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1 BROOKHAVEN SCIENCE ASSOCIATES Accelerator Systems Installation F. Willeke, ASD Director 6 th ASAC October 22-23, 2009.

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Presentation on theme: "1 BROOKHAVEN SCIENCE ASSOCIATES Accelerator Systems Installation F. Willeke, ASD Director 6 th ASAC October 22-23, 2009."— Presentation transcript:

1 1 BROOKHAVEN SCIENCE ASSOCIATES Accelerator Systems Installation F. Willeke, ASD Director 6 th ASAC October 22-23, 2009

2 2 BROOKHAVEN SCIENCE ASSOCIATES Outline Magnet Girder Integration Installation Preparation Installation Schedule Installation Resource Planning Installation Overview Availability of Buildings Girder Installation Details Storage Ring Installation Logistics

3 3 BROOKHAVEN SCIENCE ASSOCIATES Magnet Girder Integration

4 4 BROOKHAVEN SCIENCE ASSOCIATES 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

5 5 BROOKHAVEN SCIENCE ASSOCIATES 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

6 6 BROOKHAVEN SCIENCE ASSOCIATES 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

7 7 BROOKHAVEN SCIENCE ASSOCIATES Storage Ring Electrical Utilities: Detailed Planning Racks will be equipped on the Mezzanine

8 8 BROOKHAVEN SCIENCE ASSOCIATES Civil Construction Sequence

9 9 BROOKHAVEN SCIENCE ASSOCIATES Installation Overview BuildingBODInstallation ActivityStart Date Pentant 1*)1-Feb-11SR Components20-Jun-11 Pentant 11-Feb-11SC RF Cavities21-Sep-12 RF Bld23-May-11RF Power Systems & Cryog’s29-Mar-12 Inj. Bld18-May-11Booster RF Cavity21-Jun-11 Inj. Bld18-May-11LINAC18-Oct-11 Inj. Bld18-May-11Booster08-Jun-12 Pentant 202-May-JunSR Components20-Oct-11 Pentant 327-Sep-11SR Components14-Feb-12 Pentant428-Nov-11SR Components16-Apr-12 Pentant 509-Feb-12SR Components28-Jun-12 *) includes central cooling tower building and access tunnels

10 10 BROOKHAVEN SCIENCE ASSOCIATES 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

11 11 BROOKHAVEN SCIENCE ASSOCIATES

12 12 BROOKHAVEN SCIENCE ASSOCIATES Planned Resources 50 FTE planned  this needs reassessment

13 13 BROOKHAVEN SCIENCE ASSOCIATES Even Cell Girders G3 G5G6G2G4 G1 Black border indicates an even cell ID Section

14 14 BROOKHAVEN SCIENCE ASSOCIATES Odd Cell Girders G1 G3 G5G6G2G4 ID Section Water manifolds are shown schematically as a double red line (Aluminum) a double green line (Copper) Red border indicates an odd cell

15 15 BROOKHAVEN SCIENCE ASSOCIATES Typical cell rack groups Blue 234 Blue border indicates a rack group 2, 3, or 4 racks wide Cable tray is shown schematically as a double dashed line G3 G5G6G2G4

16 16 BROOKHAVEN SCIENCE ASSOCIATES The first slice; Pentant 1 plus…

17 17 BROOKHAVEN SCIENCE ASSOCIATES 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

18 18 BROOKHAVEN SCIENCE ASSOCIATES Girder Transport in the Tunnel Used for RHIC New models

19 19 BROOKHAVEN SCIENCE ASSOCIATES “ 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-8 MAXIMUM LOAD CAPACITY: 13,500 LBS. (SAFETY FACTOR = 1.5) Number of WheelsWeightHeightWidthDepth Swivel Pad Diameter Distance from center of swivel pad to handle Handle Length Roller Dimensions 891 lbs.4.25"23.5"19.5"6.625"12"45"3.25" x 3.25" MODEL RT-3 MAXIMUM LOAD CAPACITY: 4,500 LBS. (SAFETY FACTOR = 1.5) Number of WheelsTotal WeightHeightWidthPad DiameterRoller Dimensions 373 lbs.4.25"18"6.625"3.25" x 3.25"

20 20 BROOKHAVEN SCIENCE ASSOCIATES Pentant 1 installation Zones 24 25272823 Experimental floor Tunnel 2425262722 Mezzanine 23 26 Service Building

21 21 BROOKHAVEN SCIENCE ASSOCIATES Storage ring Pentant 1 installation: Week 24 25272823 Exp’l floor Tunnel Service Building 2425262722 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

22 22 BROOKHAVEN SCIENCE ASSOCIATES Storage ring Pentant 1 installation: Week 24 25272823 Exp’l floor Tunnel Service Building 2425262722 Mezzanine 23 Status: Most material in building Installation on mezzanine Begin in tunnel 26 4 Activities: Stage components on floor Start racks on mezzanine

23 23 BROOKHAVEN SCIENCE ASSOCIATES Storage ring Pentant 1 installation: Week 24 25272823 Exp’l floor Tunnel Service Building 2425262722 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 24 BROOKHAVEN SCIENCE ASSOCIATES Storage ring Pentant 1 installation: Week 24 25272823 Exp’l floor Tunnel Service Building 2425262722 Mezzanine 23 Status: Multipole girder installation 26 8 Activities: Begin Girder installation Start populating racks Begin Utility installation in SB

25 25 BROOKHAVEN SCIENCE ASSOCIATES Storage ring Pentant 1 installation: Week 24 25272823 Exp’l floor Tunnel Service Building 2425262722 Mezzanine 23 Status: Half way in schedule 26 10 Activities: Girder installation Populating racks Utility installation in SB

26 26 BROOKHAVEN SCIENCE ASSOCIATES Storage ring Pentant 1 installation: Week 24 25272823 Exp’l floor Tunnel Service Building 2425262722 Mezzanine 23 Status: Most wiring pulled Process utilities connected 26 12 Activities: Girder installation Populating racks Terminating cables

27 27 BROOKHAVEN SCIENCE ASSOCIATES Storage ring Pentant 1 installation: Week 24 25272823 Exp’l floor Tunnel Service Building 2425262722 Mezzanine 23 Status: About ¾ through schedule 26 14 Activities: Girder installation Racks populated Terminating cables

28 28 BROOKHAVEN SCIENCE ASSOCIATES Storage ring Pentant 1 installation: Week 24 25272823 Exp’l floor Tunnel Service Building 2425262722 Mezzanine 23 Status: About ½ vacuum complete 26 16 Activities: Girder installation Cable pulls all done Testing underway

29 29 BROOKHAVEN SCIENCE ASSOCIATES Storage ring Pentant 1 installation: Week 24 25272823 Exp’l floor Tunnel Service Building 2425262722 Mezzanine 23 Status: About 2/3 vacuum complete 26 18 Activities: Girder installation Cable pulls all done Testing underway

30 30 BROOKHAVEN SCIENCE ASSOCIATES Storage ring Pentant 1 installation: Week 24 25272823 Exp’l floor Tunnel Service Building 2425262722 Mezzanine 23 Status: All equipment in place System testing underway 26 20 Activities: final utility connections equipment shakeout

31 31 BROOKHAVEN SCIENCE ASSOCIATES

32 32 BROOKHAVEN SCIENCE ASSOCIATES 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

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