QUARTERLY REVIEW May 1, 2002

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QUARTERLY REVIEW May 1, 2002. This page intentionally left blank. GNIRS Quarterly Review. Table of Contents Introduction Pg 4 Progress Overview Pg 5 Technical Presentation Pg 7 Project Management Pg 23 Appendices Pg 53. Introduction. This is the 8 th GNIRS Quarterly Review
Transcript
QUARTERLY REVIEWMay 1, 2002This page intentionally left blankGNIRS Quarterly ReviewTable of Contents
  • Introduction Pg 4
  • Progress Overview Pg 5
  • Technical Presentation Pg 7
  • Project Management Pg 23
  • Appendices Pg 53
  • Introduction
  • This is the 8th GNIRS Quarterly Review
  • GNIRS is in the assembly and integration phase
  • Fabrication is complete
  • Any further modifications, etc. are considered part of integration
  • Mechanism testing is almost complete
  • Final mechanism (Focus assembly) in cold test
  • OIWFS integration is complete
  • Delivery is now scheduled for late November of 2002
  • Delays in subassembly testing and rework
  • Delays in fabrication of shields
  • Flexure test facility will be late coming on line
  • Progress Overview
  • The project is currently 91% complete overall
  • We have completed 195 of 225 total project milestones
  • Major activities over this quarter:
  • Mechanism testing
  • Design cleanup and final parts fabrication
  • Fine tuning and correction of errors
  • Shield fabrication
  • Bench assembly and wiring
  • Software code
  • Component Controller code complete
  • EPICS software complete
  • Any further code changes will be considered part of integration/test
  • This page intentionally left blankTechnical Presentation
  • Subassembly testing
  • Integration procedures
  • Telescope simulator
  • Flexure testing
  • Configuration update
  • Subassembly Testing
  • Mechanism warm tests
  • Configuration time, repeatability, flexure
  • Mechanism cold tests
  • Configuration time, repeatability
  • Optical assembly tests
  • Wavefront error, alignment
  • This page intentionally left blankInstrument AssemblyTop Assembly Integration PlanTelescope Simulator
  • Beam simulator is GNIRS test fixture, not facility simulator
  • Simulates Gemini telescope beam, including pupil
  • Field of view ~30 mm
  • 1-5 microns wavelength
  • Support XYZ stage with integrating sphere, light source and pinhole masks
  • Telescope SimulatorTelescope Simulator
  • Flex rig simulates telescope motion
  • 180 degree rotation about elevation axis, optical axis
  • Sample 90 degree increments for initial tests
  • Sample 30-45 degree increments for full flexure map
  • Flexure RigFlexure Testing
  • Displacement of telescope pupil on cold stop
  • Requirement 1% or less
  • Measure with pupil viewer
  • Flexure Testing
  • Slit-to-detector flexure
  • 0.1 pixel.hour = 0.4 pixel/unit gravity
  • Measure with pinhole arrays in slit mask
  • Measure with long and short cameras
  • Adjust calibration for compensation at collimator
  • Flexure Testing
  • OIWFS to slit
  • 10 microns/hour
  • Use dual pinhole mask, image one hole in each channel, displace mask to keep OIWFS image centered (“guiding”)
  • Configuration Update
  • Weight and CG
  • Revised Value = 4094 lb
  • limit = 4409 lb
  • increase 42 lb from last QR, -19 lb from 3/01
  • Change mainly due to shields, hence only small c.g. change
  • Spot check hardware against models
  • true weights within 2% of models
  • Drawing status
  • 1508 drawings released of 1613 total
  • This page intentionally left blankSummary OverviewLast QR responseSchedule updateCurrent integration planCost and ScheduleCurrent progressWBS reportWork/FTE projectionsCapitalCost to complete projectionMilestonesDeliverables projectionsGemini payments summaryWork still outstandingTelescope simulatorOutstanding fabricationElectronics and softwareProblems and ConcernsSRC lensCollimator mirrorIFU late deliveryOIWFS prism integrationPlans for Next ReviewProject ManagementItems to be completed by this QR3D/2D designMechanical fabricationElectrical fabrication and check-outComponents controller softwareOIWFS integration/testMechanism/optical testingParts cleaningDPS Change OrderChile delivery Change OrderResponse to January QRJanuary QR ResponseSchedule Update
  • Ship date has slipped to November 29th
  • Mechanism testing and shield fabrication has taken much longer than planned
  • Final block of schedule contingency is 4th cold test – 6 weeks
  • Critical path:
  • Mechanism testing
  • Dewar vacuum checks
  • Instrument assembly and wiring
  • Flexure testing
  • SRC lens integration
  • Cold testing
  • Schedule Update
  • Top Assembly Integration should start by 15 May
  • Component assembly onto bulkhead and benches
  • Wiring
  • Test
  • Flexure testing June 10-21
  • Flexure acceptance has been delayed until 15 May.
