Tracker Integration and Installation

1

• Tracker Integration and Installation
• W. E. Cooper
• 6 December 1999

2
Introduction

• A tracker integration and installation group has
  been formed within the past month.
• Manpower for design work on tracker integration
  and installation has been assumed to come
  primarily from the Central Fiber Tracker (CFT)
  and the Silicon Microstrip Tracker (SMT) groups,
  and the existing mechanical support staff.
• The need to address issues specific to completion
  of the individual detectors has limited the
  effort available to address integration and
  installation issues.
• A concerted effort by the new tracker integration
  and installation group has begun.

3
Tracker Region
4
Basic Tracker Installation Sequence at D0

• Install CFT, make all readout and purge gas
  connections, and begin check-out
• Install central silicon, connect cables, cooling,
  dry gas, monitoring, and interlocks and begin
  check-out
• Install H-disks, connect cables, cooling, dry
  gas, monitoring, and interlocks and begin
  check-out
• Perform full system checks

5
Tracker Installation Considerations

• Safety
• Procedures must be developed and documented.
• JHAs must be written.
• Personnel must receive the appropriate training
  to properly perform their work.
• ORCs must be obtained before each critical
  operation is initiated.
• Steps at D0 before CFT arrival
• Preliminary surveys are completed.
• The CFT gas system and associated lines are
  installed and tested.
• Half of the VLPC readout cassettes are installed
  and tested.
• CFT readout bundles
• Bundles to the platform are installed after the
  CFT is in place. All CFT bundles on a given face
  of the Central Calorimeter must be in place
  before silicon cables are installed on that face.

6
Tracker Installation Considerations

• Steps at D0 before silicon arrival
• The silicon cables and readout electronics are
  installed and checked from adapter boards on the
  face of the central calorimeter onward towards
  the platform.
• The silicon cooling system is installed.
• The silicon dry gas system and associated lines
  are installed and tested.
• Silicon steps at Lab C and Lab 3
• The central silicon support cylinder is
  pre-aligned with the CFT at Lab 3. A
  reproducible connection is provided.
• Central silicon modules are cabled, checked, and
  pre-aligned within the support cylinder at Lab C.
• Reproducible H-disk mounts are pre-aligned with
  the CFT at Lab 3.
• All silicon modules are fully tested.

7
Tracker Region Before and After CFT Installation
8
CFT Move and Installation at D0

• CFT Move
• The CFT remains on its nesting cart during the
  move to D0. A sheet metal enclosure and vinyl
  sheeting surround it.
• CFT Installation at D0
• Installation relies upon techniques developed for
  installation of the solenoid magnet.
• An installation I-beam is lifted by crane and
  placed through the CFT.
• Fixturing spanning between the 3 and 9 oclock
  support points is attached to each end of the
  CFT.
• Carriages are placed between the fixturing and
  the I-beam and temporarily fastened to the beam.

9
CFT Installation Fixturing
10
CFT Installation Fixturing
11
Clearances When the Solenoid Was Installed
12
CFT Mechanical Installation

• The I-beam, with the CFT as a counterweight, is
  lifted by crane, placed through the solenoid, and
  then supported from structures built up from the
  D0 center beam.
• Hydraulic jacks under each end of the I-beam
  allow vertical positioning.
• The CFT is rolled into position and lowered onto
  shim packs between brackets extending from the
  solenoid and brackets extending from the barrel 6
  to 7 CFT connecting ring.
• Purge gas lines for the CFT are connected and
  purging is initiated.

13
CFT Installation

• CFT alignment
• A survey crew or survey equipment will be needed
  during the following alignment operations
• Shim packs are adjusted to provide equal bearing
  on the four support locations and proper vertical
  and azimuthal alignment. The I-beam and its
  jacks serve as a lifting fixture for this
  operation.
• After the 3 and 9 oclock mounts have been
  adjusted, 6 oclock mounts, which position only
  horizontally, are adjusted. Position along the
  beam line is locked at only one end.
• The carriage and I-beam are removed.
• Both ends of the CFT are cabled with clear
  readout bundles.

14
CFT Installation

• Checks associated with installation
• Check-out with light pulsers commences as clear
  readout bundles are connected.
• Check-out with cosmic rays commences when
  significant portions have been connected.

