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1 E. [email protected]

XCS Final Instrument Design ReviewEngineering Status April 21, 2009

LUSI WBS 1.4X-Ray Correlation SpectroscopyFinal Instrument Design Review

Engineering StatusEric Bong

April 21, 2009



Outline

WBS 1.4 ScopeEarly Science/CD-4 Deliverables

Progress since PIDRStatus

Engineering/Design StatusCost & Schedule PerformanceCritical PathRisk Identification & MitigationSafety

Summary



WBS 1.3 – Early Science/CD-4 Deliverables

Early Finish – August 2011Early Finish – January 2012

(B/L Early Finish – November 2012)

System WBS Early Science WBS CD-4XPP 1.2.04 XCS Early Science Detector (BNL) 1.2.04

1.4.01 XCS System Integration & Design 1.4.01

1.4.02 XCS X-ray Optics and Support Table 1.4.02

1.4.03 XCS Detector System (BNL) 1.4.03 XCS Detector System (BNL)

1.4.04 XCS Sample Environment & Diffractometer System 1.4.04

1.4.05 XCS Hutch Facilities 1.4.05

1.4.06 XCS Vacuum System 1.4.06

1.4.07 XCS Installation 1.4.07

1.5.02.01 Pop-in Profile/Wavefront Monitors 1.5.02.01

1.5.02.02 Pop-In Intensity Monitors 1.5.02.02

1.5.02.03 Intensity-Position Monitors 1.5.02.03

1.5.03.01 1.5.03.01 Large Offset Monochromator

1.5.03.02 X-ray Focusing Lenses 1.5.03.02

1.5.03.03 Slit System 1.5.03.03

1.5.03.04 Attenuators / Filters 1.5.03.04

1.5.03.05 Pulse Pickers 1.5.03.05

1.5.03.06 Harmonic Rejection Mirrors 1.5.03.06

1.5.03.07 Channel Cut Monochromator 1.5.03.07

CDA 1.6 CONTROLS AND DATA ACQUISITION 1.6 CONTROLS AND DATA ACQUISITION

XCS

DCO



Progress Since PIDR

BCR - Reconfiguration of XCS InstrumentMoved Large Offset Monochromator Addition of “Post Monochromator” to project scopeMoved Split & Delay into alcove upstream of Hutch 4Relocated diagnostics to characterize beam before and after the monochromators Eliminated long beam-line transport in XRT

XRT Beam-Line DesignExtensive modification of LLNL design requiredNegotiated redesign of XRT to minimize re-workSplit redesign cost with LCLSNow far less rework required to install XCS components



Progress Since CD-2

Translation of XCS onto CXI LineSupports Early Science

Documentation for Long Lead ProcurementPRDs, ESDs, SOWs,

DiffractometerLarge Angle Detector MoverLarge Offset Monochromator

Held Long Lead Procurement Review, April 23, 2009Commercial alternative for diagnostic stopper

Vendor indicates modification of existing stopper design to add B4C wafer on face is possibleSavings of design and fabrication timeUpdates P3 to indicate change in acquisition strategy



Progress Since CD-2XCS Engineering/Design staff

Added 1 Mech Engineer / Designer – February 2009Added 2 Mech Engineer / Designers – May 2009

Preliminary Design Reviews (PDRs)Vacuum: XRT & Hutch4Supports: XRT & Hutch 4Granite TablesLarge Angle Mover Vacuum AssemblyPDRs complete

Baseline vibration data obtained in the LCLS Far Experimental Hall

Vertical/Horizontal PSD, 1-100Hz

(Compliments P. Montanez, J. Turner)



Engineering & Design Status

Engineering & Design Staff Ted Osier, Michael Kosovsky, Henry Alvarez, Navtej Hundal, Eric Bong

Large Offset Monochromator

Post-Monochromator

Split and Delay Area

Hutch 4Optics, DiffractometerLarge Angle detector Mover

X-Ray Transport Hall (XRT)

XCS Instrument ScientistAymeric Robert

XCS Visiting ScientistSoo-Heyong Lee



Engineering/Design Status 1.4.1Documentation

CAD system model documentation hierarchy (CAD Drawing Tree/File Structure) releasedXRT& FEH H4 beamline layouts complete with all available models implemented & updatedPRDs/ESDs/ICDs/Purchasing Specs – complete.

