1. Service channels between Tracker and PP1
Installation order and Component status
Mock-up plans
TK Engineering Meeting 4 September 2007, Antti Onnela, CERN

2. Summary of installation order and component status
Installation order per PP1
Component
Status and remaining preparations 1
Cable channels
All channel pieces available at CERN ( spares of each type). Channel 1-2:
HCAL attachments and fiber supports welded and ready.
Copper plate attachment screws being prepared (drilling + welding). Cutting of channel 1 tip edges to be done.
Edges to be taped.
Channel 3:
Fiber supports made, to be welded.
Cooling pipe supports being designed, to be produced, and attachments to be made in channel 3.
Passage slots for ECAL optocables need to be cut bigger.
Channels 4 and 5:
Edges taped. READY FOR INSTALLATION.
Channel covers:
All pieces available.
Channel 1, 3, 5 covers need shortening / bending.
Other:
Channel 1-2 screws to be modified.
All other screws and washers available.
Shims for channel 1-2 being produced.

3. Summary of installation order and component status
Installation order per PP1
Component
Status and remaining preparations 2
Water cooling circuit
Preparations (Meyrin site):
10 mm pipe material available at CERN.
Copper plates in production (80% ready, rest within ~1 week).
Assembly jig designed and under construction (ready within ~1 week).
First assembly to start in week of 10 September.
Main challenge: Soldering between copper pipe and plates.
Estimated production rate (2 pers.): 2 units per day, ~1 month for all.
Installation (Point 5):
Transport and handling tools still to be developed and made.
For installing need good access to cable channel and PP1 (important!).
Normal soldered capillary fittings to be used in connections, 2 per PP1.
Soldering equipment ready.
Leak tests to be done with pressure water? Can test only in groups.
Note on the installation order:
Installation of cable channels + water cooling much simpler and safer if done before Tracker installation.
But bottle-neck and uncertainty: When will ECAL + HCAL allow installation of TK channels?

4. Summary of installation order and component status
Installation order per PP1
Component
Status and remaining preparations 3
Temp + humidity sensors
Sensors and cable material ordered.
Sensor protections being designed, and need to be produced.
Cabling of the sensors to be done.
Installation in channels simple and fast (1 day by 2 teams of 2).
PP1 connectors and connectorisation, can they be done in advance?
How is the testing done? 4
Cooling pipes leak test
(Includes special pipes from PP1 to TK end)
3D-design ready, except for last specials (pixel + thermal screen).
2D-drawings made for TEC pipes, all others made from 3D-coordinates.
3D-coordinates ready for 75% of Barrel and TEC pipes.
Order placed to pipe bending company.
14 pre-production pipes (one PP1) should be available by mid-September.
Pieces for ceramic PP1 fittings received. Vacuum-brazing done for first 50 connectors. Production speed 50 connectors per week (9 weeks to finish the production)
Argon leak testers (2) received.
Argon battery to be bought and installed in UXC.
Argon feed-lines and valves to be installed to reach the cooling manifolds at balconies. 5*
Barrel optoribbons
Optoribbon supports made + installed on TK.
Optoribbons regrouped and coiled on the supports.
Assembly help tooling being developed and tested on mock-up.
READY FOR INSTALLATION.
* After removal of the nose cone the barrel optoribbon installation can be done in parallel with pipe and barrel cable installation.

5. Summary of installation order and component status
Installation order per PP1
Component
Status and remaining preparations 6
Pipe insulation
Armaflex AF approved in June by CERN safety.
All material available for PP1’s and TK ends. Material for cable channel to be ordered.
Insulation in PP1 Y-pieces: all standards done, some specials remaining. 7
PP1 heating cable
Cable roll and end plugs received at CERN.
Cutting and connectorisation to be done. Connector choice to be made!
Support clamps to be ordered. 8
Barrel MS & Ctrl –cables
Barrel cables labeled with PP1 connector names and bundled by ½-channels on nose cones.
READY FOR INSTALLATION. 9
TEC MS & Ctrl –cables
Cables in production. 10
TEC Optoribbons
Reference point (channel 1-2 junction) marked on TEC ribbons.
TEC optoribbons regrouped and coiled in the boxes at bulkhead. 11
Other:
Short pipe sections from TK end to PP0; Heating wires and cables in special sectors; Bulkhead covers; Proto Pixel; Beam-pipe supports

6. Cabling mock-up plans 1 Dismounting of present setup 2
Step
Task
When? 1
Dismounting of present setup
Remove cables and cooling pipes from both ½ channels.
Before mid-September 2
Test installation of water cooling (2nd option: this is done directly at CMS)
Replace channel pieces where needed, to allow attachment of water cooling.
Install water cooling set.
Install temp sensors in the channel and PP1
3rd week of September 3
Test with pre-production standard pipes
Install pipes
Use final type of pipe supports (to be made)
Install insulation
Install cables (all available)
End of September 4A
Test with special channel pipes (one ½ channel)
Install pipes in one ½ channel
Pipe supports in the channel and at PP1 ?
Thermal tests?
October 4B
Test with special channel cables (one ½ channel)
Install cables in the other ½ channel (enough of cables available?)
Cable connections at PP1 ?

