Supporting Planning and Engineering Processes at XFEL Examples, Benefits and Experience

Transcription

1 Supporting Planning and Engineering Processes at XFEL Examples, Benefits and Experience Lars Hagge, Benno List SLAC,

2 Agenda > Introduction: Collaborative Engineering > Collaborative Design & Design Integration: A 3D Model of the XFEL > Civil construction (CFS): Collaborating with Construction Companies > Project management: Collaborative Planning of > 50 Work Packages > Cryomodules: Quality Management in Series Production > Summary & Conclusions Lars Hagge, Benno List Engineering Collaboration at European XFEL and ILC GDE Page 2

3 Introduction COLLABORATIVE ENGINEERING Lars Hagge, Benno List Engineering Collaboration at European XFEL and ILC GDE Page 3

4 Org Chart European XFEL Construction Project Project Board (PB) Accelerator Consortium Coordinator ACC Administrative Director of the XFEL GmbH ADG Civil Construction Coordinator CCC Cold Linac Coordinator CLC Machine Layout Coordinators MLC Photon Systems Coordinator PSC Project Office Leader POL Technical Coordinator TC WP Representatives WPRs XFEL Project Leader XPL Staff Functions Technical Coordination Project Office Safety & Health Coordination Change Management WP-Group 1 WP-Group 2 WP-Group 3 WP-Group 3 WP-Group 4 WP-Group 5 WP-Group 6 WP-01* RF System WP-02* Low Level RF WP-03* Acc. Modules WP-04* S.C. Cavities WP-05* Power Couplers WP-06* HOM Couplers WP-07* Frequency Tuners WP-08* Cold Vacuum WP-09* Cavity String Assem. WP-11* Cold Magnets WP-46* 3.9 GHz System WP-12* Warm Magnets WP-14* Injector WP-15* Bunch Compression WP-16* Lattice WP-17* Stand. Diagnostics WP-18* Special Diagnostics WP-19* Warm Vacuum WP-20* Beam Dumps WP-21* FEL Concepts WP-71 Undulators WP-72 Sim. of Photon Fields WP-73 X-Ray Opt.& Beam Tr.. WP-74 X-Ray Diagnostics WP-75 Detector Development WP-76 DAQ & Control WP-78 Optical Lasers WP-79 Sample Environment WP-81 Scient.Instr. FXE WP-82 Scient.Instr. HED WP-83 Scient Instr. MID WP-84 Scient.Instr. SPB WP-85 Scient.Instr. SQS WP-86 Scient.Instr. SCS * Work Packages, which are covered by the Accelerator Construction Consortium WP-28* Acc. Controls WP-35 Radiation Safety WP-36 General Safety WP-38 Personnel Interlock WP-39* EMC WP-10* AMTF WP-13* Cryogenics WP-32* Survey & Alignment WP-33* Tunnel Installation WP-34* Utilities WP-40* IPS Lars Hagge, Benno List Engineering Collaboration at European XFEL and ILC GDE Page 4 CLC MLC WP-31 Site & Civil Constr. WP-41/42/43 Site Lot 1-3 WP-44 Site Engineering WP-45 AMTF Hall WP-monitoring by PB-member: CCC WP-47 Lots 4-7, 9 WP-48 Lot 8 PSC TC

5 In-Kind Contributions > To a great extent, the European XFEL facility will be realized by means of in-kind contributions by shareholders and partners > Work Packages may receive contributions from more than one institute > Institutes may contribute to more than on Work Package Lars Hagge, Benno List Engineering Collaboration at European XFEL and ILC GDE Page 5

6 Collaborative Engineering Systematics >Complex facilities are developed via the interaction of many, sometimes thousands of participants, who are working concurrently on different engineering aspects >Collaborative engineering aims to provide a systematic approach for integrating engineering contributions aiming to converge on a single solution that is acceptable to all participants >XFEL is a large and complex facility with a longlasting lifecycle which is built by an international distributed collaboration Lars Hagge, Benno List Engineering Collaboration at European XFEL and ILC GDE Page 6

