US CMS Tracker Outer Barrel (TOB) Silicon Project
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Transcript of US CMS Tracker Outer Barrel (TOB) Silicon Project
CMS Si Tracker Project - US CMS Lehman Review – FNAL – May 8, 2001 - Incandela 1
US CMS Tracker Outer Barrel (TOB) Silicon Project
US CMS Tracker Outer Barrel (TOB) Silicon Project
Joe Incandela
University of California, Santa Barbara
Level 2 Manager
US CMS Silicon Tracker Project
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The PlanThe Plan
Scope has increased:• Build ~6000 modules (all of the TOB modules)
• Place them in ~700 Rods
• Fly them to CERN and install & test them
• Build the TIB cylinders and ship them to Pisa
• Help install and commission the tracker
• Beyond construction project:• Help maintain and operate the tracker
• Analyze data
• R&D for future tracker upgrades/replacements
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September ReviewSeptember Review
Project files• Resource loaded schedule
• WBS dictionary
• Cost estimates
• Basis for estimate of each task
• Contingency analysis
• Institutional responsibilities
• Task managers
PMG review Sep.14-15 (M. Crisler/chair)• Recommendations received
• Responses returned Nov. 1, 2000
PAC review Nov. 4, 2000
Approved by Director Nov. 13, 2000
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Institution Interface to Institutional Responsibilities L3 ManagerFermilab L. Spiegel Assem bly infras tructure L. Spiegel
Module assem bly L. Spiegel
Docum entation & database L. Spiegel
Tes t equipm ent setup & m aintenance S. Tkaczyk
Inner barrel cylinders D. Glenzinski
Rod assem bly B. Flaugher
Test boxes & wirebond fixtures des ign B. Flaugher
Shipping & receiving Technician TBD
UCSB J.Incandela Module repairs at UCSB C. Cam pagnari
Ins tallation & com m iss ioning at CERN J. Incandela
Dum m y rods des ign J. Incandela
Dum m y rods fabrication C. Cam pagnari
Kansas State R. Demina Probing at KSU R. Dem ina
Wirebonding & s im ple repairs at FNAL W. Kahl
Storage boxes R. Dem ina
UIC C. Gerber Burn-in of m odules at FNAL C. Gerber
Module quality tes ting C. Gerber
Testing boxes fabrication C. Gerber
Rochester P. Tipton Burn-in cooling and interlocks P. Tipton
Module inspection at FNAL Post-Doc TBD
Transport boxes des ign & fabrication P. Tipton
Kansas A. Bean Hybrid and m odule tes ting at FNAL M. Bailey
Test equipm ent & ins trum entation A. Bean
Northwestern D. Buchholz QA/QC at NU D. Buchholz
Organization in US CMSOrganization in US CMS
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Physicist ManpowerPhysicist Manpower
US CMS Sillicon Tracker Total Physicists
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Q3'03
Q4'03
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Q2'05
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% F
TE
Available
Scheduled
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Costs (FY00$)Costs (FY00$)
8 US CMS Silicon Tracker Project $3,429,715 8.1 Components $60,000 $6,0008.2 Equipment, Design, & Machining $1,600,528 8.2.1 Machine parts $310,100 $99,232 32%8.2.2 Mechanical Assembly Equipment $268,281 $95,243 36%8.2.3 Wirebonding Machinery $341,260 $45,240 13%8.2.4 Burn-in Cooling system with interlocks $133,812 $57,539 43%8.2.5 Boxes $217,204 $83,661 39%8.2.6 Instrumentation $329,871 $216,077 66%8.3 Sensor Probing $68,880 $38,573 56%8.4 Modules $1,059,312 8.4.1 Preproduction of 80 modules $69,184 $38,743 56%8.4.2 Assembly of 600 modules: ramp-up $152,495 $85,397 56%8.4.3 Assembly of 6000 modules $837,632 $469,074 56%8.5 Transportation $160,000 $100,600 63%8.6 Installation and Commissioning at CERN $303,300 $133,452 44%8.7 TIB Support Structures $108,096 $57,654 53%
Totals $3,360,115 $1,526,485 45%
520k$ of manpower at FNAL is covered by the original barter agreement between FNAL and Int’l CMS
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Schedule at ReviewSchedule at Review
Main Production Period:
~ 8 months of explicit float
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Schedule IssuesSchedule Issues
Schedule slips• Hybrids & Frames are delayed
• FEDs for testing of large quantities of FE hybrids and modules are expected to be ready in Summer of 2002
• Optical hybrids for assembly of modules into Rods will be available starting Summer 2002
Other critical items are performing better• Gantries
• PC based test stands
• Probe stations
• Sensors
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US Gantry PreparationsUS Gantry Preparations
1st Gantry at FNAL• Delivery was
delayed 2 months.
