Transcript doe_rev_07.ppt

MINERnA
Director’s CD-3b Review
11 June 2007
Kevin McFarland
University of Rochester
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 3
and downstream schedules
– Have two functioning QC tests
• both show little variation
• n.b., these two techniques don’t define
reflectivity inMINERvA
the same
way,
WBS
1,2,4:but
Scintillator and Fiber
1
MINERnA
Director’s CD-3b Review
11 June 2007
Kevin McFarland
University of Rochester
WLS Production
• We expect to start WLS production mirroring in mid January 2008
MINERvA WBS 1,2,4: Scintillator and Fiber
2
MINERnA
Director’s CD-3b Review
11 June 2007
Kevin McFarland
University of Rochester
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
MINERvA WBS 1,2,4: Scintillator and Fiber
3
MINERnA
Director’s CD-3b Review
11 June 2007
Kevin McFarland
University of Rochester
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
MINERvA WBS 1,2,4: Scintillator and Fiber
4
MINERnA
Director’s CD-3b Review
11 June 2007
Kevin McFarland
University of Rochester
•
•
•
•
•
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
MINERvA WBS 1,2,4: Scintillator and Fiber
5
MINERnA
Director’s CD-3b Review
11 June 2007
Kevin McFarland
University of Rochester
Tracking Prototype ODUs
• Estimate of failures for future production
– 5% optical + 1% epoxy failure, if no other problems
MINERvA WBS 1,2,4: Scintillator and Fiber
6
MINERnA
Director’s CD-3b Review
11 June 2007
Kevin McFarland
University of Rochester
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 and
wear on mold ejection parts
– Remediation
• new procedure removes need for ejector
• in the process of completing new hardware
• estimated startup in 4-6 weeks
MINERvA WBS 1,2,4: Scintillator and Fiber
7
MINERnA
Director’s CD-3b Review
11 June 2007
Kevin McFarland
University of Rochester
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.
MINERvA WBS 1,2,4: Scintillator and Fiber
8
MINERnA
Director’s CD-3b Review
11 June 2007
Kevin McFarland
University of Rochester
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.
MINERvA WBS 1,2,4: Scintillator and Fiber
9
MINERnA
Director’s CD-3b Review
11 June 2007
Kevin McFarland
University of Rochester
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
MINERvA WBS 1,2,4: Scintillator and Fiber
10
MINERnA
Director’s CD-3b Review
11 June 2007
Kevin McFarland
University of Rochester
Cable Production
• We expect to start tracking prototype cable production on Nov 1
2007
• Full Cable production starts on May 1 2008
MINERvA WBS 1,2,4: Scintillator and Fiber
11
MINERnA
Director’s CD-3b Review
11 June 2007
Kevin McFarland
University of Rochester
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
MINERvA WBS 1,2,4: Scintillator and Fiber
12
MINERnA
Director’s CD-3b Review
11 June 2007
Kevin McFarland
University of Rochester
Clear Cable QC
•
•
Get l = 815 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
MINERvA WBS 1,2,4: Scintillator and Fiber
13
MINERnA
Director’s CD-3b Review
11 June 2007
Kevin McFarland
University of Rochester
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
MINERvA WBS 1,2,4: Scintillator and Fiber
14
MINERnA
Director’s CD-3b Review
11 June 2007
Kevin McFarland
University of Rochester
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
(lessWBS
of a1,2,4:
problem
with
MINERvA
Scintillator
and clear
Fiber fiber than WLS) 15