7 Collaborative Engineering Systematics Facility specs, designs, parts, procedures, services, Facilitate * communication, collaboration, coordination, Lab A Lab B Distributed collaboration Lab N Establish agreement, synchronize activities Supplier I specs, designs, parts, procedures, services, Supplier II Translate languages, Supplier data formats,, X respect cultures * by information management Lars Hagge, Benno List Engineering Collaboration at European XFEL and ILC GDE Page 7

8 Collaborative Design & Design Integration A 3D MODEL OF THE ENTIRE XFEL Lars Hagge, Benno List Engineering Collaboration at European XFEL and ILC GDE Page 8

9 Design Integration at European XFEL Civil Construction (WP31) Civil construction starts 3 years ahead of all other trades Lars Hagge, Benno List Engineering Collaboration at European XFEL and ILC GDE Page 9

10 Design Integration at European XFEL Civil Construction (WP31) Lars Hagge, Benno List Engineering Collaboration at European XFEL and ILC GDE Page 10

11 Design Integration at European XFEL Lattice (BLC) Geometry generated from lattice simulation files Civil Construction (WP31) Lars Hagge, Benno List Engineering Collaboration at European XFEL and ILC GDE Page 11

12 Design Integration at European XFEL Lattice (BLC) Dump (WP20) 3D models already from four (!) different (CAD) sources Civil Construction (WP31) Lars Hagge, Benno List Engineering Collaboration at European XFEL and ILC GDE Page 12

13 Design Integration at European XFEL Lattice (BLC) Dump (WP20) RF (WP01) Civil Construction (WP31) Lars Hagge, Benno List Engineering Collaboration at European XFEL and ILC GDE Page 13

14 Design Integration at European XFEL Lattice (BLC) Dump (WP20) RF (WP01) LLRF (WP02) Civil Construction (WP31) Lars Hagge, Benno List Engineering Collaboration at European XFEL and ILC GDE Page 14

15 Design Integration at European XFEL Dump (WP20) RF (WP01) Lattice (BLC) Electrical (WP34) LLRF (WP02) Civil Construction (WP31) Lars Hagge, Benno List Engineering Collaboration at European XFEL and ILC GDE Page 15

16 Design Integration at European XFEL Dump (WP20) RF (WP01) Lattice (BLC) Electrical (WP34) Water (WP34) LLRF (WP02) Civil Construction (WP31) Lars Hagge, Benno List Engineering Collaboration at European XFEL and ILC GDE Page 16

17 Design Integration at European XFEL Dump (WP20) RF (WP01) Cryomodules (WP03) Lattice (BLC) Electrical (WP34) Water (WP34) LLRF (WP02) Civil Construction (WP31) Lars Hagge, Benno List Engineering Collaboration at European XFEL and ILC GDE Page 17

18 Design Integration at European XFEL Cryogenics (WP13) Dump (WP20) RF (WP01) Cryomodules (WP03) Lattice (BLC) Electrical (WP34) Water (WP34) LLRF (WP02) Civil Construction (WP31) Lars Hagge, Benno List Engineering Collaboration at European XFEL and ILC GDE Page 18

19 Design Integration at European XFEL Cryogenics (WP13) Interlock (WP38) Dump (WP20) RF (WP01) Cryomodules (WP03) Lattice (BLC) Electrical (WP34) Water (WP34) LLRF (WP02) Civil Construction (WP31) Lars Hagge, Benno List Engineering Collaboration at European XFEL and ILC GDE Page 19

20 Design Integration at European XFEL Cryogenics (WP13) Interlock (WP38) Dump (WP20) RF (WP01) Cryomodules (WP03) Lattice (BLC) Electrical (WP34) Racks (TC) Water (WP34) LLRF (WP02) Civil Construction (WP31) Lars Hagge, Benno List Engineering Collaboration at European XFEL and ILC GDE Page 20

