1 BROOKHAVEN SCIENCE ASSOCIATES Accelerator Installation Gregory Fries, Project Engineer 8 th ASAC meeting for NSLS-II Project May 10-11, 2011

2 BROOKHAVEN SCIENCE ASSOCIATES Outline Phasing of Installation Work Planning Site Access & Layout Rigging & Transport Storage Ring Installation Progress Schedule Injector Installation Challenges Summary

3 BROOKHAVEN SCIENCE ASSOCIATES Key Aspects of Production and Installation Accelerator Production – We procure injector sub-systems (Linac, Booster Ring) We build (integrate) Transfer Lines, B-RF and SR components Accelerator Installation – Storage Ring BNL Storage Ring RF BNL w/ vendor installing transmitter Booster RF BNL Transport Lines BNL Linac Vendor w/ BNL oversight Booster Ring Vendor using BNL technicians for all hands–on work w/ Vendor oversight

4 BROOKHAVEN SCIENCE ASSOCIATES Phasing of Construction and Installation Temp walls constructed separating BOD segments Installation and testing within these segments Components will be staged on experimental floor 1 2 B RF L Beneficial Occupancy AreaOriginal Date Actual/New Date Pentant 1 1-Feb-1114-Mar-11 RF Building 23-Mar-1120-May-11 Injector Building 18-May-1126-Jul-11 Pentant 2 2-Jun-1123-Jun-11 Pentant 3 27-Sep-11 Pentant 4 28-Nov-11 Pentant 5 9-Feb-122-Feb-12

5 BROOKHAVEN SCIENCE ASSOCIATES Work Planning Installation schedule complete, including resource loading Schedule is reviewed, updated & disseminated weekly Emergency plan & operations plan in place Site specific training for phase 1 complete One work permit will be created for each phase on installation Detailed work plans will be attached to each work permit Installation WCC for each ASD group identified Daily morning meeting on site with WCCs taking place Weekly installation meetings taking place MonthPeople Mar ’1135 Apr ‘11 – May ‘1150 June ‘11 – Sep ‘1175 Oct ‘11 – May ’12100 June ’12 – Nov ‘1275 Dec ‘12 – March ‘1350 ASD Install Labor Profile

6 BROOKHAVEN SCIENCE ASSOCIATES Site Access Sketch Access via Brookhaven Ave Dedicated parking lot “Safe zone” identified via fence to provide separation from construction site Enter at column 102 Hard hats, safety shoes & safety glasses required Signage in place No personal vehicles on site Storage Containers Loading Dock

7 BROOKHAVEN SCIENCE ASSOCIATES Experimental Floor Layout During P1 Install (8) 20’x30’ Cages for technician space on experimental floor. Will move from pentant to pentant through installation process.

8 BROOKHAVEN SCIENCE ASSOCIATES Pictures of Experimental Floor

9 BROOKHAVEN SCIENCE ASSOCIATES Rigging, Forklifts & Vehicles (2) 3-person rigging teams assigned full- time to project ASD Forklift 10,000 lbs. capacity 208” max lift to reach mezzanine from experimental floor Rigging services to provide add’l forklifts Vehicles For transport of small & fragile components 3 vehicles assigned in Feb add’l vehicles in 2-3 months

10 BROOKHAVEN SCIENCE ASSOCIATES Storage Ring Systems Installation Per Pentant Mech. & Elec. Utilities Personnel Protection System Magnet/Girder Assemblies Vacuum System Power Supplies Beam Instrumentation Controls Where Applicable RF Systems Beam Line FEs, DWs, IDs Injection Straight

11 BROOKHAVEN SCIENCE ASSOCIATES P1 Electrical & Mechanical Utilities and PPS Electrical Utilities Cable tray installation complete (3) Cells of equipment racks in place UPSs in place Starting to pull cables in mid-May Mechanical Utilities DI water piping complete in mid-May Pump skids installed in July Magnet/Girder floor plates in process PPS P1 racks installed Human interlock interfaces installed

12 BROOKHAVEN SCIENCE ASSOCIATES Magnet/Girder Floor Plate Installation Installation of magnet/girder floor plate work has begun (2 cells complete) Process includes: Survey Drilling Scarifying Plate Installation Grouting Preparation for the installation of the first magnet/girder at end-May 2011

13 BROOKHAVEN SCIENCE ASSOCIATES Magnet/Girder Transport Magnet/Girders will be transported to tunnel via experimental floor Will be transported to site and unloaded via forklift Will be pulled across experimental floor using standard dollies Will use short & tall dolly system to transition from experimental floor to tunnel (8” difference in height) Moved to final location using air casters

