vlcw06 - 20 july global design effort1 installation global system review f. asiri w. bialowons, t....

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,


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


• 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


• 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


• 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:


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


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


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


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


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


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


In the tunnel Installation work


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


• 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

vlcw06 - 20 july global design effort1 installation global system review f. asiri w. bialowons, t....

Documents