dkist overview - atst.nso.edu

DKIST Overview

J. McMullin

DKIST SOC 2015-Oct

Outline

• Main – Overview – Schedule – Budget – Scope – Issues/Risks

• Backup Slides – 2015 NSF Baseline Review – Annual Safety Report – NSF Large Facilities Manual – Email Auditing Process – Subsystem Status Details

DKIST SOC 2015-Oct

Overview of Observatory

DKIST SOC 2015-Oct

(Last SOC) 20 March 2015

DKIST SOC 2015-Oct

Building interior – offices!

DKIST SOC 2015-Oct

Solar Physicist Containment System

(Last SOC) October 2015

DKIST SOC 2015-Oct

East-West Section Through Site (work completed @ Oct 2015 shown in color)

Also completed but not shown: 1) site infrastructure & electrical transformers; 2) back-feed electrical, comm., and fiber to IfA facilities; 3) retaining wall & roadwork

Enclosure cable wraps

DKIST SOC 2015-Oct

Overview: Schedule

Project Schedule • Initial funding/start of construction 2010 Jan • Permits in place/start of site construction 2012 Dec • Site Prep, Excavation, Foundations 2013-2014 • Lower Enclosure, Enclosure 2014-

2015 • Telescope Mount Assembly 2016-

2017 • Optics systems installation/Integration 2017-

2018 • Instrument systems commissioning 2018-2019 • Start of Operations

2019 Sep (80 day slip from 2012 baseline; within planned schedule contingency).

DKIST SOC 2015-Oct

Schedule

• Status

– 81 days behind schedule • Relative to October 2012 baseline

• 5.75 years of construction

• approx. 2.75 years of site construction

• 19 Sep 2019

– Roughly 1 month/year

– Reviewing recovery plans

• Schedule Projections

- Baseline allocated 12 months of schedule contingency

- Composed of:

- 7 months funded contingency (in contract budgets for these critical path efforts)

- 6 months of liens on contingency

• Schedule Performance - Site work has exceeded

planned schedule contingency needs

- Weather (!) - Fit-up of non-

preassembled components

- Weather exposure ends after Enclosure SAT, S&O BOD

Best Site for Solar Physics

DKIST SOC 2015-Oct

Maui Unions

Protests Petrels

Schedule status

• Big picture: Schedule within projections over 5.75 years of construction/2.75 years of site construction

• Not for lack of challenges: – Ongoing/permitting restrictions:

• NPS HALE road restrictions (sunrise+30 minutes to sunset-30 minutes and can’t have traffic from 1100-1400).

• Inspection of all vehicles prior to summit use (coordinate with NPS) • Site Logistics (small footprint, limited laydown availability, other HO activities/construction) • Tropical storms/anomalous (?) rain cause work slowdowns (sometimes with NPS shutdowns) • Protests

– Other (some examples) • Crack in initial M1 Blank • DMS Vendor transition at CDR • HI issues with union/PLA, restricted bidding, hiring difficulties, PLA lanaguage • Permitting challenges/protests/etc • Petrel Mortalities • FAA finding of hazard • ARRA spendout • M1 Polishing • VBI Filters

DKIST SOC 2015-Oct

Overview: Budget

DKIST SOC 2015-Oct

Budget

• Funding – $268M (to date)

• $146M ARRA

• $122M MREFC

• Profile

- 2016: $20M

- 2017: $20M

- 2018: $20M

- 2019: $16.1M

DKIST SOC 2015-Oct

• Projections • EAC (spending as planned):

$297M • EAC (spending as past

performance): $297M • BAC: $307M

Component Company Location Status

Telescope Mount Assembly Ingersoll Tools Rockford, IL Coude Rotator: Accepted July 2014 Mount: Accepted May 2015

Enclosure AEC IDOM Bilbao, Spain Accepted Feb 2014; SAT ongoing

M1 Schott AG (blank) UA COS (polish)

Mainz, Germany Tucson, AZ

Accepted @60nm rms ; FAT ongoing

M2 (TEOA) L3 Pittsburgh, PA Factory Testing (heat stop)

M3, M4, M6 L3 Pittsburgh, PA Factory Testing

M5 Physik Instrumente Auburn, MA Accepted

M7, M8, M9 Arizona Optical Systems, LLC Tucson, AZ In Fabrication

M10 Xinetics Devens, MA Accepted May 2015

M1 Cell Assembly AMOS Liege, Belgium Factory Testing

HLS NSO, OSL * FDR Sep 2015

Site – Excavation Site – Concrete Site – Steel Erection Site – Electrical Site – FTS/Plumbing

Tom’s Backhoe & Exc Reef, Rojac Trucking Inc SteelTech Inc Du-Watts Electric Inc NSO*

