1. JLAB / SLAC – 4.5K Cold Box Schedule Review Directors Review
Newport News, VA- November 16, 2016

2. Agenda Project Scope & Design Process PDR & Lessons Learned
Post PDR & FDR Schedule Impacts
Schedule update: Improvements & Alternatives
Schedule Review
Status update on procurement activities completed
Current Schedule review
Manufacturing Phase: Fabrication sequence
Project Management: Looking Forward
7 November 2017
aB&T U.S.

3. Design – Scope & Process
Scope of Supply:
Vertical Cold Box
Lower Cold Box
Multiline cryo-duct
Structures, Platforms
8 Brazed Aluminum Heat Exchanger Cores (BAHX)
43 Cryogenic control valves
3 Adsorber vessels
4 Air Liquide Turbo-Expanders
Vacuum Enclosures
Vacuum Pumping skids
2 sets:
All equipment is custom designed for this project
Design Process:
JLAB Inputs
Performance Req.
Design & Mechanical Req.
Ref P&IDs + 3D Arrangement
AL Design Activities
PHPK Design Activities
JLAB PFD  Adapted to AL Process
8 Process Modes Developed
BAHX: Design / Selection
3D Model - Preliminary
P&IDs
3D Model - Detailed
Seismic Input Report
Equipment Specification
Adsorbers
Cryovalves, PSV, Filters…
Mechanical Calculations
Turbine Specifications
FMEA and HAZOP
Functional Analysis
Electrical Diagrams
Cryovalves selection
Components selection
7 November 2017
aB&T U.S.

4. History
PDR & Lessons Learned

5. Schedule : Contract Milestones
History
Milestones as per the Contract signature
Contract Execution: ARO  Sep 02, 2015
PDR: ARO + 90 days  Dec 01, 2015
FDR: PDR + 4 Months  Apr 01 , 2016
SLAC: FDR + 13 months  May 01, 2017
Milestone Schedule revised: Agreement reached with JLab Jan 21, 2016
Milestone dates revised: Impact on PDR, FDR & Delivery date
The revision due to:
BAHX  Dual vs. single core, Additional process modes, Carnot efficiency calculation
Amendment to Contract Milestone Schedule
PDR:  Mar 10, 2016
FDR: PDR + 4 Months  Jul 11, 2016
SLAC: FDR + 14 Months  Sep 11, 2017 (4+ months slip)
7 November 2017
aB&T U.S.

6. Lessons Learned from PDR (Mar 10, 2016)
PDR: a key deliverable:
Preliminary 3D model review in order to validate the basic design required to order long lead items
Contract Milestone: Long lead items to be ordered  PDR + 1 month
Challenges meeting PDR requirements:
PHPK requires 95% P&IDs and the completed BAHX design in order to start 3D Model
The individual tasks, required flow of inputs and the validation process needed to complete the detailed design was not mapped out in the schedule
The impact of the seismic analysis could not be accurately forecasted in the schedule until the design was matured
All parties (JLab/AL/PHPK) are heavily involved throughout entire design process
The re-iteration between stake-holders are done in series
Focus on ongoing activities and meeting milestone deliverables, distracted AL from understanding true schedule impacts
AL was not aware during the PDR time-frame the impact of the seismic validations on ordering the shell/head material
7 November 2017
aB&T U.S.

7. Time PDR
The prioritization of all task were milestone driven as seen at PDR
At PDR the intention still was to finalize the detail design by FDR
FDR : PDR + 4 months  Jul 11, 2016
7 November 2017
aB&T U.S.

8. Course corrections after PDR (1/2)
Project Management improvements:
Resources added:
AL: 2nd PM, Full time scheduler, Full time document controller and Quality Manager
PHPK: additional Engineering resources
The time required for design re-iterations documented
Action Item Tracker Spreadsheet
Schedule updated
MS Project schedule converted to Primavera P6
Scheduling logic was reviewed and improved (for manufacturing tasks)
Detailed design tasks allow progress tracking
After PDR focused on:
Finalizing the P&IDs and developing the 3D model
Preparing for the FDR (Contract deliverables)
Ordering the long lead items (BAHX, Turbines, Cryo-valves, and CB Shell)
7 November 2017
aB&T U.S.

