Mosaic-1 Upgrade Project Execution Plan - noao. · PDF fileMosaic-1 Upgrade Project Execution...

Doc. File: M1U-AD-02-0001R0.doc Created on 01/07/2010Doc. Number M1U-AD-02-0001

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Mosaic-1 UpgradeProject Execution Plan

NOAO Document M1U-AD-02-0001Revision: 0

Authored by:David Sawyer

Please send comments:[email protected]

NATIONALOPTICALASTRONOMYOBSERVATORY

SYSTEM INSTRUMENTATION GROUP950 N. Cherry Ave.P. O. Box 26732

Tucson, Arizona 85726-6732

(520) 318-8000 FAX: (520) 318-8303


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Revision HistoryVersion Date Approved Sections Affected Remarks

0 01/07/2010 All Original Version


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Table of ContentsRevision History ............................................................................................................2Table of Contents...........................................................................................................3List of Figures ................................................................................................................4List of Tables .................................................................................................................41 Introduction ..........................................................................................................52 Project Management.............................................................................................5

2.1 ReSTAR Funding Budget Allocation .................................................................62.2 NOAO Base Funding Budget Allocation............................................................62.3 Project WBS........................................................................................................62.4 Project Plan and Schedule ..................................................................................7

2.4.1 Project Management.......................................................................................72.4.2 Detector System .............................................................................................82.4.3 Dewar Assembly ............................................................................................92.4.4 Software.......................................................................................................112.4.5 System Integration and Commissioning........................................................11

2.5 Coordination between KPNO Engineering and Systems Instrumentation.....122.6 Contingency Management ................................................................................132.7 Configuration Management..............................................................................13

3 Systems Engineering...........................................................................................133.1 Requirements Management..............................................................................143.2 Risk Management .............................................................................................143.3 Error Budget Management...............................................................................143.4 Observatory Interfaces .....................................................................................15

3.4.1 Instrument Interface .....................................................................................153.4.2 Detector Interface.........................................................................................153.4.3 Facility Interface ..........................................................................................15

4 Design Reviews....................................................................................................154.1 Project Plan Review ..........................................................................................154.2 Final Design Review..........................................................................................16

5 Safety...................................................................................................................16


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List of Figures

Figure 1 - Work Breakdown Structure for the Mosaic-1 Upgrade Project ................7Figure 2 - Schedule for the Project Management Component of the Mosaic Project.8Figure 3 - Schedule for the Detector System Component of the Mosaic Project ........8Figure 4 - Schedule for the Design Component of the Dewar Assembly .....................9Figure 5 - Schedule for the Fabrication and Assembly Component of the Dewar....10Figure 6 - Schedule for the Software Component of the Mosaic Project ..................11Figure 7 - Schedule for the Integration and Commissioning Components

of the Mosaic Project..................................................................................11Figure 8 - Project vs. Functional Lines of Authority for the Matrix Organization ..12

List of Tables

Table 1 - Effort levels for the assigned resources and labor skills derived fromthe project schedule described in section 2.4 ................................................6


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1 IntroductionThe primary objectives of the Mosaic-1 Upgrade are to replace the aging (and obsolete) CCD controllerswith modern MONSOON controllers, and to replace the CCD detectors to improve observing efficiency(faster readout times) and performance (quantum efficiency and read noise). Both the controllers anddetectors must be replaced to achieve the desired gains in performance and efficiency. Beyond theseobjectives the only requirements are that the imaging performance must not be degraded, the instrumentmust use the same mechanical interface and ancillary equipment (filters, corrector, ADC, etc.), and theresulting data files must be compatible with the existing NOAO science data archive. Upgrading thecontrollers and detectors will provide the potential for several performance and operational enhancementsbeyond the scope of the requirements and these will be exploited as time and budget allow.There are two options for MONSOON controllers. One is a mature project, called Torrent, in progress todevelop a new generation of MONSOON controllers. The Torrent controllers are designed for lowpower, ease of configuration, and use readily available components. The other option is the “Orange”controller, a previous generation MONSOON controller that is in use today on many instruments. TheTorrent controllers are more suitable for the Mosaic upgrade application and thus are included in thebaseline design. However, the Orange controllers will provide a fallback option if the Torrent project isnot completed in time.

