Operations/Failure Analysis Status of Equipment/Production Readiness Plans in Case of Part/Systems Failure Per Stand

Inventory We have just completed a complete inventory of all components of used in hybrid/module/rod testing Thanks for all the help The inventory is available at http://hep.ucsb.edu/cms/inventory_needs_11_15_2004.xls In the process, we have identified many more potential failure modes Lack of DAQ equipment, cables, Vienna box interlock spares, etc. I have contacted all the people responsible for the components and hopefully we can receive all the spares we need before production fully starts

DAQ Components The request for spare components has been out of over 5 months now. We still need: 2 TSC 1 FED (replacement for broken UCSB board) 3 TPO 2 eMUX cards 7 oMUX cards 2 CCU25 4 VUTRI 6 PAACB 11 hybrid-to-utri boards All requests acknowledged and accepted. No ETA given for any of the parts

Why So Many #@*^%$ Cable Types? We have 48 different cable types in the system 29 types have no spares 8 more have inadequate number of spares Most can cause a complete system failures I’ve requested spares for all cables that we can not make ourselves Duccio has already responded We can make a number of the cables ourselves Especially ribbon cables for the TRHX box for the Module LT stands We should coordinate the build

CAEN Power Supplies With the UCR crate, we have the exact number we need We’ve looked for spares and have yet to find any. Ariella said she would “steel” one for us. Maybe Wiener could loan us their test stand in case of failure Otherwise, the UCR stand will have to be used as a spare for the production sites Keithley PS could be used in the short term With the UCR ordered controller modules: We will have spares of all modules at both UCSB and FNAL

Other Assorted Equipment Issues UCSB needs to order/manufacture a spare of all components used in 4 hybrid test box Coolie Box and Peltier spare status needs to be clarified Both FNAL and UCSB need to find a spare NIM and VME crate A spare set of LeCroy modules needs to be located for pulser logic of 4 hybrid thermal cycler Spare computers with hybrid/module software needs to be made and tested for UCSB/FNAL Spare computers with module LT/single rod/multi-rod/interlock software needs to made and tested for UCSB/FNAL

Test Stand Failure Analysis I’ve made a first draft of the US testing operations/failure analysis document that Joe requested using everyone’s input so far After checking the grammar, I’ll send it to the group for comments All comments welcome. Hopefully we will figure out scenarios for all failures we can think of. Process was really useful; got me to think of worse case failure scenarios

4 Hybrid Thermal Cycler Biggest strength is the large over-capacity we have in the group We can test ~90 hybrids per day with expected peak rate of 45 hybrid per day assuming 400 per week from company If global failure, move production to other sites As long as we have a stockpile of bonded hybrids, it will not affect production. Otherwise, production slowed due to shipping times The stands have three primary weakness: software, the Peltier element, and the NESLAB chiller Backup computer and spare Peltier elements at each site reduces these risks FNAL can borrow NESLAB chiller from BTeV. UCSB can purchase spare with 1-2 day lead time UCSB obtaining spares of all other components which could be shipped overnight in case of failure

ARCS module testing We are in the best shape with these stands We can test ~17 modules/stand/day with expected peak rate of production of 30. FNAL has 4 stands, UCSB has 3 stands, UCR has 1 stand Both sites have a complete live spare Obtaining spare cables to reduce stand down-time to minimum Repairs from Aachen have only taken 2-4 weeks in past Biggest headache would be a complete failure of CMS database No wire bonding data, sensor data, or hybrid data Will have to find all fault during testing. May require each part to be tested twice. Would have to check testing results against known failures after database is working. Running more than two stands should remove back-log of parts.

Module LT systems Since expected production rate exceeds testing capacity (30 vs 15 modules a day) any failure would increase fraction of sampled modules Only way to clear backlog is weekend testing We are exploring reduction of tests to increase capacity to 20 per day To prevent failures, spares acquired or ordered of almost all components: Power supplies, DAQ components, cables, interlocks, etc. Also modify Vienna box to be more stable/long-lived Brass plates and extender connectors Two major failures in which we don’t have spares in the foreseeable futures CAEN crate, NESLAB chiller

Module LT systems (2) In case of CAEN failure, we have to “borrow” UCR’s crate In case of failed NESLAB chiller, 1-2 lead time for replacement Maintenance really important Without a chiller, I believe system could still be run without thermal cycling. The modules’ temperature should stabilize at 30-40 C. So no cold run information, but still “long term” testing If the stand is complete non-operational, production can still continue All production should be TOB. Only produce what can be assembled/tested on rod. Would reduce production capacity to ~20 modules a day

Single Rod System Test systems have over-capacity 2-4 rod assembled a day with ~8 rod test capacity/stand/day Same issues with DAQ equipment/CAEN HV as module LT Ordered 6 extra MUX to remove need of recabling Cables from Duccio ordered: electrical and optical Two pieces of equipment with no spares in foreseeable future: OEC & Delphi LV power supply In both cases, take OEC or PS from multi-rod stand (with multi-rod loss of capacity of 7% and 12%) If single rod stand fails completely, production can still continue a slower rate Test rods as they are loaded into multi-rod stand. Adds 1 day per test cycle Will have to reduce rod assembly rate to match testing rate UCSB should switch to mostly TEC production

Multi-rod System Most complex system with least amount of experience Same potential problems as module LT or single rod systems plus: Chiller Interlocks Freezer infrastructure UR have thought about different operational scenarios for these components; will have to be revisited after accumulation of more experience Spares in hand of all components that company believe could likely fail Compressor failure would lead to long down time Plan for finding and removing leaks in the cooling system needed 1 or 2 spare C6F14 loads needed at both sites

Multi-rod System (2) Interlocks Spares of sensors, etc. that can be easily replaced already ordered If interlock hardware failed Company has 48 hour express repair plan Power supply interlocks would be used Control of system by hand until repair made If case of complete system failure, rod assembly at site can still proceed at a lower rate All rods will have to be tested with single rod stand Single rod stand would have to reproduce as many of the multi-rod stand’s testing until multi-rod available Only way to remove the backlog of rods assembled would be the reduction of the testing cycle time.