MINERvA Mini-Review Debbie Harris Jeff Nelson Kevin McFarland Jeff’s slides version 1

MINER A DOE Mini-Review Deborah Harris Fermilab 1/9/20092 Outline of talks Project Overview: Deborah Harris –MINERvA Physics –MINERvA Construction Paths Plane Assembly Technique: Jeff Nelson –Plane Ingredients and Outfitting Needs –Plane Assembly steps –Lessons Learned from Tracking Prototype Production Module Performance: Kevin McFarland –Module Definitions and Criteria –Module QC procedures and status report Schedule Acceleration Plan: Deborah Harris –Schedule –Costs –Conclusions

MINER A DOE Mini-Review Deborah Harris Fermilab The goals in this task: from scintillator bars to assembled detector elements Receive –Scintillator, mirrored fibers, optical connectors Produce –Inner detector planes (ID) 127 strips per plane 2 planes per tracker module 196 deployed in full detector –Outer detector towers (OD) 4 pairs of strips per tower 6 towers per module 648 deployed in full detector Ship to Fermilab for module assembly & detailed source scans

MINER A DOE Mini-Review Deborah Harris Fermilab WBS 3: Scintillator assembly (Jeff Nelson, L2 manager) William & Mary, Hampton University & Rochester –Rochester and W&M led development of plane and tower design –Rochester led module integration –W&M lead the plane assembly prototyping and outfitting design –HU led development of on-site QA –HU and W&M prototyped plank and tower assembly Assembly 3 sites –William & Mary (Jeff Nelson, PI) 2 plane assembly stations Tower assembly site Machine parts Supplies and parts procurement Shipping crate procurement and warehouse –Hampton (Eric Christy, PI) 2 plane assembly stations Tower assembly site Coordinates skin material procurement –Fermilab (Jim Kilmer site coordinator) Shipping for all sites Planks for all sites 4 plane assembly stations Fermilab and Rochester technical staffing

MINER A DOE Mini-Review Deborah Harris Fermilab Life cycle of a plane Preassembly planks (at FNAL) –Cut scintillator –Glue planks –Trim planks (to move to FNAL) –Reflective paint on plank ends Plane assembly (1 or 2 days) –Glue lower skin, side & planks –4hr cure time (optional) –Fill any gaps between planks –Clear fiber holes –Glue upper skin & upper combs –4hr cure time Fibers & connectors (1 or 2 days) –Attach fiber baggies –Tread fibers –Pot connectors –Let cure Polish and Pot (1 or 2 days) –Polish connectors and mount –Optically couple fibers in scint –Glue lower combs –Let cure Seal and test (1 day) –Seal fiber baggies and edges –Light leak test top –Light leak test bottom –Load into shipping crate 5 Dark Blue = on plane workstation Light Blue = on cart Red = at the Fermilab planking facility Could be done in 4 workstation days with enough staff Schedule assume 8.75 days

MINER A DOE Mini-Review Deborah Harris Fermilab Cutting scintillator and making planks For the tracking prototype this was done at W&M and HU For MIE this is being done at Fermilab –First deliveries this fall and now in routine production 1/9/20096

MINER A DOE Mini-Review Deborah Harris Fermilab 7 Plane assembly

MINER A DOE Mini-Review Deborah Harris Fermilab The first 2 planes completed at Hampton (1 st week of October) 8

MINER A DOE Mini-Review Deborah Harris Fermilab 1/9/20099

MINER A DOE Mini-Review Deborah Harris Fermilab 12/10/ Plane Workstation Staffing Based on Tracking Prototype experience, the days/plane/workstation has been around 7.5 In full production mode, for VA factories, there will also be OD work, but no planking To get aggressive but achievable rates, assume 7.5*(1.15) or 8.75 days/plane/workstation Workstation model for FNAL: –1 workstation on February 1, –4 workstations starting March 1 –Glue machine scheduled to arrive in early February Personnel requirements: 2.5 FTE’s for 1 or 2 workstations, 5 FTE’s for 4 workstations

