Fcal Readiness Checklist

DRAFT DRAFT DRAFT FCAL Fabrication Readiness Review Checklist DRAFT DRAFT DRAFT

The goal of the Forward Calorimeter Readiness Review is to assess whether the Indiana University 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?
   2. Lead glass
   3. Cockcroft Walton bases
2. Procedures:
   1. Are all procedures for handling lead glass documented?
   2. Are all procedures for assembling modules documented?umented?
   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. Pmts
   2. Lead glass
   3. Machined parts
   4. Completed modules
      • Which measurements, and what frequency is planned during assembly?
      • What documentation is recorded at each stage?
5. Recovery Procedures
   1. What are the procedures for reporting an anomally in measurements?
   2. What are the procedures for rectifying any problems encountered during assembly? Is this documented?
6. Acceptance Testing of completed module
   1. How are the dimensions checked and verified against drawings?
   2. How is the light transmission measured for a completed module?
   3. What criteria are used to accept a completed module before shipment?
   4. What testing will be done to verify performance?
   5. How many modules will be tested with cosmics?
7. Tracking
   1. Are all travelers specified for the project?
   2. What information is recorded for the pmts?
   3. What information is recorded for the lead glass?
   4. What information is recorded during assembly fabrication?
8. Schedule
   1. How is the schedule tracked?
   2. Note: Time for completion of a module should be revisited after completion of the first batch of modules.
9. Reporting
   1. Is the reporting chain to the project clear?

Contract Requirements

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

Testing and Tracking: Section 5 of the Statement of Work

SOW Section 4.0

The vendor shall prepare a Quality Assurance and Acceptance Test Plan for JLab’s approval as part of the “Readiness Review” process and shall furnish such documentation as JLab may require throughout the construction process. The vendor shall conduct quality control procedures and tests, which will guarantee that the product to be furnished by the vendor is in full conformance with this statement of work and the approved Acceptance Test Plan.

This Quality Assurance and Acceptance Test Plan must include the following:

1. A Component Inspection Plan, comprised of:
   • Inspection of all materials received from the vendor’s suppliers and subcontractors and the recording of this information.
   • Obtaining and recording of all material certifications and analyses.
   • The calibration and identification of standards and instrumentation used for testing; the intervals between calibrations are also to be defined.
   • Establishment of inspection points for the incoming components, which will measure critical parameters.
   • The recording of all inspection data in such a manner so that the history of a component can be readily traced.
   • The submittal to JLab of all data related to the above.
2. A Process Quality Plan, comprised of:
   • Step-by-step process documents, with instructions and prints pertaining to each assembly and/or manufacturing step.
   • Safety information for the job operator, including material data safety sheets
   • A method of reporting any mechanical defects found during assembly of components.
   • A mechanism for recording all job operator work sessions.
   • The submittal to JLab of all data related to the above.
3. Final Acceptance Test Plan, comprised of:
   • Acceptance of the PMTs based on their response to a nominal light source.
   • Acceptance of the PMT bases using electrical tests.
   • Acceptance of the lead glass bars based on their transparency and visual inspection for cracks, chips, or bubbles..
   • 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.