4.1 NIFS Critical Design Study
During the NIFS
Critical Design Study, the optical design is to be finalised, the mechanical
design is to be progressed through to the production of manufacturing drawings.
The detector system is to be designed in full detail and wiring for a test
cryostat is to be designed and manufactured. The overall software system design
is to be completed together with the Components Controller and Instrument
Sequencer software.
Any optical design
issues still outstanding at the Conceptual Design Review need to be addressed.
These include scattering, ghosting, tolerancing, and alignment needs and
accuracy. The manufacturing details of all optical components need to be
specified and decisions need to be made on which items will be fabricated
in-house. The blanks for in-house fabrication have to be ordered and contracts
let for the supply of gratings and filters. It would be advantageous to start
in-house fabrication early and possibly also let the external optics
manufacturing contracts.
In the area of
mechanical design, full assembly drawings of the spectrograph are to be
produced. These, together with information from NIRI will be used for flexure
and thermal analysis. Detailed manufacturing drawings of all lens and mirror
mounts, baffles, shields, and mechanisms have to be produced. We are planning a
short and intensive fabrication phase, and it would be advantageous to start
fabrication of some components early to reduce the risk of fabrication delays
due to unexpected variations in workshop staff availability and the impact of
other workloads. We would identify components for early fabrication taking into
account the least impact of possible spectrograph design changes in the latter
part of the Critical Design Study or at the CDR.
The detector and
detector controller are long lead-time items which should be ordered as soon as
possible. The operation of the controller will have to be fully verified upon
delivery. The wiring from the controller to the detector has to be 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 need
to be addressed. The test cryostat wiring has to be designed and manufactured.
The DSP code for the detector controller needs to be designed.
The overall software
system design should be finalised and the NIFS Component Controller software
should be ready for testing. The Detector Controller software design should be
completed and coding should be under way for the detector engineering software.
Other items to be
delivered are final ICDs, tables of contents for all manuals, a draft spares
list, the pre-shipment acceptance test plan and the verification and
commissioning plan.
4.2 NIRI Duplication
It is proposed that
RSAA subcontract the manufacture, assembly, and test of the "NIRI duplication"
to the Institute for Astronomy of the University of Hawaii. Except for a few
relatively minor changes, the following NIRI items will be duplicated: carrier
frame, ISS interface plate, cryostat, cooling system, OIWFS optics and
mechanics, OIWFS detector and controller, electrical control system, and
temperature control system. The full
assembly will be tested before delivery to RSAA. On delivery, it will be
re-tested to check that no transport damage has occurred.
4.3 Spectrograph Manufacturing Phase
Optical manufacture,
both in-house and subcontracted, will be continued following the Critical
Design Review. Contracts will be let for the manufacture of the IFU and of
those optical elements which were not ordered earlier during the design phase.
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 NIRI 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 NIRI 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 designed and constructed. The first to allow independent testing of all
four detector quadrants and the second for normal operation. The detector
engineering array will arrive during the manufacturing phase. It 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.
4.4 NIFS Assembly and Testing
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 fully tested and
the spectrograph has been tested warm, the optics and engineering detector can
be installed on the first cooldown cycle. The objectives of the first 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 second cooldown can start. The optical
alignment will be checked and all tests repeated. After installation of the
science detector, a third cooldown should permit full system tests to be
performed. A final period for corrective actions leads to the fourth cooldown
cycle for pre-delivery acceptance tests. At the end of this, NIFS is packed and
transported to the Gemini base facility in Hawaii. This success-oriented
scenario is somewhat optimistic and 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.
4.5 NIFS Commissioning
After transportation
to the Gemini base facility in Hawaii key acceptance tests should 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 can then be prepared for commissioning on the telescope.
Training for Gemini
operations and maintenance staff will be provided, the manuals will be updated
and the record documents will be finalised.
An overview of the schedule for the NIFS
development is depicted in Figure 2. A fully detailed
Gantt chart appears in Appendix §13.1.
Figure 2: NIFS Schedule
5.1 Milestones
The proposed
milestones for this project are shown in Table 1 below.
