Engineering Overview CD-2 Lehman Review Nadine Kurita - LUSI Chief Engineer August 19, 2008

1. Engineering Overview CD-2 Lehman Review Nadine Kurita - LUSI Chief Engineer August 19, 2008

2. Outline • Safety • Organization • Engineering Processes • Standards • Reviews • Specifications/Requirements/ICDs • Configuration Management • Value Management • Engineering Status • Requirement Document Status • Basis of Estimate • Cost Methodology • Major Milestones • Summary

3. Safety • Lead Engineer & Engineering Staff • Responsible for integrating safety into their designs • Access to ES&H staff, peer reviews and SLAC Safety Committees • Line Management • Responsible for safety • Responsible for authorizing work to proceed • Utilize verification processes: • LUSI safety review checklist • Design review process includes safety at each stage of design • Safety reviews are included in the P3 schedule • Work Authorization Form – LCLS Procedure • Instrument designs are consistent with SLAC ES&H Policy – Safety Overview Committee Review • SLAC authorization to energize machine includes sign-off by SLAC Safety Committees and SLAC Safety Officers

4. Engineering Organization

5. Engineering Organization (2) • Staffing Progress • Added 12 engineers/designers since the CD1 Review • All Lead Engineer/CAM positions filled • Manpower Requirements per Current Schedule • Q4FY2008 • 12.1 FTE Mechanical Engineers • 6.6 FTE Mechanical Designers • 1.9 FTE Controls Engineers • Currently searching for 3-4 additional engineers • AMO engineers available in September • Maximum load for mechanical engineering is in Q3FY2009 • 11 FTE Mechanical Engineers • 9.3 FTE Mechanical Designers • Maximum load for controls engineering Q2FY2010 • 5.1 FTE Controls Engineers • 1.7 FTE Controls Programmers

6. LUSI Engineering Resource Loading

7. Engineering Organization (4) • Lead Engineer • Reports to Chief Engineer • Responsible for all technical aspects of the project • Responsible for reporting cost and schedule • Control Account Manager (CAM) • Responsible for supervising daily activities of subordinate engineers, design engineers and designers • Responsible for keeping management informed on critical issues, delays, etc. • Works with upper management to make critical decisions • Design Supervisor • Responsible for design standards • Checking, approving and releasing drawings

8. Engineering Processes – Standards • Formalize Design Standards • Incorporated SLAC Mechanical Design Department standards through SP-391-000-36, LUSI Design Standard Supplement • Developed standard engineering notes • Developed Solid Edge Tool (3D parametric software) • Formalize Manufacturing Practices • LUSI Procedures and Travellers • Produced for critical equipment • Configuration controlled • History archived via LCLS/LUSI sharepoint • Non-Compliance Reports (NCRs), Inspection Reports • History archived via LCLS/LUSI sharepoint

9. Engineering Processes - Reviews • Design review goals and criteria are documented • Design reviews are milestones in our schedule • Essential to ensure the designs meet their prescribed functionality • Demonstrate value engineering • Engineering review template completed

10. Engineering Processes - Reviews (2) • Preliminary Instrument Design Review (PIDR) • Instrument System Specific (CXI, XPP, XCS) • Goal • Approve the objectives and physics requirements of the instrument • Approval of the conceptual design approach • Presents the following • Science including breadth of applications possible with the instrument • Objectives and the requirements of the system • Instrument System Physics Requirements Document complete and ready for sign off • Performance requirements of the components • “Proof of Concept” Models • Proposed approach to meet the requirements • System design • Mechanical • Electrical • Major system interfaces, organizational and technical • Major design alternatives considered (Value Management) • Safety considerations • Assessment of risk areas • Planned test program if appropriate • After closure of action items this approves the baseline design, continuation of engineering specifications and preliminary component designs

11. Engineering Processes – Reviews (4) • Preliminary Design Reviews • Component specific • Final design details are not required • Goal • Approval of the component specifications & preliminary design • Approval to complete final design • Approval to fabricate test articles and place long durationprocurements • Presents the following: • Science/technical objectives, requirements, general specification • Engineering Specification Document complete and ready for sign off • Preliminary design & engineering analyses • Design interfaces • Control/software requirements • Quality control, reliability • Safety considerations – “define hazards” • Cost & schedule • After closure of action items preliminary design approved and long duration items will be purchased. Move to final design.

