VLCW06 - 20 July Global Design Effort 1
Installation Global System Review
F. AsiriW. Bialowons, T. Shidara
Acknowledgment: C. Hauviller, R. SugaharaC. Corvin, G. Aarons, M. Munro, F. Peters, B. McKee, P. Rodriguez,
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Status
• Prepared WBS to level 5• Obtained all pertinent material on similar installation
– PEPII, SSC, SLC, Spear II, APS, Fermi Main Inj, KEKB, LHC– None offer a one-for-one scalable comparison, but collectively
they provided a range “ 2% to 12%” an average of 7%• Identified “Point of Contact” for each T.S. and A.S.• Attempted to obtained components list from T.S. and A. S.
managers– The list is lately received and is partially complete
– The equipment installation details are not yet confirmed
• Established subsystem interfaces/Boundaries– Qualitatively and softly defined
• Established an Installation and costing plan
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• Compiled, studied and discussed the data obtained for installation cost estimate of other projects– LHC, KEKB, TESLA, NLC, etc
• Visited CERN and DESY – Discussed and obtained parametric data for LHC installation– Observed installation of Cryomagnets and CMS detector – Participated in the ILC Main Linac cost model meeting in DESY
• Discussed and obtain data for installation from XFEL presentations• Discussed installation issues related to ILC Main Linac
• Applied RSMeans approach for the equipment installation cost as percentage of total project cost– RSMeans is N. America’s leading supplier of construction cost
information and provides accurate and up-to-date cost data– Established a range (5% to 8% )
Installation Cost Estimate Approach
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• Obtained the detailed WBS for installation cost estimate for USLCSC for cold machine (5% to 7%)– Compared scope, complexity and salient features
with the ILC Baseline machine– Used the parametric data available and scaled to
match – Discussed the results in numerous meetings and
made collective judgment – Results presented in the Installation WBS format
and discussed with the other installation co-leader
Installation Cost Estimate Approach
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• Each cryomagnet costs about 1000K MCHF– Procurement and Maintenance: 26 MCHF– Operation: 23 MCHF
• Due to presence of fragile components, tolerance of the internal parts must maintained with in ±0.1 mm during shipping, handling and installation– Most of the cryomagnets were installed on site, too many handling – Special customized transport system used– Special care in handling, transport an installation became necessary– In tunnel transport maximum speed, 3K/hr
• It took at least 5 days to complete on site assembly and 5 days for testing prior to installation
• Installation team consisted of total 70 people (Eng, Tech, Operator)• Installation rate: initially 10 cryomagnets per week, now up to 30
working 24 hours a day , 7 days a week
Notes from LHC Cryomagnet installation at CERN:
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Per-Unit Equipment Installation Handling Basis - Labor & Cost Add to Normal Labor & Cost in Restricted Tunnel Access Areas
2006 RSMeans $US Cost Basis Unit Weight Labor Units Unit Labor Unit Labor Labor Total Cost Total CostLbs. Kg. Hours Hours per Lb. Hours per Kg. Cost w/O&P w/O&P per Lb.
200 91 5.93 Each 0.0296 0.0652 $315.00 $470.00 $2.35500 227 8.00 Each 0.0160 0.0352 $425.00 $635.00 $1.27700 318 10.00 Each 0.0143 0.0314 $535.00 $795.00 $1.14
1000 455 13.33 Each 0.0133 0.0293 $710.00 $1,050.00 $1.052000 909 24.00 Each 0.0120 0.0264 $1,275.00 $1,900.00 $0.953000 1364 32.00 Each 0.0107 0.0235 $1,725.00 $2,550.00 $0.854000 1818 40.00 Each 0.0100 0.0220 $2,125.00 $3,175.00 $0.795000 2273 48.00 Each 0.0096 0.0211 $2,575.00 $3,800.00 $0.76