MINER A DOE Mini-Review Deborah Harris Fermilab 1/9/ Conclusions Demonstrated the industrialization of MINERvA scintillator plane assembly –Due to design changes (esp. plank-based method) made after the Full Module Prototype experience, the final assembly method is more intensive than originally envisioned but produced a better product The Fermilab planking site envisioned at the September Review is in full production –The first FNAL planks were used in planes in November and December Labor needs and production rates have been established based on experience gained over assembly of the planes for the Tracking Prototype The Fermilab ramp up model is based on the experience of the successful Hampton University turn on

1/9/200912

MINER A DOE Mini-Review Deborah Harris Fermilab Fermilab plane assembly site status Decision to go ahead with the Fermilab assembly site in late September Staffed by FNAL, Rochester, and collaborators (esp. during summer) –4 workstations Outfitting in progress –Workstations in plane –Glue machine to be delivered in early February –Polisher ready to go –Most fixturing in place Rest is in the shop and slated to come out for a February phased start –Staff being identified and/or hired Being dovetailed with plank assembly (c.f. Debbie’s slide) 1/9/200913

MINER A DOE Mini-Review Deborah Harris Fermilab Production status (TP = 45 planes) 1/6/2009 Planes Parts made 78.6 Parts machin'd 68.9 Cut Planks 82.4 Plane 45.0 Baggies 45.0 Fiber+ferrule 45.0 Polish+mount 45.0 Couple+Bott comb 44.0 Seal 41.0 Leak test 41.0 Test /9/200914

MINER A DOE Mini-Review Deborah Harris Fermilab 15 machined parts per plane Side rails (U/V or X) –Machined –Done in 3 steps 2 on Mill; 1 on table saw (slope) –Done using a vacuum chuck to save a pass (true for lowers, side and tops) –2 per plane Lower combs –Machined –Done in 3 steps 2 on Mill; 1 on table saw (groove) –2 per plane Center comb –Machined laminated small part (5” x 11”) –24 machined in a day Upper combs (x/HCAL) –Machined –Done in 3 steps 2 on Mill; 1 on table saw (slope) Upper combs (u/v) –Machined, laminated part –Done in 6 steps 2 on Mill; 4 on table saw (slope) Connector mount –Small machined part; mill, drill, tap –4 per plane Mount cover –Small machined part –Simple, same fixture as mounts –4 per plane 15

MINER A DOE Mini-Review Deborah Harris Fermilab Part production data # days #/day#/plane Days/plane center upper u/v upper x side u/v side x lower mounts covers Total

MINER A DOE Mini-Review Deborah Harris Fermilab 1/9/200917

MINER A DOE Mini-Review Deborah Harris Fermilab As-realized time motion requirements Time motionNotesTop down estimates FTE hours skins cut and splicedCurrently done at each site; propose to farm FNAL CDF techs 1 person for a quarter day; 1 person for quarter day 4 parts fitted and adjusted Currently done by measuring & cutting planks; hope to speed by making a fixture; plan to farm to FNAL lower skins & side railsGlue lower skin and side rails; 3 people 2 hours in the AM for 2 people; 1 person for an hour in the pm; 2 hrs for 2 people + 1 helper for 15 minutes 9.3 post glue cleanup One person to put stuff away and clean up glue and putty from the table; check holes; dam & backfill top skin & upper combsSame basic task (but simpler) than bottom-skin gluing; 3 people clear holes, foam & bagsClear holes; cut foam, cut and mount the bags 2 people for 8 hours16 baggie artMark the connector mounts and stay outs fiber and tapeStuff fibers and put boxes away, tape and mark fiber connector glueGlue ferrules to the fibers and fixture mount connectorsTape boxes, attach, mount boxes 1 person for 5 hours; 2 people for 3 hours 11 fly cutMove the cutter down, set up, polish, check depth, put away optically coupleUse the glue machine, includes set up, clean up, and spotter lower combsGlue lower combs light tightenTape bags, lower combs, tape sides/lower combs, Al rails 2 people for 8 hours16 leak testPMT with lights on/of for each bundle source testGuess based mostly on set up/take down load Put it into the crate Total 56.3 FTE- hours

MINER A DOE Mini-Review Deborah Harris Fermilab FTEs for production (w/o planks) 7.5 days per plane –To get the FTEs –Use 85% efficiency to get the schedule Fermilab uses only the top part HU and W&M do both Labor (hr/pln or hr/frame) Production rateFTE ID plane66.22/7.5 days 2.2 OD frame of towers /5 days 2.4 Total 4.6