Status of Type IV Cables Cables production resumed
Status of Type IV Cables • Cables production – resumed in February after 3 months stop – See ID week February ‘ 06 • Delivery of doubles harnesses completed (April) – 2125 double harnesses (4250 cables) • Installation – All racks in US side + 2 USA racks were installed last year by TC Russian teams Racks on Level 6 – Installation resumed at the end of March with a new TC team (French) US side – Very slow startup, safety issues, wrong usage of labels, mistakes – Completion of USA side was expected by the end of May • But <50% done – Russian teams will take over 1 -2 racks – expected completion end of June – Need to test last ~200 cables for acceptance – Need to test after installation to be able to cut extra length to liberate floor in USA 15 • Connector in situ (CPE) – All connectors (2000) in US 15 completed on March 10 (a few were left but they are done now) • Many racks are tested before and after plug into PS (Petr with Prague team) • Very good yield but some rework was necessary • One rack needs cables rerouting (cables were cut too long by previous company) – 2+1 techs returned on April 18, started 2 USA racks but left again: Need more USA 15 rack completed for the full team to operate efficiently – US side was reworked and racks in USA 15 will be continued when full team will be back (mid -June) 8 June 2006 A. Ciocio - SCTSG 1
PP 3 • Remaining units and parts about to be finished and will be sent “soon” • Scott will come back (June 13) for 4 -6 weeks • Much of the installation done but lots of work to complete all racks: – – Most of subracks of 30 units installed Need 7 subracks to complete all installation and “special” subracks Some subracks sitting by racks to be installed Small fraction of cables are plugged in • Issue with schedule: – Rework for damages, shorts, bad assembly has to happen when needed with technical help available – Problem of not having all the parts in hand because changing of priorities and racks not completed 8 June 2006 A. Ciocio - SCTSG 2
Type II/III & PP 1 – Production • INEO/Thurmelec are making type II-III cables in 2 steps: 1. double length harnesses as they receive information about the lengths type II cable and type III spliced type II FCI/JST connectors on both ends of double harness 2. Single length cables with FCT connector (PP 3) are produced when length finalized with test cable measurement from cryostat to PP 3 racks sector by sector • • • Delivery rate reached 300 cables/week We are ahead with cable preparation! So far good quality No fatal defect found on some cables (the color coat is gone is some section/pattern but kapton insulation OK) Fatal defect (but repairable) found on 2 -3 cables ( Only a few cables failed acceptance • PPB 1 – clamps, clips, cable tray covers were late, not used yet during installation – Clamp mounting started – Clip under production • PPF 1 – most parts available – Found the best way to crimp group of drain wires in a ferrule and catch the ferrule with the grub screws into clamp’s holes 8 June 2006 A. Ciocio - SCTSG 3
Type II/III cables – Installation • ~ 2300 cables installed • ½ bundle /day/side/team 48 cables/day but may reach 100 Old problems: (Details given in April SCTSG) • Problem with testing related to the grounding in cryostat (OK) • Mechanical problems to fit layers of 6 cables between cover/clamp holder pins (all cables installed have been retrofit) • Clamp installation Yield: • <1% cables to replace - Mechanical defects - Damage - Failed electrical test 8 June 2006 A. Ciocio - SCTSG 4
SCT Services Sequence • Sector 5 (top) and Sector 13 (bottom) – heater cables, and DCS cables (completed) • Sector 9 - Installation completed on May 1 – 878 SCT cables (384 Barrel, 494 EC) – 18 Fibre cables (EC) • Sector 3 - Installation started May 2 – completed last week – 583 SCT cables (336 Barrel, 247 EC) – 27 Fibre cables (9 EC, 18 Barrel) • Sector 1 - started in parallel 2 weeks ago – will be completed this week – 878 SCT cables (384 Barrel, 494 EC) – 18 Fibre cables (Barrel) • Sector 7 – first 300 cables arrived – installation in parallel just started – 583 SCT cables (336 Barrel, 247 EC) – 27 Fibre cables (9 EC, 18 Barrel) • Sectors 11, 15 – Double harnesses length sent to company to fabricate – single length this week – 583 + 583 SCT cables (336 Barrel, 247 EC) – 27 + 27 Fibre cables (9 EC, 18 Barrel) • Installation sequence in a sector is: – Tubes, fibres, heater cables, SCT cables, (Muon chambers), – TRT cables, pixel cables 8 June 2006 A. Ciocio - SCTSG 5
Schedule • Type II-III installation should be completed by mid-July (according to current schedule from TC) Our schedule • Type II-III installation • Type IV installation • Connector in situ/testing • PS crates • PP 3 assembly, installation • All cables plugged into PP 3 mid-July (Barrel) end of June… end of July mid-June (US side) – July (USA side) end of June mid-July We need continuous presence of people at CERN at least until mid-July (and later in August) • Critical area in the type II-III acceptance, installation and testing • SCT participation very valuable to add to people who are resident 8 June 2006 A. Ciocio - SCTSG 6
Plan 8 June 2006 A. Ciocio - SCTSG 7
Installation & Testing Activities Activity Resident Additional Tomas (Prague) 3 Petr (Prague) Prague + 2 Jessica (UCSC) Kuo-Ming (Sinica) 4 Type II-III Installation Mount d. PPB 1 and d. PPF 1 (Barrel) Squeezing the cables to fit between pin and clamp holder Plug-in of the delicate JST/FCI connectors to d. PPB 1 Placing the clamp (now), placing the clip (later) (ENDCAP) crimp group of drain wires in a ferrule and catch the ferrule with the grub screws into clamp’s holes Plug in the d. PPF 1 Jacek (Crakow) 1 Type II-III Testing Alexandre (Dubna) 3 PP 3 Scott (Melbourne) 1 Type IV Acceptance test Test in rack after installation Test of cut cables after connector in situ work Plug-in cables into PS crates Test with feedtrough Type II-III Preparation Acceptance test (partial) Visual inspection Folding the shield and cut it the right amount, fix it Organize boxes with right cables to send for installation Burn-in of units Assembly into subracks Installation into racks of subracks Plug-in the cables to PP 3 8 June 2006 Test of whole chain A. Ciocio - SCTSG 2 8
Issues • • • PP 3 – Help is coming next week but continues to be difficult to keep up with technical problems and missing subracks Connector damage – In US 15 they are left too long on the floor – Other cables installation interference Tester – Different flavor that work with different configuration of cable chain – Multiple laptops failure (~ok now) Spares installation for type II-III cables – 2 spare type ii-iii EC cables installed but too short – needed splicing extension of type III – We don’t have spares of every flavor – need rework to get the right one in place Defective d. PPF 1 – Some faulty cables were actually due to a bad channel on d. PPF 1 – missing some d. PPF 1 Type III installation & testing – Difficult conditions for testing – Extra length to reroute on additional trays – Dedicated team (Russian) available to plug-in but need assistance (and all cables tested) Type IV installation – Very inefficient and need extra interaction with new team – Interference with type II-III installation Connector in situ – With the current rate of type IV installation difficult to keep schedule as planned – The very first rack has 200 cables to reroute under the rack to absorb the extra length More HELP for the following weeks 8 June 2006 A. Ciocio - SCTSG 9
- Slides: 9