March 7, 2007 CLAS12 Drift Chamber Review Mac Mestayer CLAS12 Drift Chamber Construction - Mac Mestayer Technical Details of Construction —buy endplates —build “box” —insert feedthroughs —string chambers Cost and Schedule

March 7, 2007 CLAS12 Drift Chamber Review Mac Mestayer CLAS12 Drift Chambers Design: same concept as present chambers: NIM A449(2000)81 6 sectors, 3 regions 18 drift chambers sense wires drift chambers

March 7, 2007 CLAS12 Drift Chamber Review Mac Mestayer Endplates: many precise holes Number of Holes 4925 feedthrough holes 12 survey 3 datum & alignment 28 bolt & attachment 1.7 m First Order Placed -due back in March -large, modern milling machine

March 7, 2007 CLAS12 Drift Chamber Review Mac Mestayer Endplate Details mm true position  “50  m”

March 7, 2007 CLAS12 Drift Chamber Review Mac Mestayer Endplates fit into Frames Receive endplates - inspect - measure hole positions - clean - shim - bolt and glue into frames

March 7, 2007 CLAS12 Drift Chamber Review Mac Mestayer Chamber Ready to String Box Assembled endplates attached attachment brackets affixed Next mount on stringing fixture - insert feedthroughs - pre-tension - string wires - attach circuit boards - QA/QC

March 7, 2007 CLAS12 Drift Chamber Review Mac Mestayer CLAS12 Stringing Fixture

March 7, 2007 CLAS12 Drift Chamber Review Mac Mestayer Parts: wire  circuit board conductive rubber circuit board crimp pin feedthrough endplate signal routing: wires  pre-amp wire

March 7, 2007 CLAS12 Drift Chamber Review Mac Mestayer Stringing wires between “slanted” endplates endplates “gravity” stringing wires: 9 cm - 4 m long wires strung individually wires attached by crimping wires positioned by “trumpet”

March 7, 2007 CLAS12 Drift Chamber Review Mac Mestayer Steps in Stringing

March 7, 2007 CLAS12 Drift Chamber Review Mac Mestayer Installing Pre-tensioning Wires Pre-tensioning - before we start stringing - use springs on guard wires - gradual release of tension

March 7, 2007 CLAS12 Drift Chamber Review Mac Mestayer Stringing the Chamber

March 7, 2007 CLAS12 Drift Chamber Review Mac Mestayer Bussing Field Wires - under the circuit board - gold-plated copper wire - one “miscellaneous part” - e.g. 16,000 ft. - $ do this before mounting circuit boards

March 7, 2007 CLAS12 Drift Chamber Review Mac Mestayer Project Overview & Responsibilities Oversight: Jefferson Lab Design & Build Region 1: ODU Region 2: JLab Region 3: Idaho State Prototyping full-sized Reg. 1 prototype: Jlab, ODU plastic vs. metal-tipped feedthroughs: Jlab, ODU, ISU

March 7, 2007 CLAS12 Drift Chamber Review Mac Mestayer Drift Chamber Schedule PED

March 7, 2007 CLAS12 Drift Chamber Review Mac Mestayer CLAS12 Drift Chamber PED test prototype this summer

March 7, 2007 CLAS12 Drift Chamber Review Mac Mestayer Drift Chamber Construction Schedule 3 YEARS

March 7, 2007 CLAS12 Drift Chamber Review Mac Mestayer Details: Stringing the Chambers ~2 yrs./ 6 chambers ~1/2 time for stringing

March 7, 2007 CLAS12 Drift Chamber Review Mac Mestayer Estimate the time; use labor cost tables “Bottoms-up” estimate - based on previous experience 2 people, 15 mins. per wire for stringing “stringing” per se takes 1/3 to 1/2 of the time 3 crews of 5 stringers for ~ 2 years techs / scientists doing support, QA/QC “Top-down” - simple scaling of total elapsed time, accounting for fewer wires Costs: Stringing the Chambers

March 7, 2007 CLAS12 Drift Chamber Review Mac Mestayer CLAS12 Drift Chamber Procurements/Expenses Task k$ stringing labor - estimate time - use labor rate

March 7, 2007 CLAS12 Drift Chamber Review Mac Mestayer CLAS12 Drift Chamber: Construction Costs PED: 0.34 M$ Const: 4.50 M$ Total: 4.84 M$

March 7, 2007 CLAS12 Drift Chamber Review Mac Mestayer CLAS12 Drift Chambers: Cost Same concept as present CLAS chambers Small extrapolations from current designs smaller cells, thicker wire, faster gas Cost estimates based on prior experience 180$ / sense wire : mechanical costs major cost is “wire-stringing” re-use most electronics Schedule and manpower allocation: prior experience Experts on staff and in CLAS collaboration

