i xfel module assembly awlc’14, 14/05/2014 o. napoly, cea

XFELX-Ray Free-Electron LaseriXFEL Module Assembly

AWLC’14 , 14/05/2014 O. Napoly, CEA

XFELX-Ray Free-Electron LaseriCryomodule Assembly at CEA-Saclay

Commitment of CEA to the E-XFEL Accelerator Consortium:

assembly of 103 accelerator modules (101 in the tunnel)

with 1 per week throughput !

operated by an industrial contractor

on the Saclay site and with CEA infrastructures


XFELX-Ray Free-Electron LaseriOverview of the Assembly Buildings


XFel Village

3

2

46

5

Bldg 124 North25x15 m²

Bldg 126 North40x11 m²

7

Bldg 126 South 30x17 m²

8

1

CourtYard

6b

©GoogleMap

Clean rooms

Assembly halls

Offices

Warehouse

XFELX-Ray Free-Electron Laseri

the XFEL Village

Coupler Area CO-WS1 & 2

Alignment Area AL-WS1 & 2

Shipment Area

SH-WS1 & 2

Roll-out AreaRO-WS1 & 2

Warehouse

Clean room Area

CO-WS1 & 2SA-WS1 & 2

Reception AreaREC-WS1

Cantilever Area CA-WS1

Assembly Hall : Workstations


XFELX-Ray Free-Electron LaseriOrganisation of Work Stations

1. Clean Room Cold Coupler Area (IS04-CC-WS1)• Cold coupler assembly (x8), leak check of cavity-coupler connection (+RGA)

2. Clean Room String Assembly Area (ISO4-SA-WS1, ISO4-SA-WS2)• String connections (1 gate valve + 8 cavities + 1 Qpole unit)• Leak check of string and N2 venting (+RGA)

3. Roll-out Area (RO-WS1, RO-WS2)• HOM adjustment, magnetic shielding, T-sensors (x6)• Tuner assembly (x8), coupler 4K and 80 K shields• 2 Ph-tube welding, NCT (LT, PT, RT)• Cold-mass/string connection

4. Alignment Area (AL-WS1, AL-WS2)• Cavity and quadrupole fine alignment (~100 µm)• Welding of 8 mm LHe filling line (x9)• Tuner and piezo electric tests

5. Cantilever Area (CA-WS1)• Welding of 4K and 70 K shields, 4K and 79 K super insulation• Cable routing and insulation, Quad current lead• Insertion into vacuum vessel and cold mass alignment

6. Coupler Area (CO-WS1, CO-WS2)• Warm couplers + coupler pumping line + leak checks (8 connections + coupler vacuum)• Cabling of flanges A (x8) and flange D• Quadrupole current lead connections and welding • Final leak check of cavity vacuum + final pumping

7. Shipment Area (SH-WS1, SH-WS2) • Control operations (RF frequency), End-caps closing, N2-insulation, CEA-Alsyom

“acceptance test”, Loading

6 May 2014 O. Napoly, XFEL MAC 5

XFELX-Ray Free-Electron LaseriCold Coupler Assembly


XFELX-Ray Free-Electron LaseriString Assembly


XM4 (String assembly) on 14/02/2014

XFELX-Ray Free-Electron LaseriRoll-out and Alignmemt

XM2 (Alignment) and XM3 (Roll-out) on 14/02/2014

AWLC’14 , 14/05/2014

O. Napoly, CEA

XFELX-Ray Free-Electron LaseriCantilever


XM1 (Cantilever) on 14/02/2014

XFELX-Ray Free-Electron LaseriWarm Coupler


XM-1 (Warm couplers) on 14/02/2014

XFELX-Ray Free-Electron LaseriCantilever and Warm Coupler


XM1 (Cantilever) and XM-1 (Warm couplers) on 14/02/2014

XFELX-Ray Free-Electron LaseriShipment



O. Napoly, CEA

Status of Assembly: 6 cryomodules delivered to DESY

AWLC’14 , 14/05/2014

Component availability at CEAXM-3 XM-2 XM-1 XM1 XM2 XM3

Cavities 7 LG + 1 FG 12/04/13 29/05/13 21/08/13 23/10/13 20/11/13Couplers 8 TTF3 8 TTF3 25/06/13 8 TTF3 18/11/13 18/11/13

BQU 1 proto 1 1 1 1 1Gate valve 1 1 1 1 1 1

Cryostat 1 1 1 1 1 1Magnetic shields 1 1 1 1 1 1

Assembly Schedulepast pos ition

current pos ition

prediction

CC (cold couplers) 17/09/12 02/04/13 02/07/13 03/09/13 16/10/13 21/11/13SA (string assembly) 22/04/13 23/07/13 01/10/13 28/11/13 07/01/14RO (roll-out) 29/05/13 02/09/13 29/10/13 27/01/14 28/01/14AL (alignment) 13/06/13 17/12/13 27/01/13 19/02/14 05/03/14CA (cantilever) 05/07/13 27/01/14 12/02/14 12/03/14 03/04/14CO (warm couplers) 17/07/13 07/02/14 25/02/14 03/04/14 17/04/14SH (shipment) 05/08/13 21/02/14 21/03/14 17/04/14 30/04/14Shipment to DESY 23/04/13 07/08/13 27/02/14 26/03/14 23/04/14 07/05/14

