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2007 Downtime PMOG Review Jose Chan

2007 Downtime PMOG Review Jose Chan. Staff. 2007 downtime installation staff Kathleen Ratcliffe – BC2 Installation Manager Greg Diaz (with Kathleen’s support)- L3 Installation Manager MFD Staff – Installation (2 supervisors & 25 techs) Ponciano Rodriguez – Cable Installation Manager

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2007 Downtime PMOG Review Jose Chan

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  1. 2007 Downtime PMOG ReviewJose Chan

  2. Staff • 2007 downtime installation staff • Kathleen Ratcliffe – BC2 Installation Manager • Greg Diaz (with Kathleen’s support)- L3 Installation Manager • MFD Staff – Installation (2 supervisors & 25 techs) • Ponciano Rodriguez – Cable Installation Manager • Phil Cutino – Water Integration Manager • Patrick Smith/Tom Graul – Area Managers • Jodi Collins/Brian Harris/Liberty Electric - Davis Bacon Contractors • Supporting Staff • Paul Emma – LCLS Linac Physicist • Richard F. Boyce – L2 & BC2 Integration Engineer • Phil Cutino – L3 & Water Integration Engineer • Carl Rago/Tom Borden – Magnet Engineers • Tim Montagne – Diagnostic Engineer • Leif Erikson – Vacuum Engineer

  3. IRR Review Summary • March 16th 2007 • Committee members • Richard M. Boyce • Darren Marsh • Mark Reichanadter • Stan Ecklund • Scott DeBarger • Tom Himel • Comments/concerns • “low priority” not implemented may reduce maximum achievable energy • Hardware needs to be tracked to ensure availability (i.e. kicker magnet • Pre-testing should be high priority to reduce in-field interference (i.e.BC2) • Better scope definition the work required for the water system and BSY not clear • Integrated schedule is required to determined if scope of work can meet the downtime constraint

  4. Objective • Linac system for 2007 downtime installations • Starts in September 4, 2007 thru December 3, 2007. • 12 weeks minus 2 weeks for PPS checkout • Scheduled power outages • Work planned in three areas • L2 – sector 21 to sector 24 • Modifying girders 24-3,4,5 & 6 • BC2 – last 3 girders of sector 24 • Modifying girders 24-7, 8 & 9 • L3- sectors 25 to 30 • Modifying girders 25-1,2,3 & 9; 27-6 & 9; 28-5 & 7; 29-4

  5. Objective • L2 • Sector 24-3: removing a DLWG and installing a new wire scanner • Sector 24-4: removing a DLWG and installing a new wire scanner • Sector 24-5: removing a DLWG and installing a new wire scanner • Sector 24-6: installing correctors from sector 24-7 • BC2 • Sector 24-7, 8 & 9: removing all components and DLWG from sectors 24-7, 8 & 9 to make room for BC2 • L3 • Sector 25-1: removing all NPI components from exit of 25-1b DLWG to upstream of Q25701 and install two DLWG from sector 24; reconfigure waveguides to feed all 4 accelerators • Sector 25-2: removing 25-2d DLWG and installing a toroid and T-Cav. (from sector 29-4d) • Connect waveguide from penetration 24-16 penetration (KLY 24-8) to sector 25-2 transverse cavity

  6. Objective • L3 (cont.) • Sector 25-3: removing 25-3d DLWG: installing a X-Kicker Magnet and OTR 22 (do not omit this work unless desperate - P.Emma) • Sector 25-9: removing all components and install OTR TCAV • Sector 27-6: removing 27-6d DLWG and install wire scanner from sector 27-9 (do not omit this work unless desperate - P.Emma) • Sector 27-9: installing drift tube • Sector 28-5: removing 25-5d drift and wire scanner; install DLWG from 28-7d and reconfigure waveguides (installing a drift tube) • Sector 28-7: removing 28-7d DLWG and install wire scanner from 28-5d (do not omit this work unless desperate - P.Emma) • Sector 29-4: removing 29-4d DLWG and install drift section and movable collimator • Water work: redistribute water to accelerators, magnet water and transverse cavity water

  7. Schedules Flow Diagram Procurement Design CF MPS/PPS MFD (VISUAL) Mech. Install (Microsoft Project) Integrated (Microsoft Project) Management P3 (Primavera) AD Planning (Excel) Control Cable Install (Microsoft Project)

