Figure 1: WBS chart for remaining NIFS work
Management Plan
NIFS
Critical Design Review Document
Research
School of Astronomy and Astrophysics
Australian
National University
Canberra,
Australia
April 19-20, 2001
This
page is left blank intentionally
Table
of Contents
1 Introduction...................................................................................................................... 7
2 The Plan as Presented in the NIFS Revised
Costing.................................................... 8
3 Current Status.................................................................................................................. 9
4 Remaining Work............................................................................................................ 15
5 Project Management..................................................................................................... 30
6 RSAA Resources........................................................................................................... 34
7 The Australian National University.............................................................................. 52
8 Appendices..................................................................................................................... 54
List
of Acronyms
AAO Anglo
Australian Observatory
ANU Australian
National University
AURA Association
of Universities for Research in Astronomy
CAD Computer
Aided Design
CC Components
Controller
CCD Charge
Coupled Device
CDR Critical
Design Review
CDS Critical
Design Study
CICADA Computerised
Instrument Control and Data Acquisition.
CNC Computer
Numerical Control
CoDR Conceptual
Design Review
CSIRO Commonwealth
Scientific and Industrial Research Organisation
CWS Cold
Work Surface
DC Detector
Controller
DHS Data
Handling System
DSP Digital
Signal Processor
EDM Electron
Discharge Machining
EPROM Erasable
Programmable Read Only Memory
ESD Electro-Static
Discharge
ESO European
Southern Observatory
GNS Geostationary
Meteorological Satellite
HAWAII HgCdTe
Astronomical Wide Area Infrared Imager
IAS Institute
of Advanced Studies
IC Instrument
Committee
ICD Interface
Control Document
ICS Instrument
Control System
IfA Institute
for Astronomy
IFU Integral
Field Unit
IOC Input-Output
Controller
IR InfraRed
IS Instrument
Sequencer
ISS Instrument
Support Structure
MUX Multiplexer
NIFS Near-infrared
Integral Field Spectrograph
NIRI Near-InfraRed
Imager
NSF National
Science Foundation
NSW New
South Wales
OCDD Operational
Concept Definition Document
OCS Observatory
Control System
OIWFS On-Instrument
Wavefront Sensor
PACE Producible
Alternative to CdTe for Epitaxy
PCB Printed
Circuit Board
PLD Programmable
Logic Device
PS Project
Scientist
QA Quality
Assurance
QAR Quality
Assurance Representative
RSAA Research
School of Astronomy and Astrophysics
SDSU San
Diego State University
SMD Surface
Mount Device
UH University
of Hawaii
UNSW University
of New South Wales
VLT Very
Large Telescope
VME Versa
Module Europe
VMS Virtual
Memory System
WBS Work
Breakdown Structure
WFI Wide
Field Imager
ZIF Zero
Insertion Force
This
page is left blank intentionally
This document contains the management information for the Gemini Near-infrared Integral Field Spectrograph (NIFS) Critical Design Review (CDR). This includes costing and planning information as well as information about The Research School of Astronomy and Astrophysics (RSAA) in the Institute of Advanced Studies (IAS) of the Australian National University (ANU) and its staff involved in the project.
RSAA has produced a detailed design for NIFS. This management plan describes the progress of the design and fabrication work and reviews the cost and time estimates previously agreed for building this instrument.
The NIFS development is being fast-tracked to ship the instrument to the Gemini base facility in Hawaii in February 2003 for deployment on the Gemini North telescope later that year. To accomplish this with as little risk as possible, the cryostat, the OIWFS, and large parts of the control system and software are being copied from NIRI. Manufacture of the cryostat and the OIWFS is well advanced, and the spectrograph detailed design is ready for critical review.
The budget and schedule presented at the Conceptual Design Review (CoDR) in March 2000 were based on fast tracking the instrument development by duplicating the NIRI cryostat and OIWFS. The fabrication, assembly, and testing of the cryostat and OIWFS was proposed to be subcontracted to the University of Hawaii. The total cost of this solution was estimated at US$2,996,319, which was considered too high.
RSAA was asked to investigate the cost and schedule implications of duplicating the cryostat and OIWFS in Australia and submitted a revised costing and schedule in time for the Gemini Instrument Forum in May 2000. These were eventually approved at a cost of US$2,443,993. After subtraction of the cost of Gemini supplied items, the contract cost was set at US$2,359,695 The NIFS design and fabrication contract was signed by ANU in July 2000.