XM-3 XM-2 XM-1 XM1 XM2 XM3


O. Napoly, CEA

XM-3 RF Test Results

AWLC’14 , 14/05/2014

cryomodule testcavity tests

XFELX-Ray Free-Electron LaseriXM-3 : ILC Cryomodule !!


A success for SRF Technology Average individual cavity gradient: 32 MV/m Average cavity pair gradient: 29 MV/m Three cavities reach gradients above 38 MV/m Cryogenics losses are low: Q0 ~ 3e10

A success for String and Module Assembly: Seven cavities are reproducing VT gradient The cryomodule reproduces gap of 230 MV Cavity 1 is degraded from 31 down to 23 MV/m

useable gradient: gate valve/cav1 connection was fautly, not for training !

A success for the industrialization process: XM-3 is the assembly demonstration cryomodule of

CEA w.r.t. ALSYOM contract.


27.7

24.7 24.9

31

33.6

28.726.8

19.8

24.4 24.7 24.9

29.9

33.6

28.726.8

19.8

CAV00523 CAV00511 CAV00512 CAV00514 CAV00521 CAV00510 CAV00526 CAV00513

10

20

30

40

Power limit

[MV

/m]

cavity name

quench limit / power limit X-rays < 10-2 mGy/min XFEL goal (23.6 MV/m)

Module XM-2

Power limit

XM-2 RF Test Results at AMTF (Dec. 2013)

AWLC’14 , 14/05/2014

O. Napoly, CEA


O. Napoly, CEA

XM-2 RF Test Results

Successful RF test for XM-2• Vert. Test average: 25,8 MV/m

• Module test Average: 24,5 MV/m

• XFEL specification: 23,6 MV/m

Gate valve CV 1 CV2 CV3 CV4 CV5 CV6 CV7 CV8 BQU

CAV00523 CAV00511 CAV00512 CAV00514 CAV00521 CAV00510 CAV00526 CAV0513 BQU-005-CEacc (VT) 27,0 26,2 26,1 33,0 33,4 28,8 27,3 22,1

Fe limit (VT) 27,0 26,2 26,1 33,0 33,4 28,8 27,3 22,1 206,4 MVAMTF 24,4 24,7 24,9 29,9 33,6 28,7 26,8 19,8 195,6 MV

VT average 25,8 MV/mAMTF average 24,5 MV/m

AWLC’14 , 14/05/2014

XFELX-Ray Free-Electron LaseriXM-1 RF Test Results at AMTF

?AWLC’14 , 14/05/2014

O. Napoly, CEA

not too good

XFELX-Ray Free-Electron LaseriStatus of Assembly


2 phase-line welding crisis

Component availability at CEAXM4 XM5 XM6 XM7 XM8 XM9 XM10 XM11 XM12 XM13 XM14

Cavities 18/12/13 19/02/14 26/02/14 19/03/14 26/03/14 02/04/14 09/04/14 23/04/14 14/05/14Couplers 16/01/14 24/01/14 13/02/14 06/03/14 18/03/14 18/03/14 25/03/14 03/04/14 10/04/14 17/04/14 25/04/14

BQU 1 1 1 1 1 1 23/04/14 0Gate valve 1 1 1 1 1 1 1 1 1 1 0

Cryostat 1 1 1 1 1 1 1 1 1 1 0Magnetic shields 1 1 1 1 1 1 1 1 1 1 1

Assembly Schedulepast pos ition

current pos ition

prediction

CC (cold couplers) 06/01/14 24/02/14 17/03/14 02/04/14 17/04/14 W20 W21 W22-23 W24 W25 W26SA (string assembly) 05/02/14 11/03/14 02/04/14 18/04/14 W20 W21 W22-23 W24 W25 W26 W27RO (roll-out) 28/02/14 25/03/14 17/04/14 05/05/14 W21 W22-23 W24 W25 W26 W27 W28AL (alignment) 25/03/14 17/04/14 W20 W21 W22-23 W24 W25 W26 W27 W28 W29CA (cantilever) 22/04/14 W20 W21 W22-23 W24 W25 W26 W27 W28 W29 W30CO (warm couplers) 30/04/14 W21 W22 W24 W25 W26 W27 W28 W29 W30 W31SH (shipment) W20 W22 W23 W25 W26 W27 W28 W29 W30 W31 W32Shipment to DESY 21/05/2014 04/06/2014 11/06/2014 W25 W26 W27 W28 W29 W30 W31 W32

XM9XM4 XM5 XM6 XM7 XM8 XM10 XM11 XM12 XM13 XM14


O. Napoly, CEA

Status of Assembly (future)

Eu-XFEL goal is to deliver XM100 in March 2016 to close the tunnel in June 2016.

