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Engineering Overview Nadine Kurita

Engineering Overview Nadine Kurita. Organization Engineering Processes Standards Reviews Specifications/Requirements/ICDs Configuration Management Value Management Reporting Engineering Status Schedule Summary. Engineering Organization. Engineering Organization (2). System Managers

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Engineering Overview Nadine Kurita

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  1. Engineering OverviewNadine Kurita • Organization • Engineering Processes • Standards • Reviews • Specifications/Requirements/ICDs • Configuration Management • Value Management • Reporting • Engineering Status • Schedule • Summary

  2. Engineering Organization

  3. Engineering Organization (2) • System Managers • Reports to Chief Engineer • Responsible for all technical aspects of the project • Responsible for reporting cost and schedule (earned value) • 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, sign off approval and releasing drawings

  4. Engineering Organization (3) • 2008 Manpower Requirements • Maximum load for engineering per current estimates • 5 FTE Mechanical Engineers • 2 - 3 FTE Mechanical Designers • Current Engineering Staff • Nadine Kurita – Chief Engineer, Mechanical Engineer • Rodd Pope – System Engineer, Mechanical Engineer • Jean-Charles Castagna – Mechanical Engineer • Michael Kosovsky – Mechanical Design Engineer • Jim Defever – Mechanical Engineer (Consultant) • Donald Arnett – Design Supervisor, Design Engineer

  5. Engineering Organization (4) • Staffing Progress • System Manager hiring status • Offer received June 26th • Junior Mechanical Engineer requisition open – interviewing • Deputy System Manager for diagnostics • 2 SLAC Designers in August/September • Design staff available due to reduction in peak LCLS and HEP personnel • Additional design staff will be available if our needs increase • LCLS will have engineers that could be matrixed if our needs increase • This will fulfill our engineering staff requirement for 2008

  6. Engineering Processes – Standards • Formalize Design Standards • Incorporate SLAC mechanical design standards • 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 LUSI sharepoint • Non-Compliance Reports (NCRs), Inspection Reports • History archived via LUSI sharepoint

  7. Engineering Processes - Reviews • Design reviews are milestones in our schedule • Essential to ensure the designs meet their prescribed functionality • Value engineering

  8. Engineering Processes - Reviews (2) • System Concept Review • Global (CXI, XPP, XCS, Controls and Data System) • Goal • Approve the objectives and physics requirements • Approval of the conceptual design approach • Presents the following • Objectives and the requirements of the system • Physics Requirements Document complete and ready for sign off • Proposed approach to meet the requirements • Major system interfaces • Major design alternatives considered • Safety issues • Assessment of risk areas • After closure of action items this approves the baseline design

  9. Engineering Processes – Reviews (3) • 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 • Presents the following: • Science/technical objectives, requirements, general specification • Engineering Speciation Document complete and ready for sign off • Preliminary design & engineering analyses • Design interfaces • Closure of actions from previous review/changes since the last review • Control/software requirements and design • Quality control, reliability • Safety • Cost & schedules • After closure of action items preliminary design approved. Move to final design

  10. Engineering Processes – Reviews (4) • 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 • Control methods for all safety hazards • Approved safety reviews as required • Identified problem areas/open issues • Cost & schedule • After closure of action items long lead items will be purchased, detail drawings completed and fabrication begins

  11. Engineering Processes – Reviews (5) • Status Reviews • Component specific as needed • Not a schedule milestone • Goal • Provides status on drawings, procurement and manufacturing • 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 • Operational requirements/procedures • checkout, testing, maintenance • Review closure of action items from the FDR • Cost and schedule update

  12. Engineering Processes – Reviews (6) • Safety Reviews • Safety Overview Committee Review • Completed December 2006 and identified the following committee reviews: • Earthquake Reviews • Radiation Safety Reviews • Laser Safety Reviews • Electrical Safety Reviews • Hoisting and Rigging Safety Committee • Fire Marshall • Hazardous Experimental Equipment Committee

  13. Engineering Process – Requirements • Physics Requirements Documents (PRD) • Defines functionality of the component • Provides detailed physics/science requirements • Basis for engineering design • Required for the System Concept Review • Approved by Science Team Leaders and LUSI Project Director • Engineering Specification Document (ESD) • General specifications & 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 Director • 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

  14. Engineering Process – Requirements • 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

  15. Configuration Management - Document Control • Document Control • Configuration control all critical project documents • Management • PEP, Acquisition Strategy, QIP, Value Management, … • Technical • PRDs, ESDs, ICDs, Design Reviews, ... • Fabrication • Procedures, travellers, ... • Installation • Procedures, travellers, ... • Design reviews will be archived

  16. Configuration Management – Drawings/Specifications • Utilize existing SLAC Document Control System and SLAC Sharepoint database • 3D-models will use SLAC Mechanical Departments Project Management Database for configuration control and archiving • Drawings and specifications • Approved by the list of “approvers” • Design review process is not required for approval • Once the document is signed by all the approvers it is released to SLAC Document Control

