M. Gilchriese

Sectors, Rings, Frame Assembly and Installation

July 18

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WBS 1.1.1.1 Mechanics – Part ICenter Frame Section (1)

Disk Section (2)

Internal End Cone (2)

LBNL responsibilities shown in red(Services not shown)

Interior Barrel Layers

Disk Rings

Disk sectors (8)

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Overview• Costs are in FY02 $K.

• All costs shown for sectors, rings and frame are in FY03 only.

• Disk assembly. Mounting sectors with modules/cables on to rings and testing.

• Disk final assembly. Putting these real disks into frame, testing and shipping to CERN

• “Installation” in FY05 only covers surface integration labor. Tooling for integration either supplied by European collaborators or will have already been made and shipped to CERN. Note that all installation costs in FY05 are currently in management contingency.

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Sectors• Deliverable: 48 sectors available for experiment, 60 will be started.• 1.1.1.1.1 Design – complete• 1.1.1.1.2 Prototyping – complete• 1.1.1.1.3 Production

– One part made with production tooling(but not with fittings). – Materials (13K) and shop labor

• All parts in hand. All tooling in hand but have budgeted some for maintenance/replacement of some parts that may wear out(2K). Supplies(2K). Thermal QA fixture /completionreplacement parts(5K). Storage boxes(1K). Parylene coating(3K)

• Shop labor of 210 hours.– Other labor(see summary later in talk)

• Assembly by J. Wirth and T. Johnson(part time).• QA by them + T. Weber, students(part time)

– Schedule• Substantial delay from problems laser welding.• ETC02 completion date: 9/27/02• ETC03 completion date: 3/31/03• Float remaining: about 1 year for production modules, but will need some sectors earlier for

practicing module mounting and system tests. Not a problem if laser welding is successful.

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Rings and Related(1)• Deliverable: 6 rings with mounts, insertable into frame available• 1.1.1.1.1 Design

– Ring-only design is complete, including of mounts to frame. Remaining production design oversight to be completed by Hytec(10K)

– Strain-reliefs of sector tubes to ring to be designed – J. Wirth(see summary at end)– Ring insertion-into-frame tooling. Prototype completed and tried successfully but

with different ring size. Design modifications to be done by F. Goozen(see summary at end).

• 1.1.1.1.2 Prototyping – complete apart from strain reliefs, included in production for convenience.

• 1.1.1.1.3 Production– Rings only(92K)

• Preproduction ring has been fabricated successfully. All materials in hand for production rings. Production contract placed but only costed in FY03(70K). Final inspection(survey) to be done at LBL(6K). Storage and shipping boxes(must include provision for sectors with real modules)(6K). Mounts to frame(10K)

– Strain reliefs(10K)• 10K for materials and fabrication only. Labor to put on rings from J. Wirth and T.

Johnson(see summary at end).

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Rings and Related(2)• 1.1.1.1.3 Production(continued)

– Ring insertion(10K)• Revised tooling(includes shop labor) for production rings

• Labor from F. Goozen(see summary at end)

– Schedule• ETC02 completion date: 9/27/02

• ETC03 completion date: 12/15/02(rings only, which is what is needed for drilling holes in frame). 6/15/03(with strain reliefs)

• Float remaining: >4 months(rings only) for starting dry fit of frame. About 1 year for production modules.

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Frame(1)• Deliverable: support frame, three pieces. Barrel delivered to

CERN empty. Disks active(see disk final assembly).• 1.1.1.1.1 Design

– Frame only. Complete apart from production oversight by Hytec(70K)– Dry fit, survey and shipping design to be done by F. Goozen

• 1.1.1.1.2 Prototyping – complete apart from minor items• 1.1.1.1.3 Production

– Frame only(121K)• Tooling(11K). Contracts placed and will be delivered and costed before end

FY02 apart from endplate tooling.• Materials. All ordered and will be delivered by end of FY02. • Assembly(110K). Contract placed. We assume all to be costed in FY03.

– Dry fit(5K)• Miscellaneous parts and tooling for simple dry fit.

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Frame(2)• 1.1.1.1.3 Production(continued)

– Survey(15K). • We don’t know yet know exactly how this will be done

– Shipping(1K)• Barrel only

• Disks covered under Final Assembly

– Schedule• ETC02 completion date: 4/7/03(frame only), dry fit complete(9/22/03)

• ETC03 completion date: 4/7/03 and 9/22/03

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Disk Assembly• Deliverable: 4 operational disks ready for insertion into frame• 1.1.1.1.1 Design

– No significant design done. See labor table at end.

• 1.1.1.1.2 Prototyping– None planned. Only real items.

• 1.1.1.1.3 Production– All tooling and materials in FY04. Labor-see table at end.– Sector pick up and place tooling– Survey and storage tooling for each disk– Test fixtures(dry/dark box, chillers, …does not include readout

electronics or power supplies)– Storage and shipment boxes– ETC02 estimate of 50K, not including technician labor still looks OK.

Need more design and experience(system test) to update.

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Disk Final Assembly• Deliverable: Disk regions at CERN• 1.1.1.1.1 Design

– No significant design done. See labor table at end.

• 1.1.1.1.2 Prototyping– None planned. Only real items.

