1 brookhaven science associates accelerator systems installation f. willeke, asd director 6 th asac...
DESCRIPTION
3 BROOKHAVEN SCIENCE ASSOCIATES Magnet Girder IntegrationTRANSCRIPT
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1 BROOKHAVEN SCIENCE ASSOCIATES
Accelerator Systems Installation
F. Willeke, ASD Director6th ASAC
October 22-23, 2009
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Outline
• Magnet Girder Integration• Installation Preparation• Installation Schedule• Installation Resource Planning• Installation Overview• Availability of Buildings• Girder Installation Details• Storage Ring Installation Logistics
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Magnet Girder Integration
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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
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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
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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
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Storage Ring Electrical Utilities: Detailed Planning
Racks will be equipped on the Mezzanine
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Civil Construction Sequence
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Installation Overview
Building BOD Installation Activity Start DatePentant 1*) 1-Feb-11 SR Components 20-Jun-11
Pentant 1 1-Feb-11 SC RF Cavities 21-Sep-12
RF Bld 23-May-11 RF Power Systems & Cryog’s 29-Mar-12
Inj. Bld 18-May-11 Booster RF Cavity 21-Jun-11
Inj. Bld 18-May-11 LINAC 18-Oct-11
Inj. Bld 18-May-11 Booster 08-Jun-12
Pentant 2 02-May-Jun SR Components 20-Oct-11
Pentant 3 27-Sep-11 SR Components 14-Feb-12
Pentant4 28-Nov-11 SR Components 16-Apr-12
Pentant 5 09-Feb-12 SR Components 28-Jun-12
*) includes central cooling tower building and access tunnels
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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
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Planned Resources
50 FTE planned this needs reassessment
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Even Cell Girders
G3 G5 G6G2 G4
G1
Black border indicates an even cell
ID Section
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Odd Cell Girders
G1
G3 G5 G6G2 G4
ID Section
Water manifolds are shown schematically as
a double red line (Aluminum)
a double green line (Copper)
Red border indicates an odd cell
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Typical cell rack groups
BlueBlue border indicates a rack group 22, 33, or 44 racks wide
Cable tray is shown schematically as a double dashed line
G3 G5 G6G2 G4
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The first slice; Pentant 1 plus…
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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
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Girder Transport in the Tunnel
Used for RHIC
New models
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“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-8MAXIMUM LOAD CAPACITY: 13,500 LBS. (SAFETY FACTOR = 1.5)
Number of Wheels Weight Height Width Depth
Swivel Pad Diameter
Distance from center of swivel pad to handle
Handle Length
Roller Dimensions
8 91 lbs. 4.25" 23.5" 19.5" 6.625" 12" 45" 3.25" x 3.25"
MODEL RT-3MAXIMUM LOAD CAPACITY: 4,500 LBS. (SAFETY FACTOR = 1.5)
Number of Wheels Total Weight Height Width Pad Diameter Roller Dimensions
3 73 lbs. 4.25" 18" 6.625" 3.25" x 3.25"
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Pentant 1 installation Zones
24 25 27 2823
Experimental floor
Tunnel
24 25 26 2722
Mezzanine
23
26
Service Building
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Storage ring Pentant 1 installation: Week
24 25 27 2823
Exp’l floor
Tunnel
Service Building
24 25 26 2722
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
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Storage ring Pentant 1 installation: Week
24 25 27 2823
Exp’l floor
Tunnel
Service Building
24 25 26 2722
Mezzanine
23
Status:
Most material in building
Installation on mezzanine
Begin in tunnel
26
4
Activities:
•Stage components on floor
•Start racks on mezzanine
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Storage ring Pentant 1 installation: Week
24 25 27 2823
Exp’l floor
Tunnel
Service Building
24 25 26 2722
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
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Storage ring Pentant 1 installation: Week
24 25 27 2823
Exp’l floor
Tunnel
Service Building
24 25 26 2722
Mezzanine
23
Status:
Multipole girder installation
26
8
Activities:
•Begin Girder installation
•Start populating racks
•Begin Utility installation in SB
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Storage ring Pentant 1 installation: Week
24 25 27 2823
Exp’l floor
Tunnel
Service Building
24 25 26 2722
Mezzanine
23
Status:
Half way in schedule
26
10
Activities:
•Girder installation
•Populating racks
•Utility installation in SB
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Storage ring Pentant 1 installation: Week
24 25 27 2823
Exp’l floor
Tunnel
Service Building
24 25 26 2722
Mezzanine
23
Status:
Most wiring pulled
Process utilities connected
26
12
Activities:
•Girder installation
•Populating racks
•Terminating cables
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Storage ring Pentant 1 installation: Week
24 25 27 2823
Exp’l floor
Tunnel
Service Building
24 25 26 2722
Mezzanine
23
Status:
About ¾ through schedule
26
14
Activities:
•Girder installation
•Racks populated
•Terminating cables
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Storage ring Pentant 1 installation: Week
24 25 27 2823
Exp’l floor
Tunnel
Service Building
24 25 26 2722
Mezzanine
23
Status:
About ½ vacuum complete
26
16
Activities:
•Girder installation
•Cable pulls all done
•Testing underway
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Storage ring Pentant 1 installation: Week
24 25 27 2823
Exp’l floor
Tunnel
Service Building
24 25 26 2722
Mezzanine
23
Status:
About 2/3 vacuum complete
26
18
Activities:
•Girder installation
•Cable pulls all done
•Testing underway
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Storage ring Pentant 1 installation: Week
24 25 27 2823
Exp’l floor
Tunnel
Service Building
24 25 26 2722
Mezzanine
23
Status:
All equipment in place
System testing underway
26
20
Activities:
•final utility connections
•equipment shakeout
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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