1 BROOKHAVEN SCIENCE ASSOCIATES NSLS-II Update & Charge to CFAC Steve Dierker Associate Laboratory...

1 BROOKHAVEN SCIENCE ASSOCIATES

NSLS-II Update & Charge to CFAC

Steve DierkerAssociate Laboratory Director for Light Sources, NSLS-II Project Director

Conventional Facilities Advisory CommitteeNov 9-10, 2009


Safety First!

•Every staff member, contractor, user, and guest has the right to go home at the end of the day without suffering injury or illness due to his or her work environment

• It's not about the numbers, it's about people•The consequences of failure to maintain a safe workplace could be severe:

•personal injury, illness, or death• loss of funding• loss of reputation and credibility with stakeholders• fiscal penalties and criminal enforcement actions

• If we cannot do work safely, we will not do it


NSLS-II Safety Record• Over 650,000 NSLS-II staff hours worked to date and one recordable injury

3/10/09 Splinter and infection from brushing against a wooden crate. Recordable injury but no lost time.

• Over 64,000 contractor hours worked to date (construction start 3/25/09)• Torcon subcontractors have incurred 7 injuries since starting construction

4/16/09 Missed a step on a ladder and fell (standing up) from the fourth rung. Fractured heal. DART.7/16/09 Placing a conduit elbow on a pallet, conduit flipped up and chipped tooth. Recordable injury, no lost time.8/5/09 Scratched arm on tiewire. First Aid Case.8/13/09 Temporary intermittent numbness in forearm. First Aid Case.9/2/09 Scratched arm on rebar. First Aid Case.9/28/09 Muscle strain in leg from walking. First Aid Case.9/30/09 Rebar impacted leg, compound fracture. Investigation underway. DART.


NSLS-II 9/30/09 Accident Investigation• Team Membership:

Ray Costa, F&O (Chair)D. Fuller, ORNLT. Conrad, S&HSD B. Tullis (consultant)S. Kane, S&HSD C. Seniuk, DOE BHSO (Observer)E. Sierra, QMO J. Zamirowski, DOE CH (Observer)S. Kessler, QMO C. Morrow, DOE CH (Observer)

• Charge: The investigation should address: • Investigation of the leg injury incident

• Adequacy of the BNL and Torcon response• Development of causal factors analysis and corrective recommendations• Any added investigation, if warranted

• Review of adequacy of contractual safety requirements and safety incentive program• Does the contract with Torcon have appropriate requirements?• Is the safety incentive program appropriately structured and designed to promote worker safety?

• Review of implementation of the construction safety program• Adequacy of Torcon safety plan implementation and flow down to subcontractors• Adequacy of BNL oversight of Torcon safety program• Recommendations to improve overall construction site safety

• Began work on Thursday, Oct 1• Report Draft due Oct 23; Final due Nov 13


Unacceptable Level of Injuries at BNL

• Well house explosion on October 13, 2008• ATF fire on Feb 18, 2009• NSLS-II construction injury on September 30, 2009

• Worker received broken leg, required surgery• Building 1005 injury on October 9, 2009

• Worker fell, required surgery on both knees• Building 801 injury on October 23, 2009

• Worker fell, required multiple stitches

• We must redouble our efforts to work safely


Start of Construction Celebration

From left to right: BHSO Manager Mike Holland, Stony Brook President Shirley Strum Kenny, NSLS-II Federal Project Director Frank Crescenzo, NSLS-II Project Director Steve Dierker, DOE Deputy Director for Science Pat Dehmer, Senator Kirsten Gillibrand, Senator Charles Schumer, BNL Director Sam Aronson, Battelle Executive Vice President Ron Townsend

June 15, 2009


Photo From BGRR Stack

11-3-09

SR Tunnel Slab

SR Tunnel Walls

Vehicle Tunnel

Column Footings

Construction Site Work Underway


Central Chilled Water Facility Expansion

Sub-basement/Pipe pit

CHW Expansion Basement

Existing CHW Plant

Finished Concreteof Basement Mat (10/23/09)

• Chilled Water Plant Expansion• Adds 5 bays to existing 4 bay chiller and two 2500 ton chillers• $15.3M Contract shared between BNL & NSLS-II• Scheduled to complete December 2010


Procurements• Magnet Procurements (840 magnets at $18M)

• 240 Quadrupole Magnets: Awarded Sep 23 to Everson Tesla and Budker• 180 Corrector Magnets: Awarded Oct 8 to Everson Tesla• 270 Sextupole Magents: Awarded Oct 14 to IHEP and Danfysik• 90 Large Aperture Magnets: Awarded Oct 19 to Buckley• 60 Dipole Magnets: Awarded Oct 27 to Buckley

• Linac• Planned issue date to industry – November 6

• Lab Office Building• Planned issue date to industry – December 11

• Booster• Planned issue date to industry - December 28•1000 requisitions/change orders processed in FY2009 for a total of

