1 brookhaven science associates accelerator systems installation f. willeke, asd director 6 th asac...

1 BROOKHAVEN SCIENCE ASSOCIATES

Accelerator Systems Installation

F. Willeke, ASD Director6th ASAC

October 22-23, 2009


Outline

• Magnet Girder Integration• Installation Preparation• Installation Schedule• Installation Resource Planning• Installation Overview• Availability of Buildings• Girder Installation Details• Storage Ring Installation Logistics


Magnet Girder Integration


Girder Integration Workflow

2 Girders /months 2 girders / week

@ 18 months (incl. learning curve effect)

Starting 04-Aug-1 Finish 13-Jan-12

High precision Alignment

Preassembly

2 days

90 MP Girders, 60 Dipole Girders


Database Entries in Support of Installation

Quadrupole magnet

Configuration type “D”

Specification (9809)

Girder 2, Cell 1

30.25 meters from ID center

De-focussing Quad

Magnet A terminal to supply Negative terminal

Magnet B terminal to supply Positive terminal

Power supply spec type “B”, 175 Amp

252 kcmil wire required

Located in mezzanine Cell 1 rack A1

19 RU from bottom of rack

Powers magnet QL1 in cell 1

Comprehensive Information on all subsystems and their relations including connecting cables will support installation


Storage Ring Magnet Conventions

Example: Wiring details for Quad QL1G2C01A

• Wire type : 252 kcmil, 175 amps max 138 amps nominal• Wire starts in tunnel : 30.25 meters from Long ID center Cell 1• Wire ends in mezzanine : Cell 01 Rack A1 Height from bottom 19 RU• Connected as a de-focus quad:

• A terminal to supply negative terminal• B terminal to supply positive terminal

• Wire marking: load / source• QL1G2C01A-A / SR-PS-QBL1-C01-A1 NEG for negative voltage conductor• QL1G2C01A-B / SR-PS-QBL1-C01-A1 POS for positive voltage conductor

• Testing of wiring via traveller (QA documentation requirements)• Hipot to 2Kv prior to connection to magnet• Continuity check for wire polarity• Electrical check for magnet polarity


Storage Ring Electrical Utilities: Detailed Planning

Racks will be equipped on the Mezzanine


Civil Construction Sequence


Installation Overview

Building BOD Installation Activity Start DatePentant 1*) 1-Feb-11 SR Components 20-Jun-11

Pentant 1 1-Feb-11 SC RF Cavities 21-Sep-12

RF Bld 23-May-11 RF Power Systems & Cryog’s 29-Mar-12

Inj. Bld 18-May-11 Booster RF Cavity 21-Jun-11

Inj. Bld 18-May-11 LINAC 18-Oct-11

Inj. Bld 18-May-11 Booster 08-Jun-12

Pentant 2 02-May-Jun SR Components 20-Oct-11

Pentant 3 27-Sep-11 SR Components 14-Feb-12

Pentant4 28-Nov-11 SR Components 16-Apr-12

Pentant 5 09-Feb-12 SR Components 28-Jun-12

*) includes central cooling tower building and access tunnels


Installation Overall Plan

• LINAC Installation: responsibility and work by vendor

• Booster Installation: responsibility of the vendor, but BNL will provide experienced and trained installation and rigging staff under a BNL installation supervisor

• Storage Ring Installation: Carried out by AS staff and

BNL rigging crews, 50% will be temporary labor


Planned Resources

50 FTE planned this needs reassessment


Even Cell Girders

G3 G5 G6G2 G4

G1

Black border indicates an even cell

ID Section


Odd Cell Girders

G1

G3 G5 G6G2 G4

ID Section

Water manifolds are shown schematically as

a double red line (Aluminum)

a double green line (Copper)

