quarterly review october 5, 2001 1 quarterly review october 5, 2001

1

Quarterly ReviewOctober 5, 2001

QUARTERLY REVIEW

October 5, 2001

2


This Page Intentionally Left Blank

3


GNIRS Quarterly Review

Table of Contents

• Introduction Pg 4

• Project Summary Pg 7

• Configuration & Integration Pg 29

• Project Management Pg 67

• Appendices Pg 89

4


Introduction• This is the 6th GNIRS Quarterly Review

• GNIRS is in the final design and fabrication phase– All bench assemblies are complete– Mechanism testing is underway– Integration will start this month

• We are still on track for delivery in fall of 2002

5


Outline

• Project summary– Last QR Response– Progress Overview– Cost and Schedule Status

• Problems and Concerns • Configuration Update• Technical Progress• Project management• Plans for next review

6



7


Project Summary

• Response to last QR report• Progress overview• Summary schedule• Work left• Budget and expenditures to date

8


Response to June QR - Issues to be reviewed

• Late delivery of the OIWFS– Contingency plan

• 2 month schedule slip

• Completion of planned items

• Documentation– ATP payment milestone

– Rotary Prototype report

– Linear prototype report

– Change orders

• Status of dewar warm-up controller

• Definition of systems engineering effort

• Fabrication delays– Vendor performance

– Amount of rework

• Flexure rig availability

• Rolling wave (labor)

• Staffing – in design drafting area

• IFU late delivery

• Status of bulkhead assembly

• Software– NIRI Code version

– OCSwish

9


Response to June QR

• Late delivery of the OIWFS - Contingency plan

– The contingency plan that was agreed upon was to install the OIWFS bench with mass models and continue with integration. Gemini would be responsible for integrating the OIWFS components at a later date.

– Implementing this plan was not necessary as the components did eventually arrive and can be integrated without serious schedule impact.

• 2 month schedule slip– The project is considered to be behind schedule by about 2 months. This

lag was specific to the Design and Fabrication phase of the project. Schedule re-planning has been done to minimize the impact on the integration phase. The effect is to deliver the instrument in September rather than in August.

10


Task StatusITEM STATUS COMMENT

Complete design of all fixed assemblies Not Complete – 17 of 19 fixed assemblies completed design

Should complete by mid-November

Complete fabrication of all mechanisms Not Complete – Focus Assembly still in fabrication Should complete early October

Complete fabrication of all benches Complete

Complete fabrication of Bulkhead Assembly Not Complete – Release delayed for completeness, delivery impacted by changes and expanded work scope

Delivery scheduled in November; includes vacuum test of complete assembly

Complete fabrication of most dewar components Not Complete Completion expected mid-December

Complete 75% of mechanism and optical sub-assembly testing

Not Complete – Mechanism testing delayed by higher priority work on benches and Bulkhead Assembly

Testing should complete by mid-December

Receive all optics Not Complete – Replica mirror contract had to be re-bid due to vendor non-performance; one camera lens failed inspection

Optics should complete by mid-November

Complete electronics thermal enclosure fabrication and checkout

Complete

Complete initial software coding (of Component controller code)

Complete – Component Controller Code finished EPICS code still in work

Start testing of Component controller software Complete – Code has been tested as far as possible until more hardware becomes available.

All testing should be complete by mid-December

Complete OIWFS component integration Not Complete – OIWFS bench required rework as components did not match ICD as specified; documentation incomplete

Integration should be complete by mid-December

11


Response to June QR

• Planned Completions by this Quarterly Review – 3D and 2D design of all fixed assemblies

– Fabrication of all mechanisms

– Fabrication of all benches

– Fabrication of the Bulkhead Assembly

– Fabrication of most dewar components

– 75% of mechanism and optical subassembly testing

– Receive all optics

– Electronics thermal enclosure fabrication and checkout

– Initial software coding

– Start testing of Component Controller software

– OIWFS component integration

12


Response to June QR

• Documentation and change orders– A draft outline of the ATP and commissioning plan has been

submitted to Gemini and reviewed. ATP is being developed, at Gemini’s request, in conjunction with the commissioning and training plan.

– A change order is in process which addresses acceptance testing, training and commissioning in Chile. Jay Elias has the action to produce a plan which will be based on the outline already submitted to Gemini.

– The rotary and linear prototype test reports were not deliverables. These items were reported on at the Mid-Fab Review and by internal emails and SDN’s sufficient to proceed with the design of the affected mechanisms.

13


Response to June QR

• Dewar warm-up controller– This controller is an ancillary box which is not needed until we

begin actual cold testing of the instrument. Fabrication is therefore a low priority task which has been scheduled to be done at a later date.

• Systems engineering effort– This effort has been reported as completed on all our status reports

as all tasks associated with the initial engineering effort in the baseline plan have been accomplished. There is a sustaining engineering function in which the systems engineer (Jay Elias) oversees the entire design effort and gives support as required. This will continue until the instrument is delivered to Gemini.