Table 1: Milestones
|
|
1 April 2000
|
|
Detector
Ordered
|
2 May 2000
|
|
Detector Bare
MUX delivered
|
4 September
2000
|
|
Delivery of CDR
documentation
|
24 November
2000
|
|
CDR
|
8 December 2000
|
|
NIRI Duplicate
delivery
|
17 May 2001
|
|
Engineering
Array delivery
|
5 April 2001
|
|
Start of first
NIFS cooldown
|
5 October 2001
|
|
Science
detector delivery
|
5 November 2001
|
|
Ship NIFS to
Hawaii
|
20 June 2002
|
|
First
commissioning night
|
August 2002
|
|
Project
closeout
|
Nov 2002
|
5.2 Spectrograph Critical Design Study
The Critical Design
Study will terminate with the Critical Design Review. The date of the review is
driven by the work to be done and the availability of suitably qualified and
experienced staff to do it. Mechanical design is on the critical path.
Completion of the design phase is planned for December 2000.
5.3 NIRI Duplication
The NIRI duplication
work needs to be started soon and delivery of the tested system 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 vacuum jacket. The main
fabrication effort should take place in mid 2000, with assembly and testing to
commence later in the year. Delivery should be in early 2001.
5.4 Spectrograph Manufacturing Phase
The manufacture of
mechanical parts for the spectrograph will be the limiting factor 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. This means that
RSAA will have to employ at least one, possibly two, extra workshop staff.
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 characterisation in the test dewar. To do this, two SDSU controllers
will be needed. The RSAA detector lab controller will be used, for which at
least one IR analog card will need to be purchased.
Software production
for test dewar operation is expected to be on the critical path to the testing
of the engineering array in the test cryostat.
5.5 NIFS Integration and Test
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 fourth
cooldown cycle is planned to accommodate pre-delivery acceptance tests. On
successful conclusion of these tests, NIFS will be warmed up, packed, and
transported to the Gemini base facility in Hawaii.
5.6 NIFS Commissioning
Commissioning will
start by repeating the acceptance tests to check for transport damage. The
instrument will then be transported to the summit and integrated into the
observatory systems. Two months will elapse from arrival in Hawaii to being
ready for the first night on the telescope. NIFS will be tested, commissioned,
and verified under varying observing conditions during the commissioning
nights, 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.
As shown in Table 2, the total cost of NIFS, excluding the detector, is
US$2,996,319. The cost of the HAWAII-2 HgCdTe/PACE detector is US$350,000.
Table 2: NIFS Cost Breakdown by Activity
|
|
Description
|
hrs
|
US$
|
US$
|
|
|
Project Scientist
|
1383
|
$ -
|
|
|
|
Project General
|
2210
|
$
77,350
|
|
|
|
System Engineering
|
2390
|
$
83,650
|
|
|
|
Mechanical Design
|
1830
|
$
64,050
|
|
|
|
Mechanical Manufacture
|
3200
|
$
112,000
|
|
|
|
Optical Design
|
710
|
$
24,850
|
|
|
|
Optical Manufacture
|
530
|
$
18,550
|
|
|
|
Detector System Design & Manufacture
|
3020
|
$
105,700
|
|
|
|
Control System Design & Manufacture
|
344
|
$
12,040
|
|
|
|
Software Development
|
3270
|
$
114,450
|
|
|
|
Assembly & Testing
|
2240
|
$
78,400
|
|
|
|
Commissioning
|
570
|
$
19,950
|
|
|
subtotal
|
|
21697
|
|
$
710,990
|
|
|
|
|
|
|
|
Major Items
|
NIRI Duplication
|
|
|
$
1,750,000
|
|
|
|
|
|
|
|
Hardware Costs
|
|
|
|
|
|
Mechanical
|
|
$
21,930
|
|
|
|
Optical
|
|
$
111,300
|
|
|
|
Detector System
|
|
$
33,275
|
|
|
|
Control System
|
|
$
7,918
|
|
|
|
Computing
|
|
$
57,306
|
|
|
|
Thermal Enclosures
|
|
$
14,000
|
|
|
|
Subcontractors (design)
|
|
$
11,385
|
|
|
|
Consumables
|
|
$
9,000
|
|
|
subtotal
|
|
|
|
$
266,114
|
|
|
|
|
|
|
|
Other Costs
|
Project Management (incl. CDR)
|
|
$
21,000
|
|
|
|
Travel (excl. commissioning)
|
|
$
17,500
|
|
|
|
Transportation
|
|
$
72,000
|
|
|
|
Extra Cooldowns
|
|
$
35,000
|
|
|
|
Support Equipment
|
|
$
43,715
|
|
|
|
Contingencies
|
|
$
60,000
|
|
|
|
Commissioning Travel
|
|
$
20,000
|
|
|
subtotal
|
|
|
|
$
269,215
|
|
total
|
|
|
|
$
2,996,319
|
6.1 Labour
Table 3 shows that the labour required for the spectrograph
design and construction, and for the instrument assembly, testing and commissioning
is 21697 hours. At the RSAA labour rate of US$35 per hour, and taking into
account that time worked by the Project Scientist is not chargeable, this comes
to $ 710990. For a full breakdown of the labour required refer to the detailed
Gantt chart in Appendix §13.1. The labour estimates are based on RSAA's previous
experience building instruments.
