Transcript Document

Quarterly Review
October 5, 2001
QUARTERLY REVIEW
October 5, 2001
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Quarterly Review
October 5, 2001
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Quarterly Review
October 5, 2001
GNIRS Quarterly Review
Table of Contents
• Introduction
• Project Summary
• Configuration & Integration
• Project Management
• Appendices
Pg 4
Pg 7
Pg 29
Pg 67
Pg 89
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Quarterly Review
October 5, 2001
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
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Quarterly Review
October 5, 2001
Outline
• Project summary
– Last QR Response
– Progress Overview
– Cost and Schedule Status
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Problems and Concerns
Configuration Update
Technical Progress
Project management
Plans for next review
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Quarterly Review
October 5, 2001
Project Summary
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Response to last QR report
Progress overview
Summary schedule
Work left
Budget and expenditures to date
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Quarterly Review
October 5, 2001
Response to June QR - Issues to be reviewed
• Late delivery of the OIWFS
– Contingency plan
• 2 month schedule slip
• Completion of planned items
• Documentation
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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
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Quarterly Review
October 5, 2001
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.
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Quarterly Review
October 5, 2001
Task Status
ITEM
STATUS
COMMENT
Complete design of all fixed assemblies
Not Complete – 17 of 19 fixed assemblies completed
design
Should complete by mid-November
Complete fabrication of all mechanisms
Not Complete – Focus Assembly still in fabrication
Should complete early October
Complete fabrication of all benches
Complete
Complete fabrication of Bulkhead Assembly
Not 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 components
Not Complete
Completion 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 optics
Not Complete – Replica mirror contract had to be rebid 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 finished
EPICS code still in work
Start testing of Component controller software
Complete – Code has been tested as far as possible
until more hardware becomes available.
All testing should be complete by mid-December
Complete OIWFS component integration
Not Complete – OIWFS bench required rework as
components did not match ICD as specified;
documentation incomplete
Integration should be complete by mid-December
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Quarterly Review
October 5, 2001
Response to June QR
• Planned Completions by this Quarterly Review
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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
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Quarterly Review
October 5, 2001
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.
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Quarterly Review
October 5, 2001
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.
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Quarterly Review
October 5, 2001
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.
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Quarterly Review
October 5, 2001
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.
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Quarterly Review
October 5, 2001
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.
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Quarterly Review
October 5, 2001
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.
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Quarterly Review
October 5, 2001
Summary Project Plan
N
D
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F
M
A
M
CY-2000
J
J
A
S
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J
D
F
M
A
M
CY-2001
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J
F
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CY-2002
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Systems Engineering
Rotary Mechanism Flexure Tests
Risk Reduction Prototypes
Fixed Assemblies Design/Fab
PFR
Integration/Alignment
Structural Analysis
MFR
ATP
IFU Modules
Bench Design/Fab/Assy
Ship
Manuals
OIWFS/Post-Slit/Pre-Slit
Training
WFS Integration/Alignment
OIWFS Hardware
Mechanism Design/Fab/Assy/Test
9 Mechanisms
Flexure Testing
Software Development/Code/Test
SW Plan/Low-Level/High-Level Code
Electronics Design/Fab/Test
Optics Procurement
Mirrors/Lenses/Filters/Gratings/Prisms
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Quarterly Review
October 5, 2001
Revised Bench Integration Plan
9/15
10/1
10/15
Design
Bench
Painting
9/27
11/1
11/15
12/1
Rad Shields
11/8
Fab
12/15
1/1
1/15
2/1
2/15
12/15
Bulkhead Assy
11/28
- Fab
- Test
Pre-Slit Integration
11/28
- Offner
- POM
- FW
- IFU Mass
- SD
Post-Slit Integration
12/10
- PT
- GT
- ACQM
- Focus
- Camera - Collimator
1/8
Mate
Benches
12/15
Assemble
& Wire
- Shields
- Wiring
