C. Parente (HL-LHC Technical Quality Officer)
Date: 28.10.2014
Contents
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Documentation management
Specifications process
Specifications template
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General approach
Contents, inputs & outputs
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Preparation of functional/engineering specifications for HL-LHC
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Documentation types
Baseline documentation:
Documentation that will have to be stored and updated until the dismantling of the LHC and
that is under configuration control
 related to “configured items”, i.e., entities within a given system architecture that are
also under configuration control (ref.: LHC-PM-QA-304)
Non-baseline documentation:
Documentation that are required for the well functioning of the project but which storage
will not be considered critical after the commissioning phase.
HL-LHC is an upgrade of LHC and therefore all documents will be
stored and managed according to the LHC procedures:
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LHC-PM-QA-202: Document types and naming conventions
LHC-PM-QA-303: Documents and parameters process and control
LHC-PM-QA-305: Drawing and 3D model management and control
LHC-PM-QA-304: Configuration management – Change process and control
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Baseline documentation (1/2)
EDMS #1361462
From system requirements
to technical solutions and
products
Project management
Acquisition
Technical
Safety
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Baseline documentation (2/2)
EDMS #1361462
Safety File
Links to already
existing documentation
will be made,
whenever required
Project management
Acquisition
Technical
Safety
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Documentation storage
EDMS/CDD*
MTF
*CDD for drawings (& 3D models)
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EDMS documents storage
Baseline documentation
Non-baseline documentation
EDMS training to all
WPL/WPE
Image in the HL-LHC
Project Documentation
Create documents in context:
HL-LHC-WP: High Luminosity LHC Workpackages
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Use appropriate templates
Template
EDMS #
Functional/engineering specifications
1372969
Interface specifications
1398340
Procedures
1398341
Reports
(except non-conformity reports)
1398344
Non conformity Report
112679
Engineering Change Requests
103574
Minutes of meetings
1311287
Other (general purpose)
1311288
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Define document reference naming
Mandatory
Baseline
Not mandatory
Non-Baseline
Idem to baseline
Controlled number (based on last used)
According to LHC-PM-QA-202
LHC naming portal & WP systems architectures
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CDD - Drawings/3D models
Example (QQS folder)
•
Associated to each equipment code (for the entities identified in the
system architecture)
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MTF
Example: LQASA
Fabrication and installation processes workflow
(quality assurance and quality controls)
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Preparation of functional/engineering specifications for HL-LHC
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HL-LHC life-cycle processes overview
Ref.: EDMS #1316570
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Specifications process
Selection of
technical standards
Definition of QA &
QC processes
Conceptual
specifications
Technical risks assessment
(reliability, maintainability)
Lower-level entities
requirements &
verification criteria
Systems requirements
& verification criteria
Engineering
specifications
FS/ES template
Launch Safety
Agreement (LSA)
Functional
specifications
Systems
architecture &
interfaces
Acquisition strategy
Interface
specifications
Specifications
tree
Concept
Detailed
Preliminary
Design
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Differences between Functional and
Engineering specifications
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Functional (“Performance”, “Design-to”)
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States the requirements in terms of the required results and the
criteria for verifying compliance, without specifically stating how
the results are to be achieved
Describes the functional requirements for an item, its
capabilities, the environment in which it must operate, and any
interface, interoperability, or compatibility requirements
Engineering (“Detail”, “Build-to-print”)
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Provides preconceived solutions to requirements and describes
exactly how an item is to be produced.
