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RPC Production

RPC Production. Sung Keun Park Department of Physics KOrea DEtector Laboratory (KODEL) Korea University Seoul, Korea Young Jin Kim University of Illinois at Urbana-Champaign. Contents. Overview of RPC detector production Bakelite production RPC gap production

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RPC Production

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  1. RPC Production Sung Keun Park Department of Physics KOrea DEtector Laboratory (KODEL) Korea University Seoul, Korea Young Jin Kim University of Illinois at Urbana-Champaign Muon Trigger Review

  2. Contents Overview of RPC detector production Bakelite production RPC gap production RPC module frame and readout strip plane production RPC half octant frame production RPC factory at BNL RPC module production RPC half octant production RPC production schedule Summary Muon Trigger Review

  3. RPC Detector Production Assembly and Installation Bakelite RPC Detector Parts RPC Detector Korea University, Korea RPC gap (CMS Endcap RPC gap vendor) Pan-Pla, Italy Bakelite manufacture (CMS bakelite vendor) RPC factory, BNL, US Assemble & Test RPC modules Assemble & Test RPC half octants CIAE, China RPC module frame and readout strip plane (CIAE has access to CMS frame/readout strip vendors) Riva, Italy Bakelite cutting (CMS bakelite cutting company) • PHENIX, BNL, US • RPC group: • Installation (help from PHENIX technicians) • Commissioning • Operation monitoring • of RPCs Hi-Tech Manufacturing, US RPC half octant frame General Tecnica, Italy Bakelite cleaning (CMS bakelite cleaning company) Nevis Lab. at Columbia University, US Electronics (use CMS RPC discriminator chip) Muon Trigger Review

  4. Flow of RPC Gaps and Parts for PHENIX frames and parts gas cell route US Korea Italy BNL China bakelite route • Bakelites are produced, cut, cleaned in Italy. • Gas gaps are produced at Korea University in Korea. • RPC module frames & readout strip planes are procured in China (CIAE). • RPC half octant frames will be produced at Hi-Tech Manufacturing in US. • Final assembly is done at BNL. • Flow is exercised with prototype C and D. Muon Trigger Review

  5. Bakelite Production and QA in Italy • Pan-Pla has been producing bakelites for the most of trigger RPC projects. • Bakelites for PHENIX RPCs has been produced for station 3. • Production of bakelites for the CMS Endcap RPC appending project will be followed. • QA for bakelites • PHENIX requirements of bakelite (same specs as CMS) • bulk resistivity of bakelites: • average = 1-6  1010cm at 20 oC • /average < 0.5 • bakelite thickness = 2  0.1 mm • Surface Roughness Ra < 0.2 μm • Measurement of the resistivity of bakelites • Use CMS instrument to measure the resistivity of bakelites. • A lot of help from CMS people • Paolo Vitulo: recommissioned CMS tool and acquired space at University of Pavia for QA, Paolo Baesso (University of Pavia) • Ian Crotty (CMS Endcap RPC production coordinator) • Giuseppe Iaselli (CMS RPC leader) • CMS automated test tool • allow to measure 9 points of resistivity on bakelite at same time. Muon Trigger Review

  6. Bakelite QA Result in Italy pistons for measuring resistivity • Result of resistivity measurement by PHENIX group (July at University of Pavia) • PHENIX RPC group for bakelite QA • K. Barish, D. Kleinjan (UCR) • R. Towell, P. Bailey (ACU) • T. Kempel (ISU), A. Vossen (UIUC) • fulfilled 252 out of 317 bakelites to the PHENIX requirements (same as CMS specs). • enough for producing RPCs at station 3 and RPC prototype at station 1. conveyor belts bakelite plate Muon Trigger Review

  7. Bakelite Cutting and Cleaning in Italy • Riva: CMS RPC cutting company • Completed cutting of bakelites for the PHENIX RPCs at station 3 • General Tecnica: CMS RPC cleaning company • Clearing bakelites for the PHENIX RPCs and the CMS Endcap RPC appending project. • A lot of help from CMS people • Giuseppe Iaselli: organized for prototype D cutting and bakelite cleaning (CMS RPC leader) • Giuseppe Belli (University of Pavia) • Ian Crotty (CMS Endcap RPC production coordinator) Muon Trigger Review

