Design, Production,

1
Design, Production, Shipping Status at FNAL

• Nelson Chester
• Fermilab
• March 4-8, 2002
• CERN EMU Meeting

2
Outline

• Design Status
• Chamber Design
• Chamber Integration Design
• Configuration Control
• Procurement / Shipping Plans
• Chamber Related
• Integration Related
• Cooling Plates
• Other Parts
• FNAL Production Activities
• Panel production
• Chamber Production
• Configuration Releases
• Other FNAL Activities

3
Design Status

• Chambers
• ME 234/2 CC Spr. 00
• ME 2/1 CC Jan. 02
• ME 1/2 CC Nov. 02
• ME 3/1 CC Apr. 02 ?
• ME 1/3 CC Jul. 02 ?
• ME 4/1 CC Sep. 02 ?
• Work started by V. Razmyslovitch mid Feb. 02.
  Funded for 6 months (until mid
  August02)
• Probably will need longer time!!

• Chamber Integration
• CC Aug.00
• CC Dec. 01
• CC Nov. 02
• CC Apr. 02 ?
• CC Jul. 02 ?
• CC Sep. 02 ?
• Design Layout
• Prototype
• Design Finalization
• CC

4
Configuration Control

• Chamber Configuration Control
• Needed to be able to provide PNPI/IHEP drawings
  to the machine frame parts.
• Needed to allow PNPI/IHEP to start relative
  chamber production.
• Cannot finalize Chamber Configuration until
  Integration Configuration is finalized.
• Integration Configuration Control
• Needed to allow FNAL and UW to begin parts
  procurement

http//tdserver1.fnal.gov/project/uscmsemu/Config
uration_Control_Documents/Released_Configurations/
5
Configuration Control (cont.)

• Communication to Foreign Sites
• Procedure in place to let foreign sites know
  about released Configuration
• Initial released Configuration transmitted by CD.
• Foreign site responsible to update drawings in
  their possession if/when new Configurations are
  approved.
• Process (Travelers) Changes communication to
  Foreign Sites
• Procedure in place to let foreign sites know
  about Assembly process changes at FNAL.
• Initial released Configuration transmitted by CD.
• Foreign site responsible to translate and update
  travelers in their possession for their own
  purposes.

http//tdserver1.fnal.gov/project/uscmsemu/Releas
ed_Specifications/Chamber_Specifications/
6
ME234/2 Cooling Plate Procurement

• All cooling plates (150) manufactured by Unique
  and shipped to FNAL.
• Half shipped to UF
• Balance being shipped to UCR and UCLA

7
ME1/2 Cooling Plate Procurement

• All Cooling Plates Manufactured by Unique and
  Shipped to Fermilab
• Half Packed at
• Unique
• Half Packed at
• FNAL

8
ME 2/1 Cooling Plate Procurement

• Quotes have Closed!
• Unique is MOST LIKELY low bid vendor.
• Bid is 860/plate vs 710 for ME1/2 and 735 for
  ME234/2
• Larger Copper Plate must be procurred
• Different Furnace Vendor (Larger Furnace)
• Lower Quantity (38 vs 74 and 140 resp.) Tooling
  and setup amortized over smaller quantity.
• Exploring cost savings by procurring SAME Cooling
  Plates NOW for ME 3/1.
• Limited risk to place an order for these SAME
  plates.
• Belief is that ME 4/1 will also use SAME plate
  but will NOT procure now because of funding
  limits.

9
Cooling Plates Budget vs Actual Cost
10
Shipments Requested

• Integration Shipments

• At FNAL
• ME1/2 Mechanical Parts (UW)
• ME2/1 AFEB-ALCT Cables (CM)
• ME1/2 CFEB (OS)
• ME1/2 Chamber-CFEB Cables (OS)
• ME2/1 CFEB (OS)
• ME2/1 Chamber-CFEB Cables (OS)
• Default approach
• CablesMechanical parts in oversea container
  shipments.
• i.e. ME2/1 AFEB-ALCT cables with ME3/1 Chamber
  parts shipment.
• Electronic by air.
• Oleg Prokofiev now tracking boxes through FNAL.

11
PNPI Shipping Plans

• 2nd Shipment Last Week Feb. 02
• ME 3/1 Panels and Unique Parts
• ME 4/1 Unique Parts
• Remaining Tooling Test Equipment
• Production Aids
• HV Distribution Parts
• ME 2/1 Integration Cables
• ME 3/1 Integration Cables
• Integration Hardware

12
PNPI Shipping Plans

• 3rd. Shipment May June 02
• ME4/1 Panels, Unique Parts
• ME2/1 Cooling Plates (possibly ME3/1 4/1 as
  well)
• Integration Parts and Hardware
• 4th. Shipment- June, 03
• Spare Chamber Parts
• ME3/1 (4/1) Cooling Plates (if not shipped
  before)
• Integration Parts and Hardware

