Accelerator Assembly & Installation Planning

1 BROOKHAVEN SCIENCE ASSOCIATES

Accelerator Assembly & Installation Planning

Gregory FriesProject Engineer, Accelerator Systems Division

ASAC Review of NSLS-IIOctober 14-15, 2010


Outline

• Storage Ring Magnet/Girder Integration• Phasing of Installation• Coordination with Conventional Facilities• Storage Ring Installation• Injector Installation• Storage and Rigging• Experimental Installation• Magnetic Measurement Lab• Labor Profile• Challenges• Summary


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/ BNL oversight


Magnet/Girder Integration

1 Magnet measurement2 Magnet inspection3 Girder preassembly4 Dipole measurement5 Front-end test set-up6 Environmental room

Building 902

Building 902

Fully Functional and Equipped Environmental Room (T < 0.1 C ) for 30 m Precision Alignment

Fully Functional and Equipped Environmental Room (T < 0.1 C ) for 30 m Precision Alignment


Magnet/Girder Integration WorkflowIn Cleanroom

• 90 MP girders• 60 dipole girders


Magnet/Girder Precision Alignment Workflow

2 girders /months 2 girders / week

@ 18 months (incl. learning curve effect)

Starting March, 2011 Finish Oct, 2012

• Will be learning curve• In beginning, 2nd

survey will occur

• Workflow flexible based on component availability

• Prec. Alignment without all magnets

• Final magnets installed in tunnel

• Pre-assemble and store partially completed girders


Phasing of Construction and InstallationBeneficial Occupancy

Area DatePentant 1, Cooling Tower, Vehicle & Utility Tunnels

1-Feb-11

RF Building 23-Mar-11Injector Building 18-May-11Pentant 2 2-Jun-11Pentant 3 27-Sep-11Pentant 4 28-Nov-11Pentant 5 9-Feb-12


Installation and Operation Zones

Key Points:

• Utilities and infrastructure are segmented as shown by pentant

• Temp walls constructed separating BOD segments

• Installation and testing within these segments

• Linac/Booster test/commission may overlap with construction activities

1

2

B

L

34

5

RFRF


Coordination with Conventional Facilities

• Lay-down area for storage containers outside of building• Beneficial occupancy conditions for installation• Systematic hand-off of completed building zones

• BNL BORE process to be used for occupancy permits• Access to space with beneficial occupancy for installation

while construction continues• Interaction of installation activity with LOB construction to

avoid potential interference• CFD represented in ASD installation meetings• ASD reviewing all CFD ECNs for impact


Storage Ring Systems Installation

Per Pentant• Mechanical Utilities • Electrical Utilities• Magnet/Girder Assemblies• Vacuum System• Power Supplies• Beam Instrumentation• ControlsWhere Applicable• RF Systems• Beam Line FEs, DWs, IDs• Injection Straight


High-Level Installation Schedule

Accelerator Installation2011 2012

J F M A M J J A S O N D J F M A M J J A

Phase 1 - Pentant 1

Phase 2 - SR RF

Phase 3 - Injector

Phase 3 - Pentant 2

Phase 4 - Pentant 3

Phase 5 - Pentant 4

Phase 7 - Pentant 5

• Installation is gross equipment location, connections, and component testing• Subsystem testing, integrated testing and commissioning will follow


Storage Ring Pentant 1 Installation: Week

24 25 27 2823

Exp’l floor

Tunnel

Service Building

24 25 26 2722

Mezzanine

23

Status:~ 1/3 of material in buildingInstallation starting

26

Activities:•Prepare tunnel•Stage components on floor•Start cable tray on mezzanine

2


Storage Ring Pentant 1 Installation: Week 6

24 25 27 2823

Exp’l floor

Tunnel

Service Building

24 25 26 2722

Mezzanine

23

Status:Most material in buildingInstallation on mezzanineInstallation in tunnel

26

Activities:•Tray and manifolds in place in tunnel•Racks well underway•Stage cable and start pulling



24 25 27 2823

Exp’l floor

Tunnel

Service Building

24 25 26 2722

Mezzanine

23

Status:Most wiring pulledProcess utilities connected

26

Activities:•Girder installation•Populating racks•Terminating cables



24 25 27 2823

Exp’l floor

Tunnel

Service Building

24 25 26 2722

Mezzanine

23

Status:All equipment in placeSystem testing underway

26

Activities:• Final utility connections• Equipment shakeout


SR RF Installation

• BOD date for RF building – Mar 23, 2011• All systems delivered directly to RF building• RF Transmitter w/ klystron installed by vendor• Remaining RF systems installed by BNL

SR RF Installation2011 2012 2013

J F M A M J J A S O N D J F M A M J J A S O N D J F M A

Mech & Elect Utilities

Cabling, Wiring, Piping

RF Transmitter

Liquid Nitrogen System

Valve Box & Piping

Refrigeration System

RF Cavity


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


Injector Installation Phases Layout

BtS TL Part 1

Booster

LtB TL Part 2Linac

LtB TL Part 1Phase Separation

Booster RF

Phase Separation (end of injector install)


