HF UPGRADE PROJECT
Y. Onel PM
Sept 17, 2012
1
Recent Highlights and News-I
•
•
•
•
•
The PMT deliveries are now completed. The PMT and Base Boards System tests with a QIE
system has started at CERN-904.
We have approved the Base Board Production. (Reports from IOWA and CERN Tests are
available)
Worked on the New HV system and formed a committee to evaluate the RFP responses..
Received a detailed report from German and Alexi. Both power supplies (CAEN and
Bulgarian) were tested and evaluated at CERN E-pool using professional equipment and
high expertise level of pool technicians.
The HV RFP and decision committee members are: Germain, Alexi, Ianos, S.Los, M.Miller,
D.Winn from HF and Magnus and S. Lusin from CMS Coordination. The charge to this
committee is written and we had our committee meeting on Friday August 3rd. The
information provided by the HF Upgrade group was well received. There were some
questions regarding Dynode 9-10 powering “Synchronization “ in the base board –S.Los has
responded to this question. The decision is taken by this committee and we received the final
recommendations by the PRR Committee to with CAEN. I have formed a sub-committee to
prepare this purchase thru CAEN and CERN E-pool and members are S.Lusin, German and
Alexi.
We have decided on the shield length- 54 mm (looks good !! the presentation by Ianos
during HF meeting on May 14th ) and got confirmation by Pawel. Mike Fountain has started
with the production.
2
Recent Highlights and News-II
There is an agreement for a new cable purchases– Thanks Chris Tully, Jeremy
Mans and Pawel De Barbaro for this. There is also a strong support from
Austin and Magnus on this. Special thanks to Joel helping on this.
HF new front end integration was presented by Ianos to the HCAL as well as
to the CMS TC. The HF Electronics Packaging as well as the agreement within
HCAL that we should pursue the Winchester Cables presented by Terry Shaw.
Terry Shaw and Ianos have finalized the specs and they will be getting the
quotes soon.
Developing our “Project Org Chart” adding Brazilian Universities and ITU,
Istanbul. Alberto Santoro and Gilvan-Augusto Alves are named as Co-L2’s for
Brazil in our org chart. E.Gulmez BU-Istanbul is L2 for Turkey.
We were reviewed by the USCMS on August 31st.
3
PMT Deliveries
• We have all the PMT’s delivered and have the data---- our group is rechecking all the parameters of these characterization measurements.
The data will then go to Ugur Akgun for his final check and authorization to
load on the DB. The DB loading will be done by George and Garrett and I am
assuming that this will take a couple of days.
• The PMT's are shipped regularly to CERN. We have an automated shipping
procedure from Iowa Shipping, Customs and CERN receiving. Several
people are on this e-mail tracking program list from Iowa and CERN Site
and monitoring the shipping and delivery.
• We stopped our shipping for about 2 weeks in August 6th since there was
a concern at CERN receiving our PMT's securely. The total shipped PMT's
to CERN on September 11 was 1117/1800. We are keep shipping daily
from Iowa to CERN. Our ast day of shipping from Iowa is on October 15th
hence hoping to complete our 1800 PMT shipping task by that day.
4
HCAL MILESTONES
• HF PMT's are shipped to CERN
• HF PMT Boards QC testing 100% at Iowa
All done, tested and delivered to CERN
10/15/2012
11/1/2012
12/7/2012
(expecting a delay for the production of the base and adaptor boards which
includes 20% spares. However we expect that 216 will be available by
January 10 to populate all of the ROBOXes).
• Sergey will receive the boards on Sep. 26, and have something ready in
hand to send to Iowa on 27th. (about 12 boards) Iowa will do a fast QC
tests, so Oct. 02 they'll be shipped to CERN via International High
Priority Fedex.
After which:
• 25% - at CERN by Oct.31
• 50% - by Nov. 31
• 75% - by Jan. 10
• 100% - by Feb. 10 (Base boards will be delivered paired with Adapter
5
boards).
