1 / 46

Engineering Overview CD-2 Lehman Review Nadine Kurita - LUSI Chief Engineer August 19, 2008

Engineering Overview CD-2 Lehman Review Nadine Kurita - LUSI Chief Engineer August 19, 2008. Outline. Safety Organization Engineering Processes Standards Reviews Specifications/Requirements/ICDs Configuration Management Value Management Engineering Status

duane
Download Presentation

Engineering Overview CD-2 Lehman Review Nadine Kurita - LUSI Chief Engineer August 19, 2008

An Image/Link below is provided (as is) to download presentation Download Policy: Content on the Website is provided to you AS IS for your information and personal use and may not be sold / licensed / shared on other websites without getting consent from its author. Content is provided to you AS IS for your information and personal use only. Download presentation by click this link. While downloading, if for some reason you are not able to download a presentation, the publisher may have deleted the file from their server. During download, if you can't get a presentation, the file might be deleted by the publisher.

E N D

Presentation Transcript

  1. Engineering Overview CD-2 Lehman Review Nadine Kurita - LUSI Chief Engineer August 19, 2008

  2. Outline • Safety • Organization • Engineering Processes • Standards • Reviews • Specifications/Requirements/ICDs • Configuration Management • Value Management • Engineering Status • Requirement Document Status • Basis of Estimate • Cost Methodology • Major Milestones • Summary

  3. Safety • Lead Engineer & Engineering Staff • Responsible for integrating safety into their designs • Access to ES&H staff, peer reviews and SLAC Safety Committees • Line Management • Responsible for safety • Responsible for authorizing work to proceed • Utilize verification processes: • LUSI safety review checklist • Design review process includes safety at each stage of design • Safety reviews are included in the P3 schedule • Work Authorization Form – LCLS Procedure • Instrument designs are consistent with SLAC ES&H Policy – Safety Overview Committee Review • SLAC authorization to energize machine includes sign-off by SLAC Safety Committees and SLAC Safety Officers

  4. Engineering Organization

  5. Engineering Organization (2) • Staffing Progress • Added 12 engineers/designers since the CD1 Review • All Lead Engineer/CAM positions filled • Manpower Requirements per Current Schedule • Q4FY2008 • 12.1 FTE Mechanical Engineers • 6.6 FTE Mechanical Designers • 1.9 FTE Controls Engineers • Currently searching for 3-4 additional engineers • AMO engineers available in September • Maximum load for mechanical engineering is in Q3FY2009 • 11 FTE Mechanical Engineers • 9.3 FTE Mechanical Designers • Maximum load for controls engineering Q2FY2010 • 5.1 FTE Controls Engineers • 1.7 FTE Controls Programmers

  6. LUSI Engineering Resource Loading

  7. Engineering Organization (4) • Lead Engineer • Reports to Chief Engineer • Responsible for all technical aspects of the project • Responsible for reporting cost and schedule • Control Account Manager (CAM) • Responsible for supervising daily activities of subordinate engineers, design engineers and designers • Responsible for keeping management informed on critical issues, delays, etc. • Works with upper management to make critical decisions • Design Supervisor • Responsible for design standards • Checking, approving and releasing drawings

  8. Engineering Processes – Standards • Formalize Design Standards • Incorporated SLAC Mechanical Design Department standards through SP-391-000-36, LUSI Design Standard Supplement • Developed standard engineering notes • Developed Solid Edge Tool (3D parametric software) • Formalize Manufacturing Practices • LUSI Procedures and Travellers • Produced for critical equipment • Configuration controlled • History archived via LCLS/LUSI sharepoint • Non-Compliance Reports (NCRs), Inspection Reports • History archived via LCLS/LUSI sharepoint

  9. Engineering Processes - Reviews • Design review goals and criteria are documented • Design reviews are milestones in our schedule • Essential to ensure the designs meet their prescribed functionality • Demonstrate value engineering • Engineering review template completed

  10. Engineering Processes - Reviews (2) • Preliminary Instrument Design Review (PIDR) • Instrument System Specific (CXI, XPP, XCS) • Goal • Approve the objectives and physics requirements of the instrument • Approval of the conceptual design approach • Presents the following • Science including breadth of applications possible with the instrument • Objectives and the requirements of the system • Instrument System Physics Requirements Document complete and ready for sign off • Performance requirements of the components • “Proof of Concept” Models • Proposed approach to meet the requirements • System design • Mechanical • Electrical • Major system interfaces, organizational and technical • Major design alternatives considered (Value Management) • Safety considerations • Assessment of risk areas • Planned test program if appropriate • After closure of action items this approves the baseline design, continuation of engineering specifications and preliminary component designs

  11. Engineering Processes – Reviews (4) • Preliminary Design Reviews • Component specific • Final design details are not required • Goal • Approval of the component specifications & preliminary design • Approval to complete final design • Approval to fabricate test articles and place long durationprocurements • Presents the following: • Science/technical objectives, requirements, general specification • Engineering Specification Document complete and ready for sign off • Preliminary design & engineering analyses • Design interfaces • Control/software requirements • Quality control, reliability • Safety considerations – “define hazards” • Cost & schedule • After closure of action items preliminary design approved and long duration items will be purchased. Move to final design.

