1. Cryoplant Installation Package - Mechanical
JLab LCLSII Cryoplant Installation Package, Director’s Progress Review
Michael Bevins
June 1, 2017

2. Outline LCLSII Cryoplant Installation Scope/Layout
Cryoplant Installation Design Roles/Activities
JLab/SmithGroup/SLAC/GC
Cryoplant Installation GC Package – Define Jlab Deliverables
Define GC Scope Categories
SOW/Specification/Drawing Package
Analysis/Reports (for SLAC BIO, not included in RFP)
P6 Schedule
Resources Assigned
JLab Deliverables, Status & Remaining work
Plan for Completion of JLab GC Package Deliverables
Summary

3. Cryoplant Scope/Layout

4. Cryoplant Scope/Layout
Tank Farm
North Slab –CP1
North Slab – CP2
CP1 Comp Room
CP2 Comp Room
Cold Box RM
CP1
Cold Box RM
CP2

5. Cryoplant Scope/Layout
CP1 Oil Removal
CP1 4.5K Cold Box
LN2 storage
CP1 Warm Compressors
GHe storage
CP1 2K Cold Box
CP1 MCCs
Control Rm
Interface Boxes
Cryoplant 1
Cryoplant 2

6. Cryoplant Installation Design Roles/Activities
Jlab
Cryoplant Arrangement/Equipment/Skid Design and equipment vendor coordination
Equipment/Skid Anchorage Design (cast in place anchors & tank farm piers coordinated with SLAC/HDR)
Warm Piping & Cryogenic Transfer Line(TL) Design w/associated ref design support/locations/loads
Engineering Analysis/Reports supporting Jlab designs
Coordination with SmithGroup on the Platform and Specifications
SmithGroup(SG) – SLAC contracted design assist services
Producing a complete set of construction specifications in CSI format, and integration of all drawings
Producing design for cold box room platform for access to cold boxes/equipment in the cold box room
SLAC
Coordination of design activities between JLab, SmithGroup, and SLAC
SOW (~ 10 Pages)
Provide information for Specification:
Site construction description(access rule, staging area, utilities provided)
Schedule, contract requirements, construction site instruction
Installation Sequences
Design review of installation
75% Design Submittal Review, held on Mar 29, 2017
100% Design Submittal Review, to be held on Jul 7, 2017
Final submittal to Procurement July 17, 2017 GC
Final piping supports design according to reference designs and locations/loads provided by JLab

7. GC Scope Categories Category Responsibility Example 0 – GC
To be procured, fabricated and installed by GC.
Warm piping, electrical wiring/cable tray
1 - GFP(GC)
Procured by JLab/SLAC, to be installed by GC, to be reassembled/welded by GC if necessary.
ORS vessels, Cryogenic transfer lines, Instrument air system, PLC cabinets
2 - GFP(E)
Existing Equipment/skid (installed before GC starts installation work)
Warm Helium Compressor skids
3 - GFP(M)
Procured by JLab/SLAC, to be installed by GC, to be reassembled/welded by Manufacturer, need coordination with SLAC/Manufacturer
4.5 K cold box, 2 K cold box
4 - GFP(SLAC)
Procured by JLab/SLAC, to be installed by SLAC/Others
Network switches, computers in the control room, U-tubes
* GFP: Government Furnished Property

8. GC Scope Categories – 0 - GC
To be procured, fabricated and installed by GC.
Example – Compressor Room Interconnecting Warm Piping

9. GC Scope Categories - Government Furnished Property 1 - GFP(GC)
Procured by JLab/SLAC, to be installed by GC, to be reassembled/welded by GC if necessary.
Example – LN2 Transfer Lines
LN2 TLs

10. GC Scope Categories - Government Furnished Property 2 - GFP(E)
Equipment installed prior to GC award
(6)Warm He Tanks, (1) LN2 Dewar, 12 Warm He Compressors, CP1 4K CB’s

11. GC Scope Categories - Government Furnished Property 3 - GFP(M)
Equipment to be procured by JLab/SLAC, to be installed by GC, to be reassembled/welded by Manufacturer, need coordination with SLAC/Manufacturer
4K coldbox platform
2K coldbox and CC
Interface Boxes
Main transfer lines

