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Installation Global System . F. Asiri W. Bialowons, T. Shidara Acknowledgment: F. Peters, M. Munro, J. Kim G. Aarons, C. Corvin, P. Rodriguez. Installation Effort. Content Introduction Overview Scope Methodology Example – Installation of Main Linac Components

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Installation global system

Installation Global System

F. Asiri

W. Bialowons, T. Shidara


F. Peters, M. Munro, J. Kim

G. Aarons, C. Corvin, P. Rodriguez

Global Design Effort

Installation effort
Installation Effort

  • Content

    • Introduction

      • Overview

    • Scope

    • Methodology

      • Example – Installation of Main Linac Components

    • RDR Installation Cost Estimate

    • First-Cut Schedule

    • Future Plan

      • Toward EDR

Global Design Effort


  • Installation activities covers a large geographical area

    • approximately 31 linear kilometers long which includes a complex network of about 72 km of underground tunnels at the depth of approximately 100m

  • Requires the installation of

    • ~2,000 cryomodules, over 13,000 magnets and approximately 650 high level RF stations

Global Design Effort

Scope of installation
Scope of Installation

  • Covers all activities required to:

    • prepare, coordinate, integrate, and execute a detailed plan for the complete installation of the ILC Technical Systems Components as well as associated site-wide logistics

  • Includes all labor, materials and equipment required to;

    • receive, transport, situate, affix, accurately position, interconnect, integrate, and checkout all components and hardware from a central storage or subassembly facility to its operational location within the Beam and Service tunnels

  • Does not include:

    • fabrication, assembly, component quality control and commissioning.

  • Elements of the installation system

    • Range from complex subassemblies to single items

    • Highest stage of pre-assembly prior to installation

    • Components are to be bundled into installation kits, which include all supports and hardware required to affix and interconnect the components in their operational

Global Design Effort

Methodology assumption
Methodology- Assumption

Installation time frame:

Project management




Project engineering




Cryomodule handling & shipping




Cryomodule underground installation





Working days per year



Number of Main Linac Cryomodules

Installation rate: Three Cryomodules per day *

* 556 days @ max rate of Cryomodule installation, plus learning curve and interrupts.

Global Design Effort

Benchmarked cryomodule example
Benchmarked Cryomodule-Example


  • One ML section and associated services tunnel completely ready for joint occupancy

  • One large and two small access shafts available during installation

  • ML installation periode of three years plus 1/2 year ramp up time

  • At least one installation zone occupied at a time, more zones as become available

  • Installation rate: One Cryomodule unit & associated services / day

Cost variables:

  • Number and size of equipment...

  • Distances to installation location and speed of transportation...

  • Man-hour estimates based on todays knowlege or general experience...

  • Number of staff in each team needed per activity/function

  • Labor productivity ~ 75 %, 6 Hours of productivity per shift, due to transport distances and dificulty in handling

Global Design Effort

Cryomodule installation example 9 8 9 cavity configuration
Cryomodule Installation- Example 9-8-9 Cavity Configuration

~ 12.7 Meter




e- Source

e* Booster

e+ keep alive

Damping rings










  • Installation premise:

  • Transport of single Cryomodule.

  • Tunnel sections optimized into well defined areas.

  • Personnel & low load traffic both directions.

  • Heavy load traffic restriction, one direction only.

  • Safety & communication systems ready to use.

  • All in tunnel utilities provided by CF&S are complete and ready for tie-in.

Global Design Effort

Cryomodule installation assumptions
Cryomodule Installation – Assumptions




Life Safety Systems

  • Fire suppression

  • Fire detection sensor

  • Area lighting

  • Backup lighting

  • Life safety circuit conduits

  • Low O2 detection & alarm

  • Exit lighting

  • Fire controls & alarm

  • Communication systems

  • Emergency all stop

  • Fire pull station

  • Conveyance charging

Ducts Long





Readiness at Joint Occupancy


  • Occupancy During Installation

  • Global Design Effort

    Methodology example
    Methodology- Example

    One of 556 Main Linac (RF) Unit

    ~ 38 Meter

    • Installation Sequence

    • Prepare tunnel section for installation…

    • Move, place, adjust and fix Cryomodule supports…

    • Move Cryomodules from access shaft to installation section…

    • Install, adjust, fix, and prepare section for Cryogenic & Beam Pipe connections…

    • Complete Cryogenic and Vacuum connections, leak check, then connect the Cryomodule sleeve coupling

    Module Connections

    Global Design Effort

    Cryomodule installation assumptions1
    Cryomodule Installation – Assumptions

    Cryomodule Connections

    • Pipe welding procedure e.g.:

    • Prepare joints, tools, etc.

