Giorgio Apollinari

1
EMU installation

• Giorgio Apollinari
• Quarterly Lehman Review
• 14th December, 2002

2
Scope of EMU Installation

• Chambers
• 396 cathode-strip chambers
• Typical size 3.3 x 1.5 m2
• Typical mass 400 kg
• Services
• Gas (Ar-CO2-CF4) Water cooling
• High voltage
• Power
• Peripheral Crates
• Testing
• Portable DAQ crate (individual chambers)
• Slice tests (sectors of chambers)

3
Chamber Installation

• Mount Chambers
• On the vertical face of each disk using posts
• At the specified ? angular rotation
• Overlap chambers on most faces
• Chamber location requirement roughly few mm from
  the trigger primitives (knowledge of location
  roughly 100-200mm)
• NO Adjustment of Chambers
• Kawasaki can drill more accurately in the disk
  face than we can measure during installation
• Drill M12 dowel holes in iron disk sectors
• Photogrammetry measurements show 0.2mm accuracy
  after assembly at CERN

4
Typical Mount
Post
5
Installation Fixture

• Installation fixture built and demonstrated at
  PSL/FNAL/CERN
• Install/remove random CSC chamber in surface hall
  SX5 or underground hall UX5
• Motorized adjustment of center of gravity
• Rotating frame (fits all size CSC chambers)
• Load test at 150
• CERN approval process
• Safety calculations accepted by TIS
• Compliance with Euro Directive 98/37/CE
• Instruction manual available
• Registered and approved for use by CERN Oct 01

6
Installation Fixture (1)
Demonstration at FNAL
Installing at CERN
7
Installation Fixture (2)
Just after Installation
Prototype CSC on YE2
8
Installation in SX5

• Begin with YE-2, then YE2 (no RPC!)
• Endcap walkways (CMS-Common Project) done
• CSC mounting posts (EMU) done
• Endcap muon shielding (before posts)
  (CMS-Infrastructure)
• Endcap connections (CMS-CI)
• Gas bulkheads done
• Piping to bulkhead (by MITEX, 80 on EMU) (CERN -
  EMU pays)
• Service boxes - HV, LV (could be added later)
  (EMU)
• Install back chambers for stations ME2, ME3 (EMU)
  feb 03
• Install cable trays (EMU)
• Connect installed CSCs with gas, water, cables
  (EMU)
• Install front ME2/1 and ME3/1 chambers
  (20-degree) (EMU)
• Connect (gas, water, cables) ME2/1 and ME3/1
  (EMU)
• Install ME2/2 and ME3/2 chambers (EMU)
• Connect all remaining gas, water, cables (EMU)

9
YE1 Problem

• Long term (up to FY 05) Installation of ME1/2,
  ME1/3 CSCs
• Following cables/services Installation for
  EE/ES/HE
• Following Installation of RE1/2, RE1/3 (RPCs)
• Prodding CERN through YE1 EDR
• Continuing task

10
Installation Sequence in SX5 (1)
Add corner posts and CSC mounts
11
Installation Sequence in SX5 (2)
Water manifold installed and 1st cable tray
Back CSCs installed and cabled, HV and LV
installed
12
Installation Sequence in SX5 (3)
20-degree CSCs installed and cabled
All CSCs installed and cabled, VME crates in place
13
YE Tower Gas Services
14
Alignment installation

• Scope
• 3 straight line monitors (SLM) per station
• 1 out of 6 chambers (ME23/2) have alignment
  mounts
• 6 link plates per station
• Procedure
• Glue island plates before installing chamber
• Attach mounting brackets and photogrammetry
  targets after cabling is complete (and tested)
• Complete SLMs and test
• Photogrammetry survey and compare with SLM results

15
Status of tasks

• Mounting Posts (EMU)
• All YE2 posts finished shipped to CERN
• YE1 posts machined, will be welded when RPC is
  approved (EDR)
• Muon Chambers
• 127 chambers finished at Fermilab (out of 148)
• 36 chambers finished at PNPI (out of 114)
• 72 chambers finished at IHEP (out of 148)
• 45 chambers have electronics assembled, tested
  shipped to CERN from USA
• Skew-clear cables (EMU)
• YE2 cables in production, some deliveries to CERN
• YE1 layout and length definitions complete,
  expect approval for production in Sept.

