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Nadine [email protected]
LUSI DOE Review July 23, 2007Engineering Overview 1
Engineering OverviewNadine Kurita
Engineering OverviewNadine Kurita
Organization Engineering Processes
StandardsReviewsSpecifications/Requirements/ICDsConfiguration Management
Value ManagementReporting Engineering StatusScheduleSummary
Organization Engineering Processes
StandardsReviewsSpecifications/Requirements/ICDsConfiguration Management
Value ManagementReporting Engineering StatusScheduleSummary
Nadine [email protected]
LUSI DOE Review July 23, 2007Engineering Overview 2
Engineering OrganizationEngineering Organization
LUSIN. Kurita
Chief Engineer
CXI WBS 1.3J.C. Castagna - acting
System Manager
XPP WBS 1.2R. Pope
System Manager
XCS WBS 1.4N. Kurita – acting
TBDSystem Manager
Diagnostics WBS 1.5N. Kurita
System Manager
Design & Document Control
D. ArnettDesign Supervisor
M. KosovskyJ.C. Castagna
SLAC Designer2
D. Arnett J. Defever
SLAC Designer1
D. ArnettMechanical Engineer1
SLAC Design StaffTBDStarts 2009
Database SupportA. Chan (LCLS)
Nadine [email protected]
LUSI DOE Review July 23, 2007Engineering Overview 3
Engineering Organization (2)Engineering Organization (2)
System ManagersReports to Chief EngineerResponsible for all technical aspects of the projectResponsible for reporting cost and schedule (earned value)
Control Account Manager (CAM) Responsible for supervising daily activities of subordinate engineers, design engineers and designersResponsible for keeping management informed on critical issues, delays, etc.Works with upper management to make critical decisions
Design SupervisorResponsible for design standardsChecking, sign off approval and releasing drawings
System ManagersReports to Chief EngineerResponsible for all technical aspects of the projectResponsible for reporting cost and schedule (earned value)
Control Account Manager (CAM) Responsible for supervising daily activities of subordinate engineers, design engineers and designersResponsible for keeping management informed on critical issues, delays, etc.Works with upper management to make critical decisions
Design SupervisorResponsible for design standardsChecking, sign off approval and releasing drawings
Nadine [email protected]
LUSI DOE Review July 23, 2007Engineering Overview 4
Engineering Organization (3)Engineering Organization (3)
2008 Manpower RequirementsMaximum load for engineering per current estimates5 FTE Mechanical Engineers2 - 3 FTE Mechanical Designers
Current Engineering StaffNadine Kurita – Chief Engineer, Mechanical EngineerRodd Pope – System Engineer, Mechanical EngineerJean-Charles Castagna – Mechanical EngineerMichael Kosovsky – Mechanical Design EngineerJim Defever – Mechanical Engineer (Consultant)Donald Arnett – Design Supervisor, Design Engineer
2008 Manpower RequirementsMaximum load for engineering per current estimates5 FTE Mechanical Engineers2 - 3 FTE Mechanical Designers
Current Engineering StaffNadine Kurita – Chief Engineer, Mechanical EngineerRodd Pope – System Engineer, Mechanical EngineerJean-Charles Castagna – Mechanical EngineerMichael Kosovsky – Mechanical Design EngineerJim Defever – Mechanical Engineer (Consultant)Donald Arnett – Design Supervisor, Design Engineer
Nadine [email protected]
LUSI DOE Review July 23, 2007Engineering Overview 5
Engineering Organization (4)Engineering Organization (4)
Staffing ProgressSystem Manager hiring status
Offer received June 26th
Junior Mechanical Engineer requisition open – interviewingDeputy System Manager for diagnostics
2 SLAC Designers in August/SeptemberDesign staff available due to reduction in peak LCLS and HEP personnelAdditional design staff will be available if our needs increase
LCLS will have engineers that could be matrixed if our needs increase
This will fulfill our engineering staff requirement for 2008
Staffing ProgressSystem Manager hiring status
Offer received June 26th
Junior Mechanical Engineer requisition open – interviewingDeputy System Manager for diagnostics
2 SLAC Designers in August/SeptemberDesign staff available due to reduction in peak LCLS and HEP personnelAdditional design staff will be available if our needs increase
LCLS will have engineers that could be matrixed if our needs increase
This will fulfill our engineering staff requirement for 2008
Nadine [email protected]
LUSI DOE Review July 23, 2007Engineering Overview 6
Engineering Processes – StandardsEngineering Processes – Standards
Formalize Design Standards Incorporate SLAC mechanical design standards Developed standard engineering notes
Developed Solid Edge Tool (3D parametric software)
Formalize Manufacturing PracticesLUSI Procedures and Travellers
Produced for critical equipmentConfiguration controlledHistory archived via LUSI sharepoint