The remaining three main challenges:

1. Alsyom staffing, training and coordination

2. 2-phase line welding issues

3. Non-conformities on components and needed evolutions

With the current schedule, acceleration of production to 1.5 module/week delivery rate sometime in 2015, is needed to meet the goal;

AWLC’14 , 14/05/2014

XFELX-Ray Free-Electron LaseriIndustrial Contract :

ALSYOM Management Plan and Staffing

O. Napoly, XFEL MAC6 May 2014

21

Off site

On site: 29 persons

1*

2 (1**)

20 (4**)1**

1*1

1*

1*

1*

Core Team (11 persons)* arrivedSept. 2012

** arrived Feb. 2013

+ 1@@


O. Napoly, CEA

Project Weeks

2012 2013 2014

Start of training phase

Start of production phase

Start of observation phase

01/04/2914, 24 persons

14/04/2014, 26 persons (+3—1)

Alsyom Staffing (SEIV not included)

AWLC’14 , 14/05/2014


O. Napoly, CEA

Status on 2-phase line weldingFour Welding Issues mentioned at the last ACB:

1 – Qualifications of Alsyom (EN3834-2) and of Alsyom welders

Problem is moslty solved

2 - NDT by Radiography

TÜV-Nord requested systematic Non-Destructive Testing by X-Ray radiography (RT) for all the welds (17 welds) of the Helium 2K two-phase line along cavity string, for all the cryomodules, to the systematic Visual Test (VT) and Leak Test (LT), and Paint Test (PT) for a 2 lip-welds.

Organizing and bringing NDT at Saclay is challenging:

1) Contract: a call for tender organized for about 92 campaigns (> 200 k€) and bids are received on 22 April

2) Safety: CEA-Saclay has very strict safety regulations for implementing X-Ray radiography : < 0.5 µSv/h in public zone

3 – Execution of NDT and TÜV

Module assembly at two different workstations will need to be synchronized (in the best case) or delayed (in the worst case) with the external action of NDT operators and of TÜV-Nord inspector, on a weekly basis ! TÜV-Nord inspector takes vacations.

4 - Non-conform Welds (pores, or blow-holes)

AWLC’14 , 14/05/2014


O. Napoly, CEA

Status on 2-phase line welding

Courtesy Kay Jensch

AWLC’14 , 14/05/2014


O. Napoly, CEA

Example of Pores

AWLC’14 , 14/05/2014


O. Napoly, CEA


Courtesy Kay Jensch

AWLC’14 , 14/05/2014


O. Napoly, CEA


XM3 : under DESY EN3834-2 coordination by certified DESY welder• 14 welds at level 1 • 1 weld at level 2 • 1 weld at level 3

XM4 : under DESY EN3834-2 coordination by certified DESY welder• 14 welds OK at level 1 • 3 welds OK at level 2 • 1 longitudinal weld beyond level 3: 2 repair welds at Level 1

XM5 : under DESY EN3834-2 coordination by certified ALSYOM/SEIV welder• 5 welds at level 1 • 7 welds at level 2 • 4 welds at level 3 – exchange decided: 6 repair welds performed by DESY

welder at Level 1

AWLC’14 , 14/05/2014


O. Napoly, CEA


XM1 XM2 XM3 XM4 XM5 XM6 XM70.00

0.50

1.00

1.50

2.00

2.50

3.00

average level

average level (w/o repair welds)

AWLC’14 , 14/05/2014

XM6 : under ALSYOM EN3834-2 coordination by certified ALSYOM welder• 9 welds OK at level 1 • 3 welds OK at level 2 • 4 welds OK at level 3

XM7 (May 12-13) : under ALSYOM EN3834-2 coordination by certified ALSYOM welder• 12 welds OK at level 1 • 3 welds OK at level 2 • 1 welds OK at level 3

XFELX-Ray Free-Electron Laser

ETAT DES NON-CONFORMITES - XFEL CRYOMODULE

34O. Napoly, XFEL MAC

Nombre de non-conformités détectées par mois (FAQ) – Situation à fin Avril 2014

Étiquettes de lignes Nombre de OrigineMar-13 7Apr-13 11May-13 4Jun-13 10Jul-13 28Aug-13 11Sep-13 37Oct-13 31Nov-13 14Dec-13 18Jan-14 40Feb-14 33Mar-14 52Apr-14 65Total général 361

34



Nombre de non-conformités détectées par mois et par origine (FAQ)


35



NC par origine (de Mars 2013 à Avril 2014) NC par origine (01/04/14 au 30/04/14)


