S. Cittolin CERN/CMS, 22/03/07 DAQ architecture. TDR-2003 DAQ evolution and upgrades
HPL for the Up-Scope of the CMS RE Low Eta as per the 1997 TDR in CMS
description
Transcript of HPL for the Up-Scope of the CMS RE Low Eta as per the 1997 TDR in CMS
Ian Crotty HPL (Bakelite) Low Eta TDR Up-Scope 05 Feb 10
HPL for the Up-Scope of the CMS RE HPL for the Up-Scope of the CMS RE Low Eta as per the 1997 TDR in CMSLow Eta as per the 1997 TDR in CMSHPL for the Up-Scope of the CMS RE HPL for the Up-Scope of the CMS RE Low Eta as per the 1997 TDR in CMSLow Eta as per the 1997 TDR in CMS
Contents
Specification
Contingency
Supply Chain
Purchasing
QA & QC
Cutting, Packing & Transport
Production Rate
Scheduling
Conclusion
Ian Crotty HPL (Bakelite) Low Eta TDR Up-Scope 05 Feb 10
CMS End-cap RPC BakeliteCMS End-cap RPC BakeliteHigh Pressure Laminate (HPL) High Pressure Laminate (HPL) CMS End-cap RPC BakeliteCMS End-cap RPC Bakelite
High Pressure Laminate (HPL) High Pressure Laminate (HPL)
• Specification was taken from the Barrel RPCs• 1-6 x10^10 Ω.cm @ 20°C. • Average roughness (Ra) = <0.2micrometre, 2mm thick• Melamine surface paper with Phenolic Bulk• Sheet dimensions according to cutting plan• Temperature coefficient w.r.t resistivity is given by the raw material and obtained for normalisation during QC
It would be good to go back and check that we are still gettingthis value for the roughness
Ian Crotty HPL (Bakelite) Low Eta TDR Up-Scope 05 Feb 10
Contingency, Past & Present for RE4Contingency, Past & Present for RE4Contingency, Past & Present for RE4Contingency, Past & Present for RE4
Chambers
An Estimate of 10% for Chamber spares gives;
72 chambers/ station/ endcap + 10% = 160 Total.
Spares in ISR today = 11.
RE2, RE3 and RE4 = 432 chambers requiring 45 – 11 = 34
Rounding this up gives puts our needs at 200.
HPL
From previous experience we have found an increase in contingency of delivered HPL quantities from 43% to 50% was necessary. This value should be retained.
Using the original 1.3m x 3.2m dimensions we will therefore need 600 sheets.
Surface area ~ 3000m2 and weight is approx 5 tons.
Financial resources necessary range from 70 kEuro to 90 kEuro dependant on the manufacturer.
Ian Crotty HPL (Bakelite) Low Eta TDR Up-Scope 05 Feb 10
HPL and Gap Supply ChainHPL and Gap Supply ChainHPL and Gap Supply ChainHPL and Gap Supply Chain
HPL ManufacturerProduction and Initial
QA & QC
Cutting to form(Riva in Milano ?)
GT (Roma)Surface treatment
with MEK
Korean Gap AssemblyShipping by Air and/or Maritime
Order from CERNTo HPL source
Final QA and QC (in
Pavia ?)
Assembly Site or SitesAssembly Site
or SitesAssembly Site or Sites
Ian Crotty HPL (Bakelite) Low Eta TDR Up-Scope 05 Feb 10
PurchasingPurchasingPurchasingPurchasing
First step is the budget.
If CERN managed then tax free
As the amount 70kEuro is > 100kchf then a divisional request is needed.
No call for tender and time for suppliers to reply.
Justification for “single source” order.
All this takes some time , we should move ahead asap
Ian Crotty HPL (Bakelite) Low Eta TDR Up-Scope 05 Feb 10
Resistivity QC inhouseResistivity QC inhouseResistivity QC inhouseResistivity QC inhouse
This device could be used to do the pre-selection
before shipping for final QC
Also used to Calibrate the Resistivity table
http://www.pv.infn.it/~vitulo/LU/misure-panpla.ppt
Ian Crotty HPL (Bakelite) Low Eta TDR Up-Scope 05 Feb 10
The Phenix QC experience July 08The Phenix QC experience July 08The Phenix QC experience July 08The Phenix QC experience July 08
Colleagues from the US have successfully used the Resistivity table that was in the Pavia University.
Nine pneumatically actuated conductive rubber pads acting as electrodes applying 1kV
Ian Crotty HPL (Bakelite) Low Eta TDR Up-Scope 05 Feb 10
A production run from 2003A production run from 2003A production run from 2003A production run from 2003
Bakelite Sheets 1.6 x 3.2m
0.00
1.00
2.00
3.00
4.00
5.00
6.00
7.00
8.00
120 130 140 150 160 170 180 190 200
Sheet No.
Res
isti
vity
x10
^10
[o
hm
.cm
]This a good run as few sheets are out side the acceptance limits of 2- 6 x 1010 Ω.cm .
Yield is 77%
Rejection rates can vary from 5 to 95% !
Ian Crotty HPL (Bakelite) Low Eta TDR Up-Scope 05 Feb 10
Yield for Phenix Yield for Phenix Yield for Phenix Yield for Phenix
There are now two levels of selection each of which will expect a certain loss. In the case of Phenix during July 2008;
1; Factory tests
Produced 410
Selected 317 Yield = 77%
2; Pavia University Jig
Received 317
Selected 262 Yield = 83%
Overall Yield = 64%
Production rates 24 – 48 sheets per day.
