1. Cryoplant Installation Cost and Schedule Installation PDR
Dana Arenius (LCLSII Cryoplant CAM)
Oct 18, 2016

2. In the baseline, JLAB’s role and responsibilities include:
Cryoplant design, specification and procurement
Cryoplant control and instrumentation
Installation (technical documentation and responsiblity)
commissioning of the cryoplant
Operational documentation and training
The design of installation (equipment, piping, instruments and controls) is still on-going at JLAB and equipment vendors.
LCLS_II Cryoplant Installation PDR

3. Outline Introduction of cryogenic system Overall schedule
Equipment list
Cryogenic system layout
Installation
Sequence and responsibilities
Cryoplant installation (CP1 & CP2), 2 phases per plant
Installation phase 1
Installation phase 2, including cryoplant Interface boxes
LCLS_II Cryoplant Installation PDR

4. 2 Cryogenic Plants for Normal Beam Operations
Equivalent capacity
~ 18 each
Power consumption
~ 4.4 MW each CP
Equivalent He
~ 30,000 liter LHe
Cryoplants
(JLAB)
CDS (FNAL)
CM (FNAL&JLAB)
Upstream string
Downstream string

5. “First Light” with Cryoplant #1
CP1 is to be installed and commissioned first to support the “First Light”
U-tube Jumper Connections
Upstream string
Downstream string

6. General Installation/Cost Design Approach
LCLSII installation completion date for First Light (CP1) is given priority
Separate building room division allows for compressed schedule in terms of separate warm helium compressor operational testing while refrigerator room installation is under construction…lessons learned
Sequence follows need for commissioning schedule
Compresses overall schedule
Allows more corrective action time if issue occurs rather than plan for full plant commissioning at one time
Have installation corrective team standby if latent problem is uncovered during commissioning (avoids delays, small missed problems causes large details for remobilization)
Labor cost is more than a single welder or electrician, but as a team
Based on JLab multiple project task labor hours adjusted to SLAC labor costs
Items which lower cost or enable installation ease has been designed into the building contract (Ex: floor loading, in slab electrical conduits, door opening, electrical panel power schedules, piping trenches, etc.)

7. Cryoplant Overall Schedule

8. Equipment List Common subsystems for CP1 and CP2
30,000 Gallon Gas Helium storage tanks (6)
30,000 Gallon LN2 storage dewar
Purification system – dual beds
Recover compressor – 18 g/s (2)
Guard vacuum system
Instrument air system (2)
Control UPS and Generator
Subsystems for each CP
Warm helium compressor and MCC(6)
Gas distribution system
Oil Removal System
4.5 K Coldbox: Upper CBX and Lower CBX
Ambient heat exchangers
10,000 liter LHe dewar
2 K coldbox, cold compressors (6)
Cryogenic transfer lines
Interface box
Control system

9. Cryoplant Building 2 CDS Transfer lines
Compressor Room 1
Compressor Room 2
Cold Box Room
2 CDS Transfer lines
LCLS_II Cryoplant Installation PDR

10. Layout of the cryoplants
LN2 storage
GHe storage
CP1 CBX
CP1 ORS
CP2 CBX
CP2 ORS
CP1 Comp
CP2 Comp
Oil
processor
2K CBX
2K CBX
Vac. Guard
Interface box
LHe
Dewar
LHe
Dewar
Instru. Air

11. Outline Introduction of cryogenic system Overall schedule
Equipment list
Cryogenic system layout
Installation
Sequence and responsibilities
Cryoplant installation (CP1 & CP2)
Installation phase 1
Installation phase 2, including cryoplant Interface boxes
LCLS_II Cryoplant Installation PDR

12. Installation Phases of 2 cryoplants
CP1
Installation
Phase 1
CP2
Installation
Phase 1
CP2
Installation
Phase 2
CP1
Installation
Phase 2
Upstream string
Downstream string