14


Response to June QR

• Fabrication delays due to vendor performance and rework– We have experienced several delays from various vendors who are

fabricating components for the instrument, including rework on several components. This has had the most serious impact on the start of mechanism testing. We are past this period and all but one mechanism has finished mechanical fabrication.

– The Bulkhead Assembly and Dewar Shells have been delayed due to design changes to incorporate ballast weights and the cryo manifold. The delay amounts to about 1 month, but is not pacing the project as the vendor has also been contracted to do vacuum testing on the assembled Bulkhead Assembly and Dewar Shells. This task is considered part of integration testing.

15


Response to June QR

• Flexure rig need date– The flexure rig need date of mid-February 2002 was impossible to

attain due to the time required to procure the rig and build a building to house it. A more realistic date for having the facility in place and operational is mid-April. We had intended to test as soon as practicable in order to identify any flexure issues. We have adjusted our schedule to accommodate the predicted availability date.

• Rolling wave (labor)– The charts in the Project Management section show that we still

have a peak in labor resource need in the month of November. The peak is down from that shown in the last QR and is dissipating. This peak should be gone by the end of December.

16


Response to June QR

• Staffing in the design drafting area– At the time of the last QR design drafting was a critical path item. This is

no longer the case as the designers have accomplished the backlog of work that kept them on the critical path.

• IFU late delivery– Because of the delay, we are proceeding with mass modules. We will try

to accommodate Gemini in integrating the IFU when it becomes available.

• Status of Bulkhead Assembly– The design took longer than originally planned, and the final release to

fabrication was further delayed in order to ensure that the design was complete. Some design changes were required after the release. This is a complicated assembly with many parts. The unit is currently in fabrication and will be completed in October. It will then be leak tested with the Dewar Shells, which are also in fabrication at the same vendor. Images of these assemblies are shown in the Appendix.

17


Response to June QR

• Software: Which version of the NIRI Code is being used?– GNIRS is not using the NIRI code. This decision was based on much

discussion and on the recommendation of Hubert himself.

• Software: Look at using OCSwish– We have finally received the OCSwish tool and are using it. So far we

see no problems in using it for integration with our EPICS code. This is discussed in more detail in the software portion of this review.

18


Summary Project PlanJ F M A M J J A S O N D J F M A M J J A S O N D

CY-2001 CY-2002

Fixed Assemblies Design/Fab

Integration/Alignment

Bench Design/Fab/Assy

OIWFS/Post-Slit/Pre-Slit

WFS Integration/Alignment

Mechanism Design/Fab/Assy/Test

IFU Modules

Software Development/Code/Test

SW Plan/Low-Level/High-Level Code

Electronics Design/Fab/Test

Manuals

ATP

Ship

Training

MFR

Rotary Mechanism Flexure Tests

Mirrors/Lenses/Filters/Gratings/Prisms

Flexure Testing

N D J F M A M J J A S O N DCY-2000

Risk Reduction Prototypes

PFR

Structural Analysis

Bench Design/Fab/Assy

OIWFS/Post-Slit/Pre-Slit

Mechanism Design/Fab/Assy/Test

9 Mechanisms

Electronics Design/Fab/Test

Optics Procurement

OIWFS Hardware

Rotary Mechanism Flexure Tests

Systems Engineering

Mirrors/Lenses/Filters/Gratings/Prisms

19


Revised Bench Integration Plan9/15 10/1 10/15 11/1 11/15 12/1 12/15 1/1 1/15 2/1 2/15

Rad ShieldsDesign 11/8 Fab 12/15

Bulkhead Assy 11/28- Fab- Test

Assemble & Wire 2/4- Shields- Wiring- Cooling

1/8

Pre-Slit Integration 11/28 - Offner - POM - FW - IFU Mass - SD

Bench Painting

9/27 Post-Slit Integration 12/10 - PT - GT - ACQM - Focus - Camera - Collimator

Mate Benches 12/15

Install into top assy 2/5

OIWFS Integration

Camera Barrel Testing 11/15

Mechanism Testing 12/10

Warm Optics Test

Cold Tests

20


Project Status - Progress from August ’99

WBS element Mar Review Jun Review Oct Review5.0 Overall project 53% 66% 80%5.1 Management & Reporting 51% 61% 71%5.2 Systems Engineering 100% 100% 100%5.3 Mechanical 52% 70% 87%5.3.1 Mechanisms 66% 84% 92%5.3.2 Benches 55% 70% 100%5.3.3 Fixed Assemblies 16% 36% 62%5.4 Electronics 63% 59% 86%5.5 Software 49% 63% 85%5.6 Integration 0% 0% 2%5.7 Deliverables 0% 0% 0%5.8 Procurement 54% 67% 77%

21


Progress Overview

• The delivery date of the instrument is now September 25, 2002– Delays in vendor fabrication

– Bench and mechanism rework and testing delays

– Late release of assemblies to fabrication

• The project is currently 80% complete overall

• We have completed 131 of 224 total project milestones

• Our critical path is 3D and 2D design and fabrication of Radiation Shields

• Optics are complete except for the POM, Acquisition Mirror, one camera lens

• Electronics design and fabrication is 86% complete

• Software Component Controller code is functional – Limited testing completed

22


Comments on Last Quarter of Work

• Design activity concentrated on– Bench modifications and completion– Bulkhead Assembly fabrication– Fixed Assembly design and fabrication– General design cleanup (configuration control)