12. Statement of Work (SOW)
SLAC authoring Statement of Work for the Cryoplant Equipment Installation
JLab provides content for Appendix A:
A-1 - Tech Specifications and Requirements… See SG Table of Contents (addressed in Specification slides)
A-2 – JLab Drawings for Cryoplant (addressed in dwg package slides)
A-3 – GFP equipment and delivery schedule (addressed in Specification slides)
A-4 – List of pipe lines & equip interfaces (addressed in dwg package slides)
A-5 – Subsystems requirements definition and need dates
A-6 – Work performed by other subcontractors working directly for SLAC (scope, interfaces and schedule)(details pending JLab vendor definition)
JLab deliverable – IN BLUE

13. Specification
SmithGroup is producing the complete set of construction specifications in CSI format
JLab is responsible for reviewing and providing content for:
Division 01, General Requirements
Includes list of Government Furnished Property (GFP)
Division 05, Metals
Platform coordination
Division 40, Process Integration
8 sections related to process piping/supports
Includes GC procured component lists
Includes pipe line and equip interface lists (addressed in dwg package slides)
JLab deliverable – IN BLUE

14. Specification - GFP Equipment List
List includes:
Equipment Description
Applicable cryoplant (C1, C2, or common C)
Tag #
Quantity
GC Scope Category
Designed by (eg., Jlab, vendor…)
Fabrication/delivery responsibility
General Arrangement dwg
Offloading responsibility
Set in position/anchoring responsibility
Field re-assembly responsibility (GC, Vendor...)
Elec/Inst./Piping
Expected Delivery time
Installation location

15. Specification - GFP Equipment List
GFP: a total of 140 lines for mechanical

16. Specification – GC Procured Component Lists
List of electric valves, solenoid valves (<=2”), check valves (<=2”), filters (<=2”), and pressure regulators to be procured by the GC

17. Drawing Package Block Diagram/P&IDs Line List & Interface List
Layout Drawings
Piping Drawings
Piping Assembly/Spools
Piping supports
Build-to-Print (Tank Farm)
Support Location/Load drawings
Standard details
Equipment Drawings
Equipment/Skid General Arrangement
Equipment/Skid Installation
3-D model will be provided to GC for reference
JLab deliverable – IN BLUE

18. Drawing Package - Cryogenic Plant Block Diagram

19. Drawing Package - P&IDs
LCLSII P&IDs Include:
*Instrument/Valve Tags
*Installation/GC Scope Category/Boundary
Line numbering
*Interface Numbering
*Information shown on mech piping dwgs

20. Drawing Package - P&ID List
NUMBER
DRAWING #
Released REV.
DRAWING TITLE
Duplicate for CP2 1 A
FLOW DIAGRAM SYMBOLS NO 2 B
CRYOGENIC PLANT BLOCK DIAGRAM 3
MAIN COMPRESSOR SYSTEM (MCS)
YES 4 D
LP STAGE COMPRESSOR 5
MP STAGE COMPRESSOR 6
HP STAGE COMPRESSOR 7
OIL REMOVAL SYSTEM (ORS) 8
MCS DEPRESSURIZATION MANIFOLD (DPM) 9
OIL MANAGEMENT SYSTEM (OMS) 10
OIL PROCESSOR SKID 11
He GAS DISTRIBUTION SYSTEM (HGD) 12
COOLDOWN/CLEAN UP DISTRIBUTION SYSTEM (CDUS) 13
RELIEF VALVE DISCHARGE COLLECTOR 14 -
He GAS ANALYZER SYSTEM 15
MAIN 4.5K COLD BOX TEST 16
MAIN 4.5K COLD BOX (MCB) (ALAT DESIGN) 17 C
2K COLD BOX WITH COLD COMPRESSOR (SCB) 18
INTERFACE BOX SYSTEM 19
He RECOVERY SYSTEM (HRS) 20
He PURIFIER SYSTEM 21
He RECOVERY COMPRESSOR 22
COOLING WATER SYSTEM (CWS) 23
COOLING WATER SYSTEM (FOR TURBINES & COLD COMPRESSORS) 24
INSTRUMENT AIR SYSTEM (IAS) 25
INSTRUMENT AIR DISTRIBUTION SYSTEM 26
He GAS STORAGE SYSTEM (HGS) 27
LHe STORAGE DEWAR SYSTEM (LHD) 28
LN2/GN2 DISTRIBUTION SYSTEM (NDS) 29
LN2 DEWAR 20,000 GAL 30
GUARD VACUUM SYSTEM (GVS) 31
80K BED VACUUM PUMP CART

21. Drawing Package - P&ID Example
Line Number
Installation GC Scope Category/ Boundary
Interface Number

22. Drawing Package – GC Scope Piping Line List
Line numbers: a total of 410

23. Drawing Package – GC Scope Interface List
Interface: a total of 630
Interface #’s Identified on Piping Assy Dwgs

24. Drawing Package - Drawing TreeLP
Spool 2 LP
Spool 1 LP
Piping Assembly
Comp Room Equip Installation LP
Spool 3 MP
Piping Assembly
Helium Piping Arrangement, West
Swing Suction Spool 3

