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Coherent X-ray Imaging WBS 1.3

Coherent X-ray Imaging WBS 1.3. CXI Component Status, Cost and Schedule Paul Montanez CXI Lead Engineer/CAM June 3, 2009. Outline. WBS 1.3 Scope Early Science/CD-4 Deliverables Progress since CD-2 Status Engineering/Design Status Cost & Schedule Performance Critical Path Milestones

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Coherent X-ray Imaging WBS 1.3

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  1. Coherent X-ray ImagingWBS 1.3 CXI Component Status, Cost and Schedule Paul Montanez CXI Lead Engineer/CAM June 3, 2009

  2. Outline • WBS 1.3 Scope • Early Science/CD-4 Deliverables • Progress since CD-2 • Status • Engineering/Design Status • Cost & Schedule Performance • Critical Path • Milestones • Risk Identification & Mitigation • Safety • Summary

  3. Acronyms • PRD • Physics Requirements Document • ESD • Engineering Specifications Document • SOW • Statement of Work • ICD • Interface Control Document • PDR • Preliminary Design Review • FDR • Final Design Review • BAC • Budget at Completion • BCR • Baseline Change Request • XRT • X-ray Transport Tunnel • FEH H5 • Far Experimental Hall Hutch 5

  4. WBS 1.3 – Early Science/CD-4 Deliverables Early Science: Early Finish – April 2011 (B/L Early Finish – May 2011) CD-4: Early Finish – January 2012 (B/L Early Finish – November 2011)

  5. Progress Since CD-2 Vertical/Horizontal PSD, 1-100Hz Measured near location of 1µm KB system • CXI Engineering/Design staff • Added 1 Mechanical Engineer & 1 Mechanical Designer – October 2008 • Added 2 Mechanical Engineers & 1 Mechanical Designer – March 2009 • Added 1 Mechanical Engineer – April 2009 • All documentation completed & released • PRDs, ESDs, SOW’s, etc. • 1µm Kirkpatrick-Baez mirror system • Authorization to proceed with advanced procurement • Vendor site-visits • Mirror system RFP released, proposals received and vendor selection made April 27, 2009 • Award in June 2009 • Design Reviews • Preliminary Design Reviews completed • CXI 1µm Sample Chamber & Reference Laser – March 2009 • CXI Detector Stage & 1µm Precision Instrument Stand – May 2009 • Baseline vibration data obtained in the LCLS Far Experimental Hall

  6. Engineering/Design Status Diagnostics/Common Optics Diagnostics & Wavefront Monitor 1 micron Sample Environment 0.1 micron KB & Sample Environment, Particle Injector and IToF 1 micron KB Reference Laser CXI Early Science CXI CD-4 • CXI Engineering/Design staff • Armin Busse, Kay Fox, Paul Montanez, William Olson, Michael Ramos, Donald Schafer, Nathaniel Stewart

  7. Engineering/Design Status (2) • Documentation • CAD system model documentation hierarchy (CAD Drawing Tree/File Structure) released • XRT/FEH H5 beamline layout complete with all available models implemented & updated • 26 PRDs/ESDs released, 10 SOWs/ICDs released • Hutch Design • Reviewed 30%, 60%, 90% & 100% A/E drawings • FEH Hutch construction – June thru December 2009 (LCLS) • APP and Risk Identification/Registry complete and up-to-date

  8. Engineering/Design Status (3) • CXI 0.1µm KB system (WBS 1.3.02.01) • PRD, ESD & SOWs released • Procurement included as an “option” for the CXI 1µm KB contract • Delivery November 2010 • BAC ≈ $1,400K • CXI 1µm KB system (WBS 1.3.02.02) • PRD, ESD & SOWs released • Prime vendor to provide complete and integrated KB system, including: • Figured & Polished Substrates • Mirror Mechanics/Manipulators • Vacuum chamber and support stand • MOU for independent metrology/coating of the substrates • LLNL likely candidate based on past experience with LCLS OMS mirrors • Secured the services of an optics expert to assist with the evaluation of all procurement documents and to participate as a member of the Proposal Evaluation Committee • Procurement Activities • Advance Procurement Review – October 2008 (required for advanced procurement authorization) • Design Review Report TR-391-003-10 “CXI 1 Micron K-B Mirror System Advanced Procurement Technical Review” • Vendor site-visits by CXI staff – Q1 FY09 • Prequalification of vendors – December 2008/January 2009 • Posted on Federal Business Opportunities (FedBizOpps) website • RFP sent to vendors – January 2009 • Vendor proposals received – 24 March 2009 • Proposal Evaluation Committee Meeting – 9 April 2009 • Recommend a vendor to the Source Selection Official on April 27th • Award in June 2009 • Delivery October 2010 • Budget at Completion (BAC) ≈ $1,280K ($970,000 in long lead procurement)