The 2000 schedule assumed that design work would start in April 2000 and the cryostat fabrication in May. The re-costing and the contract negotiations resulted in a delayed start of the spectrograph design work. It ramped up from May. The start of the cryostat and OIWFS duplication was hampered by unavailability of NIRI as-built information and delays in employing extra contract workshop staff, because of the contract delay. The workshop effort did not start till August. By the end of September RSAA had committed US$200,000 to the project in labor costs and orders, while the NIFS contract was still awaiting National Science Foundation ratification. RSAA suspended the processing of further orders and allowed the NIFS designers to spend part of their time on other projects in order to limit its liabilities in case the contract would not be ratified. When the contract was finally ratified in November, it was clear that a December CDR, as planned, was no longer feasible. The CDR date was first delayed till February 2001, but the impact of the Christmas break and summer holidays was greater than expected, so a date in March was proposed. However, the first logistically possible time slot was in April.
There was little progress on the duplication and adaptation of the NIRI control system, apart from obtaining quotations for items to be ordered, due to the unavailability of NIRI as-built information. In January RSAA started its own design work and the Association of Universities for Research in Astronomy (AURA) quickly agreed to fund the extra cost through a contract amendment.
The four months delay of the CDR is reasonable considering the re-costing and contract delays. The time frame for delivery of the detectors was also delayed by a similar amount of time. Consequently, the schedule presented in this updated Management Plan now shows NIFS shipment on 20 February 2003.
The information in this section gives an overview of the project schedule and cost as presented in the document “NIFS Revised Costing”, with some amendments following contract negotiations.
The defined milestones most easily reflect the schedule for the project as originally envisaged. Table 1 shows these milestones as they appear in the NIFS contract, with their current status.
Table 1: Milestones and their Status.
|
Event |
Date |
Status |
|
|
|
|
|
(1) Contract fully signed |
August 2000 |
Completed Nov 2000 |
|
(2) Placement of order for vacuum jacket
forging |
August 2000 |
Completed July 2000 |
|
(3) AURA approval of Final FPRD and OCDD |
5 December 2000 |
Submitted Feb 2001 Approval at CDR |
|
(4) AURA approval of Detailed Design
Documentation after CDR |
January 2001 |
CDR 19 April 2001 Approval May 2001 |
|
(5) Start of first Cryostat and OIWFS cooldown |
14 May 2001 |
|
|
(6) Completion of Cryostat and OIWFS
Duplication (As task is described in Conceptual Design Documentation) |
4 October 2001 |
|
|
(7) Completion of Spectrograph Construction
(As task is described in Conceptual Design Documentation) |
22 March 2002 |
|
|
(8) Authorization to ship instrument given by
AURA |
19 July 2002 |
|
|
(9) Completion of all Work and Final
Acceptance given by AURA |
1 October 2002 |
|
Table 2 shows the top level cost breakdown for the project as presented in the document “NIFS Revised Costing”, amended to reflect the contract price by removal of the cost of Gemini supplied items and the contract amendment to cover extra work on the design of the control system.
Table 2: Top-Level Cost Budget Breakdown.
|
|
Labor |
Labor
Cost |
Fixed
Cost |
Total |
|
|
(hrs) |
(US$) |
(US$) |
(US$) |
|
|
|
|
|
|
|
NIFS Critical Design Study |
6,326 |
195,405 |
57,013 |
252,418 |
|
CDR |
189 |
5,390 |
3,000 |
8,390 |
|
Cryostat and OIWFS Duplication |
10,824 |
378,840 |
806,625 |
1,185,465 |
|
Spectrograph Construction |
9,610 |
336,350 |
291,242 |
627,592 |
|
NIFS Assembly and Testing |
4,276 |
138,880 |
133,400 |
272,280 |
|
Extra Cooldowns |
|
|
35,000 |
35,000 |
|
|
|
|
|
|
|
Total |
31,225 |
1,054,865 |
1,326,280 |
2,381,145 |
The NIFS Critical Design Study (CDS) is about to be finished and the cryostat and OIWFS duplication is roughly half way. Table 3 shows the financial status of the project on 2 March 2001. It indicates overruns I the labor costs, offset by larger savings in fixed costs, adding to a total cost saving of US$46,879. Further details are provided in the following sections.