25. Drawing Package - Moving Up and Down Drawing Levels
The drawing the next level down is specified in the BOM
The drawing the next level up is specified in the Title Block

26. Drawing Package - Site Plan Layout (0020)

27. Drawing Package - Building Layout (0022)
75% Design Peer / BIO Review, March 29, 2017

28. Drawing Package - CP1 Layout (0023)

29. Drawing Package - Compressor Room 1 Layout (0026)

30. Drawing Package – He Piping Arrangement (-0655)
Spool Fabrication Level

31. Drawing Package – LP He Piping Assembly (-0465)
Spool Fabrication Level

32. Drawing Package – LP Spool 1 (-0468)
Spool Fabrication Level

33. Drawing Package – O-Ring Groove
Component Detail Drawings are specified in the BOM

34. Drawing Package – Slip-On Flange Weld Detail
Fabrication Detail Drawings are specified in the drawing notes

35. Drawing Package – Equipment/Skid GA

36. Drawing Package - Equipment/Skid Installation Drawing

37. Drawing Package – Drawing Tree/List

38. Analysis/Reports
Engineering analysis supporting the GC installation scope must be submitted to the SLAC Building Inspection Office (BIO) for review/approval
Pipe Stress/Relief Valve Calculation Notes (20)
Structural/Anchorage Design Notes (27)
JLab deliverable – IN BLUE

39. P6 Schedule Activity ID Activity Start Finish CP_ED_700
Generate He Tank Farm Documentation
03-Apr-17 A
19-May-17
CP_ED_7001
Generate Oil Removal System Anchorage Documentation
10-Apr-17 A
CP_ED_7002
Generate P&ID Line Index
27-Apr-17 A
CP_ED_7003
Generate CP1 and CP2 Compressor Room Documentation
15-Jun-17
CP_ED_7004
Generate GC Installation Drawing Package and Submit Partial BIO Package
CP_ED_7005
Submit Remainder of GC BIO Package
16-Jun-17
29-Jun-17
CP_ED_70051
SLAC Review of Package Prior to BIO/FDR
30-Jun-17
14-Jul-17
CP_ED_7006
Conduct GC Installation Package BIO and FDR
17-Jul-17
CP_ED_705M
COMP: GC Installation Package Final Design Review (FDR)
CP_ED_715M
COMP: GC Installation Package Submitted to SLAC for RFP
24-Jul-17
CP_ED_735
Finalize GC Installation Package Portion of the Lhe Dewar Neck Cans Design
22-May-17
14-Jun-17
CP_ED_740
Finalize GC Installation Package Portion of the Lhe to 2k Cold Box, Cooldown & Adsorber Transfer Lines
2-Jun-17
13-Jun-17
CP_ED_745
Finalize GC Installation Package Portion of the Interface Box to 2K/4.5K Cold Box transfer
CP_ED_748
Finalize GC Installation Package Portion of the Interface Box Design and Fabrication Specification
CP_ED_770
Finalize GC Installation Package Portion of the Secondary Cooling Water Skids Design
1-May-17
3-May-17

40. Resources Assigned Count by skill type: MGT: 2 MEng: 10 MDes: 17 Name
Lab, Org
Skill Type
Location
Supporting
D. Arenius
Jlab, MSCRYO
MGT
Bldg. 89
CAM
M. Bevins
Jlab, MSMECH
Meng/MGT
Deputy CAM
B. Crahen
MEng
Bldg. 87
Warm sys
C. Dubbe
N. Laverdure
Warm/Cold sys
M. Marchlik
TEDF
S. Kaminski
SLAC
Hongyu
Cold sys
Vishy
C. Kaufman
F. Fors
S. Yang
P. Hansen
MDes
C. Butler
J. Tschirhart
D. Spell
D. Rath
R. Wilson
G. Hays
S. Gregory
T. Crahan
MDes_contract
C. Patrosso
F. Martin
R. Stori
W. Sachleben
J. Armstrong
K. Harding
C. Hutton
M. Wade
MDes - Student
Count by skill type:
MGT: 2
MEng: 10
MDes: 17

