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Rope & Cable management A vertical electro-optical backbone cable for KM3NeT

KM3Net Rope & Cable management VLVnT11. Rope & Cable management A vertical electro-optical backbone cable for KM3NeT. Gertjan Mul (gjmul@nikhef.nl) On behalf of the km3net collaboration Nikhef Mechanical department Nikhef Electronic department.

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Rope & Cable management A vertical electro-optical backbone cable for KM3NeT

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  1. KM3Net Rope & Cable managementVLVnT11 Rope & Cable management A vertical electro-optical backbone cable for KM3NeT GertjanMul(gjmul@nikhef.nl) On behalf of the km3net collaboration Nikhef Mechanical department Nikhef Electronic department

  2. KM3Net Rope & Cable managementVLVnT11 Introduction 3) Penetrator 2) Backbone (VEOC) Break out box Mechanical Rope (rope layout) Optical module Detector unit Detector unit pallet

  3. KM3Net Rope & Cable managementVLVnT11 Mechanical Rope specifications Load /part 250 kg Mechanical Rope -Dyneema(R) SK78 -4 mm diameter -breaking load of 1250kg. -1% stretch Creep of Dyneema(R) at 15 deg And 20% static load is 0.9% / 10 yrs

  4. KM3Net Rope & Cable managementVLVnT11 Ropelayout Detector Unit (DU)

  5. KM3Net Rope & Cable managementVLVnT11 Ropelayout Detector Unit (DU) Before unfurling the VEOC and Dyneema® must be stored. During unfurling and mission time of the DU the VEOC must be supported to the mechanical cable. Backbone (VEOC) Dyneema® rope Cable reel with friction

  6. KM3Net Rope & Cable managementVLVnT11 Ropelayout Detector Unit (DU) Dyneema® Belleville washers friction 100 mm

  7. KM3Net Rope & Cable managementVLVnT11 Increasing Stability Connection of the DOM Bar A B with A triangle 250 kg Constraining a degree of free dom

  8. KM3Net Rope & Cable managementVLVnT11 Test Rope management July 2011 Roll Stabilility VEOC Dyneema® Reel 4 m

  9. KM3Net Rope & Cable managementVLVnT11 Rope Summary • - No floating ropes which can tangle during deployment. (Cable reel with a friction system) • - Compact storage for deployment. • - Avoid tension on the VEOC . (spiral around the rope) • - Stability and smooth unfolding by A triangle

  10. KM3Net Rope & Cable managementVLVnT11 KM3NeT VEOC (Vertical Electrical Cable) -Layout -Goal -Design -History -Production of Prototype Nikhef

  11. KM3Net Rope & Cable managementVLVnT11 Layout Cross section of the pressure balanced cable 1) Outer shell ¼ LDPE Tube 2) 11 optical fibers 3) 2 Electrical wire 4) Oil Filling Connecting 11 DOM’s Veoc 2 860 Meter DWDM 3 2 Connecting 9 DOM’s Veoc 1 1 4

  12. KM3Net Rope & Cable managementVLVnT11 Goals • -Cable with a low drag For DU Mechanical stable • A Flexible Cable for deployment and logistics • An Easy cable to manufacture for the lowest Cost • For this Nikhef looked at an oil filled cable design. • Pressure Balanced Oil Filled (PBOF)

  13. KM3Net Rope & Cable managementVLVnT11 History 100 meter Cable by Nikhef and Seacon. 22 fibers 1” tube 4 electrical wires Test at NIOZ under pressure 600 bar Performance; OK

  14. KM3Net Rope & Cable managementVLVnT11 History 210 meter Cable by Nikhef, Baas and Seacon. 13 fibers in a bundle 2 electrical wires. (fibers are gradient-index bend bright 10 mm bend radius) Test at NIOZ and Southampton under pressure 600 bar. ¼ “ LDPE tube Performance; OK

  15. KM3Net Rope & Cable managementVLVnT11 Production of Prototype Nikhef Oil Filler Cable Tray 45 m Cabletrail New machine to Spiral the cable

  16. KM3Net Rope & Cable managementVLVnT11 Production of Prototype Nikhef 13 lose Fiber standard SMF 28 2 electrical wires ¼” LDPE tube Break Out Box Spiral Storage 45 m

  17. KM3Net Rope & Cable managementVLVnT11 Feeding direction Production of Prototype Nikhef Production Scheme 7 2 6 3 Cable guide 1 4 2 5 3 1 Data cable reel 2 Optical Fiber bundle 3 Electrical wire 4 Outer cableshell 5 Cableguide 6 Pull Cord 7 Glue 6 Cable Lengte

