sPHENIX PD-2/3 ReviewsPHENIX PD-2/3 Review May 28-30, 2019 sPHENIX PD2/3 Review 2 EMCal Block Fabrication (WBS 1.03.01) • Tungsten-powder absorber blocks with scintillating fibers

EMCal block construction at Illinois

Caroline Riedl University of Illinois at Urbana-Champaign

May 28-30, 2019

sPHENIX PD-2/3 Review

May 28-30, 2019 sPHENIX PD2/3 Review 2

EMCal Block Fabrication (WBS 1.03.01)

• Tungsten-powder absorber blocks with scintillating fibers.

• UIUC will build full Sectors 1-12 with each 96 blocks & Sectors 13-64 with each 72 blocks.

• Density and block uniformity such that energy resolution σE/E < 16%/√E ⊕5%.

• Mechanical precision of blocks: need to fit into sawtooth assembly structure with minimal (< 0.5mm) gaps between blocks.

Each block has 4 towers = physics

read-out unit

1 Sector

May 28-30, 2019 sPHENIX PD2/3 Review

• Fabrication of 1,152 pre-production blocks (Sector 1-12), 3,774 production blocks (Sector 13-64)

• UIUC Illinois:- Procurement of tungsten, meshes, molds, epoxy, supplies - Block production & machining - Block testing and QA - Shipping to BNL

• Brookhaven: procurement of scintillating fibers

3

L3 Scope

tungsten power

fiber delivery crate and sleeves

meshes with 2,668 holes

5cm × 5cm

hole ∅ = 0.65mm fiber ∅ = 0.47mm

fiber set with meshes

block right after unmolding


L3 Technical Overview (i)

factory mode?(0 to 4 stars)

0. Fiber assembly ☆☆☆☆

1. Insertion in mold ☆☆☆

2. Tungsten filling ☆☆☆

3. Epoxy filling ☆☆

4. Machining ☆☆

5. Testing ☆☆☆

6./7. Shipping to BNL ☆☆☆

• EMCal blocks = fiber / mesh assemblies in tungsten powder / epoxy compound.

• 22 different designs of blocks, molds, machining wedges.

• Block ends are diamond cut (polished) for optical transmission to readout.


L3 Technical Overview (ii)

5

64 ft (20m)

Prototype “Sector 0” construction showed what needs to be improved for “full-factory” mode.

Pre-production “Sector 1-12” construction started in April.

This period is used to address the improvements for full-factory mode and to optimize the production speed and workflow.

Some additional machining fixtures have to be produced and new molds as needed.

Receiving & QA0. Fiber assembly1. Insertion in mold

2. Tungsten filling 3. Epoxy filling

4. Machining5. Testing

6./7. Shipping

Nuclear Physics Lab high-bay area

Each block is machined on all surfaces: - sides & bottom sanded, then checked for flatness and taper - top & ends band sawed - top: shell mill to dimensions - big reflector end & small light guide end: 1. Shell mill to precision 50 mills. 2. Fine machine with diamond cutter.

machine shop

fume hood

tent

test bench

diamond cutting

Industrial shelving for

material

potting

temperature & humidity controlledfibers are exposed to light as little as necessary at all times


L3 Collaborators

• L3 and scientific supervision: Caroline Riedl (Research Assistant Professor)

• Overall project supervision: Anne Sickles (Assistant Professor)

• Technical supervision and development: Eric Thorsland (Research Engineer)

• Technical labor: Adam Wehe, Lucas Reeves (extra technical help)

• Testing and supply coordination: Tim Rinn (postdoc)

• Block testing and QA: Xiaoning Wang, Anabel Romero Hernandez (grad students), undergrad students (currently 2)

• Fiber assemblies: undergrad students (~ 20)

manpower

0. Fiber assembly undergrad

1. Insertion in mold tech / undergrad

2. Tungsten filling tech / undergrad

3. Epoxy filling tech

4. Machining tech

5. Testing grad / undergrad

6./7. Shipping to BNL tech

UIUC Nuclear Physics Lab (NPL)

NPL has built 16 (v2.1) prototype EMCal blocks for FNAL test beam and

in the past 6 months 125 (Sector 0) prototype blocks for assembly at BNL.


Schedule Drivers

• Large procurements: - Block production for Sectors 4++ driven by tungsten delivery schedule - Fiber assembly schedule for Sectors 13-64 driven by fiber delivery schedule

• Block production capabilities at UIUC: - Availability of technical workers for block potting and machining. - Fiber assemblies need substantial student labor.