March 7, 2007 CLAS12 Drift Chamber Review Mac Mestayer Phenix DC’s (“jet-cell” type with 36 super-modules) Mechanical costs: $250/sense wire (but 7-8 other wires per sense wire) $50/total wire CLEO-c DC’s (“open-cell” with “square” cells) Mechanical costs: $40/total wire (labor not included) CLAS12 DC’s (“open-cell” with hexagonal cells) Mechanical costs: $180/sense wire $49/total wire (labor included) Cost Comparison: Other Drift Chambers

March 7, 2007 CLAS12 Drift Chamber Review Mac Mestayer “Harder to do” Region 1: 7.5 mm cell; 1.8 m long wire Easier to do” smaller chambers 7 m endplate  4 m endplate chambers are flat stereo wires are all parallel sense wire: 20  m  30  m less breakage, easier to see ! Risks: Stringing the Chambers

March 7, 2007 CLAS12 Drift Chamber Review Mac Mestayer CLAS Drift Chambers : History Operating successfully for ~10 years ….

March 7, 2007 CLAS12 Drift Chamber Review Mac Mestayer CLAS Drift Chambers : History …. with good resolution mid-cell resolution is  m whole-cell average: 310, 315, 380  m; for R1, R2, R3 …. at the same voltage, with same efficiency  Ar/CO 2 shows no conventional aging

March 7, 2007 CLAS12 Drift Chamber Review Mac Mestayer Conclusions Large project: 18 chambers, 90K total wires Reliable design: should achieve resolution and efficiency goals Low risk cost and schedule: based on detailed knowledge from CLAS High probability of success: experienced people

March 7, 2007 CLAS12 Drift Chamber Review Mac Mestayer Broken wires more extensive “shake-down” better temperature control (already implemented) Circuit board corrosion go to encapsulated SIP’s better humidity control (partially implemented) finer segmentation (partially implemented) High current draw stricter irradiation procedures (already implemented) better humidity control (partially implemented) more HV channels (planned for near-term) Operational Problems & Solutions

March 7, 2007 CLAS12 Drift Chamber Review Mac Mestayer CLAS12 / CLAS costs (not labor) ratio task CLAS12 DC’s have 70% as many wires Some tasks don’t depend on wire count

March 7, 2007 CLAS12 Drift Chamber Review Mac Mestayer CLAS12 Drift Chambers : Labor task man-weeks PED tasks

March 7, 2007 CLAS12 Drift Chamber Review Mac Mestayer Methods of Cost Estimation Endplates: cost = (a + b * nwires) * inflation; a =.2, b =.8 “boxes”: cost = old cost * 0.75 * inflation Wires, pins, feedthroughs; cost = old_cost * wire_ratio * inflation

March 7, 2007 CLAS12 Drift Chamber Review Mac Mestayer Recent cost estimates (06/-07) Recent Estimates from Tom Hartlove (with backup documents) Region I endplates, $36K (quote from Master Machine) Region II endplates, $50.6K (machined, quote from Stesalit) Region III endplates, (machined, quote from Martel Marine) Region I inserts, reduced tolerances, 80K $6.2K (~$0.08/part) (quote from 4slide) Field wire, 140um Al, $94.9K (~$0.9/m)(quote from CFW) Sense wire, 20um Tungsten, (~$0.69/m)(quote from CFW, probably cheaper from Luma) DC Wire Setup charges, $135/2000ft. i.e. fresh die every 2k ft.(quote from CFW) Region I crimp pins, 70K $95.2K (~$1.36/part)(quote from Medelec) Conductive rubber tubing, 100 $330 (quote from Chomerics) Prototype HV boards 6 $1120 (quote from Accurate Circuit)

March 7, 2007 CLAS12 Drift Chamber Review Mac Mestayer Possible Sources of Cost-Saving use “angle-iron” for chamber frames pros: won’t warp, much cheaper cons: need fixture to assemble full frame increase tolerance: stainless-steel “trumpets” pros: can find a willing vendor cons: may not be as accurate or take longer to accept