• Procurement– Mechanical – Optical

• Mechanism warm test and fit checks• Envelope waiver• ATP & Commissioning Plan

23


Progress and Schedule Comments

• The beginning integration tasks have been re-planned– No significant impact on fall-2002 delivery – now September 2002– We have 6 weeks schedule contingency left

• The mechanical design effort is virtually complete– Our schedule has been impacted by Bench and Bulkhead assembly

changes– 3D design is nearly complete

• Radiation Shields and the Thermal Distribution Assembly remain

• Fabrication will continue through November• Mechanism assembly/test has begun

– Filter wheel ready for cold test– Grating and Prism Turrets are ready for final warm test– Acquisition Mirror has been warm tested

24



25


Budget and Expenditures• Baseline Estimate (Jan 99 to completion)

• Labor $3,391,232• Capital $ 836,462• Total $4,227,694

• Current Forecast March Review June Review October Review

Labor $2,866,775$3,002,938 $2,957,389Capital $1,074,798$1,181,900 $1,138,285Total $3,941,573$4,184,838 $4,095,674

• Performance ratios March Review June Review October Review

BCWS $ 1,754,979 $ 2,863,855 $ 3,085,811 BCWP $ 1,611,542 $ 2,011,383 $ 2,526,319ACWP $ 1,742,651 $ 2,113,212 $ 2,762,963CPI 0.92 0.95 0.91SPI 0.92 0.70 0.82

26



27


Problems and Concerns• Optics – Pick-off and Acquisition mirrors, Camera lens

• New vendor contracted for replica optics - November delivery• Last camera lens has predicted November delivery

• Mechanical rework• Delay in mechanism testing• Design additions• Impact on vendor delivery of Bulkhead and Dewar Shell Assemblies

• OIWFS• OIWFS delivery was incomplete

• documentation incomplete

• Component interfaces were not well defined in the “ICD”

• IFU anticipated delivery in March 2002• We will use mass models and proceed

• Flexure testing delayed to mid-April 2002• Flexure rig delivery later than planned

28


Configuration Image

29


Configuration - Overview

• Additions• Envelope waivers• Weight & CG update• Design/fabrication status

30


Configuration - Additions• Cryocooler related items: differential pressure switch implementation

requested by Gemini in order to protect system against loss of pressure due to compressor shut-down; also has software implications (detector protection); helium gas heater required to ensure reliable operation at low temperature; system developed for Phoenix; minimal heat dissipation into environment with line insulation.

• Ballast weights: need indicated at last QR; 10-lb increments; allow shift of instrument moment up to ~350 ft-lb.

• Cable/hose routing & brackets: routing of all coolant/gas lines, cables with required brackets and attachment points. Patch panel on instrument facilitates installation, removal and service.

31


Configuration - Additions

• Cryocooler related items:– Differential pressure switch– Helium gas heater

• Ballast weights– Need indicated last QR; now located

• Cable/hose routing & brackets– Attachment points– Instrument patch panel

32


Configuration Image

33


Configuration - Envelope

• Envelope waiver approved prior to last QR• Additional waiver requested to accommodate

Instrument Patch Panel and He manifold approved

34


Configuration Image

35


Configuration - Weight• Weight updated

– New value is 3996 lb (1813 kg)– Change of +66 lb from June QR

• Mostly DPS & Gas Heater

– Small change does not justify effort to recompute center of gravity location given existence of ballast weights

• Weight estimates history– 3/01: 4113 lb (1866 kg)– 6/01: 3930 lb (1782 kg)– 9/01: 3996 lb (1813 kg)– Requirement (budget): 4413 lb (2000 kg)

36


Configuration - Design Status• Few remaining items: “punch list”

– Optical:• Telescope simulator

– Mechanical• Shields• Thermal distribution system• Test fixtures• Telescope simulator

– Electrical• Cabling • Dewar and mechanism wiring

– Software• Sequencer and interfaces

37


Configuration - Design Status

• Configuration control - drawing status (9/26/01)

– 957 drawings defined on the instrument• Released

– Assemblies - 156

– Details - 663

• Not Released– Assemblies - 54

– Details - 84

– Percent of drawings released – 86%

38



39


Integration & Test - Overview

• Subsystem testing– Fit checks

– Mechanism tests

– Optics tests

• Integration and alignment

40


Subsystem TestingGNIRS Subsystem tests

Test StatusSubsystem Test Type Warm Shop Warm Clean Cold Remarks

Environmental Cover M Partial Requires dewar shell for completion

Complete Bench O,E Cold check in assembled instrumentPre-Slit Bench M PartialOffner+Pickoff O Needs pickoff mirrorFilter Wheels (2) M Done Needs rest of bench for next stageSlit+Decker Slides M Partial In rework

Post-Slit Bench M Done Waiting for completion of mechanism testsCollimator Compensator M In fabPrism Turret M Needs fixturingGrating Turret M Needs fixturingAcquisition Mirror M Done Needs mirror replication & cleaningCamera Turret M Refers to assembled turretHub M Done Needs fixturing, cleaningShort Red Camera O Missing lensShort Blue Camera O Needs cleaningLong Red Camera O In fabLong Blue Camera O In fabFocus Mechanism M In fabDetector Mount E Status ?