  17. Configuration Management - ECOs • Engineering Change Orders • Implementing an engineering change order process • Keeps detailed revision history • Increase efficiency of implementing and documenting design and manufacturing changes • Allows for quick approval of implementing changes • Helps to maintains these changes in the supporting design/fabrication documents

  18. Value Management • Consistent with DOE Value Management, DOE order 413.3 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 • Final report pending • LUSI Value Management principles are applied to all LUSI engineering tasks

  19. LUSI Reporting • Monthly Reports to the DOE after achieving CD2a • Technical status • Earned value performance. LUSI Project Management Cost & Schedule system is based on, • B-Factory Project - 2000 Award for the Program and Project Management • SPEAR3 – 2004 Secretary's Excellence in Acquisition Award • GLAST • LCLS • 60% CAMS participated in PEP-II,SPEAR3, GLAST and/or LCLS • Change Control Log

  20. Engineering Status • X-ray Pump Probe • Overall layouts developed for both CD4a and CD4b • Diffractometer • PRD reviewed and approved by team leaders in May ’07 – CRITICAL PATH ITEM for CD4-a • Preliminary concepts of the diffractometer developed. Starting to work with vendors • Monochromator • Preliminary concepts developed

  21. Laser System (Fundamental) X-Ray Pump Probe Layout Small Angle Scattering X-ray Diffractometer Wavelength Conversion Offset Monochromator X-ray Pump-Probe Instrument

  22. Engineering Status (2) • Coherent X-Ray Imaging (CXI) • Conceptual layouts developed for both CD4a and CD4b • Met with team leaders to discuss sample chamber requirements in May 2007 • Developed multiple sample chamber approaches. CRITICAL PATH ITEM FOR CD4a

  23. CXI Sample Chamber Design Approach #1

  24. Engineering Status (3) • X-Ray Correlation Spectroscopy (XCS) • Conceptual layout completed • Diagnostics • Electro-Optic Timing Device • Draft of the Engineering Specification Document completed • Preliminary design near completion • Preliminary Design Review in October 2007 ahead of schedule EO Device

  25. Engineering Status (4) • Position Monitor & Intensity Monitor Pop-in • Alternate concepts developed • Hard X-Ray Intensity/Position Monitor Leave-in • Alternate concepts developed Pop-in Diode Intensity Monitor Pop-in Position Monitor Leave In Monitor

  26. XPP Critical Path Diffractometer long Lead item Vacuum supports low risk, occurs last in the design process

  27. CXI Critical Path Slit System manpower limited, could be expedited Sample Chamber critical design, incorporates numerous experiments Low risk, vacuum system follows after critical components designed.

  28. Major Milestones • Jul ’07 CD1 Review • Aug ’07 XPP System Concept Review • Sep ’07 CXI System Concept Review • Oct ’07 Diagnostic System Concept Review • Oct ’07 EO Monitor Final Design Review • Nov ’07 Diffractometer Final Design Review • Nov ’07 Be Lenses Preliminary Design Review • Dec ’07 CD2a

  29. Major Milestones (2) • Jan ’08 Sample Chamber Preliminary Design Review (PDR) • Jan’07 Hard X-Ray IO PDR • Jan ’07 Be Lenses Final Design Review (FDR) • Feb ’08 CXI Pulse Picker PDR • Mar ’08 Hard X-Ray Intensity Monitor FDR • Apr ’08 XPP Diffractometer non-recurring engineering • May ’08 CXI Sample Chamber & Pulse Picker FDR • May ’08 Position Monitor & Pop-in IO monitor FDR • Jul ’08 Slits FDR • Jul ’08 CD3a

  30. Major Milestones (3) • Jul ’08 Start procurement for CXI and XPP • Jul ’08 Start fabrication of XPP Diffractometer • Jul ’08 Award Sample Chamber • Jan ’09 All major CD4a components received • Apr ’09 All major CD4a components ready for installation • Sep ’09 CD4a installation complete • Sep ’09 XPP Detector installed • Oct ’09 CD2b • Nov ’09 Particle Injector received • Feb ’10 CD4a • Mar ’10 CD3b • Mar ’12 CD4b

  31. Summary • Engineering/Scientist teams have made significant design progress to date • LUSI has an established conceptual design with a consistent cost estimate. Over 50% of the fabrication estimates came from vendor quotations, catalogs, or previous orders • The technical scope of LUSI has converged • Preliminary resource loaded schedule for planned CD4a deliverables is established and consistent with the funding profile

  32. Summary (2) • LUSI engineering staffing is currently at 70% of its peak expected load • Staff consists of experienced SLAC (SSRL, LCLS, HEP) mechanical engineers and design engineers • Staff is informed in quality and trained in ES&H issues in their area of expertise • Working organization with well understood processes • Excellent communication and interfacing with partner labs, LCLS and sub-systems

  33. Summary (3) • Future work • Complete hiring or matrixing LCLS engineering staff • Finalize the details on the design scope and requirements • Complete preliminary designs • Engineering staff is ready to move on to the CD-2 phase of the project!

  34. End of Presentation

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