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Accelerator Installation

This document outlines the phasing, work planning, site access, and progress of the accelerator installation project, including challenges and key aspects of production and installation.

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Accelerator Installation

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  1. Accelerator Installation Gregory Fries, Project Engineer 8th ASAC meeting for NSLS-II Project May 10-11, 2011

  2. Outline • Phasing of Installation • Work Planning • Site Access & Layout • Rigging & Transport • Storage Ring Installation Progress • Schedule • Injector Installation • Challenges • Summary

  3. Key Aspects of Production and Installation Accelerator Production – • We procure injector sub-systems (Linac, Booster Ring) • We build (integrate) Transfer Lines, B-RF and SR components Accelerator Installation – • Storage Ring BNL • Storage Ring RF BNL w/ vendor installing transmitter • Booster RF BNL • Transport Lines BNL • Linac Vendor w/ BNL oversight • Booster Ring Vendor using BNL technicians for all hands–on work w/ Vendor oversight

  4. Phasing of Construction and Installation 1 B RF RF 2 5 L • Temp walls constructed separating BOD segments • Installation and testing within these segments • Components will be staged on experimental floor 4 3

  5. Work Planning • Installation schedule complete, including resource loading • Schedule is reviewed, updated & disseminated weekly • Emergency plan & operations plan in place • Site specific training for phase 1 complete • One work permit will be created for each phase on installation • Detailed work plans will be attached to each work permit • Installation WCC for each ASD group identified • Daily morning meeting on site with WCCs taking place • Weekly installation meetings taking place ASD Install Labor Profile

  6. Site Access Sketch • Access via Brookhaven Ave • Dedicated parking lot • “Safe zone” identified via fence to provide separation from construction site • Enter at column 102 • Hard hats, safety shoes & safety glasses required • Signage in place • No personal vehicles on site Storage Containers Loading Dock

  7. Experimental Floor Layout During P1 Install • (8) 20’x30’ Cages for technician space on experimental floor. • Will move from pentant to pentant through installation process.

  8. Pictures of Experimental Floor

  9. Rigging, Forklifts & Vehicles • (2) 3-person rigging teams assigned full-time to project • ASD Forklift • 10,000 lbs. capacity • 208” max lift to reach mezzanine from experimental floor • Rigging services to provide add’l forklifts • Vehicles • For transport of small & fragile components • 3 vehicles assigned in Feb. 2011 • 2 add’l vehicles in 2-3 months

  10. Storage Ring Systems Installation Per Pentant • Mech. & Elec. Utilities • Personnel Protection System • Magnet/Girder Assemblies • Vacuum System • Power Supplies • Beam Instrumentation • Controls Where Applicable • RF Systems • Beam Line FEs, DWs, IDs • Injection Straight

  11. P1 Electrical & Mechanical Utilities and PPS Electrical Utilities • Cable tray installation complete • (3) Cells of equipment racks in place • UPSs in place • Starting to pull cables in mid-May Mechanical Utilities • DI water piping complete in mid-May • Pump skids installed in July • Magnet/Girder floor plates in process PPS • P1 racks installed • Human interlock interfaces installed

  12. Magnet/Girder Floor Plate Installation • Installation of magnet/girder floor plate work has begun (2 cells complete) • Process includes: • Survey • Drilling • Scarifying • Plate Installation • Grouting • Preparation for the installation of the first magnet/girder at end-May 2011

  13. Magnet/Girder Transport • Magnet/Girders will be transported to tunnel via experimental floor • Will be transported to site and unloaded via forklift • Will be pulled across experimental floor using standard dollies • Will use short & tall dolly system to transition from experimental floor to tunnel (8” difference in height) • Moved to final location using air casters

  14. Short & Tall Dolly System • Courtesy of • Lewis Doom Experimental Floor Tunnel

  15. High-Level Installation Schedule • Taken from P6 • on May 3, 2011 • Does not include subsystem testing, integrated testing and commissioning • Hatched section of SR RF schedule indicates 2nd RF Cavity

  16. SR RF Installation • Taken from P6 • on May 3, 2011 • RF Cavities moving toward critical path • 2nd Cavity may be installed during ID installation • RF Transmitter w/ klystron installed by vendor • Remaining RF systems installed by BNL

  17. Injector Installation Phases • Mechanical & Electrical Utilities • Booster RF • LtB Transport Line Part 1 • Through wall, up to vac valve in booster vault, needed to commission linac • Linac • Booster • LtB Transport Line Part 2 • TL complete, need to commission booster • BtS Transport line Part 1 • Up to beam dump, needed to commission booster

  18. Injector Installation Phases Layout Phase Separation (end of injector install) BtS TL Part 1 Booster RF Booster Linac LtB TL Part 2 Phase Separation LtB TL Part 1

  19. Linac Installation • Vendor responsible for installation • Installation plan & HASP being created • Linac to be delivered Sep. 2011 • BNL will run AC power to their racks to expedite • BNL will install shielding • BNL will need to complete LtB TL Part 1 for commissioning • Vendor will work with BNL on ARR • Ready for commissioning Dec. 2011 • Linac commissioning will overlap with booster & SR installation

  20. Booster Installation • Vendor responsible for installation using BNL technicians for all hands–on work • Technicians will perform tasks assigned by vendor • BNL will supervise technicians • Technician labor requirements & install plan being finalized • Booster to be delivered Feb. 2012 • Magnet/Girders will arrive assembled • BNL will need to complete BR RF, LtB TL and BtS TL Part 1 for commissioning • Vendor will work with BNL on ARR • Ready for commissioning Dec. 2012

  21. Injector Installation Schedule • Taken from P6 • on May 3, 2011 • Installation of Linac is approx. 3 months early • Hatched section of LtB TL Part 1 indicates diagnostics that are not needed for Linac commissioning • BtS Part 2 is not needed for Booster commissioning

  22. Challenges • Coordinating multiple activities & teams during installation • Beneficial occupancy dates close to pushing installation schedule • Maintaining component delivery schedules (i.e. magnets, RF cavity) • Adapting to delivery delays • Cleanroom in 902 for precision alignment of magnets may become bottleneck • Tight coordination with XFD installation needed to avoid conflicts with required flexibility of ASD installation schedule (hand-over delays)

  23. Summary • Accelerator installation fully underway in pentant 1 • Currently approx. 6 weeks behind schedule in pentant 1 • Planning in process for installation in RF & Injector buildings • Focus on flexibility in installation schedule based on availability of building and components • Rigging, storage & logistics plans in place • Required installation staff in place • Good communication established with CFD & XFD • Conclusion: Installation progressing very well

  24. 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. Skaritka, T. Tanabe, F. Willeke, P. Zoccoli & many others

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