OIWFS O,E Done Optical alignment after cleaningGimbal Mirror M Done Done Mechanisms tested at IfAFilter Wheel M Done Mechanisms tested at IfA; no cold testing on FWFocus Stage M Done Done Mechanisms tested at IfADetector Mount E Done Done Mechanisms tested at IfA

Test Types:M: mechanical, including optomechanical and switchesO: opticalE: detector tests

Test not possible or not requiredDone Testing complete for this phase

41


Subsystem Testing

• Qualifies sub-assemblies for integration– Performance can be checked prior to final integration

– Problems are isolated

– Maximum time for problem fixes

42


Subsystem Testing

• Fit checks– Done prior to final cleaning and painting

– Check of interfaces

– Includes vignetting checks

– Complete for all bench assemblies and all mechanisms except focus and collimator; including OIWFS assemblies

43


Subsystem Testing

• Testing of mechanisms as outlined in previous reviews– Warm functionality

– Warm flexure

– Cold functionality

– Tests (especially cold tests) without optics

44


Subsystem Testing

• Mechanism test plans– Test fixtures required for 3 turrets (2 fixtures)

– Forward bench tested as assembly• requires adaptor for cold test (test filter wheels, decker and slit

slides).

– Complete acquisition mirror & environmental cover tests

• requires assembled bench and dewar shell respectively

45


Subsystem Testing• Mechanism test status

– Initial warm tests complete for:• All 3 turrets• Filter wheels• Acquisition Mirror• All OIWFS mechanisms• Slit/decker slide in rework, retest on completion

– Final warm tests (after cleaning, w/ motor drives):• All OIWFS mechanisms done• Waiting for cleaning & fixturing on 4 mechanisms

– Cold tests will start in late October

46


Subsystem Testing

• Optics testing of “powered” sub-assemblies– Four cameras

– Offner relay

– Verifies performance, not required for alignment

– Camera tests require calculation of thermal, wavelength shifts

47


Subsystem Testing

• Optics test status– Short blue camera is ready for test

– Remaining camera tests waiting for mechanical fabrication(LR & LB) or lens fabrication (SR) to be completed

– Offner waiting for pick-off mirror (vendor problems)

48


Subsystem Testing

• Bench Temperature Control– Warm bench test– Cold test (9.4 kg mass 20 minute time constant)– Adjust control parameters for final

configuration

49


OIWFS Issues

• There are missing or corrupted detector micro-code files– readout from mux shows no noise

– potentially more serious, requires IFA support

• Some setup information incomplete

• Electronics documentation incomplete

• Operating software is working

• Mechanism status (9/20/01)– Zero is displaced on gimbal Y-axis

– Otherwise, hardware appears ok

50


Bench Integration• Add subsystems to bench after qualification

– Main (Post-Slit) bench painting complete • ready for sub-assembly integration

• integrate prism and grating turrets, acquisition mirror after tests

• add focus, collimator assembly on completion of fab & test (Dec.)

– Integrate Pre-Slit assembly (Offner, filter wheels, slit/decker) as a unit• testing should complete by end of November or early December

• add to main bench

– OIWFS assembly and alignment • As time allows

• Should complete by end of November

51


Bench Integration• Add subsystems to bench after qualification• 3 major assemblies integrated in parallel

– Main (Post-Slit) bench

– Pre-Slit assembly

– OIWFS

• Dewar assembly also parallel

52



53


Bench Integration

• Integration into bench permits warm optics and mechanical check (uses warm MUX)– Check (re-check) fit, alignment, repeatability

– Check image quality (“warm” predictions)

– Check flexure compensation calibration & performance (but not flexure calculations)

54


Dewar Integration

• Integration of cold structure into vacuum vessel – Dewar shell tested at vendor; should be delivered by December – Cryostat integration in parallel to bench integration

• Shield installation• Wiring and cold-stationing• Trusses, window, environmental cover

• Re-test with MUX– Possible limited flexure test

• Install engineering array• Last chance for installation of OIWFS prism or IFU without

disassembly

55


Dewar Integration

• Integration of cold structure into vacuum vessel • Re-test with MUX• Install engineering array• Last chance for easy OIWFS prism, IFU

installation

56


Dewar Integration

• Initial cool-down followed by tests outlined in August ‘99 test plan– Start February 2002

– Flexure testing using NOAO facility (copy of Gemini rig)• Scheduled for April 2002

• Opportunities for IFU installation during testing– Schedule penalty varies

57


Acceptance and Commissioning

• Acceptance Test Plan– Pre-ship AT - Tucson– Post-ship AT - CP lab– Final-AT - Gemini South telescope