Red border indicates an odd cell


Typical cell rack groups

BlueBlue border indicates a rack group 22, 33, or 44 racks wide

Cable tray is shown schematically as a double dashed line

G3 G5 G6G2 G4


The first slice; Pentant 1 plus…


Dolly assembly is removed from girder with air casters inflated

Blocks are positioned at sides of floor mounting plates

Note: Threaded support shafts and hardware will not be installed at this stage

Installation of Magnet Girders


Girder Transport in the Tunnel

Used for RHIC

New models


“Stearman” Type Dolly system components

The dolly system includes “Stearman” Dolly components rated at 9000# and 13,500#

Expected girder weight is 17,000#

MODEL ST-8MAXIMUM LOAD CAPACITY: 13,500 LBS. (SAFETY FACTOR = 1.5)

Number of Wheels Weight Height Width Depth

Swivel Pad Diameter

Distance from center of swivel pad to handle

Handle Length

Roller Dimensions

8 91 lbs. 4.25" 23.5" 19.5" 6.625" 12" 45" 3.25" x 3.25"

MODEL RT-3MAXIMUM LOAD CAPACITY: 4,500 LBS. (SAFETY FACTOR = 1.5)

Number of Wheels Total Weight Height Width Pad Diameter Roller Dimensions

3 73 lbs. 4.25" 18" 6.625" 3.25" x 3.25"


Pentant 1 installation Zones

24 25 27 2823

Experimental floor

Tunnel

24 25 26 2722

Mezzanine

23

26

Service Building


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 building

Installation starting

26

2

Activities:

•Prepare tunnel

•Stage components on floor

•Start cable tray on mezzanine



24 25 27 2823

Exp’l floor

Tunnel

Service Building

24 25 26 2722

Mezzanine

23

Status:

Most material in building

Installation on mezzanine

Begin in tunnel

26

4

Activities:

•Stage components on floor

•Start racks on mezzanine



24 25 27 2823

Exp’l floor

Tunnel

Service Building

24 25 26 2722

Mezzanine

23

Status:

Most material in building

Installation on mezzanine

Installation in tunnel

26

6

Activities:

•Tray and manifolds in place in tunnel

•Racks well underway

•Stage cable and start pulling



24 25 27 2823

Exp’l floor

Tunnel

Service Building

24 25 26 2722

Mezzanine

23

Status:

Multipole girder installation

26

8

Activities:

•Begin Girder installation

•Start populating racks

•Begin Utility installation in SB



24 25 27 2823

Exp’l floor

Tunnel

Service Building

24 25 26 2722

Mezzanine

23

Status:

Half way in schedule

26

10

Activities:

•Girder installation

•Populating racks

•Utility installation in SB



24 25 27 2823

Exp’l floor

Tunnel

Service Building

24 25 26 2722

Mezzanine

23

Status:

Most wiring pulled

Process utilities connected

26

12

Activities:


•Populating racks

•Terminating cables



24 25 27 2823

Exp’l floor

Tunnel

Service Building

24 25 26 2722

Mezzanine

23

Status:

About ¾ through schedule

26

14

Activities:


•Racks populated

•Terminating cables



24 25 27 2823

Exp’l floor

Tunnel

Service Building

24 25 26 2722

Mezzanine

23

Status:

About ½ vacuum complete

26

16

Activities:


•Cable pulls all done

•Testing underway



24 25 27 2823

Exp’l floor

Tunnel

Service Building

24 25 26 2722

Mezzanine

23

Status:

About 2/3 vacuum complete

26

18

Activities:


•Cable pulls all done

•Testing underway



24 25 27 2823

Exp’l floor

Tunnel

Service Building

24 25 26 2722

Mezzanine

23

Status:

All equipment in place

System testing underway

26

20

Activities:

•final utility connections

•equipment shakeout


Conclusion

• Magnet Girder Integration re-planned: is the backbone for the installation activity

• Installation of utilities on the mezzanine and cabling well planned making use of the equipment relational data base

• Installation schedule has recently been re-optimized and aligned with building schedule

• Resource for installation still need to be revised and optimized, concern is large number of temporary staff (~30)

• Installation logistics, intermediate storage and space management well advanced

• Conclusion: Installation Planning is very advanced

1 brookhaven science associates accelerator systems installation f. willeke, asd director 6 th asac...

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