1 BROOKHAVEN SCIENCE ASSOCIATES Installation & Integrated Testing Status & Plans Gregory Fries, ASD Project Engineer 9 th ASAC meeting for NSLS-II Project February 1-2, 2012

2 BROOKHAVEN SCIENCE ASSOCIATES Outline Phasing of Installation Storage Ring Installation Progress Injector Installation Progress Schedule & Status Labor Profile Photon Division Installation Integrated Testing Overview Challenges Summary

3 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-1116-Jun-11 Injector Building 18-May-1112-Aug-11 Pentant 2 2-Jun-1121-July-11 Pentant 3 27-Sep-1121-Oct-11 Pentant 4 28-Nov-1121-Dec-11 Pentant 5 9-Feb-1213-Feb-12

4 BROOKHAVEN SCIENCE ASSOCIATES Storage Ring P1 Installation Highlights 12 multipole & 2 dipole magnet/girders installed Cell 25 fully populated with magnets; survey & bellows installation to start with bakeout to follow All cables pulled (excluding front ends) Cable termination & power supply installation in process Rack tie-in to PCW complete AC power work complete & tested Vacuum component installation in process DI pump skid complete in Feb. EPOCH 3 survey in process PPS interlocks wiring in process Many install resources focused on linac

5 BROOKHAVEN SCIENCE ASSOCIATES Storage Ring P1 Photos

6 BROOKHAVEN SCIENCE ASSOCIATES Storage Ring P2 & P3 Installation Highlights Pentant 2 AC power work complete Racks installed; tie-in to PCW in process Rack shelving & equipment installation in process Cable pulling in process (Quads complete) Floor plates installed DI piping complete (Torcon) Pentant 3 Beamline AC boxes installation in process Rack installation in process DI piping in process (Torcon) Pentant 4 Cable tray installation in process (Torcon)

7 BROOKHAVEN SCIENCE ASSOCIATES SR RF & Computer Room Installation Highlights RF Transmitter Installation in Process KSUs, klystrons, waveguide, water manifolds installed Electrical work and check out in process PCW tie-in in process Installation complete early Feb. followed by testing Blockhouse AC power and PPS interlock work to start DI piping complete & pump skid testing in process PCW tied-in to computer room racks Computer room powered & controls testing in process UPSs operational

8 BROOKHAVEN SCIENCE ASSOCIATES Storage Ring RF Photos

9 BROOKHAVEN SCIENCE ASSOCIATES Linac &TL Installation Highlights Linac installation to be complete in Feb. Linac modulator acceptance testing in process All LtB TL P1 magnets & vacuum chambers are installed Cable pulling complete; cable termination in process LtB TL P1 racks 90% wired Dumps installed; balance of shielding being installed Installation of diagnostics & vacuum equipment in process Testing of PPS interlocks in process Testing of other subsystems starting in early Feb. DI system scheduled to be turned over mid-Feb. Linac ARR scheduled for Feb

10 BROOKHAVEN SCIENCE ASSOCIATES LtB TL Photos Dec. 7, 2011 Jan. 11, 2012

11 BROOKHAVEN SCIENCE ASSOCIATES Linac & LtB TL Photos

12 BROOKHAVEN SCIENCE ASSOCIATES Booster Installation Highlights DI piping installation in process (contractor) Cable tray installation in process (BNL) Survey & floor drilling in process First booster delivery arrived (girder pedestals) Second booster delivery in transit (5 magnet/girders) Booster installation work planning in process Planning space for staging & testing Fabrication of girder transport fixtures to start PPS interlock installation to start Girder installation to start in March

13 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 Jan. 19, 2012 Phase JFMAMJJASONDJFMAMJJASONDJFMAMJJA Pentant 1 Current Baseline Storage Ring RF Injector Pentant 2 Pentant 3 Pentant 4 Pentant 5

14 BROOKHAVEN SCIENCE ASSOCIATES SR RF Installation 2 nd Cavity may be installed during ID installation RF Transmitter, refrigeration system & RF cavities installed by vendor Remaining RF systems installed by BNL Taken from P6 Jan. 19, 2012 Phase JFMAMJJASONDJFMAMJJASONDJFMAMJJAS Mech & Elec Utilities Current Baseline RF Transmitters Low Level RF Liquid Nitrogen System Refrigeration System RF Cavities

15 BROOKHAVEN SCIENCE ASSOCIATES Injector Installation Schedule Taken from P6 on Jan. 19, 2012 BtS Part 2 is not needed for Booster commissioning Phase JFMAMJJASONDJFMAMJJASONDJFM Mech & Elec Utilities Current Baseline Booster RF LtB TL Part 1 Linac Booster LtB TL Part 2 BtS TL Part 1 BtS TL Part 2

16 BROOKHAVEN SCIENCE ASSOCIATES High-Level Installation Schedule Status Installation is approx. 15% complete (baseline called for 43%) Installation is currently 4 months behind schedule; end date has shifted from March ‘13 to July ‘13 Install work and labor profile now have prolonged peak due to shifted work Resource leveling & schedule analysis in process to determine true schedule impact of delayed work & develop plan to mitigate Additional labor (i.e. cable pullers, electrical installers) may need to be added to keep current schedule Schedule may soon be driven by labor and not hardware

17 BROOKHAVEN SCIENCE ASSOCIATES Installation Percentage Complete

18 BROOKHAVEN SCIENCE ASSOCIATES ASD Installation Labor Profile

19 BROOKHAVEN SCIENCE ASSOCIATES Photon Division Installation Hutch installation contact established The current schedule for hutch construction is: Cell 23 (CSX) – Mar ’12 Cell 28 (XPD) – May ’12 – June ‘12 Cell 3 (HXN) – Mar ’12 – May ‘12 Cell 5 (SRX) – July ’12 – Aug ‘12 Cell 10 (IXS) – Sep ’12 – Oct ‘12 Cell 11 (CHX) – Oct ‘12 – Dec ’12 Cleared necessary space on experimental floor Moving of utilities causing interference in process Hutch survey in process Working planning in process

20 BROOKHAVEN SCIENCE ASSOCIATES Integrated Testing Planning Testing of the subsystems through the control system w/o beam Will be performed by pentant or even cell Task force leader named (G. Ganetis) Schedule has been updated & resource loaded Test applications are being developed for control, monitoring, long term logging, and alarming Focusing on getting infrastructure in place to start Integrated testing scheduled to start in April ‘12 in P1 (Cell 25)

21 BROOKHAVEN SCIENCE ASSOCIATES Challenges Finding ways to makeup time in schedule Coordinating multiple activities & teams during installation Coordinating to avoid interferences between systems Adapting to component delivery delays Space for work is limited, especially in linac & booster Spike to occur in required installation labor Significant schedule float has been reduced Tight coordination with PD & CFD needed to avoid conflicts Moving material during & after hutch installation

22 BROOKHAVEN SCIENCE ASSOCIATES Summary Linac & LtB TL P1 installation complete in Feb. for ARR Installation very advanced in P1; working on completion of 1 st cell Installation progressing in P2 and starting in P3 Focus will return to P1 (starting at cell 25) after linac installation Preparing for the start of booster installation Currently 4 months behind schedule Schedule & labor analysis in process Working with PD to prepare for the start of their installation Integrated testing planning in process

23 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. T. Tanabe, G. Visnefsky, W. Wahl, F. Willeke, P. Zoccoli & many others