WBS

TYPE (pull down

menu) PREFIX DOCUMENT NUMBER REV. LUSI SYSTEM TITLE AUTHOR STATUS (pull down menu)1.6 PRD SP 391-000-03 0 Controls & DA Controls and Data System Feng release1.5 PRD SP 391-000-04 1 Diag & Opt Pop-in Profile Monitor Feng release1.1 ICD SP 391-000-05 0 Management LUSI to XTOD Fritz in work1.6 PRD SP 391-000-06 0 Controls & DA Data Management Feng release1.5 PRD SP 391-000-07 0 Diag & Opt Wavefront Sensor Feng release1.5 PRD SP 391-000-08 1 Diag & Opt Intensity-Position Monitor Feng release1.5 PRD SP 391-000-09 1 Diag & Opt Pop-in Intensity Monitor Feng release1.5 PRD SP 391-000-10 1 Diag & Opt LUSI Attenuator System Fritz release1.5 PRD SP 391-000-11 1 Diag & Opt X-Ray Focusing Lens System Robert release1.5 PRD SP 391-000-14 1 Diag & Opt Slit System Boutet release1.5 PRD SP 391-000-15 0 Diag & Opt Wavefront Monitor Feng release1.5 PRD SP 391-000-16 0 Diag & Opt Offset Monochromator Robert in work1.5 PRD SP 391-000-23 1 Diag & Opt Pulse Picker Boutet release1.5 PRD SP 391-000-34 1 Diag & Opt Harmonic Rejection Mirror System Fritz release1.1 DS DS 391-000-36 0 Management Mech Design Standards Arnett release1.5 ESD SP 391-000-54 0 Diag & Opt Slit System Jackson release1.5 ESD SP 391-000-58 0 Diag & Opt X-Ray Focusing Lens System Campell release1.5 ESD SP 391-000-60 0 Diag & Opt Attenuators Campell release1.5 ESD SP 391-000-61 0 Diag & Opt Harmonic Rejection Mirror System Busse approvals1.5 ESD SP 391-000-66 0 Diag & Opt Pulse Picker Kurita in work1.6 DOC SP 391-000-77 0 Controls & DA Controls-Data-Systems-Dictionary Feng approvals1.5 ESD SP 391-000-80 0 Diag & Opt Intensity-Position Monitor Mechanical Requirements Ortiz release1.5 ESD SP 391-000-81 0 Diag & Opt Pop-In Intensity Monitor Mechanical Requirements Reeck in work-finalize1.5 ESD SP 391-000-82 0 Diag & Opt Wavefront Monitor Mechanical Requirements Reeck in work-finalize1.5 ESD SP 391-000-83 0 Diag & Opt Pop-In Profile Monitor Mechanical Requirements Reeck in work-finalize1.2 PRD SP 391-000-97 0 XPP XPP 2D Detector van Bakel approvals1.4 PRD SP 391-000-98 0 XCS XCS 2D Detector van Bakel approvals1.2 ICD SP 391-001-01 0 XPP SLAC BNL Detector Interface Control Langton Review1.4 PRD SP 391-001-17 0 XCS XCS Instrument Start-up Plan Robert release1.6 ESD SP 391-001-19 0 Controls & DA LUSI Common Diag. & Optics Controls ESD Anthony release1.6 ESD SP 391-001-24 0 Controls & DA XCS Controls ESD Anthony release1.6 ICD SP 391-001-25 0 Controls & DA XCS Controls ICD Anthony release1.6 ESD SP 391-001-26 0 Controls & DA XCS Data Acq. ESD Weaver approvals1.6 ESD SP 391-001-27 0 Controls & DA LUSI Intensity-Position/Intensity Monitor Front End Electronics Freytag in work1.5 Purchase Spec PS 391-001-28 0 Diag & Opt Attenuator Silicon Filters Campell in work1.4 ESD SP 391-001-29 0 XCS XCS Instrument Specification Bong approvals1.4 ESD SP 391-001-30 0 XCS XCS Diffractometer System Bong release1.4 ESD SP 391-001-31 0 XCS XCS Large Angle Detector Mover Bong draft review1.4 PRD SP 391-001-32 0 XCS XCS Diffractometer system Robert release1.4 PRD SP 391-001-33 0 XCS XCS Wide Angle Detector Stage Robert release1.4 PRD SP 391-001-35 0 XCS XCS Instrument Robert release1.4 ESD SP 391-001-38 0 XCS Hutch 4 of the FEH Robert transferred to LCLS docs1.4 ESD SP 391-001-39 0 XCS XCS Room of the FEH Robert transferred to LCLS docs1.3 ESD SP 391-001-40 0 CXI Eng. Spec. for the Common Room of the FEH Boutet transferred to LCLS docs1.5 Purchase Spec PS 391-001-46 0 Diag & Opt Slit System Jackson release

