Baseline Change Request BCR Title: EBD New 6 Ton Bridge Crane Installation BCR #: N/A Presenter’s Name: Robert Law CCB Presentation Date:

2 BCR Summary This BCR entails the requirement for a new 7 ton motorized chain hoist & bridge crane system to be installed in EBD Area to efficiently, safely and timely facilitate the removal and/or installation EBD system activities as follows: Removal of (2) existing LCLS dumps shielding with combined weight of approximately 92 tons (57 tons for South dump; 35 tons for North dump) Installation of LCLS-II new dumps shielding with combined weight of approximately 408 tons (204 tons each for both North and South dumps) including 90 plates weighing 2 tons/plate, Relocation / Installation of EBD hard & soft beam lines components / devices including (3) permanent magnets, and (2) dump slugs with shielding coffins weighing between 5 and 6 tons each. Installation of over 200 new shielding components for both hard & soft beam lines components / devices. CCB Presentation – MM-DD-YYYY

3 BCR Form CCB Presentation – MM-DD-YYYY

4 Background In Electron Beam Dump (EBD) housing there are (2) monorail cranes on the North and the South sides. Each rail starts with a short piece and finishes with short piece assumable 20.5’ each. The middle section is a long rail assumable 41’ long. The two crane rails are parallel ( field verified). Distance between rails is 98.5”. The distance from South and North walls to the South and North rails center is 39.25”. Both cranes have lifting capacity of 5 tons (10,000 lbs) each. Based on current SLAC crane records, only the South monorail crane has anchored fixture for crane certification with quadrennial certification date of November 1, Refer to Figures 1 & 2 for existing monorail cranes arrangement. CCB Presentation – MM-DD-YYYY Background, Problem, Solution

5 Background (Continued) CCB Presentation – MM-DD-YYYY Background, Problem, Solution (Continued) BEAM Monorail crane rails - 41’ EBD Housing End Figure 1: Existing monorail crane rail view from the South side

6 Background (Continued) CCB Presentation – MM-DD-YYYY Background, Problem, Solution (Continued) Figure 2: Existing monorail cranes view downstream Monorail crane rails ” apart EBD Housing 177”W X 150”H

7 Problem -Relocation of (3) permanent magnets in EBD will be a challenge since the current crane rails do not fully align with both North and South beam lines as shown in Figure 3. -New beam lines after the BYD magnets are not parallel to each other and to the existing crane rails. Existing cranes will cover very limited service areas as shown in Figure 4. -Existing shielding was put in the pit with forklift when there was no East wall in the housing and there were no obstructions on the North side. -New dump will have two similar beam lines on the North and South sides with very limited space between them and forklift access will be either unsafe or not feasible. CCB Presentation – MM-DD-YYYY Background, Problem, Solution (Continued)

8 Problem (Continued) -New shielding will be much larger than the existing ones in magnitude of more than 4 (total combined new dumps shielding quantity will be about 408 vs total existing dumps shielding quantity of 92. The average single shielding plate weighs about 2 tons. Besides new shielding, there will be over 200 new shielding components to be installed for both hard & soft beam lines components / devices. - A single heaviest device to be lifted, the dump slug with shielding coffin required by RP, weighs between 5 to 6 tons. CCB Presentation – MM-DD-YYYY Background, Problem, Solution (Continued)

9 Problem (Continued) CCB Presentation – MM-DD-YYYY Background, Problem, Solution (Continued)

10 Problem (Continued) CCB Presentation – MM-DD-YYYY Background, Problem, Solution (Continued) Figure 4: Top view of existing cranes coverage areas

11 Solution -Install a new 7 ton motorized chain hoist / trolley and bridge crane system in EBD Area using existing monorail crane rails to meet EBD System’s crane capacity and space dimensions requirements as outlined in Figures 5 & 6. -The new crane system will provide the required coverage area as shown in Figure 7. -Installing shielding and beam lines components / devices with the new bridge crane will be safer, reduce potential worker injury, equipment damage, and maintain the project’s fast paced installation schedule. -The entire EBD Area will be modified and the installation of the new crane system will not impact EBD system installation schedule. CCB Presentation – MM-DD-YYYY Background, Problem, Solution (Continued)