Table 3: NIFS Cost
Breakdown by Development Phase
|
Phase
|
PS hrs
|
Paid
hrs
|
Labour
|
Fixed Cost
|
Total Cost
|
|
Critical Design Study
|
627
|
6303
|
$
220,605
|
$
119,026
|
$
339,631
|
|
Cryostat and OIWFS Duplication
|
140
|
140
|
$
4,900
|
$
1,785,500
|
$
1,790,400
|
|
Spectrograph Construction
|
70
|
9419
|
$
329,665
|
$
201,188
|
$
530,853
|
|
NIFS Assembly and Testing
|
308
|
3688
|
$
129,080
|
$
118,615
|
$
247,695
|
|
Extra Cooldowns
|
|
|
|
$
35,000
|
$
35,000
|
|
Commissioning
|
238
|
764
|
$
26,740
|
$
26,000
|
$
52,740
|
|
total
|
1383
|
20314
|
$ 710990
|
$ 2285329
|
$
2,996,319
|
A large part of the
total NIFS project cost is for the duplication of NIRI (US$1.75M). The cost of
all further items to be purchased for the construction comes to US$ 535329. The
uncertainties associated with the capital cost estimates are identified in Table 5.
The line-item
"Consumables" in Table 2 refers to minor parts and materials such as
fasteners, common cables, and other small items which will be needed but are
not yet identified.
The line-items
"Computing" and “Thermal Enclosures" are Gemini supplied items
for which the cost has to be included in the NIFS budget. The
"Computing" costs are itemised in Table 6: Gemini Supplied Items.
6.3 Travel and Miscellaneous
The travel budget
allows for two visits of project staff to Hawaii related to the NIRI
duplication and three more trips, possibly to other destinations, as the need
arises.
Travel for the
Commissioning phase has been included as fixed cost in one of the commissioning
tasks. The allocation is for four people travelling to Hawaii, staying there
for 3.5 weeks on average.
The cost of
transportation of NIFS to Hawaii is covered under the heading
"Shipping". Transportation of the NIRI duplicate to Australia is
included in the "NIRI Duplication" cost.
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.
6.4 Contingency
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
such as cost variations of the NIRI duplication.
The NIFS project plan
contains a contingency for the cost of extra cooldowns, 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. Two more “Contingency”
items are listed, one for the spectrograph construction phase and one for the
assembly and test phase. They are intended to cover items missed in costing,
underestimated, fabrication mishaps, printed circuit redesign, equipment
failures, etc. The total of these contingency items is $60000, a very modest
4.8% of the spectrograph cost (excluding the NIRI duplication).
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.
6.5 Cost Profile per Quarter
The cost profile of
the NIFS project is shown in Figure 3. This information is only indicative of the cashflow
for the project. It was generated by Microsoft Project on the assumptions that
labour costs are accrued as work is executed, and fixed costs become payable at
the start of their associated tasks, with the exception of the NIRI duplication
where pro-rata cost accrual over the whole construction period has been used.
During the first half of the project, in the design and construction
phases, 87% of the cost is accrued.
Figure 3: NIFS Cost per Quarter
Listed in Table
5 are all items to be purchased for the NIFS
development as they have been identified during the conceptual design study. The
accuracy of the costs in the table is indicated by the “code” as defined in Table 4.
