wbs 1 - endcap muons

US CMS DOE/NSF Review: May 8-10, 2001 1

WBS 1 - Endcap MuonsWBS 1 - Endcap MuonsWBS 1 - Endcap MuonsWBS 1 - Endcap Muons

Guenakh Mitselmakher

DOE/NSF Review

May 8, 2001


OutlineOutlineOutlineOutline• 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


Endcap Muon SystemEndcap Muon SystemEndcap Muon SystemEndcap Muon System


CMS Endcap Muon SystemCMS Endcap Muon SystemCMS Endcap Muon SystemCMS Endcap Muon System

360 CSCs, not counting ME1/1 and ME4•144 Large CSCs (3.4x1.5 m2):72 ME2/2 chambers72 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 chambers36 ME3/1 chambers

•Frontend Electronics:•170K Cathode channels 140K Anode channels

•Trigger&DAQ (on-chamber part) •Alignment&Services


EMU - Yearly BCWSEMU - Yearly BCWSEMU - Yearly BCWSEMU - 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 EMU BCWS by Fiscal Year

0

1,000,000

2,000,000

3,000,000

4,000,000

5,000,000

6,000,000

7,000,000

8,000,000

9,000,000

FY96 FY97 FY98 FY99 FY00 FY01 FY02 FY03 FY04 FY05


US CMS EMU ResourcesUS CMS EMU ResourcesUS CMS EMU ResourcesUS CMS EMU Resources

EMU Resource Usage

0

10

20

30

40

50

60

70

FY98 FY99 FY00 FY01 FY02 FY03 FY04 FY05

FTE

's

Tech

Eng

Phys

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


CSC Production SitesCSC Production SitesCSC Production SitesCSC 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


EMU Chamber StatusEMU Chamber StatusEMU Chamber StatusEMU 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


Chamber AssemblyChamber AssemblyChamber AssemblyChamber AssemblyGluing 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)


Week From To Total Total Total Total Total TotalME234/2 ME1/2 ME2/1 ME1/3 ME3/1 ME4/1

October 10/1/99 10/31/99 - - - - - - November 11/1/99 11/30/99 - - - - - - December 12/1/99 12/31/99 - - - - - - January 1/1/00 1/31/00 - 1 - - - - February 2/1/00 2/28/00 - 1 - - - - March 3/1/00 3/31/00 1 - - - - - April 4/1/00 4/30/00 1 - - - - - May 5/1/00 5/31/00 - - - - - - June 6/1/00 6/30/00 2 - - - 1 - July 7/1/00 7/31/00 1 - - - - - August 8/1/00 8/31/00 2 - - - - - September 9/1/00 9/30/00 2 - - - - -

FY00 Summary 9 2 - - 1 - Grand Total 9 2 - - 1 - October 10/1/00 10/31/00 3 - - - - - November 11/1/00 11/30/00 3 - - 1 - - December 12/1/00 12/31/00 3 - - - - - January 1/1/01 1/31/01 4 - - - - - February 2/1/01 2/28/01 4 - - - - - March 3/1/01 3/31/01 4 - - - - - April 4/1/01 4/30/01 - - - - - - May 5/1/01 5/31/01 - - - - - - June 6/1/01 6/30/01 - - - - - - July 7/1/01 7/31/01 - - - - - - August 8/1/01 8/31/01 - - - - - - September 9/1/01 9/30/01 - - - - - -

FY01 Summary 21 - - 1 - - Grand Total 30 2 - 1 1 - October 10/1/01 10/31/01 - - - - - - November 11/1/01 11/30/01 - - - - - - December 12/1/01 12/31/01 - - - - - - January 1/1/02 1/31/02 - - - - - - February 2/1/02 2/28/02 - - - - - - March 3/1/02 3/31/02 - - - - - - April 4/1/02 4/30/02 - - - - - - May 5/1/02 5/31/02 - - - - - - June 6/1/02 6/30/02 - - - - - - July 7/1/02 7/31/02 - - - - - - August 8/1/02 8/31/02 - - - - - - September 9/1/02 9/30/02 - - - - - -

FY02 Summary - - - - - - Grand Total 30 2 - 1 1 - October 10/1/02 10/7/02 - - - - - - November 11/1/02 10/14/02 - - - - - - December 12/1/02 10/21/02 - - - - - - January 1/1/03 10/28/02 - - - - - - February 2/1/03 11/4/02 - - - - - - March 3/1/03 11/11/02 - - - - - - April 4/1/03 11/18/02 - - - - - - May 5/1/03 11/25/02 - - - - - - June 6/1/03 12/2/02 - - - - - - July 7/1/03 12/9/02 - - - - - - August 8/1/03 12/16/02 - - - - - - September 9/1/03 12/23/02 - - - - - -

FY03 Summary - - - - - - Grand Total 30 2 - 1 1 -

FNAL Factory Status - Chamber assembly at MP9

• 32 large CSCs assembled by May 2001

• > 20% complete

• Production ~ at nominal rate

• ~ On schedule

CSC Production at MP9(ME234/2)

-40

0

40

80

120

1 3 5 7 9 11 13 15 17 19 21 23 25 27 29 31 33 35 37 39 41 43

Month in productionN

um

be

r o

f C

ha

mb

ers

Shortage

DONE

Goal = 148 Chambers

FY00 FY01 FY02 FY03


CSC Production at PNPICSC Production at PNPICSC Production at PNPICSC Production at PNPI