Tungsten company order date delivery date used

Sector 1-3 Starck October 9, 2018

October 22, 2018 0%

Sector 4-12 Starck ? tba n/a n/a

Sector 13-64 Starck ? tba n/a n/a

Fibers company order date delivery dates used

pre-production (Sector 1-12) St. Gobain April 13, 2018 Jul 11 - Nov

21, 2018 30%

production (Sector 13-64) St. Gobain January 2019 April 2019 -

Feb 2021 n/a


Cost Drivers

• Materials:

• Tungsten powder ~ $1.2M ($61/kg - 20 metric tons)

• Scintillating fibers $1.2M ($0.4-0.5 / m - 2,600km)

• Labor:

• Students for fiber filling ~ $217k

• Technical labor for block production & machining ~ $580k

Fibers company total [$] total [km] $ / m

pre-production (Sector 1-12) St. Gobain 320,000 800 0.48

production (Sector 13-64) St. Gobain 840,000 1,800 0.47

Tungsten company total [$] total [kg] $ / kg kg / sector

pre-production (Sector 1-3) Starck 73,140 1,200 60.95 400

pre-production (Sector 4-12) Starck ? 219,420 3,600 60.95 400

production (Sector 13-64) Starck ? 950,820 15,600 60.95 300

(descoped)

May 28-30, 2019 sPHENIX PD2/3 Review count

bloc

k de

sign

123456789

101112131415161718192021222324

0 4 8 12 16 20 24 28 32 36 40 44 48 52

at BNL (7)

ready to be shipped (6)

ready for testing (5)

machining started (4)

potted (3)

W filled (2)

in mold (1)

fibers filled (0)

EMCal Sectors 1-12 block construction: status

count

bloc

k de

sign

123456789

101112131415161718192021222324

0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19

at BNL (7)




potted (3)

W filled (2)

in mold (1)

fibers filled (0)

EMCal Sector 0 block construction: status

9

Status and Highlights

• Sector 0 block production and shipping to BNL completed, Sector 1-12 block production ramping up. Fiber filling for Sector 1-12 >60%, production & testing started.

• Block testing procedures refined and new manpower trained.

count

bloc

k de

sign

123456789

101112131415161718192021222324

0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19

at BNL (7)




potted (3)

W filled (2)

in mold (1)

fibers filled (0)

EMCal Sector 0 block construction: status

shipment

number of

blocksleft

UIUC

1 12 Oct 4, 2018

2 24 Nov 16, 2018

3 24 Mar 5, 2019

4 24 Mar 18, 2019

5 24 April 10, 2019

6 17 May 3, 2019

fibers filled ready to be shipped


Saad AltafZander Leja

Shash SardesaiEmily Pasetes

Mason HousengaAmanda Skittone

Mina MazeikisSiddhant Rao

Will WaltonBen Dibuz

Janais PeaceAri Krause

Mostafa ShehataJustine Rich

Vrishin SutariaParker Hays

Nabeeha AhmedEyal FrilingYuxuan Hu

Ritvik DesaiSara Shahid

Yatharth DhootVedant Agrawal

Chirag JainHarsha Marupudi

Shanay Gandhi

0 25 50 75 100

2019 2018 2017

Highlight: UIUC undergrad student workers

10

Block testing: Anmol RainaJoseph FoySA, YH

Some of the experienced students cut fibers and also help with placement in mold, tungsten filling, and block testing.

Assembled fiber sets

Sector 1-12 fiber assembly >60% complete

Saad AltafZander Leja

Shash SardesaiEmily Pasetes

Mason HousengaAmanda Skittone

Mina MazeikisSiddhant Rao

Will WaltonBen Dibuz

Janais PeaceAri Krause

Mostafa ShehataJustine Rich

Vrishin SutariaParker Hays

Nabeeha AhmedEyal FrilingYuxuan Hu

Ritvik DesaiSara Shahid

Yatharth DhootVedant Agrawal

Chirag JainHarsha Marupudi

Shanay Gandhi

0 25 50 75 100

2019 2018 2017

Aug 2019Oct 2018


Highlights: Sector 0 mechanical precision5 measurements: - Dimensional with digital height meter: 2 height (SH, BH) 1 length (L) - 2 wedge extrusions measurements: Probe dimensions BB, BT, SB, ST, and block taper. Directly probe the dimensions that the sawtooth design is sensitive to.

11

Tolerance =10 mills for each dimension.

h h

L(meas) - L(exp) [in]

0

5

10

15

20

-0.05-0.04

-0.03-0.02

-0.010.00

0.010.02

0.030.04

0.05

Deviation of block length from design

H(meas) - H(exp) [in]

0

20

40

60

-0.05-0.04

-0.03-0.02

-0.010.00

0.010.02

0.030.04

0.05

Deviation of block height from design

W(meas) - W(exp) [in]

0

20

40

60

80

-0.05

-0.04

-0.03

-0.02

-0.01

0.00

0.01

0.02

0.03

0.04

0.05

Deviation of block width from design


scintillation [mV]

0

2

4

6

8

10

12

182.

89

220.

98

235.

98

250.

98

265.

98

280.

98

295.

98

310.

98

325.

98

340.

98

355.

98

370.

98

385.

98

400.

98

415.

98

430.

98

433.

92

439.

37

Scintillation response, Sector 0

Highlights: Sector 0 testing & QA• Block density = mass / volume as determined from dimensional and

wedge measurements. Average = 9.25 g/cm3, accept 9 g/cm3.

• Optically transmitting fibers: average is 98.15%, accept 98%.In addition each block must have 96% of fibers counted in each tower (quarter) + no entire missing row + no region with more than 13 connected fibers lost.