  18. KM3Net Rope & Cable managementVLVnT11 Feeding direction Production of Prototype Nikhef Production Scheme 7 2 6 3 Cable guide 1 4 2 5 3 1 Data cable reel 2 Optical Fiber bundels 3 Electrical wire 4 Outer cable shell 5 Cable guide 6 Pull Cord 7 Glue 6 Cable Lengte

  19. KM3Net Rope & Cable managementVLVnT11 Feeding direction Production of Prototype Nikhef Production Scheme 7 2 6 3 Cable guide 1 4 2 5 3 1 Data cable reel 2 Optical Fibers 3 Electrical wire 4 Outer cableshell 5 Cableguide 6 Pull Cord 7 Glue 6 Cable Lengte

  20. KM3Net Rope & Cable managementVLVnT11 Production of Prototype Nikhef Coiling Tempering d2 d1 d3 Steam Boiler -100 °C -5 min -.1 MPa D1 =167 mm 110 °C during 1 hour D2 =190 mm 90 °C during 1 hour D3 =320 mm no heat treatment

  21. KM3Net Rope & Cable managementVLVnT11 Production of Prototype Nikhef Production of the proto type

  22. KM3Net Rope & Cable managementVLVnT11 Test of the proto type Break Out Box Connector Box VEOC Spiral

  23. KM3Net Rope & Cable managementVLVnT11 Production of Prototype Nikhef Test of the proto type 40 m Attenuation 2.731 dB Not stretched Stretched over a length Green laser 125 mW Attenuation 3.21 dB Stretched

  24. KM3Net Rope & Cable managementVLVnT11 Production of Prototype Nikhef Test of the proto type Sharp bend < 30 mm Attenuation Problems loose fibers -Because of length differences in tube optical fiber twist at some points in the tube resulting in a small bend < 30 -Standard fibers have a min. bend radius of 30 mm

  25. KM3Net Rope & Cable managementVLVnT11 Production of Prototype Nikhef Test of the proto type 40 m New 40 meter Cable, Optical 0,227 dB 5 fibers standard smf28

  26. KM3Net Rope & Cable managementVLVnT11 Production of Prototype Nikhef Summarized 2 pressure balanced cables tested proof the system works. 1 spiral cable with the 13 smf28 standard fibers. -Due to length differences many twists with small bending radius occured. 2 new spiraling test tubes to build. To test if losses can be reduced by improving the production method. -Instead of loose fibers a bundle is used for pulling into the tube. -Use of bend bright fiber.

  27. KM3Net Rope & Cable managementVLVnT11 Penetrator A reliable high pressure penetrator. By reducing the stress in the glass

  28. KM3Net Rope & Cable managementVLVnT11 Design principle Load 60 MPapressure Penetrator Stress in glass near hole 1000 MPa Penetrator Ti grade 39 Stress in glassnear hole 500 MPa

  29. KM3Net Rope & Cable managementVLVnT11 Penetrator Feedthrough Test 1) 16 Optical Fibers 2) Silicon Seal 3) Glass Epoxy Plate 4) Conical Plug 5) Test flange for Hera Pressure Vessel

  30. KM3Net Rope & Cable managementVLVnT11 600 bar 0 Bar Pressure difference 600 Bar for 3 weeks

  31. KM3Net Rope & Cable managementVLVnT11 Penetrator Test Mechanical Test -5 conical plugs distributed over 1 hemisphere 80% of the sphere is filled with water for safety The sphere is submerged in the NIOZ pressure tank. Test Pressure 600 Bar for 1 hour. After removing the sphere from the tank the conical plugs and holes were inspected: OK

  32. KM3Net Rope & Cable managementVLVnT11 Proto design Connector Fiber protection tube Silicon seal Connector jacket Epoxy bulkhead Silicon fiber protection Conical penetrator 6 Electrical pins

  33. KM3Net Rope & Cable managementVLVnT11 Summarized The design reduced stress at the hole edge. Test of the penetrators at 600 bar show no problems. Test of the penetrators feedthrough at 600 bar shows no problems. Optimized design will be implemented in the BEOC.

  34. KM3Net Rope & Cable managementVLVnT11 Rope & Cable management To summarize • -Keep the ropes under tension with a cable reel and break system. • -Locking the VEOC around the Dyneema® rope in a spiral. • -Connection of the DOM bar with an A triangle. • VEOC performs well with gradient-index fiber (bend bright). • The spiraled VEOC must be optimized with gradient-index fiber. • -Conical plug reduces stress on the edge of the hole. • -Optimization for production.

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