HF Schedule
6
Milestones 2012
HF UPGRADE PROJECT MILESTONS
•
•
•
•
•
•
•
•
•
PMT Testing 50% Complete 1/1/2012
Production Readiness Review 1/12/2012
New YETS 2012 ROBOX manufactured, tested and installed in CMS 2/17/2012
New cable purchase decision 2 or 4 channel 7/1/2012
Start of CMS 2012 Shutdown
2/11/2013
Equip ROBOX test stands at SX5
1/26/2013
Gather Miscellaneous Hardware/Equipment for in-situ HF Testing in Garages 1/26/2013
Install Miscellaneous Hardware/Equipment for in-situ HF Testing in Garages 2/22/2013
HF Plus Moved into Garages
3/7/2013 TO BE CHECKED
•
HCAL INTERNAL MILESTONES
•
•
•
•
•
•
New HV system purchase decision
HF PMT characterization and testing 100% done
HF PMT's are shipped to CERN
HF PMT Boards QC testing 100% at Iowa
Start of the HF ROBOXes shipping to CERN
HF PMT's are shipped to CERN
8/15/2012
10/1/2012
10/15/2012
11/1/2012
11/1/2012
10/15/2012
7
PCB production
12x Jumper base board production/checking
jumper board testing
PCB production
Board assembly/testing
Testing and QC at Iowa
First shipment of PCB's to CERN
50% board production done
All done, tested and delivered to CERN
3/1/12 --- 4/15/12
4/15/12 ---5/15/12
5/15/12—6/15/12
6/15/12– 12/1/12
6/30/12 - 7/15/12
7/31/12 (Int. Milestone)
10/1/12 (Int. Milestone)
12/7/12 (Int. Milestone)
SL
SL, IS, AM
SL
SL
MM, JC, DS, ZJ, GF, JK
ZJ
SL
SL
8
PMT's
Delivery dates at CERN
Set 1
05/15/12
Set 2
06/01/12
Set 3
06/15/12
Set 4
07/01/12
Set 5
08/01/12
Set 6
08/14/12
Set 7
09/01/12
Set 8
09/14/12
9
Test stand setup
Test new box ( set-up new ROB)
Produce and assemble test equip
Establish Testing Procedures
Produce Test stand equipment
4/23/12 - 5/15/12
3/31/12 - 6/30/12
4/23/12 - 7/31/12
4/15-6/30
IS, AM
IS, MF, PD, TK
AM, IS, AP
IS, MF, PD, TK
AM Tests new Box
New ROBOX at 904- operating
Move New ROBOX to SX5
Test Stands at SX5—operating
5/15 - 6/7/12
7/31/12 - 8/31/12
1/26/13
2/28/13
AM, HB, EB
AM, IS, AP, GA, YG
AM, IS, AP, GA, YG
AM, IS, AP, GA, YG, SD,
YOz, FO, SS, SC, NB
Adding two students
Marcos and Thiago from
Brazil.
10
ROB mechanics
Finalize Shield dimensions
All materials ordered
Start shipment to CERN
CERN P5 Setup
HF+ mechanics pre-assembly
ROB Completion Dates
25% completion
50% completion
75% completion
100% completion
Production contingency
04/01/12 - 05/14/12
ZJ, ET, GF, JC, JK, DS
09/15/12
11/14/12 - 12/01/12? Olga, TK, PD, (+2 crews x2)
12/1/12 - 03/01/13 Olga, TK, PD, (+2 crews x2)
05/01/12 - 06/31/12
07/01/12 - 08/31/12
09/01/12 - 10/31/12
11/01/12 - 12/21/12
12/22/12 - 02/28/13
11
Assembly and Testing
Base board population
learning/training
07/31/12 - 08/21/12
AM, IS, DK, MK, OK
HF+ Q1 (27)
08/22/12 - 09/07/12
HF+ Q2 (54)
09/07/12 - 09/22/12
AM, IS, FO, EA, MK, OK, EE,
OO, BU, MY, SD, YOz, HO,
KD
HF+ Q3 (81)
09/22/12 - 10/07/12
HF+ Q4 (108)
10/07/12 - 10/22/12
HF- Q1 (135)
10/22/12 - 11/07/12
HF- Q2 (162)
11/07/12 - 11/22/12
HF- Q3 (189)
11/22/12 - 12/07/12
HF- Q4 (216)
12/07/12 - 12/22/12
Populate and test baseboards
12
Activities on HF (HF+ HF-)
HF +
HF+ ROB’s out
2/11/13 - 02/25/13
Disassemble
2/26/13 – 4/12/13
Reassemble + testing
4/13/13 – 2/1/14
“Integration”/commissioning
3/1/14 – 5/1/14
HF+ Up
9/10/14 - 9/21/14
HF- ROB’s out
2/26/13 – 3/27/13
Disassemble
3/28/13 – 5/31/13
Reassemble + testing