  • Rig installation may further delay testing
  • Cold testing and characterization from June – November
  • Four cold cycle periods planned
  • Last cycle is for contingency
  • Documentation deliverables have started and will complete during testing over the summer
  • Three Manuals (hardware and software maintenance, operation)
  • Design documentation
  • Summary Project PlanIntegration PlanFocus of Last Quarter of Work
  • Design/fabrication activity concentrated on
  • Radiation shield fabrication
  • Mechanism testing, rework
  • Assembly cleaning and wiring
  • Collimator assembly and mirror testing
  • Telescope simulator design/fabrication
  • General design cleanup (configuration control)
  • Procurement
  • Mechanical
  • Optical
  • SRC lens
  • Telescope simulator optics
  • WBS Report - % Complete since MFR Mar ’01Budget and ExpendituresMechanism %Camera 100Detector Focus 98Environ Cover 100Acquisition Mirror 100Slit 95Decker 100Filter Wheel 100Grating Turret 100 Gratings 100Prism Turret 100 Prisms 100Motor Drives 100Bench %Post-Slit 100OIWFS 100Collimator 100POM/Offner 100Fixed Assembly %Entrance Window 100Cryo-cooler 94Molecular Sieve 100Thermal Dist. 75LN2 Pre-Cool 83Opt Bench Mount 100Environ Cover Filter 100Bulkhead 100Passive Rad Shield 100Active Rad Shield 100Front Dewar Shell 100Rear dewar Shell 100Vert Inst Frame 100Horiz Inst Frame 100Dewar Mount Truss 100TE Mount Truss 100Shipping Container 0Handling Fixture 100Ballast Weights 100Project Status – WBS 5.3MechanicalProject Status – WBS 5.2Systems Engineering
  • Activities over this quarter
  • Mechanism testing
  • Collimator mirror assembly testing
  • Work left
  • Complete mechanism testing
  • Oversee instrument assembly
  • Integrate collimator assembly
  • Flexure testing
  • Cold testing
  • Contribute to the Hardware Maintenance Manual
  • Write the Operations Manual
  • Resources
  • 1.5 Scientists
  • Project Status – WBS 5.3Mechanical
  • All fabrication complete
  • Only activity is rework found in testing/integration
  • Telescope simulator still in fabrication
  • Assemblies in final processing
  • Cyrocooler assembly cleaning, assembly, installation
  • Thermal distribution copper strapping sizing and assembly
  • Dewar wiring
  • Radiation shield cleaning and assembly
  • 3D/2D design complete
  • Only clean-up items remain
  • Resources for this QR period
  • 2 ME’s, 3 MD, 4 IM, 1 M&P Eng, 1 Procurement
  • Resources after May 1st
  • Part-time M&P for cleaning/assembly during top assembly integration
  • 1 ME, 2 MD, 2 IM, 1 Procurement
  • Project Status – WBS 5.4Electrical
  • Work Remaining
  • Final mechanism testing support
  • Assist in instrument assembly
  • Fabricate the Thermal Enclosure to Dewar cables
  • Harness the Bulkhead Assembly
  • Resources
  • 0.25 EE, 1 ET
  • Project Status – WBS 5.5Software
  • Component Controller code complete
  • EPICS code complete
  • Work remaining
  • Participate in instrument assembly and checkout
  • Complete Software Maintenance Manual
  • Finalize code
  • Resources
  • 1 SE
  • Project Status – WBS 5.8Procurement
  • Procurement in process
  • SRC lens
  • Two gratings
  • Simulator optics
  • Miscellaneous mechanical items
  • Work remaining
  • Complete optics procurement
  • Records cleanup
  • Participate in instrument assembly and checkout
  • Resources
  • 1 Tech Associate, production
  • Project Status – Optics
  • Filters
  • 7 filters ordered through UH consortium; 2 failed spec and vendor may replace
  • We will install what we have
  • Tasks left include
  • Collimator testing, alignment and integration
  • Install optics in Prism and Grating turrets
  • Install filters
  • SRC camera lens installation
  • Grating installation
  • Resources
  • 1 Optical Tech, 0.25 OE
  • Planned FTE ProjectionFTE Projection
  • Table shows the resources forecast through delivery and training
  • Approximately10,000 hrs total needed to finish the project
  • This does not include commissioning or the impact of the pending change order for delivery to Chile
  • Project Milestones by QuarterAs of 4/22/02Deliverables Projection
