trt barrel status

Pauline Gagnon – Indiana UniversityASSO meeting – 17 December 2002

TRT barrel status

Pauline Gagnon – Indiana University

Production status

Acceptance test plans

Integration plans


Barrel TRT assembly32 modules each of type 1, 2 and 3

Insertion in Barrel Space Frame: start Oct 2003 - end Nov 2004


ATLAS barrel TRT production:3 universities involved

Hampton– Component production

Straw Assemblies

HV plate testing

Dividers and wire supports

Gain mapping of all modules

Stringing

Duke– Module Assembly

Modules of type 2 and 3

wire joints and HV plate assembly

Indiana - Module Assembly

Modules of type 1 and 3

Shells and radiators

Since wire-joint decision:

Module mechanical production reorganized for efficient use of the assembly teams at the three sites.

Wire stringing recommenced in August.

Need to finish wire stringing by the summer of 2003.


Steps for module completion

1) Shell inspection

2) Stacking radiator material


Module constructionInsert radiator stacks and dividerInsert strawsInstall tension and HV plates14 modules to be done

To be completed by March 03


Wire-joint production

Still 16000 joints to produce

2 stations in operation

80 joints/station/8 hr shift

Task to be completed by April 2003


Parts production completionpart needed completion

Straws 64000 all done

Radiator sheets 37776 all done

Shells 105 all done

Wire joints 70086 Apr 03

Wire supports 240000 all done

HV plates 204 Feb 03

Tension plates 204 Feb 03

Dividers 1500 Feb 03


The last straw – 4 Dec 2002


Stringing64/102 modules to be strung 18 type 1

20 type 2

26 type 3

6 stringing stations in operation; one more in Hampton in January

Training ongoing Complete all modules by June 03


Total module production status

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Mechanical Assembly Start PlanMechanical Assembly Start ActualMechanical Assembly Completed PlanMechanical Assembly Completed ActualModule Completion Start PlanModule Completion Start ActualModule Completion Finished PlanModule Completion Finished ActualModules Gain Tested PlanModules Gain Tested Actual


Complete mapping by August 2004

Gain mapping at Hampton

Each completed module will be gain mapped in Hampton

Engineering run took place in September Temperature control

problem now fixed

2 modules mapped in December

There have been delays but full scale mapping due to start Jan 2003


Module Test stand exterior


Module Test Stand interiorElectronics

Module

X-ray

source

XZ motion

system


Gain mapping results (Sept 02)

Transient variation in monitor gain correlated with room temperature variation

Problem is now corrected


Shipping containersAll cylinders built

Prototype used to ship module to Dubna then CERN

No damage found

inner cylinder

outer crate (multiple module now)


Acceptance tests at CERN

All in building 154

Production plans: start March 2003

test 102 modules

1 week/module

1 year for two full-time technicians

Done by Sept 2004

Dimensional checks

Leak test

Tension test

HV checks

Gain mapping

HV conditioning

Rework if necessary

Repeat all checks done in USA


Acceptance tests at CERN

The way it

looked in

September


Acceptance test facility now

Dimensional tests and

database

Leak test


Stringing and HV test stations


Wire tension measurementTension measured

by finding resonant frequency

T

Lf

2

10


16-channel tension tester output


Test results stored in database and compared to production


Acceptance test statusAll equipment is in place except: HV conditioning cabinet to process 12 modules at a time

Gain mapping station

Storage rack (on order)

Database is given a shake down

Final adjustments made on all stations


TRT barrel integration

Proceed by sector

1 sector = 2 modules of each type

First, top and bottom

Then the equator

Next, top half

Finally, bottom half


Module installation in tool

Place assembly stands

Install inner ventilation gas fitting

Secure module in insertion tool

Position and align insertion tool

Install mounting hole pins and shims


For each module in a sector:

Install module

Install ventilation gas module ‘’grommets’’

Connect HV fuse box to Kapton connectors

Test each HV channel at capacitor barrel hole


Grommet: connector to allow radiator gas flow between modules

Current design Alternative Grommit under study


For each sector :

Install Type 1 inner modules

Install Type 2 and Type 3 modules

Install outer ventilation gas fitting

Install ventilation gas test manifold

Conduct Ventilation Gas Test

Disconnect gas test supply line


Sector system test in March 03

6 modules placed in space frame

All services connections made: electronics, cooling, gas and HV

Goal is to validate overall mechanical design


Electronics insertion on sector Install electronics stacks and cooling plates

Install roof boards or snake cables

Install cooling supply and return lines

Electronics Testing

Disconnect cooling lines

Install temporary gas manifolds for cooling, active gas and ventilation gas

Install cooling and active gas interconnect tubes for six modules

Repeat at the back – test front & back in parallel


Active and ventilation gas lines

cooling

system

ventilation gas

manifold

active gas supply


Barrel Final AssemblyInstall final gas manifolds (cooling, active gas, ventilation)

Turn on cooling pump and test for leaks

Turn on all electronics at both ends

Measure temperatures and balance system

Measure & record flow rates

Turn off electronics and cooling pump

Conduct active gas leak test

Install ventilation gas supply lines

Conduct leak test

Complete Faraday shield connections

Conduct noise tests (and possibly cosmic ray tests)

Fill barrel with inert gas


TRT barrel insertion scheduleduration start end

sector #1 18 days Oct 03 Nov 03

15 other sectors 238 days Nov 03 Oct 04

final barrel 27 days Oct 04 Nov 04

final system test 60 days Nov 04 Jan 05

For all details, see John Callahan’s presentation TRT Oct meeting

http://edmsoraweb.cern.ch:8001/cedar/doc.info?cookie=1421419&d

ocument_id=357795&version=1


Do we need more manpower?


Human ResourcesProduction

+1 new post-doc IU

Stretched thin but managing

Gain mapping

2 physicists at HU

+1 post-doc sought

Acceptance

1 physicist at CERN

+1 tech – 3/03

+1 technician and 3 physicists by 9/03

Integration

1 engineer – 9/03

1 tech – 9/03


SummaryModule production coming to completion, including spare modules and spare parts

No show stoppers in view

Many delays with the gain mapping station at Hampton but we will meet schedule for final assembly at the end of 2004

Equipment, software, database getting a shake down for acceptance tests

Plans/tooling for insertion being finalized

trt barrel status

Documents