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WBS 1 - Endcap Muons. Guenakh Mitselmakher DOE/NSF Review May 8, 2001. 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 - PowerPoint PPT Presentation
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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
US CMS DOE/NSF Review: May 8-10, 2001 2
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
US CMS DOE/NSF Review: May 8-10, 2001 3
Endcap Muon SystemEndcap Muon SystemEndcap Muon SystemEndcap Muon System
US CMS DOE/NSF Review: May 8-10, 2001 4
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
US CMS DOE/NSF Review: May 8-10, 2001 5
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 DOE/NSF Review: May 8-10, 2001 6
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)
US CMS DOE/NSF Review: May 8-10, 2001 7
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
US CMS DOE/NSF Review: May 8-10, 2001 8
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
US CMS DOE/NSF Review: May 8-10, 2001 9
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)
US CMS DOE/NSF Review: May 8-10, 2001 10
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
US CMS DOE/NSF Review: May 8-10, 2001 11
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
US CMS DOE/NSF Review: May 8-10, 2001 12
CSC Production at PNPICSC Production at PNPICSC Production at PNPICSC Production at PNPI
PreproductionPrototype (P3) assembled at PNPI
US CMS DOE/NSF Review: May 8-10, 2001 13
CSC production at IHEPCSC production at IHEPCSC production at IHEPCSC production at IHEP
Critical tooling received
Wire Tension measurement machine
US CMS DOE/NSF Review: May 8-10, 2001 14
CSC production at IHEPCSC production at IHEPCSC production at IHEPCSC production at IHEP
Assembly of a preproduction prototype started
US CMS DOE/NSF Review: May 8-10, 2001 15
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
US CMS DOE/NSF Review: May 8-10, 2001 16
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
US CMS DOE/NSF Review: May 8-10, 2001 17
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.
US CMS DOE/NSF Review: May 8-10, 2001 18
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
US CMS DOE/NSF Review: May 8-10, 2001 19
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
US CMS DOE/NSF Review: May 8-10, 2001 20
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.
US CMS DOE/NSF Review: May 8-10, 2001 21
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
US CMS DOE/NSF Review: May 8-10, 2001 22
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.
US CMS DOE/NSF Review: May 8-10, 2001 23
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 $15, 486, 246
Oct-99 Nov-99 Dec-99 J an-00 Feb-00 Mar-00 Apr-00 May-00 J un-00 J ul-00 Aug-00 Sep-00 Oct-00 Nov-00 Dec-00 J an-01 Feb-01 Mar-01
US CMS DOE/NSF Review: May 8-10, 2001 24
EMU – Estimate to CompleteEMU – Estimate to CompleteEMU – Estimate to CompleteEMU – Estimate to Complete
EMU - ETC 18.9 AYM$
EDIA (k$)
M&S (k$)
Mfg Labor (k$)
EMU Estimate to Complete: 18.9 Actual Year M$ Dominated by M&S (mostly electronics)
US CMS DOE/NSF Review: May 8-10, 2001 25
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
US CMS DOE/NSF Review: May 8-10, 2001 26
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
US CMS DOE/NSF Review: May 8-10, 2001 27
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)
US CMS DOE/NSF Review: May 8-10, 2001 28
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