Cost estimation for production & installation of Calorimeter System V. Issakov Physics Department, Yale University, New Haven, CT /9/2004

Photon Calorimeter for KOPIO The requirements to the KOPIO Photon Calorimeter: Energy resolution  3.5[%]/  E. Time resolution  100[psec]/  E. Photon detection inefficiency (due to holes-cracks)  Granularity  11  11 cm 2. Active area  5.7  5.7 m 2 Radiation length  16X 0 (18X 0 including Preradiator). Physical length  60 cm. The Shashlyk technique with the APD photo readout satisfies the KOPIO requirements. All sizes are millimeters

Calorimeter System Calorimeter System includes: I.Mockup of Calorimeter System - the complete-equipped prototype of Calorimeter system (16  8 modules), to study the performance parameters of the Calorimeter & Preradiator/Calorimeter systems and to develop the pattern recognition algorithms. II.Photon Calorimeter – the matrix of the 52  52 APD-instrumented modules with a beam hole of 18  2 modules, Calorimeter mechanics (including two mobile halves of Calorimeter frame, Calorimeter railways and Calorimeter installation/service equipment) & Calorimeter cooling system. III.Instrumentation of Photon Calorimeter - Calorimeter High-Voltage control system, Calorimeter LV power supply system, Calorimeter “cosmic- ray” Pre-calibration System, Calorimeter Monitoring/Calibration System, Calorimeter WFD-readout System. IV.The cable system of Photon Calorimeter – 3,172 signal cables, 2704 HV control cables & 2704  3 LV power supply cables.

Cost estimation for Calorimeter System WBS #Description Sub.Mat.EDLab.Tot.Con Cost of Calorimeter System (CS) 1,2073, ,465*9,05422% KOPIO Contribution (NSF)1,2073, ,130*7,71924% IHEP Contribution** (RUSSIA)000359*35923% YALE Contribution (DOE)000976*97620% Mockup of the CS (The complete-equipped matrix of 128- modules to study the Performance Parameters of CS) % Photon Calorimeter (2704 APD-instrumented modules, Calorimeter mechanics & Cooling system) 602, ,0734,72625% Instrumentation of Photon Calorimeter (2704 channels of HV- control, monitoring, calibration & WFD-readout electronics) ,76322% Shipping of Photon Calorimeter (Shipping formula: 600 mod.  3, Mechanics, 904 mod.) % Assembly & Test of the delivered modules (APD/mod. assembly, mech. & optical tests, a “cosmic-ray” calibration) % Installation of Photon Calorimeter (modules into frames, monitoring-calibration system, readout electronics) % Cabling of Photon Calorimeter (Production and installation of cables) % Commission of CS (The mechanical & “cosmic-ray” tests of the full-loaded CS) % Scientific-technical coordination & management % Travel expenses (Meetings, consultation, supervision of production) % *) Support of the FTE scientists: KOPIO - $1,069k, IHEP - $359k, YALE - $976k. **) IHEP contribution in past: Scintillator factory (~$3,000k), Test facility (~$200k).

Calorimeter mockup production WBS #DescriptionSub.Mat.EDLab.Tot.Con Mockup of the CS (The complete-equipped matrix of 128- modules to study the Performance Parameters of CS) *18% Fabrication of 100 “mass-production” modules % Instrumentation of 100 “mass-production” modules by APD units (APD, preamplifier, LV-HV converter) % Production of the mockup mechanics (Frame & Rotating lift-platform) % Prototype of the cooling system (Refrigerating-circulator & Heat-exchanger) % Prototype of the HV control system (D-A converters for control of APD HV-chips) % Prototype of the “cosmic-ray” pre-calibration system (LTD & Trigger logic, CAMAC) % Prototype of the monitoring-calibration system (LED-flash system & Fiber optics) % Production of the readout system prototype (10-bit & 250 MHz WFDs, VXI or VME) Shipping of the Calorimeter mockup % Test & Study of Calorimeter mockup performance % *) Production cost of Calorimeter mockup is $313k. Support of the FTE scientists for study of Calorimeter mockup performance is $191k (Yale – $145k, KOPIO – $46k).

Photon Calorimeter production WBS #DescriptionSub.Mat.EDLab.Tot.Con Photon Calorimeter (2704 APD-instrumented modules, Calorimeter mechanics & Cooling system) 602, ,073*4,72625% Design of Photon Calorimeter (Conceptual design & detailed drawings) % Modification of test-equipment & the production tool for the mass-production cycle % Fabrication of 2672 “regular” Calorimeter modules ,86920% Instrumentation of 2672 “regular” Calorimeter modules by APD units (APD, preamplifier, LV-HV converter) 01, % “Cosmic ray” test of 2672 instrumented “regular” Calorimeter modules % The production of “special” Beam-Liner modules (32 APD-instrumented modules) % Photon Calorimeter mechanics (Frame, cooling & railway systems, service-equipment, etc.) % *) IHEP support of the FTE scientists for supervision and tests of modules, APD-units & APD-instrumented modules is $359k.

