STATEMENT OF WORK FOR DESIGN, FABRICATION, INTEGRATION AND TESTING OF THE TELESCOPE STRUCTURE SYSTEM TMT.STR.MGT REL01

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S

TATEMENT OF

W

ORK FOR

D

ESIGN

,

F

ABRICATION

,

I

NTEGRATION AND

T

ESTING OF THE

T

ELESCOPE

S

TRUCTURE

S

YSTEM

TMT.STR.MGT.12.001.REL01

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TMT.STR.TEC.12.001.DRF01 Page 2 of 13

Telescope Structure System SOW 7/27/2012

Table of Figures

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1. INTRODUCTION

1.1 P

URPOSE

This document defines the tasks to be performed in the design-build contract for supplying the TMT Telescope Structure System (STR). This is an abbreviated version of the Statement of Work (SOW) intended to provide background information for an independent cost estimate for this Work.

1.2 A

BBREVIATIONS

CAD Computer-Aided Design

DRD Design Requirements Document ES&H Environmental, Safety and Health EVM Earned Value Management FAB Fabrication

FDP Final Design Phase FDR Final Design Review FEA Finite Element Analysis

FMECA Failure Modes and Effects Criticality Analysis ICD Interface Control Document

INT Integration

MCS Mount Control System PDP Preliminary Design Phase PDR Preliminary Design Review PSR Pre-shipment Review QA Quality Assurance SOW Statement of Work

STR Telescope Structure System TMT Thirty Meter Telescope

1.3 D

EFINED

T

ERMS

Capitalized terms used in this document have the specific meanings described below: Deliverables The Deliverables include the information, hardware and software that are to be

delivered to the TMT Project as a result of the activities in this Statement of Work

Work The term Work includes all of the activities described in this Statement of Work; and, depending on the context, the term may also include the Deliverables.

1.4 L

ANGUAGE

Unless otherwise specified, all deliverables involving language, including documents, drawings, software source codes, etc., shall be in English.

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2. SCHEDULE

2.1 P

ROJECT

P

HASES

The Work will be performed in several phases, each of which will have the acitivities and deliverables described in Section 3 of this document. These phases are:

Preliminary design phase (PDP) Final design phase (FDP) Fabrication phase (FAB Phase) Integration phase (INT)

2.2 B

ASELINE

S

CHEDULE

The Work to be estimated should be assumed to start in January, 2013. The baseline schedule for this work is shown in Figure 1. Summary schedule lines for other TMT activities that could interact with the STR schedule are shown in green.

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3. TASKS AND DELIVERABLES FOR EACH PHASE

3.1 P

RELIMINARY

D

ESIGN

P

HASE

(PDP)

3.1.1 PDP Activities

The Telescope Structure is currently in the middle of the PDP. Additional engineering activities are required to complete this phase.

During the PDP the design of each subsystem shall be developed to the point that required design trades have been made and the design has been shown to be capable of meeting the requirements of the Design Requirements Document (DRD) and the Interface Control Documents (ICDs). The designs should be cost effective and fabrication feasibility shall be established for all subsystems. Prototypes should be developed and tested as required to accomplish these goals.

Contractor shall develop a software design for the control of each of the electromechanical subsystems according to the TMT requirements.

A key part of the preliminary design work is a seismic design study. Contractor shall develop a seismic isolation system that allows the STR to meet all of its requirements, including earthquake survival of the structure and limiting accelerations of telescope-mounted subsystems, as well as achieving the required pointing repeatability and structural stiffness. Sufficient finite-element analysis shall be done to demonstrate compliance with requirements. In addition, power spectral density (PSD) information shall be developed for each major telescope-mounted subsystem to define the accelerations that the subsystem would be exposed to in 200-year and 1000-year return period earthquakes.

