Installation Package – Mechanical / Piping S. Kaminski LCLS-II Cryoplant Installation PDR October 18, 2016

Outline Purpose Topics Installation Contractor Work Tasks To detail the mechanical / piping work in the CP1 Installation Specification. Topics Scope Applicable Codes / Standards / Specifications Installation Contractor Work Tasks Material Procurement Equipment Receipt and Installation Material Handling Fabrication Cleaning Examination Piping Installation Testing Quality Assurance Documentation Turnover Design Drawings Compressor Rigging / Installation Questions Based on SNS / FRIB LCLS-II Cryoplant Installation PDR Installation - Mechanical, Oct 18, 2016

Scope Mechanical Piping Structural Architectural Civil Coating Insulation Phase 1 Tank Farm North Slab Compressor Room Cold Box Room Phase 2 LCLS-II Cryoplant Installation PDR Installation - Mechanical, Oct 18, 2016

Applicable Codes / Standards / Specifications 10 CFR 851 LCLS-II Project BIO Codes and Standards of Record (LCLSII-1.1-TS- 0035) LCLS-II Pressure System Requirements (LCLSII-1.2-EN-0020-R2) Cryogenic Plant Seismic Design Criteria (LCLSII-4.8-EN-0227-R2) CBC / CMC – 2013 Edition ASME B31.3 – 2014 Edition ASME B31E – 2008 Edition (2010 Addenda) ASME BPVC – 2015 Edition ASCE 7-10 ACI 318 – 2014 Edition AWS D1.1 – 2012 Edition LCLS-II Cryoplant Installation PDR Installation - Mechanical, Oct 18, 2016

Material Procurement Owner Provided Components Equipment Valves (Relief and Actuated, Pressure Regulators) Material properties specified on drawing and reiterated, expanded in specification (source restrictions, etc) Process Owner approval prior to purchase Contractor Receipt Inspection Documentation Pipe CMTR Valves CMTRs Certified Drawing IOM / Recommended Spare Parts Test Records LCLS-II Cryoplant Installation PDR Installation - Mechanical, Oct 18, 2016

Equipment Receipt and Installation Detail expected delivery dates Define required coordination for delivery location / site preparation (Owner responsible for delivery) Detail Owner inspection of equipment upon arrival Define Vendor documents / interfaces and Owner requirements for developing rigging, lifting, movement, installation plans Detail Owner approval process of plans Specify required concrete preparation in Civil section Detail Owner inspection of equipment upon installation Detail required coordination for vendor re-assembly Procurement Status Report or equivalent LCLS-II Cryoplant Installation PDR Installation - Mechanical, Oct 18, 2016

Specify lifting / handling requirements (slings for pipes, etc) Material Handling Specify lifting / handling requirements (slings for pipes, etc) Specify material control requirements Specify storage requirements LCLS-II Cryoplant Installation PDR Installation - Mechanical, Oct 18, 2016

Requirements that broadly apply, including Fabrication – General Requirements that broadly apply, including Codes Work processes (cleanliness, installation, etc) Welding (WPS / PQR, WPQ) Threaded / Bolted Connections Examination (AWS / ASNT personnel, procedures) Testing Repair Documentation By Phase, By Area, By System LCLS-II Cryoplant Installation PDR Installation - Mechanical, Oct 18, 2016

Fabrication – Specification Work Descriptions System description Define system List work tasks List relevant design drawings Detail special or additional requirements LCLS-II Cryoplant Installation PDR Installation - Mechanical, Oct 18, 2016

Fabrication - Demolition Minor portion of overall scope At equipment / prior Phase connection points Communicated through specification work description and drawings Location Type http://www.pipeline-conference.com/sites/default/files/papers/Mohamed.pdf LCLS-II Cryoplant Installation PDR Installation - Mechanical, Oct 18, 2016

Fabrication – per Design Drawings LCLS-II Cryoplant Installation PDR Installation - Mechanical, Oct 18, 2016

Fabrication – per Design Drawings Drawings identify design conditions, test conditions, materials specification and all welds / cuts Identify higher level assembly drawings Copies used to track welders / examination / heat numbers LCLS-II Cryoplant Installation PDR Installation - Mechanical, Oct 18, 2016

Fabrication – Field Routing Information that would appear on drawing provided in system description Start / end points Design / Test Conditions Material properties Support type / frequency Material quantity / distance estimates 3D Model for reference LCLS-II Cryoplant Installation PDR Installation - Mechanical, Oct 18, 2016

Fabrication – Phase Work Install blind flanges / pipe caps to allow commissioning of Phase 1 prior to / during Phase 2 Communicated through specification work description and drawings Location Type LCLS-II Cryoplant Installation PDR Installation - Mechanical, Oct 18, 2016