ESD SP 391-001-50 0 Diag & Opt Pulse Picker Jackson release1.5 SOW PS 391-001-64 0 DCO Slit Systems Ortiz release1.6 ESD SP 391-001-67 0 Controls & DA Online/Offline Data Processing and Storage Specification for the XCS Experiment Weaver in work1.5 Purchase Spec PS 391-001-69 0 DCO Bid Evaluation Guide for Slits Ortiz release1.4 Purchase Spec PS 391-001-70 0 XCS XCS Instrument Diffractometer System Procurement Specification Bong Release1.4 Purchase Spec PS 391-001-71 0 XCS Bid Evaluation Guide for XCS Diffractometer Robert release1.4 Purchase Spec PS 391-001-75 0 XCS XCS Large Angle Mover Procurement Specification Bong in work1.4 Purchase Spec PS 391-001-76 0 XCS Bid Evaluation Guide for XCS Large Angle Mover Robert in work1.5 Purchase Spec PS 391-001-77 0 DCO DCO Offset Mono Procurement Specification Bong in work1.5 Purchase Spec PS 391-001-78 0 DCO Bid Evaluation Guide for DCO Offset Mono Robert in work

Hutch DesignReviewed 30%, 60%, 90% & 100% A&E drawingsFEH Hutch construction – June thru December 2009 (LCLS)

APP and Risk Identification/Registry complete and up to date



Engineering/Design Status 1.4.2XCS Optic & Support Tables (WBS 1.4.2)

Hutch 4 Granite Support Tables (WBS 1.4.2.2)

Modification of XPP support table designGranite base with movable strong-backPDR 29 May 2009Leveraging existing designs (when applicable) reduces overall engineering & design effort. Use of common parts reduces maintenance costs.Safety: Earthquake restraint of granite base, covered pinch points.Budget at Completion (BAC) ≈ $200k

Stoppers (WBS 1.4.2.3)Diagnostic stoppers not PPS.Changed plan from modification to PPS stopper design to Commercial Item.Worked with vendor on modification of an off-the shelf product to incorporate 10mm on face of stopper. Commercial stopper uses same controls as vacuum valves.Issued BCR to change P3.Budget at Completion (BAC) ≈ $187k



Engineering/Design Status 1.4.4

XCS Diffractometer (WBS 1.4.4.1)Planed as SLAC assemble. Changed to build to spec, same as XPP. Processed BCR.PRD, ESD & Purchase Spec completeProcurement Review Held.Ready to release RFQSafety: Earthquake restraint pinch points, interlock of automatic motion.Design reviews required at vendor.LUSI controls interface required. Budget at Completion (BAC) ≈ $685k

XCS Large Angle Detector Mover (WBS 1.4.4.3)

Processed BCR to split effort between carriage motion and upper assemblies.

Carriage motion build to spec.Vacuum, detector positioner and beam stop; SLAC design.