Table 3: NIFS Financial Status
|
WBS |
Task Name |
|
Budget (US$) |
Actual (US$) |
Remaining (US$) |
Variance (US$) |
|
|
|
|
|
|
|
|
|
2 |
NIFS Critical Design Study |
labor |
195,405 |
173,110 |
30,940 |
-8,645 |
|
|
|
fixed cost |
57,013 |
34,457 |
10,892 |
11,664 |
|
4 |
Cryostat and OIWFS Duplication |
labor |
378,840 |
170,695 |
269,010 |
-60,865 |
|
|
|
fixed cost |
806,625 |
258,621 |
443,280 |
104,724 |
|
|
|
|
|
|
|
|
|
|
NIFS to 2
March 2001 |
|
1,437,883 |
636,883 |
754,122 |
46,879 |
The NIFS Critical Design Study ends just before the Critical Design Review. The status described in this section is as reported in the end-of-month records for February 2001 on 2 March, complemented with an estimate of work expected to be completed before CDR.
All planned design work for the Critical Design Study will be completed within budget. Unfortunately, the NIFS contract delays caused the schedule to slip, and some planned advanced effort on the spectrograph construction phase has not been realized.
During the NIFS Critical Design Study, the optical design has been finalized, the mechanical design has been progressed through to the production of a 3D model of the spectrograph and its assemblies. The detector system has been designed in full detail. The overall software system design has been completed together with most of the Components Controller and Instrument Sequencer software.
Any optical design issues still outstanding from the Conceptual Design Review have been addressed. These include scattering, ghosting, tolerancing, and alignment needs and accuracy. The manufacturing details of the optical components have been completed and a test sample of the pupil mirror array has been manufactured and assessed.
In the area of mechanical design, assembly drawings of the spectrograph have been produced. These, together with information from NIRI, have been used for flexure analysis. Because of the relatively minor changes from the NIRI overall design, detailed thermal analysis was not deemed necessary.
The detector has been ordered by AURA, and the detector controller has been ordered by RSAA. The wiring from the controller to the detector has been fully detailed with circuit diagrams showing all signals, connectors and printed circuit boards. Some issues identified during the conceptual design, such as choice of materials for printed circuit substrates and flexible circuits have been addressed. First-pass DSP code for the detector controller is available.
The overall software system design has been finalized and the NIRI Components Controller has been modified to accommodate the NIFS mechanisms and is running in simulation mode.. Some detail of the control of the Lake Shore temperature controller and the fine motion control of the NIFS spectrograph mechanisms remain to be finalized. The Detector Controller software design has been completed.
Other items delivered for the CDR are the Operational Concept Definition Document (OCDD), the Functional and Performance Requirements Document (FPRD), the control software Interface Control Documents (ICDs), tables of contents for all manuals, a draft Spares List, the Acceptance Test Plan, and the Verification and Commissioning Plan. These documents are included in Vol. 3 of the CDR documentation.
Table 4 shows the labor involved in the Critical Design Study detailed to the second level of the Work Breakdown Structure. The budgeted, actual, and remaining work are tabulated, together with the variance. Each of these is broken up in Project Scientist effort, provided free of charge by RSAA, and paid work. The monetary value of the work is also stated.
Remaining effort over about five weeks to CDR is estimated for project management and CDR documentation preparation.
Table 4: Critical Design Study Work.
|
WBS |
Task |
Budget |
Actual |
||||
|
(PS hrs) |
(paid hrs) |
(US$) |
(PS hrs) |
(paid hrs) |
(US$) |
||
|
|
|
|
|
|
|
|
|
|
2.1 |
Project General |
49 |
605 |
21,175 |
135 |
433 |
15,155 |
|
2.2 |
Scientific Requirements |
70 |
70 |
2,450 |
325 |
26 |
910 |
|
2.3 |
System Design |
406 |
567 |
19,845 |
78 |
1,328 |
46,480 |
|
2.4 |
Optical Design |
218 |
636 |
22,260 |
17 |
729 |
25,515 |
|
2.5 |
Mechanical Design |
|
1,505 |
52,675 |
6 |
1,247 |
43,645 |
|
2.6 |
Detector Control |
|
728 |
25,480 |
14 |
368 |
12,880 |
|
2.7 |
Control Software Design |
|
1,472 |
51,520 |
|
815 |
28,525 |
|
|
|
|
|
|
|
|
|
|
2 |
NIFS
Critical Design |
743 |
5,583 |
195,405 |
575 |
4,946 |
173,110 |
|
WBS |
Task |
Remaining |
Variance |
||||
|
(PS hrs) |
(paid hrs) |
(US$) |
(PS hrs) |
(paid hrs) |
(US$) |
||
|
|
|
|
|
|
|
|
|
|
2.1 |
Project General |
|
70 |
2,450 |
-86 |
102 |
3,570 |
|
2.2 |
Scientific Requirements |
|
|
|
-255 |
44 |
1,540 |
|
2.3 |
System Design |
189 |
814 |
28,490 |
139 |
-1,575 |
-55,125 |
|
2.4 |
Optical Design |
|
|
|
201 |
-93 |
-3,255 |
|
2.5 |
Mechanical Design |
|
|
|
-6 |
258 |
9,030 |
|
2.6 |
Detector Control |
|
|
|
-14 |
360 |
12,600 |
|
2.7 |
Control Software Design |
|
|
|
0 |
657 |
22,995 |
|
|
|
|
|
|
|
|
|
|
2 |
NIFS
Critical Design |
189 |
884 |
30,940 |
-21 |
-247 |
-8,645 |
The variance columns show a large overrun in System Design, which is compensated by underruns in the individual design areas, adding up to a 4% overrun over the whole of the Critical Design Study. This is largely an artifact caused by the difficulties of keeping design effort separated from the preparation of the CDR documentation. From the end of January, all work, except project management, has been recorded as CDR documentation preparation to simplify bookkeeping.