2 Project ManagementThe responsibility of managing the Mosaic-1 Upgrade project has been assigned to the team of DavidSawyer (Project Manager, or PM) and Steve Howell (Project Scientist, or PS). The PM will focusprimarily on the administrative aspects of the project (budget, schedule, resource allocation, etc) whilethe PS focuses on the scientific and operational aspects (developing requirements, engaging thecommunity, etc), although they will work together on most project-related activities.

The PM reports to the NOAO System Technology Center (NSTC) Director, David Sprayberry, while thePS reports to the Kitt Peak National Observatory (KPNO) Director, Buell Jannuzi. The project is a jointKPNO/NSTC effort and both centers will provide the direction and oversight for the project.The management team is responsible for defining the requirements and scope of the project, developing aplan for completing the project, conducting reviews as appropriate, and providing suitabledocumentation. The management team will report on the status of the project at the weekly KPNOprojects meeting and provide monthly written progress reports to the KPNO and NSTC Directors.It is expected that a broad group of people from within NOAO will be involved in the Mosaic-1 upgradeduring the process of defining the project as well as during the construction, integration andcommissioning phases. The management team will engage the NOAO group as appropriate and definework packages as required.


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2.1 ReSTAR Funding Budget AllocationThe total ReSTAR allocation to the Mosaic-1 Upgrade is $520,000. This amount is notionally allocatedto capital equipment purchases in the approximate distribution of $500K for replacement detectors and$20K toward computers to drive the replacement controllers. Adjustments to the allocation of the fundsmay occur as the project progresses. The CCD detector selection was a critical component of the projectregarding budget, science and mechanical design decisions and thus the detectors have been ordered frome2v Technologies as of December 2009. The cost of the replacement detectors was $520K, or $20K overthe ReSTAR allocation, and so the difference will be covered in the base budget.

2.2 NOAO Base Funding Budget AllocationNOAO will supplement the ReSTAR funds with approximately $200K for labor from the base budget,and another $20K to make up the difference in the actual detector cost. These funds will pay for the PMand staff from the NOAO technical pool at the levels shown in Table 1. In addition, the PS will be paidfrom the KPNO operations budget.

Table 1 - Effort levels for the assigned resources and labor skills derived from the project scheduledescribed in section 2.4.

Resource Skill Hours FTEDitsler Tech support – vacuum, detectors 293 0.17Daly Software engineer 370 0.22Dryden Electronic technician 190 0.11ET TBD MONSOON electronic technician 140 0.08Hunten Detector engineer 64 0.04NOAO Shop TBD Instrument maker 160 0.09KPNO Instrument Support Trainee 140 0.08KPNO Support Staff Instrument change 38 0.02Moore Detector engineer 8 0.00Rath Mechanical designer/Instrument maker 467 0.27Rosin Draftsman 140 0.08Sawyer Project manager/Systems engineer 1192 0.69Schweiker Instrument specialist 260 0.15DHS Programmer TBD Software engineer 40 0.02

Totals 3502 2.04

2.3 Project WBSThe work breakdown structure for the Mosaic-1 Upgrade project is shown graphically in Figure 1. Thereare six major categories that, with the exception of project management, are matched to projectdeliverables. The detector system, Dewar assembly and software components can be developed inparallel and delivered independently. After that the project becomes more serial in that the systemintegration effort must follow the delivery of the components and the commissioning effort must followthe completion of system integration. In most cases the WBS is detailed to three levels, and at most fourlevels. The WBS is designed to provide adequate accounting and tracking for a project of this size whilekeeping the administrative effort modest.


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Work Breakdown Structure for the Mosaic-1 Upgrade ProjectFigure 1

2.4 Project Plan and ScheduleA detailed schedule has been developed that accomplishes the primary objectives of the upgrade effortwith realistic estimations of the resources available. The schedule follows the WBS organization and thusthis description of the project plan and schedule will be broken down into the major WBS categories.

