Engineering Overview

1
Engineering Overview CD-2 Lehman Review Nadine
Kurita - LUSI Chief Engineer August 19, 2008
2
Outline

• Safety
• Organization
• Engineering Processes
• Standards
• Reviews
• Specifications/Requirements/ICDs
• Configuration Management
• Value Management
• Engineering Status
• Requirement Document Status
• Basis of Estimate
• Cost Methodology
• Major Milestones
• Summary

3
Safety

• Lead Engineer Engineering Staff
• Responsible for integrating safety into their
  designs
• Access to ESH staff, peer reviews and SLAC
  Safety Committees
• Line Management
• Responsible for safety
• Responsible for authorizing work to proceed
• Utilize verification processes
• LUSI safety review checklist
• Design review process includes safety at each
  stage of design
• Safety reviews are included in the P3 schedule
• Work Authorization Form LCLS Procedure
• Instrument designs are consistent with SLAC ESH
  Policy Safety Overview Committee Review
• SLAC authorization to energize machine includes
  sign-off by SLAC Safety Committees and SLAC
  Safety Officers

4
Engineering Organization
5
Engineering Organization (2)

• Staffing Progress
• Added 12 engineers/designers since the CD1 Review
• All Lead Engineer/CAM positions filled
• Manpower Requirements per Current Schedule
• Q4FY2008
• 12.1 FTE Mechanical Engineers
• 6.6 FTE Mechanical Designers
• 1.9 FTE Controls Engineers
• Currently searching for 3-4 additional engineers
• AMO engineers available in September
• Maximum load for mechanical engineering is in
  Q3FY2009
• 11 FTE Mechanical Engineers
• 9.3 FTE Mechanical Designers
• Maximum load for controls engineering Q2FY2010
• 5.1 FTE Controls Engineers
• 1.7 FTE Controls Programmers

6
LUSI Engineering Resource Loading
7
Engineering Organization (4)

• Lead Engineer
• Reports to Chief Engineer
• Responsible for all technical aspects of the
  project
• Responsible for reporting cost and schedule
• Control Account Manager (CAM)
• Responsible for supervising daily activities of
  subordinate engineers, design engineers and
  designers
• Responsible for keeping management informed on
  critical issues, delays, etc.
• Works with upper management to make critical
  decisions
• Design Supervisor
• Responsible for design standards
• Checking, approving and releasing drawings

8
Engineering Processes Standards

• Formalize Design Standards
• Incorporated SLAC Mechanical Design Department
  standards through SP-391-000-36, LUSI Design
  Standard Supplement
• Developed standard engineering notes
• Developed Solid Edge Tool (3D parametric
  software)
• Formalize Manufacturing Practices
• LUSI Procedures and Travellers
• Produced for critical equipment
• Configuration controlled
• History archived via LCLS/LUSI sharepoint
• Non-Compliance Reports (NCRs), Inspection Reports
• History archived via LCLS/LUSI sharepoint

9
Engineering Processes - Reviews

• Design review goals and criteria are documented
• Design reviews are milestones in our schedule
• Essential to ensure the designs meet their
  prescribed functionality
• Demonstrate value engineering
• Engineering review template completed

10
Engineering Processes - Reviews (2)

• Preliminary Instrument Design Review (PIDR)
• Instrument System Specific (CXI, XPP, XCS)
• Goal
• Approve the objectives and physics requirements
  of the instrument
• Approval of the conceptual design approach
• Presents the following
• Science including breadth of applications
  possible with the instrument
• Objectives and the requirements of the system
• Instrument System Physics Requirements Document
  complete and ready for sign off
• Performance requirements of the components
• Proof of Concept Models
• Proposed approach to meet the requirements
• System design
• Mechanical
• Electrical
• Major system interfaces, organizational and
  technical
• Major design alternatives considered (Value
  Management)
• Safety considerations
• Assessment of risk areas

11
Engineering Processes Reviews (4)

• Preliminary Design Reviews
• Component specific
• Final design details are not required
• Goal
• Approval of the component specifications
  preliminary design
• Approval to complete final design
• Approval to fabricate test articles and place
  long duration procurements
• Presents the following
• Science/technical objectives, requirements,
  general specification
• Engineering Specification Document complete and
  ready for sign off
• Preliminary design engineering analyses
• Design interfaces
• Control/software requirements
• Quality control, reliability
• Safety considerations define hazards
• Cost schedule
• After closure of action items preliminary design
  approved and long duration items will be
  purchased. Move to final design.

