cf status update

1 BROOKHAVEN SCIENCE ASSOCIATES

CF Status Update

Marty FallierConventional Facilities Division Director

Conventional Facilities Advisory Committee ReviewNovember 9-10, 2009


Outline

• Progress & Events Since Last Review (March 10, 09)• Begin Ring Bldg construction• Accelerated elements of the Ring Bldg schedule• Award & issue NTP for all construction contracts (except LOBs)• Award all pre-purchased equipment contracts• Begin LOB design 1 year early• Executed LOB design, contractor outreach and prepare RFP• Experience 1st construction site injuries

• Scope Status - Project Change Requests - PCRs• EVMS Status• Cost Status & Schedule Status• Risks• Issues• Action Items (separate PDF file)


Progress

• Started Ring Bldg Construction (CP-2) – – NTP March 25th, construction start April 15th

– Adopted revised phasing plan accelerating Injection and RF Bldgs – no added cost

– Mobilization went smoothly until an injury occurred- Carpenter fell from step ladder fracturing heel bone 4/25

– Instituted changes in field safety presence as a result- Discussed in detail in Steve Hoey’s presentation

– Construction progressed ahead of baseline until combination of bad weather and adopting Torcon “Early Finish” schedule as baseline was done in July 09

– Ring Bldg has since regained most of schedule and baseline has been revised to be more realistic


Progress cont’d

Photo From BGRR Stack 9-21-09Vehicle Tunnel

SR Tunnel Wall FormsSR Tunnel

Slab

Status of construction Site at FY09 End


Progress cont’d

Photo From BGRR Stack 11-5-09

Vehicle Tunnel

SR Tunnel Wall Forms

SR Tunnel Slab

SR Tunnel Walls

Column Footings

Ring Bldg Progress from month to month is substantial

Monthly billing is ~$4M - $5M


Progress cont’d

• Awarded Balance of Construction Contracts – – Awarded Electrical Substation (CP-3) July 17th

– Awarded Chilled Water Plant Expansion (CP-4) July 1st

– Awarded Chilled Water Piping (CP-5) August 28th

• Net bid results of three CP’s were within $10k of baseline

• Awarded balance of pre-purchased equipment contracts

– All awarded on or ahead of schedule – Delivery of equipment for each procurement running about 2-3

months ahead of schedule


Progress cont’d

• ARRA funds enable advance of LOB design, procurement & construction

– Perform design in FY09 instead of FY10 – Start construction in FY10 instead of 12– Complete construction FY12 ~16 months early

• Enables procurement during favorable market and early occupancy by beamline staff during beamline construction

• Creates some potential contractor coordination issues– Have worked closely with Torcon to minimize impacts

• A/E Design nearly complete• Held contractor informational meeting – more scheduled• RFP to DOE for approval – expect release in early-mid Dec


Progress cont’d

• First Construction Accidents/Injuries• Progress in the sense that we need to learn from these events to

prevent recurrence• 2 DART cases and one reportable plus several first aid cases to date • Each is an opportunity to improve the safety program and reduce

possibility of recurrence

• Numerous corrective actions have been implemented • Draft investigation report is topic of discussion/review

• Steve Hoey & Ray Costa presentations later today

• We welcome your comments & recommendations on how these events can be used to further improve the construction safety program


FY09 Goals & Milestones

• Complete Bid and Award of Major Contracts for:• Electrical Substation Expansion - Done• Chilled Water Plant Expansion - Done• Chilled Water Piping - Done• Owner Furnished Equipment - Done

• Complete Readiness of Construction Mgt Team - Done• Begin successful execution of construction contracts:

• Ring Building earthwork completed and start concrete & utilities - Done• Begin Chilled Water Plant foundations - Done• Begin Electrical Substation - Done• Begin CHW Piping - Done

• Confirm LOB design plan & execute detailed design- underway


EVMS Status - Cost & Schedule

• Cost Assessment: Cumulative cost variance $+24k on~$43M or 0% On budget - CPI =1.00

• Schedule Assessment: Cumulative schedule variance $-3,811k on ~$46.8M or -8.1% - Slightly behind schedule SPI =0.92