Non-Compliance Reports (NCRs), Inspection ReportsHistory archived via LUSI sharepoint
Formalize Design Standards Incorporate SLAC mechanical design standards Developed standard engineering notes
Developed Solid Edge Tool (3D parametric software)
Formalize Manufacturing PracticesLUSI Procedures and Travellers
Produced for critical equipmentConfiguration controlledHistory archived via LUSI sharepoint
Non-Compliance Reports (NCRs), Inspection ReportsHistory archived via LUSI sharepoint
Nadine [email protected]
LUSI DOE Review July 23, 2007Engineering Overview 7
Engineering Processes - ReviewsEngineering Processes - Reviews
Design reviews are milestones in our scheduleEssential to ensure the designs meet their prescribed functionalityValue engineering
Design reviews are milestones in our scheduleEssential to ensure the designs meet their prescribed functionalityValue engineering
Nadine [email protected]
LUSI DOE Review July 23, 2007Engineering Overview 8
Engineering Processes - Reviews (2)Engineering Processes - Reviews (2)
System Concept ReviewGlobal (CXI, XPP, XCS, Controls and Data System)Goal
Approve the objectives and physics requirementsApproval of the conceptual design approach
Presents the followingObjectives and the requirements of the system
Physics Requirements Document complete and ready for sign off
Proposed approach to meet the requirementsMajor system interfacesMajor design alternatives consideredSafety issuesAssessment of risk areas
After closure of action items this approves the baseline design
System Concept ReviewGlobal (CXI, XPP, XCS, Controls and Data System)Goal
Approve the objectives and physics requirementsApproval of the conceptual design approach
Presents the followingObjectives and the requirements of the system
Physics Requirements Document complete and ready for sign off
Proposed approach to meet the requirementsMajor system interfacesMajor design alternatives consideredSafety issuesAssessment of risk areas
After closure of action items this approves the baseline design
Nadine [email protected]
LUSI DOE Review July 23, 2007Engineering Overview 9
Engineering Processes – Reviews (3)Engineering Processes – Reviews (3)
Preliminary Design ReviewsComponent specificFinal design details are not requiredGoal
Approval of the component specifications & preliminary designApproval to complete final designApproval to fabricate test articles
Presents the following:Science/technical objectives, requirements, general specification
Engineering Speciation Document complete and ready for sign offPreliminary design & engineering analyses Design interfacesClosure of actions from previous review/changes since the last reviewControl/software requirements and designQuality control, reliabilitySafetyCost & schedules
After closure of action items preliminary design approved. Move to final design
Preliminary Design ReviewsComponent specificFinal design details are not requiredGoal
Approval of the component specifications & preliminary designApproval to complete final designApproval to fabricate test articles
Presents the following:Science/technical objectives, requirements, general specification
Engineering Speciation Document complete and ready for sign offPreliminary design & engineering analyses Design interfacesClosure of actions from previous review/changes since the last reviewControl/software requirements and designQuality control, reliabilitySafetyCost & schedules
After closure of action items preliminary design approved. Move to final design
Nadine [email protected]
LUSI DOE Review July 23, 2007Engineering Overview 10
Engineering Processes – Reviews (4)Engineering Processes – Reviews (4)
Final Design ReviewsComponent specificGoal
Approval of the final design, cost and scheduleApproval to complete detail drawingsApproval to start procurement & fabrication
Presents the following:Science/technical objectives, requirements & specificationsReview closure of actions from the Preliminary Design ReviewFinal design and analysesTest results and design marginsControl methods for all safety hazardsApproved safety reviews as requiredIdentified problem areas/open issuesCost & schedule
After closure of action items long lead items will be purchased, detail drawings completed and fabrication begins
Final Design ReviewsComponent specificGoal
Approval of the final design, cost and scheduleApproval to complete detail drawingsApproval to start procurement & fabrication
Presents the following:Science/technical objectives, requirements & specificationsReview closure of actions from the Preliminary Design ReviewFinal design and analysesTest results and design marginsControl methods for all safety hazardsApproved safety reviews as requiredIdentified problem areas/open issuesCost & schedule