Contractor shall also develop the system design of the observatory foundation and pier, to establish the properties they must have in order to properly support the telescope and react dynamic and seismic loads exerted by the telescope. Contractor will not be responsible for construction of the foundation and pier, but will be responsible for the performance of the STR mounted on the pier. During the PDP, Contractor shall conduct a Failure Modes and Effects Criticality Analysis (FMECA) that considers failure modes and risks for each STR subsystem for all phases of the work. The FMECA shall be documented in a written report. Where failure modes are identified, design alternatives will be developed to reduce the risk, reduce the impact of a failure, and increase the reliability of the systems.

During the PDP Contractor shall initiate a formal Environmental, Safety and Health (ES&H) program, with the Contractor's ES&H Plan to be approved by TMT. The ES&H plan shall be based on

appropriate environmental and safety standards for each aspect of the work, including US Federal and State of Hawai'i standards for all work performed in Hawai'i. Safety of software systems shall also be addressed in this ES&H Plan.

Potential safety hazards shall be evaluated for all activities and phases of the Work and for operation of the finished observatory, including: prototype testing, fabrication, trial assembly, shipping, erection, integration, testing, operation and maintenance. Where potential safety hazards are identified, design alternatives shall be developed to eliminate the hazard or reduce the severity of the risk.

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Contractor shall conduct a preliminary design review (PDR) at the end of the PDP. Contractor shall present the preliminary design of the STR and all its subsystems, as well as the system design of the foundation and pier.

3.1.2 PDP Deliverables

During the PDP, Contractor shall conduct biweekly teleconferences with TMT to provide summaries of progress and any issues that have developed. Face-to-face progress review meetings shall be held at least every three months.

Contractor shall provide monthly reports summarizing progress and costs, providing the information needed to allow TMT to use Earned Value Management (EVM) to track the progress.

Contractor shall provide updated CAD models of the STR every two months. Contractor shall also deliver an updated finite-element analysis (FEA) model of the STR every two months.

Contractor shall deliver the FMECA report, the ES&H plan and the ES&H Hazard Assessment to TMT before the PDR.

At the PDR, Contractor shall deliver a documentation package including:

Layout drawings and documents describing the preliminary designs of all subsystems, including the foundation & pier

CAD models of the STR, foundation & pier

Description of the software architecture for the control systems including: a draft Software Design Description; a Software Requirements Document; and a proposed Application Programming Interface for each of the electromechanical subsystems

Compliance matrix showing that all design requirements will be met Reports describing the trade studies that led to the design presented

Technical reports describing the calculations and analyses used to evaluate the performance of the subsystem designs, particularly including the seismic design report

Reports describing prototype development and testing activities and other risk reduction or technology development activities undertaken

Information sheets on all subassemblies to be purchased as commercially-available components

Descriptions of suitable manufacturing processes for components to be fabricated Preliminary assembly, integration, and verification plans

3.2 F

INAL

D

ESIGN

P

HASE

(FDP)

3.2.1 FDP Activities

During the FDP, Contractor shall develop the detailed design of the STR and all its subsystems, including the software design for the control systems.

Contractor shall also design all ancillary equipment and falsework structures required for the trial assembly, shipping, handling, erection and assembly of the STR at the observatory, as well as any special tools, fixtures and equipment that will be needed to maintain the STR for its 50-year lifetime. During the FDP, Contractor shall continue its analysis activities as required to develop the detailed designs, and shall update the performance modeling to show that the detailed designs will meet all requirements.

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Contractor shall develop plans required for the fabrication and integration phases, including an updated ES&H Plan, a Fabrication Plan covering all components to be fabricated, a Quality

Assurance (QA) Plan, a Trial Assembly Plan, an Integration Plan, a Verification Plan and a preliminary Maintenance Plan.

Risk reduction activities should be conducted, as appropriate, including development and testing of prototype components and subsystems, including code prototyping of software systems.

Contractor shall conduct a Final Design Review (FDR) at the end of the FDP.

3.2.2 FDP Deliverables

During the FDP, Contractor shall conduct monthly teleconferences with TMT to provide summaries of progress and any issues that have developed. Face-to-face progress review meetings shall be held at least every three months.

Every three months during the FDP, Contractor shall deliver to TMT updated CAD models, FEA models and control system models.

