B02$7&&402.04.04&Cassettes · 2016-01-30 · B02$7&&402.04.04&Cassettes JamesStrait&(L3&Manager&402.04.04) Zoltan Gecse (DeputyL3&Manager) February3,&2016 2016February+3 Director's+Review+

B02-7 402.04.04 Cassettes

James Strait (L3 Manager 402.04.04)Zoltan Gecse (Deputy L3 Manager)February 3, 2016

1Director's Review -‐-‐ Endcap Calorimetry Cassettes2016 February 3

§ WBS definition

§ R&D Status and Plans for Construction

§ Basis of Estimate

§ Schedule

§ Cost and Labor Profiles

§ Risk and Contingency

§ ES&H and QA

§ Summary

2

Outline

Director's Review -‐-‐ Endcap Calorimetry Cassettes 2016 February 3

§ Jim Strait – Fermilab Scientist III§ LBNE/F Project Director 2010-2015§ Fermilab Particle Physics Division Head 2004-2008§ US LHC Accelerator Project Manager 1996-2004§ CDF End Plug Upgrade 1992-1996

§ Zoltan Gecse – Fermilab Associate Scientist§ ATLAS TRT DAQ Upgrade 2014-2015§ ATLAS Electroweak SUSY Co-convenor 2012-2013§ CMS Muon HLT Coordinator 2009-2010

3

Who Are We?


4

402.04 Organization Chart


402.04Endcap Calorimetry

Jeremiah Mans (UMN)

402.04.03Sensors and ModulesNural Ackchurin (TTU)Manfred Paulini (CMU)

402.04.04Cassettes

Jim Strait (FNAL)Deputy: Zoltan Gecse

(FNAL)

402.04.05Backing Calorimeter

402.04.06Electronics and ServicesMarkus Klute (MIT)

Institutions currently involved in the Cassette project:• Fermilab• University of Iowa• University of Minnesota• Northwestern University

WBS Definition

5Director's Review -‐-‐ Endcap Calorimetry Cassettes 2016 February 3

6

Cassettes of Forward Hadronic Calorimeter


Alveolar

§ 12 sampling layers of silicon in brass absorber§ Silicon modules assembled into cassettes§ Brass absorber forms mechanical structure

§ 12 wedges of 30 degrees each

§ 12 x 12 = 144 cassettes in each EC

Cassette dimensions: length 2.0 mwidth 0.5 -‐-‐ 1.5 mthickness 1cm Weight: ~100 kg

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Cassette Components

§ ~34 modules assembled into each cassette

§ Compact design achieved by integrating services efficiently§ CO2-based cooling including “flow-restrictors” required for system stability imbedded in copper cooling plate by means of milling and brazing two planes

§ Thin PCBs for low voltage§ Small-diameter cables for high voltage§ Thin Twinax cables for data links

Power and data links Sensor modules Cooling plate


Module Installation on Cassettes

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• M1.2 socket head cap screws (for now)• 1.5 mm locating pins• 4.5 mm mouse bites• Lost area due to mouse bites: ~0.5 %

§ Sensors and PCBs will have corner ‘mouse bites’ to access the baseplates allowing pinning/screwing for kinematic mounting to Cu cooling plate.


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402.04.04 Cassettes Summary


§ Second-stage unit of complexity in the EC design: copper cooling plate onto which are mounted the modules O(34)/cassette§ US is responsible for the FH calorimeter cassettes (288 units)

R&D Status and Construction Plans


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R&D: Electrical Services

§ Extraction of data and supplying power to the electronics in the narrow gap§ Default or “baseline scope”

o Twinax cables for the signals and PCB for the low voltage

§ “Opportunity scope”:o Combine functionality: embed transmission lines in PCBs

§ R&D will continue over the next 2 years leading to TDR (end of 2017)

1.05 m at 6.4 Gbpswith passive equalizer

2016 February 3Director's Review -‐-‐ Endcap Calorimetry Cassettes

12

R&D: Cooling

§ Cooling will be CO2 evaporative cooling.§ Viscosity of liquid CO2 is 100 times less than water.

§ CO2 leaves plate colder than when it entered, due to decrease in pressure.

§ Pressure drop increases inversely to tube radius to the power of 4.7.

