1. ECAL End Cap Schedule issues Justin Greenhalgh This presentation will be at http://www.eng-external.rl.ac.uk/cms-gen/Project_papers under EE356

2. Jul 2003 ECAL End Cap EE/356/RJSG/2003Justin Greenhalgh - RAL 2 Agenda outline Part one - introductory comments (Justin) Part two – comments from –Paul (crystals) –Brian (supercrystals) –Lucy (Dee lab) –Jordan (Electronics) –Ken (Commission, test, integration) Part three – a schedule? (Justin) Part four – other issues (Austin, Dave)

3. Jul 2003 ECAL End Cap EE/356/RJSG/2003Justin Greenhalgh - RAL 3 (Part 1) Attempt to reach a coherent picture But things are changing fast…

4. Jul 2003 ECAL End Cap EE/356/RJSG/2003Justin Greenhalgh - RAL 4 Key issues connected with crystals Supercrystal production rate –Deliveries of parts (esp crystals - PAUL) –Rate of work in RC (BRIAN) Speed to assemble a Dee: –Speed to assemble the SC onto a Dee (LUCY) –Speed to assemble the electronics onto a Dee (JORDAN) Dee commissioning, test, integration (KEN)

5. Jul 2003 ECAL End Cap EE/356/RJSG/2003Justin Greenhalgh - RAL 5 Not to forget… Services Integration activities (Dee fitting to HE, etc) Etc etc

6. Jul 2003 ECAL End Cap EE/356/RJSG/2003Justin Greenhalgh - RAL 6 Basis of estimates John Connolly (with Brian and Tony) developed estimates for SCs We have more experience now, but beware: –Based on barrel –Do not forget start-up times Who prepares the estimates? –Justin (beware) –Whoever is going to do it (much safer)

7. Jul 2003 ECAL End Cap EE/356/RJSG/2003Justin Greenhalgh - RAL 7 (Part 2) ECAL planning, main milestones, v33.1/ new profile for EE crystal productionP Lecoq SC build estimatesB Smith Dee mechanical assembly profilesL Linssen Profile for EE prototype and final electronics/ Dee electronics integrationJ Nash Dee installation and commissioning in CMSK Bell

8. Jul 2003 ECAL End Cap EE/356/RJSG/2003Justin Greenhalgh - RAL 8 (Part 3) An attempt at a coherent schedule Done last night, BEFORE I had seen most of what has just been said – but after discussion with Jordan and email from Lucy, and having seen Paul’s slides from Tuesday. What’s involved Assumptions – what would happen if… “Scenario 4” schedule –excludes comm, test, integration Caveats

9. Jul 2003 ECAL End Cap EE/356/RJSG/2003Justin Greenhalgh - RAL 9 What’s involved? SC - See Brian’s talk Dee pre-assembly (NOT dependent on SC) –Fit Dees 1+ 2 together –Fit cooling pipes to BP –Fit Env shield to Dee –Test OES + BP cooling systems (Arbitrary split…)

10. Jul 2003 ECAL End Cap EE/356/RJSG/2003Justin Greenhalgh - RAL 10 Dee lab –SC, FOM, HV cabling –Fitting the inner and front moderators (the front moderator may be quite an awkward thing to assemble around the umbilicals) –Fitting the piping for the power cooling (which will probably go in after the front and inner moderators) –fitting any required thermal shield –fitting the low voltage cabling layer –fit the support rails for combs and mothercards –fitting the mothercards which includes wiring them to the SC with any knitting required –fitting the combs that support the cooling bars, and the cooling bars –prefit the cooled rear moderator –testing the power + rear moderator cooling circuits –remove the cooled rear moderator Sequence??

11. Jul 2003 ECAL End Cap EE/356/RJSG/2003Justin Greenhalgh - RAL 11 Integration centre Integration lab tasks: –fitting the VFE, FE, and regulator cards –fitting the fibres –system tests that need, or may need, access to the electronics Integration lab mechanical tasks –refit the cooled rear moderator –retest piping (hope nothing leaks!!!) –retest system (cooling + electrical)

12. Jul 2003 ECAL End Cap EE/356/RJSG/2003Justin Greenhalgh - RAL 12 Crystal numbers

13. Jul 2003 ECAL End Cap EE/356/RJSG/2003Justin Greenhalgh - RAL 13 Assumptions – crystal delivery EE crystals in production quantities in Q4 of 2005 AT THE RCs Some deliveries sooner than that to allow –Refinement of production processes –Staff training –Staff continuity (we don’t lose Brian!) NO STOCK at RCs Uniform delivery over the quarter – ideally, front-loaded.

14. Jul 2003 ECAL End Cap EE/356/RJSG/2003Justin Greenhalgh - RAL 14 Assumptions – SC production rate Slow for the first year, but that gives time to fully develop all processes, buy tooling, etc. Transfer of expertise to second RC before production quantities arrive Ramp abruptly from 2/week to 5/week at both RC. –No point in going faster because of crystal production rate limits. Partial SCs keep up

15. Jul 2003 ECAL End Cap EE/356/RJSG/2003Justin Greenhalgh - RAL 15 Crystal delivery + SC production Jump

16. Jul 2003 ECAL End Cap EE/356/RJSG/2003Justin Greenhalgh - RAL 16 Learning process 4 months in the Dee lab post-learning 4/day = 20/week, 8 weeks for 160 SC Dee has 138 full and 18 partial = 156 SC/Dee –==>2 months to assemble SC –2 months for mechanical bits of mechatronics 2 months Integration centre (B 867) –1 month for electronic bits (assumes wires etc pre-cut using a mockup) –2- 4 weeks retest + cooled rear mod Times – Dee lab + integration centre Lucy Justin Jordan

17. Jul 2003 ECAL End Cap EE/356/RJSG/2003Justin Greenhalgh - RAL 17 Scenario 4 100 3004503200 per quarter………..

18. Jul 2003 ECAL End Cap EE/356/RJSG/2003Justin Greenhalgh - RAL 18 BEWARE How to build up trained staff quickly enough in the RC? There is little room for slack or contingency –EQUALS RISK (time and money) This is broad brush planning - the devil may be in the detail as regards cost or time –So detailed planning is required by the folk who will do it. Delivery at RC, not from Bogoroditsk No stock at RC (unrealistic) Costs have been ignored

19. Jul 2003 ECAL End Cap EE/356/RJSG/2003Justin Greenhalgh - RAL 19 (Part 4) Cabling/service installation deadlinesA Ball E0' and Dee beam testsD Cockerill Conclusions and action planAll