Facility Preparedness: Current Facility And Cleanroom Upgrade / Tooling .

Facility Preparedness: Current facility and Cleanroom upgrade / Tooling and HPR S. K. Suhane/ RRCAT PIP-II Technical Workshop 02/12/2020 A Partnership of: US/DOE India/DAE Italy/INFN UK/UKRI-STFC France/CEA, CNRS/IN2P3 Poland/WUST

Movement of Cavity in the Cleanroom Assembly and Vacuum Testing 2 2/12/2020 S. K. Suhane Technical Workshop PIP-II

HPR and Cleanroom Processing External HPR of cavity & hardware Shift inside class 100 cleanroom and assemble End flange with vacuum valve and burst disk Area ‘4’ HPR of cavity (3 Pass) Area ‘3’ Shift inside class 100 cleanroom and assemble top flange, MC &FP flange Area ‘4’ Drying in the HPR station (Class 100) Area ‘3’ Shift to HPR station for second HPR HPR of cavity (3 Pass) Area ‘3’ No Vacuum Pump Down Area ‘4’ 3 2/12/2020 Leak Test Area ‘4’ Leak Test OK S. K. Suhane Technical Workshop PIP-II Yes Shift to VTS Facility

HPR set up for HB650 cavity HPR Set up details 4 Structure 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 2/12/2020 Nozzle tip Filter Bare Cavity HPR Trigger Gun External HPR Arrangement S. K. Suhane Technical Workshop PIP-II Jacketed Cavity HPR Nozzle Tip Nozzle Holder

High Pressure Rinsing Process HPR Parameters 80-100 bar Pump Flow rate 8-10 LPM Flushing of piping is done before every HPR cycle Wand Rotation 2-5 RPM HPR structure, fixtures, clean enclosure walls are thoroughly cleaned with Cavity travel 5 Q.C. in HPR process Jet pressure vertical 5-20 mm/min Online monitoring of UPW parameters IPA using lint free cloth regularly Water from rinsed cavity is collected and sent for microbial analysis Nozzles type 40 fan jet Wand filter cartridge is changed every year Nozzle arrangement Two oppositely placed nozzles Polisher unit is run in recirculation mode to maintain purity of UPW HPR duration (3 1 3) passes of HPR after light EP, total duration of 7 hours. 2/12/2020 Collection of water from rinsed cavity for particulate analysis (Planned in new HPR set up) S. K. Suhane Technical Workshop PIP-II

Tooling for Cavity Handling in Cleanroom S.S. cart with swivel castors for movement of cavity in the cleanroom Fixture with toggle clamps for holding the cavity cage Loading of cavity on HPR set up Cleanroom compatible cart for cavity lifting and swivelling 6 2/12/2020 S. K. Suhane Technical Workshop PIP-II Holding fixture for jacketed cavity

Cleanroom Preparation of Cavity Cavity Assembly Process 7 All tools and hardware cleaned with ultrasonic cleaning before taking them inside the cleanroom Flanges and fasteners are rinsed with ultrapure water and after drying, cleaned with nitrogen using ionizing blow-off gun. Particle count measured during each step of cavity assembly Torque wrench used for bolt tightening Aluminum seal and copper gasket carefully checked and cleaned with IPA then purged with nitrogen blow-off gun High purity nitrogen gas (99.9995 %) is used for purging All movements and operations inside cleanroom are performed slowly and cautiously Thorough cleaning of cleanroom walls, floor and furniture regularly 2/12/2020 Cleanroom assembly of Cavity S. K. Suhane Technical Workshop PIP-II

Cavity Vacuum Pumping screen capture of RGA analog spectrum Bypass Line 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 8 2/12/2020 S. K. Suhane Technical Workshop PIP-II Leak Valve RGA

Ultrapure Water Generation Plant Ultrapure water generation plant installed close to new mini cleanroom facility Parameter Value Storage tank made of virgin PP fitted with 0.22 micron PTFE vent filter Resistivity 18 MΩ-cm Pump MOC: SS316 TOC Total Bacteria Count 30 ppb 1 cfu/100ml Piping made of electropolished Stainless Steel grade 316 Online Conductivity, Resistivity meter and TOC monitor Flow Rate Final Storage Tank 800 LPH 2500 litre Sample collection port for microbial analysis Gasket PTFE 9 2/12/2020 S. K. Suhane Technical Workshop PIP-II

