Ian Crotty HPL (Bakelite) Up-Scope 27 Aug 08 HPL for the Up-Scope of the RE in CMS Contents Specification Contingency Supply Chain Purchasing QA & QC Packing & Transporting Production Rate Scheduling Conclusion

Ian Crotty HPL (Bakelite) Up-Scope 27 Aug 08 CMS End-cap RPC Bakelite High Pressure Laminate (HPL) Specification was taken from previous RPCs production 1-6 x10^10 20°C. Average roughness (Ra) = <0.2 micrometre, 2 mm thick Melamine surface paper with Phenolic Bulk Sheet dimensions according to cutting plan Temperature coefficient w.r.t resistivity is given by the raw material and obtained for normalisation during QC It would be good to go back and check that we are still getting this value for the roughness

Ian Crotty HPL (Bakelite) Up-Scope 27 Aug 08 Contingency from past experience The contingency was decided upon after the calculation of the nominal number of sheets. The nominal sheet quantity is given by the cutting plan. Chamber spares was decided upon at 10% The initial order to cover low eta RE1, 2 & 3 for the EndCap included 43% HPL. A rejection rate of 30% at gap production and final chamber QC test in the ISR was assumed. In total a 50% contingency on HPL production was decided. We consider this to be sufficient for the up-scope.

Ian Crotty HPL (Bakelite) Up-Scope 27 Aug 08 HPL Supply Chain Frati Laminat Milano Production and QA & QC Riva (Milano) Cutting to form GT (Roma) Surface treatment with MEK Korean Gap Assembly Shipping by Air and/or Maritime Order from CERN To PanPla Pakistani Chamber Assembly Belgium Chamber Assembly Indian Chamber Assembly

Ian Crotty HPL (Bakelite) Up-Scope 27 Aug 08 PurchasingPurchasing First step is the budget. If CERN managed then tax free As the amount is > 100kchf then a divisional request is needed. No call for tender and time for suppliers to reply. Justification for “single source” order. All this takes some time, we should move ahead asap

Ian Crotty HPL (Bakelite) Up-Scope 27 Aug 08 Resistivity QC in Pan Pla This device is now used to do the pre-selection in PanPla before shipping to Pavia Also used to Calibrate the Resistivity table

Ian Crotty HPL (Bakelite) Up-Scope 27 Aug 08 Pan Pla HPL Production and QC Dedicated Resistivity measurement rig Bar code and visual inspection of raw material. Finished productsorted according to resistivity. This operation is run by colleagues from Pavia with a representative from RE.

Ian Crotty HPL (Bakelite) Up-Scope 27 Aug 08 The Phenix QC experience July 08 Colleagues from the US have successfully used the Resistivity table that is now installed in the Pavia University facilities. Pneumatically actuated conductive Rubber pads Logistic to be improved

Ian Crotty HPL (Bakelite) Up-Scope 27 Aug 08 Table reinstalltion and upkeep There is some maintenance work to be done such as temperature gauge and perhaps the elastomeric electrodes which have increased in resistivity over the 8 years of operation. Now that we no longer have access to the dedicated forklift the logistics of moving around loaded palettes is far more difficult and occupies more space. The operating team requires 5 people that will have to come from the collaboration as Pavia will not be able to man the test sessions as previously done.

Ian Crotty HPL (Bakelite) Up-Scope 27 Aug 08 A production run from 2003 This a good run as few sheets are out side the window of 2- 6 values Rejection rates can vary from 5 to 95% !

Ian Crotty HPL (Bakelite) Up-Scope 27 Aug 08 Yield for Phenix There are now two levels of selection each of which will expect a certain loss. In the case of Phenix during July Factory tests Produced410 Selected317Yield = 77% 2Pavia University Jig Received 317 Selected262Yield =83% Overall Yield= 64% Phoenix and CMS use the same panel size 1.6 x 3.2m

Ian Crotty HPL (Bakelite) Up-Scope 27 Aug 08 Production Rate A production rate of panels per day can be expected when full scale production is underway. New RE2 requires about 1000 sheets which equates to 40 working days or 3 months Within one month of the contract being received they can start our requests. The same contractual conditions should apply in terms of accepting only good panels at the second stage, the remainder returning to the factory.

Ian Crotty HPL (Bakelite) Up-Scope 27 Aug 08 Riva Milano Cutting to Form CNC tooling Cycle time 5mins/sheet HPL QC on dimensions. Tolerance +0mm and -0.5mm Checking cutting head and stability of panel retention

Ian Crotty HPL (Bakelite) Up-Scope 27 Aug 08 TransportingTransporting In this international collaboration there is a large overhead in the supply chain. Regulations for “triangular traffic” to retain the tax free status Phytosanitary regulation in most countries for the packing materials. High costs due to large distances. Packing Design

Ian Crotty HPL (Bakelite) Up-Scope 27 Aug 08 PackingPacking Fork lift damage A simplified version The Load is not attached to the base and has slipped Looks fine but is heavy and expensive

Ian Crotty HPL (Bakelite) Up-Scope 27 Aug 08 Production or Throughput Rates The production rate capability of PanPla is large. However the HPL has to stabilised in the Air-conditioned hall for QC were its humidity and temperature can be controlled to some degree. This limits the quantity per production batch to some 300 sheets, weighing in at approx 2.5 tonnes, it takes a few days to stabilise. This quantity was sufficient on occasions, if the yield was ~70%, for the 200 sheets required to build half a full station. Riva will take 2-5 days to cut this material and repack but will not want to work continuously as the main machine is occupied as is the floor space and personnel. This results in 2 boxes of some 600kg to ship to Korea where space is also limited.

Ian Crotty HPL (Bakelite) Up-Scope 27 Aug 08 Installations possible in September 09 and February 10 First HPL to Kodel in Early December 08 Four Gap production periods REplus 2 RE minus 2

Ian Crotty HPL (Bakelite) Up-Scope 27 Aug 08 ConclusionsConclusions Heavy shipping around the world, firstly within Italy then to Korea, India, Belgium and Pakistan and back to CERN The initial outlay is high for the HPL contract High transport costs especially by air freight Different QC stages require people and time We managed for the past and we can do it again but committed people are needed