P. Shanahan May 29, 2003 Page 1 MINOS WBS 2.3: Electronics, DAQ and Database Status Accomplishments...
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Transcript of P. Shanahan May 29, 2003 Page 1 MINOS WBS 2.3: Electronics, DAQ and Database Status Accomplishments...
![Page 1: P. Shanahan May 29, 2003 Page 1 MINOS WBS 2.3: Electronics, DAQ and Database Status Accomplishments since Dec. 2002 review Near Detector Electronics production.](https://reader036.fdocuments.us/reader036/viewer/2022062519/5697bff81a28abf838cbf311/html5/thumbnails/1.jpg)
P. ShanahanMay 29, 2003Page 1
MINOS WBS 2.3: Electronics, DAQ and Database
• Status
• Accomplishments since Dec. 2002 review
• Near Detector Electronics production• False positive cost variance• MENU production• Schedule• Possible contingency usage Peter Shanahan
Department of Energy
Review of the NuMI Project
MINOS Parallel Session
May 28-30, 2003
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P. ShanahanMay 29, 2003Page 2Overview of 2.3 Status
• Schedule Status (BCWP/Total Budget): • 89% complete
• Near Electronics: WBS 2.3.1 (Argonne, Fermilab)• In production – focus of this talk
• The rest of WBS is summarized below
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P. ShanahanMay 29, 2003Page 3WBS 2.3 Accomplishments Since
December, 2002 Review
• L3 Milestones:• WBS 2.3.1.0.MS.6 Begin Menu Card Checkout
* completed on time, 4/15/03
• WBS 2.3.1.0.MS.5 ND Order Production Boards * completed on time, 4/18/03
• Production Started on All Near Detector Electronics Components • Fabrication and Assembly for all Printed Circuit Boards
• Orders issued for All Crates, Power Supplies
• Schedule Logic Improvements (Mostly 2.3.1)• More natural logic flow more realistic progress tracking
•(Except 2.3.6: VME Timing Module Redesign – 15 units)
…cont…
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P. ShanahanMay 29, 2003Page 4WBS 2.3 FD FEE, DAQ, DATABASE
• WBS 2.3.2 Far Detector Front End Electronics (Harvard, Oxford, FNAL)• Complete
• WBS 2.3.4 DAQ & Triggering (RAL, Argonne)• Far Detector:
* Final readout crate commissioned in February 2003
• Near Detector* Planning with WBS 2.5 Installation group for ND installation
* DAQ Code: used at CALDET, daily use at ANL test stand
• WBS 2.3.5 Database (UMinn, Oxford, Fermilab)• Gathering module construction data
• Testing data distribution system
• Work on implementing Oracle database
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P. ShanahanMay 29, 2003Page 5WBS 2.3 Aux Systems, DCS, HV
• WBS 2.3.6 Auxiliary Systems (Oxford, FNAL, IIT)• Far clock system installation will be completed next month• Near clock modules: see below
• WBS 2.3.8 Slow Control & Monitoring (UMD, UWisc, FNAL)• Detector Control System: Automatic HV control• Rack Protection (RPS)
* Near: equipment being staged at FNAL, procurement will finish this summer, with assembly to follow
• Software: HV, Environmental, Magnet, and RPS data now logged to database
• WBS 2.3.9 High Voltage (Texas A&M)• Far: HV dropouts traced to bad power conditioner – fixed• Near: Power conditioner purchased
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P. ShanahanMay 29, 2003Page 6Change Requests in WBS 2.3
• CR 218 - $580K overrun (burdened) on electronics• Near Detector EDIA : $194K
• Near Detector Parts Order & Assembly: $129K * Fixed Errors in early CR
• Far Detector EDIA: $82K
• Far Detector Parts Order & Assembly: $146K
• Far Detector Production Checkout: $26K
• CR 223 – Schedule Logic Change• Gave every task predecessor and successor tasks
• Thinned out unnecessary predecessor/successor relationships
• Results: more ‘natural’ production schedule, more meaningful floats
• $25K increase from escalation
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P. ShanahanMay 29, 2003Page 7New Milestones
• Level 2:• WBS 2.3.0.MS.2
* Change “Electronics ready for installation – Near” to “Electronics ready to begin installation – Near”
* Emphasizes pipeline of production and installation
• WBS 2.3.0.MS.4 * New: “Electronics production complete – Near”* Emphasized completion of all electronics
• Level 3:• 2.3.1.0.MS.6 Begin MENU Card Checkout• 2.3.1.0.MS.7 Complete Shipping for CalDet • 2.3.1.0.MS.8 Begin Near FE Electronics Installation
