Fiber Milestones: WLS Fiber for Tracking Proto

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MINERA Director’s CD-3b Review

11 June 2007Kevin McFarland

University of Rochester

MINERvA WBS 1,2,4: Scintillator and Fiber

Fiber Milestones:WLS Fiber for Tracking Proto.

• Quick summary– All Tracking prototype WLS fiber arrived in 2 shipments

• 60% shipment & 40% shipment• 2 shipments due to availability of funds

– 60% shipment shipped in July– The 40% shipment is about ½ finished at the shutdown

• 40% shipment ready to ship about 1 month after shutdown finishes– Shutdown finishes Oct 12, but PPD will try to get crew back earlier

• very large loss of schedule contingency

– Not expected to impact WBS 3and downstream schedules

– Have two functioning QC tests• both show little variation• n.b., these two techniques don’t define

reflectivity in the same way, butboth are sensitive to mirror variations

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WLS Production

• We expect to start WLS production mirroring in mid January 2008

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Upgrades since Dir Rev

• We have added 2 new technicians– One went from part time to full time in July– One starting ½ time in Aug & Sep (shared with CMS ) and full

time in Oct– Both of these technicians are being trained for ODU production

• We have doubled the number of gluing stations from 60 to 120• We have more than doubled our table space for production• We have identified the table space for boot production

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Fiber Milestones:ODU for Tracking Proto.

• Quick summary– ODUs approximately 60% complete– some Q/C issues identified and addressed– ODU quantities required were updated by downstream factories

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ODUs

• For tracking prototype we are supposed to ship 543 ODUs• 335 ODUs have been shipped

– Pass optical QC & fit test• Another 120 ODUs have passed the optical QC

– We are modifying the fit test and are waiting for test hardware from Lab 7• Another 200 are in various stages of production • Optical QC test

– Optical QC requires each fiber in a ODU must have its value > 90% of the transmission mean for that channel

– 5.7% failed the optical QC– In addition…

• Another 2.0% of ODUs failed because we purposely pushed the diamond to its limit before relapping/replacing to test its lifetime

• 7.5% failed to clip into box because of epoxy on back end of ferrule. – We noticed this problem after producing 300 ODUs– In the last 100 ODUs the problem did not occur– In the future we think < 1% of the ODUs will fail this test.

• The failure rate is slightly higher than before as we bring on these new people

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Tracking Prototype ODUs

• Estimate of failures for future production – 5% optical + 1% epoxy failure, if no other problems

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Fiber Milestones: Cable Production

• In a slide…– Work on cable mold significantly delayed

• conscious choice because of large float

– Cable production problems identified • change in ferrule length implies

needed mold modifications• problems with pouring process and

ES&H impact of the material(polyurethane with Al(OH)3 fire retardant)

• material flow into andwear on mold ejection parts

– Remediation• new procedure removes need for ejector• in the process of completing new hardware• estimated startup in 4-6 weeks

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Optical Cable R&D

• New Mold– Use sliding clamp to press connector against mold to prevent

mold material from flowing to front of connector• The Alumilite polyurethane did not flow into around the connector to

the polished fibers as it was doing with the old mold

– No extraction pins which got gummed up in previous mold• Use straps put in the boot

• Mold cheaper by more than a factor of 2

– We have successfully made boots with new mold and our original molding material, Alumilite polyurethane

– Problem with mold, connectors fit too tight in the mold right now • material will have to be removed in the mold

• about 1 week of work.

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Mold Material

• But the Alumilite is not ideal– It is fluid than we want– Will require a chemical hood, restricts how we do production

• We have identified 2 epoxies which look very promising to replace the Alumilite, but we have not finished the R&D– Both epoxies packaged for 2 component mixing guns– Both have about the right viscosity

• Heigl MP5405bk – 1st choice– Hardens in 15 minutes, no chemical hood needed– Successfully & easily put boots on 5 cables with original mold– Problem, Its black material transmits red light

• Heigl will work with us to fix this problem.

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Mold Material

• Resinlab EP1046fg– Can pull boot out after 1.5 hours, not ideal, but good enough to

finish project– Epoxy is fine, other than the setting time

• None of these 3 products are fire retardant– ES&H suggestion is to paint with fire retardant paint– Sent initial set of Heigl painted sample to for fire test

• Had problems at sharp corners, but successful otherwise

– Made new samples to fire test which fixed problems with sharp corners

• Made samples of all 3 materials

• They have been given to Jim Priest

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Cable Production

• We expect to start tracking prototype cable production on Nov 1 2007

• Full Cable production starts on May 1 2008

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Clear Fiber QC

• We measured the attenuation length for the ODU fiber

• Measured attenuation length of ODU fiber– 5 m pieces– Cut back test– Use 1 m WLS jumper

• Get a 50 cm longer number as opposed to a 50 cm clear jumper

• CMS and some early MINERvA tests we used 50 cm clear jumper

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Clear Cable QC

• Get cm

• Equivalent to 770 cm in measuring it in the way that CMS did and we got about 800 cm for the attenuation length in CMS for 0.94 mm S-35 fibers

– So CMS and MINERvA clear fibers are fairly close in attenuation length

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ESH/QA Changes

ESH/QA:• WBS 1:

– Removed weekly cosmic ray light yield check with extruded strips• always tracked more precise source tests which are performed daily

• WBS 2:– QC procedure uses razor blades for cutting fiber at 45°

• recent concern raised by PPD ES&H. no directive yet, but in communication

• WBS 4:– QC improvements already discussed

– We are working with ES&H on the new mold material both for personal safety and fire safety

• Heigl epoxy does not require a chemical hood

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Identified Risks at CD-3a:WBS 4 (Fiber Cables)

• Final tests of light-tight mold essentially failed to hold up in a production situation– Solution is seen in either redesigning the mold or getting a new mold material

and we did both– R&D should be finished in September 2007

• Fiber costs carry significant contingency to reflect past changes in pricing from Kuraray (less of a problem with clear fiber than WLS)

Documents

Fiber Milestones: WLS Fiber for Tracking Proto