Only sheets that are within our spec are paid for.Phoenix and CMS use the same panel size 1.6 x 3.2m
Ian Crotty HPL (Bakelite) Low Eta TDR Up-Scope 05 Feb 10
Riva MilanoRiva MilanoCutting to FormCutting to Form
Riva MilanoRiva MilanoCutting to FormCutting to Form
CNC tooling
Cycle time 5mins/sheet HPL
QC on dimensions.
Tolerance +0mm and
-0.5mm
Checking cutting head and stability of panel
retention
Ian Crotty HPL (Bakelite) Low Eta TDR Up-Scope 05 Feb 10
Packing for International TransportPacking for International TransportPacking for International TransportPacking for International Transport
Fork lift damage
A simplified version
The Load is not attached to the base and has slipped
Looks fine but is heavy and expensive
Ian Crotty HPL (Bakelite) Low Eta TDR Up-Scope 05 Feb 10
Production or Throughput RatesProduction or Throughput RatesProduction or Throughput RatesProduction or Throughput Rates
• The production rate capability of PanPla was large.
• However the HPL has to stabilised in the Air-conditioned hall for QC were its humidity and temperature can be controlled to some degree.
• This limits the quantity per production batch to some 300 sheets, weighing in at approx 2.5 tonnes, it takes a few days to stabilise. This quantity was sufficient on occasions, if the yield was ~70%, for the 216 sheets required to build half a full station, with 30% contingency.
• Riva will take 2-5 days to cut this material and repack but will not want to work continuously as the main machine is occupied as is the floor space and personnel.
• This results in 2 boxes of some 600kg to ship to Korea where space is also limited.
Ian Crotty HPL (Bakelite) Low Eta TDR Up-Scope 05 Feb 10
ID Task Name Duration
1
2
3 Budget allocation 1 day?
4 "Single source" 10 days
5 Contract Pan Pla 10 days
6 1/4 batch delivery 20 days
7 QC in Pavia 1 5 days
8 Riva 1 5 days
9 GT 1 5 days
10 Shipping to Korea 1 10 days
11 Gap production 1 50 days
12 Shipping to assembly facility 1 10 days
13 2/4 batch delivery 20 days
14 QC in Pavia 2 5 days
15 Riva 2 5 days
16 GT 2 5 days
17 Shipping to Korea 2 10 days
18 Gap production 2 50 days
19 Shipping to assembly facility 2 10 days
20 3/4 batch delivery 20 days
21 QC in Pavia 3 5 days
22 Riva 3 5 days
23 GT 3 5 days
24 Shipping to Korea 3 10 days
25 Gap production 3 50 days
26 Shipping to assembly facility 3 10 days
27 4/4 batch delivery 20 days
28 QC in Pavia 4 5 days
29 Riva 4 5 days
30 GT 4 5 days
7/278/38/108/178/248/319/79/149/219/2810/510/1210/1910/2611/211/911/1611/2311/3012/712/1412/2112/281/41/111/181/252/12/82/152/223/13/83/153/223/294/54/124/194/265/35/105/175/245/316/76/146/216/287/57/127/197/268/28/98/168/238/309/69/139/209/2710/410/1110/1810/2511/111/811/1511/2211/2912/612/1312/2012/271/31/101/171/241/312/72/142/212/283/73/143/213/28July August September October November December January February March April May June July August September October November December January February March
24 Shipping to Korea 3 10 days
25 Gap production 3 50 days
26 Shipping to assembly facility 3 10 days
27 4/4 batch delivery 20 days
28 QC in Pavia 4 5 days
29 Riva 4 5 days
30 GT 4 5 days
31 Shipping to Korea 4 10 days
32 Gap production 4 50 days
33 Shipping to assembly facility 4 10 days
34
35 Assembly in Be, In and PK 1 50 days
36 Assembly in Be, In and PK 2 50 days
37 Assembly in Be, In and PK 3 50 days
38 Assembly in Be, In and PK 4 50 days
39 QC 1 21 days
40 QC 2 21 days
41 QC 3 21 days
42 QC 4 21 days
43 Shipping 1 10 days
44 Shipping 2 10 days
45 Shipping 3 10 days
46 Shipping 4 10 days
47 QC CERN 1 21 days
48 QC CERN 2 21 days
49 QC CERN 3 21 days
50 QC CERN 4 21 days
51 Installation YE+1 10 days
52 Installation YE-1 10 days
Installations possible in
September 09 and February 10
First HPL to Kodel in Early December 08 Four Gap
production periods
REplus 2
RE minus 2
Ian Crotty HPL (Bakelite) Low Eta TDR Up-Scope 05 Feb 10
ConclusionsConclusionsConclusionsConclusions
• The consequences of shipping around the world ,firstly within Italy then to Korea and on to the production site(s) and back to CERN are;
Many people involved, costs, errors and delaysDamage during transitLoss of control of environmental conditions.Very high lead time
• The initial outlay is high for the HPL contract• High transport costs especially by air freight.• Different QC stages require people and time.• Insurance should cover any losses but not the delay
We managed for the Baseline and we can do it again but with better organisation for the Up-scope