A Lanaro UW Madison CMS Upgrade Week April 26-30, 2010 1 CSC Phase 1 Upgrade Installation – Logistics - Planning Armando Lanaro UW Madison CMS Upgrade

A Lanaro UW Madison CMS Upgrade Week April 26-30, 2010 1

CSC Phase 1 UpgradeInstallation – Logistics - Planning

Armando LanaroUW Madison

CMS Upgrade Week April 26-30 Cern


outline

• Phase 1 upgrade scope: ME4/2 and ME1/1 r/o electronics & motivations

• Plans for parts procurements and chamber production• Status of building 904 infrastructure and chamber factory

plans• CSC production timeline and possible installation

scenarios• Summary and Conclusions


Upgrade scope (Phase 1)

– ME4/2 re-scope: build 72 new large chambers• for high-luminosity triggering in = 1.1-1.8

– Upgrade ME1/1 r/o electronics: • coop with high rates: DCFEBs• Ungang strips to improve reconstruction for 2.1-

2.4• Restore trigger capability for 2.1-2.4: TMB• High rates of trigger stubs: MPC, CSCTF

Alexei Safonov talk


Complete the ME4 stations

R-Z cross-section “Empty” YE3 disk ready for ME4/2


Five ME+4/2 chambers installed

1 Sep 2009

ME4/2 Residual

ME4/2

Including CSC built at FNAL in 2009


ME4/2 physics motivation

Fill CSCTF efficiency gaps

Target Rate 5 kHz

The high-luminosity L1 pT trigger threshold is reduced from 48 18 GeV/c

Ingo Bloch, Norbert Neumeister, Rick Wilkinson

Vadim Khotilovich, Alexei Safonov


Plans for chamber production

• Panel production (FNAL) – need 7 panels/CSC– FR4 skins (most critical component)

• GE (old vendor) discontinued production• New vendors: Aurora Tech, US Laminate, Plascore

– Prototype built with 4 (US Laminate) + 3 (GE) panels

– Panels cutting, drilling, strip milling at FNAL (Lab 8)– Estimated cost for 550 panels (tot production) ~1.2 M$

• Chamber production-assembly-testing at CERN (b-904)


Panel production at FNAL


Panel Production at FNAL (Lab8)EMU CMS Panels production at LAB8 at FY 00 Panel' s

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Muon CMS Production Status for FY00 (ME234/2)Production Rate for GERBER

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Gerber Production Speed =13.2 panels/week

Muon CMS Production Status for FY00.

Panels Production at Axxiom.

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Goal=770 panels

DONE

Axxiom production rate = 14.1 panels/week

Production rate:

- Axxiom – 14.1 panel/week - Gerber – 13.2 panel/week - Labor – 2.2 FTE/month - QC/QA, travelers – 1.0 FTE/month

ME4/2 upgrade (72 x 7 plus spares ~550 panels)

Production time: 550/13 = 42 weeks (~1 year) technicians (3.2 FTE/year) floor manager (0.5 FTE/year) engineering support (0.25 FTE/year)

Labor: panel cutting, drilling, milling, QC/QA, packing


Chamber factory in bld. 904

Make 904 a facility for CMS upgrades:– A. Sharma has been leading a task force with the aim to organize

and schedule activities and analyze/allocate the needed resources– Cern general services, CMS TC, RPC and CSC representatives are

members of the task force and have been attending the organized meetings [http://indico.cern.ch/categoryDisplay.py?categId=45]

– 904 project lines:• Building consolidation and refurbishing• space allocation• general infrastructures and services • Safety and security• CSC and RPC factory layouts and tooling integration • Schedule and responsibilities

– Another task force, lead by D. Loveless, is addressing all issues related to the integration and infrastructure services of ME4, RE4 and the YE4 disk in UXC.


904 organization chart

Project Manager: A. Ball, A. Sharma Project Coordination: D. Hay Infrastructure Manager: A. Gaddi


Building consolidation (Cern GS responsibility)

Effort to bring the building up to the latest standards Roof, walls, floor, thermal insulation, windows

Most urgent: repair leaking sky-domes (~30 KCHF) New heating and air conditioning units Increase/revamp toilette and shower capacity to ~50 people Double access doors are not safety conform – will be replaced Create storage spaces (130 m2 platform within CSC factory area –

useful for panel storage: max load 500Kg/m2) (done)

Some of the above activities are already underway or planned

Building hand-over to subsystems by Oct-Nov ’10 – Final T,H ambient control by May ‘11


Bld 904 (today)


Space allocation

– The building is roughly split 50/50 between RPC and CSC chamber production factories for a total area of ~1000 m2 each

– Other “space sharing” issues involving the participation and cooperation of other groups and institutions are being addressed

– A storage tent (greenhouse-like ~700 m2) will be installed outside, on the back of 904, to store SX5 tooling, detector spare parts and accessories (possibly including completed/boxed CSC)

– Office space will be created in 904 and 933 (nearby barrack)

– Plans to develop a CMS control centre in 904 to allow remote

monitoring and diagnostic


Prevessin layout area

Office area Storage tent (~700 m2)


904 proposed layout (CMS Int.)


