Quarterly Review October 5, 2001 QUARTERLY REVIEW October 5, 2001 1
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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 3
Quarterly Review October 5, 2001 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 4
Quarterly Review October 5, 2001 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 5
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Quarterly Review October 5, 2001 Project Summary • • • Response to last QR report Progress overview Summary schedule Work left Budget and expenditures to date 7
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 – – 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 8
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. 9
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 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 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 10
Quarterly Review October 5, 2001 Response to June QR • Planned Completions by this Quarterly Review – – – 3 D and 2 D 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 11
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. 12
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. 13
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 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. 14
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. 15
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. 16
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. 17
Quarterly Review October 5, 2001 Summary Project Plan 18
Quarterly Review October 5, 2001 Revised Bench Integration Plan 19
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% 20
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 • • The project is currently 80% complete overall We have completed 131 of 224 total project milestones Our critical path is 3 D and 2 D 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 21
Quarterly Review October 5, 2001 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 22
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 – 3 D 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 23
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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 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 25
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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 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 27
Quarterly Review October 5, 2001 Configuration Image 28
Quarterly Review October 5, 2001 Configuration - Overview • • Additions Envelope waivers Weight & CG update Design/fabrication status 29
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. 30
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 31
Quarterly Review October 5, 2001 Configuration Image 32
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 33
Quarterly Review October 5, 2001 Configuration Image 34
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 – – 3/01: 4113 lb (1866 kg) 6/01: 3930 lb (1782 kg) 9/01: 3996 lb (1813 kg) Requirement (budget): 4413 lb (2000 kg) 35
Quarterly Review October 5, 2001 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 36
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% 37
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Quarterly Review October 5, 2001 Integration & Test - Overview • Subsystem testing – Fit checks – Mechanism tests – Optics tests • Integration and alignment 39
Quarterly Review October 5, 2001 Subsystem Testing 40
Quarterly Review October 5, 2001 Subsystem Testing • Qualifies sub-assemblies for integration – Performance can be checked prior to final integration – Problems are isolated – Maximum time for problem fixes 41
Quarterly Review October 5, 2001 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 42
Quarterly Review October 5, 2001 Subsystem Testing • Testing of mechanisms as outlined in previous reviews – – Warm functionality Warm flexure Cold functionality Tests (especially cold tests) without optics 43
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 44
Quarterly Review October 5, 2001 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 45
Quarterly Review October 5, 2001 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 46
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) 47
Quarterly Review October 5, 2001 Subsystem Testing • Bench Temperature Control – Warm bench test – Cold test (9. 4 kg mass 20 minute time constant) – Adjust control parameters for final configuration 48
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 • • 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 49
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 50
Quarterly Review October 5, 2001 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 51
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Quarterly Review October 5, 2001 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) 53
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 54
Quarterly Review October 5, 2001 Dewar Integration • • Integration of cold structure into vacuum vessel Re-test with MUX Install engineering array Last chance for easy OIWFS prism, IFU installation 55
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 56
Quarterly Review October 5, 2001 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 57
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Quarterly Review October 5, 2001 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 59
Quarterly Review October 5, 2001 Software Work Remaining - Design • Alarm and Status Propagation – Minor impact at various levels – All other design complete • WCS/DHS header information 60
Quarterly Review 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) 61
Quarterly Review October 5, 2001 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 62
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, 63
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 GEM 7 or GEM 8 64
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 65
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 66
Quarterly Review October 5, 2001 Project Management • • • 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 68
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 Bench % Post-Slit OIWFS Collimator POM/Offner 100 95 100 Entrance Window Cryo-cooler Thermal Dist. Bulkhead Rad Shield LN 2 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 3 D design remaining – Radiation shields (passive and active) – Thermal distribution assembly – Cryo-cooler and manifold • Fixed assembly 2 D 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 Ba. F 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 75
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Quarterly Review October 5, 2001 Project Milestones by Quarter As of 9/21/01 77
Quarterly Review October 5, 2001 78
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Quarterly Review October 5, 2001 Planned FTE Projection 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
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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 Administrative Assistant M. Bowersock Project Assistant D. Eklund (. 5) 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
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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
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Quarterly Review October 5, 2001 Appendix B Milestones WBS Chart 111
Quarterly Review October 5, 2001 Milestones since MFR (3/01) 112
Quarterly Review October 5, 2001 WBS - Total Project 113
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Quarterly Review October 5, 2001 Appendix C Envelope Waiver 115
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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
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