RPC Production at GT A Mass scale RPC
- Slides: 43
RPC Production at GT A Mass scale RPC Production RPC 2005 VIII Workshop on Resistive Plate Chambers 10 -12 Oct, Seul - South Korea Domenico della Volpe - INFN Naples VIII Workshop on RPC, Oct 2005, Seul - RPC Production at GT - D. della Volpe
Outline The Production Chain The Quality Assurance The Production Planning Efficiences of Production Stages Summary VIII Workshop on RPC, Oct 2005, Seul - RPC Production at GT - D. della Volpe 2
Where we start • In the late 90’ several INFN experiment decided to use RPC technology form their detector • They were: ATLAS, CMS, ARGO, OPERA, LHCb, ALICE. • Each of them had milestones and the risk of clashes was high • In the meanwhile the Babar crisis, pointed out some the critical item in the RPC Production • INFN management had two main worries: – The Gap Quality – The Production Rate VIII Workshop on RPC, Oct 2005, Seul - RPC Production at GT - D. della Volpe 3
The Creation of CCRPC • In 2001 the INFN put together a Committee for Control of RPC Production (CCRPC), involving expert from each experiment with the goal of test the maximum production rate at GT to set-up new QC & QA procedures. • Between September and December 2001 a first test was accomplish proving that 15 gap/per day was achievable and a set of QA & QC was setup. VIII Workshop on RPC, Oct 2005, Seul - RPC Production at GT - D. della Volpe 4
The beginning • In 2002 the need of detailed planning was clear. • It was started a planning agreed by experiment and a supervisor for this coordination between them was hired • In the last 3 year this activity had a deep impact on the GT in terms of performances and quality. • Here I will report the actual status, the production procedures, and QC & QA introduced VIII Workshop on RPC, Oct 2005, Seul - RPC Production at GT - D. della Volpe 5
The Production chain VIII Workshop on RPC, Oct 2005, Seul - RPC Production at GT - D. della Volpe
Graphite coating PET Film Gluing Gas Inlet PET Frame Experiment QA & Test Cleaning Gap Finishing Selection Gap Oiling Frame Sealing Gap Assembly Bakelite preparation Quality Controls The Production Chain Leak Test VIII Workshop on RPC, Oct 2005, Seul - RPC Production at GT - D. della Volpe 7
Bakelite Preparation • • • Selection (by eye) MEK Wasking (Washing machine) Plate masking (manual) Graphite coating (automatic) R measurement (QC) PET Film Gluing VIII Workshop on RPC, Oct 2005, Seul - RPC Production at GT - D. della Volpe 8
Gas Gap Assembly The Gluing Machine – – – 2 table (2 gas gap at cycle) 18 slot “Pizzeria” 12 spacer per row 5 minute for spacer positioning 10 for frame and corner-pieces positioning and gluing VIII Workshop on RPC, Oct 2005, Seul - RPC Production at GT - D. della Volpe 9
Gas Gap Finishing - Hot Melt • Frame sealing with an hot melt. • The sealing is a crucial operation: – important for gas tightness – prevent HV leak. • The smoothness of this operation has impact on HV leak • Needs this special tool to handle big gap like OPERA or ARGO VIII Workshop on RPC, Oct 2005, Seul - RPC Production at GT - D. della Volpe 10
Gas Gap Finishing - Gas Inlet • Positioned after the sealing • In the past years drilled in. • The drilling powder very dangerous: start local sparks • Policarbonate corner pieces used where gas inlet are inserted later on. ATLAS VIII Workshop on RPC, Oct 2005, Seul - RPC Production at GT - D. della Volpe 11
Gas Gap Finishing - PET Frame • Soon after the mass electric test started, was clear that a big amount of gas gap didn’t pass the experiment QA becase of current leak through lateral frame • ATLAS proposed to reinforce the HV tightness adding a Cshape PET Frame • This was tested to be very effective but the realization of such profile needs to be done automatically • A tool for the realization of the PET frame and a press cut to cut the hole for gas inlet was realised VIII Workshop on RPC, Oct 2005, Seul - RPC Production at GT - D. della Volpe 12
