Cost estimation for production & Cost estimation for production & installation of Calorimeter Systeminstallation of Calorimeter System

V. Issakov

Physics Department, Yale University, New Haven, CT 06511Physics Department, Yale University, New Haven, CT 06511

11/9/200411/9/2004

Photon Calorimeter for KOPIOPhoton Calorimeter for KOPIO

The requirements to the KOPIO Photon Calorimeter:• Energy resolution 3.5[%]/E.• Time resolution 100[psec]/E.• Photon detection inefficiency (due to holes-cracks) 10-4.• Granularity 1111 cm2.• Active area 5.7 5.7 m2 • Radiation length 16X0

(18X0 including Preradiator).• Physical length 60 cm.

The Shashlyk technique with the APD photo readout satisfies the KOPIO requirements.

All sizes are All sizes are millimetersmillimeters

Calorimeter SystemCalorimeter System

Calorimeter System includes:I. Mockup of Calorimeter System - the complete-equipped prototype of

Calorimeter system (168 modules), to study the performance parameters of the Calorimeter & Preradiator/Calorimeter systems and to develop the pattern recognition algorithms.

II. Photon Calorimeter – the matrix of the 5252 APD-instrumented modules with a beam hole of 182 modules , Calorimeter mechanics (including two mobile halves of Calorimeter frame, Calorimeter railways and Calorimeter installation/service equipment) & Calorimeter cooling system.

III. Instrumentation of Photon Calorimeter - Calorimeter High-Voltage control system, Calorimeter LV power supply system, Calorimeter “cosmic-ray” Pre-calibration System, Calorimeter Monitoring/Calibration System, Calorimeter WFD-readout System.

IV. The cable system of Photon Calorimeter – 3,172 signal cables, 2704 HV control cables & 2704 3 LV power supply cables.

Cost estimation for Calorimeter SystemCost estimation for Calorimeter System WBS # Description Sub. Mat. ED Lab. Tot. Con.

1.2.3

Cost of Calorimeter System (CS) 1,207 3,249 133 4,465* 9,054 22%KOPIO Contribution (NSF) 1,207 3,249 133 3,130* 7,719 24%IHEP Contribution** (RUSSIA) 0 0 0 359* 359 23%YALE Contribution (DOE) 0 0 0 976* 976 20%

1.2.3.1 Mockup of the CS (The complete-equipped matrix of 128-modules to study the Performance Parameters of CS) 38 188 10 273 509 18%

1.2.3.2 Photon Calorimeter (2704 APD-instrumented modules, Calorimeter mechanics & Cooling system) 60 2,480 113 2,073 4,726 25%

1.2.3.3 Instrumentation of Photon Calorimeter (2704 channels of HV-control, monitoring, calibration & WFD-readout electronics) 779 491 10 483 1,763 22%

1.2.3.4 Shipping of Photon Calorimeter (Shipping formula: 600 mod. 3, Mechanics, 904 mod.) 100 0 0 0 100 20%

1.2.3.5 Assembly & Test of the delivered modules (APD/mod. assembly, mech. & optical tests, a “cosmic-ray” calibration) 60 30 0 572 662 21%

1.2.3.6 Installation of Photon Calorimeter (modules into frames, monitoring-calibration system, readout electronics) 0 0 0 354 354 20%

1.2.3.7 Cabling of Photon Calorimeter (Production and installation of cables) 70 60 0 75 205 20%

1.2.3.8 Commission of CS (The mechanical & “cosmic-ray” tests of the full-loaded CS) 0 0 0 35 35 20%

1.2.3.9 Scientific-technical coordination & management 0 0 0 600 600 20%

1.2.3.10 Travel expenses (Meetings, consultation, supervision of production) 100 0 0 0 100 20%

*) Support of the FTE scientists: KOPIO - $1,069k, IHEP - $359k, YALE - $976k.**) IHEP contribution in past: Scintillator factory (~$3,000k), Test facility (~$200k).

Calorimeter mockup productionCalorimeter mockup production WBS # Description Sub. Mat. ED Lab. Tot. Con.

1.2.3.1 Mockup of the CS (The complete-equipped matrix of 128-modules to study the Performance Parameters of CS) 38 188 10 273 509* 18%

1.2.3.1.1 Fabrication of 100 “mass-production” modules 0 34 0 41 75 10%

1.2.3.1.2Instrumentation of 100 “mass-production” modules by APD units (APD, preamplifier, LV-HV converter)

0 112 0 11 123 10%

1.2.3.1.3Production of the mockup mechanics

(Frame & Rotating lift-platform) 0 13 3 13 29 25%

1.2.3.1.4Prototype of the cooling system(Refrigerating-circulator & Heat-exchanger) 0 7 2 5 14 25%

1.2.3.1.5Prototype of the HV control system(D-A converters for control of APD HV-chips) 0 16 0 0 16 25%

1.2.3.1.6Prototype of the “cosmic-ray” pre-calibration system(LTD & Trigger logic, CAMAC) 0 0 5 5 10 25%

1.2.3.1.7Prototype of the monitoring-calibration system (LED-flash system & Fiber optics) 0 6 0 7 13 25%

1.2.3.1.8Production of the readout system prototype (10-bit & 250 MHz WFDs, VXI or VME) 23 0 0 0 23 255

1.2.3.1.9 Shipping of the Calorimeter mockup 10 0 0 0 10 30%

1.2.3.1.10 Test & Study of Calorimeter mockup performance 5 0 0 191 196 21%

*) Production cost of Calorimeter mockup is $313k. Support of the FTE scientists for study of Calorimeter mockup performance is $191k (Yale – $145k, KOPIO – $46k).

