QA, QC, Test plan F. Pietropaolo CERN / INFN Padova Quality - - PowerPoint PPT Presentation

QA, QC, Test plan

• F. Pietropaolo

CERN / INFN Padova

Quality Assurance / Quality control

• The Quality Assurance (QA) plan is as set of acAviAes for ensuring quality

in the process by which products are fabricated and assembled. The quality is determined by how well the final product meets the defined

• requirements. The QA plan aims to prevent defects proacAvely by

prototyping, tesAng, and documenAng the process. The QA plan is designed to miAgate the Risks and Hazards.

• Quality Control (QC) is a set of acAviAes for ensuring quality in product.

The acAviAes focus on idenAfying defects in the actual products produced.

• The first step for insuring that the detector meets requirements is the

creaAon of an integrated model of the enAre TPC to evaluate interfaces and installaAon methods. This integrated model will facilitate the development of installaAon plans and insure that all components fit together as expected. Link to …!!!.

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Planned QA Program

• Incorporate lessons learned into design
• Perform comprehensive stress analysis from component level to full detector

structure

• 2D and 3D electrostaAc studies of the electric field in the high field regions of

the TPC

• Transient analysis of CPA, FC electrical behavior in a HV discharge
• Material test

– ResisAve material electrical tests

– Electrode material test

• FC end cap tests
• Fiberglass material mechanical/thermal tests
• Small scale full E field FC test in 50l
• Full voltage HV test in 35ton cryostat
• Divider component and assembly thermal and electrical tests
• Ash River full scale mockup assembly

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QA: ResisAve panels R&D

InvesAgated materials:

• NORPLEX, Micarta, NP 315, phenolic laminate (“bakelite”) with graphite,

– Intrinsic bulk resisAvity in the required range (few MOhm/cm) – Density comparable to LAr

• FR4 glass/epoxy coated with resisAve layers:

– resisAve ink (~100kOhm/square) printed with specific pa`erns; – laminated resisAve kapton foil Dupont 100XC10E7 (25 µm thickness, graphite loaded, available with resisAvity in the 0.5 to 50 MOhm/square range available in 1.2 m wide rolls)

• Preferred choice: due to lower radioacAvity, more uniform resisAvity,

be`er aging to sparks, high stability in LAr (~50% increase in resiAvity, no planarity deformaAon)

• Also considered:

– Graphite loaded (outer layers) FR4 – Thin films of Germanium Coated Polyimide (vacuum deposited)

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LaminaAon of resisAve Kapton foils on FR4

• Standard PCB technique applied at CERN to develop

resisAve thick-GEM’s (max 0.6x0.7 mq)

– Stack of FR4 panel + 75 um prepreg + 25 um Kapton foil placed in between metallic sheets and unmoulding foils – Press cycle at 20 Kg/cm2 for about 1 hour at 160-200°C – Press available (Italy, Japan) for dimensions amply larger that 1.2 m x 2.4 m – LaminaAon on both sides of FR4 also possible

• Several samples produced at CERN with size up to 0.6

x 0.7 mq ( 3mm FR4 thickness)

• Measurement of resisAvity uniformity (2-3 MOhm/

square in present sample)

• Long term immersions in LAr (weeks) with several

thermal cycle from room to LAr temperatures to check stability against delaminaAon performed posiAvely.

• No planarity deformaAon in LAr observed

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Prototypes for Lar-TPC’s

• Two 35x35 cm2 panels fabricated and

machines as cathode plane for the 50-liter LAr-TPC available at CERN.

– already operated several Ames in various test runs, with behavior completely equivalent to that of the metallic planes in term of mechanical stability, electric field uniformity and LAr purity.

• MDT produced a full size 1.2 m x 2.1 m

prototype panel (double sided) following the CERN fabricaAon procedure.

– machined by them into smaller elements to be installed in the 35 ton HV test at FNAL.

• The resisAve strip, required for be`er electric

field uniformity around the CPA frame will

– Being these elements much smaller with respect to the CPA panels and requiring in addiAon more precise machining and hole drilling, they could be fabricated at CERN. – A first set has been already produced for the 35 ton HV test at FNAL.