At the FDR, Contractor shall deliver a documentation package including:

Drawings, documents and schematic diagrams describing the final designs of all subsystems List of long-lead-time items requiring early procurement

CAD models of the STR

Detailed design documentation for control software, including construction-ready versions of the Software Design Description, Software Requirements Document, and an Applications

Programming Interface for each software subsystem.

Updated compliance matrix showing that all design requirements will be met

Technical reports describing the calculations and analyses used to evaluate the performance of the subsystem designs

Reports describing prototype development and testing activities and other risk reduction or technology development activities undertaken

Information sheets on all subassemblies to be purchased as commercially-available components

Updated FMECA Report Updated ES&H Plan

Updated ES&H Hazard Assessment

Fabrication Plan covering all components to be fabricated QA Plan

Trial Assembly Plan

Integration Plan, including plans for shipping, handling and on-site storage, as well as a software integration test plan

Verification Plan

Draft Maintenance Plan

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3.3.1 FAB Phase Activities

Following the FDR, Contractor shall request TMT approval to purchase any long-lead-time items that require early procurement in order to meet the schedule.

Contractor shall prepare a complete bill of materials for all components, subsystems and structural pieces. Fabrication drawings shall be prepared for all parts to be manufactured, based on the designs approved at the FDR. Fabrication drawings shall be prepared for the components of the STR, as well as special tooling and fixtures for assembly or maintenance. If special processes are required for fabrication of some parts, process documentation shall be prepared.

If it becomes necessary to change designs to facilitate fabrication, approval of the design changes shall be obtained from TMT.

Specifications and procurement documents shall be prepared, as required, for purchase of custom components and subsystems.

In general, fabrication drawings, specifications and process documents are not required to be in English. However, a full set of drawings of the delivered hardware, in English, will be required as part of the maintenance documentation to be supplied at the end of the contract.

Contractor shall implement a formal QA Program, which shall include:

Configuration control of fabrication drawings, specifications and process documents Obtaining material certifications

Controlling critical process steps

Tracking the status and location of all components of the bill of materials; Defining inspection procedures

Calibration of inspection equipment Control of discrepant items or materials Maintaining quality records

TMT shall have the right to inspect any quality records and to witness any tests and inspections. Verification of some STR requirements, for example, interface requirements, may be done as part of the QA process during the FAB Phase.

Contractor shall manufacture and purchase the component parts of the STR, as well as dummy masses, special tooling and fixtures required for assembly or maintenance, and falsework structures required for assembly of the STR.

Contractor shall develop the software for each control system according to the TMT agile

development process that includes development of frequent code releases, each with a complete, automated test suite, full simulation capability, and up-to-date documentation.

All component parts shall be permanently marked with a part number, serial number and other information as specified by TMT. In cases where this isn't practical, Contractor shall obtain TMT approval to leave the part number off.

Any design changes that occur during this phase shall be documented and submitted to TMT for approval. Any parts that deviate from their drawing requirements shall not be used unless approved by TMT, and if approved, the as-built condition shall be documented in the drawing package.

During the FAB Phase, Contractor shall prepare plans for the integration work. In particular, the Environmental Impact Statement for constructing the observatory on Mauna Kea requires development and approval of several plans:

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Construction Activities Reporting Plan Safety and Accident Prevention Plan Waste Minimization Plan

Fire Prevention & Response Plan Materials & Waste Storage Plan Spill Prevention & Response Plan

Best Management Practice Plan covering: o Erosion & Water Quality

o Hazardous Materials

o Air Quality & External Lighting

o Additional Disturbance & Encroachment

o Invasive Species Prevention & Control Program

3.3.2 FAB Phase Deliverables

Contractor shall conduct monthly teleconferences with TMT to provide summaries of progress and any issues that have developed. Face-to-face progress review meetings shall be held at least every three months.

During the FAB Phase, Contractor shall make available regularly scheduled software releases. For each software system this shall culminate in delivery of the final versions of the Software Design Description, Application Programming Interface and Software User Manual.