PRD, ESD & Purchase Spec complete.Procurement Review Held.Requisition in purchasing.Safety: Earthquake restraint pinch points, interlock of automatic motion.Design reviews required at vendor for carriage.LUSI controls interface required. Budget at Completion (BAC) ≈ $856k




XCS Hutch Utilities (WBS 1.4.5)Hutch layout design complete.LCLS responsible for hutch construction.Crane installation moved from LUSI to LCLSXCS responsible scientist and engineer involved hutch 4 specification and design reviews.Tasks to be completed by XCS

Raised flooringStorage cabinets, work benches and tool chestsUtilities distribution

Budget at Completion (BAC) ≈ $369k




XCS XRT Vacuum (WBS 1.4.6.1)Quantity of drift tubes finalized.Vacuum component selection complete.Vacuum support design well advanced.Completed preliminary design report.Ready to purchase all vacuum equipment.Safety: Pressure vessel code requirements mitigated using burst disks.Budget at Completion (BAC) ≈ $363k

XCS Hutch 4 Vacuum (WBS 1.4.6.2)Designed to shift to CXI line.Vacuum component selection complete.Uses many XRT support designs.Completed preliminary design report.Ready to purchase all vacuum equipment.Safety: Pressure vessel code requirement mitigated using burst disks.Budget at Completion (BAC) ≈ $400k



Engineering/Design Status 1.4.7XCS Installation (WBS 1.4.7)

LUSI Installation CoordinatorObtain required installation permits.Conduct daily tailgate meeting w/ UTR (University Technical Representative).Conduit to engineering for field installation issues.Provide installation status for incorporation into LUSI schedule.

XCS XRT InstallationPhased with LCLS and CXI installations.Advanced schedule could combine all XCS XRT installation with CXI except monochromators. Budget at Completion (BAC) ≈ $351k

XCS Hutch 4 InstallationEarly Science

All components except XCS detectorInstall duplicate XPP detector to commission and early scienceEarly Finish – June 2011

CD-4XCS DetectorEarly Finish – January 2012

Budget at Completion (BAC) ≈ $613k



Engineering/Design Status 1.4.6Large Offset Mono (WBS 1.5.3.1 )

Planed as build to specification. Vendor build completeOption for SLAC to build crystal holder

PRD, ESD & Purchase Spec complete.Procurement Review Held.Review requires revisions to PRD, ESD & Purchase SpecSafety: Earthquake restraint.Design reviews required at vendor for carriage.LUSI controls interface required. Budget at Completion (BAC) ≈ $1,778k

1.5.3.7 Post Mono (WBS 1.4.6.2)Fabrication of existing ANL design.ANL drawings have been requested.SLAC will review drawings prior to purchasing components.Safety: Earthquake restraint.LUSI controls interface required. Budget at Completion (BAC) ≈ $455k



XCS Instrument Design Status SummarySystem/Component Review Baseline Advanced

1.4.1 Integration FIDR 8/5/09 6/30/09

1.4.2.2 Hutch Granite Table PDR 6/29/09 5/29/09

1.4.2.3 Diagnostic Stopper COTS 6/9/09 5/15/09

1.4.4.1 Diffractometer LLPR 4/21/09 4/23/09

1.4.4.3 Large Angle Mover Carriage LLPR 12/14/09 4/23/09

1.4.4.3 Large Angle Mover Vacuum PDR 5/29/09

1.4.5.1 Hutch Specification FDR 2/28/09 2/28/09

1.4.5.2 Hutch Utilities & Equipment PDR 10/2/09 10/2/09

1.4.6.1 XCS XRT Vacuum Design PDR 3/4/09 5/19/09

1.4.6.2 XCS H4 Vacuum Design PDR 3/2/09 5/19/09

1.5.3.1 Large Offset Monochromator LLPR 6/5/09 4/23/09

1.5.3.7 Chanel Cut Monochromator PR 8/31/09 8/31/09



Cost and Schedule Performance (2)