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QA: Mini-field cage tests

• To validate the field cage concept in pure LAr
• Designed to fit in the ICARUS 50 liter cryostat (60 cm diameter,

1.1 m height; ~300 liters total volume)

• Roll-formed metal profiles with UHMW PE caps

– Choice of metal (Al, SS) and surface finish

• Pultruded fiberglass I-beams form 4 mini panels
• All profiles are at same potenAal to simplify HV connecAon
• Perforated ground planes 66mm away: 1/3 of FD

bias voltage required: to reach design E field ~ 60 kV are needed

• Corona-discharge monitor on Power supply cable

(based ICARUS scheme)

• Video camera to visually detects light flashes for

from arching/discharges and monitor LAr thermal stability (LED illuminated)

• High HV stability in pure LAr up to 80 kV/cm and

up the 100 KV if thermally stable (no bubbles)

• No difference on material choice (AL, SS), surface

finish (roll formed vs extruded) surface quality (up to 100 um scratches)

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R&D on aluminum field cage

• Malter effect in Liquid Argon?
• Test effects of possible charge-up due to
• xidaAon on uncoated aluminum surface
• f FC:

– A new field cage of 50 liter LAr-TPC has been built. – 50 rings made of uncoated extruded 10x10 mm2 aluminum bars with rounded outer corners (4 mm radius) – Spaced by 10 mm – Coupled with resisAve cathode – Minimum distance of rings from detector vessel wall: 5cm – Max local e-field at ring surface ~ 26 kV/cm (for Vcath=-25 kV, 500 V/cm driu field) similar to ProtoDUNE SP case

• Under test by beginning of November to

verify HV stability, electronic noise on wires, possible producAon of UV light

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Long term operaAon (several weeks) maybe required to measure charging up effects due to cosmic rays

Extruded aluminum profiles for FC

• ProducAon:

– OpAmizaAon of sAffened aluminum extruded profiles; mechanical properAes verified (with FEA calculaAon) at CERN. – Same outer shape as roll formed profiles, compaAble with standard locking nuts and tooling for mounAng – ProducAon of prototypes started at selected producers (ALEXIA-Italy, MIFA-Netherland) with different aluminum alloy and with conducAve coaAng (at some cost increase). – Prototypes (1.5 m long) verified at CERN. – First 100 m available on 11/15th (sufficient for second phase of the 35 ton HV test): 50m with conducAve coaAng (SURTEC). – Full producAon (~3km) for ProtoDune SP available in few weeks Ame – Cost ~ 1 to 2 Euro/m

• Full compaAbility between SS roll formed

and extruded aluminum profiles; final choice can be made at very last moment

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QA: Mechanical mock-up in Ash River, MN

• Full scale ProtoDUNE-SP

components (FC, CPA, support structures)

• Tests of interfaces and

handling

• Test of assembly

procedures Presently underway

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Ash River InstallaAon components

• One APA frame (no wires)
• 4 CPA columns (without resisAve laminaAon)

– FR4 Frames completed with FR4 panels

• 4 Top/Bo`om FC Panels:

– 2 Panels with latest design (No splice joint and latest modificaAons) – 2 panels older version with stainless hardware just for mockup.

• 4 End-wall Panels:

– Top panel with hangers – Panel with beam plug mockup. – 2 Regular End wall panels.

• Most panels fully populated with field shaping profiles
• Few end caps missing.
• AddiAonal weight on the panels to make up for missing weight due to

missing ground planes (replaced by plywood) .

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Ash River present Achievements

• Hanging the first CPA
• Geyng elevaAons in TPC correct
• Moving the first CPA Pair
• Hanging the first Field Cage
• RotaAng the FC
• Packaging for shipping

Phase 1 of the ProtoDUNE Trial Assembly

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QA Plan: HV

• HV feed-through

– Follow/contribute to ConstrucAon and tests in collaboraAon with the DP ETH/CERN group.

• Perform HV test at 35-ton, including the following:

– Tested ability to hold voltage at full scale; – Tested expected current and stability of current at all monitoring points; – Tested mechanical integrity of all components auer full cool-down, warm-up cycle; – Tested discharge miAgaAon system using induced HV discharge.