March 7, 2007 CLAS12 Drift Chamber Review Mac Mestayer Detailed CLAS Costs from P.O.’s Region II Endplates, $30K/plate, $420K Installer, $24.5K Stringing booms, $3K Scaffolding, $3.8K Attachment parts, $27K Trapezoid, $9.5K Strongback, $4.8K U-channels, $3K Posts, $11.2K Crane for cleanroom, $4.6K Cable supports, $20K Misc. stringing stuff, $13K Inserts, 125K $ 19.6K Crimp pins, 125K $19.3K Feedthroughs, 125K $17.5K Region I Boss Ring, $10k Prototype chamber, $49.5K Finite element analysis, $13.1K Additional prototyping costs, $9.2K Helmholtz coils, $14K Transport cart, $5K Endplates, 12 $50K Procure feedthrough assemblies, etc. $75K Procure parts, fabricate 6 chambers, $250K

March 7, 2007 CLAS12 Drift Chamber Review Mac Mestayer Original Detailed CLAS Costs from P.O.’s WIRE, all regions combined. Sense, 20um Tungsten, 118 km, $15.5K (~$0.13/m) Field, 140um Aluminum, 344 km, $357.1k (~$1.04/m) Guard, No records found. Bus wire, $7K Region III Skin connectors, $61.8K Skins, $234.9K Endplate material and machining, $400.2K Closure bars, $70.2K Hole inspection, $5K Alignment fixture materials, $17K Stringing platform, $36.3K Chamber to Torus mounting posts, $72K Eagle claws, $8K Transporter, $6K U-channels, $3K Inserts, 110K $31.3K (~$0.29/part) + additional parts from inferior vendor Feedthroughs, 122K $54K (~$0.44/part) Crimp pins, 152K $34.3K (~$0.23/part) Plastic plugs for rubber connectors, $0.9K Rubber connectors, $15K (approx.)

March 7, 2007 CLAS12 Drift Chamber Review Mac Mestayer On-chamber electronics - 310K$ estimate Signal Translator Boards -- Board Only R1_STBQTY# SectorsTotalsCost EachTotal $ Layer 17642$315.00$13, Layer 27642$315.00$13, R2_STBQTY# Sectors Layer 17642$335.00$14, Layer 27642$335.00$14, R3_STBQTY# Sectors Layer 17642$375.00$15, Layer 27642$375.00$15, $86, STB Components Per BoardBoard MultTotal QTYCost Each HV Capacitors $1.25$34, PreAmp $3.00$72, Regulator $1.65$6, Power Connector1252 $1.75$ Output Connector $3.15$4, Resistors $0.05$ Capacitors $0.05$ $119,586.60

March 7, 2007 CLAS12 Drift Chamber Review Mac Mestayer High Voltage Boards R1_HVBQTY# SectorsTotalsCost EachTotal $ Layer 17642$125.00$5, Layer 27642$125.00$5, R2_HVBQTY# Sectors Layer 17642$125.00$5, Layer 27642$125.00$5, R3_HVBQTY# Sectors Layer 17642$200.00$8, Layer 27642$200.00$8, $37, HVB Components Per BoardBoard MultTotal QTYCost Each HV Capacitors $1.25$3, Resistors $0.05$1, Solder Posts $0.25$1, $5,544.00

March 7, 2007 CLAS12 Drift Chamber Review Mac Mestayer LOW VOLTAGE CABLE R1_STBQTY# SectorsTotalsCost/FtLength(Ft)Total $ Layer 17642$1.256$ Layer 27642$1.256$ Cable Connectors286168$1.50$ R2_STBQTY# Sectors Layer 17642$1.257$ Layer 27642$1.257$ Cable Connectors286168$1.50$ R3_STBQTY# Sectors Layer 17642$1.258$ Layer 27642$1.258$ Cable Connectors286168$1.50$ $2, HIGH VOLTAGE CABLE R1_STBQTY# SectorsTotalsCost/FtLength(Ft)Total $ Layer 17642$3.006$ Layer 27642$3.006$ Cable Connectors14684$5.00$ R2_STBQTY# Sectors Layer 17642$3.007$ Layer 27642$3.007$ Cable Connectors14684$5.00$ R3_STBQTY# Sectors Layer 17642$3.008$1, Layer 27642$3.008$1, Cable Connectors14684$5.00$ $6,552.00

March 7, 2007 CLAS12 Drift Chamber Review Mac Mestayer PreAmp Output Cables -- (0.025" Pitch) R1_STBQTY# SectorsTotalsCost/FtLength(Ft)Total $ Layer $4.006$6, Layer $4.006$6, Cable Connectors $3.15$3, R2_STBQTY# Sectors Layer $4.007$7, Layer $4.007$7, Cable Connectors $3.15$3, R3_STBQTY# Sectors Layer $4.008$8, Layer $4.008$8, Cable Connectors $3.15$3, $51,861.60