CMS Si Tracker Project - US CMS Meeting at Riverside – May 19, 2001 1

US CMS Tracker Outer Barrel (TOB) Silicon Project

US CMS Tracker Outer Barrel (TOB) Silicon Project

Tim Bolton

(for Regina Demina)

Kansas State University

US CMS Silicon Tracker Project

CMS Si Tracker Project - US CMS Meeting at Riverside – May 19, 2001 2

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

CMS Si Tracker Project - US CMS Meeting at Riverside – May 19, 2001 3

CMS tracker layoutCMS tracker layout

Outer barrel

CMS Si Tracker Project - US CMS Meeting at Riverside – May 19, 2001 4

Outer Barrel Space FrameOuter Barrel Space Frame

CMS Si Tracker Project - US CMS Meeting at Riverside – May 19, 2001 5

Outer Barrel RodsOuter Barrel Rods

CMS Si Tracker Project - US CMS Meeting at Riverside – May 19, 2001 6

Rod installationRod installation

CMS Si Tracker Project - US CMS Meeting at Riverside – May 19, 2001 7

Outer barrel geometryOuter barrel geometry

ModuleWidth, cm 11.8Length,cm 21# sensors 2Strip pitch, mm 140/210Thickness, mm >400# of APV25chips 6|4

layer # r, cm pitch, mm # sides # of mod/side1 75 140/210 2 6442 85 140 1 7283 95 140/210 2 8124 105 140 1 8965 115 140 1 952

total number of modules 5488

Rods# of modules 6

Outer Barrelrmin, cm 75rmax, cm 115length, cm 273

CMS Si Tracker Project - US CMS Meeting at Riverside – May 19, 2001 8

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

CMS Si Tracker Project - US CMS Meeting at Riverside – May 19, 2001 9

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

CMS Si Tracker Project - US CMS Meeting at Riverside – May 19, 2001 10

Physicist ManpowerPhysicist Manpower

US CMS Sillicon Tracker Total Physicists

0

200

400

600

800

1000

1200

1400

Q1'01

Q2'01

Q3'01

Q4'01

Q1'02

Q2'02

Q3'02

Q4'02

Q1'03

Q2'03

Q3'03

Q4'03

Q1'04

Q2'04

Q3'04

Q4'04

Q1'05

Q2'05

Q3'05

Q4'05

% F

TE

Available

Scheduled

CMS Si Tracker Project - US CMS Meeting at Riverside – May 19, 2001 11

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

CMS Si Tracker Project - US CMS Meeting at Riverside – May 19, 2001 12

US Gantry PreparationsUS Gantry Preparations

1st Gantry at FNAL• Delivery was

delayed 2 months.

• Expect to have it operational this month or next.

CMS Si Tracker Project - US CMS Meeting at Riverside – May 19, 2001 13

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

CMS Si Tracker Project - US CMS Meeting at Riverside – May 19, 2001 14

Tracker I&CTracker I&C

Tracker Outer Barrel (TOB)~3.5 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.

CMS Si Tracker Project - US CMS Meeting at Riverside – May 19, 2001 15

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

CMS Si Tracker Project - US CMS Meeting at Riverside – May 19, 2001 16

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

CMS Si Tracker Project - US CMS Meeting at Riverside – May 19, 2001 17

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 and 1 electronics engineers

• Senior researcher

CMS Si Tracker Project - US CMS Meeting at Riverside – May 19, 2001 18

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.

CMS Si Tracker Project - US CMS Meeting at Riverside – May 19, 2001 19

Back up slidesBack up slides

CMS Si Tracker Project - US CMS Meeting at Riverside – May 19, 2001 20

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

CMS Si Tracker Project - US CMS Meeting at Riverside – May 19, 2001 21

Schedule at ReviewSchedule at Review

Main Production Period:

~ 8 months of explicit float

CMS Si Tracker Project - US CMS Meeting at Riverside – May 19, 2001 22

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

$100

$200

$300

$400

$500

$600

AY

K$

BCWS (K$)

BCWP (K$)

ACWP (K$)

0.00

0.20

0.40

0.60

0.80

1.00

1.20BCWP/BCWS

ACWP/BCWP

-5.0%

0.0%

5.0%

10.0%

15.0%

20.0%

BCWP/EAC

(EAC-Base)/Base

CMS Si Tracker Project - US CMS Meeting at Riverside – May 19, 2001 23

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)

** In all cases, resources scheduled for scientists correspond to the 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

CMS Si Tracker Project - US CMS Meeting at Riverside – May 19, 2001 24

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

CMS Si Tracker Project - US CMS Meeting at Riverside – May 19, 2001 25

Current Schedule* Current Schedule*

*This is not official. It is our current conservative best guess.