1. Internship final presentation Paula Skrobucha September- October 2015 Cracow University of Technology Paula Skrobucha PH-DT26/10/2015

2. Paula Skrobucha PH-DT26/10/2015 Main tasks  Become familiar with industrial calibration station  Test and calibrate motherboards  Leak and electrical tests of old 5mm flow cells  Leak and electrical tests of new 3mm flow cells  From the above tests verify method of manufacturing  Calibrate new 3mm flow cells using different numbers of set points to investigate nominal calibration method  Check modifications to manifold mounting pins, opening/closing clearances, bar code reader mask.  Test old and new, 5mm and 3mm flow cells using new test program. Investigate repeatability of flow readouts and accuracy/tolerance

3. Paula Skrobucha PH-DT26/10/2015 Calibration station General information

4. PT100 Flow Cell Paula Skrobucha PH-DT26/10/2015 Approximately 3000 installed in LHC experiments.

5. How it works Paula Skrobucha PH-DT26/10/2015

6. Paula Skrobucha PH-DT 26/10/2015

7. Modifications of calibration station. At the beginning the space between pistons and manifold was to too small and made manifold unable to open. New magnet straps New solid pegs Paula Skrobucha PH-DT26/10/2015

8. Paula Skrobucha PH-DT26/10/2015 Motherboards Testing and calibrating

9. Motherboard Potentiometers Setting 100Ω for potentiometers P5, P6 and P7. Visual check- motherboard should contain all the selected items. Paula Skrobucha PH-DT26/10/2015

10. Standard lines Input (white) and output (red) plots should be between standard lines (green). For this purpose we adjust potentiometers to change plots positions. Paula Skrobucha PH-DT26/10/2015 Calibrating motherboard

11. Standard lines When input and output plots are between standard lines we can carry out the cabling test. Paula Skrobucha PH-DT26/10/2015

12. Flow cells Testing and calibrating Paula Skrobucha PH-DT26/10/2015

13. Leak test Pressure value Open the valves to obtain the required pressure, then close valves and estimate the pressure drop over time (e.g. 3 minutes). Max. pressure drop for 1 manifold= 3mbar/min. Setting the flow rate. Paula Skrobucha PH-DT26/10/2015

14. Due to large leaks we used two new methods of bonding in order to obtain better results of leak test. Also some of flow cells were re-machined- all the old adhesive has been removed from the bonding surface. 1st method of gluing 2nd method of gluing Re-machined flow cells are much better than not re-machined. Glue Paula Skrobucha PH-DT26/10/2015

15. Test pressure 0.5 bar 1 bar 1.5 bar 1 2.6 mbar/min 0.005 l/h 5.4 mbar/min 0.011 l/h 12 mbar/min 0.024 l/h 2 1.3 mbar/min 0.003 l/h 3 mbar/min 0.006 l/h 7.7 mbar/min 0.015 l/h 3 1.3 mbar/min 0.003 l/h 2.7 mbar/min 0.005 l/h 3.1 mbar/min 0.006 l/h 1- batch of original flow cells 2- batch of re-glued flow cells 3- batch of re-machined and re-glued flow cells *occasionally even re-machined are leaking Paula Skrobucha PH-DT26/10/2015

16. Cabling test of flow cells. Failed cabling test. If individual values are not similar it’s necessary to check all the connections and carry out the test again. Paula Skrobucha PH-DT26/10/2015

17. Passed cabling test. Paula Skrobucha PH-DT26/10/2015 If everything is working properly individual values are similar.

18. Calibration of flow cells Paula Skrobucha PH-DT26/10/2015 To configure the calibration, scan IDs of flow cells first.

19. Calibration configuration The more points, the curve is more accurate but calibration time is extended. Paula Skrobucha PH-DT26/10/2015

20. Calibration curves Good curve Paula Skrobucha PH-DT26/10/2015

21. Paula Skrobucha PH-DT26/10/2015 Flow cells with curves like these give us bad results during testing.

22. Testing flow cells. Paula Skrobucha PH-DT26/10/2015

23. Paula Skrobucha PH-DT26/10/2015

24. Test results for flow cells calibrated with 6 set points Paula Skrobucha PH-DT26/10/2015

25. Test results for flow cells calibrated with 6 set points * Difference in %- difference between mass flow controler and measured flow. Flow cells calibrated with 6 set points. Paula Skrobucha PH-DT26/10/2015 5 l/h

26. Repeatability tests At nominal flow rates max. deviation between successive measurements is less than 0.7% of flow range.

27. Comparison of test results for flow cells calibrated with 4 and 6 set points Flow cells calibrated with 4 set points Paula Skrobucha PH-DT26/10/2015 Flow cells calibrated with 6 set points

28. Comparison for 4 and 6 set points calibrated flow cells. For low flow range (5 l/h) results are much better for flow cells calibrated with 6 set points. Paula Skrobucha PH-DT26/10/2015 * Difference in %- difference between mass flow controler and measured flow. Flow cells calibrated with 4 set points Flow cells calibrated with 6 set points

29. 5mm flow cells 3mm flow cells Comparison of test results for 5mm and 3mm flow cells. Paula Skrobucha PH-DT26/10/2015 Flow cells calibrated with 4 set points.

30. Summary  New test program had some bugs but is now working properly  3mm flow cells give better results than 5mm flow cells (both types were calibrated with 4 set points)  3mm flow cells calibrated with 6 set points give better results than 3mm flow cells calibrated with 4 set points, with considerable improvement at lower flow set points (max. error compared to set point approx. 1.7% achieved across entire flow range)  3mm flow cells exhibit good repeatability characteristics  Current method of manufacture (gluing/soldering) is generally acceptable at 0.5 bar - by testing at higher pressure a more leak tight method of gluing has been established (and in some cases re-machining the aluminum cut-outs)  Over 200 old 5mm flow cells tested, 200 new 3mm flow cells tested and calibrated Paula Skrobucha PH-DT26/10/2015

31. Thank you for your attention! Paula Skrobucha PH-DT Cracow University of Technology 26/10/2015 Thanks to my supervisor Steve Pavis Thanks to the gas team for hosting me!