WBS 1 - Endcap Muons

1. WBS 1 - Endcap Muons • Guenakh Mitselmakher • DOE/NSF Review • May 8, 2001

2. Outline • Project Overview • Status and Technical Progress (chambers and electronics) • Installation schedule and technical progress on installation tooling • Critical Path Analysis • Cost/Performance and Estimate To Complete • Plans for the next six months and SOWs • Issues • Summary and Conclusions

3. Endcap Muon System

4. CMS Endcap Muon System • 360 CSCs, not counting ME1/1 and ME4 • 144 Large CSCs (3.4x1.5 m2): • 72 ME2/2 chambers • 72 ME3/2 chambers • Small CSCs (1.8x1.1 m2): • 72 ME1/2 chambers • 72 ME1/3 chambers • 20o CSCs (1.9x1.5 m2): • 36 ME2/1 chambers • 36 ME3/1 chambers • Frontend Electronics: • 170K Cathode channels • 140K Anode channels • Trigger&DAQ • (on-chamber part) • Alignment&Services

5. EMU - Yearly BCWS • FY01 is the second largest year of EMU funding: • Production of chambers at Fermilab at nominal rate • Purchasing of significant part of FE electronics • Finalization of integration and installation design

6. US CMS EMU Resources • FY01 is the peak year for manpower usage: • Chambers and FE- electronics are in production • Finalization of design (electronics, integration, installation)

7. CSC Production Sites • 398 chambers ME1/2, ME1/3, ME2/1, ME2/2, ME3/1, ME3/2, ME4/1, (ME4/2-staged) • 148 ME2/2 and ME3/2: Fermilab, University of Florida, University of California • 148 ME1/2 and ME1/3: IHEP-Beijing, • 114 ME2/1, ME3/1, ME4/1: PNPI-St.Petersburg • 72 chambers ME1/1 • Dubna • Typical production rate at each of the sites: ~ 1 chamber per week for three years

8. EMU Chamber Status • Fermilab Site (Panels for 410 CSCs; Assembly of 148 Large CSCs): • Panel production since May 1999; 52% of chambers done; on schedule • CSC assembly since July 2000; 32 out of 148 large CSCs done; ~2 wks late • UF and UC Sites (Final Assembly and System Tests of 148 Large CSCs) • First 5+5 CSCs arrived to UC and UF and will be set for long term HV test • Assembly with electronics and Tests will begin in September 2001, ~3 mo. late • Delivery of on-chamber electronics is on critical path • PNPI Site (114 smaller CSCs) • Critical tooling commissioned, 2 chambers assembled • PRR—June 7-8, Start of production in August • IHEP Site (148 smaller CSCs) • Critical tooling arrived and mostly commissioned, assembly of the 1st CSC began • PRR—July 30-31, Start of production in September

9. Chamber Assembly Gluing Station (anode bars, gap bars are glued to panels) Winding Station (wires are wound directly on panels) Soldering Station (automated soldering of wires) Wire Tension/Spacing Station (tension and spacing of wires are checked) Ionized Air Knife Station (dust is removed from wires and panels) Assembly Station (panels are stacked to make chamber)

10. FNAL Factory Status - Chamber assembly at MP9 • 32 large CSCs assembled by May 2001 • > 20% complete • Production ~ at nominal rate • ~ On schedule

11. CSC Production at PNPI • Critical tooling delivered from Fermilab • Preproduction started • PRR June 7-8 Winding machine at PNPI

12. CSC Production at PNPI Preproduction Prototype (P3) assembled at PNPI

13. CSC production at IHEP • Critical tooling received Wire Tension measurement machine

14. CSC production at IHEP • Assembly of a preproduction prototype started

15. Cathode LCT - Trig Motherboard DAQ Motherboard Clock Control Board PC Interface Board VME cont ro l CLCT TMB PCI Bus Muon Sector Receiver Lev-1 Trigger ) (DAQ data PC DDU DM B C C B M P C Slow Control Trigger-Timing-Control (TTCrx) VME Crate 1 of 5 1 of 5 Cathode Front-end Board 3x6 ASICs, 2 FPGAs, channel Links, Buffers CFEB CFEB CFEB CFEB CFEB Anode LCT Board FPGA’s, ASICs Channel Links 1 of 24 ALCT Anode Front-end Board 1 ASIC CSC CSC Electronics