General infrastructure and services (Cern and CMS TC)

– Power network to be reassessed based on specific needs: 230/400 V-50Hz and 110V-60Hz available plus a standalone stabilized UPS system. CSC will need max ~11kW to operate the factory tooling and HV and fast site test stands

– Instrument air system capacity to be revised (6-7 bar). CSC needs high purity N2 (P=20 bar, flow~0.5m3/min) and vacuum line (panel cleaning), and Ar line (test)

– Cooling: expand existing system. CSC will not be main user (can use just a chiller)

– Gas: gas hut located outside 904 supplying primary and mixed gases to the main distribution system (inside 904). Gas types, number of lines and pick points, flow and pressure under discussion with Cern gas group.

– Machine workshop: will be setup in a corner of 904– IT network: standard socket distribution + WiFi - Remote monitoring

and diagnostic of CMS


904 Gas system• 3 months delay from conception to completion –• Preliminary cost estimate for new mixer rack (2 mixtures) 21 KChf

and pipe/distribution layout 40 KChf.• Main Distribution panel and rotameters recuperated from SX5

DRAFTRoberto Guida


Safety and security

– Smoke, fire detection and ODH safety equipment will be installed. CSC will need ODH detection in clean room due to large N2 consumption

– Building security: MIFARE card access readers and possibly security cameras (at night)

SAFETY FILE

• Risk assessments including the applicable protection measures• Technical specifications design reports if applicable • Documents and certificates related to the procurement / operation of equipment • Special criteria where applicable for the selection of equipment and protective systems• Certificate of commissioning and authorization to put equipment into service• Records of executed maintenance and inspections, malfunctions • Records of repairs and change, records of non-conformities • Records of possible stoppages in operation due to the lack of Safety• Classification of hazardous areas including drawings• Records of corrective actions • Warning Notices• Specific Safety Instructions if applicable• ..


CSC factory in bld 904

Loadiingarea

20m

Incoming parts

Packing

8m

Fast site / chamber HV test

Gas

Panel gluing area

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Automatic soldering

Assembly Panel storage Wire gluing

Strip Gluing

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Clean areaClean area

35m 12m

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Hand soldering

Storage kit preparationPanel

cleaning

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Safe area


Schedule

• Tentative start-up plan:– Shipping of tooling and chamber parts (2 containers) (June 2010)

• There are parts at FNAL for producing 3 CSC

– 904 floor occupancy (October 2010)• Organization of factory areas (storage, inventory, production, testing)

• Clean room construction

• Tooling installation and testing

– CSC factory setup readiness (+5-6 months)– Ready for launching pre-production ( May 2011)– First full pre-production chamber and test (+2-3 months)– Production of 3 CSC (ME4/2) (~Dec 2011)


Factory Tooling

List of tooling used for prototype production Automatic panel cleaning machine - not used Axiom machine (panel cutting and drilling) – restored Gerber machine (strip milling) - restored Epoxy strip gluing machine – restored Clamping tables for anode and gap bar gluing – restored Winding machine – restored Soldering machine - not used but will be restored and tested Wire spacing and tension measuring machine – restored automatic strip connectivity tester - restored Automatic wire and strip capacitance setup - restored Ionized air cleaning machine - not used Ionized air gun - restored Panel and chamber carts – restored Assembly table – restored RTV sealing equipment – restored leak test measurement device – restored gas mixture system - restored HV test stand – restored

Labor estimation that was required for tooling restoration: ~ 300 hours for Axiom and Gerber machines ~ 200 hours for the rest tooling


CSC production line - bar gluing


Winding

Semi-clean room (class 1000) – overpressure-ventilation-lighting

Cost ~20k$ (kit assembly)


Soldering (will use Panasonic soldering machine)


Completed Anode panel

Anode side HV side


Wire tension and spacing measurements (automatic)


Strip and wire capacitance measurement (automatic)


Chamber assembly, sealing, test


Chamber production timeline Breakdown time analysis from first CSC production (G. Apollinari)

Confirmed during ME4/2 prototype production at FNAL (O. Prokofiev 2009)


Timeline scenario for Project completion

T0: receive DOE approval• CSC parts procurement and panel production at FNAL

– First panel delivery to FNAL ~ 6 months from order

– 70 panels ready to be shipped to Cern in 9-10 months

– Completion of panel production at FNAL in ~12 months (rate: 14 panels/week)

• Chamber production at CERN– Start chamber production at T0 + 11 months (T1)– Complete 1 station (36 CSC) at T1 + 10 months (3-4 CSC/month)

– Complete full ME4/2 production at T1 + 20 months

Total lead time for the ME4/2 project completion is ~2.5 yearsReceiving funds of 300-400k$ for panel production will save 6-9 months


Summary and conclusion

• CMS is moving ahead with the setting up of the logistics, space and infrastructures to house the muon upgrade construction facilities in building 904

• Except for few pending issues (storage and office space) the allocation of ~1000 m2 to the CSC factory is granted by CMS

• CSC requests for services have already been submitted to the 904 project coordination

• Fall of 2010 seems to be a realistic date for beginning setting up the CSC factory area (machine & tooling, storages)

• We could envisage beginning the first prototype production in the spring 2011, and have parts to build 3 CSC

• We have spare electronics to equip 1 CSC station, thus do not need CFEBs from ME1/1

• The delivery of 36 CSC by the 2012-2013 LHC shutdown depends on getting the green light from DOE and funding