  12. Engineering Processes - Reviews (3) • Final Instrument Design Review (FIDR) • Instrument System Specific (CXI, XPP, XCS) • Prerequisite • All major Component Preliminary Design Reviews must be completed. • Goal • Approve final instrument design / configuration & verify that they meet requirements • Presents the following • System requirements for the instrument • Instrument PRD, ESD and procurement specifications are complete and ready for sign-off • Layout Update - Identify changes from PIDR layout • Component design status and description • Design and analyses to meet the requirements • Major design alternatives considered (value management) • Major system interfaces, organizational and technical • Identify operational modes • Maintenance requirements • Planned test program if appropriate • Installation & alignment plans • Cost & schedule • Safety – status and description of hazard and mitigation • After closure of action items this approves the final design and configuration of the instrument.

  13. Engineering Processes – Reviews (5) • Final Design Reviews • Component specific • Goal • Approval of the final design, cost and schedule • Approval to complete detail drawings • Approval to start procurement & fabrication • Presents the following: • Science/technical objectives, requirements & specifications • Review closure of actions from the Preliminary Design Review • Final design and analyses • Test results and design margins • “Analyze and develop controls” for all safety hazards • Approved safety reviews as required • Identified problem areas/open issues • Cost & schedule • After closure of action items this approves the final design and detail drawings are completed. Approval to purchase items and begin fabrication.

  14. Engineering Processes – Reviews (6) • Manufacturing Readiness Review • Component specific • Schedule milestone • Goal • Provides status on drawings, procurement, manufacturing and safety documents. • Presents the following: • Status of assembly and detail drawings • Approval process per Mechanical Department standards • Procedures, travellers, inspection and testing plans • Status of procurement and manufacturing • Installation plans & documents • Work Authorization, Statement of Work • Operational requirements/procedures • checkout, testing, maintenance • “Develop and implement” hazard controls • Safety documents • Review closure of action items from the FDR • Cost and schedule update • After closure of action items this approves the start of assembly, testing and installation.

  15. Engineering Processes – Reviews (7) • Safety Reviews • Safety Overview Committee Review (SOC), K. Moffeit • Completed December 2006 and identified the following required committee reviews: • Earthquake Reviews • Radiation Safety Reviews • Laser Safety Reviews • Electrical Safety Reviews • Hoisting and Rigging Safety Committee • Fire Marshall • Hazardous Experimental Equipment Committee • SOC approval ensures that the hazard analysis is adequate, controls planned to mitigate or eliminate hazards are adequate, and that the activity will conform to SLAC ES&H policy

  16. Engineering Process – Requirements • Physics Requirements Documents (PRD) • Defines functionality of the component • Provides detailed physics/science requirements • Basis for engineering design • Required for the Preliminary Instrument Design Review • Approved by Science Team Leaders and/or LUSI Project Manager • Engineering Specification Document (ESD) • General & engineering specifications to meet the PRD • Covers additional requirements not in the PRD • Space constraints, environment, etc. • Required for the Preliminary Design Review • Approved by Chief Engineer, Scientist, Project Manager • ESD template created • Interface Control Documents (ICD) • Describes the boundaries of one system with respect to another • Physical interface between the two • Responsibilities • Required for the Preliminary Design Review • Approved by all involved system managers

  17. System Engineering Flow Diagram

  18. Engineering Process – Requirements (3) • Statement of Work/Technical Purchase Specifications • Mandates the technical, quality and procurement specifications for a purchased item • Engineering Notes • Documents engineering analysis and other information critical to the design of the component • These documents are all configuration controlled via LCLS/LUSI Sharepoint or SODA (SLAC Online Database Access)

  19. Engineering Processes – Drawing Tree/Structure • Roadmap for building components and installing in the hutch • Assemblies & installations thought through – streamlines modeling and drawing preparations • Organizes the assemblies & models • Integration between design teams

  20. Document Control • Utilize existing SLAC MD Document Control System and Sharepoint database • 3D-models will use SLAC MD Project Database Management (PDM) for configuration control and archiving • Drawings and specifications • Check, approval and release process as defined in DS-391-000-36, “LUSI Design Standards Supplement” • Project documents are released and subject to revision control • Management • PEP, Acquisition Strategy, Hazard Analysis, QIP, Value Management, … • Technical • PRDs, ESDs, ICDs, ... • Fabrication & Installation • Procedures, travellers, ... • Design reviews will be archived

