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Conventional Facilities Status

Conventional Facilities Status. Martin Fallier, Conventional Facilities Div. Director Conventional Facilities Advisory Committee Review October 5-6, 2010. Outline. Baseline Overview Scope, Cost & Schedule Organization Progress Since Last R eview Technical Progress

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Conventional Facilities Status

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  1. Conventional Facilities Status Martin Fallier, Conventional Facilities Div. Director Conventional Facilities Advisory Committee Review October 5-6, 2010

  2. Outline Baseline Overview Scope, Cost & Schedule Organization Progress Since Last Review Technical Progress Cost & Schedule Performance Risks Issues Charge Items Recommendation tracking

  3. Baseline Scope WBS 1.5 Conventional Facilities Added Scope 1.5.3.7 HXN Beamline Addition Addition to LOB 3 structure

  4. NSLS-II Site Plan N NSLS-II With Full LOB Build-Out 100 0 200

  5. Ring Bldg Overall Floor Plan LOB 1 Storage Ring & Booster Tunnel Experimental Floor Access Corridor Service Buildings LOB’s 1, 2, & 3 Base Scope Future LOB’s Earth Berm Lobby RF Injection LOB 2 LOB 5 Process Cooling Water Bldg Vehicle Tunnel LOB 4 LOB 3

  6. Ring Building Section

  7. LOB First Floor Plan • 57 One person Offices • Two people Offices • Six people Offices • Wet Laboratories • Dry Laboratories • Machine Shop • Conference Rooms • 1 Loading/Storage Area Total = 38,000 gsf Each Lab = 480 nsf

  8. LOB Exterior Perspectives LOB Roofline LOB Entry

  9. WBS 1.5 Cost Baseline 1 2,3,4 5 Major Increases or changes: Includes added CM staffing (~$0.9M) and holding place for const. safety incentive ($1M) Incorporated cost for larger LOBs after LOB award (~$9M) Incorporated post bid addendum and miscellaneous scope and field changes Incorporated HXN beamline building cost (~$1.6M) Incorporated full data and communication cost in Integrated control, comm & data

  10. CF Schedule

  11. CF Organization

  12. Technical Progress • Ring Building contract Excellent progress, maintaining status on or ahead of schedule • SR Tunnel concrete complete except opening at Pentant 5 • Opening used for interior courtyard access • Experimental Floor complete to Pentant5 • Structural steel complete except opening at P5 and Injection Bldg • Building enclosure, roofing and siding making good progress • Utility system installation nearing completion in interior of ring • Unit substations 6 of 8 are installed, last two in progress • Cooling Tower Building enclosure 95% complete, MEP underway • Mechanical, electrical, plumbing underway in P1, P2, P3, & P4 • Booster and Linac tunnel concrete nearly complete

  13. Technical Progress • Chilled Water Plant Expansion Contract Running on/ahead of schedule • CCWF, Cooling Tower and Pump-house Buildings complete • Equipment installation in all areas nearly complete • Instruments and controls installation underway • Equipment start-up and commissioning to begin in October • Electrical Substation Expansion Contract Running on schedule • Ductbank installed & 15kV switchgear installed in building • 20 MVA transformer delivered, placed & tied-in • Installation of cabling in progress • Major cable pull to NSLS-II site in October

  14. Technical Progress cont’d • Chilled Water Piping Tie-in at central main and NSLS-II site complete • Last section of pipe to be installed and tested this week • Site restoration and contract completion in October • Chilled water available for the site for start-up and commissioning • LOB Construction Contract awarded, mobilization underway • Bonds and insurance received • HASP reviewed and being revised, NTP likely within 1 week • Held Torcon/EW Howell site coordination mtg • Held kick-off and schedule planning mtgs • Submitted HXN Building addition pkg to GC’s for price proposal • Construction underway in October, complete spring of 2012

  15. One Year Ago Photo From BGRR Stack 9-21-09 Vehicle Tunnel SR Tunnel Wall Forms SR Tunnel Slab Status of construction Site at FY09 End