- Cooling
Warm Optics Test
2/4
Install
into top
assy
2/5
Cold Tests
OIWFS Integration
Camera Barrel Testing
11/15
Mechanism Testing
12/10
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Quarterly Review
October 5, 2001
Project Status - Progress from August ’99
WBS element
5.0 Overall project
5.1 Management & Reporting
5.2 Systems Engineering
5.3 Mechanical
5.3.1 Mechanisms
5.3.2 Benches
5.3.3 Fixed Assemblies
5.4 Electronics
5.5 Software
5.6 Integration
5.7 Deliverables
5.8 Procurement
Mar Review
53%
51%
100%
52%
66%
55%
16%
63%
49%
0%
0%
54%
Jun Review
66%
61%
100%
70%
84%
70%
36%
59%
63%
0%
0%
67%
Oct Review
80%
71%
100%
87%
92%
100%
62%
86%
85%
2%
0%
77%
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Quarterly Review
October 5, 2001
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
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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
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Quarterly Review
October 5, 2001
Comments on Last Quarter of Work
• Design activity concentrated on
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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
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Quarterly Review
October 5, 2001
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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Quarterly Review
October 5, 2001
Budget and Expenditures
• Baseline Estimate (Jan 99 to completion)
• Labor
• Capital
• Total
$3,391,232
$ 836,462
$4,227,694
• Current Forecast
Labor
Capital
Total
March Review
$2,866,775
$1,074,798
$3,941,573
June Review
$3,002,938
$1,181,900
$4,184,838
October Review
$2,957,389
$1,138,285
$4,095,674
March Review
$ 1,754,979
$ 1,611,542
$ 1,742,651
0.92
0.92
June Review
$ 2,863,855
$ 2,011,383
$ 2,113,212
0.95
0.70
October Review
$ 3,085,811
$ 2,526,319
$ 2,762,963
0.91
0.82
• Performance ratios
BCWS
BCWP
ACWP
CPI
SPI
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Quarterly Review
October 5, 2001
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
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Quarterly Review
October 5, 2001
Configuration Image
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Quarterly Review
October 5, 2001
Configuration - Overview
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Additions
Envelope waivers
Weight & CG update
Design/fabrication status
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Quarterly Review
October 5, 2001
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.
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Quarterly Review
October 5, 2001
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
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Quarterly Review
October 5, 2001
Configuration Image
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Quarterly Review
October 5, 2001
Configuration - Envelope
• Envelope waiver approved prior to last QR
• Additional waiver requested to accommodate
Instrument Patch Panel and He manifold approved
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Quarterly Review
October 5, 2001
Configuration Image
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Quarterly Review
October 5, 2001
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
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3/01: 4113 lb (1866 kg)
6/01: 3930 lb (1782 kg)
9/01: 3996 lb (1813 kg)
Requirement (budget): 4413 lb (2000 kg)
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Quarterly Review
October 5, 2001
Configuration - Design Status
• Few remaining items: “punch list”
– Optical:
• Telescope simulator
– Mechanical
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Shields
Thermal distribution system
Test fixtures
Telescope simulator
– Electrical
• Cabling
• Dewar and mechanism wiring
– Software
• Sequencer and interfaces
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Quarterly Review
October 5, 2001
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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Quarterly Review
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Integration & Test - Overview
• Subsystem testing
– Fit checks
– Mechanism tests
– Optics tests
• Integration and alignment
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Quarterly Review
October 5, 2001
Subsystem Testing
GNIRS Subsystem tests
Subsystem
Test Type
Test Status
Warm Shop
Environmental Cover
M
Partial
Complete Bench
Pre-Slit Bench
Offner+Pickoff
Filter Wheels (2)
Slit+Decker Slides
O,E
M
O
M
M
Post-Slit Bench
Collimator Compensator
Prism Turret
Grating Turret
Acquisition Mirror
Camera Turret
Hub
Short Red Camera
Short Blue Camera
Long Red Camera
Long Blue Camera
Focus Mechanism
Detector Mount
M
M
M
M
M
M
M
O
O
O
O
M
E
Done
OIWFS
Gimbal Mirror
Filter Wheel
Focus Stage
Detector Mount
O,E
M
M
M
E
Done
Warm Clean
Cold
Remarks
Requires dewar shell for completion
Cold check in assembled instrument
Partial
Needs pickoff mirror
Needs rest of bench for next stage
In rework
Done
Partial
Waiting for completion of mechanism tests
In fab
Needs fixturing
Needs fixturing
Needs mirror replication & cleaning
Refers to assembled turret
Needs fixturing, cleaning
Missing lens
Needs cleaning
In fab
In fab
In fab
Status ?
