engineering management and coordination · 5/4/2019 · engineering management april 9-11, 2019...

April 9-11, 2019 sPHENIX Director's Review 1

James Mills

April 9-11, 2017

Brookhaven National Laboratory

Engineering Management and Coordination


April 9-11, 2019 2sPHENIX Director's Review

– Engineering Management and Staff

– Engineering Controls

– Standing Meetings

– Technical Project Reviews

– sPHENIX Documents and Procedures

– Integration

Engineering Management


sPHENIX Senior Engineering Staff

– J. Mills – Project Engineer

– R. Feder – Chief Mechanical Engineer (start 4/8/2019)

– R. Ruggiero – Chief Design Engineer

– L. Stiegler/A. Franz – Safety Engineering

– C. Gortakowski – Quality Assurance

Departmental Engineering Management (Support)

– J. Tuozzolo – Chief Mechanical Engineer – CAD

– J. Sandberg – Chief Electrical Engineer – CAD

– M. Anerella – Chief Mechanical Engineer – SMD

– C. Folz – Head, Facilities and Experimental Support - CAD

– B. Wahl – Chief Mechanical Engineer NSLS II

• Experienced Senior Staff 25+ years experience

• Senior Engineering Support from CAD/SMD/NSLS II

• BNL ESH and Quality

WBS No. Detector Element Engineering LeadInstitution-

DeptSupport Engineering

1.02 TPC J. Cozzolino BNL - SMDS. Bellavia (CAD), M. Anerella (SMD), J. Kuczewski (ID), C. Miraval (ID), R. Pisani

(PH)

1.03 EMCal S. Stoll BNL - PH D. Cacace (PH), R. Pisani (PH)

1.04 Hcal R. Ruggiero BNL - PH R. Pisani (PH), C. Pontieri (PH), J. Mills (CAD), D. Cacace (PH)

1.05 CalElect S. Boose BNL - PH E. Mannel (PH), S. Polizzo (PH)

1.06 DAQ/Trigger E. Desmond BNL - PH J. Kuczewski (ID)

1.07 Min-Bias Trigger Detector TBD TBD

2.02 Magnet M. Anerella BNL - SMDR. Than (CAD), C. Schultheiss (CAD), P. Orfin (CAD), P. Rosas (CAD), T. Tallerico

(CAD), D. Phillips (CAD)

2.03 Carriage - Structural Components C. Pontieri BNL - PH J. Hock (CAD), J. Mills (CAD)

2.04 Infrastructure R. Pisani BNL - PH B. Streckenbach (CAD), M. Mapes (CAD)

2.05 Installation and Integration R. Feder (4-8-2019) BNL - PH D. Phillips (CAD), R. Ruggiero (PH), B. Streckenbach (CAD)

3.01 INTT D. Cacace BNL- PH C. Miraval (ID)

3.02 MVTX W. Sondheim LANL Jason Bessuille (MIT), James Kelsey (MIT), Joseph Dodge (MIT)

Safety Engineering L. Stiegler/A. Franz BNL - PH B. Streckenbach (CAD)

Q/A C. Gortakowski BNL - PP&QM D. Passarello (CAD)

BNL-ID Instrumentation Division MIT Bates - Massachusetts Institute of Technology

BNL-CAD Collider Accelerator Dept. LANL Los Alamos National Laboratory

BNL-PP&QM Planning, Performance and Quality Mngt. BNL-SMD Superconducting Magnet Division

BNL-PH Physics Department

sPHENIX Engineering Staff


Experienced Staff – Most Leads have been with sPHENIX since 2014. Some

turnover of key people.

Engineering Design Staff


– Chief Design Engineer/Detector Integration - R. Ruggiero (PH)– TPC - A. Ruga (PH), C. Miraval (ID)

– Cradle/Carriage - J. Scheblein (PH), D. Puleo (CAD)

– Magnet Cryogenics System – R. Meier (CAD)

– Calorimetry – D. Cacace (PH), R. Ruggiero (PH)

– Electronics – S. Polizzo

– INTT – C. Miraval (ID), D. Cacace (PH)

– MVTX – MIT/LANLExperienced Staff – Most 20+

Years Experience

Engineering Controls


• Engineering –– Follows sPHENIX Procedures, CAD Procedures, BNL SBMS Engineering Design Standards, Applicable Industry

Codes and Standards

• Documentation –

– Drawing Numbering Plan and Revision Control is documented in procedure.

– Archiving of all Engineering Documents to be at sPHENIX Project office.

– Final approval to be from the sPHENIX Project Office and L2 Managers.

– Design changes will follow change control procedures, requiring approvals as appropriate and as designated by project office.

– Autodesk Vault to be used for sPHENIX released drawing and document revision control.