Étiquettes de lignes Nombre de OriginePRODUCT 199PROCESS 125TOOLING 35MISSING 3Total général 362

Étiquettes de lignes Nombre de OriginePRODUCT 37PROCESS 25TOOLING 2MISSING 1Total général 65

36



NC par WS (de Mars 2013 à Avril 2014) NC par WS (Avril 2014)


Nombre de WSWS TotalCO 14SA 12CC 10RO 9CA 8REC 7AL 5Total général 65

Nombre de WSWS TotalRO 76REC 67SA 53CO 44CC 43AL 39CA 29SUP 9SH 1Total général 361

37



REPARTITION DES NON CONFORMITES PAR CRYOMODULE


38



REPARTITION DES NON CONFORMITES (FAQ) PAR COMPOSANTS (cumul de Mars 2013 à Avril 2014)


39


O. Napoly, CEA

Problems of Non-conformities

AWLC’14 , 14/05/2014

XFELX-Ray Free-Electron LaseriConclusions

6 May 2014


• XM-2 successful RF test qualifies the remainder of CEA equipment (pumping system)

• XM-1 revealed the challenges and difficulties of the Helium tank welding: qualification, radiography, conformity

these problems are now under control

• Ramp-up is in progress and 1-week assembly rate is around the cornero CEA assembly ‘tool’ is operationalo Alsyom just finished staffing, slight overstaffing is neededo 1-week assembly depends on

training of Alsyom staff on each workstation fewer Non-conformities on components

• Documenting the module assembly (BOM, NCR, AR, ADP, etc…) in EDMS has been an outstanding effort from DESY-CEA-Alsyom over the past 2 years. However the QA resources put on ‘virtual modules’ are badly missing for the ‘real module’ (QA controls).


Back-up slides

O. Napoly, XFEL MAC6 May 2014

42



NC Cavités (de Mars 2013 à Avril 2014) – REC WS 1/2


FAQ Date d'ouverture Ref cryomodule N° de Série Acronyme WS Origine Object

FAQ-2014-0199 29/04/2014 XM11

CAV_FE00081, CAV_FE00102, CAV_FE00105, CAV_FE00121, CAV_FE00132, CAV_FE00622, CAV_FE00623, CAV_FE00667.

CAV_FE REC PRODUCT Reworked He Tubes not aligned properly

FAQ-2013-0002 12/03/2013 XM-2 CAV00512 CAV_FE REC PRODUCT Threaded rods too long on cavity beantube adapter flange - short sideFAQ-2013-0003 13/03/2013 XM-2 CAV00510 CAV_FE REC PRODUCT High Q Antenna flange misorientedFAQ-2013-0004 13/03/2013 XM-2 CAV00510 CAV_FE REC PRODUCT Cavity elbow valve mispositionnedFAQ-2014-0194 29/04/2014 XM11 CAV_FE00623 CAV_FE REC PRODUCT Yellow Plastic particles inside the He tube (origin : caps)

FAQ-2013-0015 19/04/2013 XM-2CAV00509, CAV00510, CAv00513, CAV00514, CAV00526.

CAV_FE REC PRODUCTFive cavities are out RF-measurement acceptance regarding the HOM RF rejection criteria

FAQ-2014-0132 01/04/2014 XM8 CAV_FE00052 & CAV_FE00558 CAV_FE REC PRODUCT Irregular surface of the bracket

FAQ-2013-0018 15/04/2013 XM-2 CAV00523 CAV_FE REC PRODUCT High Q Antenna flange and Cavity flange (Long side) misorientedFAQ-2013-0019 25/04/2013 XM-2 CAV00513 CAV_FE REC PRODUCT Flange of elbow valve is dirty FAQ-2014-0065 21/02/2014 Non affecté CAV_FE00011 CAV_FE REC PRODUCT Missing weld between 8mm He pipe and cavity He tankFAQ-2014-0064 20/02/2014 Non affecté CAV_FE00517 CAV_FE REC PRODUCT Scratches on the lower surface of the cavity bracket / Missing Leak test data

FAQ-2014-0010 14/01/2014 Non affecté

CAV_FE00517 - CAV_FE00525 - CAV_FE00534 - CAV_FE00538 - CAV_FE00545 - CAV_FE00550 - CAV_FE00552 - CAV_FE00561 - CAV_FE00574 - CAV_FE00575 - CAV_FE00582 - CAV_FE00584 - CAV_FE00604 - CAV_FE00615 - CAV_FE00623 - CAV_FE00624.

CAV_FE REC PRODUCT 2Ph Pipe to be repaired at DESY

FAQ-2013-0032 26/06/2013 XM-1 CAV_FE00515 CAV_FE REC PRODUCT Pressure increase from 1E-7 mbar to 5E-03mbar.