Auspace Pty. Ltd seconded a mechanical designer to RSAA to temporarily fill a vacancy. As this work appeared in the project plan as RSAA labor and Auspace charged a rate equal to the labor rate for the NIFS contract, this expense has been recorded as labor, rather than fixed cost as is usual for subcontract work.
Table 5 shows the fixed costs involved in the Critical Design Study detailed to the second level of the Work Breakdown Structure. The budgeted, actual, and remaining work are tabulated, together with the variance.
The optical and mechanical design areas show considerable savings resulting from the optical design subcontract work being less extensive than estimated, and letting no subcontracts for stability and thermal analysis. A smaller saving occurred in the software area, where purchase of a VME computer board and accessories was cheaper than estimated.
Printing the CDR documentation is a remaining project management expense. Not all expenditure planned in the detector control area has been committed yet. These are costs associated with printed circuit board manufacture and connectors. Together with the remaining costs for unused travel, it will be transferred to complimentary tasks in the spectrograph construction phase. On close-out of the CDS phase, the variance will also be transferred to the spectrograph manufacturing phase, as an extra contingency.
A detailed list of fixed cost expenditure and commitments is provided in Appendix 8.3.
Table 5: Critical Design
Study Fixed Cost
|
WBS |
Task Name |
Budget (US$) |
Actual (US$) |
Remaining (US$) |
Variance (US$) |
|
|
|
|
|
|
|
|
2.1 |
Project General |
6,500 |
141 |
6,359 |
0 |
|
2.4 |
Optical Design |
3,300 |
689 |
0 |
2,611 |
|
2.5 |
Mechanical Design |
8,085 |
0 |
0 |
8,085 |
|
2.6 |
Detector Control |
26,835 |
22,302 |
4,533 |
0 |
|
2.7 |
Control Software Design |
12,293 |
11,325 |
0 |
968 |
|
|
|
|
|
|
|
|
2 |
NIFS Critical Design Study |
57,013 |
34,457 |
10,892 |
11,664 |
The status of the cryostat and OIWFS duplication work described in this section is as reported in the end-of-month records for February 2001 on 2 March.
The largest gains in fast-tracking the NIFS development come from duplicating as much as possible from NIRI. Except for a few relatively minor changes, the following NIRI items are being duplicated: the integration frame, the ISS interface plate, the cryostat, the cooling system, the OIWFS optics and mechanics, the OIWFS detector and controller, the electrical and temperature control systems. The Instrument Sequencer, Components controller, OIWFS Components Controller, and Engineering Interface software are being duplicated too, but are covered as part of the software development.
At the time of writing about 70% of the work involved in RSAA parts fabrication had been completed. The Integration Frame and ISS interface plate have been delivered, and the Vacuum Jacket is expected to be delivered before CDR. The control system Thermal Enclosures arrived soon after CoDR. The control system computers and operating system software have been delivered and are actively being used for NIFS software development. The temperature controllers and most connectors needed for the control system implementation have been delivered.
The cryostat window, the OIWFS lenses and mirrors, the OIWFS Optable, and the cryocoolers have been ordered. RSAA is subcontracting the manufacture, assembly, and test of the OIWFS detector subsystem to the Institute for Astronomy (IfA) of the University of Hawaii. IfA is also fabricating the OIWFS mechanisms under a NIRI contract amendment. The SDSU detector controller for the OIWFS detector has been ordered. Only the OIWFS filters remain to be ordered.
