Integration & Commissioning T.A. Sebring 13,14 July 2005 Feasibilty/Concept Study Mid Term Status Review

Challenges of Integration & Commissioning Difficulties Include Logistic, Environmental, and Technological Difficulties Increased by Size, Precision, and Location Transportation of Large Systems Overland and By Sea a Traditional Challenge Remote Nature of Atacama Challenges Availability of Services and Labor Transition from Project to Operations Difficult Planning and Execution the Key to Successful Integration, Commissioning, and Handover to Operations

Methodologies for I & C Develop Detailed Plans Prior to Initiation of Integration Review Plans with Project, Contractors, and Chilean Support Test Subsystems at Manufacturers Implies Trial Assembly and Partial or Full Operability Ensures that Parts Fit and Systems Work Prior to Arrival in Chile Can Include Integration with CCAT Control System Rework Difficult Once System is in the Atacama Packaging & Shipping Systems Designed to Facilitate Shipping Using Standard Containers & Racks As Possible Contractors Responsible to Get Systems to Nearest Port CCAT Will Arrange Transport from Port to Site Better to Have One Entity than Many Figuring this Out Customs and Entry of Systems Into Chile Will Need Management

SOAR Mount Shipping

Mount Goes on Board Last Minute Insurance Change Nets ~$10 K Savings Ship Change by Line Causes $6K Insurance Surcharge SOAR Organizes Load Consolidation For <$ and Part Safety SOAR Mount Goes to Sea – 2 February 2002

Site Development & General Construction Anticipate Continued Use of M3 Engineering & Technology for Design Will Almost Certainly Use Chilean Contractors for Road Building, Site Improvement, General Construction CCAT Site Manager Hired Shortly Prior to Construction & Will Manage Contractors Will Need a Mechanical Technician Almost Immediately Integration Phase of Project Will Begin When Facilities are Completed (or Nearly So) This Will Provide Housing & Workspace for Integration Activities

General Construction Complete Power, Networks, Sanitary Facilities, Cranes, etc. In Place Facility Stocking Develop Full Inventory Based on Other Telescopes Order All Equipment & Supplies in US Containerize and Ship in One Shipment to Site Eliminate “Trips to the Atacama Hardware Store!” General Construction Contractor and/or Subcontractors Supply Support to Integration

Large System Integration Dome & Mount Must Be Coordinated High Lift Through Dome Opening…May Want to Install Major Mount Components First Large Cranes Required In Any Event…Largest Lift ~60-80 Tons Geometry of Building Affects Crane Access Contractors Will Provide Technical Assistance Detailed Assembly and Test Plans On Site Support for ~4 Weeks for Each System Separate Support to Heavy Erection & Controls/Sensors Integration Same Personnel As Worked with Trial Erection And Debug in US Steel Workers Provide Majority of Hand Labor Same Personnel as Worked on General Construction of Facility One Work Force Through Entire Large Scale Integration Activities

Small System Integration Small Systems Installed by Project Team May Include Some Support Contracts for Trades Electrical, Mechanical, Painting, etc. Culminates in Installation of Initial Instrument/s and Sensors (Guider/Wavefront Sensor) Completion of Integration Culminates in First Light All Systems Operating Under Central Control System Command Performance is a Useful Fraction of Nominal Specified “Images” Adequate to Serve as “Good Press” Initiates Commissioning

Commissioning Period of Optimization of Telescope Performance Jointly Pursued by Project and Operations Teams Pattern of Nighttime Observation Noting Performance Shortfalls and Daytime Engineering Optimization in Response Typically a Lot of Software Improvement Progressively Greater Time Spent on Science Observations Culminates in Final Performance Test & Handover to Operations

Manpower Initial Presence is Site Manager, Full Time Chilean Post Project Team Gradually Takes Us Residence in Chile as General Construction is Complete Anticipate Project Team Lives in Santiago and Works Tourno Shifts as Ops Team Will Supplemental Labor Steel Erection Contractor from General Construction “Local” Trades Contractors Technical Support from Contractors Supplying Major Systems Operations Team: Added as Early as Possible Become Familiar with Facility and Systems Obviates Us vs Them Mentality Provides Additional Required Manpower

Feasibility: Good Concept Has Worked Successfully for Several Chilean Telescopes Sufficient Labor is Available in the Atacama Minimizing Rework on Site Will Save $$$$ Additional Cost for Pre-Integration at Contractors is Money Well Spent Will Need to Pay Attention to Crane Geometry wrt Lifts and Obstructions Detailed Costs for Integration Can be Developed During Engineering Concept Phase