Endcap Muon System FNAL

1
Endcap Muon System - FNAL

• Giorgio Apollinari
• Technical
• April 29-30, 1999

2
Outline - Site Manager

• Presentations
• Yuri Pishialinikov
• Lab 8 Status
• Panel/Chamber measurements
• RD - QA/QC Tools for Panel production
• Oleg Prokofiev
• PNPI Tooling Shipment/Plans for Russia
• Wire QA/QC
• Definition of HV Training (discussion)
• Giorgio Apollinari
• Gluing Proposal
• P2 (ME234/2) Production Status
• ME1/2 Status
• MP9 Setup

3
FNAL Gluing Proposal

• Propose to glue all panels (anode/cathode) and
  dry-assemble chambers before shipment to
  PNPI-IHEP.
• Scenarios
• Ship all chamber parts in kits (frames in bulk)
  without cleaning and assembly
• Clean and glue all panels at FNAL, dry-assemble
  the chamber and use final Shipping Crates for
  shipment.
• Why
• Anode Bar/Guard Strip gluing is one of the most
  critical operation in CSC construction
• Chamber Requirement Performance
• Cleanliness/Glue Amount Dark Current
• Height over Cathode Plane HV Plateau
• Uniformity of Application Gas Leak

4
FNAL Gluing Proposal

• Pros
• Effective use of tooling in one place, no need
  for shipment of assembly aids.
• Cleaning Machine
• G10 Parts Cleaning
• Glue Dispenser Machine
• Use Shipping Crate for all shipments
  (FNAL-PNPI,IHEP and PNPI,IHEP-CERN).
• Develop only one kind of bag to prevent panel
  (chamber) oxidation/deterioration for the oversea
  shipment.
• Full chamber protection available also for
  FNAL-PNPI,IHEP shipment.
• Full QA/QC of chamber/frame interface on 100 of
  the shipment. Vendor mistakes are an internal
  (USA) issue.
• Standard FNAL QA/QC on panel gluing
• Epoxy life-time under control
• QA/QC Measurements
• Good synergy between task and estimated manpower

5
FNAL Gluing Proposal

• Cons
• Cost of Tooling
• Need extra clamping tables.
• Cost of manpower.
• Cost Analysis
• Cost Increases
• 4 FNAL, 2 PNPI and 4 IHEP chambers/month
• Panel Cleaning/Chamber Assembly 5 to 6 FTE
• (2 techs / 3 years)
• Kit preparation for frames 1.5 FTE
• (0.5 techs / 3 years)
• Total Cost Increase 310-410 (FY97) k
• Cost Decreases
• Less crating (50 crates)/custom costs 50 k
• Less engineering time 0.25 FTE 25 k
• Total Cost 230 - 330 k

6
P2 Production Status

• Engineering Drawings
• Design Review February 1998
• Design Changes/Additions
• Alignment System
• Extra holes on top Cathode Panel
• Test Strip Connectors
• End Guard Strip Change (HV problem)
• Anode Protection Board
• Head-on connector
• Status
• Chamber/Common parts Released
• Frame Drawings Released (UW)
• Assembly Drawings Being Checked
• Electrical Drawings Being Compl.
• Anode Protection Boards
• Complete Chamber Electrical Scheme

7
P2 Production Status
After
Before
Clearing gas sleeves
8
P2 (and Tooling) Drawings

• DCS
• Document Control System
• Release drawings for procurement
• Official source for paper copies
• Historical record of changes controlled
  versions
• Released ( i.e. signed-off) drawings
  availability
• Paper copies
• DCS released -to-date drawings
• Only certain source of up-to-date drawings
• CAD ( and EPS ? ) Versions
• Available on the WEB at FNAL site
• Not officially maintained
• Unreleased Drawings
• Not available ( i.e. visit FNAL - IB2 )