  • Documentation DraftFinal
  • Hardware Maintenance Manual June Aug
  • Software Maintenance Manual July Sept
  • Operations Manual Aug Oct
  • As-Built Drawings Oct – Nov
  • Testing* Approx Scheduled Dates
  • Pre-ship AT Nov 25
  • Instrument Hardware Ship Nov 29
  • Post –Ship AT Dec 16-17**
  • Final AT Jan 6-31
  • Commissioning Feb ’03
  • *Earlier if 4th cold test cycle not needed.**Based on approval of Chile delivery change orderGemini Payments Summary – Current Work ScopeMilestonePaymentDateOriginalNewTest Plans Delivered $50,000* Mar-01 Mar-02Parts Fabrication Complete 25,000 Jun-01 May-02Manuals Complete 75,000 Aug-01 Oct-02Warm Tests Complete 25,000 Dec-01 Jun-02Cold Cycle Testing Complete 25,000 Mar-02 Sep-02Pre-Ship Acceptance 80,000 Jun-02 Nov-02Final Acceptance 300,857 Sep-02 Dec-02 Total $580,000Change orders submitted - DPS $ 2,683 - Chile Delivery 176,925 Total $179,618*Billed to GeminiDesignDocumentation cleanupAssembly drawingsAs-built drawingsAssemblyBulkheads and shieldsTop assemblyTestingVacuum testsWarm testsFlexure testCold testsTelescope simulatorIn fabrication, assembly/testCollimator mirrorTesting/characterizationFabrication Cleanup miscellaneous itemsDocumentationSoftwareSmall code fixes as testing progressesMaintenance manualElectronicsWiring and assemblyMechanismsFocus cold testSlit rework and testGratings and prism installationsSRC lens replacementManualsHardware/software maintenanceOperation Work Still OutstandingProblems and Concerns
  • No contingency left in the schedule
  • Mechanism testing and shield fabrication took much longer than anticipated
  • Flex Rig installation schedule delay
  • Moderate risk of impacting integration schedule
  • Short Red Camera lens replacement
  • Lens will be received in June timeframe - integration at first opportunity
  • Low schedule risk but requires complete instrument disassembly
  • Collimator mirror may degrade instrument performance
  • OIWFS prism
  • Installation by Gemini after delivery and acceptance of instrument
  • requires complete instrument disassembly by Gemini
  • IFU
  • Delivery will be late - proceeding with mass model
  • Low schedule risk – require only partial instrument disassembly
  • Conclusions
  • The current project status shows us to be 91% complete
  • We are in the integration phase
  • Focus mechanism testing in process
  • Slit mechanism rework and retest
  • Instrument top assembly is the next major activity
  • The next issue is flexure testing
  • Facility delays are becoming a major concern
  • The estimated cost of GNIRS is $ 4,443,187
  • January ’99 to delivery
  • We are under budget on labor but over budget on capital
  • We have slipped schedule by 45 days
  • There is no effective schedule contingency left
  • Milestones for Next Review
  • The next Quarterly Review will be held in the August 2002 timeframe
  • Flexure testing will be complete
  • Two cold test cycles will have completed
  • Draft manuals will be complete and to Gemini for review
  • Design documentation deliverable will be complete
  • Shipping container
  • Specified and designed
  • Either in fabrication or in procurement
  • Appendix A – ImagesAppendix B – Organization Chart Milestones WBS ChartAppendix AFabrication and Integration ImagesFull Assembly on Handling CartClean Room AssemblyCamera BarrelsCamera Test FixturePreAmp BoxPrism TurretsActive ShieldsActive Shields (cont)Appendix BOrganization ChartMilestonesWBS ChartDirector, NOAOJ. MouldETSL. DaggertGemini Projects Project ManagerN. GaughanProject AssistantD. Eklund (.5)Administrative AssistantM. BowersockProject Scientist, Systems Engineering J. EliasMechanical EngineerG. MullerOpticalEngineerM. LiangProgrammerP. RuckleElectrical EngineerJ. PenegorProcurement & Vender LiaisonA. DavisElectrical TechR. GeorgeGeneral TechnicianJ. PinaSupport ScientistsD. JoyceB. GregoryMechanical DesignersJ. AndrewD. RosinInstrument MakersJ. SteinR. HarrisM&PB. DitslerMilestones since MFR (3/01)WBS - Total Project
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