Specify cleaning steps / criteria following spool fabrication By system Specify cleaning steps / criteria following spool fabrication Specify cleaning steps / criteria following system assembly Approve Contractor cleanliness / cleaning procedures LCLS-II Cryoplant Installation PDR Installation - Mechanical, Oct 18, 2016

Visual, Radiography or/and In-Process Dimensional verification Examination Visual, Radiography or/and In-Process Dimensional verification Define procedure requirements (B31.3, Section V) Define personnel qualifications (AWS / ASNT) Detail approval / coordination requirements http://www.acuren.com/services/NDE-NDT-Inspection/Radiographic_Testing.html LCLS-II Cryoplant Installation PDR Installation - Mechanical, Oct 18, 2016

Specify support fabrication requirements in Structural section Piping Installation Specify support fabrication requirements in Structural section Provide pipe installation instructions Specify guide assembly / installation requirements LCLS-II Cryoplant Installation PDR Installation - Mechanical, Oct 18, 2016

Testing Pressure Leak Test Helium Leak Test Define procedure requirements (B31.3) Detail approval / coordination requirements Helium Leak Test Define procedure requirements (B31.3, Section V, ASTM) http://www.inspection-for-industry.com/vessel-pressure-testing.html LCLS-II Cryoplant Installation PDR Installation - Mechanical, Oct 18, 2016

Quality Assurance SLAC approval of SLAC witness Quality program Receipt inspection procedure Lift / etc plans Material storage / control process WPS / PQR / WPQ Cleaning procedures NDE procedures / personnel (Third Party) Traveler Examination records (Third Party) As-builts / documentation SLAC witness In-process examination (Third Party) Leak tests Cleaning Dimensional verification LCLS-II Cryoplant Installation PDR Installation - Mechanical, Oct 18, 2016

Purchased component documentation Procedures / Plans / Processes (weld / NDE / etc) Inspection / Examination / Testing documentation As-builts with materials / welds / joints tracked LCLS-II Cryoplant Installation PDR Installation - Mechanical, Oct 18, 2016

Completion defined as full SLAC sign-off on traveler Turnover By system Completion defined as full SLAC sign-off on traveler Last item on traveler is transfer of system documentation https://creativeoverflow.net/how-to-become-an-artworker/ LCLS-II Cryoplant Installation PDR Installation - Mechanical, Oct 18, 2016

Design Drawing Types P&IDs Assembly Plans / Sections Piping Spool Drawings Details LCLS-II Cryoplant Installation PDR Installation - Mechanical, Oct 18, 2016

Design Drawings - P&ID LCLS-II Cryoplant Installation PDR Installation - Mechanical, Oct 18, 2016

Design Drawings - Cryoplant 3D Model/Drawing Breakdown Swing Suction Spool 2 79120-0480 MPH-LP Piping Assembly 79120-0465 Swing Suction Spool 1 79120-0481 MP – Swing Suction Piping Assembly 79120-0475 Swing Suction Spool 3 79120-0482 MPH Piping Assembly 79120-0485 LCLS-II Cryoplant Installation PDR Installation - Mechanical, Oct 18, 2016

Design Drawings - Site Plan Layout (0020) LCLS-II Cryoplant Installation PDR Installation - Mechanical, Oct 18, 2016

Design Drawings - Building Layout (0022) LCLS-II Cryoplant Installation PDR Installation - Mechanical, Oct 18, 2016

Design Drawings - CP1 Layout (0023) LCLS-II Cryoplant Installation PDR Installation - Mechanical, Oct 18, 2016

Design Drawings - Compressor Room 1 Layout (0026) LCLS-II Cryoplant Installation PDR Installation - Mechanical, Oct 18, 2016

Design Drawings - MP/Swing Suction Piping Assembly (0475) Assembly Level Drawing Level at which P&ID references are made. LCLS-II Cryoplant Installation PDR Installation - Mechanical, Oct 18, 2016

Design Drawings - Swing Suction Piping Spool 1 (0481) Spool Fabrication Level LCLS-II Cryoplant Installation PDR Installation - Mechanical, Oct 18, 2016

Design Drawings - Detail Spool Fabrication Level LCLS-II Cryoplant Installation PDR Installation - Mechanical, Oct 18, 2016

Compressor Rigging / Installation Motor skid bolt holes will be surveyed along with suction intake location at PHPK. Cooler skid will also be surveyed, and once assembled for testing, the skid-to skid relative positions will be measured. These hole locations will be used to drill the anchor and shear key holes in the slab in advance of shipment. Anchor holes will be started with a core drill to maintain correct position, then finished with an impact drill: 8” diameter holes for shear keys and 7/8” diameter holes for anchors LCLS-II Cryoplant Installation PDR Installation - Mechanical, Oct 18, 2016

