402.2.5.2.2 outer tracker modules - components mechanics ......fabricating the module mechanics for...

402.2.5.2.2 Outer Tracker Modules - Components - Mechanics (“Module Mechanics”)

Lenny Spiegel (FNAL, co-L3 for Modules)

HL-LHC CMS CD-3a Director’s Review

February 20, 2020

▪ Technical aspects▪ Context: L3 scope and U.S. Deliverables

▪ Design of Module Mechanics

▪ Technical Maturity of Module Mechanics

▪ QA/QC plans associated with Module Mechanics

▪ Managerial aspects▪ Cost, Schedule, and Risks associated with Module

Mechanics

▪ ES&H

▪ Summary

Outline

2/20/20 L. Spiegel HL-LHC CD-3a Director's Review OT L3 - Modules 2

▪ We request approval to procure the raw materials for fabricating the module mechanics for the OT upgrade prior to CD-3 approval▪ It will also be necessary to start the layup and curing of the

carbon fiber prepreg under CD-3a scope

▪ Early procurement of the mechanical components is required to avoid delaying the completion of the project

▪ The scope of the procurement includes▪ 20% of the carbon fiber prepreg needed for stiffeners and

baseplates for all Outer Tracker modules

▪ 20% of the aluminum carbon fiber needed for machining bridges and spacers for the US built Outer Tracker modules

Scope of CD-3a Procurements

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Charge #1

▪ Outer Tracker Modules L3 managers▪ Lenny Spiegel

▪ Institution: FNAL▪ Previous experience

• L3 for FPIX Electronics CMS Phase-1• Sensor R&D for the CMS Tracker project

• In charge of TOB module assembly at FNAL for the Phase-0 construction.

• Associate Head, SiDet Fabrication facility, Tevatron Detectors

▪ L3 for module assembly at FNAL (including CF layups at MAB)

▪ Meenakshi Narain▪ Institution: Brown University▪ Previous experience

• Sensor R&D for the CMS Tracker project.

• CMS L3 HCAL Database• CMS Phase-2: L2 for Physics and Performance Studies

• L3 for L1 Track Trigger for DZero

• PI for Silicon Track Trigger NSF MRI for Dzero

▪ L3 for module assembly at Brown (including Al-CF piece procurement and contracting for machining of bridges and spacers)

Biographical sketches

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Context of the Module Mechanics

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▪ There are 5592 PS modules in the TBPS and TEDD regions▪ These have 1.6, 2.6, and 4.0mm sensor separation variants

• Exploded view is for 1.6mm

▪ The US proposes to build 2500 of these (plus 10% spares)• All 3 types

▪ The CF and Al-CF piece counts are• 1.6mm: 1 CF baseplate, 6 CF stiffeners, 4 Al-CF corner spacers, and 3 Al-CF spacers• 2.6/4.0mm: 1 CF baseplate, 6 CF stiffeners, 5 Al-CF spacers

PS Module Components

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▪ There are 7608 2S modules in the OT TB2S and TEDD regions▪ These have 1.8 and 4.0mm sensor separation variants▪ The US proposes to build 2000 of these (plus 10% spares)

• Only the 1.8mm type (shown in the exploded view)

▪ The CF and Al-CF piece counts are• 1.8mm: 7 CF stiffeners and 2 Al-CF bridges

• 4.0mm: 5 CF stiffeners, 2 Al-CF bridges, and 2 Al-CF spacers

2S Module Components

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▪ At the time of the CD-1 review last October the OT module design were judged to be about 90% final.

▪ However, the designs of the mechanical components are closer to 100% complete.▪ And the proposed CD-3a scope

simply provides for the raw materials needed stiffeners, baseplates, bridges, and spacers.

▪ Although the CF prepreg will be cast into panels following reception.