2.4.1 Project ManagementThe project management component of the schedule is shown in Figure 2. The general projectmanagement responsibilities for the Mosaic upgrade project are projected to require one day a week eachfor the project manager and the project scientist for the duration of the project. In addition, there arespecific project management tasks to development requirements and a project plan (this document), aswell as preparing for two design reviews. The detailed design of the Dewar assembly is linked to Review1 and is shown in Figure 4. The fabrication of the Dewar assembly is linked to Review 2 and is shown inFigure 5. The transition module component of the schedule is shown in Figure 3 and is linked to Review2 (link not shown) because it is expected that the decision about the controller option will be finalized atthat time.


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Schedule for the Project Management Component of the Mosaic ProjectFigure 2

2.4.2 Detector SystemThe CCD Detector component of the schedule involves the procurement and testing/characterization ofthe detectors selected for the Mosaic upgrade. The detectors have been ordered from e2v Technologiesand are expected to arrive by April 15, 2010. In the meantime there is design, fabrication and assemblywork scheduled to build a chip mount for a universal test Dewar to allow testing the e2v devices in thelab. The plan is to build a chip mount that will allow the e2v detectors to be installed and tested two at atime.

Schedule for the Detector System Component of the Mosaic ProjectFigure 3


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Before testing the e2v CCDs in the lab it will be necessary to configure the MONSOON controllerelectronics (Torrent or Orange) for the devices. This configuration is scheduled to begin immediatelyafter the first design review so it can be completed by the time the detectors are delivered in mid-April asshown by the link (items 25 and 18) in Figure 3. The assembly and testing of the MONSOON controllerelectronics needed for the Mosaic upgrade is being provided by the MONSOON group as a deliverableand is thus not shown in this schedule.

Following the Torrent configuration tasks, the Torrent transition module assemblies are scheduled forassembly and testing. The fabrication of the transition modules requires the enclosures to be fabricatedand thus the module assembly task (item 29 on the schedule) is linked to item 47 (Figure 5).

2.4.3 Dewar AssemblyThe first two components of the Dewar Assembly are the conceptual design and the detailed designphases as shown in Figure 4. The conceptual design phase primarily involves determining viablesolutions for the upgrade components, including a new chip mount for the e2v detectors and the interfaceand mounting of the MONSOON controllers (either Torrent or Orange). The original Mosaic design wasdone using AutoCAD and since Solidworks is now the adopted CAD tool used at NOAO, there is amodest effort scheduled to convert the AutoCAD drawing to solid models. At the completion of theconceptual design there will be a design review (Review 1) where the proposed design solutions will bescrutinized. Following the approval of the conceptual designs, the detailed design phase will begin. Theproduct of the detailed design phase will be fabrication-ready drawings for all new components and anymodifications to existing components. A final design review is scheduled to occur at this point on March23, 2010 and after that, upon acceptance of the final design, fabrication will begin.

Schedule for the Design Component of the Dewar AssemblyFigure 4

Figure 5 shows the fabrication and assembly components of the Dewar Assembly. The machining of thechip mount assembly will be done in the NOAO machine shop using a CNC mill to achieve the necessarymachining tolerances for the CCD mounting holes and surface flatness. The machining of the connectorpods and Torrent transition modules is scheduled to be done by S. Rath in the model shop, but using theNOAO machine shop as an additional resource is a viable option. During the fabrication phase, the newconnector pods and their associated connectors and wiring will also be completed.


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Schedule for the Fabrication and Assembly Component of the DewarFigure 5

Following the completion of the fabrication phase, the Dewar rework and assembly phase begins with theassembly of the new focal plane. This involves mounting the eight CCD detectors on the chipmount andmeasuring/verifying the flatness of the detector focal plane. In the meantime, the Mosaic imager will betaken out of service on June 11, 2010, removed from the telescope and transported to the NOAO labs inTucson. Once the instrument arrives in Tucson, the Dewar assembly will be separated from thefilter/shutter mechanisms and the two components will be reworked in parallel. D. Dryden is scheduled tooverhaul the filter/shutter mechanism to improve its performance and reliability (This is not actually partof the upgrade project, but is an opportune time to do this necessary servicing), while B. Ditsler isscheduled to complete the Dewar upgrades.The Dewar upgrade starts by removing the existing focal plane assembly and all of its associated wiringand placing it into safe storage. This will preserve the option of returning Mosaic to its currentconfiguration as a technical contingency measure. During the removal of the focal plane carefulmeasurements will be made to ensure that the focus position can be precisely duplicated with the newdetectors. After disassembly, the Dewar will receive standard servicing (e.g., cleaning, bake desiccant,etc.) and any modifications that may be needed (e.g., grinding the surface of the radiative cold plate thatattaches to the chip mount if better flatness is required.) The new focal plane will then be installed andmeasured through the Dewar window for focus position and tilt. The shims at the mounting posts will belapped to adjust any positional errors. Once the focal plane is positioned the new wiring modules will beinstalled and, after attaching the radiative cold plate, they will be checked for continuity. The remainderof the Dewar will be assembled (LN2 tank, desiccant, and housing), checked for vacuum leaks and putthrough several pump-flush-pump cycles to maximize the vacuum and hold time.Once the Dewar rework is complete there is a week scheduled to cool the instrument and conduct thermalstability tests, and another week to test the detectors. These are really just functional verification tests butthere is a two-week contingency scheduled at this point in case any problems are found or additional testsare required.