§ Three full-scale test structures follow predicted temperature behavior§ Planning test with fourth structure that embeds capillary for pressure regulation


§ Building small ECAL Testbeam Prototype

§ The prototype will have fully functional two-sided cassettes. (14 cassettes of 2 sensor)

§ Learn issues of building cassettes (especially brazing of cooling plates)

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Prototype for Test Beam


§ The cassettes are made from three major subassemblies:§ Cooling plates, which will be made or procured by a university group

§ Sensor modules, which will be delivered by the Sensors and Modules (WBS 402.04.03) subproject

§ PCBs and cables to provide HV and LV and extract the signals, which will be made or procured by a university group.

§ All three subassemblies will be delivered to Fermilab (SiDet) where they will be assembled into complete Cassettes, tested, and shipped to CERN

14

Cassette Assembly


§ Cassettes will be assembled at SiDet in Fermilab

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Construction Site Setup


§ Cassette Assembly : crane, electrical connectivity tools

§ Cassette Test Stand : simplified readout in a mobile readout rack; 2 test stands for two assembly lines

§ Multi-‐cassette testing : Dedicated insulated enclosure with mounting points and dry gas ; Cooling plant

§ Cassette Repairs : access to crane ; simple electrical connectivity checkout ; optical inspection of modules

§ Repair modules : electrical equipment, optical inspection

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Construction Site Specialized Equipment


• Cassette production site ready for pilot cassette assembly: Q2 2018

• Cassette production site and procedures set up: Q1 2019

• Cassette production site and procedures qualified: Q1 2020

• 10% preproduction: Q1 – Q3 2021

• Full production: Q4 2021 – Q2 2023

Schedule Milestones


§ Cassette WBS is dominated by labor costs§ Technician labor for mounting and major steps in QC§ Labor estimate is based on similar projects such as the assembly of pixel endcaps for CMS and megatile construction for the barrel hadron calorimeter

§ M&S costs§ Cassette cost estimated based on material cost and machining costs from thermal prototypes

§ LV/data PCB costs are based on vendor quotes for preliminary designs

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Basis of Estimate


Cost and Labor Profiles


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Cost

Cost = AY $k(No Contingency)

L4 Area M&S Labor Total R&D+OPC

Cooling Plates 288 186 474 325

Data/LV PCBs 295 285 580 350

Cassette Assembly 787 2669 3457 704

Total (402.04.04) 1371 3140 4510 1379


0

200

400

600

800

1000

1200

1400

FY16 FY17 FY18 FY19 FY20 FY21 FY22 FY23 FY24

AY k$

R&D Construction

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Cost Profile


0

0.5

1

1.5

2

2.5

3

FY16 FY17 FY18 FY19 FY20 FY21 FY22 FY23 FY24

FNAL Engineer FNAL Tech University Engineer University Tech

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Labor FTE Profile


Contingency and Risk


§ The project is at a conceptual design level, hence contingency on all activities is considered to be M5/L5 (40-60%) § Technical design choice still to be made which would shift from 30° cassettes to 60° cassettes. This would not significantly affect cost of the cassettes in total or the labor required for assembly and testing. Shipping costs could increase somewhat with heavier unit items.

§ Risk § Risk analysis will be done within the next few months, well in advance of CD-1

§ Technology of cassettes is relatively well understood => do not expect major risks

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Contingency and Risk


ES&H and QA


§ Hazards or hazardous work environments§ Handling of heavy objects and usage of cranes§ Operation of electrical equipment with high voltage§ Work with high pressure CO2 cooling system

§ QA and QC areas§ Mechanical properties§ Electrical functionality§ Compliance with thermal cycling

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ES&H & QA


Summary


§ US-CMS deliverables for the HGCal Cassettes (as described in the Technical Proposal) builds from our expertise and experience from original CMS and Phase 1 upgrades§ Deliverables led by institutes with previous experience and strong infrastructures

§ Labor estimate based on similar projects such as the assembly of pixel endcaps for CMS and megatile construction for the barrel hadron calorimeter

28

Summary


Backup



BOE


Cost Details


Labor Details

B02$7&&402.04.04&Cassettes · 2016-01-30 · B02$7&&402.04.04&Cassettes JamesStrait&(L3&Manager&402.04.04) Zoltan Gecse (DeputyL3&Manager) February3,&2016 2016February+3 Director's+Review+

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