9. Course corrections after PDR (2/2)
Challenges after PDR:
Long Lead items : Cold box shell & heads couldn’t be ordered one month after PDR as required per contract due to:
P&ID and BAHX finalization continued after PDR
BAHX: Reiterations with BAHX manufacturer, PHPK & JLab took longer than anticipated
HAZOP (JLab required) had to be completed prior to finalizing the P&IDs
Design impact of seismic requirements underestimated due to:
Not understanding the seismic design process and validations required to proceed to order long lead items
Impacted the ordering of shell/head material (critical path items)
Difficulty meeting seismic option 2 not anticipated
7 November 2017
aB&T U.S.

10. Post PDR & FDR Schedule Impacts
History
Post PDR & FDR Schedule Impacts

11. Schedule: June update
Additional technical adjustments and status update showed the CB1 system  + 6 weeks delay from Sep 11, 2017
VCB Delivery  Sep 08, 2017
HCB Delivery  Nov 02, 2017
Main drivers for the delivery delays
The design delays (BAHX and P&ID finalization) caused the delay in 3D model design and review
The delay in 3D model review caused the delay starting the seismic analysis
Seismic validation soon became critical path
The seismic validation was still forecasted to take 6 weeks
Validation process between JLab, AL & PHPK was happening in series vs. in parallel
Amplifying delays by slowing collaboration process
In June design teams focused on FDR deliverables
FDR delayed from Jul 11, 2016  Sep 07, 2016 (attempt to deliver 92 documents)
Prioritization of FDR deliverable to meet Milestones rather than critical path activities
Eg: Preparing non critical documents such as Vacuum system design, Lifting plans, etc..
Diverted resources from 3d model design and seismic activities
7 November 2017
aB&T U.S.

12. Schedule update @ FDR (Sep 07, 2016)
By FDR the Schedule had slipped an additional 6 weeks
Schedule was update (in Aug) to reflect current activities
The seismic analysis continues to be a critical path
The results of the mechanical calculations were not meeting Seismic Option 2 requirements
Design reiterations continue between PHPK and Hopper Eng. (PHPK California PE)
The ordering of Shell/Head materials delayed (critical path item)
The mechanical calculations were not mature enough for AL to approve the shell POs
7 November 2017
aB&T U.S.

13. Lessons Learned after FDR
Expediting the seismic approval process
Joint engineering discussion with all parties as required (AL/JLab/SLAC/PHPK) to expedite approvals & validations
Seismic calculations released by PHPK reviewed in parallel by all parties
Releasing the Final Seismic Analysis package in phases
This process helps order the long lead items and not dependent on the entire final seismic analysis package
Eg. The mechanical calculation inputs for the shell material validated by AL & JLab and risk evaluated. The process allowed AL to approve the POs for shell material based on a known risk profile
Weekly AL/PHPK meeting to now include JLab key contributors
To minimize time required for reiterations between all parties
Weekly schedule status updates on all activities using a “4-Week Look Ahead” schedule
The “4-week look ahead” to focus on the on-going task including critical task items
A real time status update and ability to make “real time” course corrections
PHPK currently is focused on finalizing the design in order to progress to the manufacturing phase
7 November 2017
aB&T U.S.

14. Improvements & Alternatives
Schedule Update
Improvements & Alternatives

15. Schedule improvements (1/2)
Delivery Improvements:
VCB FDR Oct 18,  Today Forecast  Aug 21, 2017
HCB FDR Dec 12,  Today Forecast  Nov 01, 2017
Revising the sequence of issuing manufacturing drawings to align with manufacturing priorities
The Manufacturing activities that are not dependent on the final seismic package can start end of Nov 2016
Vertical cold box manufacturing start end of Nov due to VCB top-head material already ordered in Sep 2016
Resource loaded the manufacturing activities
Shortened some activity durations based on adding more resources to the activity as necessary
Piping manufacturing & installation: 12 weeks to 6 weeks
Installation of vessels, adsorbers and internal frame: 12 weeks to 7 weeks
Installation of BAHX: 12 weeks to 6 weeks
7 November 2017
aB&T U.S.

16. Schedule improvements (2/2)
Re-sequenced the manufacturing activities based on the most recent design information
Modified the logic to reflect the latest manufacturing priorities
Eg: Shell and VCB top-head material ordered separately
Added AL/JLab critical approval activities to complete final design
Previous schedule didn’t have critical approval dates & durations
7 November 2017
aB&T U.S.