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2.4.4 SoftwareThe user interface and user software must be changed as part of the upgrade project. Currently Mosaic-1is run with an IRAF ARCON package as well as a few independent GUIs that control specific features ofthe instrument/telescope combination. Given the success of NEWFIRM’s user interface and controlsystem (NOCS), we are proposing this option to use for the new Mosaic-1 user interface. The advantagesof choosing NOCS are 1) it has had two years of use and tuning at the Mayall telescope, 2) has completeand plentiful documentation, 3) a number of 4-m users are already experienced with its use, 4) thesoftware will be going to Chile with NEWFIRM and so manuals already exist to teach the “new” systemto the CTIO staff, 5) it is likely that NOCS will be used by KOSMOS at the Mayall, and 6) 90% of thefunctionality required to operate the new Mosaic-1 upgrade is already written and operational. TheNOCS interface is already integrated with a Data Handling System (DHS) for NEWFIRM and onlyminor changes will be needed to modify the existing DHS for Mosaic.

There is a modest software effort required to adapt the NOCS interface and DHS system for the Mosaicinstrument. Figure 6 shows the tasks with rough estimates of time to complete them. These are onlyrough estimates of time, but there is plenty of schedule slack in this effort (item 74 to 75, almost twomonths) to absorb any increase in effort that may result from better estimates.

Schedule for the Software Component of the Mosaic ProjectFigure 6

2.4.5 System Integration and CommissioningThe system integration phase of the project will involve the final assembly of all the subsystems in thelab where they will be tested as an end-to-end system. This component of the schedule requires that theDetector System, Dewar Assembly, and Software subsystems have all been completed, and thus the startdate for this effort is driven by those links. The lab testing will involve functional verification,troubleshooting if required, and conducting the acceptance tests. An acceptance test plan will be preparedin advance and will ensure that the project requirements have been met. KPNO operations staff will beengaged during this system integration phase to provide a training opportunity.Once the integration is completed and the instrument has been accepted, it will be send to KPNO to startthe commissioning phase. There is a two-week period scheduled for test and engineering in the telescopeenvironment. Although the schedule shows the instrument being installed on the telescope at the start ofthe T&E period, it will probably occur a few days later to allow the functionality to be verified at thetelescope before installation on the telescope. Most of the T&E testing will be done during the daytimeand should not impact nighttime operations at the telescope, but a few T&E nights will be scheduled as


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well. After the T&E period, there will be a few nights scheduled for conducting science programs to tunethe operational efficiency and verify the scientific performance of the instrument.

Schedule for the Integration and Commissioning Components of the Mosaic ProjectFigure 7

During the commissioning phase it is expected that KPNO staff will be involved to receive training andaccept hand-over of the instrument. The user documentation will be completed and delivered as well.

2.5 Coordination between KPNO Engineering and Systems InstrumentationThe PM will work with the appropriate managers within KPNO Engineering (T. Abraham) andNSTC/Electronics (M. Hunten) to identify and utilize their resources to the extent possible. The PM willutilize these resources in a matrix fashion by providing the project-related assignment and direction to theindividuals, while leaving the functional obligations to their respective managers. Resource conflicts orconcerns will be raised with the responsible manager and if a resolution cannot be reached theappropriate Director(s) will be notified. The PM will report the project status to both the KPNO Director(B. Jannuzi) and NSTC Director (D. Sprayberry) on a regular basis and, as part of the report, will providea summary of the resource commitment and schedule status.