Cost of the module production Materials, LaborCost Materials $ scintillator tiles $ lead tiles$65,55 3. Assembling parts$37, m of WLS fiber (Kuraray Y11-200MS-1mm) $ Packing box$12.50 Labor$ Molding of the scintillator tiles$ Stamping of the lead tiles$ Formation of the WLS fibers$15.00 Assembling & Testing$ Assembling of module$ Test of module$ Packing of module$9.00 Total$ Module’s production rate is 6 modules/shift The module’s design includes 15 assembling details

Cost of the module instrumentation Materials, LaborCost Materials $ A 16 mm diameter, blue, windowless APD $ A charge-sensitive preamplifier $ A LV-HV converter, capacitors and resistors $ Assembling parts$19,00 Labor$ HV PC-board$ Preamplifier PC-board$ APD’s PC-board$ Mechanic of APD cage$30.00 Assembling & Testing$ Assembling of the APD unit $ Test of the APD unit$ Packing of the APD unit$4.50 Total$ Cost of the module’s instrumentation Module’s instrumentation rate is 6 units/shift APD LV - HV Preamp Quoted price of the LV-HV Model: C20 Quantity: 2,500 Unit Price: $ John Bianchi EMCO High Voltage Corp Ridge Road Sutter Creek, CA 95685, USA Phone: (209) Quoted price of APD Model: SD Quantity: 3,000 Unit Price: $ Paul Sharman Advanced Photonix, Inc Avenida Acaso Camarillo, CA 93012, USA Phone: (805)

Calorimeter instrumentation WBS #Description Sub.Mat.EDLab.Tot.Con Instrumentation of Photon Calorimeter (2704 channels of HV- control, monitoring, calibration & WFD-readout electronics) ,76322% Calorimeter HV control system (2740 D-A converters for control of APD HV-units) % Calorimeter “cosmic-ray” pre-calibration system (LTD & Trigger logic, VME/VXI) % Calorimeter monitoring-calibration system (2740 channels of LED-flash system) % Calorimeter readout electronics (10-bit & 250 MHz WFDs, PCI or VXI) % Calorimeter LV power supply & Racks for Electronics % HV control system for control of APD HV-units. System includes 2704 programmable D-A VME converters. A base unit is a commercial 12-bits D/A converter (XIP-TVME200/XIP-5220, produced by Xycom Automation Inc.). The production cost per channel is ~ $72. “Cosmic-ray” pre-calibration system for adjustment of APD HV, a Calorimeter pre-calibration (accuracy better than 4%) and online long-term monitoring of the APD gain (accuracy better than 1%). System is based on detection of signals from the “cosmic-ray muons”, vertically traversing Calorimeter modules, and includes 468 programmable Low-Threshold Discriminator & Trigger Programmable Logic. A base units are the commercial LTD & TPL (V814 & V495, produced by CAEN). The production cost per channel is ~ $69. Monitoring-calibration system for online short-term monitoring of the APD gain & timing. System is based on the "ultrabright LED-lamps" with an electronic method of stabilization of the light output and includes 44 special LED modules. The similar system has been developed and tested for LHCb project. We propose to adapt the LHCb system for our project. The production cost per channel is ~ $63. Calorimeter readout electronics include 176 WFDs boards and 12 crate-collector boards. The production cost per channel is ~ $301.

Assembly & test of the delivered modules WBS #Description Sub.Mat.EDLab.Tot.Con Assembly & Test of the delivered modules (APD/mod. assembly, mech. & optical tests, a “cosmic-ray” calibration) % Complete assembling, mechanical/optical test of the delivered modules 60 (Room) % “Cosmic ray” test & pre-calibration of the delivered modules % “Cosmic ray” test & pre-calibration of the delivered module include the accumulation procedure of data-base for APD- instrumented Calorimeter modules

Installation of Calorimeter System WBS #Description Sub.Mat.EDLab.Tot.Con Installation of Photon Calorimeter (modules into frames, monitoring-calibration system, readout electronics) % Installation of modules into Calorimeter frame % Installation and testing of monitoring and calibration system (44 LED boards & LV power supply, 2704 optical cables) % Installation and testing of 2704 readout-electronics channels (12 mainframes & controllers, 12 collector boards & 176 readout boards) % WBS #Description Sub.Mat.EDLab.Tot.Con Installation of Railway and Cabling systems % Installation of Calorimeter support frame % Installation of Assembling and Service system % Installation of the power supply on the Calorimeter top % Installation of the electronic racks on the Calorimeter top % Installation of The Calorimeter Mechanics (for R. Brown)

Cost Evolution for Calorimeter System 1.The old base cost for the Calorimeter System has been estimated for TDR-2001 as$4,698k 2.The new base cost for the Calorimeter system (NSF Contribution) has been estimated for WBS-2004 as$7,719k 3.The Calorimeter cost has risen due to: a)The increasing of the Calorimeter size (52  52 modules instead of 48  48 modules) $673k b)The input of the new additional expenses for:  Mockup of Calorimeter System (the former R&D program) $364k  The Wave-Form-Digitizing readout electronics (the former item ) $815k  Management & Supervision of Subsystem (a new required item) $600k  Support of IHEP group at BNL (a new required item) $469k  Travel support (a new required item) $100k NSF Contribution

Calorimeter System schedule