Gas Gap Oiling • Fast leak test is performed by GT – 5 mbar is applied – Less that 0. 2 mbar leak in 20 minutes • Oiling facility temperature: 30 °C • 8 -12 hrs to thermalize. • 3 hrs for oil filling • 36 -73 hrs of purified air. VIII Workshop on RPC, Oct 2005, Seul - RPC Production at GT - D. della Volpe 13
Oiling QC Quality Control for the oiling are made: – Oil viscosity (every tank filling up) – Oil Sample • Chemical analysis for checking polimerization – Sacrificial gas gap • Gap visual inspection • Surface analysis of sacrificial gap with FTIR using ATR VIII Workshop on RPC, Oct 2005, Seul - RPC Production at GT - D. della Volpe 14
Oiling QC - Visual Inspection For each oiling cycle a sacrificial volume is chosen and open for a visual inspection Also a sample of the gap is taken to undergo a surface analysis VIII Workshop on RPC, Oct 2005, Seul - RPC Production at GT - D. della Volpe 15
Oiling QC - Lineseed analysis Good Oiling Line seed oil peaks Bad Oiling No line seed oil peaks VIII Workshop on RPC, Oct 2005, Seul - RPC Production at GT - D. della Volpe 16
Experiment QA VIII Workshop on RPC, Oct 2005, Seul - RPC Production at GT - D. della Volpe 17
Experiment QA • Each experiment has specific requirements and then its own Quality Assurance. • Anyway even if with different criteria, basically the QA check can be grouped in two classes: – Spacer gluing (Push Test) – Gap Current VIII Workshop on RPC, Oct 2005, Seul - RPC Production at GT - D. della Volpe 18
Spacer Gluing • Each experiment has a maximum number of unglued spacer that can tolerate depending on their mechanics or overpressure supposed to be present on gas gap on installation site. • CMS needs gap that can stand an overpressure of 20 mbar without unglued spacer • The over pressure is so high that unglued spacer can be seen by eyes. • In order to check unglued button the Babar people set-up a test method (Push-Test) used also by Atlas and OPERA VIII Workshop on RPC, Oct 2005, Seul - RPC Production at GT - D. della Volpe 19
Push test • The gap is positioned on the table • An overpressure of 5 mbar is applied to the gas gap. • A weight of 600 grams is applied on each button in a single row by mean of a bar. • In case of unglued button the weight can press the gap reducing the volumes a causing an increase in measured overpressure. • The procedures is then repeated row by row VIII Workshop on RPC, Oct 2005, Seul - RPC Production at GT - D. della Volpe 20
Push Test GOOD GAP BAD GAP • In case a bad row is found, the bad buttons can be found by lifting each weight until a depression in the shape is found. VIII Workshop on RPC, Oct 2005, Seul - RPC Production at GT - D. della Volpe 21
Push Test • OPERA can accept just gaps without unglued button, so decided to setup an automatic test pushing all their chamber VIII Workshop on RPC, Oct 2005, Seul - RPC Production at GT - D. della Volpe 22
Current test • Almost every experiment does a gas gap current measurement. • Here I will report about the one done by ATLAS, because is the one a know better. • The test is performed in two phase: – a test with pure Argon before gap oiling (to check construction characteristic such as ohmic resistance, bulk resistivity, etc. ) – a test with the final gas mixture after the gap oiling (to check gap performances using the V-A characteristic) VIII Workshop on RPC, Oct 2005, Seul - RPC Production at GT - D. della Volpe 23
Argon Test Bulk Ohmic dominates Bad Chamber (early ignition) Ignition point Linear slope (or slowly logarothmic) VIII Workshop on RPC, Oct 2005, Seul - RPC Production at GT - D. della Volpe 24
Argon test What for? – find patological gap to reject . . but also to check. . – Bulk resistance – Plate resistance VIII Workshop on RPC, Oct 2005, Seul - RPC Production at GT - D. della Volpe 25
