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CF Status Update

CF Status Update. Marty Fallier Conventional Facilities Division Director Conventional Facilities Advisory Committee Review November 9-10, 2009. Outline. Progress & Events Since Last Review (March 10, 09) Begin Ring Bldg construction Accelerated elements of the Ring Bldg schedule

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CF Status Update

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  1. CF Status Update Marty Fallier Conventional Facilities Division Director Conventional Facilities Advisory Committee Review November 9-10, 2009

  2. 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)

  3. 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

  4. Progress cont’d Photo From BGRR Stack 9-21-09 Vehicle Tunnel SR Tunnel Wall Forms SR Tunnel Slab Status of construction Site at FY09 End

  5. Progress cont’d Photo From BGRR Stack 11-5-09 SR Tunnel Wall Forms Column Footings SR Tunnel Slab SR Tunnel Walls Vehicle Tunnel Ring Bldg Progress from month to month is substantial Monthly billing is ~$4M - $5M

  6. 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

  7. 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

  8. 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

  9. 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

  10. 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

  11. 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

  12. Scope Status – Project Changes PCRs • Approved changes since last CFAC 3/10/09

  13. Scope Status – Project Changes PCRs • Changes in preparation for near term • *Pending LOB bid results in 2QFY10

  14. Costs – Management & Engineering

  15. Costs - Construction • 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

  16. Schedule

  17. 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

  18. 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

  19. 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.

  20. 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

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