Photon Calorimeter productionPhoton Calorimeter production

WBS # Description Sub. Mat. ED Lab. Tot. Con.

1.2.3.2 Photon Calorimeter (2704 APD-instrumented modules, Calorimeter mechanics & Cooling system) 60 2,480 113 2,073* 4,726 25%

1.2.3.2.1Design of Photon Calorimeter(Conceptual design & detailed drawings)

0 0 42 0 42 25%

1.2.3.2.2 Modification of test-equipment & the production tool for the mass-production cycle 60 25 0 17 102 25%

1.2.3.2.3 Fabrication of 2672 “regular” Calorimeter modules 0 697 0 1172 1,869 20%

1.2.3.2.4 Instrumentation of 2672 “regular” Calorimeter modules by APD units (APD, preamplifier, LV-HV converter) 0 1,575 0 351 1.926 30%

1.2.3.2.5 “Cosmic ray” test of 2672 instrumented “regular” Calorimeter modules 0 0 0 166 166 25%

1.2.3.2.6The production of “special” Beam-Liner modules(32 APD-instrumented modules)

0 63 6 27 96 40%

1.2.3.2.7Photon Calorimeter mechanics(Frame, cooling & railway systems, service-equipment, etc.)

0 120 65 340 525 25%

*) IHEP support of the FTE scientists for supervision and tests of modules, APD-units & APD-instrumented modules is $359k.

Cost of the module productionCost of the module production

Materials, Labor Cost Materials $259.581. 300 scintillator tiles $36.532. 300 lead tiles $65,553. Assembling parts $37,004. 108 m of WLS fiber

(Kuraray Y11-200MS-1mm)$108.00

5. Packing box $12.50Labor $245.401. Molding of the scintillator tiles $108.002. Stamping of the lead tiles $122.403. Formation of the WLS fibers $15.00Assembling & Testing $171.001. Assembling of module $126.00

2. Test of module $36.00

3. Packing of module $9.00

Total $675.98

Module’s production rate is 6 modules/shift

The module’s design includes 15 assembling details

Cost of the module instrumentationCost of the module instrumentation

Materials, Labor Cost

Materials $563.00

1. A 16 mm diameter, blue, windowless APD

$425.00

2. A charge-sensitive preamplifier $25.00

3. A LV-HV converter, capacitors and resistors $94.00

4. Assembling parts $19,00Labor $45.001. HV PC-board $5.002. Preamplifier PC-board $5.003. APD’s PC-board $5.004. Mechanic of APD cage $30.00Assembling & Testing $63.001. Assembling of the APD unit $54.00

2. Test of the APD unit $4.503. Packing of the APD unit $4.50

Total $671.00

Cost of the module’s instrumentation (APD)

Module’s instrumentation rate is 6 units/shift

AP

DA

PD

LV - HVLV - HV

PreampPreamp

Quoted price of the LV-HV Model: C20Quantity: 2,500Unit Price: $ 79.00John Bianchi EMCO High Voltage Corp.11126 Ridge RoadSutter Creek, CA 95685, USAPhone: (209) 223-3626www.emcohighvoltage.com

Quoted price of APDModel: SD630-70-74-510Quantity: 3,000Unit Price: $ 425.00Paul Sharman Advanced Photonix, Inc.1240 Avenida AcasoCamarillo, CA 93012, USAPhone: (805) 987-0146www.advancedphotonix.com

Cost of the module instrumentationCost of the module instrumentation

Materials, Labor Cost Materials $476.001. A 30 mm diameter, green-extended PMT & PMT socket $198.00

2. A charge-sensitive preamplifier $25.00

3. A LV-HV converter, PMT base, capacitors and resistors $124.00

4. Assembling parts, including antimagnetic shielding $129,00

Labor $45.001. HV PC-board $5.002. Preamplifier PC-board $5.003. APD’s PC-board $5.004. Mechanic of APD cage $30.00Assembling & Testing $63.001. Assembling of the APD unit $54.002. Test of the APD unit $4.50

3. Packing of the APD unit $4.50Total $584.00

Cost of the module’s instrumentation (PMT)

Module’s instrumentation rate is 6 units/shift

•Requirement for the PMT instrumentation is the low magnetic field (< 100 Gauss) into the PMT-location volume•Cost economy is $230k (~ 3% of the total cost)•Energy resolution will be 3.5%/E, instead 3.0%/E

Calorimeter instrumentationCalorimeter instrumentation WBS # Description Sub. Mat. ED Lab. Tot. Con.