  8. RPC Gap Production in Korea Responsible to Korea University Faculty: B. Hong, S. Park, K. S. Lee, K. -S. Sim Graduate student: H. H. Shim Technical Staff: J. H. Bae, B. D. Kim, C. S. Park Procedures Applying all the procedures and tools used for the CMS Forward RPCs 1. Graphite coating for RPC electrodes - Silkscreen method - Surface resistivity of electrode ranges from 50 to 200 k/square - Dry of the silk ink in room temperature for 4 days 2. PET film coating for protection of graphite electrodes - 1 layer of 200 micron PET film - 1 extra layer of PET to be attached during the RPC assembly - A serious caution is needed to avoid scratches, especially on HV side during handling and transportation. silkscreen table silkscreen test silk ink drying silk ink storage Muon Trigger Review

  9. Pluck and weld PET film PET film insulation machine PET film Insulated bakelite machine control unit Muon Trigger Review

  10. RPC Gap Production in Korea (continue) 3. Cleaning of surfaces of bakelites - Cleaning with isobutylene-base thinner - Cleaning with IPA just before the gap assembly - No scratching on spacer positions 4. Gap assembly - 3 layers of metric tables for the assembly and glue curing - Glue curing time : 24 hours - Glue : DP460, 3M production - Selection of spacers : 2 mm  20 microns - Use spacer jigs for the location of spacers Accuracy of positions < 1 mm 5. Oiling - Linseed oil + heptane (Ratio : 40 % + 60 %) - Polymerization with air Rate : 60 – 100 liter/h/gap Period : 72 – 96 hours Humidity : 40% linseed oil tank with vacuum pump linseed oil tank RPC gap storage for linseed oil coating linseed oil distribution panel Muon Trigger Review

  11. RPC Gap Production in Korea (QA) 5. Tests for pop spacers and leak (QA) - No pop spacer allowed at + 20 hPa - Gas leak : less than 0.2 hPa drop for 10 mins at +20 hPa 6. Extra sealing of periphery of gaps with EVA glue along to stop leak current along the edge of gaps 7. HV tests (QA) - Total period of test : 6 days 1.5 days for gas circulation : 10 volume- circulation before applying HV to the gaps 0.5 day at 8.5 kV to observe Ohmic currents 4 days at working voltage to observe the current behavior at the initial stage of gas operation - Selection criteria Current limit : 2.0 µA for RPC3a 4.0 µA for RPC3b 5.0 µA for RPC3c - If the behavior of the current shows a tendency of increasing  reject (The current should show a stability for QA) H.V test results Current (μA) begin end Gap ID number Muon Trigger Review

  12. RPC Gap Production in Korea (shipping) 8. Extra protection for PET surfaces - Protection from scratches for both sides 9. Shipping boxes - Loading gaps vertically inside the boxes. - Need 2 boxes to load 40 sets of RPCs. So, total 7 boxes needed for RPC3 - Sizes of the shipping box Small size : RPC3a Medium size : RPC3b Large size : RPC3c - All the gas pipes should be fully open to adapt any sudden change of air pressure top view of shipping boxes Muon Trigger Review

  13. RPC Detector Module Frame Production in China Production of detector module frames and readout strip planes is responsible to CIAE. CIAE PHENIX RPC group Scientist: X. Li, S. Hu F. Zhou, S. Zhou Production site: Beijing Honeytech Co. honeycomb panel detector module frame computer control honeycomb producing/cutting machines Honeycomb panel: 5 mm Al honeycomb core in between 0.5 mm 2 layer Al sheets Al frame: 16 x 16 mm2 Al bar with modification for services Muon Trigger Review

  14. RPC Detector Module Frame Production Procedure in China 1. Make honeycomb panels 2. Design in the computer 3. Manufactured by program control 4. Production Muon Trigger Review

