assembly, string

assembly, tuning and high temperature degassing is under constructionin the cavity fabrication and processing facility building

• An improved HPR facility common for bare and jacketed HB650 cavity isunder construction and will be installed in the integrated cleanroom


Thank you for your kind attention


facility preparedness: current facility and cleanroom

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