Cons Gattuso AD Shutdown Installation Manager

1. Cons Gattuso AD Shutdown Installation Manager DOE Accelerator Safety Workshop Summer Shutdown Planning September 20-22, 2016

2. Outline • Introduction to Accelerator complex • Shutdown planning and execution • Planning Timeline: • Scope of Work Prioritization • Resource Allocation • Job Planning • ALARA planning • Pre/post shutdown work • Hazard mitigation C. Gattuso | Summer Shutdown Planning

3. Fermilab Accelerator Complex Shutdown coordination covers the above along with maintenance and power outages. Second biggest accelerator complex in the world C. Gattuso | Summer Shutdown Planning

4. Accelerator Division Summer Shutdown Planning • Machine/System Coordinators • Gather work/tasks to be done for their own systems • Prioritize tasks at the machine level • Provide high level management of the work • Project/ Maintenance level C. Gattuso | Summer Shutdown Planning

5. Shutdown Planning and Execution • Planning time line • Set target dates to keep our planning on track • Work oversight • Resource allocation • Installation Strategy • Task sequencing • Radiation concerns • Beam turn on schedule • Lessons Learned from previous shutdowns • Number and type of people involved • Shutdown priorities • Defined by Laboratory Management • Projects • Accelerator Improvements • Maintience • Duration is set by highest priority task • Typical shutdown last 8-12 weeks C. Gattuso | Summer Shutdown Planning

6. Accelerator Division Summer Shutdown Planning We take the approach of “Plan your work and work your plan” at all levels C. Gattuso | Summer Shutdown Planning

7. Shutdown Gantt Chart (Resourced leveled) • Assumptions made… • Work day is 6 hours • Work week is 5 days • External help rated at 80% efficiency factor This allows us to be able to absorb some schedule creep and slippage that may occur during the shutdown. C. Gattuso | Summer Shutdown Planning

8. Installation- Work Oversight Machine Coordinator level Crew level • 8:00 Daily (Tool Box) Meeting and updates • Crew Leaders • Email messages sent the day before • Outlines up coming work (daily level) • Tool box meeting to review each day’s tasks • Review the Job • Address any resource issues • Address any ESH issues • Division wide meeting • 09:00 Meeting held 3 times per week (M/W/F) • Status updates • Schedule • ES&H • Updates • Changes • Schedule shifts • Revisions • Schedule creep C. Gattuso | Summer Shutdown Planning

9. Recycler Collimation system. • The conceptual design of the Recycler Collimation System is based on a Main Injector Collimation System design. • Recycler collimation system consist of Primary collimator, plus two Secondary collimators and Masks. LCW Recycler beam line 20 tons Mask Secondary collimator Primary collimator 3 tons MI Dipole C. Gattuso | Summer Shutdown Planning

10. Collimator example • Manpower • Mechanical Crew sizes (typically 4 techs with varied experience) • Training and experience • Iron Workers are brought in to supplement the crew • Number of people • Equipment limitation • Magnet removal/installation equipment • Specialized Lifting Equipment/Fork lift (riding)/RECO tm (walk behind Forklift)/Transportation dollies • Assembly logistics Issues • Collimator must be designed and broken down to parts/pieces of less than ~3 tons (lift capability of RECO). • Tunnel space • Heavy device that will need to be stacked above head height Design and installation sequence driven • Work sequencing for hazard mitigation • Both task and tunnel traffic levels C. Gattuso | Summer Shutdown Planning

11. Safety • Task sequencing • Other task in area • Other resources needed Planning/Design Stage of a Single Job (Collimator) Safety • Safety • Machine • Operations • Safety • Stand stability • Component size • Lift points Safety • Safety • Time sensitivity • Other tasks • with in the • area • Safety • HA (Hazard Analysis) • Equipment used • Matched skill sets Safety Safety C. Gattuso | Summer Shutdown Planning

12. Saving realization using this process • Time • 3 weeks of schedule saving • Cost • ~3K/day or ~$135K in total • Iron workers • Electricians • Pipe fitters • Related safety • Radiation dose • 2.5 mrem/hr x 6 hrs/day X12 people X 15 days = 2700 person-mrem • Injury Risk Reduced • Work smarter • Modularized installation process • Better use of equipment we have C. Gattuso | Summer Shutdown Planning

13. Shutdown Planning and Execution • Pre shutdown work Planning • Define tasks that can occur Prior to the shutdown that will not impact machine operations but take pressure off critical resources during the shutdown. • Take Advantage of planned and opportunistic access periods • Staging equipment that will be installed • Cable • Devices to be installed • Completed alignment AS-found of tunnel components • Further review jobs in the tunnel • Mitigating possible interference issue • Refining our installation plans C. Gattuso | Summer Shutdown Planning

14. ALARA PLANNING RR RF Tasked during Week 5-9 Task sequencing to minimize total dose MI/RR Beam stops RR Col. TSP 2 IP Tasked during Week 1-15 Tasked during Week 1-3 Tasked during Week 1-13 Staging area C. Gattuso | Summer Shutdown Planning