Contractor shall make available any or all fabrication drawings, specifications and process documents upon request from TMT. If these are not in English, TMT will obtain translations as required.

Contractor shall make available any of the QA information, upon request.

3.4 I

NTEGRATION

P

HASE

(INT

P

HASE

)

The Integration Phase includes: trial assembly; shipping; structure erection; integration of mechanical systems; acceptance testing; and a Final Acceptance Review.

3.4.1 Trial Assembly

To verify proper fabrication of the structure, Contractor shall conduct trial assembly of selected subassemblies. TMT's baseline plan does not include a complete trial assembly of the telescope, because of the high cost involved. The baseline plan includes trial assembly of:

Azimuth track

Pintle bearing assembly Central azimuth structure Nasmyth platforms Lower tube

Mirror cell

Elevation journals

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The baseline plan also includes trial assembly and functional testing of: Segment handling system

Aerial service platform Cable wraps

The trial assembly efforts should be conducted in parallel with the completion of the fabrication work to the extent possible.

If it becomes necessary to make any design changes as a result of the trial assembly work, approval of the design changes shall be obtained from TMT, and all changes shall be documented.

Deliverables from the trial assembly include measurement and inspection reports and test reports, written in English.

3.4.2 Shipping

When the components of the STR are ready for shipping, Contractor shall conduct a Pre-shipment Review (PSR). At the PSR Contractor shall present to TMT:

QA information showing that all components and subsystems meet their requirements and are ready to ship

Packing and Shipping Plan

Plans for the Work to be done in Hawai'i, including: Construction Activities Reporting Plan

Safety and Accident Prevention Plan Waste Minimization Plan

Fire Prevention & Response Plan Materials & Waste Storage Plan Spill Prevention & Response Plan Best Management Practice Plan Acceptance Test Plan

Upon receiving TMT approval, Contractor shall pack and ship all components and subsystems to the island of Hawai'i.

In order to ensure no invasive species are transported to Mauna Kea in the containers or packing materials, the shipping containers must be unloaded and the loads inspected at sea level. If any damage has occurred during shipping, Contractor shall make repairs to completely restore the satisfactory condition of all components.

Laydown area at the Mauna Kea summit will be limited, so in general, transport of the STR components to the summit should be staged as the work progresses. Storage areas suitable to protect the STR components from the weather will be needed at sea level.

3.4.3 Erection of Structure

The TMT Integrated Project Schedule plans for the erection of the telescope structure to start at the point when the enclosure is weather tight. The structure shall then be erected, surveyed and adjusted so that it will meet all applicable requirements when loaded and oriented as specified in the DRD.

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The erection of the structure at the summit shall be planned and managed to comply with all applicable state and federal safety and environmental regulations, including provisions specific to work on Mauna Kea regarding: (1) avoiding encroachment outside the designated construction area; (2) prevention of waste water discharge and site erosion; (3) control of air pollution; (4) avoidance of external lighting at night; (5) prevention of introduction of invasive species.

Contractor shall follow a rigorous construction safety program for all work in Hawai'i. This program shall include safety training of all personnel involving, but not limited to: safe work at high altitude; fall protection; safe use and disposal of hazardous materials; working in confined space/limited

access/egress work areas; reporting of all mishaps, failures or malfunctions that result in a safety hazard or injury. A Safe Work Permit system must be used to ensure that: all hazardous activities are carefully planned; potential hazards are identified and mitigated; personnel are trained for the specific activity; emergency equipment and personnel protective equipment are available in the correct locations and are used by all personnel; safety monitors are provided; and personnel certifications for hazardous activities such as use of cranes are obtained and enforced.

3.4.4 Integrate Mechanical Subsystems

Contractor shall install and integrate all the electromechanical subsystems, including the mount

control system (MCS), hydrostatic bearing system, cable wraps, elevators, aerial service platform, and segment handling system. Control systems for these systems shall be integrated with the systems and with the TMT summit networks.

The utility services required for these subsystems shall be connected. Additional utility services to supply other telescope-mounted subsystems shall be run to the specified distribution points on the structure.