21 Design Integration at European XFEL Cryogenics (WP13) Interlock (WP38) Dump (WP20) RF (WP01) Cryomodules (WP03) Lattice (BLC) Electrical (WP34) Racks (TC) Water (WP34) Transportation (WP33) LLRF (WP02) Transportation needs to block space for handling components Civil Construction (WP31) Lars Hagge, Benno List Engineering Collaboration at European XFEL and ILC GDE Page 21

22 Design Integration at European XFEL Cryogenics (WP13) Interlock (WP38) Dump (WP20) RF (WP01) Cryomodules (WP03) Lattice (BLC) Electrical (WP34) Racks (TC) Water (WP34) Transportation (WP33) LLRF (WP02) Civil Construction (WP31) Lars Hagge, Benno List Engineering Collaboration at European XFEL and ILC GDE Page 22

23 Design Integration at European XFEL Cryogenics (WP13) Interlock (WP38) Dump (WP20) RF (WP01) Cryomodules (WP03) Lattice (BLC) Electrical (WP34) Racks (TC) Water (WP34) Transportation (WP33) LLRF (WP02) Safety (WP35) Safety needs to block space for escape routes Civil Construction (WP31) Lars Hagge, Benno List Engineering Collaboration at European XFEL and ILC GDE Page 23

24 Design Integration at European XFEL Cryogenics (WP13) Interlock (WP38) Dump (WP20) RF (WP01) Cryomodules (WP03) Lattice (BLC) Electrical (WP34) Racks (TC) Water (WP34) Transportation (WP33) LLRF (WP02) Safety (WP35) Civil Construction (WP31) Lars Hagge, Benno List Engineering Collaboration at European XFEL and ILC GDE Page 24

25 Design Integration at European XFEL Cryogenics (WP13) Interlock (WP38) Dump (WP20) RF (WP01) Cryomodules (WP03) Lattice (BLC) Electrical (WP34) Racks (TC) Water (WP34) Transportation (WP33) LLRF (WP02) Safety (WP35) Survey (WP36) Civil Construction (WP31) Survey needs to block space for laser beams of alignment system Lars Hagge, Benno List Engineering Collaboration at European XFEL and ILC GDE Page 25

26 Design Integration at European XFEL Cryogenics (WP13) Interlock (WP38) Dump (WP20) RF (WP01) Cryomodules (WP03) Lattice (BLC) Electrical (WP34) Racks (TC) Water (WP34) Transportation (WP33) LLRF (WP02) Safety (WP35) Survey (WP36) Civil Construction (WP31) Lars Hagge, Benno List Engineering Collaboration at European XFEL and ILC GDE Page 26

27 Design Integration at European XFEL Cryogenics (WP13) Interlock (WP38) Dump (WP20) RF (WP01) Cryomodules (WP03) Lattice (BLC) Electrical (WP34) Racks (TC) Water (WP34) Transportation (WP33) LLRF (WP02) Safety (WP35) Survey (WP36) Civil Construction (WP31) Lars Hagge, Benno List Engineering Collaboration at European XFEL and ILC GDE Page 27

28 Design Integration at European XFEL Cryogenics (WP13) Interlock (WP38) Dump (WP20) RF (WP01) Cryomodules (WP03) Lattice (BLC) Save costs Electrical detect (WP34) Racks (TC) and remove collisions Water (WP34) before fabrication Share visions, communicate better, develop faster Transportation (WP33) LLRF (WP02) Safety (WP35) Survey (WP36) Civil Construction (WP31) Accept contributions from anyone, at any time, by any system Lars Hagge, Benno List Engineering Collaboration at European XFEL and ILC GDE Page 28

29 Design Integration at European XFEL Lars Hagge, Benno List Engineering Collaboration at European XFEL and ILC GDE Page 29