Data up to Sept 30, 09

/wEPDwU/wEPDwU


EVMS Status - Variance Analysis

• Cost Variance - None• Schedule Variance WBS 1.5 – aggregate – ($3.81M)

• Ring Bldg variance (-$1.3M or -5.4%)– Contractor early finish schedule for steel fabrication is most of this– Some utility work and submittals account for balance– None affect critical path and contractor is making up ground

• Chilled Water Plant Expansion (-$1.8M variance)• Electrical Substation (-$0.2M)• Chilled Water Piping (-$0.2M)

– All 3 contracts scheduled for on-time completion– Baseline profile for these contracts did not reflect reasonable cost plan– PCR required to adopt contractor schedule/cost profile as baseline for each– PCR to be processed in October 09


Scope Status – Project Changes PCRs

• Approved changes since last CFAC 3/10/09

PCR # PCR Description Approval Impact PCR-09-048 Ring Bldg Contract Award Adjustment 4/13/2009 $5.73M PCR-09-049 A/E Design & T-III Svcs Cost Adjustment 4/13/2009 $1.62MPCR-09-060 Site Preparation Scope Addition 4/9/2009 Scope PCR-09-071 CF Compressed Air/N2 System Changes 10/28/2009 $0.394MPCR-09-072 Advance Ring Bldg Sched. due to ARRA 5/28/2009 Sched PCR-09-082 Re-Plan Timephasing of Ring Bldg Contract 8/13/2009 Sched PCR-09-094 Ring Bldg Cost Correction /Profile Mod 10/14/2009 Sched

•Pending changes PCR-10-095 Additional LOB Engineering and Design 11/05/2009? $1.9MPCR-10-098 Ring Bldg Post Bid addendum cost change Pending ~$3.1MPCR-10-099 CF Construction Staff Change due to LOB Pending ~$0.4MPCR-10-095 Integrate Contract Schedules CCW & Elect Pending Sched


Scope Status – Project Changes PCRs

• Changes in preparation for near term

PCR # PCR Description Approval ImpactPCR-10-0xx Misc. Ring Bldg Field Changes I ~11/09 ~$0.35MPCR-10-0xx LOB Earthwork Preparation ~11/09 Sched PCR-10-0xx Misc. Ring Bldg Field Changes II ~12/09 ~$0.35MPCR-10-0xx Added Data and Comm. Network Costs 2Q FY10 ~$0.40MPCR-10-0xx Scope Change for larger LOBs 2Q FY10 ~ $15M

*Pending LOB bid results in 2QFY10


Costs – Management & Engineering

1.05 Conventional Facilities 1.05.01 Conventional Facilities Management 1.05.01.01 CF Design Phase Management 1,299,302 1,299,302 1,335,889 0 -36,588 1,299,302 1,335,889 -36,588 1.05.01.02.01 CF Project Office Construction Management1,242,837 1,242,837 1,294,128 0 -51,291 6,246,867 6,246,867 0 1.05.01.02.02 CF Field Office Construction Management1,614,239 1,614,239 1,406,313 0 207,926 6,640,834 6,640,834 -0 WBS[3]Totals: 4,156,378 4,156,378 4,036,330 0 120,048 14,187,003 14,223,590 -36,588 1.05.02 Conventional Facilities Engineering and Design 1.05.02.01.01 CF Title I A/E Design 2,002,491 2,002,491 2,117,831 0 -115,340 2,002,491 2,117,831 -115,340 1.05.02.01.02 CF Title I Design Coordination 53,604 53,604 37,367 0 16,236 53,604 53,604 -0 1.05.02.01.03 CF Title I Design C/M Support 136,843 136,843 407,193 0 -270,350 136,843 407,193 -270,350 1.05.02.02.01 CF Title II A/E Design 10,371,198 10,371,198 11,183,940 0 -812,742 12,101,980 14,101,980 -2,000,000 1.05.02.02.02 CF Title II Design Coordination 203,750 203,750 487,713 0 -283,963 203,750 487,713 -283,963 1.05.02.02.03 CF Title II Design C/M Support 920,761 920,761 364,807 0 555,955 920,761 920,761 0 1.05.02.03.01 CF Construction Phase A/E Support 690,693 690,693 570,554 0 120,139 3,966,415 3,966,415 0 1.05.02.03.02 CF Construction Phase Coordination 234,378 195,234 56,930 -39,143 138,305 1,287,455 1,287,455 0 WBS[3]Totals: 14,613,719 14,574,576 15,226,335 -39,143 -651,760 20,673,299 23,342,952 -2,669,653