Contractor shall commission the electromechanical subsystems and adjust them as required to ensure they are able to achieve all their functional and performance requirements.

3.4.5 Acceptance Testing

Contractor shall prepare the STR for its acceptance tests, including installation of the 492 segment support subcells supplied by the TMT Optics Group, and installation of dummy masses to represent the primary mirror segments, secondary mirror system, tertiary mirror system and instrument masses. Contractor shall provide all measurement equipment required for the acceptance tests, and shall ensure it is all in calibration.

Facility power and chilled water will be available by the time of the acceptance tests, and Contractor shall complete the connections to these utility services.

At the time of the acceptance tests, the telescope optics and science instruments will not have been installed. Therefore, the acceptance tests will not involve making measurements using observations of stars, and will not involve opening the dome. Requirements related to on-sky performance, e.g., for pointing, tracking and image jitter, shall be verified by tests of the components of the STR. For example, this is expected to involve measurements of the flatness of the azimuth track and of the ability of the MCS to follow motion commands, as measured at the encoders.

The Contractor software team shall participate in on-site integration testing of each of the

electromechanical subsystems that include software. The Contractor team will update the software or support the TMT on-site software team as needed.

Contractor shall conduct a comprehensive program of acceptance tests to demonstrate that all STR requirements have been met. TMT will witness all acceptance tests.

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The acceptance tests shall include:

Inspections of the condition of the STR Measurement of critical dimensions Verification of characteristics of interfaces Test of proper function of STR subsystems

Measurement of performance of the STR, including: Acceleration, velocity, range and smoothness of motions Control stability margins

Matching of drive torques among motor sectors Smoothness and consistency of braking deceleration

Stiffness/flexure of the structure (e.g., change of the mirror cell shape with zenith angle) Ability of control systems to reject disturbances

Positional accuracy and motion smoothness of segment handling crane Vibration level caused by telescope mechanical systems

Contractor shall remedy any problems identified in the acceptance tests, and shall make corrections and adjustments until all requirements are met.

3.4.6 Final Acceptance Review and Final Deliverables

After the acceptance tests have been successfully completed, Contractor shall submit a Final Data Package, including:

A summary of inspection reports, material certifications and fabrication submittals from the fabrication phase (that were previously provided to TMT)

Documentation of all inspections, tests and measurements conducted as part of the acceptance tests

An updated compliance matrix listing each requirement, stating that it has been met, and indicating how compliance was verified

Documentation, including user manuals, maintenance manuals and training materials, as appropriate, that will allow TMT observatory staff to operate and maintain the TSS for the life of the observatory

Updated as-built drawings documenting all components of the STR

Updated software design documentation including all of the source code for the control system software

List of any deviations from requirements, including deviations that TMT has previously approved Certification that all contractual requirements have been met

Contractor shall provide training of TMT personnel in the proper operation and maintenance of the STR and shall explain any diagnostic systems or procedures.

Contractor shall deliver to TMT special tooling and fixtures required to maintain the STR and an initial complement of spare parts required for STR maintenance.

Contractor shall conduct a Final Acceptance Review to present to TMT the results of the acceptance tests and to certify that all aspects of the Work are finished and that all requirements of the contract have been met.

STATEMENT OF WORK FOR DESIGN, FABRICATION, INTEGRATION AND TESTING OF THE TELESCOPE STRUCTURE SYSTEM TMT.STR.MGT REL01

S

TATEMENT OF

W

ORK FOR

D

ESIGN

,

F

ABRICATION

,

I

NTEGRATION AND

T

ESTING OF THE

T

ELESCOPE

S

TRUCTURE

S

YSTEM

TMT.STR.MGT.12.001.REL01

Table of Contents

Table of Figures

1. INTRODUCTION

1.1 P

1.2 A

1.3 D

T

1.4 L

2. SCHEDULE

2.1 P

P

2.2 B

S

3. TASKS AND DELIVERABLES FOR EACH PHASE

3.1 P

D

P

(PDP)

3.2 F

D

P

(FDP)

3.4 I

P

(INT

P

)