Project vs. Functional Lines of Authority for the Matrix OrganizationFigure 8


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2.6 Contingency ManagementThe contingency for budget and schedule are being managed through the scope of the upgrade effort. Theschedule presented in section 2.4 was developed to meet the budget and schedule constraints of theproject. There was a strong desire (goal) to build a new Dewar instead of retrofitting the existing one tominimize science downtime and risk associated with the upgrade project. However, this goal was notpossible within the budget and timeline available and was not necessary to achieve the projectrequirements and thus was eliminated from the Project Plan. Additional project goals relating to usertools and operational modes may or may not be completed as time and budget allow.

A source of schedule contingency will be available through additional labor (i.e., an increase in the basebudget). The project will utilize staff from the KPNO and NSTC groups and, provided resources areavailable within those groups, they could be reassigned to the project to increase the work force.

There is a modest cash contingency of $50K from the KPNO operations budget. Some of thiscontingency may be used to fabricate new Dewar parts if they have to be done by outside machine shops.This provides a contingency for the NOAO instrument shop that is notionally available for the Mosaicwork but is currently involved in a large project (ODI) that could impact their availability.

One of the technical risks of the project is the completion of the Torrent controllers. Torrent is well alongtoward meeting a production readiness state in March 2010 but is not complete and has not demonstratedperformance at this time. A contingency plan to mitigate this risk will be to use the existing MONSOONOrange controllers instead of Torrents. The choice of controller will have minimal impact on the designphase of the project and thus this decision will be postponed until the Mosaic final design review (March23, 2010) to give the Torrent project more time to progress.

2.7 Configuration ManagementThis project will implement modest configuration management techniques to maintain revision control ofdrawings and documents. The PM and PS will have overall authority for acceptance of releaseddocuments and approval of changes thereafter. PDMWorks Enterprise software will be used as thedocument database for version control.The mechanical solid models will be developed in an “initiated” state where all project staff has access tothem. Once the drawings are “released” by the PM or lead engineer the shop personnel will have accessto them and no changes will be allowed unless the PM or lead engineer approve the changes and modifythe drawing state to “in revision”. This process has been used effectively for several recent projects atNOAO.Documents will be entered into the PDMWorks database upon their initial release. There will be groupaccess levels to the database that are appropriate for the types of documents. For instance, only a“management” group will have full access to documents with sensitive financial information, whereas the“technical” group can have full access to the technical documentation. In most cases any “general” userwill have read-only access to project documents.

3 Systems EngineeringThe PM, David Sawyer, will also act as the Systems Engineer (SE) for the Mosaic-1 Upgrade project.The SE will ensure that the technical requirements and engineering decisions flow down from the sciencerequirements as appropriate. Since this is a project to upgrade certain components of an existinginstrument, only those components require validation. As such, this project will define a limited set of


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requirements documents including the Science Requirements (SRD) in the context of the CCD detectors,and an Operations Concept Document (OCD) to define the user interface, observing modes anddiagnostic tools.In addition to the requirements documents, the SE will be responsible for developing the Acceptance TestPlan (ATP) as well as any interface control documents (ICD) that are required for the mechanical,electrical and software interfaces.

3.1 Requirements ManagementThe PS will lead the effort to define the science requirements. Once that is complete the operations andtechnical requirements can be defined as they flow down from the science requirements. The PS will leadthe effort to define the operations requirements and the SE will lead the development of any technicalrequirements.

For each operations and technical requirement that is defined, it will include statements about why therequirement is justified and how the requirements will be verified. The justification may include “direct”flow down from science requirements, “derived” to meet a science requirement, or “allocated” as adesign choice. The verification methods may include “demonstration” of an actual component,“controlled test” of an experiment, or “analysis” through calculations or modeling. The verificationstatement will be used as the basis for developing the acceptance tests.