WBS[2] CURRENT PERIOD CUMULATIVE TO DATE AT COMPLETION

WBS[3] ACTUAL

Control Acct BUDGETED COSTBUDGETED COST COST VARIANCE

WORK WORK WORK WORK BUDGETED ESTIMATED VARIANCE

ITEM SCHEDULEDSCHEDULED PERFORMED PERFORMED SCHEDULE COST

(1) (2) (7) (8) (9) (10) (11) (14) (15) (16)


Costs - Construction WBS[2] CURRENT PERIOD CUMULATIVE TO DATE AT COMPLETION

WBS[3] ACTUAL

Control Acct BUDGETED COSTBUDGETED COST COST VARIANCE

WORK WORK WORK WORK BUDGETED ESTIMATED VARIANCE

ITEM SCHEDULEDSCHEDULED PERFORMED PERFORMED SCHEDULE COST

(1) (2) (7) (8) (9) (10) (11) (14) (15) (16) 1.05.03 Conventional Facilities Construction 1.05.03.01 Site Prep (Contract) 1,167,496 1,167,496 1,076,134 0 91,363 1,167,496 1,167,496 0 1.05.03.02.01 General Requirements 9,055,460 9,812,246 9,193,215 756,786 619,031 35,256,175 37,756,175 -2,500,000 1.05.03.02.02 Site Work 3,365,869 3,242,349 3,246,112 -123,520 -3,763 5,927,981 5,927,981 0 1.05.03.02.03 Pentant 1 and Service Building 3,205,805 2,580,752 2,453,885 -625,054 126,867 20,948,158 19,684,889 1,263,269 1.05.03.02.04 Pentant 2 and Service Building 1,571,521 920,851 929,972 -650,670 -9,121 18,297,726 18,405,943 -108,217 1.05.03.02.05 Pentant 3 and Service Building 900,044 319,940 337,532 -580,104 -17,591 17,681,852 17,323,584 358,268 1.05.03.02.06 Pentant 4 and Service Building 607,197 320,046 337,641 -287,150 -17,595 17,989,580 17,996,311 -6,731 1.05.03.02.07 Pentant 5 and Service Building 2,129,109 1,907,684 1,892,646 -221,426 15,038 18,789,144 18,784,161 4,983 1.05.03.02.08 Injection Building 189,699 336,641 360,004 146,942 -23,364 8,494,897 9,298,568 -803,671 1.05.03.02.09 RF and Compressor Building 826,900 611,540 601,107 -215,359 10,433 7,517,429 8,183,375 -665,946 1.05.03.02.10 Lobby 103,209 104,339 101,959 1,130 2,380 3,071,094 2,927,145 143,949 1.05.03.02.11 Cooling Tower and Process Water 63,568 32,348 25,588 -31,220 6,760 4,075,953 4,751,858 -675,905 1.05.03.02.12 Underground Mechanical Utilities 722,916 1,391,543 1,299,706 668,627 91,837 8,478,155 7,988,155 490,000 1.05.03.02.13 Site Electrical Utilities 1,421,771 1,165,017 1,274,235 -256,754 -109,218 9,356,456 9,356,455 1 1.05.03.02.14 LN2 and GN2 Systems 0 0 0 -0 0 715,599 1,315,599 -600,000 1.05.03.03 Electrical Substation and Feeder (Contract)515,152 310,677 173,081 -204,475 137,596 3,606,562 2,760,000 846,562 1.05.03.04 Chilled Water Plant (Conract) 1,836,199 0 249,608 -1,836,199 -249,608 9,142,578 9,142,578 0 1.05.03.05 Chilled Water Piping (Contract) 196,561 0 106,600 -196,561 -106,600 914,003 1,600,000 -685,997 1.05.03.06.01 LOB 1 0 0 0 0 0 10,241,494 15,241,494 -5,000,000 1.05.03.06.02 LOB 5 0 0 0 0 0 10,241,494 15,241,494 -5,000,000 1.05.03.06.03 LOB 4 0 0 0 0 0 5,501,020 10,501,020 -5,000,000 WBS[3]Totals: 27,878,477 24,223,469 23,659,024 -3,655,008 564,445 217,414,846 235,354,281 -17,939,435