• Commissioning Plan– Probably 2 runs– Flows into science verification

• Complete sequence ~4 months long

58



59


Software Components

• Top Level– Instrument Sequencer– Interfaces to detector, wavefront sensor, components controller,

OCS

• Components Controller– Control (CAD, CAR, Apply)– Status and Alarm database (SAD)

• Low Level Software– Motor Control– Temperature readback– Pressure monitoring

60


Software Work Remaining - Design

• Alarm and Status Propagation– Minor impact at various levels

– All other design complete

• WCS/DHS header information

61


Software Work Remaining - Coding

• Low Level (Hardware Interfacing)– No remaining coding planned

• Components control– Alarm and Health propagation

• Instrument Sequencer and Interfaces– Alarm and Health propagation

– Engineering User interface (ongoing)

62


Software Work Remaining - Testing

• Low Level– Prefer fully wired system for end-to-end test– Motors

• Multiple motors simultaneously• Determine distances between limits, switches, etc• Set speeds, acceleration, backlash parameters• Actual mechanism(s) needed

– Temperature Probes• Set calibration curve and individual offsets

– Pressure Sensor• Verify operation in final configuration

63


Software Work Remaining - Testing

• Upper Level -- EPICS– Engineering screens provide next level of test

• Top Level -- OCS compliance– use OCSwish

• new tool, in use in Hawaii, verifies OCS interface,

64


Software Work Remaining

• Simulation allows testing without hardware– Works only for motors.

• Hardware testing to take 2-5 days• Additional work

– Lab Support

– Conversion to GEM7 or GEM8

65


Software Work Remaining

• Software is done when – Motors, temperature readback, etc, work at command

line (low level)

– Engineering Screens provide required control and readback

– OCSwish/Acceptance test proves compliance with Gemini system

– GNIRS works on the telescope

66


Software Interface Issues

• Array Controller– Testing will verify correct interface to instrument sequencer

• OCS– OCSwish has been tested and is working

• OIWFS– Limited testing done shows mechanisms are functional

– We assume the OIWFS will provide good data• We have no means of testing actual data output

67


Project Management

• Project Status• Schedule & Planning• Milestones• Budget and Expenditures• Organization• Plans for Next Review

68


Project Status – Overview

• Critical path is Radiation Shield design and fabrication

• Bench integration starts in October– All three benches (Pre and Post Slit, OIWFS)

• Mechanisms and optics integration into benches starts in October– Bench fit checks are done

• Software and electronics checkout slated for completion by 15 December– Further checkout is waiting for mechanisms to be finished

69


Project Status – WBS 5.2 Systems Engineering

• Systems Engineering activities over this quarter included– Oversight of the top level design and interfaces

– Writing of the Acceptance Test Plan & Commissioning Plan

– Optical element evaluation• Included prisms/gratings/mirrors/lenses

– Envelope waiver submission

– Mechanism warm tests

– Bench temperature control tests

70


Project Status – WBS 5.3 MechanicalMechanism %Camera 90

Detector Focus 67

Environ Cover 99

Acquisition Mirror 93

Slit Decker 90

Filter Wheel 95

Grating Turret 97

Gratings 100

Prism Turret 98

Prisms 100

Motor Drives 100

Bench %Post-Slit 100

OIWFS 100

Collimator 95

POM/Offner 100

Fixed Assembly %Entrance Window 100Cryo-cooler 59Thermal Dist. 26Bulkhead Rad Shield 5LN2 Pre-Cool 91Opt Bench Mount 100Environ Cover Filter 15Bulkhead 75Front Rad Shield 8Rear Rad Shield 18Front Dewar Shell 70Rear dewar Shell 61Vert Inst Frame 77Horiz Inst Frame 57Dewar Mount Truss 44TE Mount Truss 70Shipping Container 0Handling Fixture 100

71


Project Status – WBS 5.3 Mechanical

• All mechanism fabrication complete except two camera barrels and the focus assembly.

• All benches complete; collimator assembly nearly done

• Fixed assembly 3D design remaining – Radiation shields (passive and active)

– Thermal distribution assembly

– Cryo-cooler and manifold

• Fixed assembly 2D detailing in-work– Dewar mount truss assembly

72


Project Status – WBS 5.4 Electrical

• Design activities are completed• Work remaining

– Fabricate the Thermal Enclosure to Dewar cables

– Harness the cold mechanisms and cold bench as they become available

– Support software testing

– Harness the Bulkhead Assembly

– Dewar warm-up controller fabrication

73


Project Status – WBS 5.5 Software

• Component Controller code virtually complete• Code has been tested as far as possible before integration

• Testing with mechanisms is underway

• High level (EPICS) code 70% complete

• Gemini OCSwish module received

74


Project Status – WBS 5.8 Procurement

• Major items remaining in procurement are the Bulkhead Assembly and Dewar Shells

• Two replica mirrors remain to be fabricated– New vendor is under contract, delivery expected in

November

• There are no major vendor fabrication contracts left to let– Remaining work is small parts/components