Kula, HI Wailuku, HI Lahaina, HI Wailuku, HI Pukalani, Maui, HI

Complete Complete Ongoing (Enclosure, S&O Building) Ongoing FTS ongoing

Instruments – WFC Instruments – PA&C Instruments – Cameras* Instruments – VBI Instruments – ViSP Instruments – VTF Instruments – Cryo-NIRSP Instruments – DL-NIRSP

NSO NSO UK Consortium (QUB lead) NSO HAO KIS UH/IfA UH/IfA

Boulder, CO* Boulder CO* Belfast, N. Ireland UK Boulder, CO Boulder, CO Freiburg, Germany Pukalani, Maui, HI Pukalani, Maui, HI

CDR 2015 July PDR 2016 Fabrication Lab Testing & Integration Fabrication Contract Approvals pDR June 2015 In Fabrication In Fabrication

DKIST SOC 2015-Oct

March 2015 SOC

• Identified Issues – M1 Mirror Polishing

• Delayed but now deterministic

– TEOA • FAT went well; Heat Stop still an issue (residual risk to operations)

– FTS • Catching up (Union impact)

– PA&C • Team assembled and planning for 2016 PDR

• Long lead time optics in fabrication/testing

– Visible Camera • Moving forward (DKIST supporting management of the effort)

DKIST SOC 2015-Oct

Risks • Risk Summary

– 95 (High Level) Risks – Exposure at $28.4M – 80% probability at $31.7M

• Highest exposure risks (>$1M): – Schedule delays – Permitting/Legal – Instrument system

Fabrication/Integration – Incomplete System Design

• TMA Optical/Mechanical configuration interface problems

– Staffing Levels

• Changes in Risk Exposure – FTS (contract->self perform->PLA) – PA&C Reboot – Instrument Fabrication – Expanded storage/security

requirements in Maui • Protests, water damage

– Enclosure Site Assembly

• Contingency - $37.8M - % contingency: 31% (ETC1) - % contingency: 32% (ETC2) - Identified Risk/Contingency:

- 83% - (80% prob/available)

• Legal • 2 outstanding cases both

under review by the HI Supreme Court

DKIST SOC 2015-Oct

Summary

• Project is roughly on schedule after 5.75 years of construction (2.75 years of site construction); 2019 start of operations

• Project is within budget projections

• Accepted components/designs have met the challenging performance specifications.

• Successful (ongoing) site/project safety program.

• IT&C challenges ahead; working to ameliorate these in advance

Long way to go… DKIST SOC 2015-Oct

Backup Slides

• 2015 NSF Baseline Review

• Annual Safety Report

• NSF Large Facilities Manual Impact

• Email Auditing Process

• Subsystem Status Details

DKIST SOC 2015-Oct

NSF Baseline Review

• Tucson, AZ

• December 7-9

• Panel

– Tony Beasley, NRAO Director

– Jonathan Cirtain, NASA MSFC, Heliophysics Team Lead

– Brenna Flaugher, Fermilab, Department Head, Astrophysics

– Alistair McPherson, SKA, Head of Project

– Gary Sanders, TMT, Project Manager

DKIST SOC 2015-Oct

NSF Baseline Review

Charge is to Assess: • Project Performance (scope, cost, schedule, risk) • Project Processes for Project Management and

Control (change control, risk management, EVM, Requirement & Compliance tracking, contracting/procurement)

• Cost Estimation History/Performance • Safety • Engagement with Stakeholders • +?

DKIST SOC 2015-Oct

2015 Annual Safety Review

• August 2015 (composed of multi-day field/site inspection and one day face to face meeting)

• Panel

– Richard Hislop (Chair; Hislop & Associates, Inc)

– Shawn Bradfield (NREL; Bradfield Safety Consultants)

– Chuck Gessner (LSSR Head of Safety)

– Mark Grushka (MJGrushka Consulting)

DKIST SOC 2015-Oct

2015 Annual Safety Review

• Findings

– Many positives (leader in safety by Design approach, hazard analysis process, hurricane incident handling, etc)

– Areas of concern:

• Construction incident rate

– Repeat offenders

• Medical evac

• IT&C Electrical system handling (energization/de-energization; arc flash analysis), formal site management responsibility transitions, Plan-of-the-Day coordination, etc

DKIST SOC 2015-Oct

NSF Large Facilities Manual Impact

DKIST SOC 2015-Oct

Large Facilities Manual Summary Changes

• January 4, 2013 – 72 pages – Outline

• Intro

• Planning and Managing for the MREFC Account (4 pages)

• Planning and Managing LF Projects not MREFC

• Detailed Considerations and Requirements (17 pages)

