Sectors, Rings, Frame Assembly and Installation

1
Sectors, Rings, Frame Assembly and Installation

• July 18

2
WBS 1.1.1.1 Mechanics Part I
Center Frame Section (1)
Disk Section (2)
Disk sectors (8)
Internal End Cone (2)
Interior Barrel Layers
LBNL responsibilities shown in red (Services not
shown)
Disk Rings
3
Overview

• Costs are in FY02 K.
• All costs shown for sectors, rings and frame are
  in FY03 only.
• Disk assembly. Mounting sectors with
  modules/cables on to rings and testing.
• Disk final assembly. Putting these real disks
  into frame, testing and shipping to CERN
• Installation in FY05 only covers surface
  integration labor. Tooling for integration either
  supplied by European collaborators or will have
  already been made and shipped to CERN. Note that
  all installation costs in FY05 are currently in
  management contingency.

4
Sectors

• Deliverable 48 sectors available for experiment,
  60 will be started.
• 1.1.1.1.1 Design complete
• 1.1.1.1.2 Prototyping complete
• 1.1.1.1.3 Production
• One part made with production tooling(but not
  with fittings).
• Materials (13K) and shop labor
• All parts in hand. All tooling in hand but have
  budgeted some for maintenance/replacement of some
  parts that may wear out(2K). Supplies(2K).
  Thermal QA fixture /completionreplacement
  parts(5K). Storage boxes(1K). Parylene
  coating(3K)
• Shop labor of 210 hours.
• Other labor(see summary later in talk)
• Assembly by J. Wirth and T. Johnson(part time).
• QA by them T. Weber, students(part time)
• Schedule
• Substantial delay from problems laser welding.
• ETC02 completion date 9/27/02
• ETC03 completion date 3/31/03
• Float remaining about 1 year for production
  modules, but will need some sectors earlier for
  practicing module mounting and system tests. Not
  a problem if laser welding is successful.

5
Rings and Related(1)

• Deliverable 6 rings with mounts, insertable into
  frame available
• 1.1.1.1.1 Design
• Ring-only design is complete, including of mounts
  to frame. Remaining production design oversight
  to be completed by Hytec(10K)
• Strain-reliefs of sector tubes to ring to be
  designed J. Wirth(see summary at end)
• Ring insertion-into-frame tooling. Prototype
  completed and tried successfully but with
  different ring size. Design modifications to be
  done by F. Goozen(see summary at end).
• 1.1.1.1.2 Prototyping complete apart from
  strain reliefs, included in production for
  convenience.
• 1.1.1.1.3 Production
• Rings only(92K)
• Preproduction ring has been fabricated
  successfully. All materials in hand for
  production rings. Production contract placed but
  only costed in FY03(70K). Final
  inspection(survey) to be done at LBL(6K). Storage
  and shipping boxes(must include provision for
  sectors with real modules)(6K). Mounts to
  frame(10K)
• Strain reliefs(10K)
• 10K for materials and fabrication only. Labor to
  put on rings from J. Wirth and T. Johnson(see
  summary at end).

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Rings and Related(2)

• 1.1.1.1.3 Production(continued)
• Ring insertion(10K)
• Revised tooling(includes shop labor) for
  production rings
• Labor from F. Goozen(see summary at end)
• Schedule
• ETC02 completion date 9/27/02
• ETC03 completion date 12/15/02(rings only, which
  is what is needed for drilling holes in frame).
  6/15/03(with strain reliefs)
• Float remaining gt4 months(rings only) for
  starting dry fit of frame. About 1 year for
  production modules.

7
Frame(1)

• Deliverable support frame, three pieces. Barrel
  delivered to CERN empty. Disks active(see disk
  final assembly).
• 1.1.1.1.1 Design
• Frame only. Complete apart from production
  oversight by Hytec(70K)
• Dry fit, survey and shipping design to be done by
  F. Goozen
• 1.1.1.1.2 Prototyping complete apart from minor
  items
• 1.1.1.1.3 Production
• Frame only(121K)
• Tooling(11K). Contracts placed and will be
  delivered and costed before end FY02 apart from
  endplate tooling.
• Materials. All ordered and will be delivered by
  end of FY02.
• Assembly(110K). Contract placed. We assume all to
  be costed in FY03.
• Dry fit(5K)
• Miscellaneous parts and tooling for simple dry
  fit.

