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

2. 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

3. 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

4. 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

5. 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

6. 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

7. 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

8. 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

9. 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

10. Fabrication - Demolition
Minor portion of overall scope
At equipment / prior Phase connection points
Communicated through specification work description and drawings
Location
Type
LCLS-II Cryoplant Installation PDR Installation - Mechanical, Oct 18, 2016

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

12. 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

13. 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

14. 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

15. 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

16. 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
LCLS-II Cryoplant Installation PDR Installation - Mechanical, Oct 18, 2016

17. 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

18. 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)
LCLS-II Cryoplant Installation PDR Installation - Mechanical, Oct 18, 2016

19. 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

20. 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

21. 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
LCLS-II Cryoplant Installation PDR Installation - Mechanical, Oct 18, 2016

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

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

24. Design Drawings - Cryoplant 3D Model/Drawing Breakdown
Swing Suction Spool 2
MPH-LP
Piping Assembly
Swing Suction Spool 1
MP – Swing Suction
Piping Assembly
Swing Suction Spool 3
MPH
Piping Assembly
LCLS-II Cryoplant Installation PDR Installation - Mechanical, Oct 18, 2016

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

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

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

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

29. 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

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

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

32. 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

33. 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

34. 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

35. 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

36. 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

37. 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

38. 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

39. 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

40. 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

41. 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

42. 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

43. 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

44. 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

45. 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

46. 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

47. 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