1 brookhaven science associates conventional facilities update marty fallier director for...
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1 BROOKHAVEN SCIENCE ASSOCIATES
Conventional Facilities Update
Marty FallierDirector for Conventional Facilities
NSLS-II PAC MeetingMay 24, 2007
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Outline
• Current CF Scope• CF Issues
• CR impacts• Vibration Management• Lab Support
• Organization• Schedule • Cost• Risks• Path Forward
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CF Technical Performance Goals
• Structurally stable facility with low vibration (<25nm Rms)• Tunnel design that provides required shielding and accessibility• Tunnel temperature stability of +/- 0.1 deg C• Utility capacity for up to 3.6 GeV operation• Utility services & expansion capability to support full beamline build-out• Facility layout enabling future long beamlines• Experimental Floor noise level <NC60• Design for LEED Certification to meet sustainability requirements (DOE
likely to require LEED Gold Rating)
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NSLS
LOB Typ 4
1 in Base Scoope, 3 Future
RF-LINAC AREA
Service Bldg Typ 4
CFN
Ring Bldg
Future JPsi
Future Guest House
Future Conf. Center
UnderpassLoading
CLOB
Scope at Previous Review
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Current NSLS II Facility Overview
Access Tunnel
LOB (1 of 3)JPSINSLS
CFN
BLOC
NSLS II
Service Bldgs (1 of 5)
CHW Plant
Bldg 603 Substation
Future LOB’s
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NSLS II Facility Overview cont’dNSLS II Floor Plan
1.BLOC – Booster/LINAC/ Operations Center
2.LOB – Lab Office Buildings (3 base scope up to 5 future)
3.Service Buildings (5)
4.RF Area
5.Tunnel Area
6.Electrical Mezzanine
7.Experimental Floor
8.Access Corridor
1
4
3
2
2
2
2
23
3
3
3
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NSLS II Facility Overview cont’d
Access Corridor
Lab-Office Bldg
SR Tunnel
Experimental Floor
Service Bldg 1st Floor
(earlier concept)
7
5
8
6Electrical Mezzanine
(above tunnel)
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Compact Booster 1st Floor Plan
Operations Center Entry Lobby
Linac Injection to Booster
Booster Injection to Storage Ring
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Compact Booster 2nd Floor Plan
Operations Center Viewing Gallery and Bridge to Control Room Area
Linac Klystrons
Booster RF, Magnet Power Supplies, Cooling Systems and HVAC Service Areal
Control Room Area
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Revised LOB Program
• The 2 LOB’s (1 integrated in CLOB, the other standalone) in CDR were insufficient to support full beamline buildout• Intended to support initial suite of beamlines (~10)• Would require substantial additional construction to support future beamlines (at least 3
more larger LOB’s plus expansion of original LOBs)• Revised plan will provide 3 larger LOB’s to support more rapid build out of
beamlines and transfer of NSLS beamlines
Each LOB Total Each LOB TotalNo. LOB's 2 3Offices 30 60 72 216Labs 5 10 6 18GSF 11,000 22000 21000 63000Direct Cost $3.3 M $6.6M* $6.3 M $18.9 MTPC Cost $5.0 M $10.0M* $10.5 M $31.6 M
* Cost of 1 LOB included in CLOB
LOB ProgramCDR Program Current Program
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Facility Program
Base Scope Full Build-Out Base Scope Full Build-OutGSF GSF GSF GSF
Ring Building 242,000 242,000 242,000 242,000 No ChangeService Buildings 32,000 32,000 32,000 32,000 No ChangeLINAC/RF Area 21,000 21,000 21,000 21,000 No Change
55,000 55,000 Deleted Deleted Staff not directly required for NSLS II operation moved to other bldgs
NA NA 24,000 24,000 Only supports staff directly required for operation (9ksf) & includes compact booster (15ksf)
11,000 44,000 63,000 105,000
Changed to 3 @21,000 gsf ea. from 1 @11,000 gsf in CDR. CDR also had 11,000 gsf equivalent LOB space in CLOB
Conference Center NA 15,000 NA NA Deleted
Total GSF 361,000 409,000 382,000 424,000