• Expect to have it operational this month or next.
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Other US ActivitiesOther US Activities
Probe station at KSU is ready to go• Waiting for first silicon which will arrive here soon
Mock-up frames for training gantries• Last minute request to our group to make these
• We completed 80 frames in early March
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Scheduled & Performed Work, Actual Work CostsScheduled & Performed
Work, Actual Work Costs
Track Record• Not really meaningful yet
• Short lever arm and recently revised schedule
• Increased manpower allocated to I&C CR: +225,038 FY01$
$0
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BCWS (K$)
BCWP (K$)
ACWP (K$)
0.00
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1.00
1.20BCWP/BCWS
ACWP/BCWP
-5.0%
0.0%
5.0%
10.0%
15.0%
20.0%
BCWP/EAC
(EAC-Base)/Base
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Tracker I&CTracker I&C
Tracker Outer Barrel (TOB)~3 Million channels
Run 2 CDF and D0 combined
CERN and USA only• USA has to contribute heavily
• Final testing and repair of Rods at CERN
• Installation of Rods in the TOB support frame
• Testing of Rods in place
• System Ops: • Software development,
determination operational settings, calibration methods, database management, data quality assurance…
CDF and D0 Experience• A direct scaling implies
many tens of physicists required for I&C and M&O.
• E.g. Continuous monitoring and analysis of data to catch and correct operational problems will require a lot of manpower
Mitigating considerations• TOB has relatively few
module types and only 2 hybrid types.
• We expect there to be a remote control room and ready access to data in the USA.
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I&C Manpower EstimatesI&C Manpower Estimates
• TOB Assembly period: 1/03 – 7/04
• Two shifts per day and several parallel efforts
• Final test/repair of rods
• Installation/test of rods
• System software development/test
• US Contribution at CERN• 5 FTE Physicists**
• 1 Technician (Rod repair - disassembly and reassembly)
** For scientists the project includes only resources for incremental cost of residence at CERN (dislocation and travel).
• TOB commissioning: 7/04 – 9/30/05
• 3 shifts per day and several parallel efforts
• Debugging/Optimization
• Online ops, calibration
• Software development for monitoring data quality and catching problems.
• Offline analysis of data
• US contribution at CERN• 7 FTE physicists**
• 1 FTE technician
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SOW 01 - SiTrkrSOW 01 - SiTrkr
Silicon Tracker SOWs FY01 -- $.8M
University of California-Santa Barbara
Fermilab
University of Illinois-Chicago
University of Kansas
Kansas State University
University of Rochester
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PlanningPlanning
•Components Schedules & Updated Milestones• Now know the sensor deliveries from tender• Other tenders will occur this year for hybrids and frames• Update milestones when all vendor schedules are known
• Plan is to have updated milestones in October 2001
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Current Schedule* Current Schedule*
*This is not official. It is our current conservative best guess.
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US PlansUS Plans
• Preparations• First gantry
• Complete installation this spring• Some Module assembly this summer• Study wirebonding with mechanical prototypes
• Resolve fixturing and module handling issues
• Prototype working modules by this Fall
• Install second gantry this Autumn• Test stands
• Obtain a pc-based test station this Summer for testing modules made here.
• Prepare a preliminary burn-in station
• Full production• Will not start until we see steady parts flow• Need to prepare final burn-in and test facility• Probable start of ramp-up is Spring/Summer 2002
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Capacity fall-back planCapacity fall-back plan
Capacity Issues• Run2b
• Large overlap at SiDet appears unavoidable
• Contingency production line at UCSB• Planning a 3rd gantry to do assembly, also wirebonding
and testing of ~2000 modules at UCSB • Additional needs: 1 gantry, 1 high-speed wirebonder
• Purchase via startup funds and exchanges with CMS
• Probably no use of contingency required
• Gain additional experienced manpower• 2-3 Faculty
• 2-3 silicon, 1 electronics engineers
• Senior researcher
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Summary & ConclusionsSummary & Conclusions
• Scope has increased
• Some components are delayed• New schedule and milestones this October
• Currently estimate 6-8 month delay for start-up of full production
• Expect significant overlap with Run 2b
• 3rd US gantry production line at UCSB • ~30% of modules, relieve strain at SiDet, help make up
lost time if necessary
• No production until component deliveries reach a steady, sustainable rate.