  21. Document Control (2) • Engineering Change Orders (ECO) • Working with MD on a sitewide ECO process • ECO procedure is under review • Keeps detailed revision history • Increase efficiency of implementing and documenting design and manufacturing changes • Allows for quick approval for implementing changes • Helps to maintain these changes in the supporting design/fabrication documents

  22. Value Management • Consistent with DOE Value Management, DOE order 413.3A and OMB Circular A-131 • LUSI Value Management Plan completed, PM-391-000-02 R0 • Executed LUSI Value Management Plan • Conducted with internal and external reviewers • 4 alternative solutions identified • Savings of $355K executed • LUSI Value Management principles are applied to all LUSI engineering tasks • Design alternatives • Part of the engineering review process • Applying common designs • Value Management principles assisted in finalizing the LUSI scope

  23. Engineering Status - XPP • X-ray Pump Probe • Extensive engineering and design progress for CD-2 • Engineering Staff • J Langton - Lead Engineer • Jim Defever – Mechanical Engineer • Jim Delor – Mechanical Engineer

  24. XPP Instrument Location Near Experimental Hall X-ray Transport Tunnel AMO (LCLS) XPP Endstation XCS CXI Far Experimental Hall

  25. Engineering Status – XPP (3) • CD-2 Activities • Completed –Preliminary Instrument Design Review • Approved by team leaders in 2007 - System PRD • Completed – System ESD released • Completed - Drawing Tree/File Structure • Completed - High level models & their drafts • Completed - Hutch definitive layout • Completed - Laser table layout & pump laser to FEL interface • Completed - Detector mover ESD released • Completed - Detector mover “proof of concept” • Testing just completed in August • Completed - Diffractometer ESD released • Documented the interfaces and deliverables with vendor • Completed - Diffractometer definitive layout • Completed – About 85% complete on design effort of all the supports and laser tables

  26. Engineering Status – CXI • Coherent X-ray Imaging • Significant engineering and design progress since CD-1 • Engineering Staff • Paul Montanez - Lead Engineer • Jean-Charles Castagna – Mechanical Engineer • Armin Busse – Mechanical Engineer • Rick Jackson – Design Engineer

  27. CXI Instrument Location Near Experimental Hall X-ray Transport Tunnel AMO (LCLS) XPP CXI Endstation XCS Source to Sample distance : ~ 440 m Far Experimental Hall

  28. Engineering Status – CXI (3) • CD-2 Activities • Completed –Preliminary Instrument Design Review • Approved by team leaders in 2007 - System PRD • Completed – Draft System ESD • Completed –Drawing Tree/File Structure • Completed – XRT/FEH5 beamline layout • Complete drafts for the following ESDs • Completed – Sample Chamber • Completed – Detector Stage –in review • Completed – Precision Instrument Stand –in review • Completed – Reference laser –in review • Completed – 1 m KB mirror system • Completed – Hutch 5, Common Room & Control Cabin ESD • Completed – ICD LUSI to LCLS Sample Chamber & Injector Fixed Target Configuration

  29. Engineering Status – CXI (4) • Hutch Layout Drawings • Completed – Stay Clears • Completed – Utilities • Completed – Hutch Layout • Preliminary component designs • ~75% complete – Sample Chamber for the 1 m KB system • ~75% complete– Detector stage • Preliminary design nearly developed • Detector packaging details needed • Completed – Precision instrument stand conceptual design • ~90% complete - Reference Laser preliminary design • 1 m KB system • Budgetary Inquiry

  30. Engineering Status - XCS • X-ray Correlation Spectroscopy (XCS) • Major engineering and design progress since CD-1 • Engineering Staff • Eric Bong – Lead Engineer • Jim Delor – Mechanical Engineer • Jean-Charles Castagna – Mechanical Engineer • Armin Busse – Mechanical Engineer • Ted Osier – Designer • Don Arnett – Designer • Ben Bigornia – Designer

  31. XCS Instrument Location Near Experimental Hall X-ray Transport Tunnel (200m long) AMO (LCLS) XPP XCS Hutch Source to Sample distance : ~ 420 m CXI Hutch Far Experimental Hall

  32. Engineering Status – XCS (3) • CD-2 Activities • Completed –Preliminary Instrument Design Review • Approved by team leaders in 2008 - System PRD • Completed – Drawing tree/file structure • Completed – Higher level models/draft • Completed – Definitive hutch and XRT layout • Completed – Detector mover layout • Completed – Diffractometer definitive layout • Completed – Detector mover proof of concept • Completed – Draft detector mover ESD/SOW • Completed – Draft diffractometer ESD • Completed – Conceptual design for tables and supports • Completed – Hutch Design • Completed – Hutch 4 & Control Cabin ESD • Completed– Interface Control Document (ICD) LUSI to LCLS • Hutch Layout Drawings • Completed – Stay Clears • Completed – Utilities • Completed – Hutch Layout