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P. ShanahanMay 29, 2003Page 8Upcoming Schedule Milestones
WBS Task Schedule Float
2.3.0.MS.2 Electronics Ready to Begin Installation - Near 10/15/2003 170d
2.3.0.MS.4 Electronics Production Complete - Near 03/01/2004 161d
2.3.1.0.MS.5 ND Order Production Boards 04/18/2003 378d
2.3.1.0.MS.6 Begin MENU Card Checkout 04/15/2003 113d
2.3.1.0.MS.7 Complete Shipping for CalDet 07/10/2003 29d
2.3.1.0.MS.8 Begin Near FE Electronics Installation 04/05/2004 198d
Total WBS 2.3 Float is 54 days – partially over-constrained by constant scheduled effort in aiding with electronics installation
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P. ShanahanMay 29, 2003Page 9Near Detector Electronics
MASTERModule
MINDERCrate
Trigger/Keeper
MINDERmodules
MA
ST
ER
Crate
Control
Read-Out Channel 0
Read-Out Channel 1
Read-Out Channel 2
Read-Out Channel 3
Read-Out Channel 4
Read-Out Channel 5
Read-Out Channel 6
Read-Out Channel 7
1818181818181818
MASTER MODULEVME Read-Out Board
Front End Crate
KE
EP
ER
68
Rea
d-O
ut B
uffe
r
VME Computer
Located Near MUX BoxEach Crate Hosts 16 MINDERs
Located in Front End VME Crate
VMEBackplane
Located in Front End VME Crate
Trig
ger
VM
E In
terf
ace
Each MINDER Module supports16 Channels, or 1/4 PMT
Each MASTER supports8 MINDERs, or 2 PMTs
VME Clock Fanout
RF ClockNUMI Interface
Tim
ing
MIN
DE
R
MIN
DE
R
MIN
DE
R
MIN
DE
R
MIN
DE
R
MIN
DE
R
MIN
DE
R
MIN
DE
R
GRD991101
To Other Crates
Component Count (not counting ~10% spares):
9328 MENUS
583 MINDERS
81 MASTERS
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P. ShanahanMay 29, 2003Page 10Near Detector Electronics Status
• Schedule Status (BCWP/Total Budget):• 85% March 03 (88% April 03)
• All 2.3.1 system components are in production• Problems with MENU startup
• Minder schedule is tight for CALDET run at CERN
• Artificial Large Favorable Cost Variances:• +$1M in March mostly due to “statusing” order tasks
• Some production orders are under budget
• Some overruns on labor
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P. ShanahanMay 29, 2003Page 11Near Detector Electronics Status
Item Number for Detector
Operation
Number for CALDET Operation
Assembled Number in Hand
Comments
MENUs 9328 1456 1600 90% passing checkout
MINDERs 583 91 10
KEEPERs 45 8 5 Balance expected week 5/27
MASTERs 81 16 4 7-10 more due 5/21
MINDER CRATEs 45 8 10
MINDER PS 45 8 10
MASTER CRATEs 9 2 11
MASTER PS 9 2 11
VME Timing Module 10 2 4 Caldet won’t use prod. version
Minder Timing Module 45 8 45 ~few need repair post-checkout
Master Clock Controler 1 1 3
Clock Fanout 6 1 7
Spares (~10%) not included in this table. Various Auxillary cards not included (which have CALDET quantities met).
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P. ShanahanMay 29, 2003Page 12MENU
• Front-end daughter card• Supports and reads out QIE
• Stores digital data in pipeline
• 9328 in system
• 1440 plus spares required for CALDET
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P. ShanahanMay 29, 2003Page 13MENU Production Problems
• Sporadic production startup:
• Fabrication• Solder on gold contacts – not noticed until fabrication began.• Vendor has accepted responsibility: inspection+new boards• Vendor inspection insufficient (no microscope on QC line!)
* Additional Fermilab technician time
• Assembly• Incorrect 1st articles• Overheated “burn-in” by vendor on 200 boards• Poorly tuned initial automated optical inspection by vendor• Wrong solder flux on several hundred boards• All problems addressed by vendor
* but with substantial FNAL tech time
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P. ShanahanMay 29, 2003Page 14MENU Good News
• 1600 boards in hand
• Checkout rate of boards with no acute problems is >90%• Assumed 67% in checkout schedule
• CALDET schedule virtually assured
• IIT Undergrads for Checkout• Resident at FNAL for 5 weeks
• Will later take test-stand to IIT
• Long-term production• Rate of 330/wk will complete production by 12/31/03
MENU Module Production ChartMechlab Deliveries, No. Cards Checked Out
19-May-2003 C. Nelson(Data points for 5/23 are projections.)