12
Engineering Processes - Reviews (3)

• Final Instrument Design Review (FIDR)
• Instrument System Specific (CXI, XPP, XCS)
• Prerequisite
• All major Component Preliminary Design Reviews
  must be completed.
• Goal
• Approve final instrument design / configuration
  verify that they meet requirements
• Presents the following
• System requirements for the instrument
• Instrument PRD, ESD and procurement
  specifications are complete and ready for
  sign-off
• Layout Update - Identify changes from PIDR
  layout
• Component design status and description
• Design and analyses to meet the requirements
• Major design alternatives considered (value
  management)
• Major system interfaces, organizational and
  technical
• Identify operational modes
• Maintenance requirements
• Planned test program if appropriate
• Installation alignment plans
• Cost schedule

13
Engineering Processes Reviews (5)

• Final Design Reviews
• Component specific
• Goal
• Approval of the final design, cost and schedule
• Approval to complete detail drawings
• Approval to start procurement fabrication
• Presents the following
• Science/technical objectives, requirements
  specifications
• Review closure of actions from the Preliminary
  Design Review
• Final design and analyses
• Test results and design margins
• Analyze and develop controls for all safety
  hazards
• Approved safety reviews as required
• Identified problem areas/open issues
• Cost schedule
• After closure of action items this approves the
  final design and detail drawings are completed.
  Approval to purchase items and begin fabrication.

14
Engineering Processes Reviews (6)

• Manufacturing Readiness Review
• Component specific
• Schedule milestone
• Goal
• Provides status on drawings, procurement,
  manufacturing and safety documents.
• Presents the following
• Status of assembly and detail drawings
• Approval process per Mechanical Department
  standards
• Procedures, travellers, inspection and testing
  plans
• Status of procurement and manufacturing
• Installation plans documents
• Work Authorization, Statement of Work
• Operational requirements/procedures
• checkout, testing, maintenance
• Develop and implement hazard controls
• Safety documents
• Review closure of action items from the FDR
• Cost and schedule update
• After closure of action items this approves the
  start of assembly, testing and installation.

15
Engineering Processes Reviews (7)

• Safety Reviews
• Safety Overview Committee Review (SOC), K.
  Moffeit
• Completed December 2006 and identified the
  following required committee reviews
• Earthquake Reviews
• Radiation Safety Reviews
• Laser Safety Reviews
• Electrical Safety Reviews
• Hoisting and Rigging Safety Committee
• Fire Marshall
• Hazardous Experimental Equipment Committee
• SOC approval ensures that the hazard analysis is
  adequate, controls planned to mitigate or
  eliminate hazards are adequate, and that the
  activity will conform to SLAC ESH policy

16
Engineering Process Requirements

• Physics Requirements Documents (PRD)
• Defines functionality of the component
• Provides detailed physics/science requirements
• Basis for engineering design
• Required for the Preliminary Instrument Design
  Review
• Approved by Science Team Leaders and/or LUSI
  Project Manager
• Engineering Specification Document (ESD)
• General engineering specifications to meet the
  PRD
• Covers additional requirements not in the PRD
• Space constraints, environment, etc.
• Required for the Preliminary Design Review
• Approved by Chief Engineer, Scientist, Project
  Manager
• ESD template created
• Interface Control Documents (ICD)
• Describes the boundaries of one system with
  respect to another
• Physical interface between the two
• Responsibilities
• Required for the Preliminary Design Review
• Approved by all involved system managers

17
System Engineering Flow Diagram
18
Engineering Process Requirements (3)

• Statement of Work/Technical Purchase
  Specifications
• Mandates the technical, quality and procurement
  specifications for a purchased item
• Engineering Notes
• Documents engineering analysis and other
  information critical to the design of the
  component
• These documents are all configuration controlled
  via LCLS/LUSI Sharepoint or SODA (SLAC Online
  Database Access)

19
Engineering Processes Drawing Tree/Structure

• Roadmap for building components and installing in
  the hutch
• Assemblies installations thought through
  streamlines modeling and drawing preparations
• Organizes the assemblies models
• Integration between design teams

20
Document Control

• Utilize existing SLAC MD Document Control System
  and Sharepoint database
• 3D-models will use SLAC MD Project Database
  Management (PDM) for configuration control and
  archiving
• Drawings and specifications
• Check, approval and release process as defined in
  DS-391-000-36, LUSI Design Standards Supplement
• Project documents are released and subject to
  revision control
• Management
• PEP, Acquisition Strategy, Hazard Analysis, QIP,
  Value Management,
• Technical
• PRDs, ESDs, ICDs, ...
• Fabrication Installation
• Procedures, travellers, ...
• Design reviews will be archived

