Conventional Facilities Status

1 BROOKHAVEN SCIENCE ASSOCIATES

Conventional Facilities Status

Martin Fallier, Conventional Facilities Div. DirectorConventional Facilities Advisory Committee Review

October 5-6, 2010


Outline• Baseline Overview

• Scope, Cost & Schedule

• Organization• Progress Since Last Review

• Technical Progress• Cost & Schedule Performance

• Risks• Issues • Charge Items• Recommendation tracking


Baseline Scope

Description

1.5.1 Conventional Facilities Management CF Engineering & Construction Management Team1.5.2 Conventional Facilities Engineering & Design A/E Design, CM Estimating and BNL Design Support1.5.3 Conventional Facilities Construction All CF Construction Packages

1.5.3.1 Site Preparation Preparation of site for construction1.5.3.2 Ring Building Ring Bldg and supporting service and utility buildings1.5.3.2 Electrical Substation Expand BNL Substation by 20MVA for NSLS-II1.5.3.4 Chilled Water Plant Expand BNL Chilled Water Plant by 2500 tons for NSLS-II1.5.3.5 Chilled Water Piping CHW connecting piping from NSLS-II to BNL CHW main1.5.3.6 Lab-Office Buildings (LOBs) 2 fully fitted out and one shelled Lab & Office Bldg

1.5.4 Integrated Controls & Communications Control, communication and data infrastructure1.5.5 Standard Equipment Building furnishings and equipment1.5.6 Conventional Facilities Commissioning Start-up and testing service contract

WBS

WBS 1.5 Conventional Facilities

Added Scope 1.5.3.7 HXN Beamline Addition Addition to LOB 3 structure


NSLS-II Site Plan

N

0 100 200

NSLS-II With Full LOB Build-Out


Ring Bldg Overall Floor PlanStorage Ring & Booster TunnelExperimental FloorAccess CorridorService BuildingsLOB’s 1, 2, & 3 Base ScopeFuture LOB’sEarth Berm

RFInjection

LobbyLOB 1

Vehicle Tunnel

LOB

5

LOB 4LOB 3

LOB 2

Process Cooling Water Bldg


Ring Building Section


57 One person Offices6 Two people Offices7 Six people Offices3 Wet Laboratories7 Dry Laboratories8 Machine Shop9 Conference Rooms1 Loading/Storage Area

LOB First Floor Plan

Total = 38,000 gsf

Each Lab = 480 nsf


LOB Exterior Perspectives

LOB Entry

LOB Roofline


WBS 1.5 Cost BaselineWBS

BaselineLast CFAC (Nov‘09)

Current Baseline

($K)Change

($K)

1.5.1 Conventional Facilities Management 14,187 16,100 1,913

1.5.2 Conventional Facilities Engineering & Design 22,563 22,741 178

1.5.3 Conventional Facilities Construction 217,415 230,705 13,290

1.5.4 Integrated Controls, Communication & Data 561 1,256 695

1.5.5 Standard Equipment 1,026 1,026 0

1.5.6 Conventional Facilities Commissioning 578 578 0

Grand Totals 256,330 272,406 16,076

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

1

2,3,45


CF Schedule WBS

CD-3 Approve Start of Construction Jan 09

Detailed Design CompleteBegin Detailed Design Issue RFP

Dec 07 Sept 08 Award Ring Bldg Contract Award LOBs Bore Pentant 1 Ring Building Complete CF CompleteFeb 09 Sept 10 Feb 11 April 12 June 12 LOB Complete

1.5.1 Design Phase ManagementCF Management Construction Phase Management

Close Out

Ring Bldg Detailed Design LOB Detailed Design

1.5.2Contractor Outreach/Prep RFP Prepare CF Bid Packages

Design Prepare LOB RFP&

Procurement Bid & Award Ring Bldg Contract Bid & Award CF Const. Pkgs & LOBs

Site Prep

1.5.3 Ring Building ASD Installation

Construction Elect. Substation Expansion

Packages CHW Plant

CHW Piping

LOB's

1.5.4 Integ. Ctrls & Comm. Integrated Controls & Communications

1.5.5 Standard Equipment Std Equip

1.5.6 Commissioning Ring Bldg & LOB Cx

Legend Actual Completed Planned Level 0 Control Schedule Critical Milestone Milestone Contingency Path

FY13FY08 FY09 FY10 FY11 FY12


CF Organization


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 Pentant 5– 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


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 ContractRunning 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


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 ConstructionContract 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


One Year Ago

Photo From BGRR Stack 9-21-09Vehicle Tunnel

SR Tunnel Wall FormsSR Tunnel Slab

Status of construction Site at FY09 End


Technical ProgressTodayPhoto From BGRR Stack 9-20-10

Opening @ P5

Booster Tunnel Roof DeckRoof Insulation

Exterior Siding

• 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

Lobby Curtain-wall

Clg Twr Bldg

Finished SSM Roof

Opening for LOB 1


Technical Progress cont’d

Exterior Siding

Pentant -1 – Ductwork & Piping In Place

SR Tunnel – Painted, Conduit , Lighting & Ductwork Installed


Technical Progress cont’d

Vehicle Tunnel Nearly Ready For Use

Injection Bldg Booster Ring Tunnel

RF Area Unit Substation


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


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


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


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


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


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 1st Ring Bldg beneficial occupancy 2/11 & Ring

Bldg construction completion 4/12


Charge Items1. Are Conventional Facilities Division’s plans & performance consistent

with achieving project cost, schedule, and technical objectives• Covered in multiple status presentations

2. 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 3. 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 Coexistance4. 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

Documents

Conventional Facilities Status