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

2. 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

3. 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

4. SOAR Mount Shipping

5. 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

6. 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

7. 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

8. 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

10. 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

11. 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

12. 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

13. 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