14 BROOKHAVEN SCIENCE ASSOCIATES Short & Tall Dolly System Courtesy of Lewis Doom Experimental Floor Tunnel

15 BROOKHAVEN SCIENCE ASSOCIATES High-Level Installation Schedule Does not include subsystem testing, integrated testing and commissioning Hatched section of SR RF schedule indicates 2 nd RF Cavity Taken from P6 on May 3, 2011 Accelerator Installation JFMAMJJASONDJFMAMJJASONDJFMAM Phase 1 - Pentant 1 Current Baseline Phase 2 - SR RF Phase 3 - Injector Phase 4 - Pentant 2 Phase 5 - Pentant 3 Phase 6 - Pentant 4 Phase 7 - Pentant 5

16 BROOKHAVEN SCIENCE ASSOCIATES SR RF Installation RF Cavities moving toward critical path 2 nd Cavity may be installed during ID installation RF Transmitter w/ klystron installed by vendor Remaining RF systems installed by BNL Taken from P6 on May 3, 2011 SR RF Installation JFMAMJJASONDJFMAMJJASONDJFMA Mech & Elect Utilities Cabling, Wiring, Piping RF Transmitters Low Level RF Liquid Nitrogen System Refrigeration System RF Cavities

17 BROOKHAVEN SCIENCE ASSOCIATES Injector Installation Phases Mechanical & Electrical Utilities Booster RF LtB Transport Line Part 1 Through wall, up to vac valve in booster vault, needed to commission linac Linac Booster LtB Transport Line Part 2 TL complete, need to commission booster BtS Transport line Part 1 Up to beam dump, needed to commission booster

18 BROOKHAVEN SCIENCE ASSOCIATES Injector Installation Phases Layout BtS TL Part 1 Booster LtB TL Part 2 Linac LtB TL Part 1 Phase Separation Booster RF Phase Separation (end of injector install)

19 BROOKHAVEN SCIENCE ASSOCIATES Linac Installation Vendor responsible for installation Installation plan & HASP being created Linac to be delivered Sep BNL will run AC power to their racks to expedite BNL will install shielding BNL will need to complete LtB TL Part 1 for commissioning Vendor will work with BNL on ARR Ready for commissioning Dec Linac commissioning will overlap with booster & SR installation

20 BROOKHAVEN SCIENCE ASSOCIATES Booster Installation Vendor responsible for installation using BNL technicians for all hands–on work Technicians will perform tasks assigned by vendor BNL will supervise technicians Technician labor requirements & install plan being finalized Booster to be delivered Feb Magnet/Girders will arrive assembled BNL will need to complete BR RF, LtB TL and BtS TL Part 1 for commissioning Vendor will work with BNL on ARR Ready for commissioning Dec. 2012

21 BROOKHAVEN SCIENCE ASSOCIATES Injector Installation Schedule Taken from P6 on May 3, 2011 Installation of Linac is approx. 3 months early Hatched section of LtB TL Part 1 indicates diagnostics that are not needed for Linac commissioning BtS Part 2 is not needed for Booster commissioning Injector Installation JFMAMJJASONDJFMAMJJASOND Utilities - Mech & Elec Phase 1 - Booster RF Phase 2 - LtB TL Part 1 Phase 3 - Linac Phase 4 - Booster Phase 5 - LtB TL Part 2 ` Phase 6 - BtS Part 1 Phase 7 - BtS Part 2

22 BROOKHAVEN SCIENCE ASSOCIATES Challenges Coordinating multiple activities & teams during installation Beneficial occupancy dates close to pushing installation schedule Maintaining component delivery schedules (i.e. magnets, RF cavity) Adapting to delivery delays Cleanroom in 902 for precision alignment of magnets may become bottleneck Tight coordination with XFD installation needed to avoid conflicts with required flexibility of ASD installation schedule (hand-over delays)

23 BROOKHAVEN SCIENCE ASSOCIATES Summary Accelerator installation fully underway in pentant 1 Currently approx. 6 weeks behind schedule in pentant 1 Planning in process for installation in RF & Injector buildings Focus on flexibility in installation schedule based on availability of building and components Rigging, storage & logistics plans in place Required installation staff in place Good communication established with CFD & XFD Conclusion: Installation progressing very well

24 BROOKHAVEN SCIENCE ASSOCIATES Acknowledgements A. Boerner, M. Bromfield, A. Byon, S. Buda, R. Chmiel, L. Dalesio, L. Doom, O. Dyling, M. Fallier, R. Fliller, G. Ganetis, E. Golnar, D. Hatton, H. Hseuh, S. Hoey, E. Johnson, F. Lincoln, T. Mendez, J. O’Malley, S. Ozaki, P. Ribaudo, J. Rose, S. Sawch, T. Shaftan, W. Scheuerer, S. Sharma, R. Sikora, O. Singh, J. Skaritka, T. Tanabe, F. Willeke, P. Zoccoli & many others