6/01/13 – 3/1/14
“Integration”/commissioning
3/1/14 – 5/1/14
HF- Up
9/18/14 – 9/30/14
HF -
~4 months contingency
13
Integration group -Milestones
•
•
•
•
•
•
•
LS1 CMS Open 2/11/13 -11/24/14
CMS Ready for Beam 11/24/14
HF PMT replacement 2/27/13 – 3/25/14
HF out of Garage 7/23/14 - 7/23/14
HF Down after MMT 8/20/14 – 9/02/14
HF +Z Up 9/10/14 9/21/14
HF –Z Up 9/18/14 – 9/30/14
14
Gantt Chart Integration group
15
16
TC Schedule LS1
Date
2/11/13
2/11/13
2/18/13
2/19/13
2/20/13
2/20/13
2/21/13
2/21/13
2/25/13
2/27/13
2/27/13
3/12/14
8/20/14
9/11/14
11/5/14
Task
Install HFs tracking system
Remove HF strain sensor fibers
Open HF+ T2 BSC PLT
Prepare+lower HF+on 3 risers
lower HF+ to ground level
Open HF- T2, BSC +prepare for lowering
lower HF- to ground level
lower HF on 2 risers
Move HF+ in garage
Move HF- in garage
Replace HF pmts
Insert HF/CT2-Z BP
Lower HF-Z
Bring HF-Z to normal position + install T1-Z
CMS ready for beam
17
HF Schedule Gantt Chart
18
HF Upgrade Project Funding FY 2013
• We provided an excel file describing of our request
for the LS1 operations and the details of new HV
system cost estimate.
• Need new HV budgeted in the project files
• Need new cables budgeted in the project files
• Need a minimum of 200 additional PMT’s to meet
DOE “Spare” 15% guidelines LS1 2013-14 ( US and
International collaborators ??)
19
Cable & PMTs
Cable Purchases (2 Anode Readout)
PMT Box Pigtails
350
$216.75
$75,862.50
* ~10% Spares Included
5m Cables
350
$505.14
$176,799.00
* ~10% Spares Included
Adapter Cables
350
$191.94
$67,179.00
* ~10% Spares Included
PC Board Connectors
360
$250.00
$90,000.00
* ~10% Spares Included
2
$7,500.00
$15,000.00
*4 Weeks test for 350 cables
1
$21,000.0
$21,000.00
*FY 2012
Cable Testing
Technician Time (1 U.S. + 1 CERN)
PO Change Order
PMT Shipping, dark boxes, cables, additional
PMT box machining and material
Spare PMTs
PMT Purchase
200
$1,000.00 $200,000.00
20
Backup-I
21
ROB with new adapter boards and recessed connectors
22
Components of new design
Upgrade HF ROBOX
Base board + adapter board
New signal connectors
and/or connector support
Sleeve
Plate2 (G-10)
PMT + socket
Plate1
(Grade XX Garolite)
Shield
Kapton insulator
23
Summary of components
Parts
Number needed
Approximate
production time *
Completed
Plate2’s
76
4 months
41 (54%)
Shields
1824
4 months
>840 (46%)
Insulators
1824
2 months
Production starts ~10
September.
Spacer tubes
304
4 Days
322 (100%)
Connector plates
152
2 weeks
0
Connector mounting
extensions
152
2 weeks? Only needed
if re-cabling postponed
0
Custom hardware
76 sets
3 Days
0
Assembly jigs
2
1 Day
0
Hardware (off shelf)
76 sets
-
0
Strain relief bars
288
PC fab?.(Fermilab)
-
CLI housings
76
2 weeks
-
Depends on cabling
decision and final cabling
connector specs.
Expect to place
order by Oct1
* Production will be in batches spread out over the year. Expect >3/4 done by fall. Finished by end of year, but have few
months contingency in early 2013.
24
Winchester cabling solution
Consists of 3 parts:
• Cable for inside PMT Boxes,
• 5m cables to FEE,
• Adapters to connect to existing
FEE
Assessment of Winchester cables
mechanical properties
Four complete sets of cables were provided in advance of the October
2011 testbeam period.
