NSLS-II Accelerator Installation Plan

1 BROOKHAVEN SCIENCE ASSOCIATES

NSLS-II Accelerator Installation Plan

Gregory FriesProject Engineer, Accelerator Systems Division

CFAC Review of NSLS-IIOctober 5-6, 2010


Outline

• Phasing of Installation• Coordination with Conventional Facilities• Storage Ring Installation• Injector Installation• Storage and Rigging• Installation Schedule• Experimental Installation• Potential Obstacles• Summary


Phasing of Construction and Installation

Description SR Column BODCCW CW

Pentant 1, Cooling tower, Vehicle tunnel Utility tunnel

100 21 1-Feb-11

RF Building - - 23-Mar-11Injection building - - 18-May-11Pentant 2 21 37 2-Jun-11Pentant 3 37 60 27-Sep-11Pentant 4 60 83 28-Nov-11Pentant 5 83 100 9-Feb-12

Beneficial Occupancy

BOD Installation Activities TechnicalInst'l Cmp

1-Feb-11 Storage Ring Components 20-Jun-11

Storage Ring RF cavities 21-Sep-1223-Mar-11 RF Power Systems 29-Mar-1218-May-11 Booster RF Cavity 21-Jun-11

Linac 18-Oct-11Booster 8-Jun-12

2-Jun-11 Storage Ring Components 20-Oct-1127-Sep-11 Storage Ring Components 14-Feb-1228-Nov-11 Storage Ring Components 16-Apr-129-Feb-12 Storage Ring Components 28-Jun-12

Installation


Installation and Operation Zones

Key Points:• Utilities and infrastructure

are segmented as shown• BOD handovers aligned

with support infrastructure• 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 (O. Dyling)• ASD reviewing all CFD ECNs for impact• ASD installation coordinator named


Key Aspects of Production and InstallationAccelerator 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• 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


Storage Ring Systems InstallationPer Pentant• Mechanical Utilities • Electrical Utilities• Magnet/Girder Assemblies• RF Systems• Vacuum System• Power Supplies• Beam Instrumentation• Beam Line FEs, DWs, IDs

(where applicable)• Injection Straight


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:About 2/3 vacuum complete

26

Activities:• Girder installation• Cable pulls all done• Testing underway


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

LinacBooster

LtB TL Part 1Phase Separation

BtS TL Part 1

Booster RF

Phase Separation (end of injector install)

LtB TL Part 2


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


Rigging RequirementsItem Qty. UOM Date Hours

(team)Total

Hours(team)

Weight(lbs)

Total Weight(lbs) Dimensions From To Comments

RF Group

SR Transmitter 1 EA Jun-11 8 8 5,000 5,000 6 x 2 x 2.3mtentative Truck RF Building

SR Transmitter 1 EA TBD 8 8 5,000 5,000 6 x 2 x 2.3mtentative Truck 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 Truck RF Straight in Tunnel Installed 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 Truck RF 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 Truck Tunnel Mezzanine at RF

Verify 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 Tunnel As 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

Jul-1

0

Sep-1

0

Nov-1

0

Jan-

11

Mar-1

1

May-1

1Ju

l-11

Sep-1

1

Nov-1

1

Jan-

12

Mar-1

2

May-1

2Ju

l-12

Sep-1

2

Nov-1

20

5

10

15

20

25

30

35

40

45

Rigging Team Days Needed Per Month For Installation

Series1

Rig

ging

Tea

m D

ays

Nee

ded


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, Testing & Commissioning Schedule


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


Potential Obstacles

• Coordinating multiple activities/teams/access during installation

• Maintaining component delivery schedules• 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

• 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• Conclusion: Installation Planning is very advanced

Documents

NSLS-II Accelerator Installation Plan