  15. RPC Readout Strip Panel Production in China Production site: Beijing Kedi Co. Laminate 0.1 mm mylar film on 0.25 mm thickness readout strip panel at both side Signal readout strip planes Muon Trigger Review

  16. RPC Half Octant Frame Production (Prototype D) half octant skin (Al plate) half octant frame (Al C frame) RPC detector module patch panel half octant support frame (Al bar) detector module support brace (Al bar) Muon Trigger Review

  17. RPC Prototype D Half Octant Frame Manufactured in China • RPC half octant placed on half octant assembly table at the RPC factory in BNL • All half octant parts are made of aluminum. • Half octant contains three RPC modules. • We found a competitive US company, Hi-Tech Manufacturing for mass production. • Responsible to UIUC • J. Blackburn (Engineer), E. Thorsland (Technician) • C. McKinney (Graduate Student) • N. Mucia, G. Deinlein, A. Burnap (Undergraduate Student) Muon Trigger Review

  18. RPC Factory at Bldg. 912 in BNL gas distribution racks and bubblers electronics and H.V supply racks dark current test temporary RPC gap storage/module debugging table DAQ and data base computers cosmic ray RPC module test stand spacer pop, gas leak test table RPC module assembly table RPC module parts preparation area Muon Trigger Review

  19. RPC Gap Storage and Half Octant Assembly Area Two large shelves for the storage of RPC gaps Plastic curtain will be installed around shelf. Temperature and humidity sensor/control unit will be installed. Humidified gas (e.g. nitrogen or argon) distribution system for storing half octants will be set up. Movable large table for half octant assembly Muon Trigger Review

  20. RPC Group at RPC Factory UIUC: Y. J. Kim, A. Vossen (Postdoc) D. Northacker (Technician) R. Yang, B. Meredith (Graduate Student) ACU: R. Towell (faculty) K. Andrews, P. Bailey, A. Basye, T. Jones, D. Thomas (Undergraduate Student) Muhlenberg College: B. Fadem (faculty) C. Harper, D. Broxmeyer, T. Sodre, A. Caringi (Undergraduate Student) GSU: X. He (faculty) J. Ying (Senior Scientist) C. Butler (Technician) K. Dayana, C. Oakley (Graduate Student) Korea University: B. I. Kim, K. B. Lee (Graduate Student) UCR: D. Kleinjan (Graduate Student) RBRC: R. Seidl (Scientist) Muon Trigger Review

  21. Education and Training Graduate/undergraduate students are actively participated to RPC detector assembly and test. Muon Trigger Review

  22. Incoming QA at BNL spacer position template on RPC gap • Incoming QA for RPC gap and module frame • RPC gap (follow same procedure as Korea Univ.) • Gas leakage test: • Monitor pressure change over 30 min. and accept the gap has less than 5% change. • Spacer pop test: • Put spacer position marked template on top of RPC gap and press each spacer position. • If spacer bonding is broken, pressure gauge shows large variation. Allowance  2. • Dark current (all measured values are recorded into data base) • Allowance:  5 A at 9.5 kV(same criteria at Korea University and compare to their values) • RPC module frame • Visual inspection and measure dimensions. • Put all values into database. • Compare to design values. gas leakage/spacer pop test dark current test monitor example of PHENIX RPC database Muon Trigger Review

  23. RPC Detector Module Production at BNL Lay down Mylar foil • Prepare all RPC detector parts • 8 mil Mylar foil, 5 mil Cu foil • Readout strip plane with transition card • Polyethylene gas tube, Ground bus cable • CPE H.V cable, Kapton tape, Cu tape, etc. • RPC detector module assembly procedure • Clean honeycomb panels and Al frames • Attach Al frames to bottom honeycomb panel • Lay down Mylar foil • Lay down Cu foil • Attach Mylar foil on H.V side at bottom RPC gap • Connect Polyethylene gas tube to bottom RPC gap • Place bottom RPC gap into detector module housing • Connect CPE cable to H.V cable on bottom RPC gap Lay down Cu foil Connect Polyethylene gas tube to bottom RPC gap Place bottom RPC gap into detector module housing Connect CPE cable to H.V cable on bottom RPC gap Muon Trigger Review