•
Diameter of cable ~2cm.
•
Minimum bend radius of ~10cm easily attained.
•
Cables are robust, and very pliable.
Suggested improvements:
–
Cable is stiff at the shrink tubing used to terminate the outer sheath. This
could present some difficulties if too long as tightest bends are required
near the ends of the cables.
–
Would prefer longer and knurled connector nuts so that they could be
turned by hand without need of a screw driver.
•
–
–
–
•
Over tightening of jack screws on the existing D-sub connectors has
been a persistent problem.
Cable connectors should be identically keyed so that cables can be easily
swapped. Very important for rapid trouble shooting and fast cable
replacement if necessary.
Would like grips on cable connectors to ease connecting/disconnecting.
Would like protection of the contacts to prevent damage during handling
and installation.
Modifications discussed with Winchester in July. Essentially
excepted.
HF QIE Card
27
HF Card concept
Dual QIE board unit 2x24 channels =48 / unit
6U crates with 1.2” module spacing.
28
Cable integration
• Cable volume will substantially increase
• Detailed evaluation was performed to confirm that the
proposed solution was feasible given the space constraints
within the HF shielding and support structures
(also for 4-anode readout).
Upper level cable storage
shelves
Cable exit port in shielding
Critical choke point
Lower level cable storage under
floor
Cable storage areas remain accessible when HF’s are in garages.
- keeps HF cabling off critical path of UXC activities.
29
Schedule Scenarios
• Purchase of the cables is subject to the
spending profile
• Scenarios:
1) Purchase all cables within the next 3 months and be ready for
installation during LS1. Later on, FE Electronics replaced.
2) Purchase cables for single quadrant within next 3 months, Delay
purchase of remaining cables into 2013, but in time to install at end
of LS1.
• Requires investment in infrastructure for testing/burn on the surface.
• Pushes cabling and commissioning to end of LS1.
3) Put cable purchase off for X years, and install cables at time of
FE electronics upgrade.
•
•
Uncertain when this could happen.
Big job, risky for a short shutdown.
Current status
•
•
•
•
•
•
Meeting with Winchester July 25
- Make quote good through Oct.2012.
- Two quotes, one for total cable purchase, another for all
pigtails, and 50 long+adapter cables.
- Essentially accepted list of modifications.
- Delivery time of 3+ months.
- 75 ohm board mount connectors are in production (will be for
10 years). Simulation to be performed by Winchester.
Backup -II
32
LS1 Plans
33
SCOPE
•
•
•
•
HF work to be done during LS1:
PMT Replacement
Cable upgrade for new FEE (part of LS2)
HV PSU Installation
•
2
34
35
Readout boxes on HF
There are 36 readout boxes on each HF for a total of 72 boxes.
Boxes are located at a radius of ~1.3m from the beam axis.
Each box houses 24 PMT’s and serves ~ a 10 degree slice of the detector.
(total number of PMT’s on HF is 1728)
All of these boxes are to be dismounted, reworked on surface, tested, and
remounted.
36
ROB work flow
UXC
Remove boxes
from both HF’s
RP screening
Refurbishment
USC
Disassembly
Testing
• Work starts as soon as HF’s are in garages and
boxes accessible.
• Refurbishment will happen in SX5, HCAL alcove
• Boxes will be processed in groups of “quadrants”,
9 boxes that make up 90 degrees in phi on HF.
• Boxes will be remounted and commissioned by
quadrants (Smallest unit due to shared HV).
• Burn in and commissioning happens whenever
services are available.
– Off critical path. Have flexibility here
Testing/burn-in,
commissioning
Sourcing
UXC
Remount on HF’s
37
Reception of
cables
Inspection, testing
(continuity, &
mapping)
Labeling/barcoding
Bundle, installation
prep.
Cable work
Installation /
modification of
cable storage
Cleaning and
consolidation of
existing cables and
services
Remove existing FE
cables
Including other CMS
subsystems
•Cabling will be performed in units of
quadrants.
• Ideally cable prep, and installation work
is pipelined with ROB work to maximize
testing, burn-in, and commissioning in
the UXC.
Re build rack cable
supports
Cable installation
ROB
install
Estimate 1 week to cable a
quadrant, two weeks for first one.