  9. Engineering/Design Status (4) • CXI Reference Laser (WBS 1.3.03.1) • PRD & ESD released • Successful PDR held March 2009 • Design Review Report TR-391-003-19-0 • Consider Class 2, 1mW, green laser (initially Class 3R, red) • Appropriate signage for laser safety • Additional interlocks for equipment protection • FDR scheduled for July 2009 • Start fabrication drawings • No significant design/cost changes since CD-2 • Use mechanical designs for the vacuum chamber and 6-DOF alignment stage that have previously sustained reviews • Leveraging existing designs (when applicable) reduces our overall engineering/design effort. Additionally, helps to ensure commonality within the LUSI instruments • Budget at Completion (BAC) ≈ $126K Vacuum chamber cover/laser cover removed/sectioned for clarity

  10. Engineering/Design Status (5) • Particle Injector (WBS 1.3.04.01) • PRD & ESD released • Existing Injector design from LLNL • CXI will advance the current design • Optimization of particle beam throughput • Remote operation of equipment • SLAC/LLNL Memorandum of Understanding (MOU) signed-off February 2009 • “Collaboration on the sample particle injector for the Coherent X-ray Imagining (CXI) instrument” • generation or exchange of research and test results, data, and know-how • fabrication or exchange of equipment • financial or other contributions to activities being undertaken • exchange of personnel • Physics Level of Effort (LOE) began upon MOU sign-off, engineering to follow as required • PDR scheduled for September 2009 • BAC ≈ $1,470K

  11. Engineering/Design Status (6) • CXI Sample Chambers (WBS 1.3.05.01.01) • 1µm Sample Chamber • PRD & ESD released • Successful PDR held March 2009 • Design Review Report TR-391-003-20-0 • Currently addressing PDR “Action Items” • Piezo-stage vibration/stability due to stack-up • Equipment protection for in-vacuum stages (potential for clashing) • FDR “Early Finish” scheduled for September 2009 • FDR will be accelerated to July 2009 • BAC ≈ $620K • 0.1µm Sample Chamber • PRD & ESD released • PDR scheduled for March 2010 • Chamber proper will likely be an integral part of the 0.1µm KB vacuum chamber • BAC ≈ $500K

  12. Engineering/Design Status (7) • CXI Precision Instrument Stands (WBS 1.3.05.01.02) • 1µm Precision Instrument Stand • PRD & ESD released • Support /Interface with 1µm Sample Chamber and Detector Stage (in all experimental configurations) • Engineering/Design effort, beyond conceptual design, began in March 2009 • PDR completed May 15, 2009: Design Review Report TR-391-003-27-0 • Determine the effect of lateral seismic loads on rod ends • Evaluate potential back-driving of ball screws due to seismic loading and ameliorate any effects • FDR scheduled for July 2009 • BAC ≈ $240K • 0.1µm Precision Instrument Stand • PRD & ESD released • Support 0.1µm Sample Chamber, Detector Stage and 0.1µm KB System • PDR scheduled for April 2010 • BAC ≈ $330K

  13. Engineering/Design Status (8) Cornell/SLAC detector with variable aperture CXI Detector Stage with Cornell/SLAC detector Detector Stage (WBS 1.3.05.01.03) • PRD, ESD, SOWs & ICDs released • Cornell detector mechanical design progressing • SLAC PPA mechanical engineering completing design for a variable aperture detector • Complete assembly by October 2009 to meet LCLS CD-4 • Purchase order placed in March 2009 with a local design firm for the mechanical design and drafting of the CXI Detector Stage – CXI was resource limited • Move design forward in the schedule • Vendor design reviews • PDR completed May 15, 2009: Design Review Report TR-391-003-27-0 • Explore options to prevent any interference between the detector and valve aperture • Consider methods to determine the vibration amplitude of the cantilevered detector • Develop plans for the fiducialization of the detector relative to the vacuum chamber • FDR – July 2009 • BAC ≈$330K

  14. Engineering/Design Status (9) B4C “throttles” & Guard • CXI Hutch Facilities (WBS 1.3.06.01 & 1.3.06.02) • Hutch layout design • Raised flooring • Storage cabinets, work benches and tool chests • Utilities distribution • BAC ≈$350K • CXI Vacuum System (WBS 1.3.07.01 & 1.3.07.02) • Requirements • In general, beamline vacuum better than 10-7 Torr • Better than 10-9 Torr for KB Systems – isolation/differential pumping from HV required • Preliminary design of a compact, 2 stage, differential pump system complete • Vacuum equipment: pumps, valves, gauges, etc. • Bellows and Spools • Use LCLS support stands where applicable (diagnostics supports/beampipe supports) to leverage existing engineering/design effort • PDRs • Vacuum Equipment – June 2009 • Vacuum Supports – November 2009 • BAC ≈$700K

  15. Engineering/Design Status (10) • Installation (WBS 1.3.08.01) • LUSI Installation Coordinator • Obtain 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 • CXI has a “phased installation” • Early Science • Diagnostics/Common Optics • Reference Laser • 1µm Sample Chamber & Precision Instrument Stand • 1µm KB System • Detector Stage • Vacuum • Equipment/Hardware/Supports • Early Finish – May 2011 • CD-4 • Diagnostics/Common Optics • 0.1µm Sample Chamber & Precision Instrument Stand • 0.1µm KB System • Particle Injector/IToF • Vacuum • Equipment/Hardware/Supports • Early Finish – January 2012