Lab Office Buildings
Building /Area/Function
Central Lab/Office Bldg (CLOB) [Replaced by smaller Operations Center]
Booster, LINAC & Operations Center (BLOC) Building [Replaces CLOB]
Comments
CDR Program Current Program
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Conventional Facilities Issues
• Reliance on NSLS lab/office space• Reliance on BNL to;
• Complete replacement of Warehousing area• Share in expansion of Central Chilled Water Plant
• Impacts of continuing resolution on design schedule• How to support future upgrade paths
• Extra long beamlines• Super long straights
• Cost vs Beam Stability Goals
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BNL Support
• Warehouse Demolition & Replacement– Must remove Bldgs 86, 100, 210, 211, and 481 before FY 09– Warehouse facility replacement is underway as GPP project– Demolition planned for Spring FY08
• Chilled Water Plant Expansion– NSLS II and Lab must share expansion cost as both need added
capacity– A/E selected and ready to begin design– Lab planning $4.9 M GPP/IGPP project– Design to run concurrent with NSLS II ACD, T-I and T-II– Construction start in FY09 and complete early FY11.
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Existing Site Building 603
CCWF
Bldg 100
Bldg 209
Bldg 86
Bldg 210
Bldg 481
Bldg 211
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Continuing Resolution Impacts
• Prior Schedule had CD-1 in February, now likely in June• Result - Funding for T-I delayed and limited• Goal – minimize schedule impacts• Approach
• Establish basic ordering agreement contract with selected A/E [HDR]• Issue tasks for Advance Conceptual Design (ACD) to progress investigation
of design concepts and alternatives• Revised T-I A/E scope to address specific T-I deliverables
• Result – maintained overall schedule goal of readiness for CD-2 in 1st Qtr FY08• Lehman review and EIR scheduled for early November
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CF Program for Vibration Management
• Assessment of “green-field” conditions• Active participation in Beam Stability Task Force• Identification and mitigation of cultural sources (where feasible)
• FE Modeling of site and facility design• Needed to understand & predict facility response • Design optimization tool
• Analysis of other facilities (CFN, APS & SPring 8 thus far)• Draw upon lessons learned• Provide input for model • Model performance verification
• During & after construction, implement monitoring and maintenance program
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Conventional Facilities Organization
Conventional FacilitiesDirector
M. Fallier
Design A/E T-I, I, IIIHDR
Giffels [C]
Asst. Director CF Design Management
O. Dyling
Commissioning ContractorTBD [C]
PE Trade Shop Support – Various
[M]
Subconsultants Vita-tech
Colin -Gordon VJ Assoc.[C]
Construction Management PM
Agent CM – TBD [C]
I C & C Project Manager
TBD
Civil Construction Project Manager
TBD
Building Project Manager
TBD
Chilled Water Project Manager
TBD
[M] – Matrixed
[C] - Contracted
Asst. Director CF Construction Management
TBD
ESH Manager R. Casey•Design Review•Industrial Hygiene •Health Physics •Construction Safety
Project Support • Procurement• Project Controls• Document Mgt• Human Resources• Information Management
NSLS II Project Director
S. Dierker
CF Advisory CommitteeJ. Hands, Chair
Construction Analysts [C]
Project Schedulers[C]
Field Inspectors[C]
Cost Estimators[C]
ASD & XFD Technical Interface Managers
ASD - E. Johnson, EFD- L. Micelli
Site Prep Contractor[C]
Building Contractor
[C]
CHW Contractor[C]Construction Safety
Specialists [C]
IC&C Contractor[C]
Project ArchitectT. McEvaddy [M]
Mech. EngineerG. Leskody [M]
Civil/Struct. Engr.T. Joos [M]
Elect. EngineerD. Danseglio [M]
Sr Mech. Engr.C. Channing [M]
ECS Design Supervisor J. Mills [M]
QA Manager C. Porretto
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CF Schedule (CDR funding profile)
Title I Design
CD-2
Title II Design
CD-3
Site Prep. Const.