Metric: ~53.50/hour $US, (~79.17/hour $US with Overhead & Profit)~1676 hours/year
Installation Cost Model for Equipment in Tunnels
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Installation Cost Model in Tunnels
724 Main Linac HLRF AC-DC Power Units
With: Added Tunnel Equipment Handling $104,182,594Without: Added Tunnel Equipment Handling - $ 95,855,560 $ 8,327,034Percent added = 7.99% @ ~100M $US Level
HLRF 50/50 AC-DC Power Cost - RSMeans 2006 Data USA Labor Unit Material Labor Equip. Total Total $US Extended Extended ExtendedQty Item Descriptions Hours $US $US IL $US $US +O&P Hours Material Total Cost
363 Shielded cable, copper, XLP, grounded neutral, 35 kV, 1/0, in RSC 4.706 CLF 410.00 251.00 0.00 661.00 830.00 1708 $148,830 $301,2904344 Cable terminations, separable, 34.5 kV insulation dia, .975" to 1.570" 1.509 Ea. 183.00 80.50 0.00 263.50 320.00 6555 $794,952 $1,390,080
90 Shielded cable, copper, XLP, grounded neutral, 35 kV, 1/0, in RSC 4.706 CLF 410.00 251.00 0.00 661.00 830.00 424 $36,900 $74,7001086 Cable terminations, separable, 34.5 kV insulation dia, .975" to 1.570" 1.509 Ea. 183.00 80.50 0.00 263.50 320.00 1639 $198,738 $347,520181 Liquid-filled dead front transformer, 34.5 kV pri, 277/480 V sec, 3 ph, 500 kVA 50 Ea. 16300.00 2625.00 340.00 19265.00 22200.00 9050 $3,011,840 $4,018,200181 Transformer handling in restricted areas, approximately 3000 Lb, 500 kVA 32.00 Ea. 0.00 1725.00 0.00 1725.00 2550.00 5792 $0 $461,550724 Liquid-filled dead front transformer, 34.5 kV pri, 277/480 V sec, 3 ph, 225 kVA 36.364 Ea. 12535.00 1900.00 247.00 14682.00 16798.50 26328 $9,254,168 $12,162,114724 Transformer handling in restricted areas, approximately 1600 Lb, 225 kVA 18.462 Ea. 0.00 985.00 0.00 985.00 1450.00 13366 $0 $1,049,800724 Dry type transformer, 3 phase 480 V pri. 120/208 V sec, 75 kVA, shielded 22.857 Ea. 3875.00 1225.00 0.00 5100.00 6075.00 16548 $2,805,500 $4,398,300181 Switchboards, main circuit breaker, 3 pole, 4 wire, 277/480 volt, 600 amp 14.55 Ea. 3250.00 775.00 0.00 4025.00 4725.00 2633 $588,250 $855,225724 Switchboards, main circuit breaker, 3 pole, 4 wire, 120/208 volt, 225 amp 13.333 Ea. 3105.00 710.00 0.00 3815.00 4445.50 9653 $2,248,020 $3,218,542
1086 Circuit breakers, 3 pole, 480 V, to 100 amp, for feeder section 2 Ea. 475.00 107.00 0.00 582.00 685.00 2172 $515,850 $743,9105792 Circuit breakers, 3 pole, 240 V, to 60 amp, for feeder section 1.509 Ea. 246.00 80.50 0.00 326.50 390.00 8740 $1,424,832 $2,258,8801955 Wire, copper, stranded, 600 volt, #12, type THWN-THHN, in raceway 0.727 CLF 7.10 38.50 0.00 45.60 65.50 1421 $13,881 $128,0535129 Wire, copper, stranded, 600 volt, #2, type THWN-THHN, in raceway 1.78 CLF 76.50 94.50 0.00 171.00 226.00 9119 $392,369 $1,159,154724 Wire, copper, stranded, 600 volt, 4/0, type THWN-THHN, in raceway 3.64 CLF 200.00 194.00 0.00 394.00 510.00 2632 $144,800 $369,240
18100 Wireway, screw cover, 6" x 6", NEMA 1, incl fittings and supports 0.267 L.F 19.10 14.20 0.00 33.30 42.00 4833 $345,710 $760,200128235 Rigid steel conduit, 1" dia, incl 2 terminations, 2 els, 11 clamps per 100 LF 0.123 L.F 3.97 6.55 0.00 10.52 14.10 15773 $509,093 $1,808,11414500 Rigid steel conduit, 2" dia, incl 2 terminations, 2 els, 11 clamps per 100 LF 0.123 L.F 6.40 6.55 0.00 12.95 16.80 1784 $92,800 $243,600
724 Circuit breaker, 3 pole, 600 volt, 400AF amp, enclosed NEMA 1 10 Ea. 2175.00 535.00 0.00 2710.00 3200.00 7240 $1,574,700 $2,316,800724 Electronic rack enclosures, 72" H x 30" W x 36" D 6.667 Ea. 2100.00 355.00 0.00 2455.00 2850.00 4827 $1,520,400 $2,063,400
2172 Hi-Hz Switching PS, Cap. Charge .48kVAC~12kVDC ALE 303 15kV, 30kJ/sec 47.619 Ea. 19400.00 2500.00 325.00 22225.00 25400.00 103428 $42,842,700 $55,168,8001368 Ground wire, copper wire, bare stranded, 4/0 2.807 CLF 178.00 150.00 0.00 328.00 420.00 3840 $243,504 $574,560
