1 BROOKHAVEN SCIENCE ASSOCIATES Conventional Facilities Update Marty Fallier Director for Conventional Facilities NSLS-II PAC Meeting May 24, 2007

1 BROOKHAVEN SCIENCE ASSOCIATES

Conventional Facilities Update

Marty FallierDirector for Conventional Facilities

NSLS-II PAC MeetingMay 24, 2007


Outline

• Current CF Scope• CF Issues

• CR impacts• Vibration Management• Lab Support

• Organization• Schedule • Cost• Risks• Path Forward


CF Technical Performance Goals

• Structurally stable facility with low vibration (<25nm Rms)• Tunnel design that provides required shielding and accessibility• Tunnel temperature stability of +/- 0.1 deg C• Utility capacity for up to 3.6 GeV operation• Utility services & expansion capability to support full beamline build-out• Facility layout enabling future long beamlines• Experimental Floor noise level <NC60• Design for LEED Certification to meet sustainability requirements (DOE

likely to require LEED Gold Rating)


NSLS

LOB Typ 4

1 in Base Scoope, 3 Future

RF-LINAC AREA

Service Bldg Typ 4

CFN

Ring Bldg

Future JPsi

Future Guest House

Future Conf. Center

UnderpassLoading

CLOB

Scope at Previous Review


Current NSLS II Facility Overview

Access Tunnel

LOB (1 of 3)JPSINSLS

CFN

BLOC

NSLS II

Service Bldgs (1 of 5)

CHW Plant

Bldg 603 Substation

Future LOB’s


NSLS II Facility Overview cont’dNSLS II Floor Plan

1.BLOC – Booster/LINAC/ Operations Center

2.LOB – Lab Office Buildings (3 base scope up to 5 future)

3.Service Buildings (5)

4.RF Area

5.Tunnel Area

6.Electrical Mezzanine

7.Experimental Floor

8.Access Corridor

1

4

3

2

2

2

2

23

3

3

3


NSLS II Facility Overview cont’d

Access Corridor

Lab-Office Bldg

SR Tunnel

Experimental Floor

Service Bldg 1st Floor

(earlier concept)

7

5

8

6Electrical Mezzanine

(above tunnel)


Compact Booster 1st Floor Plan

Operations Center Entry Lobby

Linac Injection to Booster

Booster Injection to Storage Ring


Compact Booster 2nd Floor Plan

Operations Center Viewing Gallery and Bridge to Control Room Area

Linac Klystrons

Booster RF, Magnet Power Supplies, Cooling Systems and HVAC Service Areal

Control Room Area


Revised LOB Program

• The 2 LOB’s (1 integrated in CLOB, the other standalone) in CDR were insufficient to support full beamline buildout• Intended to support initial suite of beamlines (~10)• Would require substantial additional construction to support future beamlines (at least 3

more larger LOB’s plus expansion of original LOBs)• Revised plan will provide 3 larger LOB’s to support more rapid build out of

beamlines and transfer of NSLS beamlines

Each LOB Total Each LOB TotalNo. LOB's 2 3Offices 30 60 72 216Labs 5 10 6 18GSF 11,000 22000 21000 63000Direct Cost $3.3 M $6.6M* $6.3 M $18.9 MTPC Cost $5.0 M $10.0M* $10.5 M $31.6 M

* Cost of 1 LOB included in CLOB

LOB ProgramCDR Program Current Program


Facility Program

Base Scope Full Build-Out Base Scope Full Build-OutGSF GSF GSF GSF

Ring Building 242,000 242,000 242,000 242,000 No ChangeService Buildings 32,000 32,000 32,000 32,000 No ChangeLINAC/RF Area 21,000 21,000 21,000 21,000 No Change

55,000 55,000 Deleted Deleted Staff not directly required for NSLS II operation moved to other bldgs

NA NA 24,000 24,000 Only supports staff directly required for operation (9ksf) & includes compact booster (15ksf)

11,000 44,000 63,000 105,000

Changed to 3 @21,000 gsf ea. from 1 @11,000 gsf in CDR. CDR also had 11,000 gsf equivalent LOB space in CLOB