8
Frame(2)

• 1.1.1.1.3 Production(continued)
• Survey(15K).
• We dont know yet know exactly how this will be
  done
• Shipping(1K)
• Barrel only
• Disks covered under Final Assembly
• Schedule
• ETC02 completion date 4/7/03(frame only), dry
  fit complete(9/22/03)
• ETC03 completion date 4/7/03 and 9/22/03

9
Disk Assembly

• Deliverable 4 operational disks ready for
  insertion into frame
• 1.1.1.1.1 Design
• No significant design done. See labor table at
  end.
• 1.1.1.1.2 Prototyping
• None planned. Only real items.
• 1.1.1.1.3 Production
• All tooling and materials in FY04. Labor-see
  table at end.
• Sector pick up and place tooling
• Survey and storage tooling for each disk
• Test fixtures(dry/dark box, chillers, does not
  include readout electronics or power supplies)
• Storage and shipment boxes
• ETC02 estimate of 50K, not including technician
  labor still looks OK. Need more design and
  experience(system test) to update.

10
Disk Final Assembly

• Deliverable Disk regions at CERN
• 1.1.1.1.1 Design
• No significant design done. See labor table at
  end.
• 1.1.1.1.2 Prototyping
• None planned. Only real items.
• 1.1.1.1.3 Production
• We assume all tooling and materials are done in
  FY04. Labor see table
• Disk frame support, temporary cable support and
  assembly table/guides
• Cable/pipe strain reliefs
• Disk insertion tooling, including cable holding
• Testing tooling(dry box, temporary supports for
  pipes, cables)
• Shipping boxes and shipping
• ETC02 estimate of 107K, not including technician
  labor still looks OK. Requires more design and
  experience(system) test to update.

11
Disk Final Assembly

• Production(more)
• Final assembly and testing will occur in clean
  room (Bldg. 77) at LBL
• Expectation is that results from evolving system
  testing to start end this year will guide scope
  of testing during and after assembly.
• We dont understand yet how to cool any
  significant part and actually complete the final
  assembly. No evaporative cooling available at
  LBL. So we either test with temporary inlet
  cooling fittings or figure out some way to cool
  with the capillary fittings in place. Note that
  disk testing will be done with temporary fittings
  and liquid cooling.
• Conservative assumption is that we disassemble
  disks from frame and ship individually to CERN
  and then reassemble there.

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Preliminary Summary

• Significant cost increase(roughly 100K), but will
  take to October to get better
• 6 month delay in sector completion, much more
  prototype work, laser welding problems, much more
  labor required in FY03.
• Basic cost of rings and frame very close to
  estimate, but forgotten items(survey, strain
  reliefs, ) now added
• Reduced base program support at LBL projected.

13
Integration/Installation

• Initial support tube installation(barrel) in
  FY04. Final in FY05.
• Conservative assumption is that we have to put
  disks into frame at CERN
• Unpack tooling sent from US and setup up
• Unpack testing equipment sent from US and setup
  or duplicate at CERN or some combination
• Unpack disks and test each one
• Put disks into frames and test separately from
  barrels
• Integrate disks and barrels, testing(somehow) as
  we go
• Partial test of barrels disks without service
  panels
• Integrate beam pipe/service panel support
• Install service panels/PP1
• Test as one goes.
• Final 10 cold test before lowering into pit
  for installation
• Slide in, hook up and test

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FY04/FY05/FY06

• Preliminary plan produced and sent to
  Rossi/Stapnes based on this schedule. Note
  schedule is in calendar years.

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Installation Costs

• Personnel-related costs in FY02 K.
• Costs for SR building and other infrastructure
  covered under MO(we hope). No costs for CERN
  operations(cranes, consumables) yet included.

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Design Labor(1.1.1.1.1)

• Engineers, designers, engineering interns
  travel/supplies
• Includes external contracts eg. Hytec who has
  been responsible for ring and frame design
  completely.
• FY02 manpower is about(in FTE)
• 3 engineers
• 1 designer
• 1.5 mechanical engineering student(multiple
  people)
• Beam pipe support is currently separately funded
  project but only for FY02 at the moment.
• Installation is not included here.
• Increase in FY04/FY05 results from reduced
  expectations for base support, delays and better
  understanding of scope