Done
Done
Done
Done
Done
Done
Done
Done
Done
Optical alignment after cleaning
Mechanisms tested at IfA
Mechanisms tested at IfA; no cold testing on FW
Mechanisms tested at IfA
Mechanisms tested at IfA
Test Types:
M: mechanical, including optomechanical and switches
O: optical
E: detector tests
Test not possible or not required
Done
Testing complete for this phase
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Quarterly Review
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Subsystem Testing
• Qualifies sub-assemblies for integration
– Performance can be checked prior to final integration
– Problems are isolated
– Maximum time for problem fixes
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Quarterly Review
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Subsystem Testing
• Fit checks
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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
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Quarterly Review
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Subsystem Testing
• Testing of mechanisms as outlined in previous
reviews
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Warm functionality
Warm flexure
Cold functionality
Tests (especially cold tests) without optics
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Quarterly Review
October 5, 2001
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
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Quarterly Review
October 5, 2001
Subsystem Testing
• Mechanism test status
– Initial warm tests complete for:
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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
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Quarterly Review
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Subsystem Testing
• Optics testing of “powered” sub-assemblies
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Four cameras
Offner relay
Verifies performance, not required for alignment
Camera tests require calculation of thermal, wavelength
shifts
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Quarterly Review
October 5, 2001
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)
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Quarterly Review
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Subsystem Testing
• Bench Temperature Control
– Warm bench test
– Cold test (9.4 kg mass 20 minute time constant)
– Adjust control parameters for final
configuration
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Quarterly Review
October 5, 2001
OIWFS Issues
• There are missing or corrupted detector micro-code files
– readout from mux shows no noise
– potentially more serious, requires IFA support
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•
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
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Quarterly Review
October 5, 2001
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
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Quarterly Review
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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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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)
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Quarterly Review
October 5, 2001
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
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Quarterly Review
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Dewar Integration
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Integration of cold structure into vacuum vessel
Re-test with MUX
Install engineering array
Last chance for easy OIWFS prism, IFU
installation
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Quarterly Review
October 5, 2001
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
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Quarterly Review
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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
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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
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October 5, 2001
Software Work Remaining - Design
• Alarm and Status Propagation
– Minor impact at various levels
– All other design complete
• WCS/DHS header information
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October 5, 2001
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)
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October 5, 2001
Software Work Remaining - Testing
• Low Level
– Prefer fully wired system for end-to-end test
– Motors
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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
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Quarterly Review
October 5, 2001
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,
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Quarterly Review
October 5, 2001
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
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Quarterly Review
October 5, 2001
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
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Quarterly Review
October 5, 2001
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
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Quarterly Review
October 5, 2001
Project Management
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•
•
•
Project Status
Schedule & Planning
Milestones
Budget and Expenditures
Organization
Plans for Next Review
67
Quarterly Review
October 5, 2001
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
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Quarterly Review
October 5, 2001
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
69
Quarterly Review
October 5, 2001
Project Status – WBS 5.3 Mechanical
Mechanism
%
Fixed Assembly
Camera
Detector Focus
Environ Cover
Acquisition Mirror
Slit Decker
Filter Wheel
Grating Turret
Gratings
Prism Turret
Prisms
Motor Drives
90
67
99
93
90
95
97
100
98
100
100
Bench
%
Post-Slit
OIWFS
Collimator
POM/Offner
100
100
95
100
Entrance Window
Cryo-cooler
Thermal Dist.