17. Schedule Alternatives
Current schedule based On: 5 day work weeks (Holidays:1 week during Thanksgiving & 2 weeks during Christmas)
VCB Delivery  Aug 21, 2017
HCB Delivery  Nov 01, 2017
Alternate Scenario 1: Increase work week from 5 days to 6 days (working Saturdays)  for the HCB activities only
VCB Delivery  No Change
HCB Delivery  Sep 28, 2017
Alternative Scenario 2: Increase work week from 5 days to 7 days (working weekends) during peak work periods for the HCB activities only
HCB Delivery  Sep 05, 2017
Alternatives will be further considered as fabrication drawings are issued
Will optimize resources required for each manufacturing task
7 November 2017
aB&T U.S.

18. Key Challenges & Risk No float in the current schedule
Design delays are responsible for current negative float
For each day added to our remaining critical design/review/approval activities, there’s a corresponding effect in our ability to maintain the final delivery date
The AL cold box scope being impacted by outside influences
Eg: Latest impact to schedule  the relocation of the stairs for the VCB
Impact on seismic final package  +1 week (forecasted)
Design needs to be completed and frozen
Completing the seismic is the critical path to begin manufacturing
Seismic final package delayed  Nov 28, Week (delay due to relocation of stairs)
7 November 2017
aB&T U.S.

19. Procurement Detailed Schedule review

20. Procurement Activities: Completed
Long Lead items procurement
BAHX
PO issued  Apr 25, 2016
First batch port  Nov 12, 2016
Turbine
Status On-time delivery for assembly
Cryo-valves
PO issued  Jul 21, 2016
Status Manufacturing phase complete Jan 19, 2017
VCB top Head
PO issued  Sep 22, 2016
Status  Delivery expected Nov 18, 2016
Shell material
PO issued  Nov 01, 2016
Review the Schedule – (past completed activities)
7 November 2017
aB&T U.S.

21. Procurement Activities: Long Lead items

22. Schedule overview: Discussion on Schedule
- Review the current schedule -
7 November 2017
aB&T U.S.

23. Manufacturing sequence overview
Schedule Review
Manufacturing sequence overview

24. VCB Vacuum Shell Upper Head Assembly
2103: Top Section Weldment: Adds and lifting lugs
7 November 2017
aB&T U.S.

25. VCB Assemble Vacuum Shell Upper Head Assy
2102: Top Section Weldment: Adds bayonets and valves
5220 thru internal spools
Relief valves and external piping
7 November 2017

26. (ASME Coded Pressure Vessel) VCB Fab 80K Purifier
2400: 80K Purifier Final Assy brings in the following assemblies:
2401 Top Head Weldment
• 2402 Top Head Hole Cutting
• 2403 Top Head Detail
• 2404 Bottom Head Weldment
• 2405 Bottom Head Hole Cutting
• 2406 Bottom Head Detail
• 2407 Cylinder Weldment
2408 Cylinder Hole Cutting
• 2409 Cylinder Detail
• 2410 and Inlet Headers
7 November 2017
aB&T U.S.

27. VCB Fab Vacuum Shell Lower Shell
2201: Vacuum Shell Assy brings in the following assemblies:
• 2202: Bot Cylinder W2
• 2205: Bot Shell Head W1
• 2208: Bot Shell Skirt
• 2212: Skirt Base Ring
• 2215: Manway Cover Assy
• 2218: Davit Assy
7 November 2017
aB&T U.S.

28. (ASME Coded Pressure Vessel) VCB Fab LN2 HX
2500: Final Assy brings in the following assemblies:
• 2501: Top Head Weldment
• 2502: Top Head Hole Cutting
• 2503: Top Head Detail
• 2504: Bottom Head Weldment
• 2505: Bottom Head Hole Cutting
2506: Bottom Head Detail
• 2507: Cylinder Weldment
• 2508: Cylinder Hole Cutting
• 2509: Cylinder Detail
• 2510: Saddle Assy
Note: Wrap vessel OD with MLI per dwg instructions.
7 November 2017
aB&T U.S.

29. 2301: Heat Exchanger Installation • 2302: HX-1A Assy
VCB Install Heat Exchangers, Press. Vessels & Adsorbers, and Internal Frame
2300: Bottom Section Internal Piping Assy Brings in the following assemblies
2301: Heat Exchanger Installation
• 2302: HX-1A Assy
• 2303: HX-1B Assy
• 2304: HX-2 Assy
• 2307: Internal Frame Assy
Note: The frame will be constructed from the bottom up as it is laying on its side for a horizontal build.
More frame structure will be added as the heat exchangers and associated piping are added.
7 November 2017
aB&T U.S.