22806 Grounding clamp, bronze, 5/8" diameter 0.25 Ea. 4.20 13.30 0.00 17.50 24.50 5702 $95,785 $558,747724 Other: EMS, SCADA, RF X-Locks, Hardware 5.25 Lot 715.00 280.00 0.00 995.00 1293.00 3801 $517,660 $936,132
SubTotal 269008 $69,321,281 $97,366,9100 Material staging area limited, not adjacent, add to total project cost % 0.02 5,380 $1,947,3380 Restricted work space, add modifications to total project cost summaries % 0.05 13,450 $4,868,346
Total 50/50 HLRF AC Power Construction Cost 287839 $104,182,594
HLRF 50/50 AC-DC Power Cost - RSMeans 2006 Data USA Labor Unit Material Labor Equip. Total Total $US Extended Extended ExtendedQty Item Descriptions Hours $US $US IL $US $US +O&P Hours Material Total Cost
363 Shielded cable, copper, XLP, grounded neutral, 35 kV, 1/0, in RSC 4.706 CLF 410.00 251.00 0.00 661.00 830.00 1708 $148,830 $301,2904344 Cable terminations, separable, 34.5 kV insulation dia, .975" to 1.570" 1.509 Ea. 183.00 80.50 0.00 263.50 320.00 6555 $794,952 $1,390,080
90 Shielded cable, copper, XLP, grounded neutral, 35 kV, 1/0, in RSC 4.706 CLF 410.00 251.00 0.00 661.00 830.00 424 $36,900 $74,7001086 Cable terminations, separable, 34.5 kV insulation dia, .975" to 1.570" 1.509 Ea. 183.00 80.50 0.00 263.50 320.00 1639 $198,738 $347,520
181 Liquid-filled dead front transformer, 34.5 kV pri, 277/480 V sec, 3 ph, 500 kVA 50 Ea. 16300.00 2625.00 340.00 19265.00 22200.00 9050 $3,011,840 $4,018,200724 Liquid-filled dead front transformer, 34.5 kV pri, 277/480 V sec, 3 ph, 225 kVA 36.364 Ea. 12535.00 1900.00 247.00 14682.00 16798.50 26328 $9,254,168 $12,162,114724 Dry type transformer, 3 phase 480 V pri. 120/208 V sec, 75 kVA, shielded 22.857 Ea. 3875.00 1225.00 0.00 5100.00 6075.00 16548 $2,805,500 $4,398,300181 Switchboards, main circuit breaker, 3 pole, 4 wire, 277/480 volt, 600 amp 14.55 Ea. 3250.00 775.00 0.00 4025.00 4725.00 2633 $588,250 $855,225724 Switchboards, main circuit breaker, 3 pole, 4 wire, 120/208 volt, 225 amp 13.333 Ea. 3105.00 710.00 0.00 3815.00 4445.50 9653 $2,248,020 $3,218,542
1086 Circuit breakers, 3 pole, 480 V, to 100 amp, for feeder section 2 Ea. 475.00 107.00 0.00 582.00 685.00 2172 $515,850 $743,9105792 Circuit breakers, 3 pole, 240 V, to 60 amp, for feeder section 1.509 Ea. 246.00 80.50 0.00 326.50 390.00 8740 $1,424,832 $2,258,8801955 Wire, copper, stranded, 600 volt, #12, type THWN-THHN, in raceway 0.727 CLF 7.10 38.50 0.00 45.60 65.50 1421 $13,881 $128,0535129 Wire, copper, stranded, 600 volt, #2, type THWN-THHN, in raceway 1.78 CLF 76.50 94.50 0.00 171.00 226.00 9119 $392,369 $1,159,154
724 Wire, copper, stranded, 600 volt, 4/0, type THWN-THHN, in raceway 3.64 CLF 200.00 194.00 0.00 394.00 510.00 2632 $144,800 $369,24018100 Wireway, screw cover, 6" x 6", NEMA 1, incl fittings and supports 0.267 L.F 19.10 14.20 0.00 33.30 42.00 4833 $345,710 $760,200
128235 Rigid steel conduit, 1" dia, incl 2 terminations, 2 els, 11 clamps per 100 LF 0.123 L.F 3.97 6.55 0.00 10.52 14.10 15773 $509,093 $1,808,11414500 Rigid steel conduit, 2" dia, incl 2 terminations, 2 els, 11 clamps per 100 LF 0.123 L.F 6.40 6.55 0.00 12.95 16.80 1784 $92,800 $243,600
724 Circuit breaker, 3 pole, 600 volt, 400AF amp, enclosed NEMA 1 10 Ea. 2175.00 535.00 0.00 2710.00 3200.00 7240 $1,574,700 $2,316,800724 Electronic rack enclosures, 72" H x 30" W x 36" D 6.667 Ea. 2100.00 355.00 0.00 2455.00 2850.00 4827 $1,520,400 $2,063,400
2172 Hi-Hz Switching PS, Cap. Charge .48kVAC~12kVDC ALE 303 15kV, 30kJ/sec 47.619 Ea. 19400.00 2500.00 325.00 22225.00 25400.00 103428 $42,842,700 $55,168,8001368 Ground wire, copper wire, bare stranded, 4/0 2.807 CLF 178.00 150.00 0.00 328.00 420.00 3840 $243,504 $574,560
22806 Grounding clamp, bronze, 5/8" diameter 0.25 Ea. 4.20 13.30 0.00 17.50 24.50 5702 $95,785 $558,747724 Other: EMS, SCADA, RF X-Locks, Hardware 5.25 Lot 715.00 280.00 0.00 995.00 1293.00 3801 $517,660 $936,132
SubTotal 249850 $69,321,281 $95,855,560