16. EMU on-chamber electronics status • Three out of four on-chamber boards: Cathode Front-End Boards (CFEB), Anode Front-End Boards (AFEB) and Low Voltage Distribution Boards (LVDB) designed and tested • Most of the components for these boards (excluding rad hard LV-regulators) procured in quantities sufficient to start the production • Production costs are at or below estimates • LV-regulators (CERN design, standard for LHC experiments) are not available. Will define the schedule of production of CFEB and LVDB. On the critical path • ALCT is redesigned using faster reloading FPGA (Zilinx) to solve the radiation damage problem. Preproduction boards to be delivered by August 2001. On the critical path

17. EMU off-chamber electronics status • Updated versions of the prototype off-chamber boards will be delivered to the FAST sites during this summer. They will be used for tests of mass-produced on-chamber electronics assembled with chambers.

18. Integration and installation design • EMU integration design advanced (mechanical, gas, cooling, power) • Installation procedures • being defined • Installation fixture • fully designed and built

19. CSC installation fixture Counterweight movement keeps balance w/ or w/o chamber Chamber can rotate at any angle Demonstration of installation on May 9 at MP9 (tour) Counterweight

20. Chamber Production and Installation Schedule (V31) • CMS Schedule V31: Installation of all CSCs on the surface at SX5, beginning in 2002 • Very tight, advanced by ~1 year compared to previous schedule. Pressure on production and installation rate. Optimization may be necessary.

21. EMU Critical Path Analysis -I • FY01: Delivery of on-chamber electronics is on the critical path: • ALCT Board redesign and start of production • Rad Hard Voltage regulators:  CFEB, LVDB production • FY02: CSC production at FAST sites and installation at CERN is on the critical path

22. EMU Critical Path Analysis -II • FY03: CSC Installation (station ME3) is on the critical path: • short installation window (two shifts necessary) • FY04: CSC Installation (station ME1) is on the critical path: • RPC must be installed before CSCs • HE, EE, SE, ME1/1 cables should be installed before CSCs • Short installation windows (two shifts) • Available Slack analysis: ~25-30 working days in 2002. Very tight in 2003 –2004. Need two shifts for production at IHEP and installation.

23. EMU cost/performance analysis

24. EMU – Estimate to Complete • EMU Estimate to Complete: 18.9 Actual Year M$ • Dominated by M&S (mostly electronics)

25. Plans for the next 6 months • Continue chamber production at Fermilab • Start chamber production at PNPI, IHEP • Continue FE-electronics production • Start electronics assembly with chambers and tests at FAST sites • Complete chamber/electronics integration drawings for all chamber types • Begin preparations for chamber receiving and installation at CERN

26. SOW 01 - EMU • EMU SOWs FY01 : Total $6.1M • Fermilab – chamber production, on-chamber integration • Wisconsin – design: off-chamber integration, installation • OSU, CMU, UCLA – electronics production • UF, UCLA – FAST sites (electronics installation, tests) • Northeastern – Alignment design

27. Issues: • Electronics is on the critical path: • LV-regulators (CERN development) • trigger boards • Additional base program support needed for FAST sites operations and to provide physicists manpower at CERN for installation and commissioning • Potential cost increases should be closely monitored. This includes: • Scope increases (items not in the original MOU with CMS) – missing Russian funding, infrastructure, general integration… • Cost increases due to the overal CMS schedule slippage (marching army costs)

28. Summary and Conclusions • Nominal rate of chamber production at Fermilab achieved. Chamber production on schedule • FE- Electronics production started, first cost experience positive • LV-regulators and trigger boards on the critical path. Define the beginning of assembly at the FAST sites • Installation fixture designed • Adequate base program support is critical to maintain the schedule