Because of lack of availability of as-built NIRI information on the control system, RSAA is now designing the NIFS control system using the NIRI design information as a guide. A NIFS contract amendment has been agreed to cover the cost of the extra work. This cost has been included in the figures in this section.
Table 6 shows the labor involved in the cryostat and OIWFS duplication detailed to the second level of the Work Breakdown Structure. The budgeted, actual, and remaining work are tabulated, together with the variance. The monetary value of the work is also stated.
Table 6: Cryostat and OIWFS duplication work.
|
WBS |
Task Name |
Budget |
Actual |
Remaining |
Variance |
||||
|
(hrs) |
(US$) |
(hrs) |
(US$) |
(hrs) |
(US$) |
(hrs) |
(US$) |
||
|
|
|
|
|
|
|
|
|
|
|
|
4.1 |
Project General |
930 |
32,550 |
96 |
3,360 |
250 |
8,750 |
584 |
20,440 |
|
4.2 |
Mechanical |
4,652 |
162,820 |
4,441 |
155,435 |
2,534 |
88,690 |
-2,323 |
-81,305 |
|
4.3 |
Control System |
3,569 |
124,915 |
340 |
11,900 |
3,229 |
113,015 |
0 |
0 |
|
4.4 |
OIWFS Detector System |
0 |
0 |
0 |
0 |
0 |
0 |
0 |
0 |
|
4.5 |
Integration and Test |
1,673 |
58,555 |
0 |
0 |
1,673 |
58,555 |
0 |
0 |
|
|
|
|
|
|
|
|
|
|
|
|
4 |
Cryostat
and OIWFS Duplication |
10,824 |
378,840 |
4,877 |
170,695 |
7,686 |
269,010 |
-1,739 |
-60,865 |
A serious overrun situation has developed in the RSAA components fabrication. All seemed to go well till the end of 2000 when the allocated hours (2880) were exhausted and only a small amount of work was reported as remaining. Soon after the engineer in charge of duplication left in January 2001, a full status review was carried out, which revealed that about 1500 hrs remained. It appears that along the chain of command from the project manager, through the chief mechanical engineer and the engineer in charge of duplication, to the workshop manager, the scope of the work was not properly communicated. At the same time, problems in the workshop wasted a considerable amount of time.
Although somewhat late, the RSAA QA system caught the problems. Procedures have been changed and direct communication between the project manager and the workshop manager has been established as a check of the line management communication.
As §0 shows, considerable savings have been made on the fixed cost of the duplication work. These savings will exceed the labor overrun.
Table 7 shows the fixed costs involved in the cryostat and OIWFS duplication detailed to the second level of the Work Breakdown Structure. The budgeted, actual, and remaining work are tabulated, together with the variance.
The projected project management costs and the generous travel allocation have been reduced as the interaction with IfA for the design changes required for NIFS has been far less than expected.
Our estimates for the main components of the cryostat and OIWFS were based on the costs incurred by IfA for NIRI. Most subcontractors have been able to quote for the NIFS components on a “repeat business” basis, so allowing good savings. The cost of materials for RSAA in-house fabrication has been considerably higher than expected, but still savings of about $75k are expected.
The OIWFS detector system is also set to return a surplus: the SDSU controller order is somewhat less expensive than planned, and the IfA subcontract became cheaper as RSAA will provide part of the cryostat wiring, the cost of which has been absorbed in the control system budget.
The estimated fixed cost savings exceed the cost overrun in the labor cost for the cryostat and OIWFS duplication.
A detailed list of fixed cost expenditure and commitments is provided in Appendix 8.3.
Table 7: Cryostat and
OIWFS Duplication fixed cost.
|
WBS |
Task Name |
Budget (US$) |
Actual (US$) |
Remaining (US$) |
Variance (US$) |
|
|
|
|
|
|
|
|
4.1 |
Project General |
55,000 |
0 |
38,000 |
17,000 |
|
4.2 |
Mechanical |
261,485 |
133,361 |
52,900 |
75,224 |
|
4.3 |
Control System |
116,730 |
57,687 |
59,043 |
0 |
|
4.4 |
OIWFS Detector System |
82,000 |
66,500 |
3,000 |
12,500 |
|
4.6 |
Consumables |
50,000 |
1,073 |
48,927 |
0 |
|
4.7 |
UH Consultancies |
100,000 |
0 |
100,000 |
0 |
|
4.8 |
Contingency |
141,410 |
0 |
141,410 |
0 |
|
|
|
|
|
|
|
|
4 |
Cryostat
and OIWFS Duplication |
806,625 |
258,621 |
443,280 |
104,724 |
Minor labor and fixed cost expenditure has been incurred on the Spectrograph Construction. It is mentioned here, but is not included in the financial status reports.
