1. Nadine Kurita - LUSI Chief Engineer
Engineering Overview
CD-2 Lehman Review
Nadine Kurita - LUSI Chief Engineer
August 19, 2008
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2. Outline Safety Organization Engineering Processes Value Management
Standards
Reviews
Specifications/Requirements/ICDs
Configuration Management
Value Management
Engineering Status
Requirement Document Status
Basis of Estimate
Cost Methodology
Major Milestones
Summary
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3. Safety Lead Engineer & Engineering Staff Line Management
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
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4. Engineering Organization
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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
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6. LUSI Engineering Resource Loading
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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
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8. Engineering Processes – Standards
Formalize Design Standards
Incorporated SLAC Mechanical Design Department standards through SP , 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
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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
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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
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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 duration procurements
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.
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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.
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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.
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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.
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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
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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
Approved by all involved system managers
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17. System Engineering Flow Diagram
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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)
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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
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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 , “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
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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
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22. Value Management
Consistent with DOE Value Management, DOE order 413.3A and OMB Circular A-131
LUSI Value Management Plan completed, PM 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
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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
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24. XPP Instrument Location
Near Experimental Hall
X-ray Transport Tunnel
AMO
(LCLS)
XPP
Endstation
XCS
CXI
Far Experimental Hall
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25. Engineering Status – XPP (3)
CD-2 Activities
Completed – Preliminary Instrument Design Review
Approved by team leaders in 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
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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
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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
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28. Engineering Status – CXI (3)
CD-2 Activities
Completed – Preliminary Instrument Design Review
Approved by team leaders in 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
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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
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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
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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
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32. Engineering Status – XCS (3)
CD-2 Activities
Completed – Preliminary Instrument Design Review
Approved by team leaders in 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
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33. Engineering Status - DCO
Profile-Intensity
Monitor
Attenuator
X-ray Focusing Lens
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
Dual Blade Slits
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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.
Monochromator
Pulse Picker
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35. Project PRD & ESD Status
35 PRDs, 91% complete
55 ESDs, 49% complete
SUMMARY
PRD
ESD
Total 35 55
10%
in work 3 4
60%
draft review (draft complete out for review) 10
80%
in work-finalize (revising & preparing final edit)
90%
approvals (out for final review and signatures) 6
100%
released 26 8
not started 2
cancelled or obsolete 12
91%
49%
XPP Summary
PRD
ESD
Total 5 3
in work
draft review
in work-finalize
approvals 2
released
not started
cancelled or obsolete
96%
100%
CXI Summary
PRD
ESD
Total 12 14
in work 2
draft review 9
in work-finalize
approvals
released 10 3
not started
cancelled or obsolete 6 4
85%
60%
XCS Summary
PRD
ESD
Total 5 6
in work 1
draft review
in work-finalize
approvals 4
released 2
not started
cancelled or obsolete
92%
45%
Controls & DAQ
PRD
ESD
Total 2 8
in work 1
draft review
in work-finalize
Approvals
Released 5
not started
cancelled or obsolete
100%
86%
Dia & Common Optics
PRD
ESD
Total 11 9
in work 1 2
draft review
in work-finalize 4
approvals 3
released 10
not started
cancelled or obsolete 7
92%
68%
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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
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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)
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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
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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
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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
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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!
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42. End of Presentation
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43. Design Review Standards
Insert pic here
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44. Review Template
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45. ESD
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46. Value Management Forms
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