MODULE : ANL-14

@MSU

ATLAS TILECAL 

OPTICS INSTRUMENTATION  CHECK LIST

Cover Sheet

REF

REV: 2.2 June 16, '00

TASK

DESCRIPTION

QC Page

1

MODULE PREPARATION

2

2

TILES INSTALLATION

3

3

ROUTING PREPARATION

 

4

PROFILES AND FIBRES INSTALLATION

4

5

FIBRES ROUTING

5

6

FIBRES BUNDLES GLUING

6

7

POLISHING AND CUTTING

 

8

SECURE FIBRES BUNDLES

7

10

CLOSEUP

 

NOTES

Work crew should initial each task that they work on.

Supervisor should indicate the date as each task is completed.

QC person should fill in the report for each QC task. The QC tasks must be completed before subsequent tasks are started.

Work crew shold fill in the materials list for all items used.

Note any problems, deviations from procedures, suggestions, etc. in the space at the bottom and on the reverse side of pages.

 

1. Module Preparation

Task

Description

Date

Work Crew

1.1

Setup Module 

7-11-00

MN, RW, BZ, TB

1.2

QC0:
Initial Inspection 

7-11-00

RJM

Item

OK

Not OK : List problems and repairs

Residual Glue

X

 

Spring Pins

X

 

Plate/Weld Bar Edges

X

See note

Submodule Shims and Spacing

X

 

Pained Surfaces

See Note

Slot Widths

See Note

Contaminants

X

 

Task

Description

Date

Work Crew

1.3

Clean out Slots

7-12

TB

1.4

Clean out Source Holes

7-12

TB

1.5

Cover Holes in Girder

7-13

TB

1.6

Clean Module Surfaces

7-12

TB

1.7

Mark Cell Boundaries

7-13

RW, BZ, TB

1.8

Install Cell & PMT Labels

7-13

RW

NOTES:

    1. This module contained some of the earlier submodules produced at ANL. The paint layer was thick in some slots. There is also a large variation in the width of slots on some of the submodules. The widths alternate, wide, narrow, wide, etc. The bevel on the edges of the master plates also alternate. This indicates that the problem is probably due to a systematic bow in the plates which alternately adds and subtracts as every other plate is reversed.

2. Tile Installation

Task

Description

Date

Work Crew

2.1

Measure gaps for shims

7-16

RJM, DD

2.2

Install Shims

7-16

DD

2.3

Record Tile Batch Numbers

7-13:16

TB, BZ, Anna

2.4

Insert Tiles

7-13:16

TB, BZ, Anna

2.5

Insert Special ITC Tiles

7-20

TB

2.4

QC1:
Tile Inspection 

7-16

RJM

Item

OK

Not OK : List problems and repairs

Tile Color

X

Tile Sizes

X

Tile End Surfaces

X

Tile Wrappers

SEE NOTE

Task

Description

Date

Work Crew

2.5

Install Rods

8-14

TB

NOTES:

2.2 The shims were installed on the wrong side of gap #2, tile layer 1. The gap was wide enough so that the shims would fall into layer 2. Not noticed until after the fibers had been glued and the problem with the fiber not centered on the tile showed up in the QC6 scan. The shims were removed an taped onto the sleeve to reinstall. Maybe this is the way to do this in the future. -RJM

    1. Had trouble with wrappers coming off of tiles because of paint in slots. Had to clean out the tile slots of the ITC submodule with saw blades.
    2. No rods were shipped with this module. We used the platics tubes to pin tiles while installing profiles.


3. Fiber Preparations

Task

Description

Date

Work Crew

3.1

Install LED Light Tubes 

7-20

RJM

3.2

Label Bottom of Aspirin Tubes

7-13

RW

3.3

Install Aspirin Tubes and Washers

7-13

RW

3.4

Install Fixation Rails

7-13

TB, BZ

3.5

Label Laser Fiber Bundles

7-25

BZ

3.6

Install Laser Fiber Bundles 

7-25

TB, BZ

3.7

Record Laser Fiber #

7-25

TB, BZ

3.8

Cover Girder Area

7-16

TB, BZ

3.9

Install ITC Fiber Supports

done

NOTES:


4. Fiber/Profile Installation

Task

Description

Date

Work Crew

4.1

Setup Profile Cart

7-16

AR, TB

4.2

Record Profile Batch Numbers

4.3

Insert Profiles/WLS Fibers

7-16

AR, TB, BZ

4.4

Install Fiber Separator Wires 

7-18

TB, BZ

4.5

Install ITC Fibers

7-19

TB

4.6

Record ITC Fiber #

7-20

RJM

4.7

Separate fibers by depth

7-18

BZ, TB

4.8

Make subbundles

7-19

AR, BZ

4.9

QC2: Verify Sorting 

7-18, 20

RJM

Item

OK

Not OK : List problems and repairs

Fiber Lengths

 