Module Mechanics

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▪ Composite materials in Outer Tracker modules▪ Carbon fiber prepreg (CF)

▪ US CMS will purchase prepreg and lay up panels for all OT modules• 20% of prepreg and layups under CD-3a

▪ Prepreg procurement will be handled by Purdue▪ Layups including curing and post-curing will be split:

• 5-ply stiffeners at Purdue

• 2019 30cmx30cm panels (80% of the layup time)• 3-ply baseplates at FNAL

• 862 30cmx30cm panels

▪ Aluminum carbon fiber (Al-CF)▪ US CMS will purchase Al-CF and machine bridges and spacer for all US

modules• 20% of pieces under CD-3a

• 1 piece = 10.250” x 6.750” x 1.500”

▪ Purchasing of raw material and outsourcing of machining will be handled by Brown

• 160 pieces for US PS and 2S module fabrication needs

Scope of CD-3a and CD-3 Projects

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Charge #1

CF and Al-CF Images from Fermilab

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Cured 60cmx60cm 5-ply CF panels

3-ply CF baseplates

2S (1.8mm) Al-CF bridges

Partially consumed Al-CF piece

CF Layup Facilities

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▪ Both Purdue and FNAL have large autoclaves

▪ 3 hours @ 80 psi, 250℉

▪ 2 hours @ 360℉ post-cure

▪ The Composites Center near Purdue is quite extensive

▪ Access to undergraduates for the layups

▪ FARO laser arm for characterizing panel flatness

▪ There is a new autoclave at Fermilab in the Meson Assembly Building

▪ Very experienced technical staff

Design Considerations for Modules Mechanics

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▪ In addition to being low mass the module composite materials have also been selected for thermal properties▪ K13D2U carbon fiber prepreg

▪ 800 W/mK along the fibers

▪ Al-CF▪ CTE of 4 ppm/℃

Charge #3

▪ March 11 Procurement Readiness Review (PRR) at CERN▪ Tracker Upgrade Composite materials

▪ https://indico.cern.ch/event/886604/

▪ The review will provide a green light to purchase both the CF prepreg (full OT) and the Al-CF pieces (US)

▪ The TenCate EX-1515 Cyanate Ester has a 6-month frozen storage life so it would make sense to begin the layups as soon as possible after reception at Purdue and FNAL.

Validation of the Module Mechanics

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Charge #3

▪ There are several planned verifications of the CF panel thickness (thickness between 500 and 600μm, variation < 50μm in any given piece)▪ Deep-throat micrometer measurements▪ FARO laser arm measurements (at Purdue)▪ Micrometer measurements at CERN of individual stiffener and

baseplate pieces

Quality Assurance and Quality Control

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Charge #7

Cost and Schedule for OT Modules - Mechanics

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▪ The cost breakdown includes▪ A $477k total CD3a cost for OT Module – Mechanics

▪ $71k estimate uncertainty, mostly from the 15% on the materials▪ An M&S component of $456k

▪ CF prepreg = $379k (all Outer Tracker needs)▪ Al-CF blocks = $74k (just US CMS needs)

▪ A Labor component of $21k▪ CF layups split between Purdue and FNAL

Cost Estimate

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Charge #3

▪ Component dimensions taken from 3D models on CERN espace for the Outer Tracker project, e.g.,

▪ Quotations from the CF and Al-CF vendors along with detailed spreadsheets for quantities needed can be found in CMS docdb

▪ 13010

▪ Component estimates include▪ An allowance for lost material because of known thickness tapering (CF) or lack of material

uniformity (Al-CF) at the perimeters.▪ Further allowances for spacing between components to allow for EDM slicing, routing,

water-jet cutting of the material.▪ Detailed counts of components cross-checked with Project Cost Book

▪ 10% extra components

▪ Standard size CF panels and Al-CF blocks

Breakdown of BOE

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Charge #3

2S (1.8mm) Quantity

Outline area

(cm2) Plys

Area x plys

(cm2) Orientation

main circuit 2 12.5 2.0 57.4 5 286.9 0/90/0/90/0

spacer 2 10.4 0.5 16.0 5 79.9 0/90/0/90/0

foldover 2 9.6 0.5 14.8 5 73.9 0/90/0/90/0

service hybrid 1 12 1.5 21.4 5 107.2 0/90/0/90/0

7 547.8

cut dimensions

Fiscal Year Cost Profile

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Charge #5

Contingency Estimate breakdown

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Charge #3

▪ Although we don’t anticipate a catastrophic failure of the sole provider for the K13D2U prepreg, there are a couple of reasons we might expect delays in delivery of the material:▪ Changes in the overall market for carbon fiber

▪ For example if Boeing suddenly overcame their 747 Max issues▪ Delays from Toray’s suppliers

▪ Mitsubishi (Japan) provides the K13D2U fiber

▪ All CF vendor delay issues have been encapsulated in a single Risk▪ RT-402-2-43-D

Risks – Module Mechanics

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Charge #4,5

Min. Likely Max.

