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Fiber Milestones: WLS Fiber for Tracking Proto.

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

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Fiber Milestones: WLS Fiber for Tracking Proto.

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  1. 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 definereflectivity in the same way, butboth are sensitive to mirror variations MINERvA WBS 1,2,4: Scintillator and Fiber

  2. WLS Production • We expect to start WLS production mirroring in mid January 2008 MINERvA WBS 1,2,4: Scintillator and Fiber

  3. 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

  4. 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

  5. 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

  6. 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

  7. 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 impliesneeded mold modifications • problems with pouring process andES&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 MINERvA WBS 1,2,4: Scintillator and Fiber

  8. 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

  9. 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

  10. 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

  11. 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

  12. 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

  13. 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

  14. 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

  15. 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) MINERvA WBS 1,2,4: Scintillator and Fiber

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