16
Status of tasks

• Gas System (CERN EMU)
• Contract with Mitek (Polish company)
• Installation begins in Feb 03
• All ME gas bulkheads produced shipped to CERN
• ASK DICK GAS PIPING SLIDES
• Cooling (EMU)
• All hoses and fittings (valves, couplings, flow
  restrictors, etc.) purchased and recd
• YE2 manifolds under contract - will be finished
  in 4 months
• YE1 manifold waiting for info from EE, HE, etc.
  (completely designed, except location of laterals
  (feed to individual chambers) ).

17
Cabling Commissioning

• Skewclear Cables (data)
• Length calculated in 3D CAD program, cables made
  up with specific lengths and labeled with type
  and length
• Cables mounted one at a time, starting at the VME
  crate, following along the walkways and the cable
  trays, then connecting to the chamber (leaving
  the loop of extra cable in the cable tray area)
• Labels added specifying locations at both ends at
  installation time
• HV, power cables
• Start at chamber and run to outer periphery of
  disk
• Connect to HV and LV as possible

18
EMU Peripheral VME rack
Skew Clear Cables
19
Installation Manpower

• People located at CERN
• Peter Levchenko -- physicist supervising the
  receiving, testing, cabling, and commissioning
• 6-8 Techs (PNPI, IHEP, UCLA, UC Davis, .)
• ISR receiving site
• Receive chambers, perform minimal tests to be
  sure shipping has not caused any damage
• SX5 installation site
• Team of 3 experts from Wisconsin available during
  installation windows -- mechanical installation
  (chambers, gas laterals, cooling piping, etc.)
• Cabling - 3-5 techs installing the cables

20
installation/commissioning schedule (V33)
21
General explanations

• Diamonds chambers arrive at ISR. Color coding is
  for chambers from US, PNPI, and IHEP (open
  diamonds for IHEP mean that these chambers can
  come much lateras late as the first full
  diamond)
• For the first shipments, there is one-month lag
  is built-in between arrival of chambers to ISR
  and beginning of installation at SX5. This is for
  pre-testing of chambers at ISR (chamber
  integrity, noise, connectivity). Alignment plates
  (each 6th chamber) are glued at the same time.
• Red bars SX5 installation windows open for EMU
  as of V33
• Blue bars Actual chamber installation/commissioni
  ng bursts at SX5 (stations and number of chambers
  are in the titles). These bars should be within
  installation windows. Full blue bars indicate the
  initial pace of 1 chamber per day (including
  everything). Later, bars become light bluethe
  pace should shrink by a factor of 2.
• Missing pieces
• VME and off-chamber electronics installation and
  commissioning
• Alignment sensor installation and commissioning
• Drop-dead end of all installation/commissioning
  at SX5 (arrow marks at the end of red bars of
  installation windows)
• YE December 2004
• YE- August 2005

22
EMU Commissioning

• Commissioning
• Commissioning of most of the EMU system will be
  funded in the US by the MO Phase (Maintenance
  Operation) and take place between CY03 and CY09.
• US CMS, IHEP China and PNPI Russia will share
  responsibilities for the commissioning of the
  ME2, ME3 and ME1/2-ME1/3 system commissioning.
  Dubna Russia will be responsible for the
  commissioning of the ME1/1 system.
• The MO Management team in the US-PNPI-IHEP
  Collaboration is structured along the lines shown
  on the side.

23
EMU Commissioning

• Commissioning Structure
• CSC Commissioning/Maintenance
• FEE Commissioning/Maintenance Integration
• DAQ Interface, Slice Test and On-line Database
• DCS Controls
• Alignment, Calibration Off-line Database
• EMU Commissioning Scope of Work
• Expected Deliverables from Construction phase
• Major Commissioning Deliverables
• Major Milestones

24
CSC Commissioning

• (Some of the) CSC Commissioning Goals
• Maintain and Repair CSCs on Disk
• Define Procedures for Gas and Cooling Water
  operations on installed CSCs
• Define Procedures for HV/LV operations and apply
  HV/LV to CSCs
• Portable HV/LV initially.
• Test of CSCs mounted on Disks.
• Portable DAQ initially (check for signs of life),
  Slice Test DAQ,
• Software for HV/LV Firmware.
• Setup CSCs repair procedures.
• Maintain Chamber/Cables Databases
• Establish and Maintain stock and spare
  mechanical parts at CERN.
• (Some of the) CSC Commissioning Milestones
• Minimal Testing of CSCs on disk (Start) 3/1/03
• Portable HV/LV to CSCs on disk 4/1/03
• Final HV to CSCs on disk 6/1/05
• On-line CSCs Monitoring (Programs
  Available) 6/1/04