Transport Line Magnet/Girder Integration

• Preassembly in injector service building

• Magnets, Girders, Vacuum, Diagnostics

• Pre-alignment• Pre-test


Injector Installation Schedule

Injector Installation2011 2012

J F M A M J J A S O N D J F M A M J J

Utilities - Mech & Elec

Phase 1 - Booster RF

Phase 2 - LtB TL Part 1

Phase 3 - Linac

Phase 4 - Booster

Phase 5 - LtB TL Part 2

Phase 6 - BtS Part 1

• Booster RF split into two phases: BR RF cavity & BR RF transmitter• BtS Part 2 is considered part of SR installation


Component Storage & Staging

• Reviewing storage requirements for each ASD group• Finalizing number of sea containers needed at site for storage

• Approx. 10-15 - 8 ft x 8 ft x 40 ft containers• Experimental floor will be used for staging

• Temporary cages may be installed


Lay-down Areas for Sea ContainersLay-down Area for SR Component Storage Containers

Lay-down Area for Linac & Booster Containers

Outside Access to Experimental Floor for Unloading(column 102)


Rigging Requirements

Item Qty. UOM DateHours (team)

TotalHours(team)

Weight(lbs)

Total Weight(lbs)

Dimensions From To Comments

RF Group

SR Transmitter 1 EA Jun-11 8 8 5,000 5,0006 x 2 x 2.3m

tentativeTruck RF Building

SR Transmitter 1 EA TBD 8 8 5,000 5,0006 x 2 x 2.3m

tentativeTruck RF Building

SR Transmitter Transformer 1 EA Jun-11 2 2 5,500 5,500 Truck RF Building Installed separately

SR Transmitter Transformer 1 EA TBD 2 2 5,500 5,500 Truck RF Building Installed separately

SR Klystron 1 EA Jun-11 4 4 2,750 2,750 Truck RF Building Horizontal-to-Vertical

SR Klystron 1 EA TBD 4 4 2,750 2,750 Truck RF Building Horizontal-to-Vertical

SR Cavity 1 EA Aug-12 16 16 10,000 10,000 TruckRF Straight in

TunnelInstalled in 20cm trench

SR Cavity 1 EA Nov-12 2 2 10,000 10,000 Truck 832 Installed in 20cm trench

Cold Box 1 EA Nov-11 8 8 5,600 5,600 TruckRF Building - Cryo

Mezzanine

Requires special forklift to 20', unit for rent identified by Bob Sikora

Dewar 1 EA Nov-11 4 4 3,800 3,800 `RF Building - Cryo

Mezzanine

Valve Box 2 EA Nov-11 6 12 3,300 6,600 TruckTunnel Mezzanine at

RFVerify difficulty to get on mezzanine

Booster Transmitter 1 EA Dec-11 8 8 5,000 5,000 Truck Injector RF Building

Booster Cavity 1 EA Dec-11 4 4 2,200 2,200 832 Booster TunnelAs soon as tunnel is available; preceeds transmitter


Rigging Summary & Status

• Reviewed requirements with the riggers• Will have two dedicated 3-man rigging teams• ASD installation coordinator will be contact to riggers• Rigging requirements will continue to be detailed


Component Transport

• Forklift has been ordered• 10,000 lbs. capacity• 208” max lift to reach mezzanine from

experimental floor

• Dolly system will be used for magnet/girder assembly transport


Installation Schedule

• Installation schedule currently being reviewed with each CAM and expanded for completeness, durations and logic

• Emphasis will be placed on installation schedule flexibility based on building and component availability


Experimental Installation

XFD Installation follows ASD installation by pentant

Activities Per Beamline• Pentant Hand-off from ASD• Pentant Clean-up• Hutches• Utilities• Beamline Components


Magnetic Measurement Lab

• 46’ x 25’ environmental room for ID measurement

• Located in building 832• 95% Complete• BORE scheduled for Oct. 18,

2010• Measurement equipment to

start arriving in Nov. 2010• No safety incidents during

construction


Installation Labor Profiles

• Installation ramps up midway through FY 11

• Peak effort is 108 FTE• ASD significant effort by term

technicians and contract labor• XFD extensive use of

installation labor provided by suppliers

• Note that this is project labor only; does not include additional beamlines or beamline transfer

0

20

40

60

80

100

120

FY11 FY12 FY13 FY14

Experimental

Accelerator

0

20

40

60

80

100

120

FY11 FY12 FY13 FY14

Assigned labor

Technician

Engineer

Scientist / Mgr


Challenges

• Coordinating multiple activities/teams/access during installation• Maintaining component delivery schedules• Adapting to delivery delays• Will epoxy floor installation on experimental floor impact ASD

installation schedule?• XFD installation needs might conflict with required flexibility of ASD

installation schedule (hand-over delays)


Summary

• Magnet/Girder integration plan well defined• Installation schedule in process of being expanded and re-

evaluated• Focus on flexibility in installation schedule based on availability of

building and components• Building to be available for start of ASD installation Feb ‘11• Detailing installation logistics • Rigging and storage requirements in process• Good communication established with CFD & XFD• Required labor profile in place• Conclusion: Installation Planning is very advanced


Acknowledgements

A. Broadbent, L. Doom, O. Dyling, R. Fliller, G. Ganetis, E. Golnar, D. Hatton, H. Hseuh, E. Johnson, J. O’Malley, J. Rose, T.

Shaftan, S. Sharma, O. Singh, J. Skaritka, T. Tanabe, F. Willeke

Documents

Accelerator Assembly & Installation Planning