  8. Schedule • P3 downtime schedule P3 Installation Schedule • Using Microsoft Project to track status, we’ll be tracking design and fabrications and kit assemblies for installation Design to Installation Schedule • LCLS 2007 downtime planning schedule • Ponciano’s cable installation plan Cable Installation Schedule • Meetings • Weekly meeting: MFD installation manager, area supervisor and integration engineer • Wednesdays –detail discussion and planning on specific installation • Weekly meeting: MFD & to discuss parts status • Thursdays – MFD & LCLS to go over material list status for installation • Weekly meeting: engineers and designers to discuss design schedule and issues • Thursdays – engineers and designers to go over design issues and schedule • Bi-weekly meeting: MFD, engineers and LCLS management • Mondays – update status with E-beam system manager • Weekly meeting: integration team (R.M. Boyce) • Tuesdays – update status to integration team • Bi-weekly meeting 2007 downtime schedule with AD

  9. Challenges & Mitigations • 2007 downtime installations • 2007 downtime 10 weeks vs. 2006 downtime 17 weeks • Plan to work two shifts • Reconfiguring 11 Linac girders vs 3 in 2006 • Schedule work on priority basis (i.e. Install BC2 first) • Longer distance from equipment lowered down to installation areas • Refurbishing an electric cart for hardware transport in LINAC • Davis Bacon Linac installations maybe competing with LTU or other installations within SLAC • Manage and schedule Davis Bacon work prior to P.O. let out • Hardware and cable installations concurrent in same area • Daily tailgate meetings to discuss tasks from integrated schedule

  10. Challenges & Mitigations • BC2 design • New articulation and support designs • Performed several iterations and reviews • Not enough time or space to test completed installation assembly in the lab. • Plan to test sub-assembly in building 26 • Bend magnets are substantial larger than BC1 bend magnets • Davis Bacon installation • L3 design • Designs for BXKIK and OTR-TCav in design stage • BXKIK design is near complete • Have an agreement with Accelerator department to remove all components from girder 25-9, except scraper (collimator 25985) and QE4 (25901) which we can make use of existing OTR design with few modifications

  11. BC2 Documentation Status • Integration engineer – Richard F. Boyce • Design inputs from: Gordon Bowden, Paul Emma, Joe Frisch, Carl Rago and Jose Chan • Two designers (Steve Score and Ted Osier) currently assigned to this area • Design more than 90% complete • Design Reviews • FDR • Supports 5/3/07 • Vacuum 5/10/07 • Vacuum Supports 5/24/07 • System 6/7/07

  12. BC2 Documentation Status • Parts status • RFI • Magnets: LINAC QEs, QMs and CQs • Diagnostics: Toroid, SLA BPM and ceramic gap • MFD fabrication • Vacuum chambers • Supports • Diagnostics • Procurement • BX2 magnets from Everson Tesla scheduled to deliver first article on June 8th • Ion pumps • Beam line pneumatic valves • Outstanding • QE strip line BPM (MFD fabrication issues with welding the bellows)

  13. BC2 Documentation Status

  14. L3 Documentation Status • Integration Engineers – Phil Cutino and Richard F. Boyce • One designer is currently working on L3 • Completed PDR on 12/19/2006 • Preliminary installation drawings being finalized • FDR scheduled for June 28th

  15. L3 Documentation Status • Parts status • RFI • Tranverse cavity • Phase cavity • Movable collimator (being vacuum processed) • Wire scanners • MFD Fabrication • S-Band Waveguide • Supports • Procurement • Ion Pumps • Ceramic chambers • Design • BXKIK • OTR T-Cavity • Finalize installation drawings

  16. Product Assurance & Safety • May require lead shielding around BC2 collimator • Using existing shielding in sector 29-4 for the movable collimator • Hoisting & Rigging bend magnets (3600-4300 lbs) in BC2 • Hoisting and rigging for other components (>40 lbs) are similar to 2006 installation • Completed seismic calculations for BC2 supports, also a peer reviewed • Magnets will be reviewed by electrical safety officer

  17. Product Assurance & Safety • Following safety documents are required prior to installation or operation (Jim Turner will collect and manage all safety approvals and requirements) • Safety Overview Approval • Penetration permits • Work authorization approval from LCLS and AD • Earthquake approvals • Building inspection approvals • Electric safety approvals • RP approvals • Non-ionizing approvals

  18. Risks and Recommendations • Risks • 2007 installation schedule very tight • Design and MFD working with integrated schedule • Control group maybe left with little time for checkout • Scheduled BC2 installation first to give sufficient time for controls to install cables and check out BC2 system • MFD will staff up two shifts, four crews for 2007 LCLS installation • BC2- articulation design is unproven • Test center table and arms before installation • Components may not available on time • Setting critical items based on installation priorities • Design issues • All designs are checked • Assemblies will be QC’d by mechanical engineers, controls and physicist prior to installation

  19. Open Items • Waiting for shielding requirement around BC2 collimator from RP, if required then we’ll plan to used existing BC1, TD11, shielding design

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