Fiber Milestones: WLS Fiber for Tracking Proto.

1
Fiber MilestonesWLS 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 dont
  definereflectivity in the same way, butboth are
  sensitive to mirror variations

2
WLS Production

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

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

4
Fiber MilestonesODU for Tracking Proto.

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

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 gt 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 lt 1 of the ODUs will fail
  this test.
• The failure rate is slightly higher than before
  as we bring on these new people

6
Tracking Prototype ODUs

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

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 andESH 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

8
Optical Cable RD

• 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.

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 RD
• 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.

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
• ESH 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

11
Cable Production

• We expect to start tracking prototype cable
  production on Nov 1 2007
• Full Cable production starts on May 1 2008

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

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

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 ESH. no directive
  yet, but in communication
• WBS 4
• QC improvements already discussed
• We are working with ESH on the new mold material
  both for personal safety and fire safety
• Heigl epoxy does not require a chemical hood

15
Identified Risks at CD-3aWBS 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
• RD 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)