Bulkhead Rad Shield
LN2 Pre-Cool
Opt Bench Mount
Environ Cover Filter
Bulkhead
Front Rad Shield
Rear Rad Shield
Front Dewar Shell
Rear dewar Shell
Vert Inst Frame
Horiz Inst Frame
Dewar Mount Truss
TE Mount Truss
Shipping Container
Handling Fixture
%
100
59
26
5
91
100
15
75
8
18
70
61
77
57
44
70
0
100
70
Quarterly Review
October 5, 2001
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
71
Quarterly Review
October 5, 2001
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
72
Quarterly Review
October 5, 2001
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
73
Quarterly Review
October 5, 2001
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
74
Quarterly Review
October 5, 2001
Project Status – Optics
• Lenses and Windows
• Only one BaF2 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
75
Quarterly Review
October 5, 2001
This Page Intentionally Left Blank
76
Quarterly Review
October 5, 2001
Project Milestones by Quarter
Number of
Calendar
Milestones Running
Year
Quarter
Due
Total
1999
4th
1
1
2000
1st
15
16
2000
2nd
13
29
2000
3rd
8
37
2000
4th
18
55
2001
1st
20
75
2001
2nd
32
107
2001
3rd
40
147
2001
4th
56
203
2002
1st
13
216
2002
2nd
3
219
2002
3rd
5
224
2002
4th
0
224
TOTAL
224
Number of
Milestones Running
Comp
Total
1
1
15
16
13
29
8
37
18
55
20
75
32
107
24
131
0
131
0
131
0
131
0
131
0
131
131
As of
9/21/01
77
Quarterly Review
October 5, 2001
GNIRS Staffing FTE by Month
40.0
35.0
30.0
20.0
15.0
10.0
5.0
0.0
Au
g99
O
ct99
De
c99
Fe
b00
Ap
r-0
0
Ju
n00
Au
g00
O
ct00
De
c00
Fe
b01
Ap
r-0
1
Ju
n01
Au
g01
O
ct01
De
c01
Fe
b02
Ap
r-0
2
Ju
n02
Au
g02
FTE
25.0
Month
Plan FTE Actual FTE
78
Au
g -9
9
Oc
t-9
9
De
c -9
9
Fe
b-0
0
Ap
r-0
0
Ju
n-0
0
Au
g -0
0
Oc
t-0
0
De
c -0
0
Fe
b-0
1
Ap
r-0
1
Ju
n-0
1
Au
g -0
1
Oc
t-0
1
De
c -0
1
Fe
b-0
2
Ap
r-0
2
Ju
n-0
2
Au
g -0
2
Hours
Quarterly Review
October 5, 2001
GNIRS Work by Month
6000
5000
4000
3000
2000
1000
0
Month
Actual
Baseline
Sep'01 Plan
79
Quarterly Review
October 5, 2001
Planned FTE Projection
Oct
FTE Type
ME
ME
MD
MD
MD
MD
EE
ET
IM
IM
IM
IM
P
P
OE
GT
ENG
PA
AA
PE
PS
PSS
PM
Name
Muller
Hileman
Andrew
Downey
Rosin
Circle
Penegor
George
Stein
Bennett
Harris
Lederer
Wolff
Ruckle
Ming
Pina
Distler
Eklund
Bowersock
Davis
Elias
Joyce
Gaughan
Total
Nov
1
1
1
1
1
1
0.25
0.75
1
0.75
1
1
1
1
0.25
0.5
0.5
0.5
1
1
1
0.5
1
Dec
Jan
Feb
Mar
Apr
May
Jun
Jul
Aug
Sept
1
0.75
1
1
1
1
1
1
1
1
1
1
1
0.75
0.75
0.75
1
1
1
1
1
1
0.5
0.25
1
0.25
0.75
1
1
1
1
0.5
0.25
0.75
0.75
0.25
1
1
0.25
0.75
1
0.25
0.75
1
0.1
0.75
0.5
0.1
0.75
0.5
0.1
0.75
0.5
0.1
0.75
0.25
1
0.5
1
0.25
0.5
0.5
0.5
1
1
1
0.5
1
0.75
0.25
0.5
0.5
0.5
0.75
0.75
0.75
0.75
0.75
1
0.25
0.5
0.5
0.5
1
1
1
0.5
1
1
0.25
0.5
0.25
0.5
1
1
1
0.5
1
1
0.25
0.5
0.25
0.5
1
1
1
0.5
1
11.25
