Organizing future KM3NeT production 06-July-2010

2 Placement of the foam core on the assembly table. positioning of 19 PMTs with bases in the foam core. Connection of the PMTs to their signal collection board. Placement, cleaning of the hemisphere on the assembly table. Gluing the piëzo-acoustic sensor to the hemisphere. Placement of the foam core with PMTs in the hemisphere. Testing Out-gassing and pouring the gel between the hemisphere and the foam core, harden for 8 hours Total amount of assembly time for this part; ~5 hours Assembly of bottom sphere half. 06-July-20102Organizing future KM3net production

3 Placement, cleaning of the hemisphere on the assembly table. Mounting a EO penetrator. Gluing of the cooling mushroom to the glass hemisphere. Mounting the converter board and connect to the penetrator. Mounting auxiliary boards on the storey logic board. Gluing of the “nano-beacon” to the hemisphere. Connection of the storey logic board with compass and tilt-metre to the power converter board, and the “nano-beacon” to the auxiliary board. Mounting storey logic board on the cooling mushroom. Fibre splice of readout fibre. Total amount of assembly time for this part; ~3 hours Assembly of top sphere half / July-20103Organizing future KM3net production

4 Assembly of top sphere half / 2. Placement of the foam core on the assembly table. Positioning of 12 PMTs with bases and pressure gauge in the foam core. Connection of the PMTs to their signal collection board. Total amount of assembly time for this part; ~1.5 hours 06-July-20104Organizing future KM3net production

5 Assembly of top sphere half / 3. Placement, cleaning of the hemisphere on the assembly table. Placement of the core over the stem of the cooling mushroom. Mounting of the signal collection board on the cooling mushroom. Testing Out-gassing and pouring the gel between the hemisphere and the foam core, harden for 8 hours. Total amount of assembly time for this part; ~5 hours 06-July-20105Organizing future KM3net production

6 Assembly of the two hemispheres. Reduction of pressure to 700mbar abs Sealing and taping assembly, attachment of the storey connection ring. Testing Assembly time for this part; ~5.5 hours Assembly of the two sphere halves. 06-July-20106Organizing future KM3net production

7 Dividing the work; First option; When there are four production sites and four years of production, each site should produce ~800 optical modules and 20 DU’s a year. Second option; There will be 3 sites that produce ~1100 OM’s a year and one site assembles 80 DU’s a year. 06-July-20107Organizing future KM3net production

8 Manpower in Fte years; Optical modules for KM3 will net be needing ~20 hours to build and test, for modules; ~180 Fte Years. The assembly of a “bar” storey with 2 multi PMT OM’s + assembly and test of the complete DU; ~35 Fte years. Internal logistics will take another two people at each site (a total of ~32 Fte years) For the test-setups another estimated 14 Fte years will be necessary, spread over a short period. 06-July-20108Organizing future KM3net production

9 Space needed; For Optical Module production it will be necessary to produce 10 or 14 OM’s (option 1 and 2) in parallel at each site, this will be ~100 or ~150 m 2 + testing ~100 m 2 each. For DU assembly another ~300m 2 (option 1) will be needed for one DU every 2 weeks (two production lines in parallel), testing ~50 m 2. For storage 0.5 years of production is estimated in all cases. If DU assembly is concentrated at one site (option 2) ~1000 m 2 will be needed at this site for integration and testing (+storage!). 06-July-20109Organizing future KM3net production

10 Transportation, numbers, costs; At IceCube a total of 700 m 3 of boxes with optical modules is transported to the South-pole, optical modules without packaging was 200 m 3. Optical modules for KM3 ~1000 m 3 without packaging, so at least 2000 M 3 of boxes (two times the net Amount instead of 3.5 at IceCube!). When using trucks similar to the ones we used for atlas we will need 20 truckloads for optical modules, ~40 k€. Transporting complete Detection Units, 320 Du’s, will probably be around 6000 m3, 60 truckloads, ~120 k€. 06-July Organizing future KM3net production

11 Comparison: Four sites that assemble OM’s as well as complete DU’s. Both DU and OM production, per site; -15 Fte -10 OM and 2 DU production lines -550 m 2 production and testing m 2 storage. -total transportation costs ~120 k€. -More satisfying to build -better QA feedback. Three sites to assemble OM’s, and one site that exclusively produces complete DU’s. OM production, 3 sites, per site; -17 Fte -14 OM production lines m 2 production and testing m 2 storage. For DU production, 1 site; -11 Fte -8 DU production lines m 2 assembly and testing. -storage (750 m 2 ?) -total transportation costs ~160 k€. -Less tooling and test equipment to be build, easier to organize. -Probably extra costs for OM packaging. 06-July Organizing future KM3net production

12 Outsourcing Has to be studied. For electronics it becomes more and more usual, even including QAQC. In the mechanics of detector building however it’s a difficult way to go, a lot of control is necessary. 06-July Organizing future KM3net production

13 Remarks, opinions or questions? 06-July Organizing future KM3net production