14 February 2006A.Ciocio - ID Week1 SCT Services Procurement & Installation Type IV PP3 Type II-III and PP1 Fibres Heaters DCS Testing MTF Workpackage

14 February 2006 A.Ciocio - ID Week 1

SCT Services Procurement & Installation

• Type IV • PP3• Type II-III and PP1• Fibres• Heaters• DCS• Testing• MTF

Workpackage https://edms.cern.ch/document/593278/


Status of Type IV Installation• Type IV cables are delivered in double lengths with connectors installed at the PP3

end and pulled between the UX15 cavern and the US/USA halls

• TC installation team: S.Malyukov, E.Kudinov, teams from IHEP Protvino

UX side US(A) sidePP3 Power Supply

Racks on Level 6US side

• US side - Length between 15-30.5 m (61 m the longest double harnesses)- Delivery and installation of 2044 cables + spares over the summer- Lower delivery rate than expected due to a series of problems (rain, drums damage, etc.) Installation between racks completed last October

• USA side - Length between 47-75 m (150 m for the longest double harnesses) - 720 cables received between Oct-Dec- Very low priority for installation of type IV since October - only half of the cables are installed- Connector problem resulted in erratic delivery for 2 months until production officially stopped


Type IV Connector ProblemThe insulation can split when the conductor is bent in a small radius.

Some strands are poorly aligned, and the insulation has thin places.


Type IV Connector (cont’d) Meeting with cable producers (Novacavi), harness producers (KontaktSysteme), Laurent Gillain (CERN purchasing), Pippa and myself to discuss solutions to resume production (January 11)

Options:

• Replace 100 Km cable already made- Novacavi can’t figure out how to improve their production- Delay of 2 months

• Use a bigger hood for less bending- Modify PP3- Delay

• Use shrink tube over or replace the insulation with shrink tube- New cost estimate


Type IV Connector (cont’d)First sample produced in January using the solution of stripping the insulation from the four power cables (8cm) and replace it with heat shrink tube

1

3 4

2


Type IV Production

– Previous pictures show a good sample but the insulation of the HV cable and the fat power cables were squashed inside the strain relief clamp

– Final sample produced more carefully 2 weeks ago significantly improved – OK for production

• Production of type IV is still on hold awaiting a financial resolution

• Installation of type IV might be even interrupted when type ii/iii installation starts

• Still undefined schedule for completion of all racks


Type IV Connectors in Situ• All double harnesses installed in US15 racks are cut on the PS end and connectors are installed in situ by an external company

• CPE(Italy) was selected to do the job • A team of 10 came in December.

– The work started 2 weeks before XMAS mostly to understand how to cut to length, make more samples, plan the big job.– 6 people came back on January 9

• Technical appendix in EDMS https://edms.cern.ch/document/624679/1 • Workpackage https://edms.cern.ch/document/593278/


Type IV Connectors in Situ

• Cables are cut to length using a dummy crate with PS channel mask plate• 2 cm contingency



• Add shrink tube on power wires because of unlikely but possible insulation problem also on this side



– First rack fully assembled on January 20

– Test of plug in PS backplane – OK

– Electrical test – a few connectors needed rework

– 3 racks are worked on in parallel

– Goal: 2 racks/week completed (realistically 1.5)

As of Feb 10: 4 racks completed 2 in progress


PP3

• PP3 units are produced in Melbourne and shipped to CERN – First 100 units were received in October– ~1000 by December and several subracks of 30 units were assembled– Currently: 1759 PP3s fully tested and 55 subracks assembled

People:• Shaun Roe coordinates the testing and burn-in of single PP3 units with SCT participation• Ashley French and Scott Moncrieff (Melbourne) worked on assembly and installation in November/December• Edward Gornicki (Cracow/CERN) worked 2 weeks on this in February• Vladimir Golovkin (Protvino) at CERN for 1 month (until February 23)• Scott M. will be back this week

• We need at least one technical person dedicated to this part


PP3 Testing

Single unit test

• 60 units can be tested at the time (2 PP3 crates) with the current number of test cables available - 40 more cables are under construction• 24 hours with monitoring continuity on all lines, while varying the dummy load so that the Vcc and Vdd currents go to zero and the full power supply voltage is seen on the PP3. • Voltage limiter test by applying 6V to each PP3 in turn (manually)

• PP3 related test: Currently the entire chain (modules/DPPB1/TypeII/TypeIII/PP3/TypeIV/PS) in SR1

- to measure how the shield works and noise generated at the PS - test OK - very low EM radiation of cables - report of G.Blanchot

http://www-atlas.lbl.gov/ciocio/SCTcables/SCT_Power_Supplies_Conducted_Emissions_Report.pdf