1800
$67,360
11.25
1800
$67,360
11
1760
$65,840
11
1760
$65,840
Dec
8.75
Jan
11.25
Spend Rate ($/mo)
19
3040
$114,480
16.25
2600
$97,760
Total $ to go
$786,432
21024
Oct
19.25
Nov25
16.25
0.5
Feb
Mar
11
11
1
1
1
1
1
1
0.5
0.25
0.5
1
0.5
0.25
0.5
1
0.5
0.25
0.5
1
0.5
0.25
0.5
1
0.5
0.25
0.5
1
0.5
1
0.5
1
1
0.5
1
1
0.5
1
1
0.5
1
1
0.5
1
1
0.5
1
9.1
1456
$54,288
9.1
1456
$54,288
9.1
1456
$54,288
8.6
1376
$51,248
8.5
1360
$50,640
7.25
1160
$43,040
Apr
9.1
May
9.1
8.6
Aug
8.5
Sept
7.25
Jul
Aug
Jun
Jul
9.1
0.5
1
20
15
FTE
10
5
0
Oct
Nov
Dec
Jan
Feb
Mar
Apr
May
Jun
Sept
80
Quarterly Review
October 5, 2001
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
81
Au
g
Se -99
pO c 99
No t-99
v
De -99
cJ an 99
Fe -0 0
b
Ma -00
r
Ap -00
r-0
Ma 0
yJ un 00
-0
J ul 0
Au -00
g
Se -00
pO c 00
t
No -00
v
De -00
cJ an 00
Fe -0 1
b
Ma -01
r
Ap -01
r
Ma -01
y
J un-01
-0
J ul 1
Au -01
g
Se -01
pO c 01
t
No -01
v
De -01
c
J an-01
Fe -0 2
b
Ma -02
r
Ap -02
r
Ma -02
y
J un-02
-0
J ul 2
Au -02
g -0
2
Hours
Quarterly Review
October 5, 2001
GNIRS Cumulative Work
90000
80000
70000
60000
50000
40000
30000
20000
10000
0
79,725h
77,730h
[78,469h w/sci.]
52,649h
Month
Actual
Baseline
Sep'01 Plan
82
Quarterly Review
October 5, 2001
GNIRS Capital Spend Plan
$1,400,000
$1,188,797
$1,200,000
$1,070,777
$800,000
$759,192
$600,000
$400,000
$200,000
g-0
2
Au
n-0
2
Ju
r-0
2
Ap
1
-02
Fe
b
De
c-0
01
Oc
t-
g-0
1
Au
n-0
1
Ju
r-0
1
Ap
-01
Fe
b
0
De
c-0
00
Oc
t-
g-0
0
Au
n-0
0
Ju
r-0
0
Ap
-00
Fe
b
9
De
c-9
99
Oc
t-
g-9
9
$0
Au
Dollars
$1,000,000
Month
Actual
Baseline
Sep'01 Plan
83
Quarterly Review
October 5, 2001
Organization Chart
84
Quarterly Review
October 5, 2001
Director, NOAO
J. Mould
ETS
L. Daggert
Gemini Projects
Project Manager
N. Gaughan
Project Assistant
D. Eklund (.5)
Administrative Assistant
M. Bowersock
Project
Scientist,
Systems
Engineering
J. Elias
Mechanical
Engineers
G. Muller
E. Hileman
Optical
Engineer
M. Liang
Support
Scientists
D. Joyce
B. Gregory
Mechanical
Designers
J. Andrew
D. Rosin
E. Downey
D. Circle
Instrument
Makers
J. Andrew
J. Stein
R. Bennett
L. Lederer
R. Davis
Electrical
Engineer
J. Penegor
Procurement &
Vender Liaison
A. Davis
Programmer
R. Wolff
Electrical Tech
R. George
General
Technician
J. Pina
Programmer
P. Ruckle
M&P
B. Ditsler
85
Quarterly Review
October 5, 2001
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
86
Quarterly Review
October 5, 2001
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
87
Quarterly Review
October 5, 2001
This Page Intentionally Left Blank
88
Quarterly Review
October 5, 2001
Appendix A – Images
Appendix B – Milestones,
WBS Chart
Appendix C – Envelope Waiver
89
Quarterly Review
October 5, 2001
Appendix A
Configuration and
Fabrication Images
90