25
FEE Commissioning

• (Some of the) FEE Commissioning Goals
• Develop power on/off Procedures
• Address System integration issues on disk (common
  noise, gourd loops, etc.)
• Most critical part of FEE commissioning
• Determine optimal AFEB thresholds, CFEB
  triggering primitive thresholds and trigger mode
• Develop methods to time in electronics and
  determine optimal timing constants
• Benefiting from cosmic m passing through CSCs
• Develop various procedures and monitoring systems
  to monitor and diagnose AFEB, CFEB, ALCT, etc.
  defining parameters and standards of operations.

26
MO Cost Estimate and Funding (1)

• Manpower and MS Cost Estimate and Funding
• High-level, Institutional Memory manpower funding
  (Engineers) allocated explicitly to EMU
  Institutions
• Funding for Foreign Collaborators allocated in
  agreement with signed MOUs
• Signed MOU with PNPI US MO to cover for cost of
  one technician and car at CERN. PNPI will provide
  3 additional technicians as contribution to the
  MO phase (300 k)
• Expected base of negotiations US MO supporting
  car at CERN for IHEP Visitors. IHEP to provide 2
  technicians as contribution to the MO phase
  (100 k)
• Low-level, technical support manpower funding
  (technicians, riggers, drafters) concentrated in
  the hands of the L2 MO Manager and maintained in
  two accounts at CERN and FNAL.
• MS funding treated similarly (funds in two
  accounts at CERN and FNAL under L2 MO Manager
  responsibility).
• Lower level justification for MS and technical
  manpower funding is provided in the MO Project
  files.
• Funding for several Software Engineers needed
  during the MO phase will be maintained at CERN
  as well to provide uniformity of quality and
  hiring practices, maybe through the CERN
  Computing Division.

27
MO Cost Estimate and Funding (2)
28
MO Cost Estimate and Funding (3)

• Total MO EMU Funding 11.0 M
• Institutional Manpower 3.4 M
• FNAL MS 3.2 M
• CERN MS 4.4 M

29
Working Scenario

• Possible CY03 Working scenario
• Completion of back-CSCs and Cables Installation
  on YE-2 disk by Mar. 03
• Water and Gas to CSCs by May-June 03
• Access to EMU Commissioning group (distinct from
  the EMU Installation group) to CSCs on disk by
  July-August 03
• Initial testing will look only for signs-of-life
  from FEE and CSCs (1-2days/CSC initially, with
  probably a rather long learning curve for the
  first 2-3 CSCs)
• Manpower Approach
• Maintain Commissioning and Installation crew
  initially separate
• Provide separate set of tools (diagnostic, DAQ
  systems, etc.) to the two teams
• Merge the two teams as Installation work and
  Parts Handling at ISR winds down
• Commissioning team
• UCLA FAST Site Personnel M.Ignatenko
• Purdue Personnel A.Bujak
• PNPI and IHEP Collaborators TBD
• Repairs
• (Difficult) CSCs repair contracted to PNPI
  assembly factory
• (Difficult) FEE repairs performed at US Home
  Institution

30
Installation/Commissioning in SX5

• Things will not go according to plan
• EMU windows will change (possibly with short
  notice)
• RPCs likely to be major delay
• Therefore
• CSC installation must be flexible -- install
  chambers as quickly as possible
• Most subsystems are late - less demand for
  facilities (cranes, cherry pickers, etc.) early,
  install chambers as they become available
• Block out 1-2 week periods with crane and
  cherry-picker control, crew available for trips
  to CERN on short notice
• Commissioning crew resident at CERN

31
Installation/Commissioning summary

• Status
• Installation fixture tested approved
• Most MS costs already spent or committed
• Manpower sufficient for installation
  commissioning
• Plans
• Install 18 chambers beginning Feb 03 (already
  delayed by 3 months)
• We will be ready to start on schedule
• Install remaining chambers as quickly as possible
• Can make up lost time quickly
• Start Minimal CSCs commissioning as soon as
  access to chambers is allowed