3.2 Risk ManagementThere is a significant schedule risk since this is a fast-track project occurring simultaneously with otherpriority projects for KPNO. There is a fixed pool of resources that are distributed among project andoperations responsibilities, and thus there is a limited group available for this project, especially in thearea of detector technicians. As such, the availability of resources may be out of the project’s control andcould impact the schedule. The fast-track plan of this project is designed to avert some of the risk byutilizing key resources before they are needed for other scheduled projects.There is moderate Base (labor) funding budget risk since this project plan has minimized the scope ofwork as much as possible to match the budget allocation. Since the labor resources will be provided bythe KPNO and NSTC groups it should be possible to supplement the Base budget by reassigningresources within those groups.

There is a moderate technical risk with the Torrent controllers since Torrent is currently a developmentproject and is not yet at a point where the performance can be demonstrated. The design of Torrent reusesmuch of the MONSOON Orange technology to mitigate the technical risk, but it also incorporates somenew technologies. A contingency plan to mitigate this risk will be to use the existing MONSOON Orangecontrollers instead of Torrents. This contingency plan will require a modest additional effort to developan electrical interface for the Orange controllers, and a mechanical package. This decision will not haveany impact on the Dewar design and thus does not have to be considered until the Mosaic Final DesignReview in late March 2010.

3.3 Error Budget ManagementError budget analyses will not be needed for this project since the components being upgraded will meetor exceed the performance of the components they are replacing.


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3.4 Observatory Interfaces

3.4.1 Instrument InterfaceThe mechanical mounting of the Mosaic-1 imager and its ancillary equipment will not be changed as aresult of the upgrade and thus a telescope interface control document (ICD) is not required. However,there will be changes to the CCD controllers that are mounted to the Dewar and so the SE will ensure thatthe new MONSOON controllers are mounted in such a way that they do not interfere mechanically orblock access to any other equipment on or around the instrument. In addition, the SE will ensure themounting of the controllers is optimal for servicing.

For electrical interfaces the new controllers will only require 115V AC power and two data fibers. Theseservices are already available at the instrument on the telescope and thus no changes are required. If theMONSOON Orange controller is used, there will have to be provisions for mounting the power supplynear the instrument. The SE will work with KPNO personnel to determine the optimal location formounting the power supply.

Interface requirements for shutter and focal plane temperature control will have to be defined by the SE.Currently these functions are controlled within the CCD controllers that are being replaced. The Torrentcontrollers will have the capability of providing the shutter and temperature control but the Orangecontrollers do not. In either case, the requirements will have to be defined so that a new control interfacecan be designed and implemented.The software interface requirements will be described as part of the Operations Concept Document(OCD). The OCD will describe the interfaces required for the user GUI, the data handling system and thedata pipeline.

3.4.2 Detector InterfaceA detector engineer will provide a detector interface document that is customized for the e2v CCD44-82detectors that have been chosen. The document will describe controller configuration requirements, suchas bias and clock voltage levels, clock timing, power sequencing, etc. The document will also detail thesignal interconnection scheme from the CCD device, through the vacuum barrier, to the MONSOONcontroller.

3.4.3 Facility InterfaceThe Mosaic-1 upgrade will have minimal impact on the telescope facility and is not expected to requireany modifications or additions to the existing facility interfaces.

4 Design ReviewsSince the Mosaic-1 upgrade project is a relatively minor project in terms of budget and scope, the reviewprocess will be limited to two reviews during the project. There will be a project plan review before thedetailed design phase, and then a final design review before the fabrication phase.

4.1 Project Plan ReviewThe project plan review will be held after the planning phase is complete and the project has beendefined. The review will include the science requirements, operations concept and project plan including


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the schedule, budget, risk assessment and contingency measures. The review will also cover thepreliminary designs for the Dewar, detector and software systems.

4.2 Final Design ReviewThe final design review will be held once the detailed mechanical design is complete. This review will bean internal review and is intended to identify any technical issues or concerns with the design before themajor fabrication phase begins. Components of the project that are considered low technical risk may befabricated before the final design review if there are cost/schedule benefits to doing so.

5 SafetyThe Mosaic-1 Upgrade project will be conducted in a way the meets the safety policies of KPNO andNOAO. The Mosaic-1 project will include handling heavy equipment, handling liquid cryogens, runningmachines, and working in observatory domes with overhead cranes. The personnel that will be requiredto conduct the work are all trained for proper safety practices. Working with liquid nitrogen will only bedone in areas that are designated for such work (i.e., they have adequate ventilation or an oxygen warningsensor).

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