Cum data through Feb09

CPI = 1.08 = BCWP/ACWP

SPI = 0.96 = BCWP/BCWS



Cost Performance ReportRun Date:4/20/2009 8:22:53 AM

At CompleteLatest

Work Work RevisedDescription Scheduled Performed Budgeted Estimate Variance

1 4 X-RAY CORRELATION SPECTROSCOPY (XCS) 749,956 704,405 717,545 -45,551 -13,141 0.94 0.98 7,227,371 7,240,512 -13,1411 4 01 XCS System Integration & Design 456,042 456,042 458,742 0 -2,700 1.00 0.99 1,208,562 1,211,262 -2,7001 4 02 XCS X-ray Optics and Support Table 0 1,175 2,160 1,175 -985 0.00 0.54 387,550 388,535 -9851 4 03 XCS Detector System (BNL) 115,664 101,500 123,022 -14,164 -21,522 0.88 0.83 1,993,468 2,014,989 -21,5221 4 04 XCS Sample Environment & Diffractometer System 2,767 9,237 11,044 6,470 -1,807 3.34 0.84 1,541,638 1,543,445 -1,8071 4 05 XCS Hutch Facilities 49,887 49,888 38,919 1 10,969 1.00 1.28 369,227 358,258 10,9691 4 06 XCS Vacuum System 125,596 86,564 83,659 -39,032 2,905 0.69 1.03 762,867 759,963 2,9051 4 07 XCS Installation 0 0 0 0 0 964,060 964,060 0

1 5 DIAGNOSTICS & COMMON OPTICS 1 5 03 01 Large Offset Monochromator 9,061 4,712 -4,349 4,712 0.52 0.00 1,292,624 1,287,912 4,7121 5 03 07 Channel Cut Monochromator 1,047 -1,047 0 0.00 0.00 426,651 426,651 0

Cumulative to Date

Rpt Period 03-31-2009

LevelWBS

Cost SPI CPI

Budgeted Cost Actual CostWork

Variance

Schedule

Perf. Indices

Run Date:6/3/2009 8:24:21 AM

At CompleteLatest

Work Work RevisedDescription Scheduled Performed Budgeted Estimate Variance

1 4 X-RAY CORRELATION SPECTROSCOPY (XCS) 911,719 819,441 836,065 -92,278 -16,624 0.90 0.98 6,995,690 7,012,314 -16,6241 4 01 XCS System Integration & Design 489,489 489,489 476,629 0 12,860 1.00 1.03 1,162,671 1,149,812 12,8601 4 02 XCS X-ray Optics and Support Table 25,585 22,454 10,080 -3,131 12,374 0.88 2.23 309,243 296,869 12,3741 4 02 02 XCS Hutch Supports, Table & Shielding 18,207 16,138 10,080 -2,069 6,058 0.89 1.60 196,564 190,506 6,0581 4 02 03 XCS Stoppers 7,379 6,316 -1,063 6,316 0.86 0.00 112,679 106,363 6,3161 4 03 XCS Detector System (BNL) 140,944 100,933 185,364 -40,011 -84,430 0.72 0.54 1,997,607 2,082,037 -84,4301 4 04 XCS Sample Environment & Diffractometer System 113,564 66,081 32,429 -47,483 33,652 0.58 2.04 1,579,767 1,546,116 33,6521 4 04 01 XCS Diffractometer System 21,675 13,072 9,714 -8,602 3,359 0.60 1.35 726,852 723,493 3,3591 4 04 03 XCS Large Angle Mover & Chamber 91,889 53,008 22,715 -38,881 30,293 0.58 2.33 852,915 822,622 30,2931 4 05 XCS Hutch Facilities 49,887 49,887 39,362 0 10,526 1.00 1.27 278,746 268,220 10,5261 4 06 XCS Vacuum System 92,250 90,597 92,202 -1,653 -1,605 0.98 0.98 746,603 748,208 -1,6051 4 07 XCS Installation 0 0 0 0 0 921,052 921,052 0