12. Engineering Processes - Reviews (3) • Final Instrument Design Review (FIDR) • Instrument System Specific (CXI, XPP, XCS) • Prerequisite • All major Component Preliminary Design Reviews must be completed. • Goal • Approve final instrument design / configuration & verify that they meet requirements • Presents the following • System requirements for the instrument • Instrument PRD, ESD and procurement specifications are complete and ready for sign-off • Layout Update - Identify changes from PIDR layout • Component design status and description • Design and analyses to meet the requirements • Major design alternatives considered (value management) • Major system interfaces, organizational and technical • Identify operational modes • Maintenance requirements • Planned test program if appropriate • Installation & alignment plans • Cost & schedule • Safety – status and description of hazard and mitigation • After closure of action items this approves the final design and configuration of the instrument.

13. Engineering Processes – Reviews (5) • Final Design Reviews • Component specific • Goal • Approval of the final design, cost and schedule • Approval to complete detail drawings • Approval to start procurement & fabrication • Presents the following: • Science/technical objectives, requirements & specifications • Review closure of actions from the Preliminary Design Review • Final design and analyses • Test results and design margins • “Analyze and develop controls” for all safety hazards • Approved safety reviews as required • Identified problem areas/open issues • Cost & schedule • After closure of action items this approves the final design and detail drawings are completed. Approval to purchase items and begin fabrication.

14. Engineering Processes – Reviews (6) • Manufacturing Readiness Review • Component specific • Schedule milestone • Goal • Provides status on drawings, procurement, manufacturing and safety documents. • Presents the following: • Status of assembly and detail drawings • Approval process per Mechanical Department standards • Procedures, travellers, inspection and testing plans • Status of procurement and manufacturing • Installation plans & documents • Work Authorization, Statement of Work • Operational requirements/procedures • checkout, testing, maintenance • “Develop and implement” hazard controls • Safety documents • Review closure of action items from the FDR • Cost and schedule update • After closure of action items this approves the start of assembly, testing and installation.

15. Engineering Processes – Reviews (7) • Safety Reviews • Safety Overview Committee Review (SOC), K. Moffeit • Completed December 2006 and identified the following required committee reviews: • Earthquake Reviews • Radiation Safety Reviews • Laser Safety Reviews • Electrical Safety Reviews • Hoisting and Rigging Safety Committee • Fire Marshall • Hazardous Experimental Equipment Committee • SOC approval ensures that the hazard analysis is adequate, controls planned to mitigate or eliminate hazards are adequate, and that the activity will conform to SLAC ES&H policy

16. Engineering Process – Requirements • Physics Requirements Documents (PRD) • Defines functionality of the component • Provides detailed physics/science requirements • Basis for engineering design • Required for the Preliminary Instrument Design Review • Approved by Science Team Leaders and/or LUSI Project Manager • Engineering Specification Document (ESD) • General & engineering specifications to meet the PRD • Covers additional requirements not in the PRD • Space constraints, environment, etc. • Required for the Preliminary Design Review • Approved by Chief Engineer, Scientist, Project Manager • ESD template created • Interface Control Documents (ICD) • Describes the boundaries of one system with respect to another • Physical interface between the two • Responsibilities • Required for the Preliminary Design Review • Approved by all involved system managers

17. System Engineering Flow Diagram

18. Engineering Process – Requirements (3) • Statement of Work/Technical Purchase Specifications • Mandates the technical, quality and procurement specifications for a purchased item • Engineering Notes • Documents engineering analysis and other information critical to the design of the component • These documents are all configuration controlled via LCLS/LUSI Sharepoint or SODA (SLAC Online Database Access)

19. Engineering Processes – Drawing Tree/Structure • Roadmap for building components and installing in the hutch • Assemblies & installations thought through – streamlines modeling and drawing preparations • Organizes the assemblies & models • Integration between design teams

20. Document Control • Utilize existing SLAC MD Document Control System and Sharepoint database • 3D-models will use SLAC MD Project Database Management (PDM) for configuration control and archiving • Drawings and specifications • Check, approval and release process as defined in DS-391-000-36, “LUSI Design Standards Supplement” • Project documents are released and subject to revision control • Management • PEP, Acquisition Strategy, Hazard Analysis, QIP, Value Management, … • Technical • PRDs, ESDs, ICDs, ... • Fabrication & Installation • Procedures, travellers, ... • Design reviews will be archived

21. Document Control (2) • Engineering Change Orders (ECO) • Working with MD on a sitewide ECO process • ECO procedure is under review • Keeps detailed revision history • Increase efficiency of implementing and documenting design and manufacturing changes • Allows for quick approval for implementing changes • Helps to maintain these changes in the supporting design/fabrication documents