After closure of action items long lead items will be purchased, detail drawings completed and fabrication begins
Nadine [email protected]
LUSI DOE Review July 23, 2007Engineering Overview 11
Engineering Processes – Reviews (5)Engineering Processes – Reviews (5)
Status ReviewsComponent specific as neededNot a schedule milestoneGoal
Provides status on drawings, procurement and manufacturingPresents the following:
Status of assembly and detail drawingsApproval process per Mechanical Department standards
Procedures, travellers, inspection and testing plansStatus of procurement and manufacturingInstallation plansOperational requirements/procedures
checkout, testing, maintenance
Review closure of action items from the FDRCost and schedule update
Status ReviewsComponent specific as neededNot a schedule milestoneGoal
Provides status on drawings, procurement and manufacturingPresents the following:
Status of assembly and detail drawingsApproval process per Mechanical Department standards
Procedures, travellers, inspection and testing plansStatus of procurement and manufacturingInstallation plansOperational requirements/procedures
checkout, testing, maintenance
Review closure of action items from the FDRCost and schedule update
Nadine [email protected]
LUSI DOE Review July 23, 2007Engineering Overview 12
Engineering Processes – Reviews (6)Engineering Processes – Reviews (6)
Safety ReviewsSafety Overview Committee Review
Completed December 2006 and identified the following committee reviews:
Earthquake ReviewsRadiation Safety ReviewsLaser Safety ReviewsElectrical Safety ReviewsHoisting and Rigging Safety CommitteeFire MarshallHazardous Experimental Equipment Committee
Safety ReviewsSafety Overview Committee Review
Completed December 2006 and identified the following committee reviews:
Earthquake ReviewsRadiation Safety ReviewsLaser Safety ReviewsElectrical Safety ReviewsHoisting and Rigging Safety CommitteeFire MarshallHazardous Experimental Equipment Committee
Nadine [email protected]
LUSI DOE Review July 23, 2007Engineering Overview 13
Engineering Process – RequirementsEngineering Process – RequirementsPhysics Requirements Documents (PRD)
Defines functionality of the componentProvides detailed physics/science requirementsBasis for engineering designRequired for the System Concept ReviewApproved by Science Team Leaders and LUSI Project Director
Engineering Specification Document (ESD)General specifications & engineering specifications to meet the PRD
Covers additional requirements not in the PRDSpace constraints, environment, etc.
Required for the Preliminary Design ReviewApproved by Chief Engineer, Scientist, Project Director
Interface Control Documents (ICD)Describes the boundaries of one system with respect to anotherPhysical interface between the twoResponsibilities Required for the Preliminary Design ReviewApproved by all involved system managers
Physics Requirements Documents (PRD)Defines functionality of the componentProvides detailed physics/science requirementsBasis for engineering designRequired for the System Concept ReviewApproved by Science Team Leaders and LUSI Project Director
Engineering Specification Document (ESD)General specifications & engineering specifications to meet the PRD
Covers additional requirements not in the PRDSpace constraints, environment, etc.
Required for the Preliminary Design ReviewApproved by Chief Engineer, Scientist, Project Director
Interface Control Documents (ICD)Describes the boundaries of one system with respect to anotherPhysical interface between the twoResponsibilities Required for the Preliminary Design ReviewApproved by all involved system managers
Nadine [email protected]
LUSI DOE Review July 23, 2007Engineering Overview 15
Engineering Process – RequirementsEngineering Process – Requirements
Technical Purchase SpecificationsMandates the technical, quality and procurement specifications for a purchased item
Engineering NotesDocuments engineering analysis and other information critical to the design of the component
These documents are all configuration controlled
Technical Purchase SpecificationsMandates the technical, quality and procurement specifications for a purchased item
Engineering NotesDocuments engineering analysis and other information critical to the design of the component
These documents are all configuration controlled
Nadine [email protected]
LUSI DOE Review July 23, 2007Engineering Overview 16
Configuration Management - Document ControlConfiguration Management - Document Control
Document ControlConfiguration control all critical project documents
ManagementPEP, Acquisition Strategy, QIP, Value Management, …
TechnicalPRDs, ESDs, ICDs, Design Reviews, ...
