id asso – sct production statusm. tyndel 117-dec-2002 atlas sct production status alex grillo...

ID ASSO – SCT Production Status M. Tyndel 117-Dec-2002

ATLAS SCT Production Status

Alex Grillo

Overview Procurement

Silicon detectors ASICs

Barrel & Endcap modules On-detector services PP1

DCS Optical LM tapes (Power & sense lines) Cooling

Barrel & Endcap support structures Power & Readout

Power supplies (LV & HV) Readout, DAQ & DCS Services PP3,PP2,PP1

SCT integration & installation Schedule


ATLAS SCT Overview

Barrel 4 cylinders Interlinks Thermal screen

Endcap-C 9 disks Support structure Thermal screens

Endcap-A 9 disks Support structure Thermal screens

20K detectors to cover ~ 60 m2

60K ASICs (x128 readout channels) 4K modules; r~23m; z ~0.5mm

4K low mass cables & optolinks 250 LM cooling circuits; power ~ 40KW Low mass, stable C structure @ -10oC Barrels, disks, X-ray survey, in-situ FSI 8K readout channels; DAQ & DCS 40 collaborating institutes; 45MSFr

Power system (via PP3, PP2, PP1) LV (FE power) HV (Detector bias)

Readout & DAQ (via PP2?,PP1) Cooling (ID – interface @ PP1) Services & DCS


SCT Procurement – Silicon sensors

Production, acceptance testing & irradiation QA of the silicon detectors is ahead of schedule

Quality is excellent with acceptance testing in the institutes keeping up with production

Delivery (including an allowance for losses during assembly) will be completed this year


SCT Procurement – FE ASICs (ABCD)

Production,acceptance testing & irradiation QA of FE ASICs is well advanced.

Yield has been variable with an integrated average of ~26%

Final production wafers (including an allowance for loses during assembly) are ordered

Recent yields are low. Reason & impact on the project under study

Irradiate samples from batches & modules with ASICs to 3 1014 p/cm2 throughout production


SCT Barrel modules

Production schedule

Based on experience to-date the schedule has been revised with the following milestones:

10% complete Feb 03

50% complete Sep 03 100% complete Mar

04

Supply of components (detectors, baseboards, hybrids, ASICs) under control.

Target module production rates not yet achieved – will be reviewed at PAR ( spring 03)


SCT Barrel modules – Hybrids & baseboards

Hybrids Baseboards


SCT Barrel modules - assembly

Module assembly sites Japan

Qualified (5 modules in spec) + Production at ~ 2modules/day

Module assembly sites

UK-B Qualified (5 modules in spec) + Now at ~1module/day 3/day 50 by Jan 03

USA Completing Qualification Production starting 3/day 40 by Jan 03

SCAND Completing Qualification Production starting 1/day 10 by Jan 03

Goal is to complete module assembly by Mar 2004 (target)


SCT End-cap modules

Background:

The K4 End-cap module was found to be unstable

The hybrid was redesigned & 16 K5 modules (outer, middle, inner) were built . They were stable and within specification pre-irradiation

The post-irradiation performance after 3 1014 p/cm2 (just) meets the specification. ( S/N performance is ~10% worse than for barrel )

Pre-production batch of 100 K5.1 hybrids are in production. First 2 modules irradiated; 4 more evaluated.

PRR on Dec 9 has given green light for production


SCT End-cap module system test


SCT End-cap module production

The hybrid assemblies are produced in industry with ASICs supplied by ATLAS

The spines are assembled by Protvino

The fanins are produced by CNM (Barcelona)

The three shapes of modules will be assembled and tested in 7 institutes/clusters