Compressor Rigging / Installation The MP motor skid will arrive first. It will be visually inspected while on the truck, and the gauge checked to see that the system is still pressurized/leak tight. The skid will be craned-off using PHPK’s provided tooling. The skid will be lowered onto heavy duty rigging dollies: Swivel top dolly with plates to straddle beam flange, and ability to steer LCLS-II Cryoplant Installation PDR Installation - Mechanical, Oct 18, 2016

Compressor Rigging / Installation Skid will be pushed with a fork lift while dollies are steered- weldment with jacking posts will allow crossing the trench: LCLS-II Cryoplant Installation PDR Installation - Mechanical, Oct 18, 2016

Compressor Rigging / Installation 7/8” diameter bars in the previously drilled holes anchor straps to pull skid west, allowing the forklift to cross the trench: LCLS-II Cryoplant Installation PDR Installation - Mechanical, Oct 18, 2016

Compressor Rigging / Installation Crossing over the hole pattern: Dolly location is important to miss the large holes. LCLS-II Cryoplant Installation PDR Installation - Mechanical, Oct 18, 2016

Compressor Rigging / Installation Establishing East/West position with respect to anchor holes. The Stops act as a positioning fixture. Final motion accomplished with straps pulling against the stops. LCLS-II Cryoplant Installation PDR Installation - Mechanical, Oct 18, 2016

Compressor Rigging / Installation The dollies are chocked, and the stops removed. Toe jacks are used to raise the skid just enough to rotate the dollies 90 degrees (and reposition if necessary). The 90 degree position is carefully checked. The jacks are released, transferring load back to the dollies. The skid is shifted North/South with straps to center over the anchor holes. The wheels are chocked. LCLS-II Cryoplant Installation PDR Installation - Mechanical, Oct 18, 2016

Compressor Rigging / Installation The skid is raised uniformly to allow removal of the dollies, possibly with ganged toe jack cylinders( metering divider control). It is then lowered on to chocks under the large beam webs. The height off the slab is to be ~1.5” (chocks are 3.5” tall, placed under beam, not the channel pieces). LCLS-II Cryoplant Installation PDR Installation - Mechanical, Oct 18, 2016

Compressor Rigging / Installation Round bar is used to check that the skid holes are all aligned with the anchor holes. A rigid foam frame is slid under the skid to act as the main inner grout frame. The frame is sealed to the slab with a fast drying construction adhesive (liquid nails?) Slow curing epoxy grout is mixed for the shear key holes. LCLS-II Cryoplant Installation PDR Installation - Mechanical, Oct 18, 2016

Compressor Rigging / Installation The shear key holes are filled almost to the top with grout. The hydraulic system is used to allow removal of the chocks, then the skid is lowered onto the slab. The skid compresses the foam grout frame, adding additional holding power. LCLS-II Cryoplant Installation PDR Installation - Mechanical, Oct 18, 2016

Compressor Rigging / Installation The ¾”-10 threaded anchor rods are installed with the Hilti Epoxy system. During this period the outer (sheet metal, foam, wood ) grout frame is installed. Epoxy grout is used to fill this cavity. Install and tighten the nuts on the following day, and remove the outer grout frame. LCLS-II Cryoplant Installation PDR Installation - Mechanical, Oct 18, 2016

Compressor Rigging / Installation A similar procedure is used to move the cooler skid into position LCLS-II Cryoplant Installation PDR Installation - Mechanical, Oct 18, 2016

Compressor Rigging / Installation Things are a bit trickier as the dollies come right up to the motor skid (There were also some interferences due to the cooler skid being higher than the motor skid, which were addressed). The skid is aligned to the anchor holes, and lowered onto the 3 1/2” tall chocks. Note that a bar(s) spanning the trench may be required to give the Toe jacks adequate support: LCLS-II Cryoplant Installation PDR Installation - Mechanical, Oct 18, 2016

Compressor Rigging / Installation At this time, two 1” pipes with are positioned to allow pumping grout into the middle shear keys, and are anchored to the slab temporarily. Connect one pipe to a grout pump: LCLS-II Cryoplant Installation PDR Installation - Mechanical, Oct 18, 2016

Compressor Rigging / Installation The Toe jacks are used to allow removal of the chocks, and the skid is lowered onto the slab. Anchor hole and mating flange alignment is checked, and any final skid adjustment is done at this time. The Hilti Anchor adhesive is pumped into the holes using flexible extension tubes, and the anchors are placed. Epoxy grout is mixed and pumped first into the middle shear keys, then the outer. The fill pipes are removed. The skid can now be framed for grouting. LCLS-II Cryoplant Installation PDR Installation - Mechanical, Oct 18, 2016

Thank you for your kind attention, The End Thank you for your kind attention, Questions? LCLS-II Cryoplant Installation PDR Installation - Mechanical, Oct 18, 2016 47