Conference Center NA 15,000 NA NA Deleted

Total GSF 361,000 409,000 382,000 424,000

Lab Office Buildings

Building /Area/Function

Central Lab/Office Bldg (CLOB) [Replaced by smaller Operations Center]

Booster, LINAC & Operations Center (BLOC) Building [Replaces CLOB]

Comments

CDR Program Current Program


Conventional Facilities Issues

• Reliance on NSLS lab/office space• Reliance on BNL to;

• Complete replacement of Warehousing area• Share in expansion of Central Chilled Water Plant

• Impacts of continuing resolution on design schedule• How to support future upgrade paths

• Extra long beamlines• Super long straights

• Cost vs Beam Stability Goals


BNL Support

• Warehouse Demolition & Replacement– Must remove Bldgs 86, 100, 210, 211, and 481 before FY 09– Warehouse facility replacement is underway as GPP project– Demolition planned for Spring FY08

• Chilled Water Plant Expansion– NSLS II and Lab must share expansion cost as both need added

capacity– A/E selected and ready to begin design– Lab planning $4.9 M GPP/IGPP project– Design to run concurrent with NSLS II ACD, T-I and T-II– Construction start in FY09 and complete early FY11.


Existing Site Building 603

CCWF

Bldg 100

Bldg 209

Bldg 86

Bldg 210

Bldg 481

Bldg 211


Continuing Resolution Impacts

• Prior Schedule had CD-1 in February, now likely in June• Result - Funding for T-I delayed and limited• Goal – minimize schedule impacts• Approach

• Establish basic ordering agreement contract with selected A/E [HDR]• Issue tasks for Advance Conceptual Design (ACD) to progress investigation

of design concepts and alternatives• Revised T-I A/E scope to address specific T-I deliverables

• Result – maintained overall schedule goal of readiness for CD-2 in 1st Qtr FY08• Lehman review and EIR scheduled for early November


CF Program for Vibration Management

• Assessment of “green-field” conditions• Active participation in Beam Stability Task Force• Identification and mitigation of cultural sources (where feasible)

• FE Modeling of site and facility design• Needed to understand & predict facility response • Design optimization tool

• Analysis of other facilities (CFN, APS & SPring 8 thus far)• Draw upon lessons learned• Provide input for model • Model performance verification

• During & after construction, implement monitoring and maintenance program


Conventional Facilities Organization

Conventional FacilitiesDirector

M. Fallier

Design A/E T-I, I, IIIHDR

Giffels [C]

Asst. Director CF Design Management

O. Dyling

Commissioning ContractorTBD [C]

PE Trade Shop Support – Various

[M]

Subconsultants Vita-tech

Colin -Gordon VJ Assoc.[C]

Construction Management PM

Agent CM – TBD [C]

I C & C Project Manager

TBD

Civil Construction Project Manager

TBD

Building Project Manager

TBD

Chilled Water Project Manager

TBD

[M] – Matrixed

[C] - Contracted

Asst. Director CF Construction Management

TBD

ESH Manager R. Casey•Design Review•Industrial Hygiene •Health Physics •Construction Safety

Project Support • Procurement• Project Controls• Document Mgt• Human Resources• Information Management

NSLS II Project Director

S. Dierker

CF Advisory CommitteeJ. Hands, Chair

Construction Analysts [C]

Project Schedulers[C]

Field Inspectors[C]

Cost Estimators[C]

ASD & XFD Technical Interface Managers

ASD - E. Johnson, EFD- L. Micelli

Site Prep Contractor[C]

Building Contractor

[C]

CHW Contractor[C]Construction Safety

Specialists [C]

IC&C Contractor[C]

Project ArchitectT. McEvaddy [M]

Mech. EngineerG. Leskody [M]

Civil/Struct. Engr.T. Joos [M]

Elect. EngineerD. Danseglio [M]

Sr Mech. Engr.C. Channing [M]

ECS Design Supervisor J. Mills [M]

QA Manager C. Porretto


CF Schedule (CDR funding profile)

Title I Design

CD-2

Title II Design

CD-3

Site Prep. Const.

