Cryoplant Installation Cost and Schedule Installation PDR Dana Arenius (LCLSII Cryoplant CAM) Oct 18, 2016

In the baseline, JLAB’s role and responsibilities include: Cryoplant design, specification and procurement Cryoplant control and instrumentation Installation (technical documentation and responsiblity) commissioning of the cryoplant Operational documentation and training The design of installation (equipment, piping, instruments and controls) is still on-going at JLAB and equipment vendors. LCLS_II Cryoplant Installation PDR

Outline Introduction of cryogenic system Overall schedule Equipment list Cryogenic system layout Installation Sequence and responsibilities Cryoplant installation (CP1 & CP2), 2 phases per plant Installation phase 1 Installation phase 2, including cryoplant Interface boxes LCLS_II Cryoplant Installation PDR

2 Cryogenic Plants for Normal Beam Operations Equivalent capacity ~ 18 kW@4.5K each Power consumption ~ 4.4 MW each CP Equivalent He ~ 30,000 liter LHe Cryoplants (JLAB) CDS (FNAL) CM (FNAL&JLAB) Upstream string Downstream string

“First Light” with Cryoplant #1 CP1 is to be installed and commissioned first to support the “First Light” U-tube Jumper Connections Upstream string Downstream string

General Installation/Cost Design Approach LCLSII installation completion date for First Light (CP1) is given priority Separate building room division allows for compressed schedule in terms of separate warm helium compressor operational testing while refrigerator room installation is under construction…lessons learned Sequence follows need for commissioning schedule Compresses overall schedule Allows more corrective action time if issue occurs rather than plan for full plant commissioning at one time Have installation corrective team standby if latent problem is uncovered during commissioning (avoids delays, small missed problems causes large details for remobilization) Labor cost is more than a single welder or electrician, but as a team Based on JLab multiple project task labor hours adjusted to SLAC labor costs Items which lower cost or enable installation ease has been designed into the building contract (Ex: floor loading, in slab electrical conduits, door opening, electrical panel power schedules, piping trenches, etc.)

Cryoplant Overall Schedule

Equipment List Common subsystems for CP1 and CP2 30,000 Gallon Gas Helium storage tanks (6) 30,000 Gallon LN2 storage dewar Purification system – dual beds Recover compressor – 18 g/s (2) Guard vacuum system Instrument air system (2) Control UPS and Generator Subsystems for each CP Warm helium compressor and MCC(6) Gas distribution system Oil Removal System 4.5 K Coldbox: Upper CBX and Lower CBX Ambient heat exchangers 10,000 liter LHe dewar 2 K coldbox, cold compressors (6) Cryogenic transfer lines Interface box Control system

Cryoplant Building 2 CDS Transfer lines Compressor Room 1 Compressor Room 2 Cold Box Room 2 CDS Transfer lines LCLS_II Cryoplant Installation PDR

Layout of the cryoplants LN2 storage GHe storage CP1 CBX CP1 ORS CP2 CBX CP2 ORS CP1 Comp CP2 Comp Oil processor 2K CBX 2K CBX Vac. Guard Interface box LHe Dewar LHe Dewar Instru. Air

Outline Introduction of cryogenic system Overall schedule Equipment list Cryogenic system layout Installation Sequence and responsibilities Cryoplant installation (CP1 & CP2) Installation phase 1 Installation phase 2, including cryoplant Interface boxes LCLS_II Cryoplant Installation PDR

Installation Phases of 2 cryoplants CP1 Installation Phase 1 CP2 Installation Phase 1 CP2 Installation Phase 2 CP1 Installation Phase 2 Upstream string Downstream string

General Process of Installation and Commissioning Installation Design/spec Review Award to Installation subcontractor Award to Rigging subcontractor JLAB/SLAC SLAC SLAC Installation of Piping (Pressure & leak check) Wiring Shipping Off-loading, Rigging, Anchoring Vendor Reassembling Inspection /check Vendor Subcontractor Vendor JLAB/SLAC SLAC Contractor Pre-commissioning - Control/ instrument test - Purge/evacuation and Purification - Training SLAC staff - etc Commissioning and performance test Commissioning Readiness and Safety review Vendor/JLAB/SLAC JLAB/SLAC 13 Vendor/JLAB/SLAC

Installation/Commissioning Responsibilities Equipment and subsystems are procured separately (Jlab) Infrastructure building readiness (SLAC) Site installation management in place (Jlab) Equipment shipped to SLAC by vendors (Jlab vendors) Equipment off loading and placement by rigging contractor (SLAC) Equipment anchoring (SLAC/Contractor) Reassembly (if needed) by JLab vendor (Example: 4.5K CBX, WHC) Interconnection installation by installation contractor (SLAC) Installation inspection/testing, as-builts (Contractor/SLAC to JLab) Operator/maintenance/repair training (Vendors/Jlab to SLAC) Commissioning and Operation Readiness Review and Approval (SLAC/Jlab) Utilities commissioning and pre-ops operations/checkout (SLAC/JLab) Plant equipment and subsystems sequential commissioning and performance testing/performance documentation (Vendor/JLab/SLAC) Corrective performance activities and reverification (if needed) (Vendor/JLab) SLAC plant acceptance and turnover to operations (Jlab/SLAC) SLAC cryogenics integration team participate actively. LCLS_II Cryoplant Installation PDR