Quarterly Review
October 5, 2001
Connector Feedthrough Panel
91
Quarterly Review
October 5, 2001
Aft Bulkhead
92
Quarterly Review
October 5, 2001
Aft Bulkhead Weldment
93
Quarterly Review
October 5, 2001
Aft Dewar Shell Top End
94
Quarterly Review
October 5, 2001
Forward Dewar Shell Top End
95
Quarterly Review
October 5, 2001
Forward Bulkhead Weldment
96
Quarterly Review
October 5, 2001
Forward Bulkhead Weldment
97
Quarterly Review
October 5, 2001
Bench with Slit-Slide
98
Quarterly Review
October 5, 2001
Bench on Handling Cart
99
Quarterly Review
October 5, 2001
Bench with Assemblies
100
Quarterly Review
October 5, 2001
Bench with Camera Turret Spindle
101
Quarterly Review
October 5, 2001
Bench with Collimator Gimbal Mount Ring
102
Quarterly Review
October 5, 2001
Camera Barrel
103
Quarterly Review
October 5, 2001
Camera Barrel
104
Quarterly Review
October 5, 2001
Collimator
105
Quarterly Review
October 5, 2001
Foreoptics Bench
106
Quarterly Review
October 5, 2001
Foreoptics Bench
107
Quarterly Review
October 5, 2001
Acquisition Mirror
108
Quarterly Review
October 5, 2001
Slit-Slide
109
Quarterly Review
October 5, 2001
This Page Intentionally Left Blank
110
Quarterly Review
October 5, 2001
Appendix B
Milestones
WBS Chart
111
Quarterly Review
October 5, 2001
Milestones since MFR (3/01)
5.4.1.2.5
5.3.1.8.2.6
5.3.3.9.1.5
5.3.1.2.2.2.4
5.3.1.104.5
5.3.1.2.3.1.3
5.3.2.4.2.3.3
5.3.3.14.1.4
5.3.3.15.1.5
5.3.3.17.1.5
5.3.3.19.4
5.3.2.3.3.2.4
5.3.2.3.2.1.5
5.3.3.13.1.5
5.3.3.9.2.6
5.3.1.8.6.4
5.3.3.12.1.5
5.3.3.6.1.3
5.3.1.2.3.2.4
5.3.3.17.2.6
5.3.2.3.2.2.4
5.3.1.7.3.2
5.3.3.3.1.4
5.3.3.2.2.4
5.3.3.12.2.6
5.3.2.1.8.3.2
5.3.2.1.8.4.4
5.3.3.13.2.6
5.3.1.6.5.3.2
5.3.2.1.6.3.2
5.8.1.3.1
5.3.1.3.2.4
5.3.2.2.3.1
5.3.1.2.6.3.4
5.3.2.1.6.4.4
5.3.2.4.2.4.4
5.3.2.3.3.3.4
5.3.3.3.2.4
5.3.3.7.3.2
5.3.3.6.2.4
5.3.2.3.1.3.3
5.3.2.1.3.3
5.3.2.2.1.3.4
5.3.3.7.4.4
5.3.2.3.2.3.2
5.3.2.1.7.3.2
5.3.3.2.3.5
5.3.2.1.7.4.4
Motor Drive / Cryohead Control Chassis Complete
Grating Turret Drafting Complete
Bulkhead Assembly Design Complete
Long Red Camera Drafting Complete
Motor Drive Assembly Complete
Long Blue Camera Design Complete
Offner Assembly Fabrication Complete
Vertical Installation Frame Assembly Design Complete
Horizontal Installation Frame Assembly Design Complete
Thermal Enclosure Mount Assembly Design Complete
Handling Fixtures Complete
Collimator Compensating Mount Design Complete
Collimator Cover Box Design Complete
Rear Dewar Shell Design Complete
Bulkhead AssemblyDrafting Complete
Grating Fabrication Complete
Front Dewar Shell Design Complete
LN2 Pre-Cool Assemby Design Complete
Long Blue Camera Drafting Complete
Thermal Enclosure Mount Assembly Drafting Complete
Collimator Cover Box Drafting Complete
