CMS Upgrade Workshop

1. CMS Upgrade Workshop Updated ME4/2 chamber construction costs and prototype Status and plans of prototype construction Cost estimation for ME4/2 chamber factory production

2. ME4/2 Chamber Prototype Construction In framework of preparation of the EMU upgrade project it was decided to construct the ME4/2 chamber prototype to be ensure that: - we can use new material (lost vendors due to out-of-business, discontinue products,…) - critical tooling is available (Axiom, Gerber, winding, tension, soldering, tension,…) - knowledge and technology has not been lost - a prototype performance meets our technical specs We have a plan to install a prototype on the disk during this shutdown that is prototype will be completed in the nearest time. It will be a working chamber. We use a production tooling with standard procedures and travelers to provide a high quality of the ME4/2 prototype.

3. Prototype Status - All required chamber parts have been prepared for prototype construction. - 10 panels have been machined with using Axxiom and Gerber machine. - All tooling and panels were relocated in Nov. 2008 from Lab.8 (original location for chamber production) to MP-9 (clean room, more space, experience people). - Started work with prototype construction last week. Hand cleaning for the anode panels have been completed. - Assembly anode and cathode panel gluing tooling will be completed on the next week. - Winding machine wasinstalled in the clean room and ready for winding. Expectation is to start winding in December.

4. Tooling Status • A list of critical tooling: • Automatic panel cleaning machine (will do not use for prototype) • Axxiom machine (panel cutting and drilling) – restored, works • Gerber machine (strip milling) - restored, works properly • Gluing machine (restored) • Clamping tables for anode and gap bar gluing (in preparation) • Winding machine – prepared for winding • Soldering machine (will do not use for prototype) • Wire spacing and tension measuring machine (will be moved from Purdue, assembled and used for prototype production) • Ionized air cleaning machine (will do not use) • Panel, chamber carts (assembled, ready for production) • Assembly table (assembled, ready for production) • Quality control and test equipment (available production) • All tension machine was disassembled and stored at Purdue. • Equipment will be shipped to FANL in the nearest time for assembly and testing. This machine will be used for prototype production.

5. Axiom and Gerber Machines Gerber machine Axxiom machine AXIOM and Gerber machines (panel cutting, drilling and strip milling) are in operation mode. 10 panels: 5 with new and 5 with old GE skins were machined. Lifting machine

6. Chamber Tooling at MP-9 All tooling and chamber pars are at MP-9. A clean room for winding, clean production area Good support from MP-9 people with experience of ME234/2 chamber production

7. Hand Panel Cleaning Completed anode panels Dents, roughness Hand cleaning Very hard and dirty work: ~ 3 hours per panel (2 technicians) For mass production automatic panel cleaning machine must be used

8. Prototype Production Plans Prototype assembly has been started at MP-9 We have a good support from TD to complete a prototype in the nearest time To restore tension and wire spacing machine we need an expert from Purdue who will help with machine assembly and testing. Preliminary, Adam Bujak from Purdue can come to FNAL to help with machine operation and help with measurements. He could come in December to setup machine and then in Jan/Feb to help with measurements and prototype tests. He could be stay at FNAL for 2 months in total. It is a great help for prototype tests We need funding for Purdue. It is planning to complete prototype production in February with shipping to CERN in March 2009. It will be a completed and working chamber. A scope of work what we are doing at MP-9 is comparable with work required for the factory setup for the ME4/2 chamber mass production. We need additional funds for prototype construction.

9. CSC Factory Production: Labor and Cost Estimation • Chamber parts cost estimation • Factory setup • Panel production (Lab.8) • Chamber production (MP-9) • Input chamber part QC/QA (IB-4) • Procurement, kit preparation, shipping • Cost comparison (CERN and FNAL)

10. Chamber Parts Cost Estimation (2008) * Price of FR-4 skin increased from $164 (2003) to $ 660 (2008)

11. FR-4 Copper Clad Skin Problems • GE who made sheets discontinued this line of production • Spent more than 3 years looking for around new vendor • 3 candidates: Aurora Technology, US Laminate, Plascore • Small quantity production: • - Aurora Technology  setup 93k$, $2,850/sheet • - US Laminate  no charge for setup, $1,250/sheet  received 10 sheets • - Plascore is interested only for large quantities production • Large quantity (1100 sheets): • - Aurora Technology  $660/sheet • - US Laminate  $719/sheet • - Plascore  no quote • It is terribly bad to have just one vendor for the production (price, quality,..) • We have had renew negotiation with Plascore and they started work to make • FR-4 sheet of 5’ x 12’ size. Plascore looking for raw material to get copper foil and • fiber glass material. It is expected to have a respond from Plascore in few weeks. • After getting quotes for raw material we will prepare a detailed R&D plan for small • quantity skin production at Plascore. We need funding for this program.