A test dewar was fitted out for evaluation of millikelvin temperature control. Together with the actual tests, this took 108 hours, valued at US$3780.
A test sample of the Integral Field Unit pupil mirror array was fabricated by the Labor Für Mikroverspanung of the University of Bremen, Germany. The cost was US$4000.
Sheet metal material was purchased for the construction of the Image Slicer. The cost was US$109.
The WBS Chart, Figure 1, shows the first two levels of the Work Breakdown Structure for the project. The full breakdown is shown in Appendix §8.2.
After completion of the parts fabrication, the next step is to assemble the vacuum jacket and the cold work surface with the cryocoolers. After verifying vacuum integrity, the first cooldown can be started. This first test will be without OIWFS mechanisms, optics, and detector. Part of the control system will be required at this time to drive the cryocoolers.
Assembly of the mechanisms and their control system will precede their bench testing. Their cold testing will be the next step, before installing the optics and detector system for full OIWFS testing. Any problems, which cannot be resolved during the two planned cooldowns in this project phase, will be deferred to the spectrograph test cooldowns.
Contracts will be let for the manufacture of the IFU and for those optical elements which are not fabricated in-house.
All mechanical parts (lens and mirror mounts, baffles, shields, and mechanisms) will be fabricated. Trial assembly of the spectrograph on a copy of the cold work surface plate incorporated in the cryostat duplication will start as soon as there are mechanisms and other items ready for assembly. When complete, optical alignment procedures can be tested and the control system can be used to check mechanism operation under full software control.
Mechanical modifications have to be designed and implemented to transform an existing 8 inch IR Labs dewar into a test cryostat for the NIFS detector. Two sets of detector circuit boards and wiring will have to be constructed, one for use in the test cryostat and the other later, incorporating modifications as required, for the spectrograph. The bare multiplexer has already been delivered and the detector engineering array will arrive during the manufacturing phase. Both will be tested in the test cryostat with the detector engineering software.
The software effort will be structured so that sufficient engineering software will be available for the tests with the engineering detector in the test cryostat and for the mechanism tests in the trial mechanical assembly.
The user and maintenance manuals will be prepared.
Following rectification of any problems found during the spectrograph trial assembly on the dummy cold work surface plate, the spectrograph can be integrated into the cryostat. As the cryostat and OIWFS system have already been tested and the spectrograph has been tested warm, the optics and engineering detector can be installed on the first cooldown cycle for the complete instrument (third cooldown overall). The objectives of this cooldown are to determine the thermal characteristics of the detector mounting and spectrograph, to verify cold operation of the mechanisms, to verify detector operation, to go through the first phase of measuring optical alignment, and to do mechanical stability tests. After rectification of problems encountered and corrective alignment of the optics, the fourth cooldown can start. The optical alignment will be checked and all tests repeated. After installation of the science detector, a fifth cooldown should permit full system tests to be performed. A final period for corrective actions leads to the sixth cooldown cycle for pre-delivery acceptance tests as detailed in the Acceptance Test Plan. At the end of this, NIFS is packed and transported to the Gemini base facility in Hawaii. This success-oriented scenario is somewhat optimistic. It allows only for limited problem rectification times between cooldowns, and does not allow for optical alignment to be iterative. The Assembly and Testing work package therefore contains a contingency for two extra cooldowns.
After transportation to the Gemini base facility in Hawaii key acceptance tests, as shown in the Acceptance Test Plan, will be repeated to check for transport damage. NIFS can now be transported to the summit and connected to the various interfaces to integrate it with the observatory systems. It will then be prepared for commissioning on the telescope as detailed in the Verification and Commissioning Plan.
Training for Gemini operations and maintenance staff will be provided, the manuals will be updated, and the record documents will be finalized.
Figure 1: WBS chart for remaining NIFS work
An overview of the schedule for the remaining NIFS development is depicted in Figure 2. A fully detailed Gantt chart appears in Appendix §8.1.