75


Project Status – Optics

• Lenses and Windows• Only one BaF2 lens for short red camera remains

• Vendor remaking the last lens

• Testing will proceed with the defective lens

• Camera testing is underway

• Mirrors• All mirrors received except for POM and Acquisition Mirror

• Filters• 7 filters ordered through UH consortium; 2 failed spec and

vendor may replace

76



77


Project Milestones by Quarter

As of 9/21/01

Calendar Year Quarter

Number of Milestones

DueRunning

Total

Number of Milestones

CompRunning

Total1999 4th 1 1 1 12000 1st 15 16 15 162000 2nd 13 29 13 292000 3rd 8 37 8 372000 4th 18 55 18 552001 1st 20 75 20 752001 2nd 32 107 32 1072001 3rd 40 147 24 1312001 4th 56 203 0 1312002 1st 13 216 0 1312002 2nd 3 219 0 1312002 3rd 5 224 0 1312002 4th 0 224 0 131

TOTAL 224 131

78


GNIRS Staffing FTE by Month

0.0

5.0

10.0

15.0

20.0

25.0

30.0

35.0

40.0

Month

FTE

Plan FTE Actual FTE

79


GNIRS Work by Month

0

1000

2000

3000

4000

5000

6000

Month

Hour

s

Actual Baseline Sep'01 Plan

80


Planned FTE ProjectionOct Nov Dec Jan Feb Mar Apr May Jun Jul Aug Sept

FTE Type NameME Muller 1 1 0.75 1 1 1 1 1 1 1 1 1ME Hileman 1MD Andrew 1 1 0.75 0.75 1 1 1 1 1 1 0.5 0.25MD Downey 1 1 0.75MD Rosin 1MD Circle 1 1 0.5EE Penegor 0.25 0.25 0.25 0.25 0.25 0.25 0.1 0.1 0.1 0.1 0.25ET George 0.75 0.75 0.75 1 0.75 0.75 0.75 0.75 0.75 0.75 1 0.5IM Stein 1 1 0.75 1 1 1 0.5 0.5 0.5IM Bennett 0.75 1IM Harris 1 1 0.5IM Lederer 1 1P Wolff 1P Ruckle 1 1 0.75 1 1 1 1 1 1 1 1 1

OE Ming 0.25 0.25 0.25 0.25 0.25 0.25GT Pina 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5

ENG Distler 0.5 0.5 0.5 0.5 0.25 0.25 0.25 0.25 0.25 0.25 0.25PA Eklund 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5AA Bowersock 1 1 0.75 1 1 1 1 1 1 1 1 1PE Davis 1 1 0.75 1 1 1PS Elias 1 1 0.75 1 1 1 1 1 1 1 1 1

PSS Joyce 0.5 0.5 0.75 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5PM Gaughan 1 1 0.75 1 1 1 1 1 1 1 1 1

Total 19 16.25 11.25 11.25 11 11 9.1 9.1 9.1 8.6 8.5 7.253040 2600 1800 1800 1760 1760 1456 1456 1456 1376 1360 1160

Spend Rate ($/mo) $114,480 $97,760 $67,360 $67,360 $65,840 $65,840 $54,288 $54,288 $54,288 $51,248 $50,640 $43,040

Total $ to go $786,432 21024

Oct Nov Dec Jan Feb Mar Apr May Jun Jul Aug Sept19.25 16.25 8.75 11.25 11 11 9.1 9.1 9.1 8.6 8.5 7.25

0

5

10

15

20

25

Oct Nov Dec Jan Feb Mar Apr May Jun Jul Aug Sept

FTE

81


FTE Projection• Table shows the resources forecast over the next fiscal year• There is a peak in the resources needed in Nov - Dec

– “Rolling wave” is spread over two months– The MS Project “wave” is an attribute of how MS Project works

when it assembles monthly data• It misrepresents the amplitude of the wave in November by the way it

handles its calendar– Hours actually spread over adjacent months can compress into one month,

showing resources overloaded one month and under utilized the next, making a peak need in resources look worse than it actually is

• We estimate approximately 21,000 hrs total needed to finish the project– This does not include commissioning or the impact of the pending

change order for delivery to Chile

82


GNIRS Cum ulative Work

0100002000030000400005000060000700008000090000

Month

Hours


77,730h

[78,469h w/sci.]

79,725h

52,649h

83


GNIRS Capital Spend Plan

$0

$200,000

$400,000

$600,000

$800,000

$1,000,000

$1,200,000

$1,400,000

Month

Dolla

rs


$759,192

$1,188,797

$1,070,777

84


Organization Chart

85


Director, NOAOJ. Mould

Director, NOAOJ. Mould

Gemini Projects Project Manager

N. Gaughan

Gemini Projects Project Manager

N. Gaughan

Administrative AssistantM. Bowersock

Administrative AssistantM. Bowersock

Project Scientist, Systems

Engineering J. Elias

Project Scientist, Systems

Engineering J. Elias

Mechanical EngineersG. Muller

E. Hileman

Mechanical EngineersG. Muller

E. Hileman

OpticalEngineerM. Liang

OpticalEngineerM. Liang

Electrical Engineer

J. Penegor

Electrical Engineer

J. Penegor

Mechanical DesignersJ. AndrewD. Rosin

E. DowneyD. Circle

Mechanical DesignersJ. AndrewD. Rosin

E. DowneyD. Circle

ProgrammerR. Wolff

ProgrammerR. Wolff

Project AssistantD. Eklund (.5)