15
Central Silicon Transport to D0

• Shipping container
• A padded shipping container is used to transport
  the central silicon tracker and the beam pipe
  from Lab C. Internal framing is likely to be
  needed.
• The silicon, low mass cables, and beam pipe are
  bagged as a unit within the shipping container.
  A dry nitrogen atmosphere is provided.
• Low mass cables
• The cables have already been connected to HDIs
  and anchored to the support cylinder.
• The 360 cables per end emerge in 18 bundles of 20
  cables each.
• The bundle length beyond the end of the support
  cylinder is about 78. The total cable weight
  extending beyond each end is about 15 pounds.
• Bundles are coiled into separate bags of perhaps
  9 bundles each.

16
Central Silicon Transport to D0

• Cooling manifolds
• Manifolds extend to the ends of the support
  cylinder, which holds them. They have been
  connected to modules and used during Lab C
  testing.
• Beam pipe
• The 97 beryllium beam pipe will have previously
  been installed through the silicon.
• It is supported by the end flanges of the silicon
  support cylinder. Its transverse motion is
  limited by internal dividers within the support
  cylinder.
• The beam pipe has been baked-out, leak checked,
  back-filled with nitrogen, and sealed.

17
Central Silicon Installation
18
Central Silicon Installation at D0

• Transport at D0
• A frame will be provided to lift the silicon
  support cylinder by its end flanges and support
  the bundles of low mass cables. The support
  cylinder, in turn, holds the beam pipe.
• Preparation of installation fixturing
• A 4 mm thick carbon-fiber cradle, extending
  approximately ?45o from 6 oclock, is installed
  through barrel 1 of the CFT. It rests on the CFT
  barrel 1 end rings and on an external stand built
  up from the D0 center beam.
• A plastic sheet is placed upon the cradle to aid
  in moving the silicon tracker.

19
Central Silicon Installation

• Mechanical Installation
• The silicon tracker is lifted from its shipping
  container and placed upon the installation
  cradle.
• Low mass cable bundles are transferred from the
  lifting frame to the plastic sheet on the
  installation cradle as silicon installation
  progresses.
• The plastic sheet on the installation cradle is
  drawn through the CFT carrying the central
  silicon and beam pipe with it.
• The weight of low mass cable bundles is
  transferred to brackets on the CC face once the
  silicon support cylinder nears its final
  longitudinal position.
• Upper half rings are pinned and screwed between
  the end flanges of the silicon support cylinder
  and the end rings of CFT barrel 1. The
  installation cradle is used as a lifting fixture
  during this operation.

20
Central Silicon Installation

• The installation cradle is lowered and removed.
  (Radial clearance 3 mm).
• Lower half rings are pinned and screwed between
  the end flanges of the silicon support cylinder
  and the end rings of CFT barrel 1.

21
Central Silicon Installation

• Connection of services
• Silicon cooling connections are made at each end
  of the support cylinder. Lines are anchored from
  the inner surface of CFT barrel 3, the solenoid,
  and the CC face. Thermal insulation is added.
  Leak checking of the cooling system commences.
• Dry gas lines to the central silicon region are
  connected and anchored from the inner surface of
  CFT barrel 3, the solenoid, and the CC face.
  Purging is initiated with dry air.
• Lines for dewpoint and cooling system
  temperature, flow, and pressure sensors are
  connected, anchored, and checked. Sensors are
  inter-calibrated.
• The monitoring and interlock system is checked.
• When these checks have been completed, flow of
  coolant, with the coolant temperature limited so
  that it is above the dewpoint, is begun.

22
Silicon Installation

• Beam pipe
• A dry nitrogen purge is established through the
  beam pipe as soon as the pipe is in its installed
  position. The purge must be properly vented.
• Low mass cables
• Low mass cables are dressed along the inner
  surface of CFT barrel 3 and anchored to the
  surface.
• Connecting of low mass cables to adapter boards
  is begun on one face of the CC and progresses to
  the other.
• The cables are dressed and anchored to the CC
  face as they are installed.
• HDIs are individually powered and checked as
  their cables are connected.
• F-disk radiation monitors
• Cables for radiation monitors on the F-disks are
  connected, anchored, and checked.

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Central Silicon Installation

• Central silicon check
• Temporary dry gas enclosures are installed in the
  H-disk region.
• Monitoring and interlocks are checked again.
• The coolant temperature is lowered to a
  temperature conservatively above the observed
  dewpoint of the central silicon region.
• The full central silicon system is powered and
  checked before H-disks are installed.