Identifies materials to be used, specific parts and components,
and how the item is to be fabricated and assembled
Functional specifications are used during the systems development and
preliminary design while engineering specifications are produced in the detailed design
phase although in they are usually a mix of functional and engineering specifications
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Preparation of functional/engineering specifications for HL-LHC
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Specifications template
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General overview
Discussed with
the QMC
Main contents of
MS/IT template
Requirements
definition
(conceptual
specifications)
Introduction
Scope of supply
Functional
specifications
In-kind/In-house
construction
Applicable documents
Industrial
procurement
Technical requirements &
Verification
Documentation
Engineering
specifications
Performance of the Contract
CERN contact persons
From existing MS/IT template
Annexes
From FS/ES template
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Acquisition process
Inputs
Outputs
Acquisition
Acquisition
strategy
Internal/Collaboration
Agreement
In-kind/in-house
construction
or
Functional
specification
MS/IT/DO
specification
Industrial procurement
Engineering
specification
SCR
Contract
Procurement
templates
List of specification
committee HL-LHC
members
SCR: Specification Committee Review
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Fundamental aspects
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The approach to the specifications template
is based on:
1. Identification of the “entities” falling under the
scope of the specification, and their architecture
2. Identification of the processes through which
each “entity” is obtained
3. Specification of requirements entity by entity, in
a bottom-up sense (grouping the entities
requirements is possible whenever they are
identical
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Entity architecture
HL-LHC
System #1
Sub-system
#1.1
Equipment
#1.1.1
Assembly
#1.1.1
Part
#1.1.1.1
Component
#1.1.1.1.1
System #2
(…)
System #N
Sub-system
#1.2
Equipment
#1.1.2
Equipment
#1.2.1
Assembly
#1.1.2
Part
#1.1.1.2
Example: entities falling under the scope
of a specification
Component
#1.1.1.1.2
Component
#1.1.1.1.3
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Example
WP4
Crab Cavities Cryomodule (SPS)
Crab cavities
(ACF)
SPS prototype
(ACF)
Cryomodule
(ACFGA)
Vacuum vessel
(ACFVT)
External
supports
(HACF)
Cryostat
components
(ACFAC)
Dressed cavities
(ACFDC)
Cryogenic
circuits
RF services
(ACFSV)
Instrumentation
(ACFIS)
Main coupler
(ACFMC)
Bare cavities with interfaces
(ACFCA)
Vacuum valves
(VVG)
LLRF & Fast
Controls
(ALL)
RF racks
(AY)
Supports
Tuning system
(ACFTU)
Slow controls
(AS)
Thermal shield
Helium vessel
(ACFHT)
Transmission
lines
(ACFWG)
Warm magnetic
shield
HOM couplers
(ACFHC)
Pick-ups
(APW)
Cold magnetic
shield
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Processes
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Materials
Machines/Equipment/Tools
Methods/Procedures
Training/qualifications
Verifications/Tests
Environment
Process(es)
#1.1.1.1.1
Component
# 1.1.1.1.1
Component
# 1.1.1.1.2
Processes through which the
entities are obtained (e.g., design,
manufacture, installation,….)
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Materials
Machines/Equipment/Tools
Methods/Procedures
Training/qualifications
Verifications/Tests
Environment
Process(es)
#1.1.1.1
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•
•
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Part
# 1.1.1.1
Component
# 1.1.1.1.3
Part
# 1.1.1.2
Materials
Machines/Equipment/Tools
Methods/Procedures
Training/qualifications
Verifications/Tests
Environment
Process(es)
#1.1.1
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Assembly
# 1.1.1
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Example
To obtain the required “entities”, or products, previously identified
Simplified processes for bare cavities (with interfaces)
Manufacturing
Shaping &
machining
Cleaning
Vacuum
Brazing
Design
EB Welding
Delivery
Packaging &
shipping
Dimensional
checks
(…)
Finalization of manufacturing process
Chemical
polishing
(…)
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Leak tightness
tests
RF expected
performance tests
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Specifications template
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Main contents
EDMS #1372969
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Scope
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Description
Life-cycle overview
Identification on the HL-LHC system
architecture
Processes identification on the HL-LHC
system life-cycle
Applicable documents
Technical requirements for [Entity #1]
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Description
Materials
Physical characteristics
Operational modes and states
Reliability
Maintainability
Inspectability
Availability
Dismountability
Interfaces
Environmental conditions
Design
Manufacturing
Delivery
Installation
Logistics
Disposal
Any other requirements…
Verification of [Entity #1]
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Technical requirements for [Entity #N]
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•
•
(…)
(…)
Verification of [Entity #N]
Documentation
Appendix(es)
Qualitative assessment
(supported by TQO)
Completed by
Interface specifications
Processes definition
(supported by TQO)
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Flexibility:
•
Sections can be added if needed
or removed (when not applicable)
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Re-adjustment of structure
(grouped requirements for entities
in each section) whenever
requirements are identical
27
Hazards assessment
EDMS #1361970
Required to obtain
Launch Safety Agreement from HSE Unit
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Per individual entities or,
Per entity life-cycle
Example:
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Dismantling (old)
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Construction (design, manufacture)
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Installation
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Operation/Maintenance/Interventions
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Dismantling (new)
Optimization will be made
whenever hazards are identical
Contact person  PSO: Th. Otto
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Specifications process
Selection of
technical standards
Definition of QA &
QC processes
Conceptual
specifications
Technical risks assessment
(reliability, maintainability)
Lower-level entities
requirements &
verification criteria
Systems requirements
& verification criteria
Engineering
specifications
FS/ES template
Launch Safety
Agreement (LSA)
Functional
specifications
Systems
architecture &
interfaces
Acquisition strategy
Interface
specifications
Specifications
tree
Concept
Detailed
Preliminary
Design
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Selection of technical standards
EDMS #1360646
Maps of standards have been created based on LHC specified technical
standards. Since LHC systems can be related with HL-LHC WPs, these
maps can be used as a starting point for the identification of the applicable
standards
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Identification of technical standards
Global overview
EDMS: 1380880
LHC / Related HL-LHC WPs
ICS Field
Generalities. Terminology. Standardization.