Ring Bldg Bid & Award

1st Pentant RFE (Pentant 1)

2nd Pentant RFE (Pentant 5)

3rd Pentant RFE (Pentant 2)

4th Pentant RFE (Pentant 3)

5th Pentant RFE (Pentant 4)

Booster/LINAC/Ops Ctr (BLOC)

Lab/Office Bldg’s (LOB’s)

CHW Plant Expansion

Mech & Elect Utilities

Integrated Ctrl & Comm.

Standard Equipment

Commissioning

Activity FY07 FY08 FY09 FY010 FY11 FY12 FY13

Begin Accelerator Installation

Full Ring Bldg Available for Accelerator & Beamline Installation

Control Room RFE

LOB’s Complete

BO for all CF Construction


Site Preparation

• Site Preparation package at start of FY09 would head-off some schedule risk

• Likely scope to include • Clearing trees and brush• Rerouting of utilities• Removal of old foundations and abandoned utilities• Grading to cut the site and verify subsoil conditions


Cost EstimateCost Change Revised CD-1

Direct $Conventional Facilities Management 1.5.1 6,619,000 6,619,000 No ChangeConventional Facilities Engineering and Design 1.5.2 16,610,000 16,610,000 No ChangeConventional Facilities Construction 1.5.3 140,594,000 148,740,000 Sum

CF Construction Management 1.5.3.1 4,830,000 4,830,000 Increased with scope changesImprovements to Land 1.5.3.2 7,416,000 7,416,000 No change

1.5.3.3 17,516,000 (6,500,000) 11,016,000

Replaced CLOB with Smaller Ops Center - went from 53 ksf to 9 ksf, added compact booster tunnel and equipment area(15ksf)

Ring Building 1.5.3.4 80,246,000 (954,000) 79,292,000 Revised shield wall to reduce HD concrete. Added ratchet wall shield doors.

Lab - Office Building 1.5.3.5 3,296,000 15,600,000 18,896,000

Increased number and size of LOB's, now have 3@ 72 person ea. instead of "two" @ 30 person ea. (1 LOB in CLOB)

Mechanical Utilities 1.5.3.6 7,729,000 7,729,000 No ChangeElectrical Utilities 1.5.3.7 10,750,000 10,750,000 No ChangeCryogenic Utilities 1.5.3.8 1,100,000 1,100,000 No ChangeChilled Water Utilities 1.5.3.9 7,711,000 7,711,000 No Change

Integrated Controls and Communications 1.5.4 616,000 616,000 No Change

Standard Equipment 1.5.5 1,600,000 1,600,000 No change, # of ofcs roughly same (220 CDR vs 222)

Commissioning 1.5.6 900,000 900,000 No Change166,939,000 - 175,085,000

Costs are Direct FY06 $ CDR Current

Booster-Linac-Operations Center (BLOC) formerly CLOB

Comments1.5Conventional FacilitiesDirect CDR

Total FY 2006


Risk Assessment

• Technical Risk• Primarily building stability, vibration & temperature control

• Schedule Risks• Title I & II Engineering are on the critical path• Construction of Ring Building is critical path

• Cost Risks• Technical and schedule risks can impact costs• Construction and material markets are still volatile

• Risk registry has been prepared • Risk assessment database integrated with cost estimate

database • Current Contingency allocated for Conventional Facilities ~ 40%


CF Path Forward

• Continue driving ACD process to finalize concepts for T-I• Freeze accelerator lattice design – Ring bldg footprint

• Confirm program requirements

• Confirm siteplan and geotechnical suitability

• Continue benchmarking study of other LS facilities

• Continue focused technical studies (vibration, thermal modeling)

• Expedite award of A/E T-I contract when CD-I is received

• Execute T-I design plan

• Expedite agent CM award for T-I, T-II support services

• Prepare supporting documents for CD-2

Documents

1 BROOKHAVEN SCIENCE ASSOCIATES Conventional Facilities Update Marty Fallier Director for Conventional Facilities NSLS-II PAC Meeting May 24, 2007