Optical Instrumentation Tasks Quality Control tasks are indicated in red Work Crew: t- senior technician; g- general technician or (2) students; QC- engineer or physicist Task/sub tasks Work Crew Duration (hours) Manpower (manhrs) 1) Prepare module: 15-21 22-34 Secure module on assembly stand 1t + 1g 1 2 Setup work platforms, light tent, supplies tables 2g 1 2 QC0: Module inspection QC 2 2 Fix as necessary: Epoxy in slots 2g 0-4 0-8 Spacer rings in slots 2g 0-1 0-2 Burrs on weld bars 2g 0-1 0-2 Clean module surfaces 1g 2 2 Insert shims in slots between sub modules 1t + 1g 3 6 Fix the rails that will hold the WLS/laser fibres 1g 2 2 Insert "aspirin" tubes 1g 2 2 Mark cell boundaries/numbers and label PMTs 1t + 1g 2 4 2) Install tiles: 9-13 17-21 Insert tiles into slots 1t + 1g 8 16 QC1: Inspect tile installation QC 1 1 Fix any displaced tiles or wrappers 1g 0-4 0-4 3) Install tubes and rods: 2 4 Install clamp rods 1t + 1g 1 2 Install temporary source tubes (for the EBs) 1t + 1g 1 2 4) Routing preparations: 3 7 Install routing QC devices (light source) 1t 1 1 Install fiber separator wires 1g 1 1 Install ITC fiber assemblies (EB) 1g 1 1 Install the laser fibre bundles 1t + 1g 2 4 5) Insert profiles/fibers: 29 60 Insert ITC fibers into profiles (EB) 1t 2 2 Insert profiles into slots and sort fibres into depth segments 2g 22 44 QC2: Verify fiber lengths and sorting QC+ 1g 4 8 Secure profiles with tape 1t + 1g 3 6 6) Route fibers: 30 60 Make fiber sub-bundles 1t + 1g 6 12 Route sub- bundles to aspirin tubes 2g 18 36 QC3: Verify routing with a light source QC+1g 6 12 7) Insert and glue sourcs tubes: NA Barrel Only Insert straight tube sections Insert and glue curved tube sections 8) Make fiber bundles: 19 38 Fill aspirin tubes with dummy fibers 2g 2 4 Adjust fiber ends in the aspirin tubes 1t + 1g 6 12 Secure the fibers at the aspirin tubes with ties 2g 5 10 Secure the sub-bundles along the girder 2g 6 12 9) Glue fiber bundles: 6-54 12 Glue the fiber bundles into the tube 1t + 1g 6 12 Wait for the glue to cure 48 0 10) Secure fiber bundles: 3 5 Cut dummy fibre ends 1g 1 1 Tie fibre bundles inside the girder 1t + 1g 2 4 11) Polish the fiber ends: 13 15 Setup the polishing machine in the girder 1t + 1g 2 4 Polish the fiber ends 1t 6 6 Remove the polishing machine 1g 2 2 QC4: Inspect the fiber ends QC 2 2 Clean out the girder 1g 1 1 12) Check/fix broken fibres: 12-18 24-36 QC5: Check for damaged fibres QC + 1g 12 24 Repair damaged fibres 1t + 1g 0-6 0-12 13) Close up the module: 6 10 Remove the fiber separator wires and trays 1g 1 1 Cover the module with Aluminum sheet 1t + 1g 4 8 Attach girder end plates 1g 1 1 14) Cleanup 3 5 Remove assembly fixtures and tables 2g 2 4 Remove empty boxes and tools 1g 1 1 15) Management 0 45 Materials and supplies 1t 10 Scheduals and training 1t 20 Record keeping 1t 10 QC documentation QC 5 Total t: 96-102 g:196-218 QC:32 150-214 324-352