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NSLS-II Accelerator Installation Plan
Gregory FriesProject Engineer, Accelerator Systems Division
CFAC Review of NSLS-IIOctober 5-6, 2010
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Outline
• Phasing of Installation• Coordination with Conventional Facilities• Storage Ring Installation• Injector Installation• Storage and Rigging• Installation Schedule• Experimental Installation• Potential Obstacles• Summary
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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
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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
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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
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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
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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
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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
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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
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Storage Ring Pentant 1 Installation: Week 12
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
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Storage Ring Pentant 1 Installation: Week 18
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
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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
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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
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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
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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
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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
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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
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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
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Installation, Testing & Commissioning Schedule
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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
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Experimental Installation
XFD Installation follows ASD installation by pentant
Activities Per Beamline• Pentant Hand-off from ASD• Pentant Clean-up• Hutches• Utilities• Beamline Components
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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)
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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
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