Ron Madaras, LBLU.S. Pixel Meeting, SCIPP, July 9-10, 2003

Patch Panel 1 (PP1)

Brief Review

Cost and Effort Estimate

Ron Madaras, LBL2 U.S. Pixel Meeting, SCIPP, July 9-10, 2003

Patch Panel 1

Services andBeam Pipe Support Structure

SCT Barrel

TRT Forward

Side C Side A

Services andBeam Pipe Support Structure

Pixel Detector

TRT Forward

Ron Madaras, LBL3 U.S. Pixel Meeting, SCIPP, July 9-10, 2003

PP1 Region Functions• Cooling

connections

• Electrical connections

• Optical fiber connections

• N2 connections

• Complete gas seal

• Complete electrical shield

PP1 Region

PP1b

PP1a

<- Towards IP

Ron Madaras, LBL4 U.S. Pixel Meeting, SCIPP, July 9-10, 2003

PP1 Requirements• Provide cooling, electrical and fiber connections as specified in

ATL-IP-ES-0007(“Pixel Services”) and described in ATL-IP-ES-0072.

• Gas seal for 4 mbar maximum pressure differential consistent with 6 l/mbar-hour leak from the pixel volume.

• Penetrations for cooling pipes to allow up to 3mm contraction from room temperature to cold temperature.

• Access to beam pipe adjustment & allowance for beam pipe survey.• Cutouts for PST rails to allow pixel package insertion.• Outer diameter consistent with insertion of pixel package with PP1

attached to service panels• Electrical connection to PST and beam pipe EMI shields.• Temporary support of beam pipe during installation of the pixel

package.

Ron Madaras, LBL5 U.S. Pixel Meeting, SCIPP, July 9-10, 2003

PP1 Endplate• Picture of prototype endplate. Machined aluminum, 6mm thick.

Seal plates

For cooling and gas connections

Slots for fibers

Slots for electrical feedthroughsFor beampipe supportand adjustment

Ron Madaras, LBL6 U.S. Pixel Meeting, SCIPP, July 9-10, 2003

Coolant Fittings• Lack of space, the need to allow contraction of the pipes and

minimize forces on the endplate and the need for an electrical break requires us to use a custom fitting.

PEEK seal to pipe

Bellows for contractionof pipes upon cooldown

Threaded insert into endplate

Tube flared in place

PEEK insertelectrical break

PEEK nut

Ron Madaras, LBL7 U.S. Pixel Meeting, SCIPP, July 9-10, 2003

More Coolant Connections• Commercial fittings at PP1b

desired but not yet selected

• Filter between PP1b and PP1a, also not selected.

• Custom wrenches for PP1a are needed (under design). Space is very limited.

• Same for PP1b? Not clear yet

Ron Madaras, LBL8 U.S. Pixel Meeting, SCIPP, July 9-10, 2003

Electrical Feedthroughs• Fabricated for simple functional tests and for mockup.

– Connections to PP0(largely already made on prototype)

– Thermal tests

– HV isolation

– Add PP1b connectors, read out real modules

Ron Madaras, LBL9 U.S. Pixel Meeting, SCIPP, July 9-10, 2003

Optical Fibers• Ericsson study of MT16 connectors with bare ribbons on the

PP0 side and corresponding cables on the PP1a side.

• Mechanical(glued) interface to PP1 endplate slot.

Ron Madaras, LBL10 U.S. Pixel Meeting, SCIPP, July 9-10, 2003

PP1 Prototype• Plan is to make enough coolant fittings for one quadrant.• Custom bellows ordered• Other parts either ready to order or sent to shops.• Would then assemble into quadrant of prototype endplate to get

experience.• Current plan is to use paper(rad-hard and cheap) gaskets for

seal. Will test this idea in small setup also after irradiation, in addition to full scale.

• Would mount endplate as shown with coolant connections(and blanked off electrical and fiber connections) to measure leak rate attached to 30cm PST prototype with flanges. Repeat after adding electrical connections.

• Fiber plan not yet clear – scope of Ericsson prototypes not likely to fill all of slot.

Ron Madaras, LBL11 U.S. Pixel Meeting, SCIPP, July 9-10, 2003

Mockup at CERN• Assembly

started

Ron Madaras, LBL12 U.S. Pixel Meeting, SCIPP, July 9-10, 2003

Cost and Effort EstimateIncluded in estimate:

• Bulkhead• Bulkhead seal ring and gasket• Bulkhead center support, bellows, connection to beam pipe• Coolant pipe feedthrus (supply and return)• Striplines• Corrugated support for PP1b electrical cable connectors• Full prototype of one PP1 quadrant• Contingency

Not included in estimate (as they are in other cost estimates):• Fiber optic cables• PP1a fiber optic cable feedthrus• PP1a beam pipe adjusters• PP1a to PP1b coolant pipes• PP1b coolant pipe connectors• PP1a to PP1b electrical cables• PP1b electrical cable connectors• PP1b filter/pressure drop devices

Ron Madaras, LBL13 U.S. Pixel Meeting, SCIPP, July 9-10, 2003

Cost and Effort EstimatePurchase Cost ($) Labor (hours) Labor cost ($)

Bulkhead Quadrant 480 40320Bulkhead Seal Ring and Gasket 30 2520Bulkhead Center Support 30 2520Center Bellows 20 1680Bellows to Beam Pipe 60 5040

Coolant Pipe Feedthrus (supply & return)PEEK 7600Nickel Bellows 17500Sliding Seal 403 33852Bellows to Bulkhead 310 26040Assemble bellows and pieces 256 14848Inner Flair Connector 217 18228Flair Bushing 93 7812Flair Outer 310 26040

StriplinesStripline fabrication 10000Solder PP1a/PP1b cables to striplines 24000Solder PP0/PP1a cables to striplines 24000Bulkhead feedthroughs 20 1680Assembly of power tapes into bulkhead 64 3712

Support for PP1b electrical cable connectors 144 12096

Full prototype of 1 PP1 quadrant 10000 305 25000

Sub-Totals 93100 2742 221388Contingency (50%) 46550 1371 110694Totals 139650 4113 332082

Total Cost: $471,732Total Effort: 27.4 FTE-months

Ron Madaras, LBL14 U.S. Pixel Meeting, SCIPP, July 9-10, 2003

Conclusion

• Preliminary design of PP1 and related items well advanced. More work is needed to complete design.

• Prototypes of critical components either fabricated or under fabrication.

• 1-to-1 mockup assembly started at CERN

• Next major steps are to complete quarter-scale prototype and to finish mockup studies.

• Preliminary cost and effort estimate:– Total cost: $472K

– Total effort: 27 FTE-months