• Reviews –

– Suite of Engineering Design and Production Readiness Reviews

• Fabrication –– Fabrication will follow BNL-Planning, Performance, and Quality Management Guidelines and Procedures.

Fabrication Documents at non-BNL facilities will be reviewed and approved by sPHENIX PM, Safety, and Q/A.

Design Software


CAD/3D modelling software to be used by engineers and designer consistent with their respective departmental requirements. Final Released Drawings to be delivered to sPHENIX project office as PDF’s with the corresponding 3D model and electronics simulation files to be supplied in industry standard format (i.e. STEP). Engineering Drawings, Specifications, and Statement of Work shall be reviewed and approved by sPHENIX Project Office, Quality, and Safety.

Department/Institution

Mechanical Computer Aided

Design Finite Element Analysis Electronics Electrical One-Lines* Gas Systems* Safety Systems*

Collider Accelerator Department PTC Creo ANSYS, ABAQUS N/A Autodesk AutoCAD Autodesk AutoCAD Autodesk AutoCAD

Superconducting Magnet Division PTC Creo ANSYS N/A N/A N/A N/A

PHYSICS Department Autodesk Inventor ANSYS ORCAD/PADS N/A Autodesk AutoCAD Autodesk AutoCAD

Instrumentation Division N/A N/A ORCAD/PADS N/A N/A N/A

Columbia University N/A N/A ORCAD/PADS N/A N/A N/A

Los Alamos National Lab Solidworks ANSYS

MIT-Bates Solidworks ANSYS

* Final Documentation to be approved and reside at Collider Accelerator Department

Engineering Meetings and Progress Review


• Regularly scheduled Subsystem-specific Engineering Working and Status Meetings – attended by subsystem lead engineer (designer and support engineers), sPHENIX Project

Scientist, Chief Engineer, Project Engineer, and L2/L3 scientists when appropriate.

• Bi-weekly sPHENIX Project Engineering Meeting – all engineers meet to review progress, problems and to discuss technical issues. General interface issues are

discussed with follow-up meetings scheduled. Chaired by sPHENIX Project Engineer and attended by Project Scientist and Chief Engineer.

• Weekly Construction Coordination and Safety Meeting – technical staff and project management meet to review ongoing scheduled work and planned future work.

Safety related issues and schedule discussed. Chaired by sPHENIX L2 Installation and Integration Manager (sPHENIX Chief Engineer), attended by sPHENIX Project Director, Project Engineer, Safety, Q/A, CAD Liaison Engineer and Scientist and Safety.

• Standing Integration Meeting – Office of Systems Integration

Meetings are usually documented via INDICO and conducted using BlueJeans video conferencing. INDICO documents are accessible for reference to all sPHENIX staff.

Technical Reviews


TYPES OF REVIEWS

• sPHENIX Conceptual Design, Preliminary Engineering and Design, Final Design Review, Interim Engineering Design Review

• sPHENIX Procurement/Production Readiness Review

• sPHENIX System Readiness and Safety Reviews to be conducted for all subsystems prior to the start of Subsystem Commissioning, Full Detector Operational Readiness Review

• Other BNL reviews - Laboratory Environment, Safety & Health Committee Review (LESHC), Experimental Safety Review (ESR), Lifting Safety (Critical Lifts), Pressure Vessel and Cryogenic Safety

• Reviews Highlights

– Follows guidelines in sPHENIX Conduct of Design Reviews

– Initiated by the sPHENIX Project Manager and Chaired by the Project Scientist or Project Engineer. Review is typically attended by subsystem lead engineer, scientific and design staff, L2 Manager, Project Director, Chief Engineer, Senior Design Engineer, Safety Coordinator, Quality Rep., Subject Matter Experts, CAD Safety Group/CAD Liaison Engineering, sPHENIX Lead Construction Technician, and members of sPHENIX Office of Systems Integration.

– Reviews design for fabrication, safety, constructability, integration, and operational effectiveness.

– More complicated components of a subsystem may have a separate design and safety review.

All Reviews are part of the sPHENIX P6Workflow

Comment Resolution Database


Recommendations from Reviews to be entered into the sPHENIX Comment

Resolution Database

Engineering Reviews


• Cradle/Carriage Conceptual Design Review

• DAQ/Trigger Pre-CD-1 Conceptual Design Review

• TPC Pre-CD-1 Conceptual Design Review

• Calorimeter Electronics Pre-CD-1 Conceptual Design Review

• EMCAL Pre-CD-1 Conceptual Design Review

• Nov HCAL Pre-CD-1 Conceptual Design Review

• sPHENIX Calorimeter Prototype v2.1 IDR closeout & PRR

• EMCAL Light Guide Preliminary Design Review

• Time Projection Chamber mini-review

• MAPs Vertex Detector mini-Review

• sPHENIX Full Field Flux Return - Mechanical Design Review

• sPHENIX Calorimeter Prototype Support Structure Mechanical design Review

• Cost and Schedule Review Magnet/Decom/Install/Integn/Infra Practice

• sPHENIX EMCal Review

• sPHENIX EMCal Practice

• sPHENIX Calorimeter Electronics Review

• sPHENIX HCal Review

• sPHENIX Decommissoning and Installation Review

• sPHENIX Magnet Review • MAGNET Preliminary Design Review and Pressure Safety Review