    • Place welding machine

    • Check setup with one test run

    • Execute welding procedure

    • Remove welding machine

    • Setup visual control monitor

    • Execute control procedure

    • Remove control monitor

    • Go to next pipe

    • Use:

    • 10 man-days per interconnect for cryogenic pipes and superconducting joints, Tom Peterson, 11/9/2006

    • 7 man-days per connection for vacuum joints,

    • John Noonan, 11/9/2006

    Global Design Effort

    Installation global system

    Installation at ML & Service Tunnel – Relative Evaluation

    * ML=Main Linac ST=Service Tunnel

    It take staff of (90) (100/20)=450 about three (3) years to install all ILC ML

    450x3x2000= 2,700,000 man-hours

    Global Design Effort

    Installation global system

    Status of WBS 1.7.3 Installation

    • Note;

      • labor rate of 55 $US does not include overhead and profit

      • Use labor rate of 70 $US to include for overhead and profit

    Global Design Effort


    Shaft 13 (9m DIA)

    Shaft 1.0 (9m DIA)

    Shaft 11 (14m DIA)

    Shaft 7 (9m DIA)

    Shaft 5 (14m DIA)

    Shaft 3 (14m DIA)

    Shaft 10 (14m DIA)

    Shaft 2 (14m DIA)

    Shaft 4 (14m DIA)

    Shaft 6 (9m DIA)

    Shaft 1.1 (16m DIA)

    4.5 km

    4.5 km

    Shaft 1.2 (16m DIA)

    Shaft 12 (9m DIA)


    1.3 km

    Installation planning of the large and complex ILC machine requires the creation of 3-D computer models of all the major components as well as the underground works.

    Underground Layout with Installation Access Shafts

    Global Design Effort

    Installation model for main linac components in underground segment
    Installation Model for Main Linac Components in Underground Segment

    Installation Rate- 3 Cryomodules per day

    Global Design Effort

    Installation global system

    Installation Plan Segment




    Start of



    Global Design Effort

    Future planning

    • Refine the 3D drawings of the tunnel and insert brief overall drawings of the technical equipment and integrate with a time and motion software

    • Superimpose the surface warehouses, the staging assembly buildings and the elevator access shafts

    • Prepare alternate installation approach systems, to facilitate the best way to perform the installation

    • Evaluate elevator transport options for materials, to support installation activities

    • Design the main material transport system, for accelerator part movement, in the tunnel, then manufacture and test, a prototype vehicle

    • Check out utility access locations for an efficient installation

    • Build a mockup of a tunnel section and using outline models of the most difficult pieces of accelerator equipment to install, go through the installation procedures, to proof out the material handling equipment and fixtures/tooling to be used

    • The mockup could also be used as an installation training site and for the evaluation of safety procedures

    • Define support equipment required. This will include vacuum support equipment, such as leak checkers, materials handling equipment, fixtures, tooling, etc.

    Global Design Effort

    Major inputs required for the underground installation
    Major inputs required for the underground installation Segment

    • Basic civil engineering layouts of the facility, including surface building locations, access roads & tunnel layouts.

    • Preliminary outline drawings of the various pieces of equipment to be installed in the tunnel. These details should include mechanical, electrical & utility equipment requirements.

    • Details of the physical locations of all pieces, of equipment to be placed in the tunnel.

    • Location of all utility connections in the tunnel.

    • Cryogenic system connection box locations, in the tunnel.

    • Develop flow charts, showing the typical sequence of events, per major equipment item, in the installation process.

    • Approximate schedule of facility completion, plus delivery dates & sequence of equipment deliveries to the site.

    • An inventory control system that incorporates input data, output data & documentation.

    • Safety/emergency features in the tunnel & on the surface.

    • Details of the quality & quantity of local labor available, to support the installation.