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H-disks Installed, ECS Moved onto Centerbeam
25
H-disk Installation

• Preparations for H-disk installation
• Power is removed from the central silicon.
• The coolant temperature is raised until it is
  conservatively above the ambient dewpoint.
• Coolant flow is halted.
• The temporary dry gas enclosures are removed from
  the H-disk region.
• H-disk installation
• H-disks are individually installed with the aid
  of a handheld installation fixture.
• Kinematic mount halves are joined to their mates
  previously installed on the inner surface of CFT
  barrel 3.
• H-disk cables, cooling lines, and dry gas purge
  lines are connected, anchored, and checked.
• Coolant flow is resumed once all H-disks have
  been installed and connected.
• Each H-disk is powered and checked.

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Silicon Installation

• Completion of installation
• Cables for radiation monitors on the H-disks are
  connected, anchored, and checked.
• Dry gas enclosures are completed.
• Sensors, monitors, and interlocks are rechecked.
• Cooldown to operating temperature and final
  check-out begin.

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Beam Pipe Connected, ECs Closed
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CFT Alignment Prior to Installation

• Survey balls mounted on the barrel 6 to 7
  connecting rings at each end of the CFT provide a
  reference system.
• Individual barrels are aligned relative to each
  other during nesting and their positions are
  measured relative to the survey balls.
• The survey balls provide the primary reference
  thereafter.
• The alignment process relies heavily upon the Lab
  3 LK coordinate measuring machine (CMM).
• Custom touch probe extensions may be needed for
  some alignment processes.

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Central Silicon to CFT Alignment

• Work at Lab 3
• The silicon support cylinder (without silicon) is
  aligned within CFT barrel 1 in Lab 3 after all
  CFT barrels have been nested.
• The work relies heavily upon the Lab 3 LK CMM.
• The reference system for module installation is
  established by balls at the ends of the support
  cylinder
• Silicon modules and cables are not present, but
  weights are used to simulate the deflections they
  would produce.
• Transverse alignment tolerance between the
  silicon support cylinder and the CFT ? 50 ?m.
• Reproducibility of alignment is set by pinning.

30
Silicon Module Installation in the Support
Cylinder

• Module installation and alignment in Lab C
• The silicon support cylinder is returned to Lab C
  and positioned on the LK CMM for module
  installation.
• Weights to simulate those of cables and modules
  are installed in the support cylinder. Weights
  are removed as modules are installed.
• Module installation progresses from z 0
  outward.
• Separable, adjustable kinematic mounts at 3, 6,
  and 9 oclock are connected as modules are
  installed.
• The kinematic mounts are adjusted to align each
  module with respect to the support cylinder to ?
  10 ?m. Alignment is performed with the aid of
  the Lab C LK CMM.

31
Silicon Module Installation at Lab C

• Connections, checks, and services
• Cooling lines and temporary cables are connected
  as modules are installed.
• An initial readout check is made as each module
  installed with cooling limited to the ambient
  dewpoint.
• The cover of the support cylinder is installed
  after all modules are in place.
• Final readout cables are installed, connected,
  and anchored.
• Individual modules are checked again as final
  cables are installed.
• When all cables are in place, module alignment is
  re-measured and adjusted.
• A temporary dry gas enclosure is installed and
  modules are checked at operating temperature.

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H-disk Alignment

• H-disk mounts and Lab 3 work
• Mounts rely upon three balls in slots to
  establish reproducibility. A single screw holds
  each separable mount assembly together.
• Reproducibility of the separable mounts is ? 3
  ?m.
• Leaf springs constrain in two directions and
  allow motion in the third.
• Mounts are brought into CFT barrel 3 using an
  installation plate and a six axis adjustment
  system.
• The Lab 3 CMM provides positioning information.
• The mounts are epoxied into place. Then they are
  disconnected so that one mount half can remain on
  CFT barrel 3 and the other can be removed along
  with the installation plate.

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H-disk Alignment

• H-disk installation at D0
• Final installation at D0 is performed with the
  aid of a hand-held lifting plate.
• Each disk is lifted into position and fastened
  with individual screws at 3, 6, and 9 oclock.
• Then the lifting plate is removed and a fourth
  screw, which aids in z-positioning only, is added
  at 12 oclock.

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Manpower for Tracker Integration and Installation

• Manpower remains to be identified by name.
  Effort listed is based upon resource needs of the
  D0 schedule.

35
Tech Effort for Tracker Integration and
Installation
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Conclusions

• A group responsible for tracker integration and
  installation has been formed.
• Much progress has been made to understand the
  steps for installing the CFT and silicon.
• Manpower remains to be identified in detail.