3 short fibers noted and replaced

Fiber Counts

X

Depth Sorting

X

Visual Light Levels

X

4.8

Remove Fiber SeparatorWires

7-19

NOTES:

4.4 We made our own D4 profiles/WLS fibers for this module.

 

5. Fiber Routing

Task

Description

Date

Work Crew

5.1

Route Sub-bundles To Aspirin Tubes

7-24

TB, BZ

5.2

Route the Laser Fibers

7-24

TB, BZ

5.3

QC3:
Verify Fiber Routing 

7-26

RJM

Item

OK

Not OK : List problems and repairs

Odd Side Cells

 

See QC sheets

Even Side Cells

 

See QC sheets

5.4

Insert Gluing tubes

7-25

TB, BZ

5.5

Insert Teflon Rods

7-25

TB, BZ

5.6

Register and Secure Fibers in Aspirin Tubes

7-25

TB, BZ

5.7

Insert Dummy fibers

7-25

TB, BZ

5.8

QC4: Check Fiber Damage 

7-26, 27

RJM

Item

OK

Not OK : List problems and repairs

Broken fibers

X

  

Stress Crazing

  

Lots of damaged fibers, See QC sheets

Cladding Damage

  

Lots of damaged fibers, See QC sheets

Fiber Curvature

X

  

Fiber Contact

  

Lots of damaged fibers, See QC sheets

5.9

Secure the Sub-bundles

7-25

TB, BZ

NOTES:

5.8 There were lots of fibers that were replaced at this stage due to cladding damage and knicks that were found during inspection with the LED tube. Some of these were caused by a sharp burr on a section of the bottom edge of the girder. The burr had not been noticed before the fibers were installed. Other problem were thought to be due to fibers that had previously been removed from Module 1 and were being reused. Some were probably also due to careless handling.


6. Glue fiber bundles

Task

Description

Date

Work Crew

6.1

Prepare Glue Cartridges

8-18

MN

6.2

Glue Odd Side 

8-18

MN

6.3

Glue Even Side

8-18

MN

6.4

Reserve Samples of Epoxy

8-18

MN

6.5

Epoxy Cure

8-18:21

  

6.6

Remove Cable Ties from Silicon Tubes

Done

?


 


7. Polish Fiber Ends

Task

Description

Date

Work Crew

7.1

Setup the Polishing Machine

8/21

RW, TB

7.2

Polish Fibers, Odd Side

8/21

MN, RW, TB

7.3

Polish Fibers, Even Side

8/21

MN, RW, TB

7.4

Remove Polishing Machine

8/21

RW, TB

7.5

QC5: Inspect Fiber Ends 

8/21

MN, RW, TB

Item

OK

Not OK : List problems and repairs

Surface Quality

X

  

Visual Light Level

  

PMT 18 has 1 buried fiber

NOTES:

    1. D cell fiber from PMT 18 was replaced. After the QC6 scan, several other problems were discovered and fixed. One fiber toPMT 8 was kinked at the exit from the profile - replaced. One fiber to PMT 15 was replaced. One fiber to PMT 33 was misrouted (found in previous QC and incorrectly reported to be fixed) - replace. About 6 fibers in PMT 38 were not polished. About 5 mm of material was milled from the surface of the girder ring and this aspirin tube was repolished.

 

8. Secure fiber bundles

Task

Description

Date

Work Crew

8.1

Cut dummy fibers 

8-21

TB

8.2

Cut Gluing tubes

8-21

TB

8.2

Tie FiberBundles to Rails

8-28

TB

8.3

Install Cotton Belt

9-15

RJM

 

10. Close up

Task

Description

Date

Work Crew

10.1

Cover Module with Plastic Sheet

9-15

RJM

10.2

Cover Girder Ends

9-18

RJM

10.3

Install Plastic Source Tubes

9-18

RJM

10.4

Cover Source holes

9-18

RJM

10.5

Tape ITC Fiber Support Panels

9-15

RJM

10.6

Install Shipping Cover

 

 

NOTES:

Shimming Data Sheet

 

   

Measured Widths

(mm)

Shims Required

Gap #

Tile

Oddside

Even side

1/2

3/4

1

1

1

4.0

4.0

2

1

4.4

4.4

3

1

4.6

4.4

1

4

1

5.0

4.6

1

5

1

5.2

4.6

1

6

1

5.4

5.4

1

1

7

1

4.2

4.4

8

1

4.6

4.4

1

9

1

5.6

5.4

1

1

Total

1

1

11

4.0

4.0

2

11

4.4

4.4

1

3

11

4.4

4.4

1

4

11

4.2

4.4

5

11

4.2

4.2

6

11

4.4

4.2

7

11

4.4

4.2

8

11

4.4

4.2

9

11

4.4

4.4

Total

11

NOTES: 1. Measure Tile Slot 1 at the bottom of the slot and Tile Slot 11 at the top