FAQ-2013-0162 16/12/2013 Non affecté

CAV_FE00014, CAV_FE00015, CAV_FE00016, CAV_FE00019, CAV_FE00020, CAV_FE00022, CAV_FE00025, CAV_FE00037, CAV_FE00039, CAV_FE00040, CAV_FE00041, CAV_FE00043, CAV_FE00044.

CAV_FE REC PRODUCT 2Ph Service Pipe diameter and thickness out of specification

43



NC Cavités (de Mars 2013 à Avril 2014) – REC WS 2/2


FAQ Date d'ouverture Ref cryomodule N° de Série Acronyme WS Origine ObjectFAQ-2013-0159 10/12/2013 Non affecté CAV_FE00545 CAV_FE REC PRODUCT Vertical axis acceleration : 2,21gFAQ-2013-0157 22/11/2013 Non affecté CAV_FE00584 CAV_FE REC PRODUCT screws imbedded in the coupler port flangeFAQ-2013-0154 26/11/2013 Non affecté CAV_FE00606 CAV_FE REC PRODUCT Visible particule inside the elbow valve of the cavity FAQ-2013-0151 19/11/2013 Non affecté CAV_FE00517 CAV_FE REC PRODUCT Frequency out of specification (9 modes)FAQ-2013-0138 25/10/2013 XM2 CAV_FE00034 CAV_FE REC PRODUCT Dents and scratches on the knife of the angle valve FAQ-2013-0135 24/10/2013 Non affecté CAV_FE00568 CAV_FE REC PRODUCT Presence of scrathces on cavity flangesFAQ-2013-0131 25/10/2013 Non affecté CAV_FE00571 CAV_FE REC PRODUCT Vertical axis acceleration : 2,32gFAQ-2013-0124 09/10/2013 Non affecté CAV_FE00016 CAV_FE REC PRODUCT |Fπ - Fth|= 0,156 Mhz - Spec : |Fπ - Fth|<0,15 (Mhz)FAQ-2013-0123 08/10/2013 Non affecté CAV_FE00025 CAV_FE REC PRODUCT |Fπ - Fth|= 0,156 Mhz - Spec : |Fπ - Fth|<0,15 (Mhz)FAQ-2013-0122 07/10/2013 Non affecté CAV_FE00037 CAV_FE REC PRODUCT Vertical axis acceleration : 3,72gFAQ-2013-0098 24/09/2013 XM-1 CAV_FE00535 CAV_FE REC PRODUCT Z axis acceleration : 2,95g

FAQ-2013-0072 29/08/2013 Non affecté

CAV_FE00020, CAV_FE00022, CAV_FE00025, CAV_FE00539, CAV_FE00543, CAV_FE00558, CAV_FE00562, CAV_FE00573.

CAV_FE REC PRODUCT Y axis acceleration : 2,35g

FAQ-2013-0071 29/08/2013 Non affecté

CAV_FE00009, CAV_FE00012, CAV_FE00016, CAV_FE00023, CAV_FE00550, CAV_FE00555, CAV_FE00559

CAV_FE REC PRODUCT X axis acceleration : 3,62g

FAQ-2013-0070 29/08/2013 XM1 CAV_FE0562 CAV_FE REC PRODUCT Brown marks on the angle valve copper seal

44



NC Cavités (de Mars 2013 à Avril 2014) – CC WS


FAQ Date d'ouverture Ref cryomodule N° de Série Acronyme WS Origine ObjectFAQ-2014-0181 23/04/2014 XM8 CAV_FE00055 CAV_FE CC PRODUCT Brown marks on the coupler flange of the cavityFAQ-2014-0164 17/04/2014 XM7 CAV_FE00609 CAV_FE CC PRODUCT Oxidation marks on the antenna / Brown mark on the sealFAQ-2014-0134 02/04/2014 XM8 CAV_FE00634 CAV_FE CC PRODUCT Water inside cavity elbow valveFAQ-2014-0089 11/03/2014 XM5 CAV_FE00641 CAV_FE CC PRODUCT Scratche on the inside part of cavity beam tubeFAQ-2013-0040 02/07/2013 XM-1 CAV_FE00520 CAV_FE CC PRODUCT Coupler flange of the cavity out of specifications double drilling) FAQ-2013-0104 26/09/2013 XM3 CAV_FE00012 CAV_FE CC PRODUCT The flange of the valve is damagedFAQ-2013-0083 06/09/2013 XM1 CAV_FE00558 CAV_FE CC PRODUCT White marks on the coupler port flange