• Special Topics and Supplementary Materials (4 pages)

• Appendices, References, List of Acronyms, etc

• March 13, 2015 – 229 pages (!) – Outline

• Intro • LF Life Cycle and the MREFC

Process (60 pages) • Life Cycle Management Plans

for Large Facilities (16 pages)

• Key Management Principles and Reqs (39 pages)

• Special Topics and Supplementary Materials (75 pages)

• Appendices, References, List of Acronyms, etc

LFM Section Changes Life Cycle Management

Plans for LF • 2015 Draft Guidance

– Project Execution Plan Contents

• Current Project Practice

– Status: Non-compliant • Project follows the PMI

framework

Action/Impact: Project will adapt/update the PEP to incorporate this draft’s requirements (4 FTE weeks)

LFM Section Changes Key Mgmt Principles and Reqs for LF

• 2015 Draft Guidance

– Cost Estimating/Budget – Management Fees – Budget Contingency Plan – Reporting Requirements

• Change Control

– System Integration, Commissioning, Testing, etc

– Documentation Reqs – Requirements for

Performance Oversight

• Current Project Practice – Status: Compliant – Status: In Discussion – Status: Compliant – Status: Compliant – Status: Analogous – Status: Analogous Definition

• Note: Need Transition Plan (1 year prior to start of commissioning)

– Status: Compliant – Status: NSF Analysis/Impact: None(?)

LFM Section Changes Special Topics and Supp

Materials - 1 • 2015 Draft Guidance

– Risk Management Plan

– Risk Register

– Determination of Risk Exp

– Risk Definition

– Risk Exposure Definition

– Allowable Contingency

– Contingency BOE • 70-90% Confidence Level

• Process for use of Contingency

– Schedule Contingency


– Status: Compliant






– Status: Compliant • Status: Compliant

• Status: Compliant

– Status: Analogous (translated to budget)

LFM Section Changes Special Topics and Supp Materials - 2


Risk Management Steps/Methodology

– Risk Management Planning

– Risk Management Plan

– Risk Identification • Risk Description

– Risk Breakdown Structure • (Tech, Ext, Org, PM)

– OMB Risk Categories – Advisory



– Status: Non-compliant

– Status: Compliant • Status: Analogous

– Status: Analogous • (Perf, Bud, Sched, PM)

– Status: Analogous



Quantitative Risk Analaysis

– Maxwell Assessment – rec

– Risk Level Matrix

– Butterfly/Mirror

– Trend Analysis

Quantitative Analysis

– Schedule

• Current Project Practice Status: Compliant* (more description needed for external)

– Status: Analogous (GAO)


– Status: Not used • opportunities tracked as

mitigations


- Status: Compliant* - Matches what was done at re-

baseline; now non-compliant.



– Risk Inflation – Risk Response Planning – Risk Monitoring and Control

• Contingency Profile • Change Control • Liens List • Updates of EAC/Risk Exposure • NSF Oversight • Documentation & Reporting

– Cyber Security – External Reviews – Environmental Considerations – Reporting Requirements – BSRs, OMB Inflators

• Current Project Practice – Status: Tracked; not reported – Status: Compliant – Status: Compliant

• Status: Tracked; not reported • Status: Compliant • Status: Analogous • Status: Defiantly non-compliant • Status: Compliant • Status: Compliant

– Status: Evolving – Status: Compliant – Status: Compliant (BR) – Status: Compliant – Status: Compliant

Summary Impact (LF Updates)

• Life Cycle Management Plans for Large Facilities – 4 FTE weeks

• Key Management Principles and Requirements for Large Facilities – Standard management

practice; no impact

• Special Topics and Supplemental Materials – 4 FTE weeks to

homogenize/conform to recommended risk content descriptions

– Assume analogous is compliant for: • RBS • Qualitative Risk Analysis • Quantitative Risk Analysis

– If Schedule regarded as non-compliant – significant effort required.

– Case study is different from project; if this gets religious=big (not useful) effort

• Liens list • RAC is bad math; probability

incorporated into MC modeling

– Unknown impact for Cyber security (being tracked) DKIST SOC 2015-Oct

Meta Summary

• Overall the revised guidelines represent best practices that we are following, though there are differences in the details.

• I believe our processes and practices are rigorously defensible. – My concerns are in the areas where we have

analogous systems; the guidelines are stated as guidelines but if they (or an individual) insisted upon strict adherence, we could waste significant time with little project benefit.