01.060 Documentation
01.080.30
01.100.01
01.100.20
01.100.30
Services. Company organization, management and
03.120.10 quality. Administration. Transport. Sociology
13.240 Environment. Health protection. Safety
13.260
17.020 Metrology and measurement. Physical phenomena
17.040.20
17.140.50
17.160
17.200.20
19.100 Testing
23.020.30 Fluid systems and components for general use
23.020.40
23.040.01
23.040.10
23.040.40
23.040.60
23.040.70
23.060
23.160
25.040.40
25.160.01 Manufacturing engineering
25.160.10
25.160.20
25.160.40
25.160.50
25.220.20
25.220.40
29.030 Electrical engineering
29.035.01
29.035.20
29.045
29.050
29.060.10
29.120.50
29.120.70
29.130.20
29.160
29.160.30
29.180
29.200
Group
Sub-group
EDMS
RF
Collimators
Powering
DC powering
and quench
protection
Cryogenics
Vacuum
Beam
monitoring
Transfer lines,
injection and
beam dumping
3
4
5
6
6&7
9
12
13
14
1360514
Quantities and units
Graphical symbols for use on mechanical engineering and
construction drawings, diagrams, plans, maps and in relevant
technical product documentation
Technical drawings in general
Mechanical engineering drawings
Construction drawings
Graphical symbols
Technical drawings
Quality
Protection against excessive pressure
Protection against electric shock. Live working
Metrology and measurement in general
Linear and angular measurements
Acoustics and acoustic measurements
Vibrations, shock and vibration measurements
Thermodynamics and temperature measurements
Non-destructive testing
Fluid storage devices
Quality management and quality assurance
Properties of surfaces
Electroacoustics
Temperature-measuring instruments
Gas pressure vessels, gas cylinders
Cryogenic vessels
Pipeline components and pipelines in general
Iron and steel pipes
Metal fittings
Flanges, couplings and joints
Hoses and hose assemblies
Technical
requirements
Pipeline components and pipelines
EB welding
Valves
Vacuum technology
Industrial automation systems
Welding, brazing, soldering
1360511
1360512
1360513
1360523
1360509
1360508
1360520
1360519
1360518
1360522
1360521
1360502
1360482
1360483
1378546
1360479
1360480
1360481
1360478
1360485
1360484
1360462
1360458
1360457
1360459
1360455
1360456
1360460
1360461
1360465
1360464
1360464
1360470
1360463
1360473
1360467
1360466
1360471
1360469
1360469
1360472
1360468
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Example
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Selected standards
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ASME BPVC Section
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IX PART- QW
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ISO 13919-2X
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X
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ASME BPVC
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Niobium – Titanium
Metallurgy
Relays
X
Switchgear and controlgear
Low voltage switchgear and controlgear
X
 Other products of non-ferrous
Rotating machinery transition pieces
Motors
metals
Transformers. Reactors
X
Rectifiers. Converters. Stabilized power supply
X
X
X
X
Fluid systems and components
for
Insulating materials in general
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X
general
Plastic and rubber insulating
materials use
X
X
 Pressure vessels
Wires
Fuses and other overcurrent protection devices
X
X
Manufacturing engineering
X
X
 Welded joints
Pressure vessel
Semiconducting materials
Superconductivity and conducting materials
Electrical wires and cables
Electrical accessories
X
Standards fields/groups
Welding, brazing and soldering in general
Welding processes
Welding consumables
Welded joints
Brazing and soldering
Surface treatment
Metallic coatings
Surface treatment and coating
1360510
Manufacturing engineering
Industrial process measurement
and control
 Welding
processes
Visual examination
of EB welds
Magnetic materials
Insulating materials
Magnets
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X
X
ASTM B884-11
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To be discussed and validated
by the project management
31
X
X
X
Quality assurance and quality controls (1/2)
Quality assurance and quality controls needed to meet the
requirements  input to MTF
Quality control step
 supported by validated technical standards
Materials EB welded joints
Equipment Supplier
Tools Supplier
EN ISO 9712 or SNT-TC-1A (ASNT) Training/qualifications minimum level 2
BC-11-QC
Visual examination
Procedure
ASME BPVC Section V
Acceptance criteria
An excel template exists but it has many limitations  a
dedicated tool (ideally embedded in MTF) would be
most advantageous
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ISO 13919-2 & Table 6 of Section 4.2.1
Report Yes
Record WIR
CERN control HP
32
Quality assurance and quality controls (2/2)
Quality assurance steps
 supported by validated technical standards and/or by CERN best practices
Materials Brazed assembly
Equipment Supplier
Tools Supplier
Materials SS flanges - Niobium tube
