Difference between revisions of "Fcal Readiness Checklist"

From GlueXWiki
Jump to: navigation, search
(→‎Contract Requirements)
 
(4 intermediate revisions by the same user not shown)
Line 7: Line 7:
 
##* Are the MSDS information sheets available for all products used during production?
 
##* Are the MSDS information sheets available for all products used during production?
 
##* What support do you get from university EH&S services?
 
##* What support do you get from university EH&S services?
−
## Fibers
+
## Lead glass
−
##* Is the lighting and handling of the fibers performed in accordance with the recommendations by Kuraray?
+
## Cockcroft Walton bases
−
##* Is the storage of fibers such that damage will be minized before and during fabrication?
+
−
## Lead
+
−
##* Are proper procedures taken to minimize worker exposure to lead during handling?
+
−
##* Is the storing and handling organized to minimize any deformations or kinks of the swaged lead?
+
 
# Procedures:
 
# Procedures:
−
## Are all procedures for handling, sorting and testing fibers documented?
+
## Are all procedures for handling lead glass documented?
−
## Are all procedures for handling, swaging and storing lead sheets documented?
+
## Are all procedures for assembling modules documented?umented?
−
## Are all procedures for assembling the lead/fiber matrix documented?
+
 
## Guidance should be given for each of the steps in the fabrication procedure for ease of estimating completion times.
 
## Guidance should be given for each of the steps in the fabrication procedure for ease of estimating completion times.
 
# Training:
 
# Training:
Line 22: Line 17:
 
## How is this documented?
 
## How is this documented?
 
# Acceptance Testing
 
# Acceptance Testing
−
## Fibers
+
## Pmts
−
##* Are the testing procedures clearly defined?
+
## Lead glass
−
##* Is the criteria for rejecting fibers to be used in the matrix clearly specified?
+
−
##* How are the fibers selected for use in a given module?
+
−
##* How is the origin, i.e. fiber batch number, traced to each module?
+
−
## Lead
+
−
##* How are the dimension tolerances checked on lead sheets?
+
−
##* How is the cleanliness of the lead assessed?
+
−
##* Is the handling the lead minimized, so as to avoid possible damage to the lead?
+
 
## Machined parts
 
## Machined parts
−
##* What acceptance will be performed to verify dimensional tolerances of all features of the Al front and base plates?
+
## Completed modules
−
## Matrix
+
##* Which measurements, and what frequency is planned during assembly?  
−
##* How often are horizontal deviations measured? (every layer?)
+
##* What documentation is recorded at each stage?
−
##* How often are transverse deviations measured? (every layer?)
+
−
##* How often are vertical deviations measured? (between pressing?)
+
−
##* Which measurements, and what frequency is planned for dimensions of the matrix during stacking?  
+
−
##* What documentation is recorded after each layer is added?
+
 
# Recovery Procedures
 
# Recovery Procedures
−
## What are the procedures for reporting an anomally in measurements during the stacking?
+
## What are the procedures for reporting an anomally in measurements?
−
## What are the procedures for rectifying any problems encountered during stacking? Is this documented?
+
## What are the procedures for rectifying any problems encountered during assembly? Is this documented?
−
# Acceptance Testing of Machined module
+
# Acceptance Testing of completed module
 
## How are the dimensions checked and verified against drawings?
 
## How are the dimensions checked and verified against drawings?
 
## How is the light transmission measured for a completed module?
 
## How is the light transmission measured for a completed module?
−
## How is the uniformity of transmission determined?
 
 
## What criteria are used to accept a completed module before shipment?
 
## What criteria are used to accept a completed module before shipment?
−
## How are the modules going to be checked with cosmic-rays?
+
## What testing will be done to verify performance?
 
## How many modules will be tested with cosmics?
 
## How many modules will be tested with cosmics?
 
# Tracking
 
# Tracking
 
## Are all travelers specified for the project?
 
## Are all travelers specified for the project?
−
## What information is recorded for the fibers?
+
## What information is recorded for the pmts?
−
## What information is recorded for the lead?
+
## What information is recorded for the lead glass?
−
## What information is recorded during matrix fabrication? How may for each layer?
+
## What information is recorded during assembly fabrication?  
 
# Schedule
 
# Schedule
 
## How is the schedule tracked?
 
## How is the schedule tracked?
−
## Note: Time for completion of a module should be revisited after completion of the first two production modules.
+
## Note: Time for completion of a module should be revisited after completion of the first batch of modules.
 
# Reporting
 
# Reporting
 
## Is the reporting chain to the project clear?
 
## Is the reporting chain to the project clear?
Line 62: Line 45:
 
== Contract Requirements ==
 
== Contract Requirements ==
 
# Final Construction Plan
 
# Final Construction Plan
−
# Final Acceptance Test Plan
+
# Final Quality Assurance and Acceptance Test Plan
−
# Quality Assurance Plan.
+
  
 
== Testing and Tracking: Section 5 of the Statement of Work ==
 
== Testing and Tracking: Section 5 of the Statement of Work ==
−
=== Testing ===
+
=== SOW Section 4.0  ===
−
The vendor shall include a draft Acceptance Test Plan with their contract proposal with the final plan to be formally approved by JLab at the Readiness Review.  The following items must be included:
+
 
−
# Acceptance of lead sheets upon receipt
+
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.
−
# Acceptance of fibers upon receipt
+
 
−
# Acceptance of swaged lead sheets
+
This Quality Assurance and Acceptance Test Plan must include the following:
−
# Acceptance of fibers during sorting
+
 
−
# Dimensional tests of aluminum base plates
+
# A Component Inspection Plan, comprised of:
−
# Dimensional tests of lead-scintillation matrix during stacking
+
#* Inspection of all materials received from the vendor’s suppliers and subcontractors and the recording of this information.
−
# Acceptance of completed modules based on the following criteria:
+
#*  Obtaining and recording of all material certifications and analyses.
−
## Dimensional testing of modules after machining
+
#* The calibration and identification of standards and instrumentation used for testing; the intervals between calibrations are also to be defined.
−
## Measurement of light transmission of completed modules.
+
#*  Establishment of inspection points for the incoming components, which will measure critical parameters.
−
## Determination of the uniformity of transmission across the face of the BCAL module, e.g. digital photos showing the number of damaged fibers.
+
#*  The recording of all inspection data in such a manner so that the history of a component can be readily traced.
−
# Measurements of the response of a sample of completed modules to cosmic rays.  
+
#*  The submittal to JLab of all data related to the above.
 +
# 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.
 +
# 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 ===
 
===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.
 
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.

Latest revision as of 15:10, 3 March 2010

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.

Retrieved from "https://halldweb.jlab.org/wiki/index.php?title=Fcal_Readiness_Checklist&oldid=17398"