1 5 DIAGNOSTICS & COMMON OPTICS 1 5 03 01 Large Offset Monochromator 6,551 14,488 5,006 7,936 9,482 2.21 2.89 2,491,467 2,481,985 9,4821 5 03 07 Channel Cut Monochromator 0 0 0 460,738 460,738 0

Cost SPI CPI

Budgeted Cost Actual CostWork

Variance

Schedule

Perf. IndicesLevelWBS

Cumulative to Date

Rpt Period 04-30-2009

March Data

April Data



XCS Critical Path

DCO Harmonic Rejection Mirror Preliminary Design

Review

DCO X-ray Focusing Lens and Harmonic Rejection Mirror Awards

XCS Diagnostics Stopper Design Effort

Removing budgetary constraints will move critical path to XCS long lead itemsRe-plan of stopper acquisition will move stopper off critical path



XCS Look AheadSix month “look-ahead” of XCS Instrument milestones

ARRA advanced schedule

MS Level Activity description

Advanced Early finish

L5 Final Instrument Design Review - XCS 6/17/2009L5 Final Design Review - XCS Long Table 9/14/2009L5 Award - XCS Stoppers 9/15/2009L5 Award - XCS Diff. System 11/20/2009L5 Award - XCS LA Detector Mover Carriage 11/16/2009L5 Final Design Review - XCS XRT Vacuum 8/3/2009L5 Final Design Review - XCS H4 Vacuum 9/7/2009L5 Design Complete Drop Floor 11/2/2009L5 Award LO Mono 10/27/2009L5 Fabrication Start Post Mono 9/2/2009

Purchasing started on Diffractometer and Detector Mover Carriage.Large Offset Monochromator purchasing start requires revision of specifications dictated by procurement review.Non LLP item purchasing must wait for CD3 approval.



Risk Identification & MitigationRisk Identification/Registry complete and up to date as per “LCLS Risk Management Plan” PMD 1.1-002-r415 risks identified at CD-2 for XCS WBS 1.4

5 Risks for BNL Detector Schedule - late MOUSchedule - late designSchedule - late fabricationSchedule - late testingTechnical – does not meet requirements

5 Risks each for for Large Angle Detector Mover & DiffractometerSchedule – Procurement PlacementSchedule - late designSchedule - late fabricationSchedule - late testingTechnical – does not meet requirements

2 risks identified at CD-2 for DCO Monochromator WBS 1.5.3.12 Risks for Monochromator

Schedule – ManufacturingTechnical – Optical Stability



SafetyLUSI Hazard Analysis Report (PM-391-001-34) completeSafety issues are considered at every stage of the design, fabrication and installation processSafety considerations (some examples)

Ionizing RadiationHutch walls will comply with SLAC Radiation Safety memo RP-RPG-080606-MEM-01 Hutch PPS

Pressure/Vacuum Vessel SafetyCompliant with 10CFR851

Seismic SafetyDesigns compliant with: Seismic Design Specification for Buildings, Structures, Equipment, and Systems, SLAC-I-720-0A24E-002-R002

MechanicalInterlocks for equipment protectionEngineered solutions that prevent potential “pinch-points” with moving machinery

Hoisting and RiggingPositioning of devices that require the use of the FEH H4 overhead crane shall be performed by only by qualified personnel with an approved lift plan.



Summary

XCS instrument configuration design is complete.All preliminary design reviews complete.XCS scope is stable following BCR to move monochromators.Acquisition strategy for stoppers and large angle detector has been integrated into the schedule.Long Lead Procurement Review for diffractometer, large angle detector mover and large offset monochromator has been completed.Purchasing of LLP items has begun.Releasing budgetary constraints moved critical path to long lead procurement items.Scheduled early CD3 spending authority advances schedule.ARRA funding re-baseline advances XCS schedule providing early science in August 2011.



Expanded CSSR – by CAM



Control Accounts & Work Packages – by WBS L2



Control Accounts & Work Packages – by CAM



P3 Files & Total Activities – by CAM



P3 Files Milestones – by WBS L2



Procurements and Dollars – WBS



Labor/Non-labor Split – WBS 1.4

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