30 Civil Construction (CFS) COLLABORATING WITH CONSTRUCTION COMPANIES Lars Hagge, Benno List Engineering Collaboration at European XFEL and ILC GDE Page 30

31 The Role of Civil Construction Drawings Room book: Required infrastructure per room Drawings are prepared by DESY for tendering, after that detailed by construction company - Drawings used with construction companies & on construction sites - Drawings must be in German language, legally and practically - Collaborators sometimes need drawings, but mostly use 3D models Lars Hagge, Benno List Engineering Collaboration at European XFEL and ILC GDE Page 31

32 Workflow for Civil Construction Drawings Civil engineer from construction company uploads drawing and starts workflow Several engineers from XFEL work packages review and comment drawing WP leader reads all comments and takes decision on approval All project members can access the drawing through EDMS Working Reviewing Approved Process 10, drawings per year in time Manage revisions and handle changes with a controlled process Include constructor in workflow & track full data exchange history Lars Hagge, Benno List Engineering Collaboration at European XFEL and ILC GDE Page 32

33 Project Management COLLABORATIVE PLANNING OF >50 WORK PACKAGES Lars Hagge, Benno List Engineering Collaboration at European XFEL and ILC GDE Page 33

34 Project Planning WP Leaders manage detailed plans of their WPs (schedule/cost) Project Office synchronizes WPs (milestones, dependencies) XFEL Project Planning Database Project Managers compare plans and progress In-Kind Contributors schedule their involvement in entire project > Need separate plans for each WP and central plan for entire project > Need different kinds of plans for different kinds of users > Need to allow users to work with their well-known tools (spreadsheets ) Lars Hagge, Benno List Engineering Collaboration at European XFEL and ILC GDE Page 34

35 Distributed Project Planning XFEL master plan WP01 Implement dependencies by propagating milestones WP02 Coordinate and consolidate project planning in > 50 WPs Follow well-defined PM process, obtain automated reports Maintain project plans within WPs & global plan in Project Office Lars Hagge, Benno List Engineering Collaboration at European XFEL and ILC GDE Page 35

36 Cryomodules QUALITY MANAGEMENT IN SERIES PRODUCTION Lars Hagge, Benno List Engineering Collaboration at European XFEL and ILC GDE Page 36

37 Quality Management in Cryomodule Production > Objective: Provide procedures for reliably gathering, recording, processing and archiving the complete fabrication information. > Approach: Use EDMS as central platform for collaboration and documentation Tuner piezo system # on Cold Mass with String (left) and in EDMS (right) Lars Hagge, Benno List Engineering Collaboration at European XFEL and ILC GDE Page 37

38 How to Build a Cryomodule > Store complete fabrication instructions in EDMS in a structured way > Include assembly procedures, test instructions and templates, design drawings, specs, Lars Hagge, Benno List Engineering Collaboration at European XFEL and ILC GDE Page 38

39 What s in a Module: Parts Tracking > Store complete module configuration in EDMS in a structured way Lars Hagge, Benno List Engineering Collaboration at European XFEL and ILC GDE Page 39

40 Keep the Process Under Control Keep the series production under control Ensure quality, handle non-conformities fast and reliable Be compliant with legal documentation requirements Lars Hagge, Benno List Engineering Collaboration at European XFEL and ILC GDE Page 40

41 SUMMARY & CONCLUSIONS Lars Hagge, Benno List Engineering Collaboration at European XFEL and ILC GDE Page 41

42 > Design collaboration started already during TESLA planning Note: CFS works in host lab s language > Well-designed tools and processes scale as project grows and evolves EDMS is a mighty tool which can support the entire project lifecycle EDMS reaches full power when offered with central collaboration services > Tools and processes may help to organize collaboration but collaboration is best when everybody has the same picture in mind Vision sharing is the best foundation for collaboration Tools and procedures should be in place already very early Collaboration needs to be organized by information mgt. Lars Hagge, Benno List Engineering Collaboration at European XFEL and ILC GDE Page 42