M. Gilchriese Sectors, Rings, Frame Assembly and Installation July 18

M. Gilchriese 2 WBS Mechanics – Part I Center Frame Section (1) Disk Section (2 ) Internal End Cone (2) LBNL responsibilities shown in red (Services not shown) Interior Barrel Layers Disk Rings Disk sectors (8)

M. Gilchriese 3 Overview Costs are in FY02 $K. All costs shown for sectors, rings and frame are in FY03 only. Disk assembly. Mounting sectors with modules/cables on to rings and testing. Disk final assembly. Putting these real disks into frame, testing and shipping to CERN “Installation” in FY05 only covers surface integration labor. Tooling for integration either supplied by European collaborators or will have already been made and shipped to CERN. Note that all installation costs in FY05 are currently in management contingency.

M. Gilchriese 4 Sectors Deliverable: 48 sectors available for experiment, 60 will be started Design – complete Prototyping – complete Production –One part made with production tooling(but not with fittings). –Materials (13K) and shop labor All parts in hand. All tooling in hand but have budgeted some for maintenance/replacement of some parts that may wear out(2K). Supplies(2K). Thermal QA fixture /completionreplacement parts(5K). Storage boxes(1K). Parylene coating(3K) Shop labor of 210 hours. –Other labor(see summary later in talk) Assembly by J. Wirth and T. Johnson(part time). QA by them + T. Weber, students(part time) –Schedule Substantial delay from problems laser welding. ETC02 completion date: 9/27/02 ETC03 completion date: 3/31/03 Float remaining: about 1 year for production modules, but will need some sectors earlier for practicing module mounting and system tests. Not a problem if laser welding is successful.

M. Gilchriese 5 Rings and Related(1) Deliverable: 6 rings with mounts, insertable into frame available Design –Ring-only design is complete, including of mounts to frame. Remaining production design oversight to be completed by Hytec(10K) –Strain-reliefs of sector tubes to ring to be designed – J. Wirth(see summary at end) –Ring insertion-into-frame tooling. Prototype completed and tried successfully but with different ring size. Design modifications to be done by F. Goozen(see summary at end) Prototyping – complete apart from strain reliefs, included in production for convenience Production –Rings only(92K) Preproduction ring has been fabricated successfully. All materials in hand for production rings. Production contract placed but only costed in FY03(70K). Final inspection(survey) to be done at LBL(6K). Storage and shipping boxes(must include provision for sectors with real modules)(6K). Mounts to frame(10K) –Strain reliefs(10K) 10K for materials and fabrication only. Labor to put on rings from J. Wirth and T. Johnson(see summary at end).

M. Gilchriese 6 Rings and Related(2) Production(continued) –Ring insertion(10K) Revised tooling(includes shop labor) for production rings Labor from F. Goozen(see summary at end) –Schedule ETC02 completion date: 9/27/02 ETC03 completion date: 12/15/02(rings only, which is what is needed for drilling holes in frame). 6/15/03(with strain reliefs) Float remaining: >4 months(rings only) for starting dry fit of frame. About 1 year for production modules.

M. Gilchriese 7 Frame(1) Deliverable: support frame, three pieces. Barrel delivered to CERN empty. Disks active(see disk final assembly) Design –Frame only. Complete apart from production oversight by Hytec(70K) –Dry fit, survey and shipping design to be done by F. Goozen Prototyping – complete apart from minor items Production –Frame only(121K) Tooling(11K). Contracts placed and will be delivered and costed before end FY02 apart from endplate tooling. Materials. All ordered and will be delivered by end of FY02. Assembly(110K). Contract placed. We assume all to be costed in FY03. –Dry fit(5K) Miscellaneous parts and tooling for simple dry fit.

M. Gilchriese 8 Frame(2) Production(continued) –Survey(15K). We don’t know yet know exactly how this will be done –Shipping(1K) Barrel only Disks covered under Final Assembly –Schedule ETC02 completion date: 4/7/03(frame only), dry fit complete(9/22/03) ETC03 completion date: 4/7/03 and 9/22/03

M. Gilchriese 9 Disk Assembly Deliverable: 4 operational disks ready for insertion into frame Design –No significant design done. See labor table at end Prototyping –None planned. Only real items Production –All tooling and materials in FY04. Labor-see table at end. –Sector pick up and place tooling –Survey and storage tooling for each disk –Test fixtures(dry/dark box, chillers, …does not include readout electronics or power supplies) –Storage and shipment boxes –ETC02 estimate of 50K, not including technician labor still looks OK. Need more design and experience(system test) to update.

M. Gilchriese 10 Disk Final Assembly Deliverable: Disk regions at CERN Design –No significant design done. See labor table at end Prototyping –None planned. Only real items Production –We assume all tooling and materials are done in FY04. Labor – see table –Disk frame support, temporary cable support and assembly table/guides –Cable/pipe strain reliefs –Disk insertion tooling, including cable holding –Testing tooling(dry box, temporary supports for pipes, cables) –Shipping boxes and shipping –ETC02 estimate of 107K, not including technician labor still looks OK. Requires more design and experience(system) test to update.

M. Gilchriese 11 Disk Final Assembly Production(more) –Final assembly and testing will occur in clean room (Bldg. 77) at LBL –Expectation is that results from evolving system testing to start end this year will guide scope of testing during and after assembly. –We don’t understand yet how to cool any significant part and actually complete the final assembly. No evaporative cooling available at LBL. So we either test with temporary inlet cooling fittings or figure out some way to cool with the capillary fittings in place. Note that disk testing will be done with temporary fittings and liquid cooling. –Conservative assumption is that we disassemble disks from frame and ship individually to CERN and then reassemble there.

M. Gilchriese 12 Preliminary Summary Significant cost increase(roughly 100K), but will take to October to get better # –6 month delay in sector completion, much more prototype work, laser welding problems, much more labor required in FY03. –Basic cost of rings and frame very close to estimate, but forgotten items(survey, strain reliefs, …) now added –Reduced base program support at LBL projected.

M. Gilchriese 13 Integration/Installation Initial support tube installation(barrel) in FY04. Final in FY05. Conservative assumption is that we have to put disks into frame at CERN Unpack tooling sent from US and setup up Unpack testing equipment sent from US and setup or duplicate at CERN or some combination Unpack disks and test each one Put disks into frames and test separately from barrels Integrate disks and barrels, testing(somehow) as we go Partial test of barrels + disks without service panels Integrate beam pipe/service panel support Install service panels/PP1 Test as one goes. Final “10%” cold test before lowering into pit for installation Slide in, hook up and test

M. Gilchriese 14 FY04/FY05/FY06 Preliminary plan produced and sent to Rossi/Stapnes based on this schedule. Note schedule is in calendar years.

M. Gilchriese 15 Installation Costs Personnel-related costs in FY02 $K. Costs for SR building and other infrastructure covered under M&O(we hope). No costs for CERN operations(cranes, consumables) yet included.

M. Gilchriese 16 Design Labor( ) Engineers, designers, engineering interns + travel/supplies Includes external contracts eg. Hytec who has been responsible for ring and frame design completely. FY02 manpower is about(in FTE) –3 engineers –1 designer –1.5 mechanical engineering student(multiple people) Beam pipe support is currently separately funded project but only for FY02 at the moment. Installation is not included here. Increase in FY04/FY05 results from reduced expectations for base support, delays and better understanding of scope