21
Document Control (2)

• Engineering Change Orders (ECO)
• Working with MD on a sitewide ECO process
• ECO procedure is under review
• Keeps detailed revision history
• Increase efficiency of implementing and
  documenting design and manufacturing changes
• Allows for quick approval for implementing
  changes
• Helps to maintain these changes in the supporting
  design/fabrication documents

22
Value Management

• Consistent with DOE Value Management,
  DOE order 413.3A and OMB Circular A-131
• LUSI Value Management Plan completed,
  PM-391-000-02 R0
• Executed LUSI Value Management Plan
• Conducted with internal and external reviewers
• 4 alternative solutions identified
• Savings of 355K executed
• LUSI Value Management principles are applied to
  all LUSI engineering tasks
• Design alternatives
• Part of the engineering review process
• Applying common designs
• Value Management principles assisted in
  finalizing the LUSI scope

23
Engineering Status - XPP

• X-ray Pump Probe
• Extensive engineering and design progress for
  CD-2
• Engineering Staff
• J Langton - Lead Engineer
• Jim Defever Mechanical Engineer
• Jim Delor Mechanical Engineer

24
XPP Instrument Location
Near Experimental Hall
X-ray Transport Tunnel
AMO (LCLS)
XPP Endstation
XCS
CXI
Far Experimental Hall
25
Engineering Status XPP (3)

• CD-2 Activities
• Completed Preliminary Instrument Design Review
• Approved by team leaders in 2007 - System PRD
• Completed System ESD released
• Completed - Drawing Tree/File Structure
• Completed - High level models their drafts
• Completed - Hutch definitive layout
• Completed - Laser table layout pump laser to
  FEL interface
• Completed - Detector mover ESD released
• Completed - Detector mover proof of concept
• Testing just completed in August
• Completed - Diffractometer ESD released
• Documented the interfaces and deliverables with
  vendor
• Completed - Diffractometer definitive layout
• Completed About 85 complete on design effort
  of all the supports and laser tables

26
Engineering Status CXI

• Coherent X-ray Imaging
• Significant engineering and design progress since
  CD-1
• Engineering Staff
• Paul Montanez - Lead Engineer
• Jean-Charles Castagna Mechanical Engineer
• Armin Busse Mechanical Engineer
• Rick Jackson Design Engineer

27
CXI Instrument Location
Near Experimental Hall
X-ray Transport Tunnel
AMO (LCLS)
XPP
CXI Endstation
XCS
Source to Sample distance 440 m
Far Experimental Hall
28
Engineering Status CXI (3)

• CD-2 Activities
• Completed Preliminary Instrument Design Review
• Approved by team leaders in 2007 - System PRD
• Completed Draft System ESD
• Completed Drawing Tree/File Structure
• Completed XRT/FEH5 beamline layout
• Complete drafts for the following ESDs
• Completed Sample Chamber
• Completed Detector Stage in review
• Completed Precision Instrument Stand in review
• Completed Reference laser in review
• Completed 1 ?m KB mirror system
• Completed Hutch 5, Common Room Control Cabin
  ESD
• Completed ICD LUSI to LCLS

Sample Chamber Injector
Fixed Target Configuration
29
Engineering Status CXI (4)

• Hutch Layout Drawings
• Completed Stay Clears
• Completed Utilities
• Completed Hutch Layout
• Preliminary component designs
• 75 complete Sample Chamber for the 1 ?m KB
  system
• 75 complete Detector stage
• Preliminary design nearly developed
• Detector packaging details needed
• Completed Precision instrument stand conceptual
  design
• 90 complete - Reference Laser preliminary
  design
• 1 ?m KB system
• Budgetary Inquiry

30
Engineering Status - XCS

• X-ray Correlation Spectroscopy (XCS)
• Major engineering and design progress since CD-1
• Engineering Staff
• Eric Bong Lead Engineer
• Jim Delor Mechanical Engineer
• Jean-Charles Castagna Mechanical Engineer
• Armin Busse Mechanical Engineer
• Ted Osier Designer
• Don Arnett Designer
• Ben Bigornia Designer

31
XCS Instrument Location
Near Experimental Hall
X-ray Transport Tunnel (200m long)
AMO (LCLS)
XPP
XCS Hutch
Source to Sample distance 420 m
CXI Hutch
Far Experimental Hall
32
Engineering Status XCS (3)

• CD-2 Activities
• Completed Preliminary Instrument Design Review
• Approved by team leaders in 2008 - System PRD
• Completed Drawing tree/file structure
• Completed Higher level models/draft
• Completed Definitive hutch and XRT layout
• Completed Detector mover layout
• Completed Diffractometer definitive layout
• Completed Detector mover proof of concept
• Completed Draft detector mover ESD/SOW
• Completed Draft diffractometer ESD
• Completed Conceptual design for tables and
  supports
• Completed Hutch Design
• Completed Hutch 4 Control Cabin ESD
• Completed Interface Control Document (ICD) LUSI
  to LCLS
• Hutch Layout Drawings
• Completed Stay Clears
• Completed Utilities
• Completed Hutch Layout

