1. HGC Cassettes Jim Freeman September 17, 2015 1 Director's Review -- Calorimetry – HGC Cassettes Jim Freeman, 2015 Sept 17

2.  Fermilab Team  Frank Chlebana  Jim Freeman  Jim Hirschauer  Don Lincoln  Slawek Tkaczk  And growing  University Participants  Alabama  Iowa  Minnesota  Northwestern  And growing 2 Goal: Develop Facility, Procedures, Tooling, Assemble ½ of Cassettes Director's Review -- Calorimetry -- HGC CassettesJim Freeman, 2015 Sept 17

3. 3 Construction Schedule Director's Review -- Calorimetry – HGC CassettesJim Freeman, 2015 Sept 17 FY25 FY24 FY23FY22FY21FY20 FY19FY18 FY17 CD4 CD1 CD2 CD3 CD0 Assembly at CERN Electronics Production Electronics Production Technical Design Report Scintillator Production Scintillator Production Senso rs Casset tes Sensors Modules Production Readiness Review Pre-series Front Calo Production BackingCalorimeter LS 2 LS 3 Physics LHC Schedule CDR PDR CD3A FDR Modules Cassettes Assembly at CERN Test & Install Test & Install

4. Cassette production site ready for pilot cassette assembly: Q2 2018 Cassette production site and procedures set up: Q1 2019 Cassette production site and procedures qualified: Q1 2020 10% preproduction: Q1 – Q3 2021 Full production: Q4 2021 – Q2 2023 Schedule Comments

5. 5 Cassette Base Plate 6mm Copper. Thermal tests Director's Review -- Calorimetry – HGC CassettesJim Freeman, 2015 Sept 17

6. 6 Modules, Special Modules to tile edges of the cassette Director's Review -- Calorimetry -- HGC CassettesJim Freeman, 2015 Sept 17 Special Shape Cassette for edges

7. 7 Loading the modules onto the cassette Director's Review -- Calorimetry – HGC CassettesJim Freeman, 2015 Sept 17

8. 8 Services: HV, LV, data out, cooling Director's Review -- Calorimetry -- HGC CassettesJim Freeman, 2015 Sept 17

9. Summary 9 Director's Review -- Calorimetry -- HGC CassettesJim Freeman, 2015 Sept 17

10. Cassette Physical Parameters Dimensions: EE: 1.5 m length x 1 m x 0.5m width FH: 2.0 m length x 1.5 m x 0.5 m width Weight: EE: 6mm Cu (9g/cm3); 5 mm W (19.25 g/cm3) 60.75 kg (Cu) + 108 kg (W) FH: 3mm Cu; 6 mm Brass (70:30 alloy) (8.53g/cm3) 54.0 kg (Cu) + 102.4 kg (Brass) Environmental:humidity control, clean

11. Floor Plan / Test Stations Receiving Assembly Testing Storage Single Cassette Test Warm Single Cassette Test Warm Repair Module testing Module storage Module assembly buffer storage Multi Cassette Test Cold Multi Cassette Test Cold Floor crane Area1 Area2 Area3

12. Cassettes can be assembled horizontally or vertically double sided cassettes need to be rotated to assembly the other side… Cassettes can be assembled in up to three Areas … Area 1 – Module handling and testing (+ rework if necessary?) Area 2 – Cassette assembly for two stations, warm test stand in the same room, Multi-cassette cold test station (share the crane) and cooling plant Largest hall needed Can be split in two halls with cranes and cooling plant! Area 3 – Cassette packing, storing and shipping Cassette Assembly Comments

13. Plan to rework the connections: electrical: micro-bonds, silver epoxy, LV, HV power, bias return, etc. Mechanical: simple gluing No plans for taking modules apart! Module Rework / Assembly

14. Floor Plan / Test Stations Area – 1: Module reception and temporary storage – Area: 30m 2 Module testing station – area: 20 m 2 Multiple module test station with water cooling Test equipment racks – 3m x 3m Tested Modules Staging area – 10m 2 Specialized equipment Parts flow Total surface: ~60-70 m2 Area – 2: Work assembly station dimension – 72m 2 horizontal – 2m x 2m vertical – 2m x 2m Work testing station – area: 72 m 2 horizontal – 2m x 2m vertical – 2m x 2m Clearance around work stations – 2m each side Handling equipment (floor crane) Specialized equipment Parts flow Total surface: ~150m 2 Area – 3: Cassette packing and shipping: Area: 30m2 Temporary storage – area: 20 m 2 Total surface: ~50 m2

15. Specialized Equipment Cassette Assembly : crane, electrical connectivity tools Cassette Test Stand : simplified readout in a mobile readout rack; 2 test stands for two assembly lines Multi-cassette testing :Dedicated insulated enclosure with mounting points and dry gas ; Cooling plant Cassette Repairs : access to crane ; simple electrical connectivity checkout ; optical inspection of modules Repair modules : electrical equipment, optical inspection

16. QC Plan Each part has unique number for tracking (barcode) “Unique Part Serialization” Can follow full history of each part, handling, repair, location,… (traveler as has been used successfully on numerous FNAL projects.) As sensor  module  cassette, value added. Must develop plan such that yield is very high. Prototyping stage of project will help develop the QC plan.

17.  Ordered 200 Sensors  Building small ECAL Testbeam Prototype  The prototype will have fully functional two-sided cassettes. (14 cassettes of 2 sensor)  Learn issues of building cassettes  Next step, building cassettes with multiple sensors  Learn about testing, placement, grounding, …  Start to develop procedures, tooling, QC plan 17 Current Activities Director's Review -- Calorimetry -- HGC CassettesJim Freeman, 2015 Sept 17

18. 18 Current Activities: Testbeam Prototype Director's Review -- Calorimetry – HGC CassettesJim Freeman, 2015 Sept 17

19. 19 Current Activities: Testbeam Prototype Director's Review -- Calorimetry – HGC CassettesJim Freeman, 2015 Sept 17 Two-sides cassette Cassette base plate

20. Team is in place to lead the Cassette Assembly Facility Planning has started on identifying lab space and specialized equipment that will be needed Prototyping is beginning Will guide us on optimizing assembly and QC plans 20 Summary Director's Review -- Calorimetry – HGC CassettesJim Freeman, 2015 Sept 17