Filter Wheel Assembly Fabrication Complete
Cryo Cooler Design Complete
Detector Mount Assembly Drafting Complete
Front Dewar Shell Drafting Complete
Bottom Camera Cover Fabrication Complete
Bottom Camera Cover Complete
Rear Dewar Shell Drafting Complete
Slit/Decker Assembly Fabrication Complete
LCFMH Fabrication Complete
Flat Mirrors Acceptance
Detector Focus Assembly Drafting Complete
Receive and Inspect IFA WFS electronics
Camera Hub Fabrication Complete
LCFMH Complete
Offner Assembly Complete
Collimator Compensating Mount Drafting Complete
Cryo Cooler Drafting Complete
Optical Bench Mount Assembly Fabrication Complete
LN2 Pre-Cool Assemby Drafting Complete
CollimatorHousing Fabrication Complete
Post-Slit Bench Fabrication Complete
OIWFS Assembly Fabrication Complete
Optical Bench Mount Assembly Complete
Collimator Cover Box Fabrication Complete
Top Camera Cover Fabrication Complete
Detector Mount Assembly Fabrication Complete
Top Camera Cover Assembly Complete
8/29/00
6/7/00
9/26/00
10/4/00
8/2/00
5/31/00
9/11/00
12/4/00
12/5/00
1/23/01
NA
NA
5/5/00
3/29/01
2/21/01
11/28/00
2/26/01
11/16/00
11/27/00
3/14/01
8/7/00
1/10/01
9/26/00
1/4/01
3/16/01
7/21/00
7/26/00
NA
3/5/01
8/1/00
6/2/00
1/26/01
9/5/00
12/4/00
8/4/00
9/22/00
NA
11/21/00
5/3/01
12/7/00
2/13/01
11/20/00
11/30/00
5/21/01
8/8/00
7/19/00
2/22/01
7/24/00
4/9/01
4/10/01
4/10/01
4/13/01
4/16/01
4/17/01
4/24/01
4/27/01
4/27/01
4/30/01
5/18/01
5/23/01
5/30/01
5/31/01
6/1/01
6/1/01
6/1/01
6/6/01
6/6/01
6/8/01
6/11/01
6/11/01
6/12/01
6/15/01
6/19/01
6/25/01
6/28/01
6/28/01
6/29/01
6/29/01
6/29/01
7/2/01
6/29/01
7/5/01
7/5/01
7/16/01
7/19/01
7/23/01
7/23/01
7/25/01
7/25/01
7/30/01
7/31/01
8/9/01
8/17/01
8/17/01
8/22/01
8/22/01
4/9/01
4/10/01
4/10/01
4/13/01
4/16/01
4/17/01
4/24/01
4/27/01
4/27/01
4/30/01
5/18/01
5/23/01
5/30/01
5/31/01
6/1/01
6/1/01
6/1/01
6/6/01
6/6/01
6/8/01
6/11/01
6/11/01
6/12/01
6/15/01
6/19/01
6/25/01
6/28/01
6/28/01
6/29/01
6/29/01
6/29/01
7/2/01
7/3/01
7/5/01
7/5/01
7/16/01
7/19/01
7/23/01
7/23/01
7/25/01
7/25/01
7/30/01
7/31/01
8/9/01
8/17/01
8/17/01
8/22/01
8/22/01
112
Quarterly Review
October 5, 2001
WBS - Total Project
113
Quarterly Review
October 5, 2001
This Page Intentionally Left Blank
114
Quarterly Review
October 5, 2001
Appendix C
Envelope Waiver
115
Quarterly Review
October 5, 2001
This Page Intentionally Left Blank
116
Quarterly Review
October 5, 2001
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.
117
Quarterly Review
October 5, 2001
Figure 1. Summary of GNIRS envelope violations, include those previously approved by
Gemini. The Gemini instrument envelope is shown overlaid on the instrument itself.
118
Quarterly Review
October 5, 2001
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.
119