( 9 weeks total).
Testing,
Commissioning
38
Cable routing and storage
At upper level racks
Work area
Readout box
removal/install,
Cabling inside
outer shielding
(ROB area)
Protection from activated areas may be needed
Removal of collars, CASTOR table.
Scaffolding for access to boxes and cables
Cabling at racks
Cable routing and
storage under floors
Sourcing: will require ~1 week/HF where access to garages would limited
39
ROBOX Work Flow
•
•
•
•
LS1 Start: Feb, 11, 2013 LS1 End: Nov 24, 2014
PMT Replacement: 27 Feb 2013 - 25 Mar 2014
HV PSU Replacement (USC): April 2013
Bring HF+ to its nominal position: 10 Sep 2014
- 22 Sep 2014
• Bring HF- to its nominal position: 18 Sep 2014
- 30 Sep 2014
40
HV Installation
• We plan to finish HV power supplies installation by
May 1st, 2013 latest.This is based on the estimate that
mid May could be the earliest to power the first HF
quadrant.
• Also based on availability of CAEN PSUs.
• Alexi M. and + helper will finish the installation
• German M. will commission the new system with
existing PVSS.
• ~1 week to do installation.
• ~1 week for commissioning.
• This planning assumes that the HF HV patch panel
and interlock interfaces have been produced, tested,
and ready for installation (as well as CAEN system).
41
LS1 Cabling
• We planned to benefit from LS1 to do as much as
possible to prepare HF for the future upgrade
(multi-anode readout). During LS1 we target for
the following objectives:
• Consolidation and clean up of cables and
services. (~8 weeks) Includes removal of existing
front end signal cables Includes the time spent on
cables and services from other subsystems.
• Modification, preparation of HF structures for cable
storage (~2 weeks)
• Prepare racks as much as possible for future
electronics. (~1 week) Could be absorbed in
consolidation step above (~8 weeks)
• Install new cables (~1 week/quadrant + 1 week for
first one = 9 weeks
42
Base Boards-Old Dates
• • 80% of Sockets are assembled and tested
• • 20% of Adapter boards are assembled
• • Base boards should arrive from assembly house by Sep. 10
•
•
•
1. 80% of PMT sockets are assembled and tested
2. 20% of Adapter boards are assembled
3. Base boards have to be delivered from assembly house by Sep. 10
• Further production plans
As soon as we have Base boards from assembly house stop Socket
assembly and switch to final assembly/testing of Base/Adapter board
sandwiches (by that time we should have enough sockets for installation quantity of
the boards – 216)
•
• 216 sets for installation should be ready by Dec.01
•
S.Los recommends purchasing the second set of board-to-board connectors for the
future multi-channel Adapter board, before they become obsolete (~$3K)
43
Back-up III
HF2013 Organization Chart
CMS HF UPGRADE 2013 ORGANIZATION CHART
P.De Barbaro
HCAL PM
Onel
HF UPGRADE PM
J. Nachtman/C.Tully
HF FE
PMT Characterization
Akgun
1.1.2.1.3
E.Gulmez
TR CMS L2 PM
Sleeves And Light Guides
Winn
1.1.2.1.4
Onel
CMS HF PROJECT
1.1.2
ROBOX Design and Prod.
