Accelerator Assembly & Installation Planning

1. Accelerator Assembly & Installation Planning Gregory Fries Project Engineer, Accelerator Systems Division ASAC Review of NSLS-II October 14-15, 2010

2. 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

3. 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

4. Magnet/Girder Integration Building 902 1 Magnet measurement 2 Magnet inspection 3 Girder preassembly 4 Dipole measurement 5 Front-end test set-up 6 Environmental room Fully Functional and Equipped Environmental Room (DT < 0.1 C ) for 30 mm Precision Alignment Building 902

5. Magnet/Girder Integration Workflow In Cleanroom • 90 MP girders • 60 dipole girders

6. Magnet/Girder Precision Alignment Workflow • 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 • 2 girders /months  2 girders / week • @ 18 months (incl. learning curve effect) • Starting March, 2011  Finish Oct, 2012

7. Phasing of Construction and Installation

8. Installation and Operation Zones 1 • 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 B RF RF 2 5 L 4 3

9. 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

10. Storage Ring Systems Installation Per Pentant • Mechanical Utilities • Electrical Utilities • Magnet/Girder Assemblies • Vacuum System • Power Supplies • Beam Instrumentation • Controls Where Applicable • RF Systems • Beam Line FEs, DWs, IDs • Injection Straight

11. High-Level Installation Schedule • Installation is gross equipment location, connections, and component testing • Subsystem testing, integrated testing and commissioning will follow

12. Storage Ring Pentant 1 Installation: Week 2 22 23 24 25 26 27 Mezzanine Exp’l floor 23 25 26 27 28 24 Tunnel • Activities: • Prepare tunnel • Stage components on floor • Start cable tray on mezzanine Status: ~ 1/3 of material in building Installation starting Service Building

13. Storage Ring Pentant 1 Installation: Week 6 22 23 24 25 26 27 Mezzanine Exp’l floor 23 25 26 27 28 24 Tunnel • Activities: • Tray and manifolds in place in tunnel • Racks well underway • Stage cable and start pulling Status: Most material in building Installation on mezzanine Installation in tunnel Service Building

14. Storage Ring Pentant 1 Installation: Week 12 22 23 24 25 26 27 Mezzanine Exp’l floor 23 25 26 27 28 24 Tunnel • Activities: • Girder installation • Populating racks • Terminating cables Status: Most wiring pulled Process utilities connected Service Building

15. Storage Ring Pentant 1 Installation: Week 20 22 23 24 25 26 27 Mezzanine Exp’l floor 23 25 26 27 28 24 Tunnel • Activities: • Final utility connections • Equipment shakeout Status: All equipment in place System testing underway Service Building

16. 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

17. 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

18. Injector Installation Phases Layout Phase Separation (end of injector install) BtS TL Part 1 Booster RF Booster Linac LtB TL Part 2 Phase Separation LtB TL Part 1

19. Transport Line Magnet/Girder Integration • Preassembly in injector service building • Magnets, Girders, Vacuum, Diagnostics • Pre-alignment • Pre-test

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

21. 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

22. Lay-down Areas for Sea Containers Lay-down Area for SR Component Storage Containers Outside Access to Experimental Floor for Unloading (column 102) Lay-down Area for Linac & Booster Containers

23. Rigging Requirements

24. 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

25. 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

26. 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

27. Experimental Installation • XFD Installation follows ASD installation by pentant • Activities Per Beamline • Pentant Hand-off from ASD • Pentant Clean-up • Hutches • Utilities • Beamline Components

28. 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

29. 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

30. 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)

31. 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

32. 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