RT-402-2-

43-D

OT - Problem with

carbon fiber vendor25% 23 79 158

Risk applies to both modules and flat barrel mechanics. Consider worst case

scenario in which we need to qualify a new vendor. Prototyping, setup, and burn

rate costs (for 6 month delay) sum to $158k.

158

Cost Impact (k$) for risk

(over full lifetime of project)Risk ID Risk Title

Prob-

abilityImplications of this risk for CD-3a scope

CD-3a risk

contingency

(k$)

▪ Relationship with US and (iCMS) Tracker projects▪ Carbon fiber prepreg material will be received and baked into

30cmx30cm panels in the US▪ 5-ply 120gsm panels for PS/2S stiffeners at Purdue

▪ 3-ply 69gsm panels for PS baseplates at FNAL

▪ All of the panels will be sent to either CERN or directly to Italy for water-jet cutting into stiffeners and baseplates.

▪ This will be followed by post-processing at CERN• Scrubbing, ultrasonic cleaning, more post-curing

▪ Baseplates will be distributed to PS assembly centers and stiffeners will be sent to hybrid vendors.

▪ Aluminum carbon fiber blocks will be sent to a vendor for machining into bridges and spacers for US PS/2S modules.

▪ This will need to wait for CD-3 approval

▪ Machined components delivered to Fermilab and Brown

Schedule Overview

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Charge #5

▪ Without CD-3a funding Module Mechanics appears on the Critical Path for the completion of the US portion of the OT modules.

▪ This is driven by the Al-CF spacers but the production of CF stiffeners is equally critical (although won’t be flagged as CF panels exit P6 and module hybrids appear in the schedule).

Critical Path items for CD-3a scope

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Charge #2

▪ With CD-3a funding Module Mechanics is no longer on the Critical Path.

▪ Since the mechanical pieces are fairly low-level components of the modules and within our control, we feel there is a strong motivation to keep them off of the Critical Path.

Critical Path items for CD3a scope

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Charge #2

▪ Preliminary Hazard Analysis Report items relevant to Module Mechanics▪ Mechanical Hazards

▪ Using autoclaves for the curing and post-curing of CF panels may present some mechanical hazards associated with the high pressure and vacuum.

▪ Toxic Material Hazard▪ Some individuals may react to the cyanate ester in the prepreg as well as

fibers in both the prepreg and the Al-CF pieces

ESH specific to Module Mechanics

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Charge #8

From Toray PDS for K13D2U/EX-1515

▪ The key points are▪ Beginning the purchase of OT module composite materials will

ensure that these US responsibility items will not delay the completion of the US built modules.

▪ This can be demonstrated in P6 for the Al-CF bridges and spacers.

▪ The cost of the raw materials needed for CD-3a is well understood.

▪ The K13D2U prepreg quote is from January of this year and the Al-CF quote is from 2017.

▪ The 2S and PS module designs were judged to be close to 90% final at the time of our CD-1 review last October.

▪ A March 11 Procurement Readiness Review organized by the Tracker Project will give the final go-ahead for the purchase of CF prepreg and blocks of Al-CF material for machining.

Summary

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Charge #10

Backup

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HL-LHC Outer Tracker

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▪ 402.2.5 Modules▪ 402.2.5.1 Infrastructure

▪ Setup of the East Coast and FNAL sites for the assembly and testing of modules. Costs include labor and equipment needed to set up and maintain the centers including general cleanroom consumables, software licenses, database development and training. Also includes project-specific fixtures, jigs, and carrier plates

▪ DocDB 13008; DocDB 13009; DocDB 13002▪ 402.2.5.2 Components

▪ Includes front-end and service hybrids, CF stiffeners, CF baseplates (PS modules), and Al-CF bridges and spacers, but not sensors.

▪ DocDB 13010▪ 402.2.5.3 Assembly

▪ Assembly of PS and 2S modules including testing through burn-in with thermal cycling. Includes wire for bonding, syringes, and other items specific to the assembly process.

▪ DocDB 13012

402.2.5 WBS Structure

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▪ Here’s the charge for your reading pleasure.

▪ L3s should answer

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