41. JLab Deliverables Status/Remaining Work – Specification
Deliverable: Review and provide content for specifications and coordinate integration of SG platform design into the plant
Division 01, General Requirements
Includes list of Government Furnished Property (GFP)
Status:
Draft specs developed and under review
GFP draft list developed
Remaining Work:
Provide comments on draft specs
Complete review/check of GFP list
Division 05, Metals
Platform coordination
Latest SG platform model integrated into JLab 3D model
Provide SG updated 3D models
Provide SG weight/CG of 2K box panels that will be mounted to the platform

42. JLab Deliverables Status/Remaining Work – Specification
Deliverable: Review and provide content for specifications and coordinate integration of SG platform design into the plant
Division 40, Process Integration
8 sections related to process piping/supports
Includes GC procured component
Status:
Draft specs developed and under review
Draft GC procured component list developed
Remaining Work:
Provide comments on draft specs
Coordinate with SG to include spec language and table of loads for GC provided piping supports

43. JLab Deliverables Status/Remaining Work – Analysis/Reports
Deliverables: Analysis/Reports
Status:
Structural/Anchorage Notes (27)
6 Approved
2 Draft complete – in review
8 In work
11 Pending vendor
Pipe Stress/Relief Valve Calculation Notes (20)
1 Approved
12 Draft complete – in review
7 In work

44. JLab Deliverables Status/Remaining Work – Drawing Package/ Line & Interface Lists
Block Diagram/P&IDs
Status:
Complete
Remaining Work:
Monitor track any corrections/edits that may be uncovered as the drawing package is finalized
Line List & Interface List
Draft line and interface lists developed
Incorporate reference to piping assembly dwg in lists
Review and finalize line and interface lists
Drawing Index
Drawing tree developed
Monitor and track and corrections/edits that may be uncovered as the drawing package is finalized
Develop drawing index with SG to best organize the drawing list for incorporation into the RFP 44

45. JLab Deliverables Status/Remaining Work – Drawing Package/ Line & Interface Lists
Deliverables: Drawings…
Status: 45

46. Plan for Completion of JLab GC Package Deliverables – Drawing Effort Estimate to Complete
A tracking/projection tool for drawing package completion has been developed which accounts for:
Number of Drawings, Drawing Type, Document Maturity
Effort to move each drawing type from 1 phase to the next
As of May 15 – 2,776 hours of effort were projected
As of May 30 – 1,812 hours of effort remain
Average 482 hrs effort completed per week – 3.76 weeks of effort remain – complete the week of June 19
Sensitivity Analysis of Estimate
25% - add one week – complete the week of June 26
50% - add two weeks – complete the week of July 3

47. Plan for Completion of JLab GC Package Deliverables
While every effort is being made to pull the completion date back to June 15th, based on the recent dwg production rate, coupled with continued uncertainties associated with time spent on other efforts (i.e, SG/SLAC coordination, vendor oversight, CAD software issues) completion the week of July 3rd is probable
A detailed week by week task based plan has been developed to track progress to completion

48. Plan for Completion of JLab GC Package Deliverables
Week of May 29
Design
Prepare for Director’s Review
Incorporate redlines / issue drawings for
Compressor Room Main Helium Piping
Main Cooling Water Piping
Depressurization Piping
Compressor Room Main Recovery Compressor Piping
Compressor Room Relief Piping
Revise, issue Standard Detail drawings
Prepare drawings for check for
Secondary Cooling Water Piping
North Slab Piping
GC Cryogenic Piping
Instrument Air Piping
Oil Piping
Main Helium Compressor Equipment Interface
Engineering
Prepare for Director’s Review
Ongoing Vendor Review and Coordination
Review SG specifications
Review Drawings
Standard Details
Compressor Room Main Helium System Piping
Compressor Room Main Recovery Compressor System Piping
Compressor Room Relief Piping
Backcheck Drawings
Main Cooling Water System Piping
Depressurization Piping
Progress Analysis
Instrument Air Piping System
UCB Platform Anchors
Cold Box Room Relief Piping
Cryogenic Piping Support Loads
Review / Revise Analysis Reports
Main Helium Piping System

49. Plan for Completion of JLab GC Package Deliverables
Week of June 5
Design
Incorporate redlines / issue drawings for
GC Cryogenic Piping
North Slab Piping
Secondary Cooling Water Piping
Main Helium Compressor Equipment Interface
Prepare piping drawings for check for
North Slab
Instrument Air System
Oil System
Engineering
Ongoing Vendor Review and Coordination
Review SG specifications
Summarize Pipe Support Loads
Review Drawings
GC Cryogenic Piping
Main Helium Compressor Equipment Interface
North Slab Piping
Secondary Cooling Water Piping
Backcheck Drawings
Progress Analysis
Instrument Air Piping
Gas Management System Anchors
Helium Distribution System Piping
Interface Box / Transfer Line Anchor Analysis
Cryogenic Piping Support Loads
Prepare Analysis Reports
CP2 Cooling Water Piping
Relief / Depressurization Piping
Review / Revise Analysis Reports
Relief Valve Sizing Notes
Revise Oil Coalescer Anchor Notes
Revise LCB Shear Key Note
CP1 Cooling Water Piping Report
Guard Vacuum Piping Report