UK Valencia MPI Nikhef Freiburg Geneva/CERN Melbourne


SCT End-cap Module production schedule

1. Pilot run to release industrial production (100 K5.1 in production)

2. Assembly site qualification (needs to be efficient)

3. Order components (hybrids, spines, fanins, washers, glue)

4. Module assembly/QA will take about 1.5 years


SCT Services - Power distribution

Modularity 1 4088 cables


SCT On-detector services

Interfaces between the modules & PP1 Off-detector: LM tapes & PP1 for the power

In production in Ljubljana• First batch ready to be shipped to

Taiwan• PP1 ready in mid Jan

Optopackages and control electronics Doric & VDC ASICs produced Optopackages are in production in

Taiwan Barrel harnesses

Will be assembled in Taiwan End-cap harnesses

Will be assembled in Taiwan Optical fibres

Rad hard fibre purchased• Needs ‘cabalisation’ – at tender stage

Endcap harness


SCT On-detector services

Barrel dogleg


SCT Cooling Pipes

Interface between the modules & PP1 Capillaries/Heaters ID evaporative cooling:

LM cooling circuits. The circuits for Barrel-3 and Disk-9 are in production

Full production will follow Cooling FDR

But -

Metallurgical analysis has indicated that the grain size is critical & 100m pipe has been ordered as a fall-back

A stringent QA procedure with thermal stressing is being initiated.

The interfaces are not finally specified:• Capillaries

• Exhaust heaters

• System parameters


SCT Barrel Sector


SCT Support Structures

End-caps 2 x 9 Carbon fibre discs

First discs expected at Nikhef ~ now Machined & equipped with pads at Nikhef 2 Support cylinders & wings

Being manufactured Thermal shields

Barrel 4 Carbon fibre cylinders Machined when delivered

First barrel delivered Geneva B6 ready to be shipped;B4 & 5 in Jan 03

Equipped with pads & module brackets Interlinks will connect all 4 barrels Thermal shields


SCT Endcap Support structure


SCT Services Installation

The first part of the SCT to be installed are the services

Urgent to finalise design, routing and place orders• Cables (Type II, III and IV)

• All cables prototyped; use LHC market survey (+ some non-member state companies)• Tender in January to enable production to finish in Summer 2004

• Fibers (Readout, Control & FSI): • Readout/control fibers produced. Will order protective cable when PP2 position final)

• Patch Panels: • PP3: finalize design and define location

Type routing number lengthCables:

power/control Type II PPF(B)1-PP2 4098 45 kmpower/control Type III PP2-PP3 4098 90 kmpower/control Type IV PP3-UA15/USA15 4098 250 kmDCS

PipesN2

Fibersreadout/control PP(B/F)1-PP2-UA15/USA15 12294 1200 kmFSI 24 km



176 PPB1 per side – serving 6 modules (half-stave) each, arranged staggered in 2 positions along cryostat bore

Type II cables in 16x48-cable and 8x36-cable bundles along bore joined by 988 LM Tapes in 16x3 bundles from end-cap at z~2800

PPF1 at cryostat bore-flange corner – EC transition to Type II cables

PPF1PPB1 Type II

LM Tape



Type II length7.9 – 11.7 m

Bunches per side

No. of Cables From

16 62 EC

16 48 B

8 36 B



Cable Routing I

To USA15

To UA15

Type IIIType IV


SCT Barrel Integration

Individual barrels are delivered to the SR building, CERN.

Acceptance tests at CERN are done in the shipping container.

Thermal screens & 4 barrels are assembled with no further tests

The barrel SCT (4-barrel assembly) is installed into TRT and then tested and surveyed (x-ray)


Attach air-con units Remove side panels, visual inspection (incl. Video record) Replace panels, reconfigure ends, attaching all cables, services. Test R/O fibres and FSI Leak test cooling system Operate DCS, measure T, hum. Seal ends, add thermal insulation. Attach and test N2 supply, measure leak rate, monitor humidity and run

until dry. Operate cooling system, monitor DCS, ensure correct operation Check module operation according to test specification (on EDMS) 6 – 8 Weeks/barrel (some parallelism possible)

SCT Barrel Acceptance


Complete End-caps arrive in temporary thermal enclosure with all services up to PPF1