13. General Process of Installation and Commissioning
Installation Design/spec Review
Award to Installation subcontractor
Award to Rigging subcontractor
JLAB/SLAC
SLAC
SLAC
Installation of
Piping
(Pressure & leak check)
Wiring
Shipping
Off-loading,
Rigging, Anchoring
Vendor
Reassembling
Inspection
/check
Vendor
Subcontractor
Vendor
JLAB/SLAC
SLAC Contractor
Pre-commissioning
- Control/ instrument test
- Purge/evacuation and Purification
- Training SLAC staff
- etc
Commissioning
and performance test
Commissioning
Readiness and Safety review
Vendor/JLAB/SLAC
JLAB/SLAC 13
Vendor/JLAB/SLAC

14. Installation/Commissioning Responsibilities
Equipment and subsystems are procured separately (Jlab)
Infrastructure building readiness (SLAC)
Site installation management in place (Jlab)
Equipment shipped to SLAC by vendors (Jlab vendors)
Equipment off loading and placement by rigging contractor (SLAC)
Equipment anchoring (SLAC/Contractor)
Reassembly (if needed) by JLab vendor (Example: 4.5K CBX, WHC)
Interconnection installation by installation contractor (SLAC)
Installation inspection/testing, as-builts (Contractor/SLAC to JLab)
Operator/maintenance/repair training (Vendors/Jlab to SLAC)
Commissioning and Operation Readiness Review and Approval (SLAC/Jlab)
Utilities commissioning and pre-ops operations/checkout (SLAC/JLab)
Plant equipment and subsystems sequential commissioning and performance testing/performance documentation (Vendor/JLab/SLAC)
Corrective performance activities and reverification (if needed) (Vendor/JLab)
SLAC plant acceptance and turnover to operations (Jlab/SLAC)
SLAC cryogenics integration team participate actively.
LCLS_II Cryoplant Installation PDR

15. CP1 Installation Phase 1

16. CP1 Installation Phase 1 (cont’d)
1/3/2017
7/14/2017
Installation
Package 1 Design/spec Review
Award Installation Package 1
GHe vessels
LN2 vessels
LN2 transfer line
Recovery compressor
Purifier
Instrument air compressor
Control
Supportive
System
installation
Commissioning readiness review
CP1 WHC (6)
CP1 MCC
Gas management panel
CP1 ORS
Oil processor skid
CP1 WHC piping
Control
WHC
installation

17. CP1 Installation Phase 1 (cont’d) - Sample pictures
6 * 30,000 Gallon GHe Tank
47’(L)*11’(W)*13’(H)
50,000 lbs
30,000 Gallon LN2 Dewar
78’(L)*11’(W)*12’(H)
103,000 lbs (E)
306,000 lbs (F)
Purifier (60g/s)
Recovery
compressor
2* 18 g/s
Instrument air system

18. Typical Warm Compressor (Qty=12)

19. CP1 Installation Phase 1 (cont’d) - Compressors
6 Warm helium compressors
Motor Skid
Cooler Skid
Qty
Power
Dimensions
LP Stage 3
800 hp
23’-1/2” (L) * 10’-8” (W) *11” (H)
MP stage 1
1000 hp
23’-1” (L) *10’-10 1/2” (W) * 11’-8” (H)
HP stage
(one swing) 2
2500 hp
25’-10” (L) *11’-5  1/4” (W) * 11’-9” (H)

20. CP1 Installation Phase 1 (cont’d)
Gas management system
Trench piping
MCC
Coalescer (6)
Main ORS
Oil Processor

21. CP1 Installation Phase 2

22. CP1 Installation Phase 2 (cont’d)
Package 2 Design/spec Review
Award Installation Package 2
3/12/2018
CP1 4.5K coldbox
CP1 LHe dewar
CP1 transfer lines
CP1 control
4.5K CBX
Installation
CP1 CC
CP1 2K cold box
CP1 cryogenic transfer lines
2K CBX control
Guard vacuum pump
Commissioning readiness review
4/9/2018
2K CBX
Installation
8/6/2018
CP1 Interface box and control
Transfer lines
Installation of IB and TL