  16. Technical ProgressToday Photo From BGRR Stack 9-20-10 Clg Twr Bldg Booster Tunnel Roof Deck Roof Insulation Finished SSM Roof Opening @ P5 Exterior Siding Lobby Curtain-wall Opening for LOB 1 • SR tunnel and structural steel complete except P5 opening • Roof deck complete, Insulation to P5, Finished SSM Roof at P1 • P1, & 2,Cooling Twr, RF & Compressor Bldg Enclosure all underway • Utility installation ~80% complete in inner courtyard

  17. Technical Progress cont’d • SR Tunnel – Painted, Conduit , Lighting & Ductwork Installed Exterior Siding • Pentant -1 – Ductwork & Piping In Place

  18. Technical Progress cont’d • Injection Bldg Booster Ring Tunnel Vehicle Tunnel Nearly Ready For Use • RF Area Unit Substation

  19. Overall Cost and Schedule Assessment • Cost Assessment: Cumulative cost variance $+2.3M or +1.8% • On budget - CPI =1.02 • Schedule Assessment: Cumulative schedule variance $+5.9M or +4.7% • On or slightly ahead of schedule - SPI =1.05

  20. Variance Analysis • Cost Variance +$2.3M • Temporary positive cost variance due to differences in accrued vs monthly invoiced values • Actual positive cost variance ~ $400k due to miscellaneous small underruns - >91% of remaining work is under fixed price contract • This variance expected to go to zero $ as contracts are closed out • Schedule Variance +$5.6 M • Work in P1 – P5 ahead of plan for concrete, steel, enclosure and mechanical, electrical & plumbing • Work on Cooling Tower & Process Water Systems ahead of plan • Remaining contracts on or close to plan

  21. Risks • Construction Safety - program must continue to be effective • Substantial performance improvement since 9/30/09 accident • Increased number of construction safety engineers to 3, soon to be 4 • Continually working with GC to improve program • Potential for field changes, errors/omissions thru construction • Running ~ 1.5% - see following slide for breakdown of status to date • Potential for design changes from ASD & XFD • Running ~ 1.5% - see following slide for breakdown of status to date • System coordination is now complete – risk reduced • Risks of Ring Bldg GC and LOB GC conflicts • Effective plan and requirements for coexisting on the site

  22. Ring Bldg Contract Change status • As of 9/30/10 will have completed $101M work – 57% • Changes due to approved scope changes or design maturity • $1.58M to date or ~1.5% of work to date • Weekly interface mtgs effective at identifying changes early • Changes due to design errors & omissions • $1.56M to date or ~1.5% of work to date • This includes projected estimate of changes not yet agreed upon • Changes due to existing conditions • Very low at just $130k – no more of these changes likely • Weekly mtg w/GC to expedite resolution of changes

  23. Issues • Continued focus on contractor safety performance is essential • Need to maintain close oversight of detailed contractor schedule activities needed to achieve BORE’s • Engineering staff heavily loaded • Process of resolving and implementing contract changes is labor intensive • Possible added scope from ASD & XFD will add to load • Engineering involvement required for start-up and commissioning Mitigating factors • LOB document submittal/review phase starting up as Ring bldg winds down • Workload should ease soon as CHW and Electric Utility pkgs are completed

  24. Conclusions • CF activities are on budget and on or ahead of schedule • Contractor safety program has improved substantially • Applying lessons learned to LOB safety program • Construction proceeding well • CHW& elect substation winding down – move focus to LOB • LOB mobilization underway and progressing well • Getting ready for equipment start-up and commissioning • On track for 1stRing Bldg beneficial occupancy 2/11 & Ring Bldg construction completion 4/12

  25. Charge Items • Are Conventional Facilities Division’s plans &performance consistent with achieving project cost, schedule, and technical objectives • Covered in multiple status presentations • Are the plans and measures to assure construction worker safety appropriate and effective at minimizing potential for worker injury? • See Ken Krasner Presentation on Construction safety • Are the proper plans, measures and resources in place for effectively managing the coexistence of the Ring Building and LOB contractors on the same construction site? • See Mike Bromfield Presentation on LOB and Ring Bldg GC Coexistance • Are the plans and measures to assume beneficial occupancy of the facilities sufficient to enable orderly installation of accelerator systems and eventual transition to operations? • Covered in multiple presentations on BORE, ASD Installation & Ops planning

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