QUARTERLY REVIEW October 5, 2001

1. QUARTERLY REVIEW October 5, 2001

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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

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

8. 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 Response to June QR - Issues to be reviewed

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 Status

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 Plan

19. Revised Bench Integration Plan

20. WBS elementMar ReviewJun ReviewOct Review 5.0 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% Project Status - Progress from August ’99

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

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25. Budget and Expenditures • Baseline Estimate (Jan 99 to completion) • Labor $3,391,232 • Capital $ 836,462 • Total $4,227,694 • Current Forecast March ReviewJune ReviewOctober Review Labor $2,866,775 $3,002,938 $2,957,389 Capital $1,074,798 $1,181,900 $1,138,285 Total $3,941,573 $4,184,838 $4,095,674 • Performance ratios March ReviewJune ReviewOctober Review BCWS $ 1,754,979 $ 2,863,855 $ 3,085,811 BCWP $ 1,611,542 $ 2,011,383 $ 2,526,319 ACWP $ 1,742,651 $ 2,113,212 $ 2,762,963 CPI 0.92 0.95 0.91 SPI 0.92 0.70 0.82

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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%

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39. Integration & Test - Overview • Subsystem testing • Fit checks • Mechanism tests • Optics tests • Integration and alignment

40. Subsystem Testing

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