  16. Cost & Schedule Performance Month end March 2009 cumulative schedule variance(-) Month end March 2009 cumulative cost variance(+)

  17. CXI Critical Path KB Mirror AWARD & Vendor Design • Critical path (thru 1µm KB System) has 9d of schedule contingency KB Mirror Design/Fabrication Effort Post Vendor Effort and Installation KB Mirror Installation Effort

  18. CXI Milestones All dates are early finish

  19. CXI Milestones (2) • L2: DOE Site Office Authority (COMPLETE/APPROVED) • L3: Interface Milestones/Major Events • L4: Systems (COMP/RCV) • L6: Commitments/Awards (AWARD) • Significant recent & near-term CXI Instrument milestones • Current schedule (March 2009 data) vs. CD-2 approved schedule (October 2008) • Moved FIDR to June 2009 so that subsequent activities allow for the CD-3 Review to occur in July 2009

  20. CXI Milestones (3) • Six month “look-ahead” of CXI Instrument milestones • Current schedule vs. CD-2 approved dates (October 2008) • 4 PDRs completed to-date • CXI Reference Laser • CXI 1µm Sample Chamber • CXI Detector Stage • CXI 1.0µm Prec. Inst. Std. • 2 Vendor Contract Awards (KBs) • 2 VendorPreliminary Design Reviews (PDR) – KBs • 5 Final Design Reviews (FDR) • LCLS –Cornell Detector Packaging

  21. Risk Identification & Mitigation • Risk Identification/Registry complete and up to date as per “LCLS Risk Management Plan” PMD 1.1-002-r4 • 3 (of 17) risks retired prior to CD-2 • 9 (of 17) risks retired since CD-2 • KB Mirror Systems • Vendor can’t meet 0.1µm mirror specifications – Technical • Vendor can’t meet 1µm mirror specifications – Technical • No vendor willing to bid on 1µm mirrors – Technical & Schedule • No vendor willing to bid on 1µm mirror mechanical system – Technical & Schedule • No resident experience designing mirror mechanical system – Technical & Schedule • 45˚ KB configuration – Technical • Sample Chambers • Custom piezo-stages for Sample Chambers cannot be made – Technical & Schedule • Cornell detector • Last minute changes to detector design – Technical & Schedule • Detector Stage • Custom linear translation stage for CXI Detector Stage – Technical • Outstanding risks relate to • Procurement – As discussed by Tom in his introduction • (2X) Delivered KB mirror systems don’t meet specifications • (2X) Particle injector • Interfaces with adjacent beamlines

  22. Safety • LUSI Hazard Analysis Report (PM-391-001-34) complete • Safety issues are considered at every stage of the design, fabrication and installation process • Safety considerations (some examples) • Ionizing Radiation • Hutch walls will comply with SLAC Radiation Safety memo RP-RPG-080606-MEM-01 • Hutch PPS • Pressure/Vacuum Vessel Safety • Compliant with 10CFR851 • Approved vacuum procedures • Seismic Safety • Designs compliant with: Seismic Design Specification for Buildings, Structures, Equipment, and Systems, SLAC-I-720-0A24E-002-R002 • Mechanical • Interlocks for equipment protection • Engineered solutions that prevent potential “pinch-points” with moving machinery • Hoisting and Rigging • Positioning of devices that require use of the FEH H5 overhead crane shall be performed only by qualified personnel with an approved lift plan. • Laser Safety • CXI Reference Laser, Class 2, 1mW • Appropriate signage

  23. Summary • CXI designs are mature and concepts are based on proven developments made at FLASH and SR sources • CXI scope is stable and has not changed since CD-2 • Long Lead Procurement • Committee evaluation of vendor proposals for the 1µm KB system occurred on April 9, 2009 • Procurement recommendation on April 27, 2009 • Contract award expected in June 2009 • 0.1µm KB system is an “option” included in the 1µm KB system RFP • Critical Path schedule contingency is 9d – continuously monitored • Most major risks associated with the KB mirror systems have been retired • Remaining KB risks will be addressed during design/manufacture and testing • FIDR is being held now as a prerequisite for the CD-3 review in July 2009 • Replanning of LUSI WBS 1.3 (CXI) due to ARRA funding and general scheduling enhancements in process • Pending BCR #2009-05-02: CXI Omnibus Replanning • CXI is on track to support an accelerated schedule

  24. Supporting Slides

  25. Cost & Schedule Performance CXI month end March data BCWS BCWP ACWP SPI CPI

  26. Cost & Schedule Performance – WBS 1.3

  27. Cost & Schedule Performance – WBS 1.3

  28. Expanded CSSR – by CAM

  29. Control Accounts & Work Packages – by WBS L2

  30. P3 Files Milestones – by WBS L2

  31. Labor/Non-labor Split – WBS 1.3

  32. Split by Phase – WBS 1.3

  33. Procurements and Dollars – WBS

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