Figure
2: Schedule for remaining NIFS work
The proposed milestones for the remainder of this project are shown in Table 8 below.
Table 8: Milestones for remaining NIFS work
|
CDR |
20 April 2001 |
|
Engineering Array delivery |
18 September 2001 |
|
Start of first Cryostat and OIWFS cooldown |
24 October 2001 |
|
Completion of Cryostat and OIWFS Duplication |
22 April 2002 |
|
Science detector delivery |
23 April 2002 |
|
Start of first NIFS cooldown |
5 June 2002 |
|
Ship NIFS to Hawaii |
20 February 2003 |
|
First commissioning night |
March 2003 |
|
Project closeout |
June 2003 |
The Critical Design Study will terminate with the Critical Design Review to be held on 19 and 20 April 2001.
The listing of delivery dates in Table 9 shows that the completion date of the assembly of the vacuum jacket for its first vacuum and cold test is determined by the delivery of the cryocooler bellows in June. The assembly and testing of the cryostat and OIWFS duplication work is planned before the end of the spectrograph manufacturing phase so that the spectrograph mechanisms can be tested warm with their actual control system and software before integration of the spectrograph into the cryostat. Assembly and testing is set to commence just before CDR.
Table 9: Suppliers and delivery dates of long lead time items.
|
Item |
Supplier |
Status/Delivery Date |
|
Integration frame |
Craigie Engineering |
Completed |
|
ISS interface plate |
Craigie Engineering |
Completed |
|
VJ forgings |
Lenape Forge |
Completed |
|
VJ machining |
Broens Toolmaking |
mid March 01 |
|
Optable |
Superior Jig |
mid May 01 |
|
OIWFS Lenses |
Janos Technology |
mid May 01 |
|
Cryostat Window |
Janos Technology |
August 01 |
|
OIWFS Filters |
OCLI |
Supplier located |
|
OIWFS Mirrors |
Optics For Research |
June 01 |
|
Gimbal Mechanism |
University of Hawaii |
June 01 |
|
Filter wheel Mechanism |
University of Hawaii |
June 01 |
|
OIWFS Detector Controller |
Astronomical Research Camera |
mid May |
|
OIWFS Detector System |
University of Hawaii |
July 01 |
|
Cryocoolers |
Leybold Cryogenics |
end April |
|
Cryocooler Bellows |
Metal Flex Welded Bellows |
mid June 01 |
Production of fabrication drawings for the spectrograph and the manufacture of mechanical parts will be the limiting factors on keeping this phase to minimum length, as long as the optical manufacture can be started early and much of it can be subcontracted. It is envisaged to have three instrument makers working full time on NIFS for this period.
A test cryostat will be built by modifying an existing dewar. The test cryostat should be ready around the time of delivery of the engineering detector. After delivery of the science detector, the detector engineer’s time is to be divided between the testing of the engineering detector in the NIFS cryostat and the science detector characterization in the test cryostat.
Software production for test cryostat operation is expected to be on the critical path to the testing of the engineering array in the test cryostat.
The installation of the spectrograph in the cryostat and three cooldown, test, warmup, and problem fixing cycles are expected to take up to seven months. As contingencies, two more cooldowns are budgeted for, but not scheduled. These would add two to three months to the schedule.
A final cooldown cycle is planned to accommodate pre-delivery acceptance tests as per the Acceptance Test Plan. On successful conclusion of these tests, NIFS will be warmed up, packed, and transported to the Gemini base facility in Hawaii, where some of the acceptance tests will be repeated to check for transport damage.
The instrument will be transported to the summit and integrated into the observatory systems. NIFS will be tested, commissioned, and verified under varying observing conditions during the commissioning nights as detailed in the Verification and Commissioning Plan, and any problems will be rectified. Gemini staff will be trained in the operation and maintenance of the instrument. The time taken will depend on the commissioning time made available and on the nature and seriousness of any problems encountered.
Although part of the NIFS design and fabrication contract, this commissioning phase has not been included in the costing, nor has it been scheduled. It will be carried out on a time and materials basis at a time to be scheduled later.
As shown in Table 2, the cost of NIFS design and fabrication, excluding the detector, is US$2,381,145. This excludes the cost of Gemini supplied equipment and includes the contract amendment for control system design. The cost of the HAWAII-2 HgCdTe/PACE detector is US$350,000.
Table 10 shows that the remaining labor cost for the completion of the NIFS project is US$641,690. For a full breakdown of the labor required refer to the detailed Gantt chart in Appendix §8.1. The labor estimates are based on previous experience building astronomical instruments at RSAA.
