Duke Production Status

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• Duke Production Status

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Module Production

• Mechanical Construction
• All Type II (M2.01 to M2.37) are completed and
  gas tight.
• All Type III (even number Type III (minus
  M3.32,M3.34)) are completed and gas tight.
• Stringing
• Type II
• M2.33 and M2.34 are remaining to string.
• Super spares (M2.35, M2.36, M2.37) will be strung
  by the end of September.
• Type III
• 5 Modules were sent to Hampton for stringing
• M3.16, and M3.30 are remaining to string.
• Either Duke or Hampton will string
• Super spares (M3.36) will be strung by the end of
  September.

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Modules to be strung
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Stringing stations
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• Duke Acceptance testing
• Type II
• M2.02, M2.03, M2.04. M2.16 are completed
  including final gas leak test and signal test.
• Type III (even)
• M3.02, M3.04, M3.06 M3.14 are completed
  including final gas leak test and signal test.
• 8 Type II, and 6 Type III are at Hampton for gain
  mapping

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Wire-joint production

• Original estimation was 65,000, but we are
  approaching 100,000.
• Original estimation was 280/day, but we have
  been producing 400/day or 2000/week.
• We have slowed down to 1200-1500/week, which is
  still enough to meet the reduced stringing rate
  at the three sites.
• After 34 modules of all three types were strung,
  the rate will be reduced to 1000/week. Need
  6000 for super spares (35/36/37).
• After 37 modules, plan is to produce 1000 for
  re-work at CERN and 2000 for reserve.
• The wire-joint production should be over by the
  end of August.

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Fuses Boxes

• The design is completed and they are being
  machined. We should have them back by the end of
  June.
• Production is 40 sets of each type module (240
  fuse boxes).
• We also need dummy fuse boxes for the other
  module side. These are being machined as well.
• Plan to start the assembly in July.
• Need fuse delivery schedule. We only have 100
  pre-production fuses.
• No good estimation for the production time yet.
• Should we test fuses through random sampling?
• Not in critical path

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Fuse Boxes
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HV capacitors

• Decision was made to go with NPO/850pf /2000
  volts.
• Passed initial testing.
• Arcing test at 2000 volts 50 capacitors
• Neutron radiation test 20 capacitors
• Co60 radiation test 20 capacitors
• HV soaking for two months at 2750 volts 50
  capacitors
• A fixture to assemble 20,000 cap is being tested
• 500 will be made for the beam test
• Final testing with the assembled capacitors
• Full production should start in August and would
  take two month.
• Long term HV soaking test (10 days at 2750 volts)
  would take six months.
• Not in critical path

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Capacitor assembly fixture
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Beam test structure
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People

• May /2003 6.5 techs stringing, wire-joints
• June /2003 5.5 techs stringing, wire-joints
• July /2003 3.5 techs stringing, wire-joints,
  fuse boxes
• Aug /2003 3.5 techs stringing, wire-joints,
  fuse boxes, capacitor assembly
• Sep /2003 3.5 techs stringing, fuse boxes,
  capacitor assembly
• Oct /2003 2 techs fuse boxes, capacitor
  assembly