Table 4: 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 5: Items to be Purchased
|
Item
|
Code
|
Est. Cost
|
Vendor
|
Order Date
|
Notes
|
|
NIRI Duplication
|
Q
|
$ 1,750,000
|
UH
|
Apr 2000
|
|
|
Spectrograph
|
|
|
|
|
|
|
Optics
|
|
|
|
|
|
|
|
E
|
$ 3,000
|
POE
|
Nov 2000
|
diamond machined
|
|
Focal Ratio Converter Mirror
|
E
|
$ 3,100
|
POE
|
Nov 2000
|
diamond machined
|
|
Cold Stop Mirror
|
E
|
$ 2,000
|
POE
|
Nov 2000
|
diamond machined
|
|
Fold 1 Mirror
|
E
|
$ 1,900
|
POE
|
Nov 2000
|
diamond machined
|
|
|
E
|
$ 1,800
|
POE
|
Nov 2000
|
diamond machined
|
|
Tri-Fold Mirror
|
E
|
$ 6,000
|
POE
|
Nov 2000
|
diamond machined
|
|
Image Slicer
|
E
|
$ 4,000
|
POE
|
Nov 2000
|
diamond machined
|
|
Pupil Mirror Array
|
E
|
$ 13,000
|
POE
|
Nov 2000
|
diamond machined
|
|
Field Mirror Array
|
E
|
$ 13,000
|
POE
|
Nov 2000
|
diamond machined
|
|
Collimator Mirror (blank)
|
E
|
$ 1,400
|
|
Jul 2000
|
Silica
|
|
Collimator Corrector
(blank)
|
E
|
$ 1,300
|
|
Aug 2000
|
CaF2
|
|
Camera Lens 1 (blank)
|
E
|
$ 1,800
|
|
Aug 2000
|
CaF2
|
|
Camera Lens 2 (blank)
|
E
|
$
1,700
|
|
Aug 2000
|
Silica
|
|
Camera Lens 3
|
E
|
$
6,000
|
JNS
|
Oct 2000
|
ZnSe: from Janos
|
|
Camera Lens 4 (blank)
|
E
|
$
1,800
|
|
Aug 2000
|
CaF2
|
|
Camera Lens 5 (blank)
|
E
|
$
1,600
|
|
Aug 2000
|
Silica
|
|
Order Blocking Filters
|
|
|
|
|
|
|
J and K
|
E
|
$
2,936
|
GEM
|
available
|
from Filter Consortium
|
|
TBA
|
E
|
$
32,064
|
|
|
2 sets of 4 @ $4000 ea
|
|
Gratings
|
|
|
|
|
|
|
TBA
|
E
|
$
10,400
|
RGL
|
|
8 @ $1300
|
|
Ronchi Grating and Occult. Masks
|
|
|
|
|
|
|
Materials and Coating
|
W
|
$
2,500
|
|
Aug 2000
|
|
|
Mechanical (materials incl. motors)
|
|
|
|
|
|
|
Set-Up Plate
|
E
|
$ 800
|
|
Sep 2000
|
1000x800x40,100 features
|
|
Spectrograph Enclosure
|
E
|
$
4,000
|
|
Dec 2000
|
Casting, 50 machined features
|
|
Disperser Enclosure
|
E
|
$ 600
|
|
Dec 2000
|
Casting, 30 machined features
|
|
Small Enclosure components
|
E
|
$ 60
|
|
Jan 2001
|
40 small pieces with repetition
|
|
Radiation Shield Oddments
|
E
|
$ 60
|
|
Feb 2001
|
6 small pieces
|
|
Entrance Baffle
|
E
|
$ -
|
|
Feb 2001
|
180 x 180 x 250, fabrication
|
|
Pick-Off Probe
|
E
|
$ 60
|
|
Sep 2000
|
8 pieces plus optics
|
|
Feed Turret
|
E
|
$
2,500
|
|
Aug 2000
|
69 pcs, motor, masks, mirrors
|
|
Filter and Folder Unit
|
E
|
$
2,500
|
|
Nov 2000
|
66 pieces, motor
|
|
Field Slicer
|
E
|
$
1,000
|
|
Sep 2000
|
46 pieces, plate rolling
|
|
Mirror Array and Folder
Unit
|
E
|
$ 60
|
|
Dec 2000
|
10 pieces
|