• 1.1.1.1.3 Production– We assume all tooling and materials are done in FY04. Labor – see

table– Disk frame support, temporary cable support and assembly table/guides– Cable/pipe strain reliefs– Disk insertion tooling, including cable holding– Testing tooling(dry box, temporary supports for pipes, cables)– Shipping boxes and shipping– ETC02 estimate of 107K, not including technician labor still looks OK.

Requires more design and experience(system) test to update.

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Disk Final Assembly• Production(more)

– Final assembly and testing will occur in clean room (Bldg. 77) at LBL

– Expectation is that results from evolving system testing to start end this year will guide scope of testing during and after assembly.

– We don’t understand yet how to cool any significant part and actually complete the final assembly. No evaporative cooling available at LBL. So we either test with temporary inlet cooling fittings or figure out some way to cool with the capillary fittings in place. Note that disk testing will be done with temporary fittings and liquid cooling.

– Conservative assumption is that we disassemble disks from frame and ship individually to CERN and then reassemble there.

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Preliminary Summary• Significant cost increase(roughly 100K), but will take to October to get better #

– 6 month delay in sector completion, much more prototype work, laser welding problems, much more labor required in FY03.

– Basic cost of rings and frame very close to estimate, but forgotten items(survey, strain reliefs, …) now added

– Reduced base program support at LBL projected.ETC02

FY03 FY04 FY05 TotalWBS Description1.1.1.1.3.1 Disk Sector 0 01.1.1.1.3.2 Disk Support Rings 0 01.1.1.1.3.3 Support Frame 130 1301.1.1.1.3.8 Disk Assembly 50 501.1.1.1.3.9/10 Final Assembly/Test 2 99 6 107

Totals 132 149 6 287

CurrentFY03 FY04 FY05 Total

WBS Description1.1.1.1.3.1 Disk Sector 77 77 From 6 month delay/laser welding1.1.1.1.3.2 Disk Support Rings 129 129 Mostly rollover of costs to FY031.1.1.1.3.3 Support Frame 142 1421.1.1.1.3.8 Disk Assembly 76 76 Remove some base program support1.1.1.1.3.9/10 Final Assembly/Test 69 69 138 Remove some base program support

Subtotals 348 145 69 562Rollover into FY03 165 165 Uncertain until October

Current total 183 145 69 397

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Integration/Installation• Initial support tube installation(barrel) in FY04. Final in FY05.

• Conservative assumption is that we have to put disks into frame at CERN

• Unpack tooling sent from US and setup up

• Unpack testing equipment sent from US and setup or duplicate at CERN or some combination

• Unpack disks and test each one

• Put disks into frames and test separately from barrels

• Integrate disks and barrels, testing(somehow) as we go

• Partial test of barrels + disks without service panels

• Integrate beam pipe/service panel support

• Install service panels/PP1

• Test as one goes.

• Final “10%” cold test before lowering into pit for installation

• Slide in, hook up and test

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FY04/FY05/FY06• Preliminary plan produced and sent to Rossi/Stapnes based on

this schedule. Note schedule is in calendar years.

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Installation Costs• Personnel-related costs in FY02 $K.

• Costs for SR building and other infrastructure covered under M&O(we hope). No costs for CERN operations(cranes, consumables) yet included.

WBS 1.1.1 Pixel System

Hours FY02($K) Travel Supplies Hours FY02($K) Travel Supplies Hours FY02($K) Travel SuppliesSystems engineer 1760 135 40 5 880 68 10 5Mechanical engineer 240 18 6 1400 107 40 10 880 68 20 5Electrical engineer 880 75 30 5 440 38 20 0Senior tech 240 20 6 880 74 30 10 220 18 10 5Junior tech 960 59 30 5 440 27 10 5

Subtotal 38 12 0 Subtotal 450 170 35 Subtotal 218 70 20

TOTAL WBS 1.1.1 50 655 308

WBS 1.1.3 RODs(Pixels only)

Hours FY02($K) Travel Supplies Hours FY02($K) Travel Supplies Hours FY02($K) Travel SuppliesElectrical engineer 300 26 10 5 300 26 10 0

Subtotal 0 0 0 Subtotal 26 10 5 26 10 0

TOTAL WBS 1.1.3 0 41 36Pixels only

FY05 FY06FY04

FY04 FY05 FY06

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Design Labor(1.1.1.1.1)• Engineers, designers, engineering interns + travel/supplies

• Includes external contracts eg. Hytec who has been responsible for ring and frame design completely.

• FY02 manpower is about(in FTE)– 3 engineers

– 1 designer

– 1.5 mechanical engineering student(multiple people)

• Beam pipe support is currently separately funded project but only for FY02 at the moment.

• Installation is not included here.

• Increase in FY04/FY05 results from reduced expectations for base support, delays and better understanding of scope

Base Project Base Project Base Project Base ProjectCurrent WBS 1.1.1.1.1 287738 452819 318642 308656 264335 186684 174013 42805ETC02 WBS 1.1.1.1.1 458000 304000 75000 0Increase 0 0 111684 42805

Current Beam Pipe 53726 84127 57658 25000Beam Pipe 65000 ? ? ?

FY02 FY03 FY04 FY05