30. VCB Install piping
Internal piping may be installed as space allows during the installation of other major components
7 November 2017
aB&T U.S.

31. VCB Final Assembly
2200: Bottom Vacuum Shell Installation Brings in the following assemblies:
• 2300: Bottom Section Internal Piping
• 2201: Bottom Vacuum Shell Assy
7 November 2017
aB&T U.S.

32. HCB Fab Vacuum Shell Upper Shell
3203: Top Vacuum Shell Hole Cutting Assy brings in the following assemblies:
• 3204: Top Vacuum Cylinder Detail
7 November 2017
aB&T U.S.

33. HCB Fab Vacuum Shell Upper Shell Assy
3200: Top Vacuum Shell Weldment brings in the following assemblies:
• 3201: Top Vacuum Shell Weldment
• 3202: Top Vacuum Shell Weldment
• 3203: Top Vacuum Shell Hole Cutting Assy
Note: 1) This assembly includes the internal frame assembly 2) Install all valves and bayonets onto Top Vacuum Shell referencing 5032-SP-9017 Equipment List and any specific instructions as noted in the dwg.
7 November 2017
aB&T U.S.

34. (ASME Coded Pressure Vessel) HCB Fab LHe Subcooler
3500: LHe Subcooler Final Assy brings in the following assemblies:
• 3210: HX-SC Assy (Customer Supplied)
• 3501: and LHe Subcooler Left and Right Head Weldment
• 3507: LHe Subcooler Cylinder Weldment
• 3520: LHe Subcooler Heater Assy
Note: 1) Wrap vessel OD with MLI in accordance per the JLAB instruction JSC ) Heater
Assembly Installation must be witnessed by Engineering during installation.
7 November 2017
aB&T U.S.

35. (ASME Coded Pressure Vessel) HCB Fab 20K Purifier
3400: 20K Purifier Final Assy brings in the following assemblies:
• 3401 and -3404: 20K Purifier Left and Right Head Weldments
• 3401: 20K Purifier Cylinder Weldment
• 3420 and -3421: 20K Purifier Lower and Upper Bed Supports
• 3422: 20K Purifier Upper and Lower Filters
• 3424: 20K Purifier Heater Installation
Note: 1) Wrap vessel OD with MLI in accordance per the JLAB instruction JSC )
Heater, Screen, and filter assemblies must be witnessed by Engineering during installation.
7 November 2017
aB&T U.S.

36. HCB Install Vessels & Adsorbers
3200: Top Vacuum Shell Weldment brings in the following assemblies:
• 3201: Top Vacuum Shell Weldment
• 3202: Top Vacuum Shell Weldment
7 November 2017
aB&T U.S.

37. HCB Install piping
3102: Top Section Internal Piping brings in the following assemblies:
• 3200: Valve and Bayonet Install
• 5300 thru -5377: Lower Cold Box Internal Pipe Spools
7 November 2017
aB&T U.S.

38. Fab Vacuum System
7000: Vacuum System Final Assy brings in the following assemblies: •
7 November 2017
aB&T U.S.

39. Moving Forward
Project Management

40. Schedule Management
Progress is tracked by our Earned Value Management System (EVMS) as physical progress is made and compared to early and late dates
Site visits and reports containing photos are also part of our progress reporting verification
Updates are completed weekly during joint AL/PHPK/JLAB calls using the “4 - week look ahead”
This allows for making real-time course corrections rather than looking back and realizing too late there is a problem
Key stakeholders are now a part of the schedule optimization process
Forward looking optimization
Evaluating local companies to hire a local inspector to follow up on manufacturing progress & quality on weekly basis
“Real time” course corrections to preventing any manufacturing delays
7 November 2017
aB&T U.S.

41. Summary
AL assumes full responsibility for the timely delivery of the cold box system and all contractual obligations
AL & PHPK are committed & dedicated to continue finding schedule improvements to mitigate the schedule delay
Expect more opportunities to be identified during manufacturing phase
AL / PHPK / JLab will continue effective and transparent communication
Address key issues upfront in a timely manner
Highest priority for AL & PHPK is the completion of the Seismic calculations and finalizing the design
Timely support to freeze the design & feedback from JLab/SLAC is critical
7 November 2017
aB&T U.S.

42. Thank You
7 November 2017
aB&T U.S.