    Global Design Effort

    Future planning1

    • There are a series of long lead items that must be addressed, before the installation can commence. These are:

      • Warehousing capacity

      • Tunnel transportation for equipment & personnel

      • Materials handling requirements for the tunnel

      • Utility requirements & locations including cryo box locations in the tunnel.

      • Data processing, including inventory control & scheduling.

    Global Design Effort

    Future planning2

    • Warehousing:

      • Based on a preliminary installation schedule, a warehouse capacity requirement can be established & thus the specs for the warehouse itself, can be developed.

      • Significant materials handing equipment, will also be required, to support the warehousing activities.

      • Installation staging area requirements, can also be considered, at the same time.

      • External contract warehousing, is an alternative approach that can also be considered, for use.

      • As an alternative to permanent buildings, temporary buildings can be considered, as a possibly less expensive solution, to provide adequate warehouse buildings, for the installation years

    Global Design Effort

    Future planning3

    • Tunnel Transportation for Equipment & Personnel :

      • As the transportation lengths are relatively long, specialized materials handling equipment will be required for both equipment & personnel.

      • Depending on the amount of traffic, some form of guidance system, may be required to control the transportation movement & thus avoid any potential damage, to the accelerator equipment.

    • Equipment Transportation:

      • The major options are battery or electrically driven vehicles. With the use of fast battery chargers, the down time for battery powered trucks, has become much shorter, but they still have their productivity limitations. A bus bar powered system, may be required to provide adequate equipment delivery, for scheduling requirements.

    • Personnel Transportation:

      • This system will use separate equipment. Several types of commercial equipment are available, to provide this service. Some relatively minor modifications to the equipment, may be required.

    Global Design Effort

    Future planning4

    Data Processing:

    • An inventory control system to cover, receiving, scheduling, installation planning & documentation reproduction, will be required. This type information should be readily accessible, at many points on the site.

    • Quick part data identification, can enhance our ability, to perform the installation. Several types of part identification equipment are available, including RFID, Data Matrix & Bar Coding; these should be evaluated regarding the site requirements, as some of them need relatively expensive writers & readers, plus some vendors, may not have this capability

    Global Design Effort

    Added values
    Added Values Segment

    • Centralized information database

      • Sharing and synchronization of records, files

    • Easy and fast communication

    • Better-informed planning decisions from

      • Operation optimization

        • Feasibility study with resource loaded production plan

        • Global optimization

      • Interference detection

        • Physical interferences detection

        • Work space conflicts detection

        • Analysis of the severity of the interferences and conflicts

    • Real-time tracking and reporting

      • Status check for individual equipment

        • Fabrication, transit, storage, sub-assembly, installation

    • Comparison between planned and actual

    Global Design Effort

    Application of virtual design construction technologies
    Application of Virtual Design & Construction Technologies Segment

    Job Site



    Mobile Technology



    4D Technology (3D CAD + schedule)

    Operation Optimization

    4D model / interference check




    4D Database


    Discrete event simulation




    3D model


    Database Technology

    Global Design Effort

    Integration of vdc database
    Integration of VDC database Segment

    • Information included in the database

      • 3D geometry of the equipment to be installed

      • Installation schedule (i.e., sequence, duration)

      • Manufacturer information

      • Status: manufactured, received, stored, assembled, installed

      • Location (i.e., x, y, z)

      • Labors needed

      • Predecessors (i.e., equipment list that need to be installed before)

      • Requirement for clearance during installation

    Global Design Effort

    Future planning5

    • Installation G.S.

      • Goal: to produce an integrated Installation process for the ILC Baseline in full cooperation with other regions

        • Set-up and manage an installation data base in FY 07 that can be expanded in a full pledged program thru FY 08 and FY 09

          • Estimate:

            FY 07;1.5 FTE and ~ $100K M&S (contract)

            FY 08; 2 FTE and ~ $200K M&S (contract)

            FY 09; 2 FTE and ~ $200K M&S (contract)

    Global Design Effort

    Future planning6

    • Miscellaneous Considerations

    • Some possible conflicts in multi country projects are:

    • Part Drawing Views Procedure: Is different, from the USA, in the rest of the world. Drawing procedures are also different.

    • Metric & Inch Designs: Used in the same project, can breed costly errors

    • Standards: Mechanical, electrical & material standards can also differ.

    • Date Number Sequence of Numbers: Is different in the rest of the world, from the USA.

    Global Design Effort