9
P2 Production Status

• BOM (Bill Of Material)
• List of components in WBS format making up a
  chamber
• BOM ready for all chambers, largely common
• Major specifications and sub-assemblies
  identified
• Resistors (leads bending)
• Capacitors (leads bending)
• Cathode Connectors
• Anode protection boards
• Copper foils for grounding
• Minimum stock quantities (8 chambers) for common
  components

10
P2 Production Status
11
P2 Production Status

• Procurement
• Goal
• Procurement of material for
• 2 chambers P2 1 spare chamber (1st
  production chamber ?)
• 1 anode panel Insurance on assembly mistakes
  (see P3 experience) or replacement for bad
  P2 plane
• Tooling and QA/QC Tools
• Lab 8 Axxiom bits on order
• Gerber bits available
• MP9 Ready
• QA/QC Mostly available.

12
P2 Production Status

• Procurement (continued)
• Materials
• Wire Available
• Panels Available, machined by May 15th
• Small Axxiom-Gerber program changes
• Alignments plates mounting
• Extra alignment grooves (Yuri)
• Gap bars UF - May 1st
• Anode bars Artwork released
• no files to vendor (programs lost !)
• Alternative use old bars design
• _at_ FNAL by May 15-20th
• Anode Protection Boards New design just released
• _at_FNAL by May 30th
• Other Components Some available (R,C), other to
  be procured
• Start cathode assembly on May 10-15th
• Start anode assembly on May 20th
• P2 Ready June 20th - 25th

13
ME1/2 Status

• Design
• Solution of conceptual design problems
• High density at Cathode Connectors
• Location of test strip connectors
• Location of gas input-output lines
• Conceptual problems to be solved
• Alignment plate - Cathode Electronic location
  (Dave E.)
• Specific Drawings available
• Wire fixation bars
• Anode - Cathode artwork
• Drawings to be worked-on
• Gap bars , insulation strips, etc.
• HV artwork
• Anode protection board

14
ME1/2 Status

• Chamber Assembly

• Wire Fixation Bar

15
Panel Production Status

• RD
• Procured new flat platens for Plascore (cost
  decrease based on lower QA at vendor)
• Received new pilot order of 14 panels
• Measurements
• Thickness
• In agreement with Specifications
• Delamination problem (to be solved
• working on Plascore procedures)
• Flatness
• Local measurement only
• Problems meeting specs (/- 10 mils), released
  to /- 15 mils
• i.e. DG/G 2.8
• Continue production of 200 panels for FY99.

16
Setup of MP9
Present Layout
17
Setup of MP9
Planned Layout
18
Setup of MP9

• Plans for Panel Cleaning Machine
• Sample Panels Cleaned
• 3M RD Machine
• Wood-working Sander
• Electrical Properties Measurements
• Interstrip Resistance OK
• Systematic Visual Inspection
• Number of Loose Fibers/Unit Length Inconcl.
• Copper Burs Presence Both OK
• Surface Finish 3M Better
• Dust/Chip Removal Both OK
• Test Chamber Assembly
• Decision on Specifications/ Procurement Apr. 1999

19
Setup of MP9

• Activity in MP9 When
• Clean Area Material in progress
• Removal machine shop in progress
• Vacuum System Installation July (after P2)
• Complete removal of MI project July
• 2 ton crane to UF (?)
• Gas System setup May
• Assemble P2 May-June
• Assemble PNPI Tooling May or July
• Setup Area for Cleaning
• Machine June
• Travelers in progress

20
Setup of MP9

• Travelers
• Gluing
• Anode Panels Spec 5520-TR-333361
• Upper Cathode Spec 5520-TR-333362
• Inner Cathode Spec 5520-TR-333363
• Lower Cathode Spec 5520-TR-333364
• Panel Winding Spec 5520-TR-XXXXXX
• Wire gluing Spec 5520-TR-XXXXXX
• Anode Soldering Spec 5520-TR-333349
• Panel Cleaning Meas. Spec 5520-TR-XXXXXX
• Wire Tension Meas. Spec 5520-TR-333352
• HV Test (Panel) Spec 5520-TR-333351