12 Solution (Continued) CCB Presentation – MM-DD-YYYY Background, Problem, Solution (Continued) Figure 5 Crane upgrade requirements: -Single hoist rail; -Capacity – 6t Min; -Dim “A” – 10” Min; -Dim “B” – 160” Min; -Dim “C” – 118” Min Existing rails Ceiling

13 Solution (Continued) CCB Presentation – MM-DD-YYYY Background, Problem, Solution (Continued) Figure 6 Crane upgrade requirements (continued): -Dim “D” – 920” min; -Dim “E” – 30” Max;

14 Solution (Continued) CCB Presentation – MM-DD-YYYY Background, Problem, Solution (Continued) New bridge crane coverage area Figure 7: Top view of new bridge crane coverage area

15 Alternative Solutions Considered -No new crane: Material handling equipment access for shielding, beam lines components / devices installation works in EBD Area will be seriously affected in terms of logistics, cost and schedule. Inadequate available crane capacity to lift heaviest object will be a problem. -Different shielding design to meet RP requirements will be a challenge in terms of cost and schedule. -Option to install a new 7 ton manual hoist / trolley and motorized bridge crane system vs the current proposed 7 ton motorized hoist / trolley and bridge crane is currently being considered as another option to lower first cost. CCB Presentation – MM-DD-YYYY Background, Problem, Solution (Continued)

16 Technical Review EBD installation bi-weekly meetings have been held for several months to plan Accelerator and Photon System installations. The group has concluded that a modified crane is required to: Install the heavier objects like shielding and dump slug. Facilitate remotely removing a radioactive dump slug in the event this will be required. CCB Presentation – MM-DD-YYYY

17 Summary of Cost/Schedule Changes For new proposed 7 ton motorized hoist/trolley and motorized bridge crane system: -Total Construction Cost: $223k -Total Estimated Cost: $235k -Installation to start after December 17, 2016 (LCLS short downtime) -No change to current construction schedule For new alternate 7 ton manual hoist/trolley and motorized bridge crane system: -Total Construction Cost: $184k -Total Estimated Cost: $196k -Installation to start after December 17, 2016 (LCLS short downtime) -No change to current construction schedule For no new crane option - Total Construction Cost Increase: $600k (ROM) - Total Estimated Cost Increase: $700k (ROM) - Construction schedule delay (short downtime): ~ 25 days - Construction schedule delay (long downtime): ~ 35 days CCB Presentation – MM-DD-YYYY

18 Impact of not approving Material handling equipment access for shielding, beam lines components / devices installation work in EBD Area will be seriously affected in terms of logistics, cost and schedule. Inadequate available crane capacity to lift heaviest object will be a problem. Design of a temporarily installed lifting device capable of moving 2-6 ton objects in a restricted area will be challenging and likely result in a less safe working environment. If the dump slug ever needs to be removed, radiation exposure time is expected to be longer relative to having a crane design optimized for this purpose. Increased risk relative to safety, hardware damage, and schedule. CCB Presentation – MM-DD-YYYY

19 Stakeholder Review Stakeholder Input Received -PMCS group: Updating P6 -System Managers and CAMs: Infrastructure Systems, Photon Systems, and Accelerator Systems have been working together on this. -ES&H: Reviewed details with Jim Healy. Jim provided feedback indicating that installing shielding and devices by crane will be safer, reduce potential worker injury, equipment damage, and maintain the project’s fast paced schedule. CCB Presentation MM-DD-YYYY

20 Documents Updated If approved, the following will be updated: Applicable ICD and RDS eCAM Book BOE’s CCB Presentation MM-DD-YYYY

21 What else should we know? CCB Presentation – MM-DD-YYYY

22 Questions? CCB Presentation – MM-DD-YYYY

23 CCB Presentation – MM-DD-YYYY