|
Collimator Reflector
|
E
|
$ 60
|
|
Jan 2001
|
8 pieces
|
|
Collimator Corrector
|
E
|
$ 60
|
|
Jan 2001
|
6 pieces
|
|
Disperser
|
E
|
$
3,000
|
|
Aug 2000
|
48 pcs, motor, enc., latching
|
|
Camera
|
E
|
$ 60
|
|
Oct 2000
|
22 mechanical pieces
|
|
Detector Mount
|
E
|
$ 60
|
|
Nov 2000
|
35 pieces
|
|
Detector Controller Mount
|
E
|
$ -
|
|
Feb 2001
|
Integrated connector
|
|
Handling Equipment
|
W
|
$
2,000
|
|
Mar 2001
|
|
|
Alignment Aids
|
W
|
$ 400
|
|
Mar 2001
|
|
|
Bearings etc. for
Mechanisms
|
|
|
|
|
|
|
Sintered Components
|
E
|
$ 250
|
|
Dec 2000
|
|
|
Bearings
|
E
|
$
1,000
|
|
Dec 2000
|
|
|
Indium Foil &
Incidentals
|
W
|
$
1,000
|
|
Dec 2000
|
|
|
Test Cryostat Mods
(materials and parts)
|
|
|
|
|
|
TBA
|
W
|
$
1,500
|
|
|
|
|
Components Surface
Treatment
|
|
|
|
|
|
|
Paint
|
W
|
$ 900
|
|
Apr 2001
|
|
|
Control System
|
|
|
|
|
|
|
Thermal Cabinets
|
Q
|
$
14,000
|
GEM
|
available
|
ready for delivery
|
|
Mechanism control
|
|
|
|
|
|
|
Hall Effect Sensors
|
E
|
$ 550
|
FWB
|
Oct 2000
|
|
|
Magnets
|
W
|
$ 50
|
|
Oct 2000
|
|
|
connectors and wiring
|
W
|
$
300
|
|
Nov 2000
|
|
|
Temperature Control
|
|
|
|
|
|
|
Temperature Controller
|
Q
|
$
5,120
|
LCI
|
Jul 2000
|
|
|
Rack Mount
|
Q
|
$ 118
|
LCI
|
Jul 2000
|
|
|
Calibrated Sensors
|
Q
|
$
1,220
|
LCI
|
Jul 2000
|
|
|
Heater Cartridges
|
W
|
$ 170
|
LCI
|
Jul 2000
|
|
|
Heater Resistor
|
E
|
$ 30
|
|
Jul 2000
|
|
|
Diode Sensors
|
W
|
$ 60
|
|
Jul 2000
|
|
|
connectors and wiring
|
W
|
$ 300
|
|
Jul 2000
|
|
|
Detector System
|
|
|
|
|
|
|
Detector Controller
|
|
|
|
|
|
|
Fiber Optic Timing Board
|
Q
|
$
2,500
|
LCH
|
April 2000
|
|
|
Dual Channel IR Video
Board (2)
|
Q
|
$
10,000
|
LCH
|
April 2000
|
|
|
Clock Driver Board
|
Q
|
$
2,500
|
LCH
|
April 2000
|
|
|
VME Interface Board
|
Q
|
$
3,750
|
LCH
|
April 2000
|
|
|
Controller Housing and
6-slot Backplane
|
Q
|
$
2,500
|
LCH
|
April 2000
|
|
|
Power Supply for 6-slot
|
Q
|
$
1,250
|
LCH
|
April 2000
|
|
|
100' Fibre Optic Cable
(2)
|
Q
|
$ 300
|
LCH
|
April 2000
|
|
|
Set of Electronics
Cables
|
Q
|
$
1,000
|
LCH
|
April 2000
|
|
|
Set of Shorting Plugs
|
Q
|
$ 375
|
LCH
|
April 2000
|
|
|
Detector Wiring
|
|
|
|
|
|
|
Shorting Connectors
|
W
|
$ 400
|
|
April 2000
|
|
|
Cryostat Internal Wiring
|
|
|
|
|
|
|
Wiring Tests
-rectification
|
W
|
$ 100
|
|
|
|
|
Detector Mounting PCB
|
|
|
|
|
|
|
Detector Sockets
|
E
|
$ 600
|
|
April 2000
|
|
|
Discrete Components
|
E
|
$ 160
|
|
May 2000
|
|
|
Flex Circuit Mating Connectors
|
E
|
$ 195
|