22. Value Management • Consistent with DOE Value Management, DOE order 413.3A and OMB Circular A-131 • LUSI Value Management Plan completed, PM-391-000-02 R0 • Executed LUSI Value Management Plan • Conducted with internal and external reviewers • 4 alternative solutions identified • Savings of $355K executed • LUSI Value Management principles are applied to all LUSI engineering tasks • Design alternatives • Part of the engineering review process • Applying common designs • Value Management principles assisted in finalizing the LUSI scope

23. Engineering Status - XPP • X-ray Pump Probe • Extensive engineering and design progress for CD-2 • Engineering Staff • J Langton - Lead Engineer • Jim Defever – Mechanical Engineer • Jim Delor – Mechanical Engineer

24. XPP Instrument Location Near Experimental Hall X-ray Transport Tunnel AMO (LCLS) XPP Endstation XCS CXI Far Experimental Hall

25. Engineering Status – XPP (3) • CD-2 Activities • Completed –Preliminary Instrument Design Review • Approved by team leaders in 2007 - System PRD • Completed – System ESD released • Completed - Drawing Tree/File Structure • Completed - High level models & their drafts • Completed - Hutch definitive layout • Completed - Laser table layout & pump laser to FEL interface • Completed - Detector mover ESD released • Completed - Detector mover “proof of concept” • Testing just completed in August • Completed - Diffractometer ESD released • Documented the interfaces and deliverables with vendor • Completed - Diffractometer definitive layout • Completed – About 85% complete on design effort of all the supports and laser tables

26. Engineering Status – CXI • Coherent X-ray Imaging • Significant engineering and design progress since CD-1 • Engineering Staff • Paul Montanez - Lead Engineer • Jean-Charles Castagna – Mechanical Engineer • Armin Busse – Mechanical Engineer • Rick Jackson – Design Engineer

27. CXI Instrument Location Near Experimental Hall X-ray Transport Tunnel AMO (LCLS) XPP CXI Endstation XCS Source to Sample distance : ~ 440 m Far Experimental Hall

28. Engineering Status – CXI (3) • CD-2 Activities • Completed –Preliminary Instrument Design Review • Approved by team leaders in 2007 - System PRD • Completed – Draft System ESD • Completed –Drawing Tree/File Structure • Completed – XRT/FEH5 beamline layout • Complete drafts for the following ESDs • Completed – Sample Chamber • Completed – Detector Stage –in review • Completed – Precision Instrument Stand –in review • Completed – Reference laser –in review • Completed – 1 m KB mirror system • Completed – Hutch 5, Common Room & Control Cabin ESD • Completed – ICD LUSI to LCLS Sample Chamber & Injector Fixed Target Configuration

29. Engineering Status – CXI (4) • Hutch Layout Drawings • Completed – Stay Clears • Completed – Utilities • Completed – Hutch Layout • Preliminary component designs • ~75% complete – Sample Chamber for the 1 m KB system • ~75% complete– Detector stage • Preliminary design nearly developed • Detector packaging details needed • Completed – Precision instrument stand conceptual design • ~90% complete - Reference Laser preliminary design • 1 m KB system • Budgetary Inquiry

30. Engineering Status - XCS • X-ray Correlation Spectroscopy (XCS) • Major engineering and design progress since CD-1 • Engineering Staff • Eric Bong – Lead Engineer • Jim Delor – Mechanical Engineer • Jean-Charles Castagna – Mechanical Engineer • Armin Busse – Mechanical Engineer • Ted Osier – Designer • Don Arnett – Designer • Ben Bigornia – Designer

31. XCS Instrument Location Near Experimental Hall X-ray Transport Tunnel (200m long) AMO (LCLS) XPP XCS Hutch Source to Sample distance : ~ 420 m CXI Hutch Far Experimental Hall

32. Engineering Status – XCS (3) • CD-2 Activities • Completed –Preliminary Instrument Design Review • Approved by team leaders in 2008 - System PRD • Completed – Drawing tree/file structure • Completed – Higher level models/draft • Completed – Definitive hutch and XRT layout • Completed – Detector mover layout • Completed – Diffractometer definitive layout • Completed – Detector mover proof of concept • Completed – Draft detector mover ESD/SOW • Completed – Draft diffractometer ESD • Completed – Conceptual design for tables and supports • Completed – Hutch Design • Completed – Hutch 4 & Control Cabin ESD • Completed– Interface Control Document (ICD) LUSI to LCLS • Hutch Layout Drawings • Completed – Stay Clears • Completed – Utilities • Completed – Hutch Layout