NC Cavités (de Mars 2013 à Avril 2014) – SA WS

FAQ Date d'ouverture Ref cryomodule N° de Série Acronyme WS Origine ObjectFAQ-2014-0191 28/04/2014 XM7 CAV_FE00509 CAV_FE SA PRODUCT White marks on cavity flangeFAQ-2014-0187 25/04/2014 XM7 CAV_FE00508 CAV_FE SA PRODUCT White marks on the cavity flange ( Tuner side)FAQ-2014-0186 25/04/2014 XM7 CAV_FE00616 CAV_FE SA PRODUCT White marks on cavity flange (tuner side)FAQ-2014-0151 14/04/2014 XM6 XM6_STR CAV_FE SA PRODUCT Brown marks on the cavity flange seal surfaces FAQ-2014-0148 10/04/2014 XM6 CAV_FE00031 CAV_FE SA PRODUCT Brown marks on the cavity flange seal surfaces FAQ-2013-0017 24/04/2013 XM-2 CAV00509 CAV_FE SA PRODUCT Presence of visible particules inside beam tubeFAQ-2014-0121 27/03/2014 XM5 CAV_FE00615 CAV_FE SA PRODUCT Pick-up connector core distortedFAQ-2014-0116 20/03/2014 XM5 CAV_FE00517 CAV_FE SA PRODUCT White marks on the cavity flangeFAQ-2014-0091 13/03/2014 XM5 CAV_FE00545 CAV_FE SA PRODUCT Browm marks on the seal of the coupler port flangeFAQ-2014-0020 21/01/2014 XM3 CAV_FE00023 CAV_FE SA PRODUCT Marks on the flange of the beam tube (Coupler side)FAQ-2014-0015 17/01/2014 XM3 CAV_FE00009 CAV_FE SA PRODUCT Marks on the flange of the beam tube (Coupler side)FAQ-2014-0014 17/01/2014 XM3 CAV_FE00023 CAV_FE SA PRODUCT Marks on the flange of the beam tube (Tuner side)

45



NC Cavités (de Mars 2013 à Avril 2014) – RO WS


FAQ Date d'ouverture Ref cryomodule N° de Série Acronyme WS Origine ObjectFAQ-2014-0172 22/04/2014 XM6 CAV_FE00031 CAV_FE RO PRODUCT Metal filings inside 2Ph pipes of the cavitiesFAQ-2014-0060 20/02/2014 XM3 CAV_FE00023 CAV_FE RO PRODUCT One clamp not fully tightenedFAQ-2013-0144 05/11/2013 XM1 CAV_FE00543 CAV_FE RO PRODUCT HOM 1 not properly setFAQ-2013-0089 12/09/2013 XM-1 CAV_FE00544 CAV_FE RO PRODUCT Screw seized in 8mm He pipe protectionFAQ-2013-0079 05/09/2013 XM-1 CAV_FE00515 CAV_FE RO PRODUCT HOM 1 not properly set

FAQ Date d'ouverture Ref cryomodule N° de Série Acronyme WS Origine Object

FAQ-2014-0104 18/03/2014 XM3 CAV_FE000023 CAV_FE AL PRODUCT CAV_FE000023 geometry out of specification

NC Cavités (de Mars 2013 à Avril 2014) – AL WS

46



NC Coupler Cold Part (de Mars 2013 à Avril 2014) – REC WS


FAQ Date d'ouverture Ref cryomodule N° de Série Acronyme WS Origine ObjectFAQ-2013-0006 29/03/2013 XM-2 AC3C45 & AC3C47 CCP REC PRODUCT Protective plastic bags are damaged (holes)FAQ-2013-0007 29/03/2013 XM-2 AC3C45 & AC3C47 CCP REC PRODUCT Valve on the cold ceramic cap misorientedFAQ-2013-0008 29/03/2013 XM-2 AC3C45 & AC3C47 CCP REC PRODUCT Connectors on the cold ceramic caps not properly screwedFAQ-2013-0009 05/04/2013 XM-2 AC3C48 & AC3C50 CCP REC PRODUCT Stainless steel screws on cold ceramic caps of the couplerFAQ-2013-0012 16/04/2013 XM-2 AC3C30 & AC3C31 CCP REC PRODUCT Fingerprints and dust on the TWGFAQ-2013-0013 16/04/2013 XM-2 AC3C30 & AC3C31 CCP REC PRODUCT Coupler bellow clamps in contact with pick-up flangeFAQ-2014-0001 06/01/2014 XM5 THRI-CP-304 CCP REC PRODUCT Valve on ceramic cap was not properly tightenedFAQ-2013-0156 27/11/2013 XM2 THRI-CP-266 CCP REC PRODUCT Visible particules on the viton seal of the TWG valve