(where the widths are assumed to be minimum)

  1. Required shims make the minimum slot width in the range 4:4.5 mm
  2. Gaps are numbered starting at the ITC end.

 

Materials List

Tile Size

Box #

Pkg. # (no of tiles) in order from ITC end

1

9,8

145,153,148,128,129,2,11

2

1

11,4,18,17,20,22,26

3

11

182,122,208,209,180,197,176

4

16,2

176,193,181,180,179,2

5

30

390,335,349,353,343,391,336

6

42,41

493,504,455,494,503,482,500

7

14,13

121,116,122,126,271,268,284

8

39

352,346,341,347,351,342,350

9

38

335,330,344,331,340,337,345

10

6,48

60,55,36,283,379,385,386

11

48,43

199,200,196,201,707,203,163,171,164

BATCH #

WLS/profile

Long Profiles

Short Profiles

A12B11

4

4

A13B11

4

4

A13B12

4

4

A14B12

4

4

A14B13

4

4

A15B13

4

4

A15B14

4

4

A16B14

4

4

A16B15

4

4

C10

Made @ MSU

Made @ MSU

D4

Made @ MSU

Made @ MSU

ITC Fibers #:

Right:71

Left:71

Aspirin Tubes :

Laser Fiber #'s

Odd Side:EB51

Even Side:EB54

Epoxy Batch #

Resin:N9C129216

Hardner:93015216

 

 

QC Problem List

Tile Layer

Cell

Side

Tile *

Problem

Fixed ?

11

D4

O

1

Fiber Crazed

Replaced

11

D4

O

5:8

Low Light

Replaced

11

D4

O,E

9:17

Mixed in ITC assembly

Replaced

10

D4

E

6

Glue on fiber

Replaced

10

D4

O

1

Crazed

Replaced

10

D4

O,E

Fibers uneven lengths

Trimmed

10

D5

E

5

Crazed

Replaced

10

D5

E

41

Crazed

Replaced

11

D6

E

6

Cladding Damaged

Replaced

10

D6

O

23

Cladding Damaged

Replaced

7

B11

E

5

Nicked Fiber

Replaced

7

B13

E

16

Nicked Fiber

Replaced

7

B13

E

28

Cladding Damaged

Replaced

6

B14

E

6

Wrong length fiber

Replaced

3

A14

E

25

Nicked Fiber

Replacedd

11

D4

O

10

Nicked fiber

Replaced

11

D4

O

13

Cladding damaged

Replaced

B12

Left bundle misrouted to A14

fixed

2

A15

O

26

Fiber misrouted into B14

Fixed (not)

10

D4

O

9

Nicked fiber

Replaced

10

D4

O

10

Nicked fiber

Replaced

11

D5

O

12

Nicked fiber

Replaced

11

D5

O

22

Nicked fiber

Replaced

11

D6

O

25

Nicked fiber

Replaced

9

C10

O

2

Fiber Crazed

Replaced

9

C10

O

4

Fiber Crazed

Replaced

9

C10

O

6

Fiber Crazed

Replaced

10

D6

E

31

Nicked Fiber

Replaced

10

D6

E

33

Nicked Fiber

Replaced

10

D6

E

37

Nicked Fiber

Replaced

11

D4

E

1

Nicked Fiber

Replaced

10

D4

E

16

Nicked Fiber

Replaced

10

D4

E

17

Nicked Fiber

Replaced

10

D5

E

1

Profile Loose

Fixed

5

B14

O

17

Fiber routed into A15

Fixed

1

A15

O

3

Damaged Fiber

Replaced

1

A15

O

3

Loose profile

Fixed

1

A15

E

14

Damaged Fiber

Replaced

1

A13

E

10

Damaged Fiber

Replaced

2

A15

E

12

Damaged Fiber

Replaced

4

B14

E

12

Cracked Fiber

Replaced

3

B14

O

2

Crazed Fiber

Replaced

4

B14

E

32

Crazed Fiber

Replaced

3

B12

E

4

Cracked Fiber

Replaced

7

C10

O

1

Fiber too short

Replaced

8

C10

O

5

Damaged fiber

Replaced

10

D6

E

37

Damaged fiber

Replaced

10

D5

O

33

Damaged fiber

Replaced

5

B15

O

1

Damaged fiber

Replaced

5

B14

E

30

Damaged fiber

Replaced

11

D4

E

17

Damaged fiber

Replaced

NOTE: Tiles are numbered from the beginning of the cell, starting at the tile closest to the ITC end of the module. Count every other profile to count the tiles. Odd tile layers start at the cell boundary (count from the first profile), even tile layers start with a spacer plate (count from the second profile). The tile counting stick makes it easier to locate the tiles.


This page maintained by: - RJM