  33. Engineering Status - DCO • Diagnostics & Common Optics • Engineering Staff • Eliazar Ortiz – Lead Engineer • Marc Campell – Mechanical Engineer • Nadine Kurita – Mechanical Engineer • Rick Jackson – Design Engineer • Don Arnett – Designer • Ben Bigornia – Designer Profile-Intensity Monitor Attenuator X-ray Focusing Lens Dual Blade Slits

  34. Engineering Status – DCO (2) • CD2 Activities • Complete Draft ESDs • Completed – Pop-In Profile Monitor • Completed – Pop-In Intensity Monitor • Completed – Intensity-Position Monitor • Completed – Wavefront Monitor • Completed – Slits • Completed – Pulse Picker • Completed – Attenuators • Completed – Be Lens System • Completed – Harmonic Rejection Mirror • Working – Complete draft ICD to instruments. • Greater than 50% complete on preliminary designs for the CD4a deliverables • Completed – Pop-In Profile Monitor , 75% complete • Completed – Pop-In Intensity Monitor , 75% complete • Completed – Intensity-Position Monitor ,50% complete • Completed – Pulse Picker, 50% complete • Completed – Slits, 50% complete • Conceptual designs for all remaining devices. • Completed – Wavefront Monitor • Completed – Attenuators • Completed – Be Lens System • Completed – Harmonic Rejection Mirror Monochromator Pulse Picker

  35. Project PRD & ESD Status 35 PRDs, 91% complete 55 ESDs, 49% complete

  36. Basis of Estimate • Contains the following • Detailed description of the component • Based on latest PRD • 3D model if applicable and available • Detailed cost estimate • Part number, drawing number, vendor, notes, weight, qty, cost, etc. • Supporting quotations, drawings, catalogs, etc. • Configuration controlled with the CD-2 baseline • Cross referenced to P3 activity ID’s

  37. Cost Methodology • Cost Methodology • Engineering labor estimates based on prior experience of similar designs • Materials & Labor estimates were driven by the latest design and Physics Requirements • Recently obtained vendor budgetary quotes • Vendor Catalogs • Engineering bottoms up estimate • Engineering judgment • Installation cost and schedule activities were discussed with LCLS installation manager(s)

  38. Major Milestones/Reviews • Completed Reviews • Dec ’06 - Safety Oversight Review • Dec ’07 - XPP Preliminary Instrument Review • Dec ’07 - CXI Preliminary Instrument Review • May ’08 - Design Review – Pop-In Profile Monitor • Jul ’08 - XCS Preliminary Instrument Review

  39. Major Milestones/Reviews (2) • Upcoming Reviews (6 month look ahead) • XPP • Q4FY08 - PDRs & FDRs Support Tables & Optical Table • Q4FY08 - PDRs & FDRs Optical Tables • Q1FY09 - PDR Diffractometer & Detector Mover • Q2FY09 - FDR Diffractometer & Detector Mover • CXI • Q42008 – PDR Detector Stage • Q1FY09 - PDR & FDR Reference Laser • Q1FY09 - PDR 1.0 m Sample Chamber • DCO • Q4FY08 - PDR Pop-In Profile & Intensity Monitor • Q4FY08 - PDR Pulse Picker • Q1FY09 - PDR Intensity-Position Monitor • Q1FY09 - PDR & FDR Slit System • Q1FY09 - FDR Pulse Picker • Controls • Q1FY09 - PDR XPP Controls

  40. Summary • Instrument teams have made significant design progress • LUSI has established designs with a consistent cost estimate. The majority of materials estimates came from vendor quotations, catalogs, or previous orders • XPP ~80% • CXI ~ 90% • XCS ~ 75% • DCO ~ 65% • Controls & DAQ ~ 95% • The technical scope of LUSI has converged • Resource loaded schedules and Basis of Estimates are complete

  41. Summary (2) • Engineering Staff • Staff consists of experienced SLAC mechanical engineers and design engineers • Additional staff will be available when AMO work ramps down – September 2008 • Staff is informed in quality and trained in ES&H issues in their area of expertise • Actively looking for additional engineering resources • Working organization with well understood processes • Excellent communication and interfacing with partner labs, LCLS and sub-systems • Engineering staff ready for CD-2 approval!

  42. End of Presentation

  43. Insert pic here Design Review Standards

  44. Review Template

  45. ESD

  46. Value Management Forms

More Related