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Proto-DUNE SP FC-CPA-HV Test at FNAL PC4

• Overview & InvesAgaAons
• EvaluaAon of the design of ProtoDUNE

from a high voltage perspecAve

• Design verificaAon
• Expose any design weaknesses.
• What voltage can be held
• MoAvaAons
• High voltage issues in liquid argon are not

completely understood

• A breakdown will likely set the operaAng

voltage of the experiment

• Breakdown can damage the detector
• Test will be performed in ultra-pure LAr in the membrane cryostat of the 35 t facility

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The field cage for the HV test

• The full-sized ProtoDUNE TPC components do

not fit in the cryostat

• However, the test will be a full-field test.
• The device will have the first 10 profiles of the

FC and a resisAve cathode at their planned voltages.

• Individual components:

– High field areas à corners near cathode – New aspects of the design: FC profiles and FRP beams, resisAve plate cathode, ground planes, – However: dedicated HV feed through (UCLA)

• And the integraAon of the pieces

– Do the pieces of the design work together?

From

• B. Yu

Cathode Resistor to ground Rela:ve Anode Poten:al (kV)

1.5m 1.5m

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Schedule

• Completed:

– Design, fabricaAon, delivery of components to William & Mary

• Now on-going:

– Clean and preassemble parts – Parts delivery to Fermilab

• Next steps (expected to be completed by end

2016)

– Test installed in cryostat – Purge, cool down, fill the cryostat

• Perform test (2017)

Assembled CPA

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Stage 2 plans (early 2017)

• Auer compleAon of stage 1 test, replace one field cage end-wall with one that

has beam plug a`ached

• Possibly replace the SS profiles of part of the field cage walls with Aluminum
• nes (with and without conducAve coaAng)

GOALS:

• Verify beam plug does not

interfere with the operaAons

• f the TPC (i.e. same HV

performance with and without the beam plug)

• Compare HV performance of

extruded Aluminum vs SS

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Cleaning procedures

• In view of the use in ultra pure LAr environment, it is criAcal to

clean all components and bag them during shipment.

• Individual pieces will be cleaned by alcohol or simple green plus a

de-ionized water rinse during construcAon so that final assembly is relaAvely clean.

• This applied to the interior surfaces of all components as well.

Components should be double bagged while sAll in clean areas prior to being exposed to dirty environments.

• Prior to taking components into the clean environment at CERN the
• uter bag will be removed. Once the component is in the clean

environment, the inner bag will be removed.

• Wires and cables will need to be wiped down with alcohol prior to

being installed in the cryostat. Auer cleaning the wiring should be dried out to remove the majority of iniAal moisture.

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QC Plans: CPA producAon

• Inspect fabricated part of the CPA frame to make sure they meet the

dimensions and tolerances on the fabricaAon drawings;

• Inspect and measure each CPA module and the completed CPA plane

to insure they meet the dimensions and tolerances on the drawings;

• ResisAve panels received from producer: measure the dimensions to

confirm they meet the drawings and setup a plan and acceptance criteria to insure that panel resisAvity is acceptable;

• Test HV at CERN for evaluaAng side to side and top to bo`om

resisAvity for each completed CPA, auer final assembly and auer hanging during installaAon.

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QC Plans: HV bus, frame-biasing

• InspecAon of fabricated part of the HV system to make sure they

meet the dimensions and tolerances on the fabricaAon drawings:

– HV bus cables – Inter-CPA "pigtails" with lug connectors – ConnecAon points on CPAs, with capAve screws – Resistor-to-frame and frame-to-FC connectors

• InspecAon of each completed HV bus cable segment for curvature
• r damage.
• Check HV cable post-annealing cooling test.
• Measure HV bus end-to-end and bus-to-CPA conAnuity and

resistance auer HV bus installaAon, compare to design values.

• Measure HV bus to frame conAnuity and resistance auer frame

electrode installaAon, compare to design values.

• HV test at CERN for evaluaAng side to side and top to bo`om

resistance for each completed CPA, including HV bus, cup, and frames, but auer final assembly and auer hanging during installaAon.

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QC Plans: FC producAon

• Inspect fabricated part of each FC (profiles, endcaps, FRP beams,

ground planes) to make sure they meet the dimensions and tolerances on the fabricaAon drawings;

• Inspect and measure each FC module and completed FC plane to

insure they meet the dimensions and tolerances on the drawings;

• Perform tests of each joint in the FC frame to insure that their

design and strength meets the load requirements.

