1 BROOKHAVEN SCIENCE ASSOCIATES NSLS-II Accelerator Installation Plan Gregory Fries Project Engineer, Accelerator Systems Division CFAC Review of NSLS-II October 5-6, 2010

2 BROOKHAVEN SCIENCE ASSOCIATES Outline Phasing of Installation Coordination with Conventional Facilities Storage Ring Installation Injector Installation Storage and Rigging Installation Schedule Experimental Installation Potential Obstacles Summary

3 BROOKHAVEN SCIENCE ASSOCIATES Phasing of Construction and Installation Beneficial Occupancy Installation

4 BROOKHAVEN SCIENCE ASSOCIATES Installation and Operation Zones Key Points: Utilities and infrastructure are segmented as shown BOD handovers aligned with support infrastructure Installation and testing within these segments Linac/Booster test/commission may overlap with construction activities 1 2 B L RF

5 BROOKHAVEN SCIENCE ASSOCIATES Coordination with Conventional Facilities Lay-down area for storage containers outside of building Beneficial occupancy conditions for installation Systematic hand-off of completed building zones BNL BORE process to be used for occupancy permits Access to space with beneficial occupancy for installation while construction continues Interaction of installation activity with LOB construction to avoid potential interference CFD represented in ASD installation meetings (O. Dyling) ASD reviewing all CFD ECNs for impact ASD installation coordinator named

6 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 Booster RF BNL Transport Lines BNL Linac Vendor w/ BNL oversight Booster Ring Vendor using BNL technicians for all hands–on work w/ BNL oversight

7 BROOKHAVEN SCIENCE ASSOCIATES Storage Ring Systems Installation Per Pentant Mechanical Utilities Electrical Utilities Magnet/Girder Assemblies RF Systems Vacuum System Power Supplies Beam Instrumentation Beam Line FEs, DWs, IDs (where applicable) Injection Straight

8 BROOKHAVEN SCIENCE ASSOCIATES Storage Ring Pentant 1 Installation: Week Exp’l floor Tunnel Service Building Mezzanine 23 Status: ~ 1/3 of material in building Installation starting 26 Activities: Prepare tunnel Stage components on floor Start cable tray on mezzanine 2

9 BROOKHAVEN SCIENCE ASSOCIATES Storage Ring Pentant 1 Installation: Week Exp’l floor Tunnel Service Building Mezzanine 23 Status: Most material in building Installation on mezzanine Installation in tunnel 26 Activities: Tray and manifolds in place in tunnel Racks well underway Stage cable and start pulling

10 BROOKHAVEN SCIENCE ASSOCIATES Storage Ring Pentant 1 Installation: Week Exp’l floor Tunnel Service Building Mezzanine 23 Status: Most wiring pulled Process utilities connected 26 Activities: Girder installation Populating racks Terminating cables

11 BROOKHAVEN SCIENCE ASSOCIATES Storage Ring Pentant 1 Installation: Week Exp’l floor Tunnel Service Building Mezzanine 23 Status: About 2/3 vacuum complete 26 Activities: Girder installation Cable pulls all done Testing underway

12 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

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

14 BROOKHAVEN SCIENCE ASSOCIATES Component Storage & Staging Reviewing storage requirements for each ASD group Finalizing number of sea containers needed at site for storage Approx ft x 8 ft x 40 ft containers Experimental floor will be used for staging Temporary cages may be installed

15 BROOKHAVEN SCIENCE ASSOCIATES Lay-down Areas for Sea Containers Lay-down Area for SR Component Storage Containers Lay-down Area for Linac & Booster Containers Outside Access to Experimental Floor for Unloading

16 BROOKHAVEN SCIENCE ASSOCIATES Rigging Requirements ItemQty.UOMDate Hours (team) Total Hours (team) Weight (lbs) Total Weight (lbs) DimensionsFromToComments RF Group SR Transmitter1EAJun-11885,000 6 x 2 x 2.3m tentative TruckRF Building SR Transmitter1EATBD885,000 6 x 2 x 2.3m tentative TruckRF Building SR Transmitter Transformer1EAJun-11225,500 TruckRF BuildingInstalled separately SR Transmitter Transformer1EATBD225,500 TruckRF BuildingInstalled separately SR Klystron1EAJun-11442,750 TruckRF BuildingHorizontal-to-Vertical SR Klystron1EATBD442,750 TruckRF BuildingHorizontal-to-Vertical SR Cavity1EAAug ,000 Truck RF Straight in Tunnel Installed in 20cm trench SR Cavity1EANov ,000 Truck832Installed in 20cm trench Cold Box1EANov-11885,600 Truck RF Building - Cryo Mezzanine Requires special forklift to 20', unit for rent identified by Bob Sikora Dewar1EANov-11443,800 ` RF Building - Cryo Mezzanine Valve Box2EANov ,3006,600 Truck Tunnel Mezzanine at RF Verify difficulty to get on mezzanine Booster Transmitter1EADec-11885,000 TruckInjector RF Building Booster Cavity1EADec-11442, Booster Tunnel As soon as tunnel is available; preceeds transmitter

17 BROOKHAVEN SCIENCE ASSOCIATES Rigging Summary & Status Reviewed requirements with the riggers Will have two dedicated 3-man rigging teams ASD installation coordinator will be contact to riggers Rigging requirements will continue to be detailed

18 BROOKHAVEN SCIENCE ASSOCIATES Component Transport Forklift has been ordered 10,000 lbs. capacity 208” max lift to reach mezzanine from experimental floor Dolly system will be used for magnet/girder assembly transport

19 BROOKHAVEN SCIENCE ASSOCIATES Installation, Testing & Commissioning Schedule

20 BROOKHAVEN SCIENCE ASSOCIATES Installation Schedule Installation schedule currently being reviewed with each CAM and expanded for completeness, durations and logic Emphasis will be placed on installation schedule flexibility based on building and component availability

21 BROOKHAVEN SCIENCE ASSOCIATES Experimental Installation XFD Installation follows ASD installation by pentant Activities Per Beamline Pentant Hand-off from ASD Pentant Clean-up Hutches Utilities Beamline Components

22 BROOKHAVEN SCIENCE ASSOCIATES Potential Obstacles Coordinating multiple activities/teams/access during installation Maintaining component delivery schedules Will epoxy floor installation on experimental floor impact ASD installation schedule? XFD installation needs might conflict with required flexibility of ASD installation schedule (hand-over delays)

23 BROOKHAVEN SCIENCE ASSOCIATES Summary Installation schedule in process of being expanded and re- evaluated Focus on flexibility in installation schedule based on availability of building and components Building to be available for start of ASD installation Feb ‘11 Detailing installation logistics Rigging and storage requirements in process Good communication established with CFD & XFD Conclusion: Installation Planning is very advanced