Brick components R&D and mass production lead emulsion CS Plastic components BAM BMS

1. OPERA SPSC meeting April 2007 CERN, Geneva, Switzerland Brick Production and Detector filling status report S. Buontempo OPERA Technical Coordinator • Brick components R&D and mass production • lead • emulsion • CS • Plastic components • BAM • BMS • Brick Production and Detector Filling schedule

2. Lead types studied before final choice: • pure lead • Pb + Ca (0,07%) • Pb + Ca (0,04%) • Pb + Sb • Pb Colaminated with pure lead • PbCa colaminated with pure lead Studies on: • Alpha activity • Chemical compatibility with OPERA emulsion films • Mechanical performance (planarity, uniformity in thickness, stickiness, shape) First choice (Mar06): PbCa Colaminated (problems in mass prod. Rate and shape) Final choice (Aug06): Pb+Ca(0,04%) Brick components R&D and mass production : Lead

3. Brick components R&D and mass production : Lead Lead vs emulsion chemical compatibility tests & radioactivity 2 months 33°C ( controlled humidity storage) Best candidates

5. Brick components R&D and mass production : Lead Mass production in JL Goslar firm (Germany) Custom production line for punching, washing and packaging was designed, constructed and is now operational. Upper limit in daily production 45000 pieces (800 bricks) in 3 shift/day mode. Now operational at 1 shift/day.

6. 30000 plastic pallets produced 1 pallet = 1 brick (56 plates) 1000 custom transportation boxes Produced Boxes are “lead cartridge for BAM”

7. Brick components R&D and mass production : Emulsion About 9 millions pieces produced by Fuji Film Company and delivered to Nagoya University

8. Brick components R&D and mass production : Emulsion Initial sensitivity Produ-ction Beam exposure Develop-ment Production Refreshing Beam exposure Development Performance of refreshed emulsion films for OPERA G.D.36/100μm F.D.1.3/1000μm３ Characteristic of refreshing (after refreshing) G.D.Under 8/100μm F.D.2.1/1000μm３ Produ-ction Beam exposure Refreshing Development Condition : 30℃98％3days Sensitivity of refreshed film G.D.35/100μm F.D.1.5/1000μm３

9. Brick components R&D and mass production : Emulsion Emulsion Refreshing Facility in Tono Mine (Japan) 24 refreshing Units construction 2003 Apr-Dec operation 2004 Jan ~ 2006 Mar Finished: 150,000 Bricks Under treatment: ~7,000 Bricks Total 9,000,000Films.

10. Brick components R&D and mass production : Changeable Sheets (CS) • CS (Changeable Sheet) is a tracking detector to match the TT with brick track. 1CS for 1ECC. • Refreshing lab equipped in LNGS to remove all the tracks taken during trip to Europe • CS box design optimized to guarantee planarity with brick, easy removal and 5 years positioning • 23,000 CSs were produced in 2006 • The production speed was 1,700/day at Maximum. • Next production will start end of March. • 15000 CS boxes available now in LNGS, rest being produced CS CS

11. Brick mechanical packaging demanded for custom metal and plastic components: • Al frame to keep the brick closed under 3 bar pressure (spider) • Plastic protection • Plastic cover Requested performances: • minimal additional mass around the brick, • cover must be flat and rigid to keep the 3 bar pressure for 5 yeas, • plastic protection must be flat, but foldable on the corners All test measurements were done in the framework of BAM activity Chemical compatibility tests done with samples produced using list of candidate materials Brick components R&D and mass production : Plastic components

12. Brick components R&D and mass production : Plastic components Sensitivity Fog density Studies on the compatibility of plastic components and OPERA emulsions. 2 months storage @ 33° C • Plastic cover and side protection

13. The BAM was conceived to maximize the brick quality stability in a mass production mode. Goal was to produce 206000 in 1 year (equivalent to 936 bricks/day 4 drums/day) Long R&D work done on vacuum vs mechanical packaging Specs document was defined for both cases solution. Tender was closed in jan 2005. TecnoCut firm (Italy) participated in the final studies for final choice Mechanical solution was the final choice (may 2005) to secure: • piling precision • long term stability • brick robustness The proposed solution based on anthropomorphic robots: very first application of this in particle physics domain  intellectual and capital investment for future large detectors Brick Assembly Machine (BAM)

14. BAM layout BAM Status of BAM layout BAM lead-drum room BAM clean-light room Lead transportation BAM clean-dark room Lead unpacking 5 piling pressing stations

