FCAL Construction Readiness Review Checklist

FCAL Fabrication Readiness Review Checklist ***DRAFT DRAFT DRAFT***

Review Check List ***DRAFT DRAFT DRAFT***

The goal of the Forward Calorimeter Readiness Review is to assess whether the University of Indiana is ready to begin production of the fabrication of the Hall D forward calorimeter modules. Specifically the following questions need to be examined:

1. Environment
   1. General
      • Are the MSDS information sheets available for all products used during production?
      • What support do you get from university EH&S services?
      • Are there any materials (e.g cleaning agents/etc) that are of particular hazard during fabrication
2. Procedures:
   1. Are all procedures for accepting fabricated parts documented?
   2. Are all procedures for assembling components documented?
   3. Guidance should be given for each of the steps in the fabrication procedure for ease of estimating completion times.
3. Training:
   1. What are the training procedures for first-time workers in each of the areas where they will work?
   2. How is this documented?
4. Acceptance Testing
   1. Lead glass
      • Are the testing procedures clearly defined?
      • Is the criteria for rejecting glass blocks clearly specified?
      • How is the location of each block recorded?
   2. PMT
      • How are the dimension tolerances checked on pmts?
      • How is the performance checked?
      • What performance characteristics are recorded?
   3. Cockcroft-Walton base
      • How are electrical components qualified?
      • How are electrical boards qualified?
      • How are the assembled boards checked?
      • How is the complete assembly tested?
      • How are noise sources characterized?
      • What are the acceptance tests at each stage of the process?
   4. Machined parts
      • What acceptance will be performed to verify dimensional tolerances of all features of the machined parts?
   5. Assembly
      • How are the mechanical tolerances checked after assembly?
      • What documentation is recorded for each module?
5. Recovery Procedures
   1. What are the procedures for reporting an anomally in measurements during the assembly?
   2. What are the procedures for rectifying any problems encountered during assembly? Is this documented?
6. Acceptance Testing of completed module
   1. Are all the items listed in Section 4.2 of the SOW addressed in the Quality Assurance and Test Plan Document?
   2. Are any of the completed modules going to be tested with a source to check overall operation?
7. Tracking
   1. Are all travelers specified for the project?
   2. What information is recorded for the lead glass?
   3. What information is recorded for the pmt?
   4. What information is recorded for each of the fabricated parts
   5. What information is recorded during assembly?
8. Schedule
   1. How is the schedule tracked?
   2. Note: Time for completion of a module should be revisited after the start of production of each subcomponent.
9. Reporting
   1. Is the reporting chain to the project clear?

Contract Requirements

1. Final Construction Plan
2. Final Quality Assurance Plan and Acceptance Test Plan.

Requirements and Quality Assurance: Section 3 and 4 of the Statement of Work

The vendor shall prepare a Quality Assurance and Acceptance Test Plan for approval by JLab at the Readiness Review. The following items must be included:

A Component Inspection Plan, comprised of

1. Inspection of all materials received from the vendor’s suppliers and subcontractors and the recording of this information.
2. Obtaining and recording of all material certifications and analyses.
3. The calibration and identification of standards and instrumentation used for testing; the intervals between calibrations are also to be defined.
4. Establishment of inspection points for the incoming components, which will measure critical parameters.
5. The recording of all inspection data in such a manner so that the history of a component can be readily traced.
6. The submittal to JLab of all data related to the above.

A Process Quality Plan, comprised of

1. Step-by-step process documents, with instructions and prints pertaining to each assembly and/or manufacturing step.
2. Safety information for the job operator, including material data safety sheets
3. A method of reporting any mechanical defects found during assembly of components.
4. A mechanism for recording all job operator work sessions.
5. The submittal to JLab of all data related to the above.

Final Acceptance Test Plan, comprised of

1. Acceptance of the PMTs based on their response to a nominal light source.
2. Acceptance of the PMT bases using electrical tests.
3. Acceptance of the lead glass bars based on their transparency and visual inspection for cracks, chips, or bubbles..
4. Acceptance of the PMT-base-light guide assembly based on dimensional tests.

Tracking

The vendor must keep a record (travelers) of all raw materials and inspections that are used in the construction of each module, and document the procedures followed during fabrication.