50. Plan for Completion of JLab GC Package Deliverables
Week of June 12
Design
Incorporate redlines / issue drawings for
North Slab Piping
Secondary Cooling Water Piping
Instrument Air Piping
Oil Piping
Prepare piping drawings for check for
Support Reference Design / Piping Load
Cold Box Room Relief Header Piping
Engineering
Ongoing Vendor Review and Coordination
Summarize Pipe Support Loads
Review Drawings
Instrument Air Piping
Oil Piping
North Slab Piping
Backcheck Drawings
Secondary Cooling Water Piping
Progress Analysis
Update MCS Piping
Update He Tank Farm
Prepare Analysis Reports
Fill Station Structural
Helium Distribution Piping
Helium Tank Farm Pipe Supports
Interface Box / Transfer Line Anchors
Updated MCS Piping
Updated He Tank Farm Piping
Gas Management System Anchors
Relief / Depressurization Piping
Review / Revise Analysis Reports
LN2/GN2 Piping
CP2 Cooling Water Piping

51. Plan for Completion of JLab GC Package Deliverables
Week of June 19
Design
Incorporate redlines / issue drawings for
Support Reference Design / Piping Load
North Slab Piping
Instrument Air Piping
Cold Box Room Relief Piping
Prepare piping drawings for check for
Equipment Installation
Engineering
Ongoing Vendor Review and Coordination
Review Drawings
North Slab Piping
Support Reference Design / Piping Load
Cold Box Room Relief Piping
Backcheck Drawings
Instrument Air Piping
Progress Analysis
Update Recovery Compressor Skid anchor analysis
Prepare Analysis Reports
LN2 Tank Farm Pipe Support
Recovery Compressor Anchors
Guard Vacuum Anchors
Review / Revise Analysis Reports
Oil Piping
Fill Station Structural
Helium Distribution Piping
Helium Tank Farm Pipe Supports
Interface Box / Transfer Line Anchors
Updated MCS Piping
Updated He Tank Farm Piping
Secondary Cooling Water Piping
Gas Management System Anchors
Relief Header / Depressurization Piping

52. Plan for Completion of JLab GC Package Deliverables
Week of June 26
Design
Incorporate redlines / issue drawings for
Support Reference Design / Piping Load
Equipment Installation
North Slab Piping
Updated Plant Layouts
Prepare piping drawings for check for
Collect For Information Only drawings
Engineering
Ongoing Vendor Review and Coordination
Collect For Information Only documents
Review Drawings
Equipment Installation
Support Reference Design / Piping Load
Updated Plant Layout
For Information Only
Backcheck Drawings
North Slab Piping
Progress Analysis
2K Cold Box Vacuum Pump Anchors
Prepare Analysis Reports
Review / Revise Analysis Reports
LN2 Tank Farm Pipe Support
Recovery Compressor Anchors
Guard Vacuum Anchors

53. Plan for Completion of JLab GC Package Deliverables
Week of July 3
Design
Finished remaining drawing redlines, issuance
Progress non-GC installation work (as time allows)
Gas Management Skid drawing revisions
Cryogenic Piping procurements
2K Cold Box Re-Design
Engineering
Finish remaining report review and revisions
Ongoing Vendor Review and Coordination
Prepare for FDR
Progress procurements (as time allows)
Gas management skid
Instrument Air System
Cryogenic Piping
Secondary Cooling Water Skids
Progress 2K CB Re-Design (as time allows)

54. Summary
The scope and level of detail of the JLab deliverables as presented here is well defined
While various formats and level of detail can be used to bid and execute projects, the current format and level of detail is considered suitable to obtain a fixed-price bid and execute the project
The present status of the JLab deliverables and remaining work is well understood and has been presented
Projections for completion of the work extend beyond the project deadline
Current resources supporting this effort have been identified and will be available for the duration of this work
Additional potential resources have been identified and will be used if their contribution will accelerate completion
A task based plan to completion has been developed and will be tracked weekly
Thank you for your time and attention - we appreciate your feedback.