  24. RPC Detector Module Production at BNL (continue) • Put readout strip plane on top of bottom RPC gap • Solder ground cable to ground bus cable • Attach Mylar foil on H.V side at top RPC gap • Connect Polyethylene gas tube to top RPC gap • Place top RPC gap into detector module housing • Connect CPE cable to H.V cable on top RPC gap • Wrap Cu foil over top RPC gap • Attach all ground cables (from CPE H.V cables, ground bus cables, and RPC gaps) to octant boundary Al frame • Solder the other end of ground bus cable on Cu foil • Lay down Mylar foil • Put top honeycomb panel and close it with screws Put readout strip plane on top of bottom RPC gap Solder ground cable to ground bus cable Place top RPC gap into detector module housing Complete RPC module Wrap Cu foil over top RPC gap Attach all ground to octant boundary Al frame Muon Trigger Review

  25. RPC Detector Module Test cosmic ray trigger (10 scintillators readout both sides) 10 shelves for RPCs NIM crate with DAQ 3 PHENIX RPC TDCs within crate cosmic ray trigger (12 scintillators readout both sides) cosmic ray test stand at RPC factory • We are measuring: Noise rate, Total (2D) and strip efficiencies, Position and time resolutions, Cluster size Muon Trigger Review

  26. RPC Detector Module QA Results PHENIX RPC Detector Requirement Noise rate: 30 - 60 Hz/cm2 Noise Rate (Hz/cm2) H.V (kV) Efficiency software threshold set to 3.6 mV Total efficiency = 95% Muon Trigger Review

  27. RPC Detector Module QA Results (continued) RPC Cluster size RPC cluster size and strip wise time resolutions fulfill with our requirement. The results from 16 readout strips show similar results. RPC Strip Timing Resolutions Muon Trigger Review

  28. RPC Half Octant Assembly Exercising half octant assembly took a place several times. Updating documentation of half octant assembly is in progress. We will start first half octant assembly on September 22nd. RPC prototype D2 module patch panel place for RPC prototype D3 module RPC module support braces half octant frame place for RPC prototype D1 module half octant assembly procedure documentation FEE panels Muon Trigger Review

  29. RPC Half Octant QA • QA at RPC factory, check/fix • gas leakage of RPC detector modules • any problem with H.V and L.V • all electronics and detector performance • QA after installation to PHENIX, check • gas leakage of RPC detector modules • damage of H.V and L.V connectors • damage of signal cables • RPCs with cosmic ray test runs Muon Trigger Review

  30. RPC Production Schedule • RPC prototype D (two half octant for run 9) • RPC detector module assembly: complete • RPC half octant assembly: 2008 September 29th – October 12th • RPC station 3 • RPC detector module assembly for north muon arm: 2009 January – June • RPC half octant assembly for north muon arm: 2009 April – July • RPC detector module assembly for south muon arm: 2009 May – October • RPC half octant assembly for south muon arm: 2009 August – November • RPC station 1 • RPC detector module assembly for north muon arm (RPC 1a): 2009 June – October • RPC octant assembly for north muon arm (RPC 1a): 2009 October – November • RPC detector module assembly for north muon arm (RPC 1b): 2009 July – November • RPC octant assembly for north muon arm (RPC 1b): 2009 November – December • RPC detector module assembly for south muon arm (RPC 1a): 2009 July – November • RPC octant assembly for south muon arm (RPC 1a): 2009 December – 2010 January • RPC detector module assembly for south muon arm (RPC 1b): 2009 July – December • RPC octant assembly for south muon arm (RPC 1b): 2009 December – 2010 January Muon Trigger Review

  31. Summary • We have completed to produce RPC prototype C and D modules. • 3 prototype C and 9 prototype D modules • Prototype test is on going. • Production chain is close to follow CMS and it is checked by production of prototype C and D. • Obtain a lot of experience for RPC detector production. • Gain operation and test skills of RPC detector. • Mass production is started. • Bakelites for RPC station 3 are produced and cut. • We have almost complete procedure for producing RPC detector. • We have a complete RPC detector production schedule. Muon Trigger Review

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