13 September 2005 A.Ciocio - SCTSG 1

Type IV Cables and PP3

• Delivery

• Installation

• Connector work

• Testing

• Summary

13 September 2005 A.Ciocio - SCTSG 2

Delivery

• 685 pieces (double length cables) delivered• 337 to complete US side• Delivery in July/August very slow

– Vacation and QA problems• Connectors quality• Bobbins damage

– Bobbins already at CERN are going to be sent back to the fabrication company (Novacavi) to get cleaned up

• Delay of components delivery from CERN to company• Need to keep contact with CERN purchasing and Vendor

• Ramp up – 200 pieces/week expected soon after bobbins damage crisis is

solved but so far the max number of pieces we have seen is 120– Hopefully all type-IV delivered by mid-November

13 September 2005 A.Ciocio - SCTSG 3

Delivery (QA - Connectors)

• Connector’s signal wires too long• Some cables couldn’t be used• One week halt of production

13 September 2005 A.Ciocio - SCTSG 4

Delivery (QA - Packaging)

• Packaging: palette were sent with only plastic wrap around bundles

• Cables were getting wet during transportation and delivery at CERN

• About 40 cables lost (~30 in one delivery)

13 September 2005 A.Ciocio - SCTSG 5

Delivery (QA - Bobbins)• Cable bobbins dirty and damaged

• Bobbins are kept outside (at CERN) for long time

• Other (than water) damage under investigation

• Company claims delay in fabrication to deal with these problems

• Don’t know yet delay due to shipping bobbins back to Italy

13 September 2005 A.Ciocio - SCTSG 6

Installation• Double length cables are pulled and routed from PP3 racks in

UX15, through holes, to power supply racks in US15 (and USA15) side– 9 PP3 racks going to US and 9 to USA

• Racks to US side– 4 racks completed– 5 half/almost completed

• Team of Russian Tech’s from TC can install 40 double length cables/day– Work closely with Sergei Malyukov and the team– Provide complete layout/mapping for racks in both sides

• Bjarne is still helping from Bergen– Regular presence to check mapping/labels and prepare racks – Discussion on installation priority and occasional revise original layout– update DB table

• Racks to USA side will be ready to accept cable in 2-3 weeks

13 September 2005 A.Ciocio - SCTSG 7

PP3 to USPP3 rack US rack hole

UX/US

Y.37-1.X6 Y.05-14.S2 12

Y.43-1.X6 Y.10-15.S2 11

Y.43-1.X6 Y.11-15.S2 10

Y.47-1.X6 Y.11-15.S2 10

Y.43-1.X6 Y.12-15.S2 9

Y.47-1.X6 Y.12-15.S2 9

Y.52-1.X6 Y.23-15.S2 7

Y.52-4.X7 Y.23-15.S2 7

Y.52-4.X7 Y.24-15.S2 21

Y.53-4.X7 Y.25-15.S2 20

Y.53-2.X2 Y.26-15.S2 6

Y.51-2.X2 Y.27-15.S2 19

Y.53-4.X7 Y.27-15.S2 19

Y.51-2.X2 Y.28-15.S2 5

Y.52-1.X6 Y.28-15.S2 5

Y.52-2.X2 Y.29-15.S2 4

13 September 2005 A.Ciocio - SCTSG 8

Installation (PP3)• Cables are plugged in a few dummy Patch Panels to be installed in the right (final)

position and tightened to horizontal bars• They will have to be all removed from the current position and plugged in by

groups/rows when the installation of the real PP3 will occur• First 100 units will arrive end of September (around the 26th) but they will be already

burned-in (ready for installation after only reception test) • The remaining 4000 will be produced 2-3 weeks later in October• Shaun Roe and Igor Ilyashenko with the help from Pamela Ferrari and Ewa Stanecka

will set up testing and burn-in• It would have been desirable to have PP3 in place while installing cables to avoid the

additional dummy plugging in and the extra (and more difficult) work of plugging cables in an already fully populated rack (Ashley French will be at Cern Oct3)

– More people will be needed to work on US side racks• By the time the units are received and burned in we will be ready with the installation

of the racks to the USA side • Units should be sent with no additional delays and burn-in plan might need to be

revised• We’ll work on a scheme that agrees with the schedule where some will be sent air

freight and the rest surface (same for steel enclosures, rails and strain relief bars)

13 September 2005 A.Ciocio - SCTSG 9

Rack Scheme for PP3

13 September 2005 A.Ciocio - SCTSG 10

Connectors work

• Double length cables are cut and connectors are installed in situ (US/A sides)

• First rack (200 cables/connectors) completed in July – Work performed by SEDELEC (subcontract of KontaktSysteme– Many mistakes (~30 connectors need repair) still to be fixed and

they raised the cost significantly• New Plan

– Engineer from TC will be the contact with a new company (suggested by Marzio) and to work with Petr Kubik (Prague).

– Meeting with company soon to discuss technical aspects and see if and for how much they can do the work

– Meanwhile cables are being cut to some extra length and ~ all tooling has been purchased to make prototypes

– Plan for working in the US15 behind the racks (Petr)

13 September 2005 A.Ciocio - SCTSG 11

Testing• Tester designed and provided by Ljubljana (Gregor, Erik)

– 2 Test box + 2 Laptops + test cables– Gregor and Erik upgraded features of tester in July– Web based DB (last week)– Next visit Sep 26

• Test steps:– Cables are tested at reception (acceptance test)– After being pulled from UX15 to US(A)15 (uncut-double length)– After they are cut in the US side at connectors are installed

• Shift planner (developed by D. Robinson) works very well for planning the activities and have people to sign up

• http://www.hep.phy.cam.ac.uk/si-bin/sctworkplanner.cgi– (and contact me)

• What is needed to be able to take a shift:1) take the safety training course (at the pompiers station)

Special course on September 27th at 12:452) make the access request on EDH3) get your safety boots & helmet (or borrow them)

13 September 2005 A.Ciocio - SCTSG 12

Testing Shift Counts• Assuming 2 people in shift for every step and 3 hour shift (9-12h or 14-17h)

– Acceptance test 100 shifts (unit=1 person-shift)– Test in rack 100 shifts– Complete cable 400 shifts

• Participation of all SCT collaboration to shifts is crucial to keep up with installation schedule– First attempt (by Mike) to consider sharing amongst all SCT institutes

• UK 150 shifts • Japan 90 shifts • US 80 shifts • Norway 30 shifts • Nikhef 20 shifts • Uppsala 20 shifts • Valencia 20shifts • Slovenia 10 shifts • Cracow 5shifts • Czech 5 shifts • Russia 5 shifts

– And 200 shifts among• Australia• CERN• Germany• Switzerland

• After Mike’s call I had a positive response but need to discuss formula that works better for smaller participation and a more predictable presence when at regime

13 September 2005 A.Ciocio - SCTSG 13

Current Shift Counts per Institute

Institute Total Completed PendingPrague 19 16 3Bergen 19 19 0Geneva 18 16 2Valencia 11 11 0CERN 5 5 0Okayama 4 4 0UC Santa Cruz 3 3 0LBL 3 3 0Kyoto 3 3 0UCL 2 2 0KEK 2 2 0Cracow 2 2 0Ioffe 1 1 0

13 September 2005 A.Ciocio - SCTSG 14

Summary

• Delivery of Cables– Need to improve QA of components– Follow up with company

• Installation– Ramping up

• Connector work– New plan

• PP3– Need units without delays and help with installation

• Testing– Will work if a more predictable presence when at regime