Project AssistantD. Eklund (.5)

Electrical TechR. George

Electrical TechR. George

Support ScientistsD. Joyce

B. Gregory

Support ScientistsD. Joyce

B. Gregory

Procurement & Vender Liaison

A. Davis

Procurement & Vender Liaison

A. Davis

ETSL. Daggert

ETSL. Daggert

General Technician

J. Pina

General Technician

J. Pina

ProgrammerP. Ruckle

ProgrammerP. Ruckle

Instrument Makers

J. AndrewJ. Stein

R. BennettL. LedererR. Davis

Instrument Makers

J. AndrewJ. Stein

R. BennettL. LedererR. Davis

M&PB. Ditsler

M&PB. Ditsler

86


Plans for Next Review• The next Quarterly Review will be held in the January 2002 timeframe• The project will be into the Integration Phase

– Alignment and testing will have begun

• Mechanical design will be complete– Some rework items as identified in integration may remain

• Mechanical fabrication will be complete– except for items associated with flexure testing and shipping container– Some rework items as identified in integration may remain

• Mechanism and optical subassembly testing should be completed• Electronics fabrication and checkout completed

– Some cables may remain to be fabricated– Some rework items as identified in integration may remain

• Component Controller Software completed and tested with the Electronics– EPICS level software will still be in work

• OIWFS components integration onto the OIWFS bench will be completed

87


Conclusions

• The current project status shows us to be over 80% complete

• We have re-planned integration to preserve fall 2002 delivery – We are on track to deliver in September 2002

• We are very near the end of the design phase

• We are nearing the end of the fabrication phase

• Mechanism testing has started

• The estimated cost of GNIRS is not significantly changed from the August ’99 baseline– Estimated total cost: $4,095,674 - January ’99 to delivery