FabricationProcedures, travellers, ...
InstallationProcedures, travellers, ...
Design reviews will be archived
Document ControlConfiguration control all critical project documents
ManagementPEP, Acquisition Strategy, QIP, Value Management, …
TechnicalPRDs, ESDs, ICDs, Design Reviews, ...
FabricationProcedures, travellers, ...
InstallationProcedures, travellers, ...
Design reviews will be archived
Nadine [email protected]
LUSI DOE Review July 23, 2007Engineering Overview 17
Configuration Management – Drawings/SpecificationsConfiguration Management – Drawings/Specifications
Utilize existing SLAC Document Control System and SLAC Sharepoint database3D-models will use SLAC Mechanical Departments Project Management Database for configuration control and archiving
Drawings and specificationsApproved by the list of “approvers”Design review process is not required for approvalOnce the document is signed by all the approvers it is released to SLAC Document Control
Utilize existing SLAC Document Control System and SLAC Sharepoint database3D-models will use SLAC Mechanical Departments Project Management Database for configuration control and archiving
Drawings and specificationsApproved by the list of “approvers”Design review process is not required for approvalOnce the document is signed by all the approvers it is released to SLAC Document Control
Nadine [email protected]
LUSI DOE Review July 23, 2007Engineering Overview 18
Configuration Management - ECOsConfiguration Management - ECOs
Engineering Change OrdersImplementing an engineering change order processKeeps detailed revision historyIncrease efficiency of implementing and documenting design and manufacturing changes
Allows for quick approval of implementing changesHelps to maintains these changes in the supporting design/fabrication documents
Engineering Change OrdersImplementing an engineering change order processKeeps detailed revision historyIncrease efficiency of implementing and documenting design and manufacturing changes
Allows for quick approval of implementing changesHelps to maintains these changes in the supporting design/fabrication documents
Nadine [email protected]
LUSI DOE Review July 23, 2007Engineering Overview 19
Value ManagementValue Management
Consistent with DOE Value Management, DOE order 413.3 and OMB Circular A-131 LUSI Value Management Plan completed, PM-391-000-02 R0Executed LUSI Value Management Plan
Conducted with internal and external reviewers4 alternative solutions identifiedFinal report pending
LUSI Value Management principles are applied to all LUSI engineering tasks
Consistent with DOE Value Management, DOE order 413.3 and OMB Circular A-131 LUSI Value Management Plan completed, PM-391-000-02 R0Executed LUSI Value Management Plan
Conducted with internal and external reviewers4 alternative solutions identifiedFinal report pending
LUSI Value Management principles are applied to all LUSI engineering tasks
Nadine [email protected]
LUSI DOE Review July 23, 2007Engineering Overview 20
LUSI ReportingLUSI Reporting
Monthly Reports to the DOE after achieving CD2aTechnical statusEarned value performance. LUSI Project Management Cost & Schedule system is based on,
B-Factory Project - 2000 Award for the Program and Project ManagementSPEAR3 – 2004 Secretary's Excellence in Acquisition AwardGLASTLCLS60% CAMS participated in PEP-II,SPEAR3, GLAST and/or LCLS
Change Control Log
Monthly Reports to the DOE after achieving CD2aTechnical statusEarned value performance. LUSI Project Management Cost & Schedule system is based on,
