NSLS – II PAC Review

1 BROOKHAVEN SCIENCE ASSOCIATES

NSLS – II PAC Review

Conventional Facilities

Marty FallierDirector for Conventional Facilities

National Synchrotron Light Source – II ProjectOctober 27, 2006


Outline

• Scope of Conventional Facilities◦WBS◦Program◦Site Plan◦Buildings◦Utilities

• CF Organization• Method of Accomplishment• CF Procurement• CF Schedule• CF Cost Estimate• CF Risk Assessment


Conventional Facilities WBSConventional Facilities 1.6

Conventional Facilities Management 1.6.1CF Design Phase Management 1.6.1.1CF Construction Phase Management 1.6.1.2

Conventional Facilities Engineering and Design 1.6.2CF Title I Design 1.6.2.1

CF Title I A/E Design 1.6.2.1.1CF Title I Design Coordination 1.6.2.1.2CF Title I Design C/M Support 1.6.2.1.3

CF Title II Design 1.6.2.2CF Title II A/E Design 1.6.2.2.1CF Title II Design Coordination 1.6.2.2.2CF Title II Design C/M Support 1.6.2.2.3

CF Construction Phase Engineering 1.6.2.3CF Construction Phase A/E Support 1.6.2.3.1CF Construction Phase Coordination 1.6.2.3.2

Conventional Facilities Construction 1.6.3CF Construction Management 1.6.3.1Improvements to Land 1.6.3.2Central Lab - Office Building 1.6.3.3Ring Building 1.6.3.4Lab - Office Building 1.6.3.5Mechanical Utilities 1.6.3.6Chilled Water Utilities 1.6.3.7Cryogenic Utilities 1.6.3.8Electrical Utilities 1.6.3.9

Integrated Controls and Communications 1.6.4Standard Equipment 1.6.5Commissioning 1.6.6


Building Program

Base Scope GSF

Full Build-out GSF

Full Build-out NASF % of Total

Ring Building 242,284 242,284 225,268 59%Service Buildings 32,000 32,000 28,696 8%LINAC/RF Area 21,000 21,000 15,862 5%Central Lab Office Building 55,128 55,128 38,820 13%Conference Center - 15,000 13,440 4%Lab Office Building 11,000 44,000 30,480 11%

361,412 409,412 352,566 100%

Building / Area / FunctionProgram Space


NSLS

LOB Typ 4

RF-LINAC AREA

Service Bldg Typ 4

CFN

Ring Bldg

Future JPsi

Future Guest House

Conf. Center

UnderpassLoading

CLOB

NSLS II Site Plan


• Divided into 5 clusters

• Service Bldg supports all services within the cluster

• Six sectors/Cluster

• CLOB & Service Bldgs contain all Accelerator systems

• Ring, CLOB, LOB 1 & service bldgs are base scope

• LOB’s 2,3,4 can be added as needed w/o interruption

Ring Building Concept


Section at CLOB


Ring Building Section at LOB


Tunnel Design

• Roof and wall thicknesses generally driven by shielding criteria except inner wall in area of berm (just structural)

• Outer wall (ratchet wall) is HD concrete• During T-I will study whether precast or poured in place

provides best balance of technical and cost performance

• Tunnel floor thickness driven primarily by vibration criteria• Will do modeling to arrive at optimal thickness and

section shape• Rigidly connected to exp. floor to create monolithic

floor

• Penetrations from above for power and cooling water• Penetrations from sidewall for HVAC Supply and

Return


Tunnel Access

• Egress for life safety achieved by exits at each service building location• Large shielded doors for equipment access provided at

Service buildings for tunnel entry• Personnel doors and labyrinth provided at each Service

building• Vehicle ramp to roll-up door at 2nd floor of each Service Bldg

provides equipment access to electrical mezzanine at top of tunnel• RF & LINAC areas integrated with CLOB structure have similar

access as Service Bldgs


CLOB Features

• Space for 190 Offices, 8 labs• Nominally 30 User Offices, 5 User labs from the total• Possible 400 seat Conference Center addition w/ vendor area and

three breakout rooms• Lobby and User Reception area• 2nd floor viewing gallery overlooking experimental floor• Bridge to electrical mezzanine and control room & RF/LINAC

areas• Close Proximity to future:

• JPSI Building• Guest house


1st Floor Plan – CLOB


2nd Floor Plan - CLOB


3rd Floor Plan – CLOB


CLOB & Ring Building


LOB Features

• Modular design – can be added when needed without interrupting operation• 11,000 SF each – Serves six sectors• 30 offices w/ conference space, interaction areas, lavs, showers• 5 labs intended for shared use• Shipping/Receiving/Storage area & chemical storage area• Potential for expansion for more offices if needed

• Egress provided for personnel and large items at each LOB• Loading area with exterior roll-up door• Roll-up door from each lab onto the experimental floor

• Designed to minimize impacts to future long beamlines


LOB & Experimental Floor Arrangement


Lab-Office Building


Utility Support to Buildings• Utilities run underground in center of ring and distributed to five

service bldgs (one in CLOB RF/LINAC area)• Minimizes pipe runs and pipe size in bldg proper• Minimizes potential noise and vibration impacts

• Mechanical Utilities include:• Chilled water from expansion of Central CHW Plant• Tower water from process cooling water tower• Steam & condensate from Central Steam System• Potable water, compressed air, sanitary to existing mains

• Electrical Utilities distributed via substation and load center at each Service bldg• Communication/Data via underground BNL F/O network