FAQ-2013-0152 20/11/2013 XM2THRI-CP-307 / THRI-CP-055 / THRI-CP-060 et THRI-CP-297

CCP REC PRODUCT Visible particules on the viton seal of the TWG valve

FAQ-2013-0130 16/10/2013 XM2 THRI-CP-024 - THRI-CP-284 CCP REC PRODUCT Visible particules on the viton seal of the TWG valve FAQ-2013-0094 20/09/2013 XM3 THRI-CP-037- THRI-CP-010 CCP REC PRODUCT Valve on TWG not fully closed. Valve on ceramic caps mispositionned FAQ-2013-0077 04/09/2013 XM1 AC3C20, AC3C29 CCP REC PRODUCT Stiffeners not properly fastenedFAQ-2013-0076 04/09/2013 XM1 AC3C24, AC3C26 CCP REC PRODUCT Valve on ceramic cap is mispositionnedFAQ-2013-0075 04/09/2013 XM1 CP3C63, CP3C54 CCP REC PRODUCT Screw on ceramic caps mispositionned, missing pin on stiffener

FAQ-2013-0035 01/07/2013 XM-1

THRI-CP-022-THRI-CP-012 THRI-CP-10539052THRI-CP-10539051THRI-CP-070-THRI-CP-034

CCP REC PRODUCT White mark on Cold Coupler bellow holders. Particles on the TWG.

47



NC Coupler Cold Part (de Mars 2013 à Avril 2014) – CC WS


FAQ Date d'ouverture Ref cryomodule N° de Série Acronyme WS Origine ObjectFAQ-2014-0184 24/04/2014 XM8 TWG 029 CCP CC PRODUCT 1 screw of the angle valve not properly tightenedFAQ-2014-0174 23/04/2014 XM7 THRI-CP-274 CCP CC PRODUCT Seal pinched between the ceramic cap and the coupler cold part FAQ-2014-0173 22/04/2014 XM8 THRI-CP-396 CCP CC PRODUCT Traces of dried water drops on the coupler antennaFAQ-2014-0163 17/04/2014 XM7 THRI-CP-381 CCP CC PRODUCT Traces of dried water drops and pigmentation on the coupler antennaFAQ-2014-0032 27/01/2014 XM4 THRI-CP-382 CCP CC PRODUCT Scraches on coupler cold part antennaFAQ-2013-0016 22/04/2013 XM-2 AC3C31 CCP CC PRODUCT Light scratches on the antenna of the cold partFAQ-2013-0169 18/12/2013 XM3 THRI-CP-297 CCP CC PRODUCT Light scratches on the antenna of the cold part FAQ-2013-0153 22/11/2013 XM2 THRI-CP-023 CCP CC PRODUCT Copper oxidation below ceramic capFAQ-2013-0140 30/10/2013 XM2 THRI-CP-024 CCP CC PRODUCT Dents on CCP antennaFAQ-2013-0139 30/10/2013 XM3 THRI-CP-284 CCP CC PRODUCT Roughness of copper platingFAQ-2013-0137 25/10/2013 Non affecté THRI-CP-303 - THRI-CP-271 CCP CC PRODUCT Visible particules on the viton seal of the TWG valve FAQ-2013-0136 21/10/2013 Non affecté THRI-CP-289 CCP CC PRODUCT Roughness of copper plating and presence of fiber FAQ-2013-0109 27/09/2013 Non affecté Several S/N CCP CC PRODUCT Coating of CCP bellow holder is removed after several cleaning

NC Coupler Cold Part (de Mars 2013 à Avril 2014) – SA WS

FAQ Date d'ouverture Ref cryomodule N° de Série Acronyme WS Origine ObjectFAQ-2014-0090 12/03/2014 XM5 THRI-CP-368 CCP SA PRODUCT Dark mark on the copper surface of the CCPFAQ-2013-0132 21/10/2013 XM1 AC3C26 CCP SA PRODUCT Leak on CCP AC3C26 assembled on cavity CAV_FE00543

FAQ Date d'ouverture Ref cryomodule N° de Série Acronyme WS Origine ObjectFAQ-2014-0075 27/02/2014 XM1 CP3C70 CCP CO PRODUCT Oxidation on the CCP (received from DESY)

NC Coupler Cold Part (de Mars 2013 à Avril 2014) – CO WS

48



NC Cold Mass (de Mars 2013 à Avril 2014) – REC WS


FAQ Month Ref cryomodule N° de Série Acronyme WS Origine ObjectFAQ-2014-0161 Apr-14 Non affecté EZ005 CM REC PRODUCT 4K Aluminium shield Cavity 1 is destortedFAQ-2013-0090 Sep-13 XM-1 IHEP-CX001 CM REC PRODUCT Missing insulation / fixed bracket not in contact w/FAQ-2013-0088 Sep-13 XM-1 IHEP-CX001 CM REC PRODUCT Circlip out of specifications (Ø= 15mm vs 16mm specified)FAQ-2013-0087 Sep-13 XM-1 IHEP-CX001 CM REC PRODUCT 5 needle supports with defective M20 thread FAQ-2013-0065 Aug-13 XM-1 IHEP-CX001 CM REC PRODUCT Scratches on the surface of the 2,2K/5K pipe flanges