B-Factory Project - 2000 Award for the Program and Project ManagementSPEAR3 – 2004 Secretary's Excellence in Acquisition AwardGLASTLCLS60% CAMS participated in PEP-II,SPEAR3, GLAST and/or LCLS
Change Control Log
Nadine [email protected]
LUSI DOE Review July 23, 2007Engineering Overview 21
Engineering StatusEngineering Status
X-ray Pump ProbeOverall layouts developed for both CD4a and CD4bDiffractometer
PRD reviewed and approved by team leaders in May ’07 – CRITICAL PATH ITEM for CD4-aPreliminary concepts of the diffractometer developed. Starting to work with vendors
MonochromatorPreliminary concepts developed
X-ray Pump ProbeOverall layouts developed for both CD4a and CD4bDiffractometer
PRD reviewed and approved by team leaders in May ’07 – CRITICAL PATH ITEM for CD4-aPreliminary concepts of the diffractometer developed. Starting to work with vendors
MonochromatorPreliminary concepts developed
Nadine [email protected]
LUSI DOE Review July 23, 2007Engineering Overview 22
X-ray Pump-Probe Instrument
OffsetMonochromator
Laser System(Fundamental)
X-rayDiffractometerWavelength
Conversion
Small AngleScattering
X-Ray Pump Probe LayoutX-Ray Pump Probe Layout
Nadine [email protected]
LUSI DOE Review July 23, 2007Engineering Overview 23
Engineering Status (2)Engineering Status (2)
Coherent X-Ray Imaging (CXI)Conceptual layouts developed for both CD4a and CD4b Met with team leaders to discuss sample chamber requirements in May 2007
Developed multiple sample chamber approaches. CRITICAL PATH ITEM FOR CD4a
Coherent X-Ray Imaging (CXI)Conceptual layouts developed for both CD4a and CD4b Met with team leaders to discuss sample chamber requirements in May 2007
Developed multiple sample chamber approaches. CRITICAL PATH ITEM FOR CD4a
Nadine [email protected]
LUSI DOE Review July 23, 2007Engineering Overview 24
CXI Sample Chamber Design Approach #1CXI Sample Chamber Design Approach #1
Nadine [email protected]
LUSI DOE Review July 23, 2007Engineering Overview 25
Engineering Status (3)Engineering Status (3)
X-Ray Correlation Spectroscopy (XCS)Conceptual layout completed
DiagnosticsElectro-Optic Timing Device
Draft of the Engineering Specification Document completedPreliminary design near completionPreliminary Design Review in October 2007 ahead of schedule
X-Ray Correlation Spectroscopy (XCS)Conceptual layout completed
DiagnosticsElectro-Optic Timing Device
Draft of the Engineering Specification Document completedPreliminary design near completionPreliminary Design Review in October 2007 ahead of schedule
EO Device
Nadine [email protected]
LUSI DOE Review July 23, 2007Engineering Overview 26
Engineering Status (4)Engineering Status (4)
Position Monitor & Intensity Monitor Pop-inAlternate concepts developed
Hard X-Ray Intensity/Position Monitor Leave-inAlternate concepts developed
Position Monitor & Intensity Monitor Pop-inAlternate concepts developed
Hard X-Ray Intensity/Position Monitor Leave-inAlternate concepts developed
Pop-in Position Monitor
Leave In Monitor
Pop-in Diode Intensity Monitor
Nadine [email protected]
LUSI DOE Review July 23, 2007Engineering Overview 27
XPP Critical PathXPP Critical Path
Diffractometerlong Lead item
Vacuum supportslow risk,occurs last in the designprocess
Nadine [email protected]
LUSI DOE Review July 23, 2007Engineering Overview 28
CXI Critical PathCXI Critical Path
Slit Systemmanpowerlimited, couldbe expedited
Sample Chambercritical design,incorporatesnumerous experiments
Low risk, vacuum system follows aftercritical componentsdesigned.