PP3 Assembly

Mechanical Problems• The plastic support feet of the PCB inside the metal casing of the PP3 had been broken in some cases and the PCB was therefore moving at one end - Replaced the broken ones - Requires careful visual inspection

Subracks are checked for shorts • Ground contact found between magnetic shields and/or strap holder due to thescrew heads protruding above the surface - Kapton tape strips to cover screw-heads• Ground contact found in the corner where units are very tight and insulation film gets damaged during assembly or when applying extra stress during installation in the rack - Extra kapton (or insulation film) inside the clamp

30 PP3 units are assembled in one subrack• Insulating film applied on individual shield case• A few drops of silicone to hold them together• External clamp for rack mounting


PP3 Installation & Plan• Installation

– Cables are plugged in a few dummy Patch Panels during installation to be placed in the right (final) position and are tightened to horizontal bars

– Cables will have to be all removed from the current position and plugged in by groups/rows when the installation of the real PP3 will occur

– 30 PP3 subracks (3 racks) have been installed so far

• Current Plan – Estimated installation of 90 units per day limited today by testing capability and

problems– But also need the rest of PP3 units soon to complete assembly and installation– Need 200 special PP3s soon to go in the first rack where bigger connector hood

were used - requires more tolerance (shorter standoffs) – Rework of remaining subracks (10) that don’t have kapton tape on screws either

by taking the subrack apart – but difficult at times and risk of damaging insulation or replacing shield case

– Rework subracks that need extra insulation on the corner unit– Installation of PP3s in racks to which type III cables arrive with highest priority– Need continue SCT participation to meet schedule and long term presence of at

least one technical staff


PP3 Installation


Type II ServicesTimescale

• Since calorimeter moved to z=0 (November) access to the cryostat is possible– ID requests should be via Nicolas Massol

• Sector 5 (top) and Sector 13 (bottom) – heater cables, and DCS cables– Just finished

• Sector 9 horizontal towards USA15 to be installed next – SCT fibres and SCT power cables (886 cables + spares)– Barrel cables (side A and C) tried last week– a small number of fibres (end cap) should be tried this week

• Sector 3 – was supposed to follow sector 5, but was held up by problems with arches above

detector and muon chamber installation – It’s going to follow Sector 9

• Sequence in a sector is:– Tubes, fibres, heater cables, SCT cables, (Muon chambers), – TRT cables, pixel cables


Sectors

View of Sectors


Type II/III and PP1• Production of double length harnesses of Type II/III spliced with FCI/JST

connectors (PP1) and then single length cable with FCT connector (PP3)– INEO/St Genis -> Thurmelec/Alsace

• Prepare tables of lengths, mapping, labels, QA of qualification samples– Pippa/Sandra/Pepe Bernabeu/Maarit White

• Testing samples of double harnesses at CERN– Martin Postranecky/Pepe Bernabeu

• TC management– Nicolas Massol, Sigi Wenig and teams (Russians, Czechs)

• Installation of dummy PP1 and Type II cables– Lars Lindquist (Uppsala) & Neil Fletcher (Liverpool) – new technicians

• are getting familiar with detector in SR1• Lars is installing DCS cables

– Andy Nichols, Janet Fraser, Jason Tarrant, Patrick Werneke to advise on installation/labeling of first examples

• Routine tests after installation– Sandra/Petr and shift crews


Type II/III & PP1 - Status• INEO/Thurmelec are at present making double length harnesses with type II

cable and type III spliced, and type II connectors on both ends. – Work is proceeding to schedule (we are late)– Problems with raw cable quality so far – minor – We needed to order about 4km more type II (sector 9 longer) and 10-

20km more type III (cables generally longer than expected)– Barrel cables (sector 3) will have the type II ends remade to reduce the

tolerance on the strip back length to the JST/FCI connectors to 2mm• Samples of the FCT (type III) connector qualified (November) • 44 double harnesses of the first production batch have been tested• First barrel dPP1 are at CERN and have been verified with production

cables and the Ljubljana test box

• PPB1 – need small clamps, cable tray covers etc. (March)• PPF1 – more parts needed. Cable clamp redesigned by NIKHEF. Other

parts on order via RAL. We just received a box with parts. Patrick will try to put them together then we can run test cable

• Will install PP3s in racks to which type III cables arrive with highest priority• First cables with connectors at both end are currently being produced


Type II/III cables – InstallationTrial with test cable:• Almost all cable trays are in place and we could measured lengths of type II/III

harnesses with trial cables before cables are trimmed and FCT connectors mounted on type III ends (leaving 1.5-2 m extra length)

• http://www-atlas.lbl.gov/ciocio/SCTcables/TypeII-III/installation_test_cable/

• Found extra (more than extra) length to trim off – new lengths sent to the company– Labels are defined and have been printed and sent to company for sector 9 which is next– Mapping is defined – drawings for installation are made– Mapping for PP1 is in progress and will be transferred to Nicolas/Sigi

