1. Quarterly Review October 5, 2001 1 QUARTERLY REVIEW October 5, 2001

2. Quarterly Review October 5, 2001 2 This Page Intentionally Left Blank

3. Quarterly Review October 5, 2001 3 GNIRS Quarterly Review Table of Contents IntroductionPg 4 Project SummaryPg 7 Configuration & IntegrationPg 29 Project ManagementPg 67 AppendicesPg 89

4. Quarterly Review October 5, 2001 4 Introduction This is the 6 th 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. Quarterly Review October 5, 2001 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

6. Quarterly Review October 5, 2001 6 This Page Intentionally Left Blank

7. Quarterly Review October 5, 2001 7 Project Summary Response to last QR report Progress overview Summary schedule Work left Budget and expenditures to date

8. Quarterly Review October 5, 2001 8 Response to June QR - Issues to be reviewed 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

9. Quarterly Review October 5, 2001 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. Quarterly Review October 5, 2001 10 Task Status ITEMSTATUSCOMMENT Complete design of all fixed assembliesNot Complete – 17 of 19 fixed assemblies completed design Should complete by mid-November Complete fabrication of all mechanismsNot Complete – Focus Assembly still in fabricationShould complete early October Complete fabrication of all benchesComplete Complete fabrication of Bulkhead AssemblyNot Complete – Release delayed for completeness, delivery impacted by changes and expanded work scope Delivery scheduled in November; includes vacuum test of complete assembly Complete fabrication of most dewar componentsNot CompleteCompletion expected mid-December Complete 75% of mechanism and optical sub-assembly testing Not Complete – Mechanism testing delayed by higher priority work on benches and Bulkhead Assembly Testing should complete by mid-December Receive all opticsNot Complete – Replica mirror contract had to be re- bid due to vendor non-performance; one camera lens failed inspection Optics should complete by mid-November Complete electronics thermal enclosure fabrication and checkout Complete Complete initial software coding (of Component controller code) Complete – Component Controller Code finishedEPICS code still in work Start testing of Component controller softwareComplete – Code has been tested as far as possible until more hardware becomes available. All testing should be complete by mid-December Complete OIWFS component integrationNot Complete – OIWFS bench required rework as components did not match ICD as specified; documentation incomplete Integration should be complete by mid-December

11. Quarterly Review October 5, 2001 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. Quarterly Review October 5, 2001 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. Quarterly Review October 5, 2001 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. Quarterly Review October 5, 2001 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. Quarterly Review October 5, 2001 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. Quarterly Review October 5, 2001 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. Quarterly Review October 5, 2001 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. Quarterly Review October 5, 2001 18 Summary Project Plan

19. Quarterly Review October 5, 2001 19 Revised Bench Integration Plan

20. Quarterly Review October 5, 2001 20 Project Status - Progress from August ’99 WBS element Mar Review Jun ReviewOct Review 5.0 Overall project 53%66% 80% 5.1 Management & Reporting 51%61% 71% 5.2 Systems Engineering100%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% 5.4Electronics 63%59% 86% 5.5Software 49%63% 85% 5.6Integration 0%0% 2% 5.7Deliverables 0%0% 0% 5.8Procurement 54%67% 77%

21. Quarterly Review October 5, 2001 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. Quarterly Review October 5, 2001 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. Quarterly Review October 5, 2001 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. Quarterly Review October 5, 2001 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 0.920.95 0.91 SPI 0.920.70 0.82

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27. Quarterly Review October 5, 2001 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. Quarterly Review October 5, 2001 28 Configuration Image

29. Quarterly Review October 5, 2001 29 Configuration - Overview Additions Envelope waivers Weight & CG update Design/fabrication status

30. Quarterly Review October 5, 2001 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. Quarterly Review October 5, 2001 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. Quarterly Review October 5, 2001 32 Configuration Image

33. Quarterly Review October 5, 2001 33 Configuration - Envelope Envelope waiver approved prior to last QR Additional waiver requested to accommodate Instrument Patch Panel and He manifold approved