$193M


Project Beamline Conceptual Designs

Hard X-ray Nanoprobe Beamline

X-ray Powder Diffraction Beamline

• Conceptual designs completed for six project beamlines

• Safety reviews have been completed• Independent Conceptual Design

Review held on October 13-14, 2009, to assess the status and adequacy of the beamline designs


Progress on NSLS-II Staffing• Total hires now at 212• 23 Open Requisitions with 3 offers in process• FY09: 2500 job apps received, 200 interviews conducted, 77 accepted offers• Conventional Facilities & Project Management hiring ~ complete• Steady increase in Accelerator Systems and Experimental Facilities staff

Cumulative New Hires by Month

0

20

40

60

80

100

120

140

160

180

200

220

Jan-

06

Feb

-06

Mar

-06

Apr

-06

May

-06

Jun-

06

Jul-0

6

Aug

-06

Sep

-06

Oct

-06

Nov

-06

Dec

-06

Jan-

07

Feb

-07

Mar

-07

Apr

-07

May

-07

Jun-

07

Jul-0

7

Aug

-07

Sep

-07

Oct

-07

Nov

-07

Dec

-07

Jan-

08

Feb

-08

Mar

-08

Apr

-08

May

-08

Jun-

08

Jul-0

8

Aug

-08

Sep

-08

Oct

-08

Nov

-08

Dec

-08

Jan-

09

Feb

-09

Mar

-09

Apr

-09

May

-09

Jun-

09

Jul-0

9

Aug

-09

Sep

-09

Oct

-09

Nov

-09

Dec

-09

Hea

ds

.

Project Management Accelerator Systems Division Experimental Facilities Division Conventional Facilities Division

20 Staff at 9/06

80 Staff at 9/07

139 Staff at 9/08

212 Staff Today

80 Staff at 9/07

139 Staff at 9/08

20 Staff at 9/06


0

50

100

150

200

250

FY05 FY06 FY07 FY08 FY09 FY10 FY11 FY12 FY13 FY14 FY15 FY16

AY

M$

MIE

Operations

Pre-Ops

Construction

PED

OPC

R&D

NSLS-II Funding

NSLS-IITEC = $791MTPC = $912M

Note: Operations & MIE funding are not part of TPC


5.830.8

80.5

333.8

474.8

627.9

787.0

858.3907.0 912.0

745.0

719.0

0

100

200

300

400

500

600

700

800

900

1,000

FY06 FY07 FY08 FY09 FY10 FY11 FY12 FY13 FY14 FY15

MIL

LIO

N $

NSLS-II Performance through September 2009On Budget -- On Schedule

Total FundsCurrent BudgetOriginal BaselineEarned ValueActual Cost

Scheduled Work 20.9% Performed Work 19.2%Actual Cost 18.9%

Scheduled Work 20.9% Performed Work 19.2%Actual Cost 18.9%

Performance Baseline


Schedule and Critical Path FY14

CriticalDecisions CD-0 CD-1 CD-2 CD-3 Approve Start of Construction CD-4

Approve Project CompletionApprove Mission Need Approve Alternative Approve

Aug 05 (A) Selection and Cost Performance Range - Jul 07 (A) Baseline - Jan 08 (A)

Conceptual Design Aug 05 Jul 07

Design of LOBs CompleteConventional Facilities Jan 11

Design

Booster Ready forExperimental Facilities Commissioning Dec 12

Procurement, Fabrication, Installation and Test Storage Ring Ready forAccelerator Systems Commissioning Apr 13

Construction& Installation

Long Lead Oct 13Conventional Facilities

Early Completion Feb 14

Commissioning BOD Commissioning & Pre-Opsand Pentant 3

Pre-Ops Sep 11EPU Install Oct 13

Legend (A) Actual Completed Planned Data Date Level 0 Milestone Schedule Contingency Critical Path

Construction

FY13

Accelerator Systems

FY08

Sep 08

FY05 FY06 FY07

Oct 08

FY09 FY10 FY11 FY12 FY15

• Need careful & thorough planning on installation & commissioning


Recent & Upcoming Project Reviews

• Experimental Facilities Conceptual Design Review on Oct 13-14• Accelerator Systems Advisory Committee meeting on Oct 22-23• Conventional Facilities Advisory Committee meeting on Nov 9-10• EVMS self assessment on November 16-18• Project Advisory Committee meeting on Dec 10-11• DOE review on Feb 9-11

• Focus likely on Safety and Schedule


Charge to CFAC

• Are the Conventional Facilities Division’s plans and performance consistent with achieving the cost, schedule, technical, and safety objectives for the Project?

• Are the plans and measures to assure construction worker safety appropriate and effective at minimizing potential for worker injury?

• Does the plan for procurement and management of the LOB construction provide the best available approach to achieving this scope element?

• Does the Conventional Facilities Division’s preliminary plan to support transition to operations address the proper issues and scope of supporting facility operations and future growth?


A Bright Future – but only if we work safely

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