12. Factory Setup Preparation CSC factory production setup: • Semi-clean room construction, area cleaning, • Tooling preparation (restoration, adjustment, calibration) • Personnel training, learning, start production FNAL estimation: Technicians: 3 techs for 6 months to construct clean room, assemble panel lifting, prepare tooling, training and start chamber production Cost: 152 k$ • Engineering support: 1 engineer for 2 months to help with tooling startup • Cost: 33 k$ • M&S: clean room parts, Gerber and Axxiom machine repair / maintenance,… • Cost: 50k ---------------------------------- Total: 235 k$ CERN estimation: • Technicians: 6 techs for 6 months • Cost: 108 k$ • Engineering support: 1 engineer from FNAL for 2 months to help with tooling startup • Cost: 33 k$ + travel (15k$) = 48 k$ • M&S: clean room parts, Gerber and Axxiom machine repair/maintenance,… • Cost: 50k • ---------------------------------- • Total: 206 k$

13. Panel Production at Lab.8 Axxiom production rate = 14.1 panels/week Labor: panel cutting, drilling, milling, QC/QA, packing Production rate at FY00 (second year of production): - Axxiom – 14.1 panel/week - Gerber – 13.2 panel/week - Labor – 2.2 FTE/month - QC/QA, travelers – 1.0 FTE/month • ME4/2 upgrade (72 x 7 plus spares  ~600 panels) • Production time: 600/13 = 46 weeks (1.0 year) • technicians (3.2 FTE/year) • floor manager (0.5 FTE/year) • engineering support (0.25 FTE/year)

14. Chamber Production at MP-9 CMS EMU chamber assembly manpower analysis (FNAL, 2001) An ME234/2 chamber requires 190 “Worked FTE (WFTE) hours” to be completed in MP9. In order to complete 4 Chambers/month, we require 190x4= 760 WFTE hours/month. At 80% efficiency utilization (vacation, thick days,…) this corresponds to 912 “Charged FTE (CFTE) hours” per month. A standard technician charges on average 173 h/month. This puts the manpower requirement in MP9 to 5.3 FTE (912/173) to achieve the stated goals. • Labor estimation for chamber production at FNAL : • production tech (5.3 FTE / year) • QC/QA tech (1.0 FTE / year) • floor manager (1.0 FTE / year) • engineering support (0.25FTE) 75 chambers production at FNAL: 4 chamber/month  2 years production

15. Procurement, QC/QA, Kit Preparation, Shipping FNAL’s experience: Procurement: parts for all chamber types were procured at FNAL QC/QA: checked 10 % of all chamber parts Kit preparation: all parts for 1 chamber production FNAL’s Labor: Procurement: ~18% overhead (possible discount for panel production) Input part QC/QA: 0.5 FTE/year tech Kit preparation: 0.3 FTE/year tech Packing, shipping: 0.2 FTE/year tech ----------------------------------------------- Total: 1.0 FTE tech/year Panel cleaning and shipping (option: only panel production at FNAL) - machine cleaning (600 panels): 14 panels/day for 2 persons  85 days ~ 0.3 FTE in total - packing, shipping: 0.2 FTE/year -------------------------------------------- Total: 0.7 FTE tech in total (FNAL rate)

16. Chamber Production Cost Estimation FNAL’s Labor estimation ( 100% overhead included): Tech: ~ $50/hour  $8.6k/month  $103 k/year Floor manager: ~$80k/hour  $13.8k/month  $165 k/year Engineer: ~ $100/hour  $17.3k  $206 k/year Procurement: 20% overhead PNPI / IHEP tech  3k$/month  36k$/year • Chamber Production at FNAL: • Chamber production (tech) : 5.3 x 2 = 10. 6 FTE/year  1,091 k$ • Input QC/QA, kit preparation, packing (tech) : 1.0 x 2 = 2.0 FTE/year  206 k$ • Floor manager: 1.0 FTE X 2 = 2.0 FTE/year  330 k$ • Engineering support: 0.25 x 2 = 0.5 FTE/year  100k$ • Shipping cost to CERN (5 containers), making treated wood crates  100k$ ----------------------------------------- • Total: 1,827 k$ • Chamber Production at CERN: • Chamber production (tech) : 5.3 x 2 = 10. 6 FTE/year  381 k$ • Input QC/QA (USA rate): 0.5 x 2 =1.0 FTE/year  52 k$ • kit preparation, (tech) : 0.3 x 2 = 0.6 FTE/year  22 k$ • Floor manager: 1.0 FTE X 2 = 2.0 FTE/year  72 k$ • Engineering support: 0.25 x 2 = 0.5 FTE/year  18 k$ • Panel cleaning, packing: 0.7 FTE/year (FNAL rate)  72 k$ • Shipping to CERN: panels, tooling, (6-7 containers), crates  120 k$ ----------------------------------------- • Total: 665 k$

17. FNAL Cost Estimation FNAL’s Labor with overhead (100%): Technician: ~ $50/hour  $8.6k/month  $103 k/year Floor manager: ~$80k/hour  $13.8k/month  $165 k/year Engineer: ~ $100/hour  $17.3k  $206 k/year Procurement: 18% overhead • Panel production at FNAL: • panel production (technician): 3.2 x 2 = 6.4 FTE/year  $659 k$ • floor manager: 0.5 x 1 =1.0 FTE/year  82k$ • engineering support: 0.25 x 1 = 0.25 FTE/year  25 k$ • M&S (repair, milling bit, diamond saw blade)  60 K$ --------------------------------------- Total: ~ 718k$ Panel cleaning and shipping (option: FNAL is used only for panel production) - machine cleaning (600 panels): 14 panels/day for 2 persons  85 days ~ 0.3 FTE in total - packing, shipping: 0.2 FTE/year -------------------------------------------- Total: 0.7 FTE tech in total (FNAL rate) - 72 k$

18. Production Scenario • Options: • CSC factory production at CERN or FermiLab • Parts procurement at FNAL or University Preliminary, ME4/2 chamber upgrade could be completed in 2.5 years (factory setup + production) The chamber factory at FNAL is the best technical solution: optimal infrastructure, technical expertise, tooling experts and QC&QA program, but it is additional cost of 1.5M$. Making chamber at CERN gives a big saving in money but we should be careful with manpower estimation, quality control and production schedule. A factory setup will be a complicated issue.