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Installation & Integrated Testing Status & Plans

Installation & Integrated Testing Status & Plans. Gregory Fries, ASD Project Engineer 9 th ASAC meeting for NSLS-II Project February 1-2, 2012. Outline. Phasing of Installation Storage Ring Installation Progress Injector Installation Progress Schedule & Status Labor Profile

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Installation & Integrated Testing Status & Plans

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  1. Installation & Integrated Testing Status & Plans Gregory Fries, ASD Project Engineer 9th ASAC meeting for NSLS-II Project February 1-2, 2012

  2. Outline • Phasing of Installation • Storage Ring Installation Progress • Injector Installation Progress • Schedule & Status • Labor Profile • Photon Division Installation • Integrated Testing Overview • Challenges • Summary

  3. 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

  4. Storage Ring P1 Installation Highlights • 12 multipole & 2 dipole magnet/girders installed • Cell 25 fully populated with magnets; survey & bellows installation to start with bakeout to follow • All cables pulled (excluding front ends) • Cable termination & power supply installation in process • Rack tie-in to PCW complete • AC power work complete & tested • Vacuum component installation in process • DI pump skid complete in Feb. • EPOCH 3 survey in process • PPS interlocks wiring in process • Many install resources focused on linac

  5. Storage Ring P1 Photos

  6. Storage Ring P2 & P3 Installation Highlights • Pentant 2 • AC power work complete • Racks installed; tie-in to PCW in process • Rack shelving & equipment installation in process • Cable pulling in process (Quads complete) • Floor plates installed • DI piping complete (Torcon) • Pentant 3 • Beamline AC boxes installation in process • Rack installation in process • DI piping in process (Torcon) • Pentant 4 • Cable tray installation in process (Torcon)

  7. SR RF & Computer Room Installation Highlights • RF Transmitter Installation in Process • KSUs, klystrons, waveguide, water manifolds installed • Electrical work and check out in process • PCW tie-in in process • Installation complete early Feb. followed by testing • Blockhouse AC power and PPS interlock work to start • DI piping complete & pump skid testing in process • PCW tied-in to computer room racks • Computer room powered & controls testing in process • UPSs operational

  8. Storage Ring RF Photos

  9. Linac &TL Installation Highlights • Linac installation to be complete in Feb. • Linac modulator acceptance testing in process • All LtB TL P1 magnets & vacuum chambers are installed • Cable pulling complete; cable termination in process • LtB TL P1 racks 90% wired • Dumps installed; balance of shielding being installed • Installation of diagnostics & vacuum equipment in process • Testing of PPS interlocks in process • Testing of other subsystems starting in early Feb. • DI system scheduled to be turned over mid-Feb. • Linac ARR scheduled for Feb. 27-29

  10. LtB TL Photos Dec. 7, 2011 • Jan. 11, 2012

  11. Linac & LtB TL Photos

  12. Booster Installation Highlights • DI piping installation in process (contractor) • Cable tray installation in process (BNL) • Survey & floor drilling in process • First booster delivery arrived (girder pedestals) • Second booster delivery in transit (5 magnet/girders) • Booster installation work planning in process • Planning space for staging & testing • Fabrication of girder transport fixtures to start • PPS interlock installation to start • Girder installation to start in March

  13. High-Level Installation Schedule • Taken from P6 • on Jan. 19, 2012 • Does not include subsystem testing, integrated testing and commissioning • Hatched section of SR RF schedule indicates 2nd RF Cavity

  14. SR RF Installation • Taken from P6 • Jan. 19, 2012 • 2nd Cavity may be installed during ID installation • RF Transmitter, refrigeration system & RF cavities installed by vendor • Remaining RF systems installed by BNL

  15. Injector Installation Schedule • Taken from P6 • on Jan. 19, 2012 • BtSPart 2 is not needed for Booster commissioning

  16. High-Level Installation Schedule Status • Installation is approx. 15% complete (baseline called for 43%) • Installation is currently 4 months behind schedule; end date has shifted from March ‘13 to July ‘13 • Install work and labor profile now have prolonged peak due to shifted work • Resource leveling & schedule analysis in process to determine true schedule impact of delayed work & develop plan to mitigate • Additional labor (i.e. cable pullers, electrical installers) may need to be added to keep current schedule • Schedule may soon be driven by labor and not hardware

  17. Installation Percentage Complete

  18. ASD Installation Labor Profile

  19. Photon Division Installation • Hutch installation contact established • The current schedule for hutch construction is: • Cell 23 (CSX) – Mar ’12 • Cell 28 (XPD) – May ’12 – June ‘12 • Cell 3 (HXN) – Mar ’12 – May ‘12 • Cell 5 (SRX) – July ’12 – Aug ‘12 • Cell 10 (IXS) – Sep ’12 – Oct ‘12 • Cell 11 (CHX) – Oct ‘12 – Dec ’12 • Cleared necessary space on experimental floor • Moving of utilities causing interference in process • Hutch survey in process • Working planning in process

  20. Integrated Testing Planning • Testing of the subsystems through the control system w/o beam • Will be performed by pentant or even cell • Task force leader named (G. Ganetis) • Schedule has been updated & resource loaded • Test applications are being developed for control, monitoring, long term logging, and alarming • Focusing on getting infrastructure in place to start • Integrated testing scheduled to start in April ‘12 in P1 (Cell 25)

  21. Challenges • Finding ways to makeup time in schedule • Coordinating multiple activities & teams during installation • Coordinating to avoid interferences between systems • Adapting to component delivery delays • Space for work is limited, especially in linac & booster • Spike to occur in required installation labor • Significant schedule float has been reduced • Tight coordination with PD & CFD needed to avoid conflicts • Moving material during & after hutch installation

  22. Summary • Linac & LtB TL P1 installation complete in Feb. for ARR • Installation very advanced in P1; working on completion of 1st cell • Installation progressing in P2 and starting in P3 • Focus will return to P1 (starting at cell 25) after linac installation • Preparing for the start of booster installation • Currently 4 months behind schedule • Schedule & labor analysis in process • Working with PD to prepare for the start of their installation • Integrated testing planning in process

  23. 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. T. Tanabe, G. Visnefsky, W. Wahl, F. Willeke, P. Zoccoli & many others

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