33
Engineering Status - DCO
Profile-Intensity Monitor
Attenuator
X-ray Focusing Lens

• Diagnostics Common Optics
• Engineering Staff
• Eliazar Ortiz Lead Engineer
• Marc Campell Mechanical Engineer
• Nadine Kurita Mechanical Engineer
• Rick Jackson Design Engineer
• Don Arnett Designer
• Ben Bigornia Designer

Dual Blade Slits
34
Engineering Status DCO (2)

• CD2 Activities
• Complete Draft ESDs
• Completed Pop-In Profile Monitor
• Completed Pop-In Intensity Monitor
• Completed Intensity-Position Monitor
• Completed Wavefront Monitor
• Completed Slits
• Completed Pulse Picker
• Completed Attenuators
• Completed Be Lens System
• Completed Harmonic Rejection Mirror
• Working Complete draft ICD to instruments.
• Greater than 50 complete on preliminary designs
  for the CD4a deliverables
• Completed Pop-In Profile Monitor , 75 complete
• Completed Pop-In Intensity Monitor , 75
  complete
• Completed Intensity-Position Monitor , 50
  complete
• Completed Pulse Picker, 50 complete
• Completed Slits, 50 complete
• Conceptual designs for all remaining devices.

Monochromator
Pulse Picker
35
Project PRD ESD Status

• 35 PRDs, 91 complete
• 55 ESDs, 49 complete

36
Basis of Estimate

• Contains the following
• Detailed description of the component
• Based on latest PRD
• 3D model if applicable and available
• Detailed cost estimate
• Part number, drawing number, vendor, notes,
  weight, qty, cost, etc.
• Supporting quotations, drawings, catalogs, etc.
• Configuration controlled with the CD-2 baseline
• Cross referenced to P3 activity IDs

37
Cost Methodology

• Cost Methodology
• Engineering labor estimates based on prior
  experience of similar designs
• Materials Labor estimates were driven by the
  latest design and Physics Requirements
• Recently obtained vendor budgetary quotes
• Vendor Catalogs
• Engineering bottoms up estimate
• Engineering judgment
• Installation cost and schedule activities were
  discussed with LCLS installation manager(s)

38
Major Milestones/Reviews

• Completed Reviews
• Dec 06 - Safety Oversight Review
• Dec 07 - XPP Preliminary Instrument Review
• Dec 07 - CXI Preliminary Instrument Review
• May 08 - Design Review Pop-In Profile Monitor
• Jul 08 - XCS Preliminary Instrument Review

39
Major Milestones/Reviews (2)

• Upcoming Reviews (6 month look ahead)
• XPP
• Q4FY08 - PDRs FDRs Support Tables Optical
  Table
• Q4FY08 - PDRs FDRs Optical Tables
• Q1FY09 - PDR Diffractometer Detector Mover
• Q2FY09 - FDR Diffractometer Detector Mover
• CXI
• Q42008 PDR Detector Stage
• Q1FY09 - PDR FDR Reference Laser
• Q1FY09 - PDR 1.0 ?m Sample Chamber
• DCO
• Q4FY08 - PDR Pop-In Profile Intensity Monitor
• Q4FY08 - PDR Pulse Picker
• Q1FY09 - PDR Intensity-Position Monitor
• Q1FY09 - PDR FDR Slit System
• Q1FY09 - FDR Pulse Picker
• Controls
• Q1FY09 - PDR XPP Controls

40
Summary

• Instrument teams have made significant design
  progress
• LUSI has established designs with a consistent
  cost estimate. The majority of materials
  estimates came from vendor quotations, catalogs,
  or previous orders
• XPP 80
• CXI 90
• XCS 75
• DCO 65
• Controls DAQ 95
• The technical scope of LUSI has converged
• Resource loaded schedules and Basis of Estimates
  are complete

41
Summary (2)

• Engineering Staff
• Staff consists of experienced SLAC mechanical
  engineers and design engineers
• Additional staff will be available when AMO work
  ramps down September 2008
• Staff is informed in quality and trained in ESH
  issues in their area of expertise
• Actively looking for additional engineering
  resources
• Working organization with well understood
  processes
• Excellent communication and interfacing with
  partner labs, LCLS and sub-systems
• Engineering staff ready for CD-2 approval!

42
End of Presentation
43
Design Review Standards

• Insert pic here

44
Review Template
45
ESD
46
Value Management Forms