15. Example of Residual Radiation Level near 309 location 5.5 D 2.5 hrs Half lives 44.5 D 312 D *~30 days in ~100 mrem/hr and with Pb shielding ~60 mrem/hr *~40 days in ~80 mrem/hr and with Pb shielding ~45 mrem/hr *~84 days in (End of the shutdown) ~40mrem/hr and with PB shielding ~25 mrem/hr With lead shielding Days from the start of the shutdown C. Gattuso | Summer Shutdown Planning

16. Example of ALARA (As Low As Reasonably Achievable) Plan in RR RF section C. Gattuso | Summer Shutdown Planning

17. Hazard Mitigation • Tunnel Rad survey to place in supervised access mode • Switch over to the Shutdown tunnel key system • Tunnel magnet system power lock out configuration • Single lockout point set up • Set up a layered safety mitigation system • Staged work in such a fashion to minimize risk exposure • Electrical disconnection done first (completed by experts) • Power Cable removal (completed by experts) • Water system isolated • Vacuum system removal • Equipment/device removal (if needed) • Work Plan • Reviewed tasks and equipment with the crews doing the work. • Verify we have all the equipment needed and its in good working order • Verify that all of drawing and installation notes are in place • Review the installation sequence with the crews • Make correction if needed C. Gattuso | Summer Shutdown Planning

18. MI-60 Girder Fabrication • Why a Girder system • Install several components at once instead of one at a time. • Pre-wire powered elements • Quick connect plugs for power elements • Pre-align elements on girder • 6 of the 10 welds are done upstairs • Magnetic shielding was added • Preliminary leak check done upstairs C. Gattuso | Summer Shutdown Planning

19. Girder Systems Dose and Time Savings Example: Girder with 2 permanent magnets two power trims and BPM • Old installation practices • Individual stands and Magnets install • ~10 hrs • Cabling/termination/field check • ~2 hrs • Alignment welding pass • ~4 hrs • Alignment final pass • ~4 hrs • Welding • ~4 hrs • Shielding • ~4 hrs Total time ~28 hrs ~ dose rate of 10 mrem/hr Total Dose per task = ~280 person-mrem • Girder process • Install girder assembly • ~4 hrs • Cabling/termination/field check • ~.1 hrs • Alignment final pass • ~2 hrs • Welding • ~2 hrs • Shielding • ~2 hrs Total time ~10 hrs ~ dose rate of 10 mrem/hr Total Dose per task = ~100 person-mrem C. Gattuso | Summer Shutdown Planning

20. RR 30 Installation Guide line Offset Correction C. Gattuso | Summer Shutdown Planning

21. Lessons learned from the past • Cable pulls • BPM system ~600K ft. of heliax cabling ( ¼ and 3/8 in)(ANU Shutdown 2012) • Re-spooling • Individual cable runs matched to delivered reels. • Original reel lengths range from 1300 ft to 5500 ft • Pull lengths ran from 180 ft to 1500 ft • Tag location for cable destination in high rad areas to aid electricians • Cost of re-spooling vs Additional time for Pulls • With out re-spooling it will take us ~2 week per service building to complete. • ~$8K/day (4-5 person crew) i.e ~$80 K service building • With re-spooling it will take us ~1 week per service building to complete • ~$8K/day (4-5 person crew) i.e ~40 K service building • For 6 service buildings it saved $240 K minus the $50K re-spool cost. • Net savings = $190,000 • Rad dose saving of ~50% • Old method ~5700 person-mrem • New method ~2800 person-mrem 1/2 the spools for a typical building C. Gattuso | Summer Shutdown Planning

22. MI 30 Tunnel Section MI/RR Shutdown 2012 C. Gattuso | Summer Shutdown Planning

23. Shutdown 2015 ESH&Q • Shutdown Radiological Exposure • 6859 person-mrem through 14 weeks. 8,000 person-mrem anticipated before shutdown with ALARA plans. • Tunnel background exposure level accounts for ~ 600 person-mrem over the course of the shutdown • Shutdown Radiological Exposure • Tracked doses for 276 shutdown workers • 0-100 mrem 258 workers – 93.6% • 100 – 150 mrem 18 workers – 6.4% • 150 + mrem 0 workers – 0% • Achieved shutdown goal of no individual worker exceeding 150 mrem. • Shutdown related injuries • One First Aid case • Two Recordable case • One case of lost work days • One case of a person placed on limited duty C. Gattuso | Summer Shutdown Planning

24. Carry over from Shutdown to Shutdown for lessons learned • Effectiveness of Intensity reduction • Cool off periods Vs. Beam Intensity run • Labor Estimates • Resource effectiveness • Types of manpower used • Task sequencing • Pre shutdown planning and preparation • Building flexibility into the schedule • Resource Management • Trades • Technicians C. Gattuso | Summer Shutdown Planning

25. Risks to Shutdown Planning and Execution • Resources • Aging workforce • Average age of one of the MI Mechanical crews is 62 years old • Loss of expertise • Availability of manpower • Competing for resources across the laboratory • Projects being ready for installation • Additional engineering and technical staff • Tunnel activation levels • As Beam power goes up loss patterns may change • Infrastructure • Tunnel lighting • Etc. C. Gattuso | Summer Shutdown Planning

26. Thank You C. Gattuso | Summer Shutdown Planning