FAQ Month Ref cryomodule N° de Série Acronyme WS Origine ObjectFAQ-2014-0114 Mar-14 XM3 CM AL PRODUCT Bushes non conformFAQ-2014-0103 Mar-14 XM3 EZ026 CM AL PRODUCT EZ026 geometry out of specificationFAQ-2014-0028 Jan-14 XM-1 IHEP-CX001 CM AL PRODUCT 8 K Coupler Copper Braids screws cannot be tightened FAQ-2014-0019 Jan-14 XM-1 IHEP-CX001 CM AL PRODUCT 8 K Coupler Copper Braids are too shortFAQ-2014-0005 Jan-14 XM-1 IHEP-CX001 CM AL PRODUCT Poor surface quality of 8mm tube endsFAQ-2014-0002 Jan-14 XM-1 IHEP-CX001 CM AL PRODUCT 70K Superinsulation folded on the coupler side

NC Cold Mass (de Mars 2013 à Avril 2014) – AL WS

FAQ Month Ref cryomodule N° de Série Acronyme WS Origine ObjectFAQ-2014-0074 Feb-14 XM3 EZ017 CM RO PRODUCT Missing needle blocksFAQ-2013-0125 Oct-13 XM3 EZ017 CM RO PRODUCT Several needle supports with defective M20 thread

NC Cold Mass (de Mars 2013 à Avril 2014) – RO WS

49



NC Cavity Bellows (de Mars 2013 à Avril 2014)


FAQ Month Ref cryomodule N° de Série Acronyme WS Origine ObjectFAQ-2014-0182 Apr-14 XM7 FEL VB1 000002-112 CBL SA PRODUCT Oxidation marks on the copper surface of the bellow FAQ-2014-0012 Jan-14 XM3 FEL VB1 000002-021 CBL SA PRODUCT Drying marks on the copper surface of the bellow FAQ-2013-0172 Dec-13 XM2 FEL VB1 000002-087 CBL SA PRODUCT Oxidation marks on the copper surface of the bellow FAQ-2013-0171 Dec-13 XM2 FEL VB1 000002-066 CBL SA PRODUCT Oxidation marks and scratches on the copper surface of the bellow FAQ-2013-0167 Dec-13 XM2 FEL VB1 000002-080 CBL SA PRODUCT Oxidation marks on the copper surface of the bellow FAQ-2013-0165 Dec-13 XM2 FEL VB1 000002-035 CBL SA PRODUCT Dents on cavity bellow FAQ-2013-0119 Oct-13 XM1 FEL VB1 000002-060 CBL SA PRODUCT Marks on inside waves of the cavity bellowFAQ-2013-0118 Oct-13 XM1 FEL VB1 000004-014 CBL SA PRODUCT Marks on inside waves of the cavity bellowFAQ-2013-0063 Aug-13 XM-1 FEL VB1 000002-018 CBL SA PRODUCT Oxidation marks on the copper surface of the bellow FAQ-2013-0059 Jul-13 XM-1 FEL VB1 000002-002 CBL SA PRODUCT Dark marks on copper plating of the bellowFAQ-2013-0021 May-13 XM-2 FEL VBI 000004-043 CBL SA PRODUCT Marks on inside waves of the cavity bellow

50



NC Vacuum Vessel (de Mars 2013 à Avril 2014) – REC WS


FAQ Month Ref cryomodule N° de Série Acronyme WS Origine ObjectFAQ-2013-0128 Oct-13 XM-1 IHEP-CX001 VVS REC PRODUCT Surface defect on Flanges H + oxidation on Flange GFAQ-2013-0069 Aug-13 XM-1 IHEP-CX001 VVS REC PRODUCT Screw not properly tightened on fixed bracket FAQ-2013-0064 Aug-13 XM-1 VB1 000002-018 VVS REC PRODUCT Scratches of the inside part of the vessel


FAQ Month Ref cryomodule N° de Série Acronyme WS Origine ObjectFAQ-2014-0067 Feb-14 XM1 EZ006 VVS CA PRODUCT Threads of vaccum vessel out of specificationFAQ-2013-0051 Jul-13 XM-2 EZ004 VVS CA PRODUCT M8 screws out of specificationsFAQ-2013-0046 Jul-13 XM-2 EZ004 VVS CA PRODUCT Paint inside threaded holes (Pos 36 D*853885)FAQ-2013-0045 Jul-13 XM-2 EZ004 VVS CA PRODUCT Paint inside the threaded holes of the Tilt balls

FAQ Month Ref cryomodule N° de Série Acronyme WS Origine ObjectFAQ-2014-0085 Mar-14 XM1 EZ006 VVS CO PRODUCT Uncorrect position of holes to fix WGB support


51

i xfel module assembly awlc’14, 14/05/2014 o. napoly, cea

Documents

cea slide

cea infrastructures

string assembly awlc14

status of assembly awlc14

mvm awlc14

cold coupler assembly

ceasaclay commitment

cantilever awlc14