Ring Bldg Bid & Award
1st Pentant RFE (Pentant 1)
2nd Pentant RFE (Pentant 5)
3rd Pentant RFE (Pentant 2)
4th Pentant RFE (Pentant 3)
5th Pentant RFE (Pentant 4)
Booster/LINAC/Ops Ctr (BLOC)
Lab/Office Bldg’s (LOB’s)
CHW Plant Expansion
Mech & Elect Utilities
Integrated Ctrl & Comm.
Standard Equipment
Commissioning
Activity FY07 FY08 FY09 FY010 FY11 FY12 FY13
Begin Accelerator Installation
Full Ring Bldg Available for Accelerator & Beamline Installation
Control Room RFE
LOB’s Complete
BO for all CF Construction
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Site Preparation
• Site Preparation package at start of FY09 would head-off some schedule risk
• Likely scope to include • Clearing trees and brush• Rerouting of utilities• Removal of old foundations and abandoned utilities• Grading to cut the site and verify subsoil conditions
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Cost EstimateCost Change Revised CD-1
Direct $Conventional Facilities Management 1.5.1 6,619,000 6,619,000 No ChangeConventional Facilities Engineering and Design 1.5.2 16,610,000 16,610,000 No ChangeConventional Facilities Construction 1.5.3 140,594,000 148,740,000 Sum
CF Construction Management 1.5.3.1 4,830,000 4,830,000 Increased with scope changesImprovements to Land 1.5.3.2 7,416,000 7,416,000 No change
1.5.3.3 17,516,000 (6,500,000) 11,016,000
Replaced CLOB with Smaller Ops Center - went from 53 ksf to 9 ksf, added compact booster tunnel and equipment area(15ksf)
Ring Building 1.5.3.4 80,246,000 (954,000) 79,292,000 Revised shield wall to reduce HD concrete. Added ratchet wall shield doors.
Lab - Office Building 1.5.3.5 3,296,000 15,600,000 18,896,000
Increased number and size of LOB's, now have 3@ 72 person ea. instead of "two" @ 30 person ea. (1 LOB in CLOB)
Mechanical Utilities 1.5.3.6 7,729,000 7,729,000 No ChangeElectrical Utilities 1.5.3.7 10,750,000 10,750,000 No ChangeCryogenic Utilities 1.5.3.8 1,100,000 1,100,000 No ChangeChilled Water Utilities 1.5.3.9 7,711,000 7,711,000 No Change
Integrated Controls and Communications 1.5.4 616,000 616,000 No Change
Standard Equipment 1.5.5 1,600,000 1,600,000 No change, # of ofcs roughly same (220 CDR vs 222)
Commissioning 1.5.6 900,000 900,000 No Change166,939,000 - 175,085,000
Costs are Direct FY06 $ CDR Current
Booster-Linac-Operations Center (BLOC) formerly CLOB
Comments1.5Conventional FacilitiesDirect CDR
Total FY 2006
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Risk Assessment
• Technical Risk• Primarily building stability, vibration & temperature control
• Schedule Risks• Title I & II Engineering are on the critical path• Construction of Ring Building is critical path
• Cost Risks• Technical and schedule risks can impact costs• Construction and material markets are still volatile
• Risk registry has been prepared • Risk assessment database integrated with cost estimate
database • Current Contingency allocated for Conventional Facilities ~ 40%
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CF Path Forward
• Continue driving ACD process to finalize concepts for T-I• Freeze accelerator lattice design – Ring bldg footprint
• Confirm program requirements
• Confirm siteplan and geotechnical suitability
• Continue benchmarking study of other LS facilities
• Continue focused technical studies (vibration, thermal modeling)
• Expedite award of A/E T-I contract when CD-I is received
• Execute T-I design plan
• Expedite agent CM award for T-I, T-II support services
• Prepare supporting documents for CD-2