23. CP1 Installation Phase 2 (cont’d) - 4.5K coldboxes
Upper CBX
90,000 lbs
Lower CBX
97,000 lbs
UCB
Base ring:
4600 lbs/ft2
Platform:
2700 lbs/ft2
LCB
9300 lbs/ft2
39.2’
Dia. 12’
14.5’
Dia. 12’
35’

24. Typical 4.5K Cold Box Section Delivery

25. CP1 Installation Phases 2 (cont’d) - Typical 4
CP1 Installation Phases 2 (cont’d) Typical 4.5K Cold Box Installation
Upper CBX
Lower CBX

26. Typical 4.5K Cold Box Installation Completed

27. CP1 Installation Phases 2 (cont’d) - 4.5K Cold Box Vendor Integration
Turbines
Instrument panel
Cabinet and wiring
Control valves
Transfer line

28. Cold Compressors used in 2K Cold Box Design
Cold box conceptual arrangement developed
Cold compressors and internal piping suspended from vessel top plate
12’ diameter vessel
~15.8’ overall height
Build to print design, same design CP-1 and CP-2
Assembly design well underway
PDR, Sept 2016
Box Design Completion January 2017
Cold Compressors Ordered
Cold Compressor
Bayonets
Vessel FEA
Compressor Suction
Internal Piping

29. CP1 Installation Phases 2 (cont’d) - Other equipment
10,000 LHe dewar
Ambient Heat exchangers
Guard Vacuum System
Transfer lines and U-tubes

30. Interface boxes to CDS 4.5K CBX 2K CBX 4.5K CBX 2K CBX Transfer line

31. Inter-connecting bayonets to the other CP
Interface boxes to CDS
Inter-connecting bayonets to the other CP
9” bayonet
Cooldown valves
CDS

32. CP2 Installation, Subset of CP1 with minor changes
Phase 2
Installation
Phase 1

33. Detailed Schedule Plan for each Phase
Located at: documentation review site, MS Project Format
Shows tasks by team group (welders/electricians/riggers)
Mechanical Fabrication Team (3 teams, #1 through 3)
Welder, fitter, helper (fire watch/crane)
Electrical Team (2 teams)
Journeyman, Apprentice
Controls (2 teams)
Part time leak check/pressure test team
Riggers (variable)
Contracted for the installation application
CP1 (~350 work days), CP2 (~308 work days) totals
Assigned tasks by team number
Includes time for installation verifications/tests, reports and as-built docs
Avoids interfering work areas between teams running in parallel
Specific skills are associated with each team
Duration task in terms of WORK DAYS, 40 hr/5 day work week
Tasks include installation verification testing and documentation
Most all teams are fully engaged through out installation phase period avoiding remobilizations
Covers from shipment to ready to commission

34. Installation Cost Estimate (Commercially sensitive)
Available to review committee
Includes:
Job trailer
Mobilization
Rigging
Tool/Equipment rental
Team hourly rate (ex: not just welder but fitter/fire watch, avg ~$200/hr per skill trade worker) Note: JLab 12 GeV contract installation labor ~$70/hr (welders/fitters)
Work verification/testing
Test reports/documents keeping needed for readiness to operate review
Divided into:
Summary of all installation phases
Separate phases (CP1/CP2 Phase 1 &2)

35. Summary JLab has leveraged installation plan after JLab’s 12 GeV
Key installation supportive details have been included in the building construction which lower cost and compress installation schedule
Cost and schedule for installation is traced to Jlab’s previous experience with adjustment to local labor costs
Labor presented is in terms of detailed task and work day duration by skill trade teams coupled with line item testing and documentation of work completion for commissioning readiness validation
Schedule plan places emphasis on completing CP1 for First Light rather than risks associated with two plant installation at same time.
Schedule breakdown shows equipment is in place prior to interconnection contract work, avoids delay in waiting for equipment arrival

36. Thank you!