0
500
1000
1500
2000
2500
3000
3/2
8/2
00
3
4/4
/20
03
4/1
1/2
00
3
4/1
8/2
00
3
4/2
5/2
00
3
5/2
/20
03
5/9
/20
03
5/1
6/2
00
3
5/2
3/2
00
3
5/3
0/2
00
3
6/6
/20
03
Date of End of Week
Nu
mb
er o
f M
EN
U M
od
ule
s
Expected Mechlab Deliveries - 500/Week
Expected Number of Checked Out Cards
Mechlabs Total No. Delivered
Total MENUs Checked Out
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P. ShanahanMay 29, 2003Page 15MINDER STATUS
• MENU Mother Board• 16 MENUs/MINDER
• 583 MINDERS in the system
• 100 needed for CALDET
• Assembly began in early May
• Testing for CALDET• >5 modules/day required
• Run 2 teststand shifts at Argonne
• Collaborator help for simpler checkout tasks may be used
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P. ShanahanMay 29, 2003Page 16Near Detector Electronics Schedule
(from Dec. ‘02 Review)
Beneficial Occupancy of Near Detector hall – Dec. 22, 2003
Near Detector CALDET Run – 1500 Channels needed starting June, 2003
Actual assembly start(fabrication for power supplies)
•Actual CALDET Run:•Sept. 4 – Oct. 4•Ship in late June
Shifting complete dates by these amounts will not affect ND schedule
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P. ShanahanMay 29, 2003Page 17CALDET
• Last year’s run• 150 channels on 1 side had Near Electronics
• Generally useful system test
• PID issues and high rate (for Far Detector Electronics) limited ability to compare ND/FD
Time of Flight
Cerenkov
,e,p
Steel/Scintillator
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P. ShanahanMay 29, 2003Page 182003 CALDET Run
• Sept. 4 – Oct. 4, 2003
• 1440 channels on Near Detector Electronics• Full instrumentation of 1 side (actual ND is one sided)
• Near only, and Near/Far running
• Production calibration of Near response• ND Electronics is principle focus of run
• Ship electronics in late June • L3 milestone 7/7/03
• Move to beam enclosure 8/26/03
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P. ShanahanMay 29, 2003Page 19Large Artificial Cost Variance in
WBS 2.3.1
• $994 K favorable cost variance
• Two main artificial components:• “Order” tasks BCWP based on technical progress, although ACWP
doesn’t accrue until item is received – temporary effect* March 03 total 2.3.1 encumbrances=$900k
• Delays between Argonne activity and Fermilab accounting
0
500
1000
1500
2000
2500
3000
3500
4000
4500
Nov-02 Dec-02 Jan-03 Feb-03 Mar-03
BCWP
ACWP
CV
k$ Production turn-on here
E.g.: “order” task including specification, bid solicitation, and purchase
time
BCWS
Favorable Cost Variance if BWCP tracks technical progress Unfavorable Schedule Variance if BWCP track receipts
M&S start to be received
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P. ShanahanMay 29, 2003Page 20
Item Budgeted cost (unburdened) Actual PO cost "Variance"
MENU Fabrication 73 27 46MENU Assembly 186 158.5 27.5VME PS 44 58 -14MINDER PS 208 246 -38MINDER Crates 129 60 69Misc. Board Fab and Assembly 240 168 72
162.5
Possible Real Favorable Cost Variances
• Sampling of recent M&S purchase orders:• Power supplies, crates, printed circuit boards
• Possible $100K+ favorable variance* Based on Purchase Order records
(excludes PMT cable overrun of ~$20K)
Preliminary, unofficial accounting
k$
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P. ShanahanMay 29, 2003Page 21Possible Contingency Use
(ignoring possible favorable variances)
• Travel for FNAL engineers: ~$20k
• Tech and Engineer Labor
• Clock system – possible c. $50k overrun
• MENU Production* Initial fabrication and assembly quality problems being addressed by high-
level FNAL techs – possible c. $50k overrun.
* Will be partially mitigated by general MENU checkout by off-project student labor
• PMT – MINDER cables
• Issue discovered just before last review: complicated patterns of 64 in to 64 out
• Fabrication: will be farmed out for $35k, about $20k over budget
• Total currently foreseen overruns for 2.3: $140K
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P. ShanahanMay 29, 2003Page 22Summary
• WBS 2.3 has had much progress since Dec. 02• WBS 2.3.2 finished
• Steady progress towards completion on DAQ, Database, DCS, HV
• Near Detector electronics in production
• Artificial large favorable cost variance in 2.3.1
• Estimates of real negative and positive variances by sub-tasks in 2.3.1/2.3.6 are approximately both $100-$200k scale
• Actual production appears in line with CALDET run and Near Detector installation• CALDET schedule is tight – may require physicist shifts on checkout
• WBS 2.3 is 89% complete