88



89


Appendix A – ImagesAppendix B – Milestones,

WBS ChartAppendix C – Envelope Waiver

90


Appendix A

Configuration and

Fabrication Images

91


Connector Feedthrough Panel

92


Aft Bulkhead

93


Aft Bulkhead Weldment

94


Aft Dewar Shell Top End

95


Forward Dewar Shell Top End

96


Forward Bulkhead Weldment

97


Forward Bulkhead Weldment

98


Bench with Slit-Slide

99


Bench on Handling Cart

100


Bench with Assemblies

101


Bench with Camera Turret Spindle

102


Bench with Collimator Gimbal Mount Ring

103


Camera Barrel

104


Camera Barrel

105


Collimator

106


Foreoptics Bench

107


Foreoptics Bench

108


Acquisition Mirror

109


Slit-Slide

110



111


Appendix B

Milestones

WBS Chart

112


Milestones since MFR (3/01)5.4.1.2.5 Motor Drive / Cryohead Control Chassis Complete 8/29/00 4/9/01 4/9/015.3.1.8.2.6 Grating Turret Drafting Complete 6/7/00 4/10/01 4/10/015.3.3.9.1.5 Bulkhead Assembly Design Complete 9/26/00 4/10/01 4/10/015.3.1.2.2.2.4 Long Red Camera Drafting Complete 10/4/00 4/13/01 4/13/015.3.1.104.5 Motor Drive Assembly Complete 8/2/00 4/16/01 4/16/015.3.1.2.3.1.3 Long Blue Camera Design Complete 5/31/00 4/17/01 4/17/015.3.2.4.2.3.3 Offner Assembly Fabrication Complete 9/11/00 4/24/01 4/24/015.3.3.14.1.4 Vertical Installation Frame Assembly Design Complete 12/4/00 4/27/01 4/27/015.3.3.15.1.5 Horizontal Installation Frame Assembly Design Complete 12/5/00 4/27/01 4/27/015.3.3.17.1.5 Thermal Enclosure Mount Assembly Design Complete 1/23/01 4/30/01 4/30/015.3.3.19.4 Handling Fixtures Complete NA 5/18/01 5/18/015.3.2.3.3.2.4 Collimator Compensating Mount Design Complete NA 5/23/01 5/23/015.3.2.3.2.1.5 Collimator Cover Box Design Complete 5/5/00 5/30/01 5/30/015.3.3.13.1.5 Rear Dewar Shell Design Complete 3/29/01 5/31/01 5/31/015.3.3.9.2.6 Bulkhead AssemblyDrafting Complete 2/21/01 6/1/01 6/1/015.3.1.8.6.4 Grating Fabrication Complete 11/28/00 6/1/01 6/1/015.3.3.12.1.5 Front Dewar Shell Design Complete 2/26/01 6/1/01 6/1/015.3.3.6.1.3 LN2 Pre-Cool Assemby Design Complete 11/16/00 6/6/01 6/6/015.3.1.2.3.2.4 Long Blue Camera Drafting Complete 11/27/00 6/6/01 6/6/015.3.3.17.2.6 Thermal Enclosure Mount Assembly Drafting Complete 3/14/01 6/8/01 6/8/015.3.2.3.2.2.4 Collimator Cover Box Drafting Complete 8/7/00 6/11/01 6/11/015.3.1.7.3.2 Filter Wheel Assembly Fabrication Complete 1/10/01 6/11/01 6/11/015.3.3.3.1.4 Cryo Cooler Design Complete 9/26/00 6/12/01 6/12/015.3.3.2.2.4 Detector Mount Assembly Drafting Complete 1/4/01 6/15/01 6/15/015.3.3.12.2.6 Front Dewar Shell Drafting Complete 3/16/01 6/19/01 6/19/015.3.2.1.8.3.2 Bottom Camera Cover Fabrication Complete 7/21/00 6/25/01 6/25/015.3.2.1.8.4.4 Bottom Camera Cover Complete 7/26/00 6/28/01 6/28/015.3.3.13.2.6 Rear Dewar Shell Drafting Complete NA 6/28/01 6/28/015.3.1.6.5.3.2 Slit/Decker Assembly Fabrication Complete 3/5/01 6/29/01 6/29/015.3.2.1.6.3.2 LCFMH Fabrication Complete 8/1/00 6/29/01 6/29/015.8.1.3.1 Flat Mirrors Acceptance 6/2/00 6/29/01 6/29/015.3.1.3.2.4 Detector Focus Assembly Drafting Complete 1/26/01 7/2/01 7/2/015.3.2.2.3.1 Receive and Inspect IFA WFS electronics 9/5/00 6/29/01 7/3/015.3.1.2.6.3.4 Camera Hub Fabrication Complete 12/4/00 7/5/01 7/5/015.3.2.1.6.4.4 LCFMH Complete 8/4/00 7/5/01 7/5/015.3.2.4.2.4.4 Offner Assembly Complete 9/22/00 7/16/01 7/16/015.3.2.3.3.3.4 Collimator Compensating Mount Drafting Complete NA 7/19/01 7/19/015.3.3.3.2.4 Cryo Cooler Drafting Complete 11/21/00 7/23/01 7/23/015.3.3.7.3.2 Optical Bench Mount Assembly Fabrication Complete 5/3/01 7/23/01 7/23/015.3.3.6.2.4 LN2 Pre-Cool Assemby Drafting Complete 12/7/00 7/25/01 7/25/015.3.2.3.1.3.3 CollimatorHousing Fabrication Complete 2/13/01 7/25/01 7/25/015.3.2.1.3.3 Post-Slit Bench Fabrication Complete 11/20/00 7/30/01 7/30/015.3.2.2.1.3.4 OIWFS Assembly Fabrication Complete 11/30/00 7/31/01 7/31/015.3.3.7.4.4 Optical Bench Mount Assembly Complete 5/21/01 8/9/01 8/9/015.3.2.3.2.3.2 Collimator Cover Box Fabrication Complete 8/8/00 8/17/01 8/17/015.3.2.1.7.3.2 Top Camera Cover Fabrication Complete 7/19/00 8/17/01 8/17/015.3.3.2.3.5 Detector Mount Assembly Fabrication Complete 2/22/01 8/22/01 8/22/015.3.2.1.7.4.4 Top Camera Cover Assembly Complete 7/24/00 8/22/01 8/22/01

113


WBS - Total Project

114



115


Appendix C

Envelope Waiver

116



117


Envelope Waiver

Supplemental Envelope Waiver Request

This request supplements our May 2001 envelope waiver request. It details some additional minor envelope violations due to routing of the high-pressure helium lines and other connections. The violations are indicated in the figures below, and described in more detail afterward.

This waiver request has been granted via e-mail as of September 27 by Doug Simons.

118


Figure 1. Summary of GNIRS envelope violations, include those previously approved by Gemini. The Gemini instrument envelope is shown overlaid on the instrument itself.

119


There are four areas where the helium lines violate the envelope:

The first location is at the bottom of the instrument, where the lines and manifold protrude approximately 66 mm outside the envelope. Although the instrument "feet" extend still further (92 mm), they can be removed if required. The footprint of the hoses is also much smaller, and we believe that it should be possible to miss them, even when the instrument is mounted up-looking and it is necessary to access the side-looking instrument located immediately above.

Hose loops from the forward cryoheads protrude outside the instrument in two locations (either side). The protrusion is about 100 mm in depth and roughly twice that in length, as indicated in the figure.

We are providing a connector panel at the instrument. All cables and hoses that run to the Gemini connector panel on the rotator would run from this instrument panel, facilitating installation of the instrument. However, the panel also protrudes outside the envelope, by a maximum of ~120 mm. The panel runs about half the height of the instrument, so there is still good access to the corners of the ISS cube, where GNIRS will be attached.

quarterly review october 5, 2001 1 quarterly review october 5, 2001

Documents