TRT Barrel assembly

1

• TRT Barrel assembly
• status schedule
• Feb. 9, 2005

2
All modules installed!
Feb. 3, 2005
3
Snap shot

• Feb. 8 snap shot
• Type 1
• All modules installed tested
• All electronics installed
• 20 modules cooling tube installed
• Type 2
• All modules installed tested
• 18 side A electronics installed
• Type 3
• All modules installed
• 28 modules with protection boards and tested

Feb. 06, 2005
4
Module installation time line
30 module mounting days
5
Module placement

• Final dead wire distribution
• Type 1
• 123.5 1.17
• Type 2
• 1210.73
• Type 3
• 572.52.26

6
Final dead wire distribution

• Whole barrel
• 817 1.55

7

• Mechanical Assembly Processes

8
Module preparation (done, except for spares)

• Capacitor installation (1-2 days/module)
• Insert capacitors
• Check capacitor connectivity
• Check HV traces
• HV test caps wires
• Seal capacitors

• Pre-insertion prep.
• (6 modules/day/2 person)
• Check ground wire
• Check cooling sleeve
• Check mounting holes
• Active gas fittings, custom made for each module
  connection leak test
• Glue purging gas gasket
• Tape HV kapton for protection
• Glue thermal sensors as needed (4 modules each
  type)

9
Module installation tests (4 last modules)

• Procedures tests
• Fold HV kapton and cover with protection plates
• Insert module fix one corner
• Set module z position to middle of BSS
• Fix module 2nd corner attach set screws
• Check purging gas flow
• Type 1 1.5 L/min lt 10 loss
• Type 12 1.5 L/min lt 15 loss
• Type 123 0.5 L/min lt 20 loss
• Unfold HV kapton check HV traces
• Attach glue active gas fittings
• Plug seal unused active gas inlets.
• Leak test active gas volume (1mB/B/min)
• Install protection boards
• HV test with Ar-CO2
• Check active gas path for obstruction (flow rate
  test)

10
Cooling lines installation (on going)

• After the electronics have been
• Installed
• Continuity check
• Noise check
• The cooling lines are
• inserted through both corners of the module
• 90 bend forced on one end
• Attachment to cooling plate at each end.
• (T1 20 modules)
• Cooling flow measurement is made.
• (T1- 20 modules)

11
Module repairs modifications

• Module repair
• Wire removal (2 bad wires some retroactive
  decisions from acceptance group)
• HV trace broken, shares from neighboring line (1)
• Cooling sleeve replacement (4)
• Three wires removed from BSS. (2 drawing excess
  current, 1 shorted).
• Two modules (T1) show a connection between 2
  signal wires (double joints) at one end. Left for
  now.

• Components modification
• Peek tubes for module cooling reduced from
  0.123-0.127 ? 0.116-0.120 (done)
• Fuse box brackets dimension change
• Fuse box screws changed from Nylon to Ultem
• CO2 flushing tube redesigned with corrigated
  PEEK.
• De-magnetized stainless steel screws for active
  gas inlet plugs (started from type 2 modules)

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Remaining mechanical work

• Finish testing the last 4 type 3 modules (1week)
• Continue to install module cooling tubes as
  electronics are installed
• Install outer cylinder
• After all modules are tested ( March, 1week)
• Before manifold can be installed
• Install services after electronics are installed
• Cooling manifold (contract, deliver April)
• Active gas manifold (drawing/review this week)
• Purging gas manifold (parts)
• Install fuse boxes
• Need to solve fuse problem and resume production
• 3 possible windows for installation (in
  descending preferences)
• Before TRT/SCT system test Oct.
• Before going in the pit Feb. 06
• In the pit, same time as harness or before (?)
• MTF migration Data base structure defined,
  entering data.

13
Electronics installation

• Type 1
• Completed Jan. 24, 2005
• Type 2
• Side A (2B) 18 modules installed
• 22 boards in repair process, 10 finished
• Side C (2F) started stuffing at ACAMAS. Should
  have pre-series at CERN end of Feb.
• Type 3
• Side A (3B) Pre-series at CERN and tested.
  Feedback to ACAMAS. No known issue.
• Side C (3F) All bare board received. Need to
  start pre-series.

14
Electronics schedule

• 3B will be the next to arrive (followed by 2F and
  3F) and available for installation April 11.
• After that we will be saturated with boards.
• Installation is the slowest part.
• 3 weeks per side for type 2
• 1 month per side for type 3
• Will need to run more than one shift to finish
  installation in June.

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Services Manifolds
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Sector Tests
17
Current Integration Schedule
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Summary

• All modules installed!
• Electronics installation is well under way.
• All type 1 installed
• gt1/4 type 2 installed.
• Parts, procedures, and drawings are in good shape
• Manifolds could cause delays and need to be
  carefully followed.
• Active Roof Boards remain the critical path and
  need to be carefully followed
• Fuse problem need to be solved