1. Cryomodule Assembly Plan
SNS PPU CRYOMODULE PDR
Cryomodule Assembly Plan
Kurt Macha
Mark Wiseman
Wednesday, February 27, 2019

2. Outline Four major assembly steps
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

3. 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

4. Cold mass assembly Cryogenic piping and leak testing
2K circuit
5K FPC
4K piping to HX
Tuner installation
Liquid level & Heaters
Wiring & 2k heat stationing
Diodes
Mounting & 2k heat stationing
Primary magnetic shielding
Install coupler bellows & leak test
2k insulation

5. 2K circuit welding Where possible orbital welding may be used
Increased quality of welds
Saves production time
Reduces risk of leaks

6. Spaceframe/ thermal shield assembly
Transfer the cavity string into the spaceframe and remove the lollipop tooling

7. 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 the thermal shield
Insulate the 50k shield
Axial restraint rods get inserted loosely
Slide the spaceframe over the cavity string assembly
Use caution around the couplers, the interferences will need attention
Ensure the coupler ceramic windows are protected
Protect the coupler bellows
Spaceframe tooling

8. 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

9. 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

10. Routing and heat stationing of instrumentation
The RF cables require routing from the 50k 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

11. 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

12. Vacuum vessel / end can assembly
Install the vacuum vessel onto carriage assemblies and stage next to the spaceframe
Vacuum
Vessel
Tooling
Portable Rail Cart

13. Spaceframe insertion into the vacuum vessel
Roll the spaceframe into the vacuum vessel

14. Alignment of the spaceframe into the vacuum vessel
Center BL Flange
To Vacuum Vessel
Flange
Align the spaceframe in the center of the vacuum vessel
Investigating differential screws for fine adjustment
Install and secure all lockdowns
Final welding and leak test of the 5K 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

15. End can installation Secure each end can to the vacuum vessel
New tooling will hold and 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 2k, 4k 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
Supply
End Can
Return
End Can

16. Beamline assembly
Install the end can plates to seal the ends of the vacuum vessel
Install the final beam line sections using portable clean room work spaces
Extra precautions to ensure reduced particulate.
Slow pump and slow backfills will be done using improved equipment and procedures

17. 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)

18. Conclusion New tooling will be needed for end can installation
Kurt Macha
Mark Wiseman
Conclusion
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