34. Quarterly Review October 5, 2001 34 Configuration Image

35. Quarterly Review October 5, 2001 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. Quarterly Review October 5, 2001 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. Quarterly Review October 5, 2001 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%

38. Quarterly Review October 5, 2001 38 This Page Intentionally Left Blank

39. Quarterly Review October 5, 2001 39 Integration & Test - Overview Subsystem testing –Fit checks –Mechanism tests –Optics tests Integration and alignment

40. Quarterly Review October 5, 2001 40 Subsystem Testing

41. Quarterly Review October 5, 2001 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. Quarterly Review October 5, 2001 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. Quarterly Review October 5, 2001 43 Subsystem Testing Testing of mechanisms as outlined in previous reviews –Warm functionality –Warm flexure –Cold functionality –Tests (especially cold tests) without optics

44. Quarterly Review October 5, 2001 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. Quarterly Review October 5, 2001 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. Quarterly Review October 5, 2001 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. Quarterly Review October 5, 2001 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. Quarterly Review October 5, 2001 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. Quarterly Review October 5, 2001 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. Quarterly Review October 5, 2001 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

51. Quarterly Review October 5, 2001 51 Bench Integration Add subsystems to bench after qualification 3 major assemblies integrated in parallel –Main (Post-Slit) bench –Pre-Slit assembly –OIWFS Dewar assembly also parallel

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53. Quarterly Review October 5, 2001 53 Bench Integration Integration into bench permits warm optics and mechanical check (uses warm MUX) –Check (re-check) fit, alignment, repeatability –Check image quality (“warm” predictions) –Check flexure compensation calibration & performance (but not flexure calculations)

54. Quarterly Review October 5, 2001 54 Dewar Integration Integration of cold structure into vacuum vessel –Dewar shell tested at vendor; should be delivered by December –Cryostat integration in parallel to bench integration Shield installation Wiring and cold-stationing Trusses, window, environmental cover Re-test with MUX –Possible limited flexure test Install engineering array Last chance for installation of OIWFS prism or IFU without disassembly

55. Quarterly Review October 5, 2001 55 Dewar Integration Integration of cold structure into vacuum vessel Re-test with MUX Install engineering array Last chance for easy OIWFS prism, IFU installation

56. Quarterly Review October 5, 2001 56 Dewar Integration Initial cool-down followed by tests outlined in August ‘99 test plan –Start February 2002 –Flexure testing using NOAO facility (copy of Gemini rig) Scheduled for April 2002 Opportunities for IFU installation during testing –Schedule penalty varies

57. Quarterly Review October 5, 2001 57 Acceptance and Commissioning Acceptance Test Plan –Pre-ship AT - Tucson –Post-ship AT - CP lab –Final-AT - Gemini South telescope Commissioning Plan –Probably 2 runs –Flows into science verification Complete sequence ~4 months long

58. Quarterly Review October 5, 2001 58 This Page Intentionally Left Blank

59. Quarterly Review October 5, 2001 59 Software Components Top Level –Instrument Sequencer –Interfaces to detector, wavefront sensor, components controller, OCS Components Controller –Control (CAD, CAR, Apply) –Status and Alarm database (SAD) Low Level Software –Motor Control –Temperature readback –Pressure monitoring

60. Quarterly Review October 5, 2001 60 Software Work Remaining - Design Alarm and Status Propagation –Minor impact at various levels –All other design complete WCS/DHS header information

61. Quarterly Review October 5, 2001 61 Software Work Remaining - Coding Low Level (Hardware Interfacing) –No remaining coding planned Components control –Alarm and Health propagation Instrument Sequencer and Interfaces –Alarm and Health propagation –Engineering User interface (ongoing)

62. Quarterly Review October 5, 2001 62 Software Work Remaining - Testing Low Level –Prefer fully wired system for end-to-end test –Motors Multiple motors simultaneously Determine distances between limits, switches, etc Set speeds, acceleration, backlash parameters Actual mechanism(s) needed –Temperature Probes Set calibration curve and individual offsets –Pressure Sensor Verify operation in final configuration