15. BAM Lead-Drum room Pictures bam in light, clean room and bam in dark, Brick Assembly Machine (BAM)

16. Brick Assembly Machine (BAM) BAM in Light, clean room with white light

17. BAM in dark, clean room with white/red light Brick Assembly Machine (BAM)

18. BAM construction started in march 2005 in firm site (Pavia, Italy). Planned construction and commissioning time in firm was 13 months. Delivery expected in GS by April 2006, postponed to June 2006 due to lead decision. Delay in lead choice decision interfered with final layout and commissioning of piling section. First “final” lead choice was PbCa Colaminated. Construction completed in firm by summer 2006 with commissioning of single units. Decision to install anyway in GS in summer 2006 to secure the brick pilot production for beam time in October 2006. Installation and preliminary commissioning in LNGS completed in October (a part drum station, being a separate order). Commissioning phase of full line was delayed by the new problems of stickiness found in colaminated lead and real emulsions Brick Assembly Machine (BAM)

19. Pilot production in GS in October 2006 good for physics and for mechanics: • 800 bricks produced in 3 weeks with many new problems in lead/emulsion stickiness. • Brick skating performance were not as good as in prototyping because of brick shape defects which were demanding thicker skate solution • CS box mechanically positioned on the brick was unstable in case of too strong pressure and friction during detector filling phase Net effects were: • a revision of the piling station cycle with addition of pulse compressed air on both emulsion and lead pile. Resulting in factor 2 in piling time (from 3 to 6 min /brick) and 1 operator needed per each piling station. • Additional job in pre-treatment of lead boxes with compressed air to open the piles. • Need to change the skates with thicker material (Tyvek) • Need to glue the CS boxes Brick Assembly Machine (BAM)

20. Brick Assembly Machine (BAM) BAM performance New skate and CS box gluing additional machines being constructed (delivery by April07) (eliminating present manual operations in BAM in light) 6 min/brick/station = 50 bricks/hour is present theoretical upper limit x 14h/day = 700 bricks theoretical upper limit (2 shifts mode and 2h lost for lab access and BAM loading). Our present goal is to secure 468 (2 drums) a day ( with 33% ineff.) To secure 702 real brick/day (3 drums) with some contingency we plan to increase theoretical limit by 25% (margins exist) and reduce inefficiency by 10%.

21. Brick Assembly Machine (BAM)

22. Responsibility of LAPP-Annecy (IN2P3/CNRS) System based on industrial automates, Profibus ground bus, C++ supervision and DB management softwares. One manipulator on each side of the detector, portico and vertically moving platform R&D, mechanical construction, cabling and tests at LAPP, installation in Gran Sasso: December 2005, March 2006. Commissioning going on. 5000 real bricks inserted in OPERA till last week Running needs: 1 expert + 1 skilled operator per shift Brick Manipulator System (BMS) Present performance (no contingency): insertion of 2 drums (468 bricks) in one shift of 8 hrs

23. Brick Manipulator System (BMS) Portico Loading station and drum for brick transfer Draw bridge for brick insertion Digital camera for positioning Manipulating platform Vacuum sucker vehicle to retrieve bricks Electric jack to insert bricks Storage Carrousel

24. Brick Manipulator System (BMS)

25. Brick Production and Detector filling schedule Internal Milestone: Produce/insert 10000 bricks in detector by April SPSC-LNGSC week Since last march 12th 2 shift/day mass production started. 9350 bricks produced till last week Technical stops were planned to update parts of BAM piling section 3 (2) days stops were needed in week 13 (15) due lack of empty drums (to BMS stop) Now we monitor the BAM/BMS stability and fatigue

26. Brick Production and Detector filling schedule • 1 drum/shift (468 brick/day) is feasible. Strong dependence by operator skill and storage units (drums) availability. We have to check now the production stability performance. • 2,5 drum/day (585 bricks/day) is technically feasible now with software improvements in the BMS procedure to be implemented in next technical stops • 3 drums/day (702 bricks/day) demands for: • improvements in BAM piling and wrapping station speed, evaluated in next 6-8 weeks during technical stops • 2 shift running mode on BMS operation Final Goal: Produce 150000 bricks by end of April 08

27. Brick Production and Detector filling schedule Detector filling schedule in 3 BAM/BMS rates (with 15% contingency time): Rate run start (sept 15th) run stop (nov 15th) det. completed (+21 weeks) (+30 weeks) 150000 bricks 2 drums/day 50680 68986 sept 12th 08 (2034 bricks/week) ( 372 evts)*(+70 weeks) 2.5 drums/day 58315 81202 June 20th 08 (2543 bricks/ week from june 1st 07) ( 441 evts)*(+58 weeks) 3 drums/day 59334 86802 May 2nd 08 (3052 bricks/week from sept 1st 07) ( 465 evts ) *(+41 weeks) * : number of CNGS events in the bricks for 1019 pot