Nadine [email protected]
LUSI DOE Review July 23, 2007Engineering Overview 29
Major MilestonesMajor Milestones
Jul ’07 CD1 ReviewAug ’07 XPP System Concept ReviewSep ’07 CXI System Concept ReviewOct ’07 Diagnostic System Concept ReviewOct ’07 EO Monitor Final Design ReviewNov ’07 Diffractometer Final Design Review Nov ’07 Be Lenses Preliminary Design ReviewDec ’07 CD2a
Jul ’07 CD1 ReviewAug ’07 XPP System Concept ReviewSep ’07 CXI System Concept ReviewOct ’07 Diagnostic System Concept ReviewOct ’07 EO Monitor Final Design ReviewNov ’07 Diffractometer Final Design Review Nov ’07 Be Lenses Preliminary Design ReviewDec ’07 CD2a
Nadine [email protected]
LUSI DOE Review July 23, 2007Engineering Overview 30
Major Milestones (2)Major Milestones (2)
Jan ’08 Sample Chamber Preliminary Design Review (PDR)Jan’07 Hard X-Ray IO PDRJan ’07Be Lenses Final Design Review (FDR)Feb ’08 CXI Pulse Picker PDRMar ’08 Hard X-Ray Intensity Monitor FDRApr ’08 XPP Diffractometer non-recurring engineering May ’08 CXI Sample Chamber & Pulse Picker FDRMay ’08 Position Monitor & Pop-in IO monitor FDRJul ’08 Slits FDRJul ’08 CD3a
Jan ’08 Sample Chamber Preliminary Design Review (PDR)Jan’07 Hard X-Ray IO PDRJan ’07Be Lenses Final Design Review (FDR)Feb ’08 CXI Pulse Picker PDRMar ’08 Hard X-Ray Intensity Monitor FDRApr ’08 XPP Diffractometer non-recurring engineering May ’08 CXI Sample Chamber & Pulse Picker FDRMay ’08 Position Monitor & Pop-in IO monitor FDRJul ’08 Slits FDRJul ’08 CD3a
Nadine [email protected]
LUSI DOE Review July 23, 2007Engineering Overview 31
Major Milestones (3)Major Milestones (3)
Jul ’08 Start procurement for CXI and XPPJul ’08 Start fabrication of XPP DiffractometerJul ’08 Award Sample ChamberJan ’09 All major CD4a components receivedApr ’09 All major CD4a components ready for installationSep ’09 CD4a installation completeSep ’09 XPP Detector installed Oct ’09 CD2bNov ’09 Particle Injector receivedFeb ’10 CD4aMar ’10 CD3bMar ’12 CD4b
Jul ’08 Start procurement for CXI and XPPJul ’08 Start fabrication of XPP DiffractometerJul ’08 Award Sample ChamberJan ’09 All major CD4a components receivedApr ’09 All major CD4a components ready for installationSep ’09 CD4a installation completeSep ’09 XPP Detector installed Oct ’09 CD2bNov ’09 Particle Injector receivedFeb ’10 CD4aMar ’10 CD3bMar ’12 CD4b
Nadine [email protected]
LUSI DOE Review July 23, 2007Engineering Overview 32
SummarySummary
Engineering/Scientist teams have made significant design progress to date
LUSI has an established conceptual design with a consistent cost estimate. Over 50% of the fabrication estimates came from vendor quotations, catalogs, or previous ordersThe technical scope of LUSI has converged
Preliminary resource loaded schedule for planned CD4a deliverables is established and consistent with the funding profile
Engineering/Scientist teams have made significant design progress to date
LUSI has an established conceptual design with a consistent cost estimate. Over 50% of the fabrication estimates came from vendor quotations, catalogs, or previous ordersThe technical scope of LUSI has converged
Preliminary resource loaded schedule for planned CD4a deliverables is established and consistent with the funding profile
Nadine [email protected]
LUSI DOE Review July 23, 2007Engineering Overview 33
Summary (2)Summary (2)
LUSI engineering staffing is currently at 70% of its peak expected load
Staff consists of experienced SLAC (SSRL, LCLS, HEP) mechanical engineers and design engineersStaff is informed in quality and trained in ES&H issues in their area of expertise
Working organization with well understood processesExcellent communication and interfacing with partner labs, LCLS and sub-systems
LUSI engineering staffing is currently at 70% of its peak expected load
Staff consists of experienced SLAC (SSRL, LCLS, HEP) mechanical engineers and design engineersStaff is informed in quality and trained in ES&H issues in their area of expertise
Working organization with well understood processesExcellent communication and interfacing with partner labs, LCLS and sub-systems
Nadine [email protected]
LUSI DOE Review July 23, 2007Engineering Overview 34
Summary (3)Summary (3)
Future workComplete hiring or matrixing LCLS engineering staffFinalize the details on the design scope and requirementsComplete preliminary designs
Engineering staff is ready to move on to the CD-2 phase of the project!
Future workComplete hiring or matrixing LCLS engineering staffFinalize the details on the design scope and requirementsComplete preliminary designs
Engineering staff is ready to move on to the CD-2 phase of the project!
J. B. [email protected]
LUSI DOE Review Jan 23, 2007Coherent Imaging (WBS 1.3)
End of PresentationEnd of Presentation