7. Installation steps 1: Cable channels + 2: Water cooling
Tracker
STEP 1:
Install cable channel, made of 5 sections (sections 1 and 2 are one unit)
All attached to HCAL with screws
Section 1
Section 2
Section 3
STEP 2:
Install 10 mm water cooling pipe, one loop around channels “A” and “C” with its copper cooling plates (not shown here)
Copper plates attached to channel pieces with screws
Section 4
Section 5
Braze connections in PP1 and leak test water circuit
PP1

8. Installation step 3: Temperature and humidity sensors
Per PP1 sector the sensors are only in one ½ channel
In top and bottom sectors the sensors are in the special ½ channels
“Min-max against ECAL”:
1 sensor at far corner away from water cooling
1 sensor next to water cooling
Route sensor wires along 10 mm cooling pipe up to connector in PP1

9. Installation step 3: Temperature and humidity sensors
Wires from ECAL area run along the 10 mm water pipes up to the connector (Note: Per channel only “A” or “C” side, never both)
“Hot at cable entry”:
Tight packing of cables entering PP1
“Cold against ribbons”:
On the inside wall below multi-ribbon cables
Total amount of sensors per channel: 2 temp sensors at ECAL + 2 in PP1 1 humidity sensor in PP1
D-SUB connector (with humidity sensor) and pre-installed cable to racks

10. Installation step 4: Pipes
Install male Lancasher fitting + first bend piece
Measure the correct length of the copper pipe end
Remove Lancasher fitting, cut the pipe and solder them together
Install the pipe definitively
Installation step 4: Pipes
Attach the pipe to the temporary mid-support (subsequent pipes attached to previous ones)
Cut the pipe to correct length
Solder the pipe with ceramic fitting
Clamp the pipe with support block (every 2 pipes)
Leak test with Argon (every 2 pipes)

11. Installation step 5: Barrel optoribbons (after removal of nose cone)
Ribbons have been pre-bundled in TIF to match the channel shapes

12. Installation step 6: Pipe insulation, from TK to mid-support
2 layers of 9 mm Armaflex AF insulation, with joining tape
In channels 1 and 2 must reduce insulation to allow space of cables. Where possible use 3 mm tape in addition
Insulation of individual pipes at TK end is still to be studied:
3 mm tape?
Tubular insulation?

13. Installation step 6: Pipe insulation at mid-support
Mid-path support with this element.
During pipe installation use temporary support
This support shall be slightly closer to optoribbons, to provide space for cables next to water pipe.
This support shall also be a bit further away from the pipe bend, to ease insulation joint.

14. Installation step 6: Pipe insulation from mid-support to PP1
From mid-supports to PP1 use 18 mm insulation or 2 layers of 9 mm.

15. Installation step 6: Pipe insulation in PP1
Inside PP1 use precut flat pieces, glued together
Glued junction from tubular to rectangular section at PP1 entry
Insulation of Y-section being done alreardy now!

16. Installation step 7: Heating cable in PP1
30 W/m heating cable,
length ~7 m / standard PP1,
Routed on outer surfaces of the pipe channel
connection

17. Installation step 7: Heating cable in PP1
Aluminium or plastic clamps and aluminium tape on top of the cable
Heating cable follows the Y-piece (not present in this photo)

18. Installation step 8: Barrel MS & Ctrl cables
Channel sections 1-4
Here we have installed 7 cooling pipes 40 multi-service cables
This represents the biggest channel occupancy, which is 7 cooling pipes 38 multi-service cables 6 ctrl-cables (≈ 2 MS-cables)
Channel section 5

19. Installation step 8: Barrel MS & Ctrl cables
The covers fit, tightly
Edges of covers 2 and 5 need to be slightly bent, to avoid scratching cables

20. Installation step 9: TEC optoribbons
Channels for these ribbons to reach the PP1 are at these phi-locations
1 cm
All pipes, including TEC pipes, must be in place and insulated before installing optoribbons
Installation step 10: TEC cables
Installation step 11: Special cables, etc.
Last 1 cm of TK volume for TEC cables