WBS[2]Totals: 46,807,809 42,996,753 42,971,802 -3,811,056 24,951 254,440,009 275,485,683 -21,045,674

As Part of FY10 Work planning Process EAC is being reevaluated and will be corrected for Oct 09 data

•Bulk of VAC is pending PCR for LOB scope, A/E LOB re-design fee & post bid addendum costs


Schedule WBS

CD-3 Approve Start of Construction Jan 09

Detailed Design CompleteBegin Detailed Design Issue RFP

Dec 07 Sept 08 Award Ring Bldg Contract Bore Pentant 1 Ring Building & LOBs Complete CF Complete

Feb 09 'Mar 10 Award LOBs Feb 11 April 12

1.5.1 Design Phase Management

CF Management Construction Phase ManagementClose Out

Ring Bldg Detailed Design LOB Detailed Design

1.5.2Contractor Outreach/Prep RFP Prepare CF Bid Packages

Design Prepare LOB RFP&

Procurement Bid & Award Ring Bldg Contract Bid & Award CF Const. Pkgs & LOBs

Site Prep

1.5.3 Ring Building ASD Installation

Construction Elect. Substation Expansion

Packages CHW Plant

CHW Piping

LOB's

1.5.4 Integ. Ctrls & Comm. Integrated Controls & Communications

1.5.5 Standard Equipment Std Equip.

1.5.6 Commissioning Ring Bldg & LOB Cx

Legend Actual Completed Planned Level 0 Control Schedule Critical Milestone Milestone Contingency Path

FY13FY08 FY09 FY10 FY11 FY12


Risks

• Construction safety program must be effective• Safety program enhancements after most recent injury must be

maintained and developed further

• Potential for field changes during construction • Site related changes nearly retired, only design related remain• Added potential for changes due to LOB & Ring contractor interface

• Potential for design changes from ASD & XFD• Thus far, only very minor changes with exception of larger LOBs

• Risks for procurement of balance of CF scope partially retired• CHW Plant & Pipe, Elect Substation, Elect Equip - Done($16M)• LOB procurement remains – ($~40M+ for larger LOBs)

• No new risks foreseen


Look Ahead

• Ring Building contractor• Improved safety performance, ramp-up concrete and utility installation, expedite

submittals, prepare for steel delivery and erection

• Electrical Substation Expansion• Begin ductbank installation and B603 modifications

• Chilled Water Plant Contractor• Install foundations, pipe headers, steel & equipment submittals

• Chilled Water Piping• Defer mobilization to 3/15/10, order & deliver piping & components

• Electrical equipment vendors• Prepare for in-process inspections and equipment delivery

• LOB Design and Construction• Prepare bid-issue bid set• Submit draft RFP: for DOE review• Continue contractor outreach


Issues

• Ring Building Contract• Torcon must maintain excellent safety performance • Torcon has implemented plan to regain schedule• Torcon slow on submittal of pricing proposals for ECN’s (management currently

focused on improving safety)• Utility conflicts have been resolved and utility submittals need to catch up

• PCR’s in preparation for newly awarded contracts• Need to incorporate CHW Plant Expansion, CHW Piping and Elect Substation

contractors cost plans into baseline for accurate performance assessment• PCRs for field changes and ECN’s need to be processed once acceptable

proposals are received.

• Advancing LOB Design & Construction • LOB RFP advancing more slowly than expected however, coordination of LOB

contractor with Ring contractor limits start of LOB construction to no earlier than 7/1/10 – thus no impact if awarded in March 10.


Conclusions

• CF activities are on budget and close to on-schedule– Will be back on schedule when contracts are incorporated– Working with Torcon to get back on early finish schedule

• Maintaining a “best in class” construction safety program remains a key objective

• Construction proceeding well – Contractor and subcontractors are technically proficient and

quality is very good

• Balance of CF procurements (except LOBs) are in place or nearly so – cost results are within baseline

• LOB design nearing completion and release for proposals when RFP is approved

cf status update

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