For installation of sector 9:100 cables will be ready on Feb16 + 1 week for Swiss Customs

Issues to pay attention to:• Grounding

– The Type II cable does not have well defined potentials before inserting into PP1 therefore recommended using a shorting plug on the cable connectors before inserting into real PP1

• ESD• DPP1 connectors

– DPP1 are used to test cables before installation (mechanical and electrical tests)– Many use cycles on the very thin gold plating could create a surface that is too abrasive for the delicate JST – Use and adapter or use a DPP1 as a test fixture only 20 times, then swap

















SCT Readout Cable Installation

SCT Readout Cables go from PPB1 and PPF1 to the SCT racks in USA 15.

PPF1 PPB1

PP1

PP2

1st layer of muon chambers

ADDITIONAL BREAK POINTS FOR INSTALLATION NOT SHOWN

To PP3 (platforms) or

directly to US(A)15

PPI1

PP1LF

From Kamil Sedlak


SCT Readout Cables and FSISCT readout cables:

• 144 cables (+2 redundant) stored in 188-1-001.

• Each cable houses 6 or 8 ribbons with 12 optical fibres. MT connectors are attached to the ribbons on both ends.

• The ends (last ~1 meter) of the cables are stripped off, bare ribbons are protected by “light duty rigging” at the ROD end, and by “plastic bubble sheet” at the PPB1/PPF1 end.

• The cables will be pulled from the detector site towards USA 15.

Light duty rigging protecting the bare ribbons. A chain is attached for convenient cable installation.

FSI Delivery Cables:• 38 cables with 6 or 7 ribbons, 8 fibres in each ribbon. • Cables are not cut to the correct lengths, they are stored in two big drums (350 and 250 kg) in building 192-S-008• Cables go from rack Y.4-11A2 to the FSI splice boxes SB1-4 located on the cryostat.


Ribbons connected to PPB1

done by Janet Fraser at UCL


SCT Readout Cables - Status• All 144+2 cables for the SCT readout and 2 long cables which will cut to 38 FSI laser

light delivery cables are at CERN• 18 readout cables (9 side A and 9 side C) will be installed in sector 9• FSI drums are moved to point 1 and cables installed directly off the drums

– Immediately after installing the cable, we plan to strip it off at the splice box end to be able to pull the cable in case of fibre damage.

– Fibres will be spooled in the splice boxes. They will be spliced together with the on-detector fibres once the ID is installed.

• Issues:• Fibre position reference points (e.g. parts of the final patch panel, well defined

position on the cryostat...) and the ribbon lengths from these reference points are almost clarified now.

• How to protect the bare ribbons in the time when other services are being installed is under discussion (ribbons for the end-cap might be protected by a garden hose, ribbons for the barrel by a temporary cover being developed by Andy Nichols).

• Stripping of the outer cladding of the cables needs to be done (at least for the barrel modules at PPB1 end). Delicate operation, as ribbons have been damaged during one of the stripping tests performed at UCL.


SCT Fibre Cable Testing• No acceptance test will be done before the cable installation to

avoid spoiling the heavy duty rigging (Cables tested by Fujikura).• After the cable installation, two test will be done:

– Test of fibre attenuation:• Check that the attenuation loss in the fibre and the MT connectors

are within spec (all ribbons in the cables will be checked).

– TOF for all TTC fibres in cables:• Measurement of the ribbon lengths.• Useful for setting up correct timing for Cosmics and the first data.

– Both attenuation and TOF test systems (described at http://agenda.cern.ch/askArchive.php?base=agenda&categ=a055165&id=a055165s0t70/transparencies ) have already been tested at CERN.


ID Heater Cable Production and Installation

Sec-5

Sec-13

Sec-9 Sec-3

Sec-7 Sec-1

Sec-11

Sec-15 Totals

Heater Pads (TE,IDEP….)

48 49 8 10 8 4 127

PIX Evaporative Power

22 22 10 11 23 88

SCT Evaporative Power

29 29 29 29 116

Thermocouple 44 44 78 80 46 58 58 408

ID Service FeedThu T 4 4 4 4 4 20

ID Service FeedThu P 4 4 4 4 4 20

56 115 82 135 136 81 87 87 779

Key To Table

Installed

Cables Ready

To be fabricated

All cables tested on productionSo far limited testing on installationThis starts this/next week.

From Steve McMahon


ID Heater Cable Production and Installation

• Production progressing well– Should be finished in time to meet installation schedule

• Installation progressing well– Testing pending and problems with visibility of labels

• Some problems with labels– Routing errors in gaps, labels being reprinted

• Missing parts for installation due March 10th in UK• Still need to consider control cables.