Final Gas mixture test After oiling another V-A scan but with ATLAS gas mixture is done. Gas Gap with less than 2 A/m 2 (@9 k. V, @20°C) Reject Suspend Accept (Volt) VIII Workshop on RPC, Oct 2005, Seul - RPC Production at GT - D. della Volpe 26
Production Planning VIII Workshop on RPC, Oct 2005, Seul - RPC Production at GT - D. della Volpe 27
The Plans • Every Year a plan of the daily GT production has been done in order to optimize the speed, material procurement and experiment Milestone. • On 3 month basis the plan has been revisited and re-arranged • To do this a continuos monitoring of the production chain and of the material procurement was done VIII Workshop on RPC, Oct 2005, Seul - RPC Production at GT - D. della Volpe 28
The Plan VIII Workshop on RPC, Oct 2005, Seul - RPC Production at GT - D. della Volpe 29
The Production Status Last Update 1/10/05 VIII Workshop on RPC, Oct 2005, Seul - RPC Production at GT - D. della Volpe 30
Overall GT Production Something like 10000 gaps produced in 42 months Even if with several stop due to material shortage a mean value of 12 gaps/day was achieved VIII Workshop on RPC, Oct 2005, Seul - RPC Production at GT - D. della Volpe 31
Monthly GT Production • The production was supposed to halve by the end of 2004 and finish by the middle of 2005 • Still on and is supposed to finish by the beginning of next year VIII Workshop on RPC, Oct 2005, Seul - RPC Production at GT - D. della Volpe 32
The Production Rate VIII Workshop on RPC, Oct 2005, Seul - RPC Production at GT - D. della Volpe 33
The Production Rate VIII Workshop on RPC, Oct 2005, Seul - RPC Production at GT - D. della Volpe 34
Production rejection factor A Preliminary and incomplete look at the ATLAS production data VIII Workshop on RPC, Oct 2005, Seul - RPC Production at GT - D. della Volpe
What for? • In 2003 both ATLAS and CMS needed to revise their cost to completion of gas gaps • Two main cause – Gap improvements (PET-frame, QA) – Big number of gap rejected • At that stage not to much coherent data were available, so a guess was done – 5% bad assembly by GT – 20% by collaboration QA • This means that 125% must be produced in order to have the 100% of layout VIII Workshop on RPC, Oct 2005, Seul - RPC Production at GT - D. della Volpe 36
GT rejection factor ) 41 (2 0) 03 (1 ) 48 (6 ) 1) 40 (7 72 (1 38 (4 0) The 5% estimation was correct VIII Workshop on RPC, Oct 2005, Seul - RPC Production at GT - D. della Volpe 37
Current test Rejection Factor VIII Workshop on RPC, Oct 2005, Seul - RPC Production at GT - D. della Volpe 38
Current test Rejection Factor Condtioned room Winter Effect VIII Workshop on RPC, Oct 2005, Seul - RPC Production at GT - D. della Volpe 39
Current test Rejection Factor VIII Workshop on RPC, Oct 2005, Seul - RPC Production at GT - D. della Volpe 40
Current test rejection factor • A significant improvement over the time • Improvement of stability test condition • Chamber reconditioning VIII Workshop on RPC, Oct 2005, Seul - RPC Production at GT - D. della Volpe 41
Conclusion - I • A deep re-organization of the production chain was needed to go from hand made to mass scale production • Big effort to organize production plan, material procurement, manage the milestone conflict • Substancial revisitation of QC and QA procedure • Delays were mainly due to material procurement (Bakelite) • Panpla attitude can represent a real threat for future RPC production VIII Workshop on RPC, Oct 2005, Seul - RPC Production at GT - D. della Volpe 42
Conclusion - II • A first look at production efficiency was given • This is a critical issue for future experiment mass scale production • An a posteriori analysis shows that our guess in term of production efficiency were conservative • The INFN goals were achieved VIII Workshop on RPC, Oct 2005, Seul - RPC Production at GT - D. della Volpe 43
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