• sPHENIX CRYOGENIC SYSTEM Procurement Readiness Review

• sPHENIX Cradle/Carriage Preliminary Engineering Review

• Calorimeter Trigger Preliminary Design Review

• Calorimeter Electronics Digitizer System Design Review

• LESHC 18-10 Review of the Cryogenic Systems for sPHENIX SC Solenoid IP8

• MVTX Interim Design Review

• Interim Design Review of Preproduction On-Detector HCAL Electronics

• EMCAL Sector 1-12 Powder Review

• sPHENIX HCAL Assembly Area Safety Review

• EMCal Sector 0 Mechanics Preproduction Design Review

• EMCal Sector 0 Electronics Preproduction Design Review

• TPC Wagon Wheel Production Readiness Review

• sPHENIX software and computing review

• Outer HCal Scintillator Interim Design Review

• EMCal Sector 0 Electronics Preproduction Design Review

• EMCAL Block Design Review

• sPHENIX Outer HCal Sector Steel Review Follow Up Review

• INTT Pre-CD-1 Conceptual Design Review

• sPHENIX Outer HCal Steel Sector Procurement Readiness/Design Review

• sPHENIX Risk Registry and Mitigation Plan Review

• EMCAL Fiber Procurement Readiness Review

• Infrastructure, Installation and Integration Pre-CD-1 Conceptual Design Review

• Over 40 Reviews Performed• All Reviews are in sPHENIX Resource Loaded Schedule

sPHENIX Project Controls and Work Management Documents


1. sPHENIX Procedure Guidelines

2. sPHENIX Configuration Management

3. sPHENIX Document Control

4. sPHENIX Quality Assurance Plan

5. sPHENIX Conduct of Design Reviews

6. sPHENIX Work Planning

7. sPHENIX Awareness Training

8. sPHENIX Bottom’s-Up Estimate Uncertainty Guidelines

9. Interface Control Document/Interface Design Drawing

10. Integrated Safety Management Plan/Safety Hazard Analysis Document/CAD Conduct of Operations

11. Comment Resolution Database

• sPHENIX Procedures and Documents for Engineering, Design, Fabrication, and Installation

• Signed and released for use

Engineering Procedures


Typical sPHENIX Procedure - sPHENIX Q/A Plan, Conduct of Design Reviews, Configuration Management



Brookhaven National Laboratory SBMS

The Standards-Based Management System (SBMS) provides Laboratory-wide

procedures and guidelines for performing work safely and in compliance

with requirements. All work at the Laboratory must comply with the

minimum requirements specified in SBMS documents, including

management system descriptions, subject areas, interim procedures, BNL

manuals, and program descriptions.

sPHENIX Engineering Project Controls and Work Management Documents will meet all SBMS requirements but will be tailored to address complex multiple institutional and departmental collaborations.

Subject Areas• Engineering Standard• Design Standard• Configuration Control• Quality

Work Planning (SBMS)


Subject Area: Work Planning and Control for Experiments and Operations

Introduction

This subject area uses the Integrated Safety Management core functions and guiding principles to establish a process for ensuring all work, operational and experimental, is properly planned and implemented to prevent accidents, injuries, and regulatory violations. It establishes requirements at Brookhaven National Laboratory (BNL) so that all work is properly managed by using a level of planning and control commensurate to the Environment, Safety, Security, and Health (ESSH) hazards, job complexities, and work coordination needs.Line management is directly responsible for the protection of the public, the workers, and the environment.