SCT DCS Cables

• 128 type II and 40 type IV• All cables for the barrel are in the pit• EC cables are still on surface waiting to have the

connectors protected• Type IV cables are not installed but ready to be installed• 12 cables on sector 5 and 12 cables on sector 13 are

installed • Cables from sector 5 are on HS on both sides. Cables

from sector 13 installed up to second ring of cable trays, rolled up and fixed to hand rails around cable trays

• 3 cables were damaged during installation (caught on sharp edge of cable tray)


Testing• Tester designed and provided by Ljubljana (Gregor, Erik)

– ID/S test: connectivity and cross talk– HV test: leak between HV lines and other lines– LR test: resistivity and length of cables– 3 Test boxes + 1 coming , 2 Laptops + 1 + test cables + termination

Type IV Sandra

Acceptance SCT

After Installation SCT In PP3 racks

After Connectors Petr + SCT In US/A at PS end

Type II/III Sandra

Acceptance Martin + Pepe Only samples of double harness batches of cables are tested

After Installation Petr + SCT Cables are tested row by row as they are installed on tray

PP3 Shaun

Burn-in SCT

Assembly & Installation Melbourne + SCT 2 techs required

Fibres Kamil, Bilge Martin at the ROD’s end

Heaters Steve 1 tech + SCT

DCS Richard + Lars


SHIFTS

• As of Dec 1, 212 shifts were taken by SCT collaboration mainly to test Type IV cables (acceptance test and test in PP3 racks)

• During December and January, not much Type IV testing due to the troubled Type IV delivery and installation

• People were re-directed mainly to PP3 testing & installation and Heater cables preparation (added SCT cabling activity)

• Connectors in situ (2 racks) tested as last week • 373 shifts have been taken so far

• Estimated 520 remaining shifts (half day/2 people) to carrying on with all the testing needed until the completion of SCT

services installation


Shift Count


What to do • Shift planner (developed by D. Robinson) works very well for planning

the activities and have people to sign up• http://www.hep.phy.cam.ac.uk/si-bin/sctworkplanner.cgi

– (and contact me because of unexpected changing in rate delivery/testing problems)

• What is needed to be able to take a shift:1) take the basic safety training course (level 1-2-3 video in B55)

http://safety-commission.web.cern.ch/safety-commission/SC-site/sc_pages/training/basic.html

2) Level 4 for working in US15 + Oxybox (we have them)If you have an AIS LOGIN (used for EDH documents), you can follow the course from anywhere (even outside CERN) with AIS login by accessing http://sir.cern.ch. If you have no AIS LOGIN, you need to register at the following [email protected]

3) make the access request on EDH4) get your safety boots & helmet (or borrow them)


Equipment IDs for MTF DB

• All equipment must have an MTF id to be installed in the pit (US/A or UX)

• Unique 14 character alpha numeric code• Discussion with ID people about the equipment ID for

MTF • Fully digital code from SCT (and Pixel) production DB is

acceptable• All other ID equipment should have a code like

20ISDAQ0001234• Defining Power Supply and ROD items• Each subsystem should have a contact person for MTF


LINKS Summary• SCT Cables Web page

http://www-atlas.lbl.gov/ciocio/SCTcables/• Mapping, technical appendices, cables related documents

https://edms.cern.ch/document/624679/1• Shifts

Shift planner (developed by D. Robinson) works very well for planning the activities and have people to sign up http://www.hep.phy.cam.ac.uk/si-bin/sctworkplanner.cgi

• Safety coursesLevel 1-2-3 basic course for access underground and point 1http://safety-commission.web.cern.ch/safety-commission/SC-site/sc_pages/training/basic.htmlLevel 4: with AIS login http://sir.cern.ch.

• Overall Safety and Health Procedure Document PPSPS– https://edms.cern.ch/document/593278/

• Rack Wizard– http://atlas.web.cern.ch/Atlas/TCOORD/Activities/Installation/Database/rack.htm

ID installation• Tuesday mornings, CRM (control room management) meetings https://edms.cern.ch/document/526887/1 • Wednesday mornings ID/TC installation meeting https://edms.cern.ch/document/462288/1

http://www-atlas.lbl.gov/ciocio/SCTcables/

https://edms.cern.ch/document/624679/1

http://www.hep.phy.cam.ac.uk/si-bin/sctworkplanner.cgi

http://safety-commission.web.cern.ch/safety-commission/SC-site/sc_pages/training/basic.html

http://sir.cern.ch/



Documents

14 February 2006A.Ciocio - ID Week1 SCT Services Procurement & Installation Type IV PP3 Type II-III and PP1 Fibres Heaters DCS Testing MTF Workpackage