33. Engineering Status - DCO • Diagnostics & Common Optics • Engineering Staff • Eliazar Ortiz – Lead Engineer • Marc Campell – Mechanical Engineer • Nadine Kurita – Mechanical Engineer • Rick Jackson – Design Engineer • Don Arnett – Designer • Ben Bigornia – Designer Profile-Intensity Monitor Attenuator X-ray Focusing Lens Dual Blade Slits

34. Engineering Status – DCO (2) • CD2 Activities • Complete Draft ESDs • Completed – Pop-In Profile Monitor • Completed – Pop-In Intensity Monitor • Completed – Intensity-Position Monitor • Completed – Wavefront Monitor • Completed – Slits • Completed – Pulse Picker • Completed – Attenuators • Completed – Be Lens System • Completed – Harmonic Rejection Mirror • Working – Complete draft ICD to instruments. • Greater than 50% complete on preliminary designs for the CD4a deliverables • Completed – Pop-In Profile Monitor , 75% complete • Completed – Pop-In Intensity Monitor , 75% complete • Completed – Intensity-Position Monitor ,50% complete • Completed – Pulse Picker, 50% complete • Completed – Slits, 50% complete • Conceptual designs for all remaining devices. • Completed – Wavefront Monitor • Completed – Attenuators • Completed – Be Lens System • Completed – Harmonic Rejection Mirror Monochromator Pulse Picker

35. Project PRD & ESD Status 35 PRDs, 91% complete 55 ESDs, 49% complete

36. Basis of Estimate • Contains the following • Detailed description of the component • Based on latest PRD • 3D model if applicable and available • Detailed cost estimate • Part number, drawing number, vendor, notes, weight, qty, cost, etc. • Supporting quotations, drawings, catalogs, etc. • Configuration controlled with the CD-2 baseline • Cross referenced to P3 activity ID’s

37. Cost Methodology • Cost Methodology • Engineering labor estimates based on prior experience of similar designs • Materials & Labor estimates were driven by the latest design and Physics Requirements • Recently obtained vendor budgetary quotes • Vendor Catalogs • Engineering bottoms up estimate • Engineering judgment • Installation cost and schedule activities were discussed with LCLS installation manager(s)

38. Major Milestones/Reviews • Completed Reviews • Dec ’06 - Safety Oversight Review • Dec ’07 - XPP Preliminary Instrument Review • Dec ’07 - CXI Preliminary Instrument Review • May ’08 - Design Review – Pop-In Profile Monitor • Jul ’08 - XCS Preliminary Instrument Review

39. Major Milestones/Reviews (2) • Upcoming Reviews (6 month look ahead) • XPP • Q4FY08 - PDRs & FDRs Support Tables & Optical Table • Q4FY08 - PDRs & FDRs Optical Tables • Q1FY09 - PDR Diffractometer & Detector Mover • Q2FY09 - FDR Diffractometer & Detector Mover • CXI • Q42008 – PDR Detector Stage • Q1FY09 - PDR & FDR Reference Laser • Q1FY09 - PDR 1.0 m Sample Chamber • DCO • Q4FY08 - PDR Pop-In Profile & Intensity Monitor • Q4FY08 - PDR Pulse Picker • Q1FY09 - PDR Intensity-Position Monitor • Q1FY09 - PDR & FDR Slit System • Q1FY09 - FDR Pulse Picker • Controls • Q1FY09 - PDR XPP Controls

40. Summary • Instrument teams have made significant design progress • LUSI has established designs with a consistent cost estimate. The majority of materials estimates came from vendor quotations, catalogs, or previous orders • XPP ~80% • CXI ~ 90% • XCS ~ 75% • DCO ~ 65% • Controls & DAQ ~ 95% • The technical scope of LUSI has converged • Resource loaded schedules and Basis of Estimates are complete

41. Summary (2) • Engineering Staff • Staff consists of experienced SLAC mechanical engineers and design engineers • Additional staff will be available when AMO work ramps down – September 2008 • Staff is informed in quality and trained in ES&H issues in their area of expertise • Actively looking for additional engineering resources • Working organization with well understood processes • Excellent communication and interfacing with partner labs, LCLS and sub-systems • Engineering staff ready for CD-2 approval!

42. End of Presentation

43. Insert pic here Design Review Standards

44. Review Template

45. ESD

46. Value Management Forms