•Critical tooling delivered from Fermilab

•Preproduction started

•PRR June 7-8

Winding machine at PNPI


CSC Production at PNPICSC Production at PNPICSC Production at PNPICSC Production at PNPI

PreproductionPrototype (P3) assembled at PNPI


CSC production at IHEPCSC production at IHEPCSC production at IHEPCSC production at IHEP

Critical tooling received

Wire Tension measurement machine


CSC production at IHEPCSC production at IHEPCSC production at IHEPCSC production at IHEP

Assembly of a preproduction prototype started


CSC ElectronicsCSC ElectronicsCSC ElectronicsCSC Electronics

DDUPCI Bus

PC) (DAQ data

Trigger-Timing-Control(TTCrx)

Muon Sector ReceiverLev-1 Trigger

Slow Control

CSC

CFEBCFEBCFEB CFEB

ALCT

1 of 24

Cathode Front-end Board 3x6 ASICs, 2 FPGAs, channel Links, Buffers

Anode Front-end Board 1 ASIC

Anode LCT Board FPGA’s, ASICsChannel Links

VME Crate

Clock Control Board

Cathode LCT - Trig Motherboard

PC Interface Board

DAQ Motherboard

CFEB

1 of 5

MPC

CCB

DMB

CLCT

TMB

VME

control

1 of 5


EMU on-chamber EMU on-chamber electronics statuselectronics statusEMU on-chamber EMU on-chamber electronics statuselectronics 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 estimatesLV-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


EMU off-chamber EMU off-chamber electronics statuselectronics statusEMU off-chamber EMU off-chamber electronics statuselectronics 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.


Integration and installation designIntegration and installation design

• EMU integration design advanced (mechanical, gas, cooling, power)

• Installation procedures being defined

• Installation fixture fully designed and built


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

Counterweight


Chamber Production and Chamber Production and Installation Schedule (V31)Installation Schedule (V31)Chamber Production and Chamber Production and

Installation Schedule (V31)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.


EMU Critical Path Analysis -IEMU Critical Path Analysis -IEMU Critical Path Analysis -IEMU 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


EMU Critical Path Analysis -IIEMU Critical Path Analysis -IIEMU Critical Path Analysis -IIEMU Critical Path Analysis -IIFY03: 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.


EMU cost/performance EMU cost/performance analysisanalysis

EMU cost/performance EMU cost/performance analysisanalysis

EMU WBS 1.0

October 1999 through March 2001

Cumulative Trends

Budget, Per f ormance, Actuals, and Obl igations

$0

$5, 000, 000

$10, 000, 000

$15, 000, 000

$20, 000, 000

$25, 000, 000

BCWS (Budget) $10, 797, 765 $11, 051, 355 $11, 222, 599 $13, 642, 582 $13, 969, 182 $14, 196, 791 $14, 458, 028 $14, 990, 124 $15, 250, 690 $15, 927, 022 $16, 629, 879 $17, 193, 933 $17, 862, 315 $18, 166, 555 $18, 395, 625 $19, 167, 494 $19, 779, 717 $20, 128, 422

BCWP (Performance) $8, 609, 964 $8, 977, 597 $9, 769, 821 $10, 052, 792 $10, 529, 122 $11, 105, 451 $12, 748, 524 $13, 227, 532 $13, 401, 315 $13, 947, 857 $14, 209, 901 $14, 956, 242 $15, 651, 386 $16, 455, 234 $17, 100, 366 $17, 593, 908 $18, 105, 148 $18, 277, 915

OBLI GATI ONS $9, 708, 958 $10, 112, 064 $10, 340, 275 $10, 713, 980 $10, 401, 367 $10, 610, 688 $10, 859, 780 $12, 814, 258 $13, 881, 502 $15, 654, 260 $16, 249, 282 $16, 748, 344 $16, 924, 830 $17, 123, 656 $17, 637, 718 $17, 902, 366 $18, 024, 349 $20, 132, 355

ACWP (Paid Actuals) $7, 421, 498 $7, 787, 463 $8, 127, 241 $8, 842, 238 $8, 531, 612 $8, 883, 122 $9, 274, 137 $9, 497, 988 $9, 828, 550 $11, 124, 106 $11, 477, 615 $12, 512, 288 $12, 756, 281 $13, 208, 820 $13, 896, 168 $14, 400, 682 $14, 812, 456 $15, 486, 246

Oct-99 Nov-99 Dec-99 J an-00 Feb-00 Mar-00 Apr-00 May-00 J un-00 J ul-00 Aug-00 Sep-00 Oct-00 Nov-00 Dec-00 J an-01 Feb-01 Mar-01


EMU – Estimate to CompleteEMU – Estimate to CompleteEMU – Estimate to CompleteEMU – Estimate to Complete

EMU - ETC 18.9 AYM$

EDIA (k$)

M&S (k$)

Mfg Labor (k$)

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


Plans for the next 6 monthsPlans for the next 6 monthsPlans for the next 6 monthsPlans 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


SOW 01 - EMUSOW 01 - EMUSOW 01 - EMUSOW 01 - EMUEMU SOWs FY01 -- $6.1M

University of California-Davis

University of California-Los Angeles

University of California, Riverside

Carnegie Mellon University

Fermilab

University of Florida

Northeastern University

Ohio State University

Purdue University

Rice University

University of Wisconsin

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


Issues:Issues:Issues: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)


Summary and ConclusionsSummary and ConclusionsSummary and ConclusionsSummary 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

wbs 1 - endcap muons

Documents