cryomodule assembly Stéphane BERRY completed from Trublet Thierry at XFEL meeting in 2015 April Coupler warm part assembly Non Conformties Coupler Cold Part Issues During the assembly of coupler warm part on the position 4 of XM18 cryomodule water has been found unde ID: 913781
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Slide1
CEA PREVENTIVE ACTIONS for XFEL cryomodule assembly
Stéphane BERRY completed from Trublet| Thierry at XFEL meeting in 2015 April
Coupler warm part
assembly
Slide2Non Conformties
Coupler Cold PartIssuesDuring the assembly of coupler warm part on the position #4 of XM18 cryomodule, water has been found under ceramic protection cap of coupler cold part THRI-CP-474 (picture 1 on page 2). Some oxidation marks on the coupler cold part copper surface are visible too (left picture).
Source
The presence of water inside the coupler cold part is probably due to his wash in BELIMED
. The cold ceramic cap are not water tight!!CorrectingactionsCEA:1. Cleaning of copper surface of the coupler cold part by sulfamic acid with class 10 tissue.2. Rinsing by ethanol with class 10 tissue.Corrective actions allow assembly operation to be continued. Result of cleaning : picture 3 on page 2.
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CEA preventive actions for XFEL crymodule assembly - coupler warm part assembly | April 2015
Slide3Non Conformties
Coupler Cold Part (FAQ-2015-0398-3C XM48)IssuesDuring the assembly of coupler warm part on several cryomodules, strong coloration of coupler
cold part
have been found even if we are
not washing the test wave guide. Some oxidation marks on the coupler cold part copper surface are visible too (left picture). Most of the time the copper under the RF contact is not affected.SourceUnknownCorrective actionsCEA:clean the copper surfaces with sulfamic acid and
rinse them immediately (no intermediate drying) with ethanol.The ceramic will NOT be in contact with neither sulfamic acid nor ethanol
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3CEA preventive actions for XFEL
crymodule assembly - coupler warm part assembly | April 2015
FAQ-2014-0258
Slide4Coupler Warm part Assembly
| PAGE 4CEA preventive actions for XFEL crymodule assembly - coupler warm part assembly | April 2015
Slide5Non ConformtiesCoupler Warm Part
IssuesScratch on warm part inner conductor (on RF contact)SourceDisassembly warm from cold partCorrective actionsLAL: sand paper to remove thickness which risk to compromise the RF contact
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CEA preventive actions for XFEL crymodule assembly - coupler warm part assembly | April 2015
Slide6Non ConformtiesCoupler Warm Part
IssuesT70K overheating SourceAntenna screw loosePreventive actionsDESY: New material for central screw and new torque (7Nm instead 5Nm)
CEA:
Update of instructions file for coupler assembly to take into account the new torque (in addition the number of the turn of the screw is indicated for memory)
Use of new torque wrenchOperators awareness to the issuePunctual Audit since XM37| PAGE 6
CEA preventive actions for XFEL crymodule assembly - coupler warm part assembly | April 2015
Slide7Non
ConformtiesCoupler Warm PartIssuesPush-rod to adjust variable coupler
Pin of the push rod not completely rotated
Preventive actions
CEA:Operators awareness to the issueSpecial Training for operatorsRF Check coupled with the actuator rotation (the possibility has to be check with the assembly process)Design can be optimized : screws arrangement compatible with 90°rotation
| PAGE 7CEA preventive actions for XFEL crymodule assembly - coupler warm part assembly | April 2015
Slide8Non Conformties
CapacitorIssuesDischarge/burnSourceCapacitor screws loosePreventive actionsCEA:Operators awareness to the issue
Control that the operators knew the instructions
Torque controlled at 100% and also le nuts M5 in copper behind the WGB
(frequently some nuts are loosed => copper elasticity?)| PAGE 8CEA preventive actions for XFEL crymodule assembly - coupler warm part assembly | April 2015
Slide9Non Conformties
ActuatorIssuesTime consuming (20% of the actuators have the screw M3x25 seized during the assembly with the preventive actions)SourceMisalignment holes between PEEK axle of WP, axle of actuator and axle of the big washer
Too fine adjustment with the screw M3x25, for this design, in regard of the misalignment
Preventive actions
CEA:Use of grease for the screwDrill the hole of PEEK axle at Ø3,1mm| PAGE 9
CEA preventive actions for XFEL crymodule assembly - coupler warm part assembly | April 2015
Slide10Non Conformties
PEEK axle IssuesThe complete push-rod need to be exchange if the connecting axle between push-rod and actuator is brokenRisk to break the PEEK axle (one broken, one damage)
Source
Fragile and preeminent
Preventive actionsdesigner:Use a removable part as TTF3 design| PAGE 10
CEA preventive actions for XFEL crymodule assembly - coupler warm part assembly | April 2015
Slide11DSM IrfuDIR
Commissariat à l’énergie atomique et aux énergies alternativesCentre de Saclay | 91191 Gif-sur-Yvette CedexT. +33 (0)1 69 08 xx xx
|
F. +33 (0)1 69 08 99 89
Etablissement public à caractère industriel et commercial | RCS Paris B 775 685 019| PAGE 11CEA preventive actions for XFEL crymodule assembly - coupler warm part assembly | April 2015