12

/ ndf 2χ 665.8 / 121Constant 4.1± 321.1 Mean 0.2± 235.9 Sigma 0.16± 21.14

Pulse Height (mV)50 100 150 200 250 300

Cou

nts

0

50

100

150

200

250

300

350

DBN 42 / ndf 2χ 665.8 / 121

Constant 4.1± 321.1 Mean 0.2± 235.9 Sigma 0.16± 21.14

DBN 42

Block # 42

• Scintillation response: comparison with good calibration block, here: accept 200 mV.

# Fibers / # Holes

0

5

10

15

20

88.6

492

.39

92.7

293

.05

93.3

893

.71

94.0

494

.37

94.7

095

.03

95.3

695

.69

96.0

296

.35

96.6

897

.01

97.3

497

.67

98.0

098

.33

98.6

698

.99

99.3

299

.65

99.9

610

0.00

Optically transmitting fibers [%], Sector 0density [g/cm3]

0

5

10

15

20

25

8.50

8.65

8.80

8.95

9.10

9.25

9.40

9.55

9.70

9.85

10.00

Block density Sector 0

Fiber count [%]

0

2

4

6

8

10

12

90.0

091

.00

92.0

093

.00

94.0

095

.00

96.0

097

.00

98.0

099

.00

100.

0010

1.00

102.

0010

3.00

104.

0010

5.00

Tower 1 [%] (count) Tower 2 [%] (count)Tower 3 [%] (count) Tower 4 [%] (count)

Fibers by tower, Sector 1


Issues and Concerns

• Careful monitoring of block densities is critical.

• Mechanical precision is essential: we changed criteria from “7 dimensions” tolerances to wedge structure that is also used for the machining.

• Currently only tungsten powder for Sector 1-3 at UIUC. After evaluation of Sector 1 blocks, order W for Sector 4-12 & half of production sectors.

• UIUC technician manpower will have to be increased for the full-scale factory.


QA and Documentation

• We are constantly improving our Q&A procedures to produce blocks that meet specifications. We will recommend updating our Q&A document to reflect these improvements.

• Google data base (DB) with up to ~ 70 entries per block, backed up every 24h.

• Child tabs in DB with procurement information, automatic tracking of progress, and automatic feed for some of the testing procedures

• Detailed descriptions of lab procedures printed and online available and shared with all workers.

• UIUC wiki to collect documents related to procurement, testing, design, project management.

• White board with magnets for quick assessment of status of each block and easy communication between lab workers.

14

cloud-based online

documentation stored in

university-funded account

block quality assurance

Illinois wiki

white board to coordinate

lab work


EMCal block database

15

ID/general fiber filling

W filling epoxy

machining

dimensionsfiber counting

scintillation test

photo

exam

ple

of 2

00 b

lock

s


Environment, Safety & Health

• The Nuclear Physics Lab (NPL) is operated in accordance to the University Division of Research Safety (DRS). We are audited annually by DRS safety experts and are kept up to date with compliance.

• Every lab worker is trained with standard online safety courses prior to work start. The training records are kept by the NPL business office and checked by the DRS.

• In addition there is a local lab safety training to make everyone aware of specific hazards of NPL.

• Working hours are Mo - Fr 8am - 5pm. Exceptions can be granted. Then a 2-person rule applies if working with hazards (sharp tools or high voltage) and/or during the weekend.

• A separate lunch room is provided and workers are obliged to wash their hands before eating and before returning to work. Eating in the lab is not allowed and drinking only from closed containers.

16


Milestones EMCal blocks• June 2019: procurement of W powder for final production

• January 2020: acquisition of W powder complete

• February 2021: acquisition of scintillating fibers complete

• July 27, 2021: EMCal block production complete

• August 3, 2021: EMCal blocks arrive at BNL.

17

time (quarterly binning)

bloc

ks

0

600

1200

1800

2400

3000

3600

4200

1/1/20

19

4/1/20

19

7/1/20

19

10/1/

2019

1/1/20

20

4/1/20

20

7/1/20

20

10/1/

2020

1/1/20

21

4/1/20

21

7/1/20

21

planned fiber filling S1-12

actual fiber filling S1-12

planned fiber filling S13-64

fiber delivered

planned shipments blocks S1-12

planned shipments blocks S13-64

Sector 1-12 complete

Sector 13-64 complete

sPHENIX EMCal block construction at UIUC


Summary: EMCal block production

• Deliverables: tungsten-powder absorber blocks with scintillating fibers. - 1,152 pre-production blocks (Sector 1-12) - 3,774 production blocks (Sector 13-64)

• Achieved: advanced prototyping (Sector 0, 125 blocks) completed at UIUC and blocks shipped to BNL.

• Next: block factory at UIUC-NPL is ramping up. During early pre-production (Sector 1-12), optimize production speed and workflow over the next few months.

• The EMCal block production is ready for PD-2/3 approval.

18

Documents

sPHENIX PD-2/3 ReviewsPHENIX PD-2/3 Review May 28-30, 2019 sPHENIX PD2/3 Review 2 EMCal Block Fabrication (WBS 1.03.01) • Tungsten-powder absorber blocks with scintillating fibers