63. Quarterly Review October 5, 2001 63 Software Work Remaining - Testing Upper Level -- EPICS –Engineering screens provide next level of test Top Level -- OCS compliance –use OCSwish new tool, in use in Hawaii, verifies OCS interface,

64. Quarterly Review October 5, 2001 64 Software Work Remaining Simulation allows testing without hardware –Works only for motors. Hardware testing to take 2-5 days Additional work –Lab Support –Conversion to GEM7 or GEM8

65. Quarterly Review October 5, 2001 65 Software Work Remaining Software is done when –Motors, temperature readback, etc, work at command line (low level) –Engineering Screens provide required control and readback –OCSwish/Acceptance test proves compliance with Gemini system –GNIRS works on the telescope

66. Quarterly Review October 5, 2001 66 Software Interface Issues Array Controller –Testing will verify correct interface to instrument sequencer OCS –OCSwish has been tested and is working OIWFS –Limited testing done shows mechanisms are functional –We assume the OIWFS will provide good data We have no means of testing actual data output

67. Quarterly Review October 5, 2001 67 Project Management Project Status Schedule & Planning Milestones Budget and Expenditures Organization Plans for Next Review

68. Quarterly Review October 5, 2001 68 Project Status – Overview Critical path is Radiation Shield design and fabrication Bench integration starts in October –All three benches (Pre and Post Slit, OIWFS) Mechanisms and optics integration into benches starts in October –Bench fit checks are done Software and electronics checkout slated for completion by 15 December –Further checkout is waiting for mechanisms to be finished

69. Quarterly Review October 5, 2001 69 Project Status – WBS 5.2 Systems Engineering Systems Engineering activities over this quarter included –Oversight of the top level design and interfaces –Writing of the Acceptance Test Plan & Commissioning Plan –Optical element evaluation Included prisms/gratings/mirrors/lenses –Envelope waiver submission –Mechanism warm tests –Bench temperature control tests

70. Quarterly Review October 5, 2001 70 Project Status – WBS 5.3 Mechanical Mechanism% Camera90 Detector Focus67 Environ Cover99 Acquisition Mirror93 Slit Decker90 Filter Wheel95 Grating Turret97 Gratings100 Prism Turret98 Prisms100 Motor Drives100 Bench% Post-Slit100 OIWFS100 Collimator95 POM/Offner100 Fixed Assembly % Entrance Window100 Cryo-cooler59 Thermal Dist.26 Bulkhead Rad Shield5 LN2 Pre-Cool91 Opt Bench Mount100 Environ Cover Filter15 Bulkhead75 Front Rad Shield8 Rear Rad Shield18 Front Dewar Shell70 Rear dewar Shell61 Vert Inst Frame77 Horiz Inst Frame57 Dewar Mount Truss44 TE Mount Truss70 Shipping Container0 Handling Fixture100

71. Quarterly Review October 5, 2001 71 Project Status – WBS 5.3 Mechanical All mechanism fabrication complete except two camera barrels and the focus assembly. All benches complete; collimator assembly nearly done Fixed assembly 3D design remaining –Radiation shields (passive and active) –Thermal distribution assembly –Cryo-cooler and manifold Fixed assembly 2D detailing in-work –Dewar mount truss assembly

72. Quarterly Review October 5, 2001 72 Project Status – WBS 5.4 Electrical Design activities are completed Work remaining –Fabricate the Thermal Enclosure to Dewar cables –Harness the cold mechanisms and cold bench as they become available –Support software testing –Harness the Bulkhead Assembly –Dewar warm-up controller fabrication

73. Quarterly Review October 5, 2001 73 Project Status – WBS 5.5 Software Component Controller code virtually complete Code has been tested as far as possible before integration Testing with mechanisms is underway High level (EPICS) code 70% complete Gemini OCSwish module received

74. Quarterly Review October 5, 2001 74 Project Status – WBS 5.8 Procurement Major items remaining in procurement are the Bulkhead Assembly and Dewar Shells Two replica mirrors remain to be fabricated –New vendor is under contract, delivery expected in November There are no major vendor fabrication contracts left to let –Remaining work is small parts/components