1.2.3.3 Instrumentation of Photon Calorimeter (2704 channels of HV-control, monitoring, calibration & WFD-readout electronics) 779 491 10 483 1,763 22%

1.2.3.3.1Calorimeter HV control system(2740 D-A converters for control of APD HV-units) 0 196 0 56 252 13%

1.2.3.3.2Calorimeter “cosmic-ray” pre-calibration system(LTD & Trigger logic, VME/VXI)

0 187 0 72 259 13%

1.2.3.3.3Calorimeter monitoring-calibration system(2740 channels of LED-flash system)

0 51 10 154 215 20%

1.2.3.3.4Calorimeter readout electronics(10-bit & 250 MHz WFDs, PCI or VXI)

779 0 0 196 975 28%

1.2.3.3.5 Calorimeter LV power supply & Racks for Electronics 0 57 0 5 62 19%

HV control system for control of APD HV-units. System includes 2704 programmable D-A VME converters. A base unit is a commercial 12-bits D/A converter (XIP-TVME200/XIP-5220, produced by Xycom Automation Inc.).The production cost per channel is ~ $72.“Cosmic-ray” pre-calibration system for adjustment of APD HV, a Calorimeter pre-calibration (accuracy better than 4%) and online long-term monitoring of the APD gain (accuracy better than 1%). System is based on detection of signals from the “cosmic-ray muons”, vertically traversing Calorimeter modules, and includes 468 programmable Low-Threshold Discriminator & Trigger Programmable Logic. A base units are the commercial LTD & TPL (V814 & V495, produced by CAEN).The production cost per channel is ~ $69.Monitoring-calibration system for online short-term monitoring of the APD gain & timing. System is based on the "ultrabright LED-lamps" with an electronic method of stabilization of the light output and includes 44 special LED modules. The similar system has been developed and tested for LHCb project. We propose to adapt the LHCb system for our project.The production cost per channel is ~ $63.Calorimeter readout electronics include 176 WFDs boards and 12 crate-collector boards.The production cost per channel is ~ $301.

Assembly & test of the delivered modulesAssembly & test of the delivered modules

WBS # Description Sub. Mat. ED Lab. Tot. Con.

1.2.3.5 Assembly & Test of the delivered modules (APD/mod. assembly, mech. & optical tests, a “cosmic-ray” calibration) 60 30 0 572 662 21%

1.2.3.5.1Complete assembling, mechanical/optical test of the delivered modules

60(Room)

20 0 284 364 21%

1.2.3.5.2 “Cosmic ray” test & pre-calibration of the delivered modules 0 10 0 288 298 21%

“Cosmic ray” test & pre-calibration of the delivered module include the accumulation procedure of data-base for APD-instrumented Calorimeter modules

Installation of Calorimeter SystemInstallation of Calorimeter System

WBS # Description Sub. Mat. ED Lab. Tot. Con.

1.2.3.6 Installation of Photon Calorimeter (modules into frames, monitoring-calibration system, readout electronics) 0 0 0 354 354 20%

1.2.3.6.1 Installation of modules into Calorimeter frame 0 0 0 117 117 20%

1.2.3.6.2Installation and testing of monitoring and calibration system(44 LED boards & LV power supply, 2704 optical cables) 0 0 0 98 98 20%

1.2.3.6.3Installation and testing of 2704 readout-electronics channels(12 mainframes & controllers, 12 collector boards & 176 readout boards)

0 0 0 139 139 20%

WBS # Description Sub. Mat. ED Lab. Tot. Con.1.2.3.6.3 Installation of Railway and Cabling systems 0 0 0 27 27 20%

1.2.3.6.4 Installation of Calorimeter support frame 0 0 0 81 81 20%

1.2.3.6.5 Installation of Assembling and Service system 0 0 0 13 13 20%

1.2.3.6.6 Installation of the power supply on the Calorimeter top 0 0 0 10 10 20%

1.2.3.6.7 Installation of the electronic racks on the Calorimeter top 0 0 0 10 10 20%

Installation of The Calorimeter Mechanics (for R. Brown)

Cost Evolution for Calorimeter SystemCost Evolution for Calorimeter System

1. The old base cost for the Calorimeter System has been estimated for TDR-2001 as $4,698k

2. The new base cost for the Calorimeter system (NSF Contribution) has been estimated for WBS-2004 as $7,719k

3. The Calorimeter cost has risen due to: a) The increasing of the Calorimeter size

(5252 modules instead of 4848 modules)$673k

b) The input of the new additional expenses for: Mockup of Calorimeter System (the former R&D program)

$364k

The Wave-Form-Digitizing readout electronics (the former item - 2.11.2.1)

$815k

Management & Supervision of Subsystem (a new required item)

$600k

Support of IHEP group at BNL (a new required item)

$469k

Travel support (a new required item)

$100k

NSF Contribution

Calorimeter System scheduleCalorimeter System schedule

Calorimeter-system spending-profileCalorimeter-system spending-profile

0

500

1000

1500

2000

2500

3000

2005 2006 2007 2008 2009 2010

Mockup

Calorimeter

Instrumentation

Shipping

Pre-inst. Test

Intallation

Commission

Tech. support

Total