Schmidt
1.1.2.1.6
S.Tkaczyk/T.Yetkin
US CMS L2 PM
PMT Cabling
Terry Shaw (FNAL)
1.1.2.1.5
G. A. Alves/A.Santoro
Brazil CMS L2 PM
Demo Box, Light Guide Phi3
Yetkin
1.1.2.1.8
Installation And Commissioning
Mestvirishvili. Penzo
1.1.2.2
Neuhaus (UI)
Candidate PMT Studies
Kent, Debbins (UI)
Sleeve Mechanics
Schmidt (UI)
Design
Terry, Shaw (FNAL)
Cable Design
Akgun, Neuhaus (UI)
Iowa Tests
Ferhat,Bakirci,Cerci,(TR)
Test Stands in SX5
Jia (UI)
Production Testing Iowa
Cremaldi (Miss)
Scintillation Tests
Fountain (UI)
Pre-Production
Fermi Tech. TBA
Cable/Connector Test
Ferhat, Kaya (TR)
904 Tests
Debbins, Kent (UI)
ROBOX Resembly And Test
Funk (UI)
Batch PMT Testing
Akgun (UI)
Radiation Damage
Fountain (UI)
Production
Fermi Tech TBA
Cable Production
Mestvirishvili, Schmidt (UI)
Installation in UXC
Cankocak,Kaya (TR)
ROBOX Testing in SX5
Tiras (UI)
Speciality Test
Winn (Fair)
New Sleeve Material
Debbins (UI)
Mechanical Testing
Dumanoglu (CU)
Production Testing Adana
Cremaldi (Miss)
Sleeve Production
Los (FNAL), Neuhaus (UI)
PMT Base Boards
Joshi (FNAL)
Database
Corse / Kingston (UI)
Database
Sulak (BU-US)
Test Beam
HF CERN Team
HF Turkish Team
Los (FNAL)
Design
Fermi Tech TBA
ROBOX Cabling
Los (FNAL), Miller (UI)
Production
HF CERN Team
ROBOX Burnin
Bulgarian HV
Sofia Group
Martinez (FIU)
CAEN HV
45
HF US Manpower
IOWA : U.Akgun, E.Albayrak, B.Bilki, W.Clarida, P.Debbins,
A.Mestvirisvili*,J.P.Merlo*,M.Miller, J.Nachtman, J.Neuhaus, Y.Onel, F.Ozok*,
I.Schmidt*,S.Sen*, J.Wetzel.
*Stationed at CERN
New Iowa Graduate Students
K.Dilsiz, T.Harrington, V.Khristenko, M. Haytmuradov, H.Ogul, E.Tiras.
Iowa Undergraduate Students
L.Adams, J.Buffon, J.Corso, G.Funk ,G.Jia, J.Kingyon, D.Squires, D.Southwick
Baylor: Kenichi Hatakeyama and students
Fairfield : D.Winn and students
FERMILAB: S.Los, T.Shaw
FIU: G.Martinez
Maryland: S.Eno and students
Mississippi : L.Cremaldi and students
HF FE R&D Additional US groups
Princeton : C.Tully and students
Minnesota: J.Mans and students
46
New Info From Turkish Manpower
ITU, Istanbul, Turkey GROUP –KEREM CANKOCAK
WILL APPLY FOR SABBATICAL for 2013
HF preparation and installation
•
Ozlem Ozcelik
•
Cemsinan Deliduman (presently at CERN, until September 2012)
•
Onur Fikri Ozturpan (July & August)
•
Other related work
•
Fuat Ilkehan Vardarli (presently at CERN, until the end of 2012)
•
Huseyin Bahtiyar
(September, November, December)
•
Mete Yucel
(September, November, December)
•
Esra Barlas
(September, November, December)
•
Kerem Cankocak
(presently at CERN, until December of 2012)
•
For the 2013, ITU will apply to fund for 5 people regarding HF system tests.
(presently at CERN, until the end of 2012)
(online software, DPG analysis, calibration, etc.)
47
CU Adana + BU Istanbul
• For 2013 The CU group asked from their funding agency for support at
CERN for their PhD students ( 4 experienced students) for 6 months each
and one new PhD student for 10 months.
They will be spending 50% of their time on LS1 work.
• The 7 young faculty members (Kenan Sogut, Numan Bakirci, Sertac Ozturk,
Huseyin Topakli, Salim Cerci, Deniz Sunar Ceci, Bayram Tali)
• They submitted a new project proposal to their funding agency in which
they are asking for 45 months of support both for 2013 and 2014. with 50%
on the average time spent on LS1 activities.
• The BU has currently 1 faculty member without M. Kaya and 2 graduate
students until end of December 2012. For 2013 the BU asked one more
additional graduate student support during the LS1.
48
Brazil
RIO-CBPF: Alves Gilvan, Henrique Gomes, E Souza
Moacyr Pol, Maria Elena, Jorge Molina, Marcos and Thiago.
RIO-UERJ: Carvalho Wagner, Oguri Vitor, Santoro Alberto
and Sznajder Andre.
SAO PAULO UNICAMP: De Moraes Gregores, Eduardo
Novaes Sergio F, Edmilson Manganotte and Jose
Chinellato.
49
Backup IV
1800 PMT’s Characterization Data plots
50