13
IHEP Shipping Plans

• 2nd. Shipment May - June, 02
• ME1/2 Cooling Plates
• ME1/2 Integration Parts and Hardware
• 3rd. Shipment Nov., 02
• ME1/3 Cooling Plates
• ME1/3 Integration Parts and Hardware
• 4th. Shipment June, - 03
• All remaining Parts and Hardware

14
Shipping Instructions

• Instructions published for parts shipped to
  Foreign Sites through FNAL, to be enforced by L3
  Manager (A.K. obtained collaborator agreements).
• Major points
• Pre-packed boxes not opened at FNAL.
• Full List of Parts attached on multiple sides of
  the box.
• Unit Value Weight on Outside
• Description of where the parts are to be shipped
  with reference to which chamber it is going to
  be used.
• Etc.

http//tdserver1.fnal.gov/project/uscmsemu/Release
d_Specifications/Chamber_Specifications/
15
Lab 8 Situation

• End of Jan. 2002 Panel Machining Snapshot
• (In units of Chambers) PLANNED
  MACHINED
• Ramp up (FY99) ME234/2 22 22
• ME234/2 126 122
• ME2/1 39 (?38) 36
• Production ME3/1 39 (?38) 36
• (FY00-01-02) ME1/2 74 72
• ME1/3 74 -
• (Re-Scoped) ME4/1 . 38
  . 36 .
• All Production Total 372 / 410
  324 / 324
• Labor Charged totaled 413k of a budget of 478 k
  or 86.4 spent.
• Produced panels for 324 of a planned 372
  chambers or 87.1.

16
Lab 8 Factory Status

• Panel Machining in full-speed production as of
  Jan 00
• Completed machining of ME234/2 panels (FNAL
  Production)
• Completed machining of ME2/1, ME3/1 ME4/1
  panels (98 ofPNPI Production)
• Completed machining of ME1/2 panels ( 50 of IHEP
  Production)
• Started machining ME1/3 panels (completion
  expected by July 02)
• Spares To Follow

17
Lab 8 Situation (cont.)

• LAB 8 PRODUCTION MEETS BUDGET ESTIMATES
• LAB 8 PRODUCTION MEETS TECHNICAL EXPECTATIONS
• LAB 8 PRODUCTION EXCEEDS SCHEDULE EXPECTATIONS
• Remaining Effort to Complete Panel Production
• ME 1/3 Panels 74 Chambers
• Spares (410-324-74) 12 Chambers
• Total Remaining 86 Chambers
• Cost to Complete Remaining Chambers
• 413K/324 1275/Chamber x 86 110K
• Remaining Funds
• 478K - 413K 65K 50K (addl upscope
  approval) 115K
• ESTIMATE COMPLETING WORK AHEAD OF SCHEDULE,
  MEETING TECH. SPECS., AND WITHIN APPROVED BUDGET.

18
MP9 Production Plans

• Production Requirements
• Per L2,L3 complete production by end of March
  03.
• Methodology
• Increase production rate to 5.6 chambers/month.
• 190 WFTE hours/chamber, need 8.4 FTE between Nov.
  02 and Mar. 03 to complete project.on or before
  March 03.
• Increase Production Workforce
• Will use the available visitor funding to pay for
  increase in trained MP9 assembly personnel from 7
  to 8 technicians.
• Additional funding to cover 0.4 FTE in overtime
  distributed over the remaining 15 months of
  production.

19
FNAL MP-9 Chamber Team
50 of ME234/2 Chambers Completed!
20
ME 234/2 Production at MP-9

• 75 Production Chambers assembled (52)

• One chamber to be re-built (006)
• Production Rates
• 3.25 Chamber/ month in FY01
• 5.0 Chambers / month Oct, Nov, 02
• 6.0 Chambers / month Dec. Feb. 02

21
Chamber Production Experience

• New Lessons
• Chamber cannot be sealed during transportation
• Old Lessons
• One case of bad wire
• Way wire is wound on spool affects wire tension.
• Dye added to 2-part RTV to insure good mix.

• Discrepancy Report at average level of
  3-4/chamber
• Most DR ME234/2-006 with 11 DRs
• Least DR Many Chambers with 0 DRs
• Most Consistent Cause Wire position/Wire Tension
• Most Dramatic/Scary Problem RTV mixing/Flaking
  Wire

22
FNAL FY01 Milestones
Canceled
23
FNAL FY01 Milestones (2)
24
Conclusion

• Chamber Integration Configuration Control
• Plan to Complete for ME 3/1, 4/1 and 1/3 before
  End FY 02.
• FNAL Factories
• Activities proceeding according to plans.
• Panel Production ahead of plan To finish by
  July, 02.
• Chamber Production rate increased to finish by
  April, 03.
• FNAL Shipment Activities
• Chamber Un-machined Frame Parts Shipments
  proceeding according to the new plans.
• 60 of PNPI/IHEP Shipments at destination
• FAST Sites Part Flow
• FNAL starting to receive boxes from Universities
  to be forwarded to IHEP/PNPI.
• Cooling Plate procurement proceeding slightly
  behind plan.