1. 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 1 KM3Net Rope & Cable management VLVnT11

2. 2) Backbone (VEOC) 1)Mechanical Rope (rope layout) 3) Penetrator Introduction Break out box Optical module Detector unit Detector unit pallet 2

3. 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 3 KM3Net Rope & Cable management VLVnT11

4. Rope layout Detector Unit (DU) 4 KM3Net Rope & Cable management VLVnT11

5. 5 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. Cable reel with friction Backbone (VEOC) Dyneema® rope KM3Net Rope & Cable management VLVnT11 Rope layout Detector Unit (DU)

6. Belleville washers friction Dyneema® 100 mm 6 KM3Net Rope & Cable management VLVnT11 Rope layout Detector Unit (DU)

7. A B 250 kg 7 Increasing Stability with A triangle Connection of the DOM Bar Constraining a degree of free dom KM3Net Rope & Cable management VLVnT11

8. Test Rope management July 2011 4 m Dyneema® Reel VEOC Roll Stabilility 8 KM3Net Rope & Cable management VLVnT11

9. Rope Summary 9 - 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 KM3Net Rope & Cable management VLVnT11

10. KM3NeT VEOC (Vertical Electrical Cable) 10 KM3Net Rope & Cable management VLVnT11 -Layout -Goal -Design -History -Production of Prototype Nikhef

11. Layout 860 Meter Veoc 1 Veoc 2 DWDM Connecting 11 DOM’s Connecting 9 DOM’s 11 Cross section of the pressure balanced cable 1) Outer shell ¼ LDPE Tube 2) 11 optical fibers 3) 2 Electrical wire 4) Oil Filling 1 2 3 4 KM3Net Rope & Cable management VLVnT11

12. -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) 12 KM3Net Rope & Cable management VLVnT11 Goals

13. History 100 meter Cable by Nikhef and Seacon. 22 fibers 1” tube 4 electrical wires Test at NIOZ under pressure 600 bar Performance; OK 13 KM3Net Rope & Cable management VLVnT11

14. 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 History 14 KM3Net Rope & Cable management VLVnT11

15. New machine to Spiral the cable Oil Filler Cable Tray Production of Prototype Nikhef 15 45 m Cable trail KM3Net Rope & Cable management VLVnT11

16. Spiral Storage 45 m Break Out Box Production of Prototype Nikhef 13 lose Fiber standard SMF 28 2 electrical wires ¼” LDPE tube 16 KM3Net Rope & Cable management VLVnT11

17. Production Scheme Production of Prototype Nikhef 17 Feeding direction Cable Lengte 1 4 2 5 6 1 Data cable reel 2 Optical Fiber bundle 3 Electrical wire 4 Outer cable shell 5 Cable guide 6 Pull Cord 7 Glue 3 3 6 2 7 Cable guide KM3Net Rope & Cable management VLVnT11

18. Production Scheme Production of Prototype Nikhef 18 Feeding direction Cable Lengte 1 4 2 5 6 1 Data cable reel 2 Optical Fiber bundels 3 Electrical wire 4 Outer cable shell 5 Cable guide 6 Pull Cord 7 Glue 3 3 6 2 7 KM3Net Rope & Cable management VLVnT11 Cable guide

19. Production Scheme Production of Prototype Nikhef 19 Feeding direction Cable Lengte 1 4 2 5 6 1 Data cable reel 2 Optical Fibers 3 Electrical wire 4 Outer cable shell 5 Cable guide 6 Pull Cord 7 Glue 3 3 6 2 7 KM3Net Rope & Cable management VLVnT11 Cable guide

20. Coiling Tempering Steam Boiler -100 °C -5 min -.1 MPa Production of Prototype Nikhef 20 d1 d3 d2 D1 =167 mm 110 °C during 1 hour D2 =190 mm 90 °C during 1 hour D3 =320 mm no heat treatment KM3Net Rope & Cable management VLVnT11

21. Production of Prototype Nikhef Production of the proto type 21 KM3Net Rope & Cable management VLVnT11

22. Break Out Box Connector Box VEOC Spiral Test of the proto type 22 KM3Net Rope & Cable management VLVnT11

23. 40 m Production of Prototype Nikhef Test of the proto type Attenuation 2.731 dB Not stretched Attenuation 3.21 dB Stretched 23 Stretched over a length Green laser 125 mW KM3Net Rope & Cable management VLVnT11

24. Production of Prototype Nikhef Sharp bend < 30 mm Attenuation 24 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 Test of the proto type KM3Net Rope & Cable management VLVnT11

25. 40 m Production of Prototype Nikhef Test of the proto type New 40 meter Cable, Optical 0,227 dB 5 fibers standard smf28 25 KM3Net Rope & Cable management VLVnT11

26. Summarized Production of Prototype Nikhef 26 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. KM3Net Rope & Cable management VLVnT11

27. Penetrator A reliable high pressure penetrator. By reducing the stress in the glass 27 KM3Net Rope & Cable management VLVnT11

28. Design principle Penetrator Load 60 MPa pressure Stress in glass near hole 1000 MPa Stress in glass near hole 500 MPa Ti grade 39 28 KM3Net Rope & Cable management VLVnT11

29. 1) 16 Optical Fibers 2) Silicon Seal 3) Glass Epoxy Plate 4) Conical Plug 5) Test flange for Hera Pressure Vessel Penetrator Feedthrough Test 29 KM3Net Rope & Cable management VLVnT11

30. 600 bar 0 Bar Pressure difference 600 Bar for 3 weeks 30 KM3Net Rope & Cable management VLVnT11

31. 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 Penetrator Test 31 KM3Net Rope & Cable management VLVnT11

32. Proto design 6 Electrical pins Fiber protection tube Connector Connector jacket Epoxy bulkhead Silicon seal Silicon fiber protection Conical penetrator 32 KM3Net Rope & Cable management VLVnT11

33. 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. 33 KM3Net Rope & Cable management VLVnT11

34. To summarize Rope & Cable management 34 -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. KM3Net Rope & Cable management VLVnT11