Table 10: Remaining Labor Cost.
|
WBS |
Task Name |
Budget (US$) |
Actual (US$) |
Remaining (US$) |
Variance (US$) |
|
|
|
|
|
|
|
|
2 |
NIFS Critical Design Study |
195,405 |
173,110 |
30,940 |
-8,645 |
|
3 |
CDR |
5,390 |
0 |
5,390 |
0 |
|
4 |
Cryostat and OIWFS Duplication |
378,840 |
170,695 |
269,010 |
-60,865 |
|
5 |
Spectrograph Construction |
336,350 |
0 |
336,350 |
0 |
|
6 |
NIFS Assembly and Testing |
138,880 |
0 |
138,880 |
0 |
|
|
|
|
|
|
|
|
|
total |
915,985 |
343,805 |
641,690 |
-69,510 |
Table 11 shows that the remaining fixed cost for the completion of the NIFS project is US$748,414. For a full breakdown of the fixed cost refer to the table in Appendix §8.3.
Table 11: Remaining Fixed Cost
|
WBS |
Task Name |
Budget (US$) |
Actual (US$) |
Remaining (US$) |
Variance (US$) |
|
|
|
|
|
|
|
|
2 |
NIFS Critical Design Study |
57,013 |
34,457 |
10,892 |
11,664 |
|
3 |
CDR |
3,000 |
0 |
3,000 |
0 |
|
4 |
Cryostat and OIWFS Duplication |
806,625 |
258,621 |
443,280 |
104,724 |
|
5 |
Spectrograph Construction |
291,242 |
0 |
291,242 |
0 |
|
6 |
NIFS Assembly and Testing |
133,400 |
0 |
133,400 |
0 |
|
7 |
Extra Cooldowns |
35,000 |
0 |
35,000 |
0 |
|
|
|
|
|
|
|
|
|
total |
1,157,880 |
293,078 |
748,414 |
116,389 |
Several levels of contingency are to be considered for the project. At the highest level Gemini will maintain a contingency for the cost of change orders and major problems.
At the project level, the uncertainty of the estimates was recorded during the preparation of the costing. Summation of all error amounts produces the total maximum expected error. Contingencies were then allocated to both the cryostat and OIWFS duplication and the NIFS Spectrograph construction.
The cryostat and OIWFS duplication uncertainty is shown in Table 12 together with the contingencies included in the costing. As the cryostat and OIWFS duplication carries lesser risks than new instrument development because there is little innovative design effort required, we consider the level of contingency provided in the costing to be adequate.
Table 12: Cryostat and OIWFS Duplication Cost Uncertainty
For the NIFS spectrograph development the uncertainties are shown in Table 13. As there is considerably more risk involved in the development of new instrumentation, in this case notably the Integral Field Unit, we think it prudent to allow contingencies close to the total uncertainty. A US$134,200 contingency is allocated to the spectrograph construction phase and the remaining contingency amount to the assembly and test phase.
Table 13: Spectrograph Construction Cost Uncertainties
The NIFS project plan also contains a contingency for the cost of extra cooldowns. It has entries for some as yet unspecified travel, and the project management tasks have fixed cost entries for the cost of photocopying, printing, telephone, etc. and to cover unforeseen expenditure which does not fit in any other category. Some individual tasks, which have a high risk of taking longer than planned in this success-oriented schedule, have been allocated extra effort in the plan.
Listed in
Table 15 are major items, which remain to be purchased for NIFS construction. Items for the cryostat and OIWFS duplication have been excluded as their purchasing has either been completed or is in hand. The accuracy of the costs in the table is indicated by the “code” as defined in Table 14.
Table 14: Cost Codes
|
Code |
Definition |
Costing Method |
|
W |
Estimate ±40% |
Extrapolation from past experience |
|
E |
Estimate ±20% |
From recent relevant experience |
|
Q |
Quoted cost |
From
manufacturer's quotation |
Table 15: Items to be Purchased
|
Item |
Code |
Est. Cost |
Vendor |
Order Date |
Notes |
|
|
|
|
|
|
|
|
Spectrograph |
|
|
|
|
|
|
Optics |
|
|
|
|
|
|
Pick-Off Mirror |
E |
$ 3,000 |
POE |
Jun 2001 |
diamond machined |
|
Focal Ratio Converter Mirror |
E |
$ 3,100 |
POE |
Jun 2001 |