– We will need to discuss with our PO

DKIST SOC 2015-Oct

Email Auditing

• Audits to date – E-mail inquiries – No site presence/interaction

• Case study – Audit of the Project’s Response to the DCAA Audit

• Recurring misunderstandings: – WBS versus Work Package – ARRA and MREFC funding – Cost books as snapshots in Time

» Change Requests » Contract Amendments

– https://www.dropbox.com/s/f1rwywzmxdwtc8q/S-WMEN3-004%20-%20Enclosure%20Fabrication%20and%20Factory%20Assembly%20and%20Testing.mp4?dl=0

DKIST SOC 2015-Oct

Project Response to DCAA

DKIST SOC 2015-Oct

Site & S&O Building

DKIST SOC 2015-Oct

S&O Building • Cladding & Roofing: Now • Platform Lift: Now-10/15 • Electrical: Now-12/15 • Mechanical: ~Now-5/16 • Plumbing: ~Now-5/16 • Fit & Finish: Now-5/16 • Site Closeout: 4/16-4/17

Enclosure

• Site Assembly & Construction In-Progress – Started Site Assembly

Feb 17, 2015

– Structural, Mechanical, Electrical Install ongoing

– Handing Equipment, Cladding, Ventilation Gates Install upcoming

– Site Acceptance Testing planned early 2016.

DKIST SOC 2015-Oct

Telescope Mount Assembly

• Coudé Rotator – Factory Acceptance Complete July

2014 – Shipped to Maui complete Nov

2014 and in storage. – Site Install starts Oct 2015. – Site Acceptance Testing complete

Jan 2017

• Telescope Mount – Factory Acceptance Testing

Complete April 2015 – Shipment arrivals started Jul 2015

and will be complete by Oct 2015. – Site Install starts April 2016 – Site Acceptance Testing complete

Nov 2017

DKIST SOC 2015-Oct

M1 Mirror

• M1 Mirror polishing is near completion.

• We expect:

– Factory Acceptance: November 2015

– Long term storage in Tucson area.

– Ship date: ~Q1 2017

– Site Integration start: Q2 2017 (coating)

DKIST SOC 2015-Oct

M1 Assembly

• Initial integration and testing underway, using the M1 prototype mirror blank.

• Factory Acceptance February 2016

• Shipment to site Q2 2016

DKIST SOC 2015-Oct

TEOA

• The TEOA is fully constructed, assembled and tested. We are at >90% completion of FAT.

• We expect: – Factory Acceptance:

September 2015 – Possible long term storage

at L3 facility – Ship date: Q4 2016 – Site Integration start: Q1

2017

DKIST SOC 2015-Oct

Feed Optics

• Transfer Optics factory acceptance complete.

• Shipment to Tucson Q3 2015

• Shipment to site 2017

• Coudé Optics in preliminary design stage.

• PDR October 2015

• FDR Q2 2016

• FAT Q4 2016

• On site Q1-Q2 2017

DKIST SOC 2015-Oct

2014 2015 2016 2017 2013

Fluid Cooler & CES AHUs Factory Acceptance Test

Facility Plant Equipment, tunnel piping, S&O Bldg HVAC and mechanical equipment room

Finish Coudé Environmental Systems, TEOA closed loop & TMA Thermal Systems

Fluid Cooler & CES AHUs rough install

Complete Enclosure Thermal Systems & Start Coudé Environmental Systems

Site close-out support, deliver as-builts, maintenance and operation manuals and provide IT&C support

2018 → IT&C

Enclosure Thermal Systems (ETS)

Facility Thermal Systems

DKIST SOC 2015-Oct

Instruments

ViSP • Fab Contract

Negotiations Underway

• LAT: 9/17-3/18 • Ship: 3/8-6/18 • Site IT&C: 6/18+

VBI • Fab 90% Complete • LAT: Now-2017 • Ship: 10/17 • Site IT&C: 11/17+

Cryo-NIRSP • Fab Underway • LAT: 10/15-2/17 • Ship: 3/17 • Site IT&C: 6/17+

VTF • In Design • LAT: 6/18-12/18 • Ship: 4/19-6/19 • Site IT&C: 7/19+

DL-NIRSP • Fab Started • LAT: 2/18-2/19 • Ship: 2/19 • Site IT&C: 3/19+

DKIST SOC 2015-Oct

Wavefront Correction System Status

• Current status & timeline: – Lab I&T, Boulder, CO: Oct 2015

– Critical Design Review: Nov 2015

– Summit IT&C: late 2017 – early 2018

• Lab I&T Safety Issues – Eye safety, Class IIIa/3R HeNe Laser, 543 nm,

2 mW

– Electrical safety

– Soldering safety

– Pinch hazards, motorized optical stages

– Heavy lifting

– Solvent use for optical cleaning

– Lab safety briefings for WFC team

Deformable Mirror

Coudé Optical Bench Layout

DKIST SOC 2015-Oct

dkist overview - atst.nso.edu

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