NSLS-II Accelerator Installation Plan

1. NSLS-II Accelerator Installation Plan Gregory Fries Project Engineer, Accelerator Systems Division CFAC Review of NSLS-II October 5-6, 2010

2. Outline • Phasing of Installation • Coordination with Conventional Facilities • Storage Ring Installation • Injector Installation • Storage and Rigging • Installation Schedule • Experimental Installation • Potential Obstacles • Summary

3. Phasing of Construction and Installation Beneficial Occupancy Installation

4. Installation and Operation Zones 1 • 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 B RF RF 2 5 L 4 3

5. 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

6. Key Aspects of Production and Installation Accelerator 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

7. Storage Ring Systems Installation Per 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

8. Storage Ring Pentant 1 Installation: Week 2 22 23 24 25 26 27 Mezzanine Exp’l floor 23 25 26 27 28 24 Tunnel • Activities: • Prepare tunnel • Stage components on floor • Start cable tray on mezzanine Status: ~ 1/3 of material in building Installation starting Service Building

9. Storage Ring Pentant 1 Installation: Week 6 22 23 24 25 26 27 Mezzanine Exp’l floor 23 25 26 27 28 24 Tunnel • Activities: • Tray and manifolds in place in tunnel • Racks well underway • Stage cable and start pulling Status: Most material in building Installation on mezzanine Installation in tunnel Service Building

10. Storage Ring Pentant 1 Installation: Week 12 22 23 24 25 26 27 Mezzanine Exp’l floor 23 25 26 27 28 24 Tunnel • Activities: • Girder installation • Populating racks • Terminating cables Status: Most wiring pulled Process utilities connected Service Building

11. Storage Ring Pentant 1 Installation: Week 18 22 23 24 25 26 27 Mezzanine Exp’l floor 23 25 26 27 28 24 Tunnel • Activities: • Girder installation • Cable pulls all done • Testing underway Status: About 2/3 vacuum complete Service Building

12. 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

13. Injector Installation Phases Layout Phase Separation (end of injector install) BtS TL Part 1 Booster RF Booster Linac LtB TL Part 2 Phase Separation LtB TL Part 1

14. 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

15. Lay-down Areas for Sea Containers Lay-down Area for SR Component Storage Containers Outside Access to Experimental Floor for Unloading Lay-down Area for Linac & Booster Containers

16. Rigging Requirements

17. 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

18. 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

19. Installation, Testing & Commissioning Schedule

20. 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

21. Experimental Installation • XFD Installation follows ASD installation by pentant • Activities Per Beamline • Pentant Hand-off from ASD • Pentant Clean-up • Hutches • Utilities • Beamline Components

22. 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)

23. 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