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ILC Installation Labor & Cost Extensions RSMeans - 2006 Ranges for All Construction
Percent Change - Total $US Cost w/O&P %Percent Change - Labor Hours % Percent Change - Material %
Available-Unavailable Material Storage Staging Area 1.5% avl 1% 2% uavl
Unlimited-Limited Material Handling-Storage 4.5% ulim 1% 2% 3% 4% 5% 6% lim
Unlimited-Limited Material Handling-Storage 5.5% ulim 1% 2% 3% 4% 5% 6% 7% lim
Available-Unavailable Work Space 4.5% avl 2% 3% 4% 5% uavl
Favorable-Unfavorable Hoisting Conditions 4.5% fav 2% 3% 4% 5% ufav
Minimum-Maximum Dust Protection 3.5% min 1% 2% 3% 4% max
Minimum-Maximum Dust Protection 9.5% min 2% 3% 4% 5% 6% 7% 8% 9% 10% 11% max
Minimum-Maximum Off-Shift Installation Work 12.5% min 5% 6% 7% 8% 9% 10% 11% 12% 13% 14% 15% ----- 30% max
Net ILC Installation Cost Applied to Project 5.8%
Overall Project Installation Cost Extension Ranges
Installation: Surface & Tunnel Cost
Percent added = 5.8% @ ~1B $US Level
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Installation: Cost Parameters
Installation Cost Adders & Scale by Size & Location
• ~10% Cost @ ~10M $US Level ~ 11.2 man-years
in Tunnels• ~ 8% Cost @ ~100M $US Level ~ 89.2 man-years
in Tunnels• ~ 6% Cost @ ~1,000M $US Level ~ 669 man-years
in Tunnels & Surface• ? 4% Cost @ ~10,000M $US Level ~ 4461 man-years
for ILC Project?
Metric: ~1676 hours/year @ ~53.50/hour $US
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Level 4 Rollup
WBS 1.7.3 Installation
WBS Component
1 7 3 Installation
1 7 3 1 General Installation
1 Logistics Management
2 Engineering Support
3 Equipment
4 Vehicles
5 Shipping-Receiving
6 Warehousing
7 Surface Transport
1 7 3 2 Area System Installation
1 Sources e- Area Installation
2 Sources e+ Area Installation
3 Damping Ring Area Installation
4 RTML Area Installation
5 Main Linac Area Installation
6 Beam Delivery Area Installation
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On the surface Installation work
WAREHOUSING•PICKING SYSTEM•RACKS•CONVEYORS•LIFT TRUCKS•DOCKS
•CUSTOM EQUIPMENT •MACHINE TOOLS•ELECTRONIC TEST •MAGNET MEASUREMENT•RF TEST •QUALITY CONTROL•ASSEMBLY
•INVENTORY CONTROL MANAGEMENT•STAGING MANAGEMENT•COST CONTROL
VEHICLES•TRUCKS•PEOPLE MOVERS
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In the tunnel Installation work
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Plans and Goals Near Term
• In this workshop meet with each T.S and A.S group– To review scope and content of each T.S. WBS – To understand scope of on site testing – To identify any omission, overlapping, double counting
• Between this and the Valencia workshop– To define scope of on site deliverable for each subsystem– To define the subsystem installation requirements– To establish subsystem interfaces/Boundaries– To review and continue to refine the parametric installation
cost Estimate – To incorporate adjustments and Inputs from Area and
Technical Systems as Required and Complete the Installation Portion of the Reference Design Report for Submission at the Valencia GDE Meeting in November, 2006
• Franz Peters has joined SLAC Installation group part time (0.5 FTE)• M. Munro, B. McKee, P. Rodriquez will provide additional support
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• Goal: to produce an integrated Installation process for the ILC Baseline in full cooperation with other regions– Set-up and manage an installation data base in FY
07 that can be expanded in a full pledged program through FY 08 and FY 09 toward TDR
– Proposed estimated level of effort for the American Region toward TDR
• FY 07;1.5 FTE and ~ $100K M&S (contract)• FY 08; 2 FTE and ~ $200K M&S (contract)• FY 09; 2 FTE and ~ $200K M&S (contract)
– Needs same level of effort from the other regions to perform a real bottom-up cost estimate
Installation G.S Long Term Plan