Equipment Supplier
Tools Supplier
Training/qualifications N/A
Training/qualifications ASME BPVC Section IX, part QB
BC-4-QA
BC-9-QA
Vacuum brazing
Chemical polishing
Procedure
Procedure
Section 3.8.5 (Annex 6.6) - to be
defined by supplier
Acceptance criteria
Section 3.8.6 & BPS (ASME BPVC
Section IX, part QB)
Acceptance criteria
N/A
N/A
Report N/A
Record MIP
CERN control N/A
Report No
Record MIP
CERN control N/A
Other CERN best practices used to support the specification (examples):
•
Niobium RRR 300 - Material Technical Specification N° 3300
•
Cleaning procedure for stainless steel components
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Risk assessment
•
Risk assessment allows to:
•
Identify the equipment, or processes, which
represent higher risks in a system life-cycle and how
these risks can be eliminated or mitigated
•
Definition and application of quality assurance
procedures and quality control tests
• Identify training/qualification requirements
• Identify and perform measurements/studies
•
•
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Identify standardization needs
Comply with CERN Safety rules
Particularly important in case of new
technologies and when technical standards for
construction are not available
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Reliability, Availability, Maintainability, Inspectability (RAMI)
Availability (A)
Technical risk assessment
Reliability (R)
Probability of a system
operating correctly over
its assigned operational
time
•
Engineering, fabrication,
assembly, installation,
verification and
commissioning processes
•
Technical
standards
•
Quality assurance
and quality control
•
Best practices
Maintainability (M)
Probability of returning a
failed/degraded system to operation in
a fixed time period, or average time to
100% repair
•
•
Spare parts policy
Environmental
constraints
– Radiation 
Remote handling
– Accessibility
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Inspectability (I)
Production time lost or
gained due to test and
inspection requirements
•
•
Regulations
Best practices
35
Thank you for your attention!
Questions?
For any questions/support on the presented activities
please contact TQO (C. Parente)
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Preparation of functional/engineering specifications for HL-LHC
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Systems architectures
HL-LHC
System
EDMS
Accelerator Physics & Performance
System #1
Sub-system
#1.1
Equipment
#1.1.1
Assembly
#1.1.1
Equipment
#1.1.2
Assembly
#1.1.2
System #2
Sub-system
#1.2
Equipment
#1.2.1
(…)
System #N
Magnets
1405220
RF & Accelerating cavities
1398306
Collimation
1405227
Cold Powering
1405222
Machine Protection
1405223
Collider-Experiments Interface
1405224
Cryogenics
1405225
Energy Deposition & Absorber
Part
#1.1.1.1
Component
#1.1.1.1.1
Part
#1.1.1.2
11 T Dipoles
1405221
Vacuum
1405228
Beam Diagnostics & Instrumentation
1405229
Beam Transfer & Kickers
1405230
Component
#1.1.1.1.2
Integration & (De-)Installation
Component
#1.1.1.1.3
Infrastructure, Logistics & CE
Hardware Commissioning
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Interface specifications
1. Identification
3. Requirements specification
External interfaces matrix
WP1 WP2 WP3 WP4 WP5 WP6 WP7 WP8 WP9 WP10 WP11 WP12 WP13 WP14 WP15 WP16 WP17
WP1
WP2
WP3
WP4
WP5
WP6
WP7
WP8
WP9
WP10
WP11
WP12
WP13
WP14
WP15
WP16
WP17
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EDMS #1398340
Can be used for external
and/or internal interfaces
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2. Definition
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Interfaces types
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Internal: within a given system
External: between different systems
Physical
External
Magnets-Cryogenics
Functional
Internal
Magnets
Temperature
Pressure
Mass-flow rate
Alignment requirements
(…)
A functional interface may exist without a physical interface.
A physical interface implies always a functional interface.
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How to specify requirements?
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Criteria:
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Each requirement shall be stated in such a way that an objective
verification can be defined for it.
Each requirement should be cross-referenced to the associated
verification.
Only requirements that are necessary, measurable, achievable, and
verifiable shall be included.
Requirements shall be worded to provide a definitive basis for
acceptance or rejection.
Requirements shall be described in a manner to encourage
competition.
Requirements shall be worded such that each paragraph only
addresses one requirement or topic.
Degree of detail: include only requirements (i.e., characteristics) of the system,
sub-system,…, component that are conditions for the entity acceptance
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