# Presentation: 534102

## EMU - CSC Production at FNAL

**Giorgio Apollinari**
**Fermilab**
**May  8-9, 2001 -  Lehman Review**
**EMU Working Session**

## Outline

**Progress since last FNAL-Lehman Review (May ‘00)**
**Preparation Plans**
- Prototypes & Tooling for Foreign Sites
- Mechanical Integration Prototyping
**FNAL Production Activities**
- Panel production
- Chamber Production
- Chamber Validation
- Parts Shipments to PNPI/IHEP

## Preparation Plans

**Prototyping Schedule**
**ME1/2 Assembled by Jan. ‘00**
**ME2/1 Assembled by May ‘00**
**ME3/1 Assembled by Jun. ‘00**
**ME1/3 Assembled by Nov ‘00****	**
**4 Pre-production ME234/2 by Jun ‘00.**
**ME4/1 Assembled by Jun ‘01**
**Tooling Schedule**
**FNAL Tooling **
**PNPI Tooling**
- Setup in PNPI
**IHEP Tooling**
- Setup in IHEP

## FNAL Factories Status

**Panel Machining in full-speed production as of ~ Jan ‘00**
**Production goal for FY’00 obtained with the expected manpower.**
**In FY’01, the production rate is well above expectations with minimal additional manpower (3.2 FTE used vs. 2.5 FTE expected)**
**Completed machining of ME234/2 panels (FNAL Production)**
**Completed machining of ME2/1 panels (30% of PNPI Production)**
**Presently machining ME1/2 panels ( ~ 25% of IHEP Production)**

## FNAL Factories Status

**L4 Milestones**
**10 *****“completed”***** ME234/2 by end of FY00**
- Major mistake on 006 sealing
- Unsolved sealing problems on 020

**32 ME234/2 Production Chambers assembled (21%) **

## FNAL Factories Status

**Chamber Issues **** **
**Production reached full speed (4 chambers/month) in first quarter of CY01**
- 32 Chambers produced by end of Apr. ‘01.
**Recent slowdown**
- Change of Leak Rate Specifications
- 1.8 cc/min at 3.00” Water Over-Pressure
- Old Spec: 1.8 cc/min at 1.00” Water Over-Pressure
- ~20% Failure rate for Chamber produced at FNAL
- First report of leaks (~4 cc/min)  from UCLA Fast Site for chambers certified at FNAL (<2 cc/min).
- Different Measuring Procedures/Data Interpretation
- Different Tools/Enviroment
- Technical reliability of RTV Sealing (?) - Leak Rate Measurement Method (?)
- Reworks for new HV Connectors/ Chamber shipments to FAST Sites
- HV Connectors flow is starting to support the Chamber Production Rate
- Failure of Panel Cleaning machine
- “Lowest-Bidderitis” case  (80 k$ vs next lowest bidders at 200 k$).
- Machine redesigned and under part Procurement
- Panel Cleaning by Hand (limited to 1 panel/day by ES&H considerations)

## Problems 
Few chambers (including  ME234/2-006) had to be re-opened to solve an undetected short between wires and ground, or shorts between strips
6 instances of incorrectly mixed RTV (one of which, in 006, trashed the chamber)

Wire positioning and/or tension	
~4-5 problems/chamber in 001 to 011
~ 1 problem/chamber from 012
Cleaning machine is “Kaput”
“Lowest Bidderitis” case

**Few chambers (including  ME234/2-006) had to be re-opened to solve an undetected short between wires and ground, or shorts between strips**
**6 instances of incorrectly mixed RTV (one of which, in 006, trashed the chamber)**
**Wire positioning and/or tension****	**
- ~4-5 problems/chamber in 001 to 011
- ~ 1 problem/chamber from 012
**Cleaning machine is “Kaput”**
*“**Lowest Bidderitis”* case

**Chamber Production Experience (1)**

**Lesson learned**
**Chambers are completely tested from the electrical point of view before sealing**
- Cathode & Anode C
- Cathode Inter-strip R
- HV in air
**Add dye to RTV hardener**
- Adequate Sealing Capabilities of RTV/Leak Rate Measurement Method under discussion after 1.00”-3.00” Specification change
**Manufacturing Process alone is not fool-proof**
- rely totally on Purdue Wire Tension/Position tester
**Group of TD Tooling Designers and Engineers on the project, hand cleaning of panels.**

## Chamber Production Experience (2)

**(Other) Lessons**
**HV training very successful**
- Tighten requirement on HV chamber validation
**I < 1 ********A @ working Voltage**
**I<0.2 ********A @ working Voltage**

**Chamber Production Experience (2)**

**Discrepancy Report (DR) summary (ME234/2-003 to *****016 *****027) **
**Average: *****5DR/Chamber (73 DRs)*****  3.8 DR/Chamber (105 DRs)**
**Most DR: ME234/2-006 with 11 DRs**
**Least DR: *****ME234/2-014 & 016 with 1*****  ME234/2-025 with 0**
**Most Consistent Cause: Wire position**
**Most Dramatic Problem: RTV mixing**

## Chamber Testing

**3-steps testing of CSC at FNAL before shipment:**
**Components testing/measurements on Factory Floors:**
- Strips Position  & Mechanical Parameters
- Anode Panel characteristics
**Wire Position**
**Wire Tension **
**Open Air HV Testing**
**Chamber testing on Factory floor:**
- HV Training & Signal Checking
**Chamber Validation as a detector on the Cosmic Stand on first 14 Production chambers:**
**Acceptance****	****	****(i.e. are all the channels working ?)**
**Efficiency****	****	****(i.e. does the CSC see particle at the operating voltage?)**
**Gas Gain****	****	****(Sources vs. Cosmics)**
**Single wire-group trigger rate**
- Very comforting results.
- Stopped Validation at Chamber ME234/2-014. One Production ME234/2 to stay in Lab 7 for continued Integration finalization.