75. Quarterly Review October 5, 2001 75 Project Status – Optics Lenses and Windows Only one BaF 2 lens for short red camera remains Vendor remaking the last lens Testing will proceed with the defective lens Camera testing is underway Mirrors All mirrors received except for POM and Acquisition Mirror Filters 7 filters ordered through UH consortium; 2 failed spec and vendor may replace

76. Quarterly Review October 5, 2001 76 This Page Intentionally Left Blank

77. Quarterly Review October 5, 2001 77 Project Milestones by Quarter As of 9/21/01

78. Quarterly Review October 5, 2001 78

79. Quarterly Review October 5, 2001 79

80. Quarterly Review October 5, 2001 80 Planned FTE Projection

81. Quarterly Review October 5, 2001 81 FTE Projection Table shows the resources forecast over the next fiscal year There is a peak in the resources needed in Nov - Dec –“Rolling wave” is spread over two months –The MS Project “wave” is an attribute of how MS Project works when it assembles monthly data It misrepresents the amplitude of the wave in November by the way it handles its calendar –Hours actually spread over adjacent months can compress into one month, showing resources overloaded one month and under utilized the next, making a peak need in resources look worse than it actually is We estimate approximately 21,000 hrs total needed to finish the project –This does not include commissioning or the impact of the pending change order for delivery to Chile

82. Quarterly Review October 5, 2001 82

83. Quarterly Review October 5, 2001 83

84. Quarterly Review October 5, 2001 84 Organization Chart

85. Quarterly Review October 5, 2001 85 Director, NOAO J. Mould Director, NOAO J. Mould Gemini Projects Project Manager N. Gaughan Gemini Projects Project Manager N. Gaughan Administrative Assistant M. Bowersock Administrative Assistant M. Bowersock Project Scientist, Systems Engineering J. Elias Project Scientist, Systems Engineering J. Elias Mechanical Engineers G. Muller E. Hileman Mechanical Engineers G. Muller E. Hileman Optical Engineer M. Liang Optical Engineer M. Liang Electrical Engineer J. Penegor Electrical Engineer J. Penegor Mechanical Designers J. Andrew D. Rosin E. Downey D. Circle Mechanical Designers J. Andrew D. Rosin E. Downey D. Circle Programmer R. Wolff Programmer R. Wolff Project Assistant D. Eklund (.5) Project Assistant D. Eklund (.5) Electrical Tech R. George Electrical Tech R. George Support Scientists D. Joyce B. Gregory Support Scientists D. Joyce B. Gregory Procurement & Vender Liaison A. Davis Procurement & Vender Liaison A. Davis ETS L. Daggert ETS L. Daggert General Technician J. Pina General Technician J. Pina Programmer P. Ruckle Programmer P. Ruckle Instrument Makers J. Andrew J. Stein R. Bennett L. Lederer R. Davis Instrument Makers J. Andrew J. Stein R. Bennett L. Lederer R. Davis M&P B. Ditsler M&P B. Ditsler

86. Quarterly Review October 5, 2001 86 Plans for Next Review The next Quarterly Review will be held in the January 2002 timeframe The project will be into the Integration Phase –Alignment and testing will have begun Mechanical design will be complete –Some rework items as identified in integration may remain Mechanical fabrication will be complete –except for items associated with flexure testing and shipping container –Some rework items as identified in integration may remain Mechanism and optical subassembly testing should be completed Electronics fabrication and checkout completed –Some cables may remain to be fabricated –Some rework items as identified in integration may remain Component Controller Software completed and tested with the Electronics –EPICS level software will still be in work OIWFS components integration onto the OIWFS bench will be completed

87. Quarterly Review October 5, 2001 87 Conclusions The current project status shows us to be over 80% complete We have re-planned integration to preserve fall 2002 delivery –We are on track to deliver in September 2002 We are very near the end of the design phase We are nearing the end of the fabrication phase Mechanism testing has started The estimated cost of GNIRS is not significantly changed from the August ’99 baseline –Estimated total cost: $4,095,674 - January ’99 to delivery