Cavity Processing Facility Building AHU for Mini Cleanroom D4 D4 D4 Mini Cleanroom D2 PLATFORM D2 D2 A 1 EP Set up CBP M/c UPW Plant D2 AHU for Large Cleanroom Large Cleanroom 10 2/12/2020 S. K. Suhane Technical Workshop PIP-II Air conditioned envelope in PEB for housing Large Cleanroom

New Mini Cleanroom 132 CHANNEL-50 975 975 975 975 975 CHANNEL-50 975 US Cleaner DOOR SIZE 1000mm INT OPE 836mm CHANNEL-50 935 975 3.8 m 666 803 100 962 670 760 1202 D2 LH 1195 839 DOOR SIZE 1000mm INT OPE 836mm 1195 CHANNEL-50 975 AIR SHOWER DYNAMIC PASS BOX-1 WALL MOUNTED INTERNAL SIZE:600X600X600 EXTERNAL SIZE:760X670X1050 DOOR SIZE 1000mm INT OPE 857mm Gowning Area SQUARE PIPE 100x100 975 975 CHANNEL-100 Air Lock (ANTE ROOM) 100 1103 1195 CHANNEL-50 Personnel Entry 1195 CHANNEL-50 165 CHANNEL-100 ANTE ROOM 1195 1103 100 1195 140 CHANNEL-100 100 1005 1800 DOOR SIZE 1500mm INT OPE 1302mm Cavity Entry DOOR SIZE 1500mm INT OPE 1302mm 975 CORNER-100 975 CORNER-100 9.6 m ISO Class-4 11 2/12/2020 ISO Class-6 ISO Class-8 S. K. Suhane Technical Workshop PIP-II

New Mini Cleanroom Features of New Mini Cleanroom Mini Cleanroom under construction Expected to be operational by Early next year 12 2/12/2020 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 S. K. Suhane Technical Workshop PIP-II

Proposed HPR set up in New Mini Cleanroom The existing HPR set up will be relocated to the new cleanroom with certain modifications in the structure New cleanroom has raised floor in the ISO 4 area. Base structure of HPR has been modified for installation on the raised floor. Suitable opening shall be made in the raised floor for installing HPR structure Vertical frame has been suitably stiffened to support both the bare as well as dressed cavity. The existing high pressure reciprocating pump will be replaced with a new diaphragm type pump. PP/PVDF pipeline for ultrapure water distribution from the UPW plant will be installed Support Structure for new HPR setup Triplex Diaphragm Pump Aerosol particle counter 13 2/12/2020 S. K. Suhane Technical Workshop PIP-II

Integrated Large Cleanroom Facility HPR PUMP ED1 Cavity Entry D3 CLASS ISO-7 CLASS D3 D3 D3 ISO-7 ED1 D2 CLASS Air Shower D3 ISO-7 HAND HPR AREA D3 Hand HPR CLASS D2 Gowning Area ISO-8 CLASS ISO-4 HPR CLASS ISO-6 CLASS CLASS Cavity Receiving High Vacuum Furnace ISO-7 CLASS CLASS ISO-4 ISO-5 Final Assembly SD1 VAC CART SD1 ISO-7 SLIDE SLIDE CLASS CLASS Personnel Entry D2 D2 D3 D3 D2 ISO-4 ISO-4 D3 CLASS ISO-8 D2 D3 D2 CLASS CLASS ISO-4 ISO-6 CLASS ISO-6 String Assembly Cavity Tuning CLASS ISO-7 D2 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 14 2/12/2020 CLASS CLASS ISO-7 ISO-7 Legends: ISO Class-4 ISO Class-6 ISO Class-5 ISO Class-7 S. K. Suhane Technical Workshop PIP-II ISO-7 D3 SD2 CLASS Ante-Room SD2

Salient Features of cleanrooms 15 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 2/12/2020 S. K. Suhane Technical Workshop PIP-II

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 16 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 2/12/2020 S. K. Suhane Technical Workshop PIP-II

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 17 Rails under raised floor for string assembly area are installed 2/12/2020 S. K. Suhane Technical Workshop PIP-II

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 to the new HPR stand in FNAL The HPR structure will be installed on the raised floor of cleanroom Base support has been modified to suit the height of raised floor. Suitable opening shall be made in the raised floor for installing the structure The facility can be used to rinse bare as well as jacketed cavity by adjusting the wand position The cavity frame holding fixture on the HPR structure is made common for both bare as well jacketed cavity Components and sub-systems required for the new HPR set 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 opening is under procurement Geared motor for wand rotation Support Structures in fabrication Linear Actuator for Cavity Translation 18 2/12/2020 S. K. Suhane Technical Workshop PIP-II Cavity Loading Cart