Connect 2 Cleanrooms Extends Over CERN with Telescopic Cleanroom

Part of CERN's Prevessin site in France is dedicated to producing beam intercepting devices, to be used in different particle accelerators across its world-leading particle physics laboratory.

This involves the assembly of highly specialised parts such as collimators to clean the halo of proton beams, beam stoppers and beam dumps to absorb the energy of particles. These beam intercepting devices are built in sections to allow parts to be decommissioned and removed for servicing & maintenance.

With these highly calibrated pieces of machinery there is a risk that exposed parts could be affected by particulate contamination during assembly or servicing. Contaminants inside the chamber could affect how the beam is travelling and render them ineffective.

Conducting the assembly inside a cleanroom would reduce the risk of particulate contamination - but some parts are up to 6 metres in length and 30 tonnes in weight. How would these colossal parts which need to be transported by overhead crane be moved into a cleanroom?

Collaborating with CERN scientists, Connect 2 Cleanrooms designed a telescopic cleanroom with three moveable modules that extend on guide rails from a closed position, tripling the floor space. So when the larger beam intercepting device sections have been craned into the servicing bay, the cleanroom can be extended, laterally enveloping the part. Doors can then be closed and locked in position for safety and integrity.

The softwall cleanroom houses six HEPA filter fan units (FFU) in total, to maintain the clean air integrity no matter what the configuration. It achieves particle counts to meet ISO 14644-1 class 8 when in the extended position, controlling the risk of contamination.

Two FFUs are housed in a sealed plenum in the ceiling of the middle section, providing a down flow of clean processed air. The other four are housed in the end walls providing horizontal clean air flow. This means that the integrity of the cleanroom is always maintained and in the closed position it achieves particle counts to meet ISO 14644-1 class 6.

When in the closed position the cleanroom can be used for work on smaller parts. This means all the beam intercepting device components can be assembled in the same environment. 

Now installed and validated at CERN’s Prevessin site, the cleanroom also delivers access to the required services with Swiss Type J power sockets and Cat6 Ethernet cable outlets. A control cabinet accessed externally allows control over the FFU speed.

CERN is a security protected site and the installation and validation team at Connect 2 Cleanrooms gained access through a comprehensive induction and validation process. Once they had achieved the required clearance, the team worked autonomously completing the complex installation and qualification in just eight days.

“Connect 2 Cleanrooms was the most competitive company who passed our tender qualification. The design stage was very fast and the principle of the layout was complete within the first iteration. The end result is unique when you see the extending cleanroom in motion.” Oliver Aberle, Project Manager at CERN.