88. Quarterly Review October 5, 2001 88 This Page Intentionally Left Blank

89. Quarterly Review October 5, 2001 89 Appendix A – Images Appendix B – Milestones, WBS Chart Appendix C – Envelope Waiver

90. Quarterly Review October 5, 2001 90 Appendix A Configuration and Fabrication Images

91. Quarterly Review October 5, 2001 91 Connector Feedthrough Panel

92. Quarterly Review October 5, 2001 92 Aft Bulkhead

93. Quarterly Review October 5, 2001 93 Aft Bulkhead Weldment

94. Quarterly Review October 5, 2001 94 Aft Dewar Shell Top End

95. Quarterly Review October 5, 2001 95 Forward Dewar Shell Top End

96. Quarterly Review October 5, 2001 96 Forward Bulkhead Weldment

97. Quarterly Review October 5, 2001 97 Forward Bulkhead Weldment

98. Quarterly Review October 5, 2001 98 Bench with Slit-Slide

99. Quarterly Review October 5, 2001 99 Bench on Handling Cart

100. Quarterly Review October 5, 2001 100 Bench with Assemblies

101. Quarterly Review October 5, 2001 101 Bench with Camera Turret Spindle

102. Quarterly Review October 5, 2001 102 Bench with Collimator Gimbal Mount Ring

103. Quarterly Review October 5, 2001 103 Camera Barrel

104. Quarterly Review October 5, 2001 104 Camera Barrel

105. Quarterly Review October 5, 2001 105 Collimator

106. Quarterly Review October 5, 2001 106 Foreoptics Bench

107. Quarterly Review October 5, 2001 107 Foreoptics Bench

108. Quarterly Review October 5, 2001 108 Acquisition Mirror

109. Quarterly Review October 5, 2001 109 Slit-Slide

110. Quarterly Review October 5, 2001 110 This Page Intentionally Left Blank

111. Quarterly Review October 5, 2001 111 Appendix B Milestones WBS Chart

112. Quarterly Review October 5, 2001 112 Milestones since MFR (3/01)

113. Quarterly Review October 5, 2001 113 WBS - Total Project

114. Quarterly Review October 5, 2001 114 This Page Intentionally Left Blank

115. Quarterly Review October 5, 2001 115 Appendix C Envelope Waiver

116. Quarterly Review October 5, 2001 116 This Page Intentionally Left Blank

117. Quarterly Review October 5, 2001 117 Envelope Waiver Supplemental Envelope Waiver Request This request supplements our May 2001 envelope waiver request. It details some additional minor envelope violations due to routing of the high-pressure helium lines and other connections. The violations are indicated in the figures below, and described in more detail afterward. This waiver request has been granted via e-mail as of September 27 by Doug Simons.

118. Quarterly Review October 5, 2001 118 Figure 1. Summary of GNIRS envelope violations, include those previously approved by Gemini. The Gemini instrument envelope is shown overlaid on the instrument itself.

119. Quarterly Review October 5, 2001 119 There are four areas where the helium lines violate the envelope: The first location is at the bottom of the instrument, where the lines and manifold protrude approximately 66 mm outside the envelope. Although the instrument "feet" extend still further (92 mm), they can be removed if required. The footprint of the hoses is also much smaller, and we believe that it should be possible to miss them, even when the instrument is mounted up-looking and it is necessary to access the side-looking instrument located immediately above. Hose loops from the forward cryoheads protrude outside the instrument in two locations (either side). The protrusion is about 100 mm in depth and roughly twice that in length, as indicated in the figure. We are providing a connector panel at the instrument. All cables and hoses that run to the Gemini connector panel on the rotator would run from this instrument panel, facilitating installation of the instrument. However, the panel also protrudes outside the envelope, by a maximum of ~120 mm. The panel runs about half the height of the instrument, so there is still good access to the corners of the ISS cube, where GNIRS will be attached.