• Inspect and measure resistor divider components and electrical

conAnuity

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QC Plans: FC resistor divider

• Develop large scale component

(resistors, varistors) tesAng setup

• Perform thermal cycles of all

components to accelerate mortality due to fabricaAon defects

• Perform thermal cycle of the assembled

divider board

• Insert screws, washers and nuts into

divider board to serve as a`achment points

• when mounted to profiles, a`ach

alligator clamp directly to profile

– Measure voltage drop for each individual stage – Convert to current – calculate equivalent resistance RA

• At CERN, conAnuity checks across

profiles

HV power supply: used at 1000 V 100kΩ pick-off resistor

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Large Scale Component QC Test Stand

à Can stack up to 5 PCBs high à Can have 2 stacks on mechanical mount à 16 MOVs per board à Can test up to 160 MOVs per cool down cycle ParAally populated test stand Use very similar setup to test resistors (based on same PCB) àcan test up to 80 resistors per cool down cycle Components are individually bagged and serialized

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Shipment to CERN

• Weights – Shipping boxes will weigh between 120kgs - 220kgs. Weight for FC

Top and bo`om panels auer they are assembled with ground plane is 200kg if SS profiles are used and 150kgs if Al profiles are used.

• FC Panel – FC Panels will be assembled in a clean environment and will be

bagged before puyng inside the shipping box.

• Handling InstrucAons – A document with handling instrucAons and hazard

analysis will be provided to CERN beforehand. FC should be handled in accordance with that document at all Ames.

• Traveler document – It will include data from tesAng that was done auer the

assembly and was approved. It will be included in each shipping box with individual panels. These documents will also be uploaded on EDMS or docdb as required by the project.

• Special tools/components – Any special tools required for tesAng/assembly

will be coordinated with CERN.

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Acceptance at CERN

• Visual InspecAon of all the components

will be performed.

• CPA panels and field strips will be

inspected for scratches or delaminaAon; resisAvity is sampled on panel surfaces

• All FC profile surfaces will be inspected

and in case of any dents and scratches the profiles will be replaced.

• All the screw connecAons will be

checked using a calibrated torque screw

• driver. These screws will be Aghtened to

a low torque spec and can become loose due to vibraAons during shipping. ReAghtening of screws may be required.

• Electrical conAnuity checks between

adjacent field cage profiles (r. divider).

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CERN mounAng/inspecAng/repairing area

• Clean room available in Bgd.182
• Overall size and door opening

adequate to host FC panels and to mount a full CPA column

• Equipped large opAcal table (4x2.5 m)

with surrounding space sufficient to replace the 2.3 m long profile

• Adequate for electrical conAnuity

measurements (and/or reparing) of FC resistor divider and CPA HV bus

• ExisAng supporAng structure available

for temporary verAcal storage of several bagged FC panels (visual inspecAon)

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QC procedures at installaAon of CPA, FC (Top/Bo`om and EW)

Staged QC procedures done during the assembly of the TPC for each of the components.

1. When unpacking the crates in the cleanroom each component is scanned in so the part number is recorded and the proper QC form comes is filled out. A carefully visual inspecAon, conAnuity of all electrical connecAons are confirmed and documented the form. This is then recorded in the hardware database. 2. Once the CPA, FC or EW construcAon is completed in the cleanroom a QC form is completed online to record that all visual conAnuity tests are done properly and the values are saved. 3. Once the final cable connecAons to the feed-through is made inside the cryostat they are checked again before the access scaffold is removed.

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Review Charges

• Charge #13

– Is the CPA/FC/HV quality assurance, quality control and test plan adequate and implemented into the QA plan?

• We are developing a complete QA plan now, idenAfying groups to

execute this plan, and working to complete the documentaAon

• TesAng and inspecAons to be performed during producAon, acceptance

at CERN, installaAon and commissioning are being defined to allow for successful operaAon of protoDUNE

• Full QC plan and procedural documentaAon will be finalized for the

ProducAon Readiness Review – Have applicable lessons-learned from previous LAr-TPC devices been documented?

• Experience from ICARUS, MicroBooNE, LArIAT and 35ton have been

incorporated whenever possible (HV feed-through, ground planes)

• The full tesAng plan and comprehensive procedural documentaAon will

be finalized in Ame for a ProducAon Readiness Review – Does the plan appropriately account for CPA/FC/HV produc:on at mul:ple interna:onal sites with different standards (metric/imperial) for available stock materials?

• Sharing of responsibiliAes have been worked out according to specific

experience, laboratory equipment and manpower of the parAcipaAng insAtuAons

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