1.01 Project

Management

1.02

TPC

1.03

EMCal

1.04

HCal

1.05

Calorimeter

Electronics

1.06

DAQ/

Trigger

1.07 Min Bias2.02 SC

Magnet

2.03 & 2.04

Infrastructure

2.05

Integration &

Installation

3.01 INTT 3.02 MVTX

N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A1.01 Project

Management

sP.SE-ICD-031 N/A N/A N/A sP.SE-ICD-004 N/A N/A sP.SE-ICD-009 sP.SE-ICD-016 N/A N/A1.02

TPC

sP.SE-ICD-032sP.SE-ICD-001sP.SE-ICD-002 sP.SE-ICD-005 N/A N/A sP.SE-ICD-010 sP.SE-ICD-017 N/A N/A1.03

EMCal

sP.SE-ICD-033sP.SE-ICD-003 sP.SE-ICD-006 N/A N/A sP.SE-ICD-011 sP.SE-ICD-018 N/A N/A1.04

HCal

sP.SE-ICD-034 sP.SE-ICD-007 N/A N/A sP.SE-ICD-012 sP.SE-ICD-019 N/A N/A

1.05

Calorimeter

Electronics

sP.SE-ICD-035 sP.SE-ICD-008 N/A sP.SE-ICD-013 sP.SE-ICD-020 sP.SE-ICD-024 sP.SE-ICD-027

1.06

DAQ/

Trigger

sP.SE-ICD-036 N/A sP.SE-ICD-014 sP.SE-ICD-021 N/A N/A 1.07 Min Bias

sP.SE-ICD-037 sP.SE-ICD-015 sP.SE-ICD-022 N/A N/A2.02 SC

Magnet

sP.SE-ICD-038 sP.SE-ICD-023 sP.SE-ICD-025 sP.SE-ICD-016282.03 & 2.04

Infrastructure

sP.SE-ICD-039 sP.SE-ICD-026 sP.SE-ICD-029

2.05

Integration &

Installation

sP.SE-ICD-040 sP.SE-ICD-030 3.01 INTT

sP.SE-ICD-041 3.02 MVTXWBS

1.1

1.2

1.3

1.4

1.5

1.6

1.7

WBS

2.1

2.2

2.3 & 2.4

2.5

WBS

3.1

3.2

sPHENIX MIE Project Elements

Project Management

Time Projection Chamber

Electromagnetic Calorimeter

Hadron Calorimeter

Calorimeter Electronics

DAQ-Trigger

Minimum Bias Trigger Detector

Infrastructure and Facility Upgrade Project

Project Management

Superconducting Solenoid Magnet System

Infrastructure and Structures

Installation and Integration

Non-MIE Subsystems (funded from other sources)

Intermediate Silicon Strip Tracker (INTT)

MVTX Maps Silicon Detector

Interface Control Document (ICD)


sPHENIX ICD MatrixICD Links 2 and only 2

Subsystems

Documents which subsystems require a formal technical Interface to another subsystem. Total of 30 required for sPHENIX.

Interface Control Document (ICD)


• Formal Handshake Between Subsystems• Describes Interface• Provides Technical Details of Interface• Specifies Deliverables between Subsystems and how to

measure success• Administered by the Office of Systems Integration

TBD

Contributors:

A

B

C

D

E

F

G

sPHENIX EMCal Engineer Dan Cacace For EMCal subsystem

sPHENIX HCal Engineer Chris Pontieri For HCal subsystem

sPHENIX Chief Engineer Don Lynch 5/30/2018, for sPHENIX Engineering Management

sPHENIX OSI Chairman Mickey Chiu For OSI, waiting approval

Approvals

Title Name Approval Date/Notes

sPHENIX Chief Engineer Don Lynch 10/12/17; 1st Draft

8. Power, Control and Signal Interface

9. Thermal & Fluid Interface

10. Subsystem Deliverables

11. Compliance Demonstration

12. Subsystem Interface Cross Reference

6. Interface Description

7. Mechanical Interface

7.1. General Description

7.2 Hardware Description & Mounting

7.3 Dimensional Specifications, Alignment Requirements and Tolerances

1. Change History Log (see above)

2. Contents (this section)

3. Acronyms & Abbreviations

4. Reference Documents

5. Purpose and Scope

1. Change History Log

Revision Effective Date: Description of Changes

2. Contents

Initial Issue

sPHENIX

Interface Control Document

Document Title:

Interface Control Document for sPHENIX EMCal and HCal (WBS 1.03 and 1.04 , respectively)

Document#

sP.SE-ICD-001

Date Effective:

Initial Issue (waiting for

approvals)

Status:

J. LaJoie, C. Woody, A. Gordeev, D. Cacace, S. Stoll

Interface Control Design Drawing (ICDD)


• Dimensional Handshake Between Subsystems• Identifies Clearances and Stay Clear Zones• Released and Available to L2 Managers• Under Revision Control

Issues and Concerns

Issues and Concerns

• Memorandum of Agreement for engineering support between sPHENIX and Collider Accelerator Department for Infrastructure needs to be finalized (4 of 5 MOAs Completed and Approved)

• Would like an additional designer for detailing.

• Some engineers are P/T - concerned about competing priorities

Proposed Resolution Plan

• MOA with Requirements Document has been drafted and is now being edited for sign-off within the next 6 weeks

• Continuing to address needs and work with CAD Chief Engineer in order to supplement as needed.

• Closely monitor engineering and design support and if required work with supporting department in order to establish clear priorities for staff.


Summary


• Engineering Organization Stable, Experienced, and Effective

• Procedures and Configuration Control Rolled Out and Followed

• Reoccurring Meetings Provides Appropriate sPHENIX Oversight and Important Conduit for Communications.



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