Acceptance test is performed on individual disks

Installed into final thermal enclosure with wings and tested and (possibly) surveyed

Wing removed, inserted into TRT and retested

SCT Endcaps Integration


SCT Endcap Tests before arriving to CERN

During Disk assembly: Before mounting modules:

Leak test cooling Check power and opto connections using dummy hybrids Temperature cycle the disk

After mounting modules, test full wheel, at room and low temperature: Thermal tests – look for unusual thermal gradients on modules Electrical tests

Results go into database As disks go into endcap:

Leak tests of cooling Electrical tests of modules Room temperature and cold

When endcap completed, crosstalk checks (on at least one endcap): Two disks at a time Quarter-endcap (quadrants)


SCT End-cap acceptance at CERN

Unpack, clean, move into testing area Open temporary thermal enclosure, make visual inspection. Close the Thermal Enclosure Working 1 disk at a time:

Connect cooling pipes, perform warm leak tests with gas, pressure and vacuum Attach PP1Ts Connect power tapes and DCS twisted pairs; check environment temperatures Test HV connections and IV (a few points at least) before cool-down at 20o C:

Power cable connections HV control and monitoring DCS

Connect and test FSI fibres Connect optical readout fibres

Switch on cooling and module power – (not clear yet if ~room temp is possible) If cold, need well-defined, automated start-up/cool-down procedure to keep

temperatures above dew point at all times. Lab-View version of this exists now in B186 system-test.

Check/monitor module and environmental temperatures


Acceptance Tests

Electrical tests: Full characterisation, i.e.

Bypass test Redundancy test Pipeline test Strobe delay test Three-point gain measurement Trim scan Response Curve measurement Noise occupancy scan Time-walk measurement

Noise occupancy vs. time Steady? Any spikes? Maybe not necessary for all disks

Cross-check results with those from module and wheel-assembly testing Warm up (if running cold), disconnect all cables/fibres

Ideally do all this, but may have to scale back depending upon time available.In red = minimal set of tests


Attach all PP1Ts, make all connections (pipes, power tapes etc.) Check environment temperatures Check HV DCS and monitoring Connect and test FSI fibres Switch on cooling and readout

monitoring temperatures and humidities Noise scans, cold, on full end-cap:

NO, ENC Cross-check with previous results

Cross-talk and common-mode checks X-ray survey possible here, but preferable to do once inside TRT Full FSI system test, confirming that all reflectors are aligned Warm up Remove front wing before insertion into TRT

SCT Endcaps Acceptance – in Thermal enclosure


SCT - Equipment for Acceptance Tests

Cold dry nitrogen supply Equipment for leak testing Test equipment for one disk (132 modules) (in zone 1) & for complete barrel

(in test area). DAQ:

• ROD etc.

• PC

• VME crate control

• software HV, LV with DCS control DCS interlocks, environmental monitoring etc. Cooling system, with pipes from PPF1 Cables, fibres PPF1 crates


SCT schedule & milestones

http://hepwww.rl.ac.uk/ppdstaff/Tyndel/Schedules/SCT_Nov02v10.mpp

Critical issues: Target

ASIC yield Feb 03 Placing the EC hybrid order & the start of EC module assembly Dec 02 Start machining of disks & equipping with Services-First disk by Feb 03 Delivery of End-caps

Achieve full production rate of barrel modules in all clusters Feb 03 Need opto-harnesses produced & tested for barrel-3 Feb 03 Need cooling circuits produced & tested for barrel-3 Feb 03 Commission C4F10 cooling for assembly sites Apr 03

Finalise the design parameters of the cooling system Nov 02 Finalise PP3 design, cable lengths & launch order Apr 03

id asso – sct production statusm. tyndel 117-dec-2002 atlas sct production status alex grillo...

Documents

batches modules

spec production

k5 modules outer

complete module assembly

target module production

k4 endcap module

barrel preproduction

final production wafers