CP1 Installation Phase 1

CP1 Installation Phase 1 (cont’d) 1/3/2017 7/14/2017 Installation Package 1 Design/spec Review Award Installation Package 1 GHe vessels LN2 vessels LN2 transfer line Recovery compressor Purifier Instrument air compressor Control Supportive System installation Commissioning readiness review CP1 WHC (6) CP1 MCC Gas management panel CP1 ORS Oil processor skid CP1 WHC piping Control WHC installation

CP1 Installation Phase 1 (cont’d) - Sample pictures 6 * 30,000 Gallon GHe Tank 47’(L)*11’(W)*13’(H) 50,000 lbs 30,000 Gallon LN2 Dewar 78’(L)*11’(W)*12’(H) 103,000 lbs (E) 306,000 lbs (F) Purifier (60g/s) Recovery compressor 2* 18 g/s Instrument air system

Typical Warm Compressor (Qty=12)

CP1 Installation Phase 1 (cont’d) - Compressors 6 Warm helium compressors Motor Skid Cooler Skid Qty Power Dimensions LP Stage 3 800 hp 23’-1/2” (L) * 10’-8” (W) *11” (H) MP stage 1 1000 hp 23’-1” (L) *10’-10 1/2” (W) * 11’-8” (H) HP stage (one swing) 2 2500 hp 25’-10” (L) *11’-5  1/4” (W) * 11’-9” (H)

CP1 Installation Phase 1 (cont’d) Gas management system Trench piping MCC Coalescer (6) Main ORS Oil Processor

CP1 Installation Phase 2

CP1 Installation Phase 2 (cont’d) Package 2 Design/spec Review Award Installation Package 2 3/12/2018 CP1 4.5K coldbox CP1 LHe dewar CP1 transfer lines CP1 control 4.5K CBX Installation CP1 CC CP1 2K cold box CP1 cryogenic transfer lines 2K CBX control Guard vacuum pump Commissioning readiness review 4/9/2018 2K CBX Installation 8/6/2018 CP1 Interface box and control Transfer lines Installation of IB and TL

CP1 Installation Phase 2 (cont’d) - 4.5K coldboxes Upper CBX 90,000 lbs Lower CBX 97,000 lbs UCB Base ring: 4600 lbs/ft2 Platform: 2700 lbs/ft2 LCB 9300 lbs/ft2 39.2’ Dia. 12’ 14.5’ Dia. 12’ 35’

Typical 4.5K Cold Box Section Delivery

CP1 Installation Phases 2 (cont’d) - Typical 4 CP1 Installation Phases 2 (cont’d) - Typical 4.5K Cold Box Installation Upper CBX Lower CBX

Typical 4.5K Cold Box Installation Completed

CP1 Installation Phases 2 (cont’d) - 4.5K Cold Box Vendor Integration Turbines Instrument panel Cabinet and wiring Control valves Transfer line

Cold Compressors used in 2K Cold Box Design Cold box conceptual arrangement developed Cold compressors and internal piping suspended from vessel top plate 12’ diameter vessel ~15.8’ overall height Build to print design, same design CP-1 and CP-2 Assembly design well underway PDR, Sept 2016 Box Design Completion January 2017 Cold Compressors Ordered Cold Compressor Bayonets Vessel FEA Compressor Suction Internal Piping

CP1 Installation Phases 2 (cont’d) - Other equipment 10,000 LHe dewar Ambient Heat exchangers Guard Vacuum System Transfer lines and U-tubes

Interface boxes to CDS 4.5K CBX 2K CBX 4.5K CBX 2K CBX Transfer line

Inter-connecting bayonets to the other CP Interface boxes to CDS Inter-connecting bayonets to the other CP 9” bayonet Cooldown valves CDS

CP2 Installation, Subset of CP1 with minor changes Phase 2 Installation Phase 1

Detailed Schedule Plan for each Phase Located at: documentation review site, MS Project Format Shows tasks by team group (welders/electricians/riggers) Mechanical Fabrication Team (3 teams, #1 through 3) Welder, fitter, helper (fire watch/crane) Electrical Team (2 teams) Journeyman, Apprentice Controls (2 teams) Part time leak check/pressure test team Riggers (variable) Contracted for the installation application CP1 (~350 work days), CP2 (~308 work days) totals Assigned tasks by team number Includes time for installation verifications/tests, reports and as-built docs Avoids interfering work areas between teams running in parallel Specific skills are associated with each team Duration task in terms of WORK DAYS, 40 hr/5 day work week Tasks include installation verification testing and documentation Most all teams are fully engaged through out installation phase period avoiding remobilizations Covers from shipment to ready to commission

Installation Cost Estimate (Commercially sensitive) Available to review committee Includes: Job trailer Mobilization Rigging Tool/Equipment rental Team hourly rate (ex: not just welder but fitter/fire watch, avg ~$200/hr per skill trade worker) Note: JLab 12 GeV contract installation labor ~$70/hr (welders/fitters) Work verification/testing Test reports/documents keeping needed for readiness to operate review Divided into: Summary of all installation phases Separate phases (CP1/CP2 Phase 1 &2)

Summary JLab has leveraged installation plan after JLab’s 12 GeV Key installation supportive details have been included in the building construction which lower cost and compress installation schedule Cost and schedule for installation is traced to Jlab’s previous experience with adjustment to local labor costs Labor presented is in terms of detailed task and work day duration by skill trade teams coupled with line item testing and documentation of work completion for commissioning readiness validation Schedule plan places emphasis on completing CP1 for First Light rather than risks associated with two plant installation at same time. Schedule breakdown shows equipment is in place prior to interconnection contract work, avoids delay in waiting for equipment arrival

Thank you!