## Chamber Testing

**Chamber Testing**

**Chamber Gas gain uniformity measured with Cs137 source and Current on Cathodes**
**Good correlation**
**Acceptable Gas Gain Variation**
- Shims to be controlled better

**STDEV********=17%**

## Chamber Testing (2)

**Wire Tension under control **
**1 un-explained 50 ********m wire low tension (in 9 chambers; i.e. ~55 k wires)**
**Few problems on 200 ********m wire (manual installation) **
**Wire position still showing ~1-2 wire/panel outside the 350 ********m specification.**
**Manageable even after ramping up production. Technology not capable of reducing problem to 0.**
**100% QC necessary**

## Factory Manpower - FY00

## Factory Manpower - FY00 (2)

**Good Understanding of Manpower Costs at FNAL**

## Status of FNAL Proposed Activities

**Two Major Additional Activities proposed to FNAL since May ‘00:**
**Frame Parts Procurement, Handling and Shipping.**
**Integration Design, Procurement, Handling and Shipping of all Mechanical and Electrical/Electronic Integration Parts to FAST sites.**
**Plans/Scope of the work still under *****“optimization”.***
**FNAL Manpower Review by end of March approved support for Manpower until end of FY’01. **
**Frames**
**Task Redefinition: PNPI and IHEP responsible for their own Frame Machining, Inspection and Handling.**
**All frame parts shipped in bulk by FNAL at the beginning of PNPI/IHEP Production.**
**Integration/FAST Site Parts Flow**
**Approved**
**Engineering/drafting covered until end of FY01.**
**Mechanical Integration Prototypes for all types of Chambers**
**Under planning/optimization**
**Mechanical Integration Procurement for all Chambers**
**Part Handling (Mechanical, Electrical/Electr.) and Shipment to FAST Sites in FY02-04**

## Status of FNAL Proposed Activities

**Proposed Plan to L2-L3 for FNAL Activities in FY02-04 beyond what is covered under the baseline “Chamber Factory” task. **
**Under consideration**
**Next Steps**
**Plan Approval or Modification by L2-L3 Management.**
**Cost Estimate of the Approved Plan.**
**L2-L3 Management  Approval of the appropriate level of funding.**

## Factory Manpower - FY01

## Factory Manpower - FY01

## FNAL FY01 Tentative Milestones

**Scope of Work **
**under Discussion**

## FNAL FY01 Tentative Milestones (2)

**Baseline Redefinition**
**"Bulk Shipments" on schedule**

## Chamber Documentation & Shipment

**All Panels and Chambers data in FNAL-TD OnBase database.**
**Default method to transfer information.**
**Travelers and Chamber Measurements actively scanned**
**All panels measurements (strip positions) entered in Database**
**Chambers travelers scanned up to chamber ~8.**
**Early “access speed problem” hopefully fixed. **
**Shipments**
**Boxes designed and Tested by ISTA Standards**
- Design Available to IHEP/PNPI to be copied and/or modified according to their needs.
**First 10 chambers shipped to UF/UCLA.**
**More to be shown during the MP9 visit.**

## Mechanical Integration Prototyping

**ME1/2 Prototype - After Soldering**

**ME1/2 Prototype - Before Soldering**

**Wisconsin Magnet Oven**

** ****ME1/2 Prototype - After Mechanical**
** ****Assembly**

## Shipments to Foreign Sites

**Shipments**
**PNPI Chambers/Frames**
- Chamber Assembly Tooling in PNPI, setup and operational
- (Part of) FAST Site tooling at FNAL ready for shipment
- Bulk Shipments Approach
- All Chamber Common Parts (ME2/1, ME3/1 and ME4/1) and all ME2/1 Chamber Unique Parts to be shipped by Summer.** **
**IHEP Chambers/Frames**
- Chamber Assembly Tooling in IHEP, setup and operational
- (Part of) FAST Site tooling at FNAL waiting for Special Kiln-Dry wood crates.
- Bulk Shipments Approach
- All Chamber Common Parts (ME1/2, ME1/3) and 60% of the ME1/2 Chamber Unique Parts to be shipped to IHEP by the Summer.
**IHEP/PNPI Integration Shipments (*****“parts flow”*****)**
- FY02-04 Planning under Review by L2-L3 Management.

## Conclusion

**FNAL Factories**
**Activities proceeding according to plans. **
**Some “catch-up” activities and technical specification changes have caused minor delays and need to be closely monitored.**
**FNAL Shipment Activities**
**Chamber Parts Shipments proceeding with some plan changes.**
- Bulk Shipments
**Frame Parts Shipments proceeding with more substantial plan changes.**
- Bulk Shipments
- Machining/Inspection at Foreign Sites
**FAST Sites***** “Part Flow”***** Activities at FNAL under L2-L3 Management Review and waiting for plan approval and human resources funding.**