Utility Support for Beamlines

• Services provided at each Beamline include:• Electric Power Panel at Ratchet Wall, 75-95kW/Cell, 120/208V• Cooling Water Supply and Return• HVAC Supply Air, Central Exhaust• Compressed Air, LN2, GN2

• DI Cooling Water (Copper and Aluminum systems) by Accelerator Group


Utility Support


Conventional Facilities OrganizationDirector Conventional

Facilities

Marty Fallier

Conventional Facilities Engineering Staff &

WBS Managers

Design A/E T-I, I, III

TBD [C]

Conventional Facilities Deputy Director

TBD

Commissioning Contractor

TBD [C]

CF Project ArchitectTBD

CF Mech. EngineerTBD

CF Civil/Struct. Engr.TBD

CF Elect. EngineerTBD

Plant Engineering ECS Support Team

J. Mills [M]

PE Project ArchitectT. McEvaddy [M]

PE Mech. EngineerG. Leskody [M]

PE Civil/Struct. Engr.T. Joos [M]

PE Elect. EngineerD. Danseglio [M]

PE Sr Mech. EngineerC. Channing [M]

PE Trade Shop Support – Various [M]

Design A/ESubconsultants [C]

Construction Manager

Agent CM – TBD [C]

Site Prep Contractor[C]

Precast Contractor [C]

Ring Bldg Contractor[C]

CHW Contractor[C]

[M] – Matrixed

[C] - Contracted


Design Activities

• CF design will be by competitively selected A/E• A/E selection underway – contract ready for award prior to CD-1• Will perform T-I & II with option for T-III support• Responsible for design of all bldgs and utilities• Must design to cost & provide construction estimates• Design for LEED certification

• PE Engineering & Construction Services will provide design & utility coordination support• Provide interface for existing utility systems• Provide QA review and verification of compliance with BNL stds• Coordinate BNL trade craft support during design and construction


Design Activities cont’d

• Construction Manager will be competitively selected • Contract award planned for early in T-I• Will be an agent CM contract• Provide constructability review, independent estimate, value

engineering and market analysis support during T-I & II design

• Commissioning agent will be competitively selected • Contract award during T-I• Provide HVAC and I&C design review • Prepare Cx plan


Construction Packages

• Pre-cast shield-wall early procurement – during T-II• Enables reduction in Ring bldg construction duration• Potential for better QA on shieldwall – uniform density• Need to verify cost and structural tradeoffs are acceptablre during T-I

• Site Preparation early procurement – during T-II• Enables reduction in Ring bldg construction duration• Reduces risk associated with existing site conditions

• Provides more time to deal with unforeseen earthwork issues• Provides longer settlement & compaction time


Construction Packages cont’d

• Ring Bldg/CLOB/LOB contract• Work will be phased to support accelerator installation schedule• Package will be as self contained as possible• Should include CHW piping, process water clg tower & LN2 system

• Chilled Water Plant Expansion• Expansion contract shared with Lab • 3 chillers for NSLS II, 1 for BNL

• Integrated Control & Communication• Could be performed by tech group or ctrls contractor

• Standard Equipment• Several OFE items & furnish and install contracts


Construction Management

• NSLS II WBS Managers responsible for performance• CM will provide field inspection and coordination services

• Oversight of contractor performance of contract• QA, Construction safety, testing, schedule, RFI’s, CO’s, Invoice review

• A/E will provide home office support• Engineer of record, shop dwg review, ECN’s, periodic inspection, RFI’s

• PE Engineering and construction Services and Trade crafts• Utility interconnect support, shutdowns, start-ups, permits

• Cx contractor - checkout and startup of systems• Document test results & performance, training & documentation for operating staff,

info for LEED certification


ESH Management• CF has the following responsibilities for ESH during the

project:• Design to applicable codes and include engineered safety features to mitigate

hazards identified in PHA• Coordinate review and input to design by ESH SME’s• Comply with environmental regulations and stay within operating envelope of the

NEPA review (EA) and FONSI• Incorporate sustainable design features and maximize sustainability within budget

and operational limits (LEED Certification & possible LEED silver rating)• Select contractors that have above average construction safety performance• Implement an effective construction safety program with 0 injury goal• Test and document all systems to verify safe and efficient performance


CF Procurement• CF scope will primarily be executed by procurement

contracts• NSLS II has dedicated procurement staff developing detailed

procurement plans for CF contracts– Early planning will provide added assurance that procurement will not

create unforeseen delays to schedule• A/E and C/M contracts will be by traditional A/E procurement

process called for in FAR and DEAR• Large construction contracts will be evaluated “best value”

procurements that take into account technical qualifications as well as cost

– Key criteria include safety performance in addition to technical experience, past performance and other weighted factors


CF Procurement Cont’d

Major CF Contracts• Design Phase

• A/E for Title I, II and option for T-III design• Construction Manager• Commissioning Contractor

• CD-3A• Site Preparation contract• HD Shield Wall Pre-cast contract

• CD-3B• Ring/CLOB/LOB Building Contract• Chilled Water Plant Expansion Contract• Standard Equipment


Schedule

• Key schedule objective – Enable start of accelerator installation June 2010• CF is critical path until the main bldg spaces are turned over for

accelerator installation • Cluster areas of Ring bldg to be released for BO in phases• Key durations:• Title I Design – 9 months• Title II Design – 11 months• Site preparation – 6 months• Main bldg contract bid & award – 6 months• Main bldg contract duration 34 months


Schedule

Title I DesignCD-2Title II DesignCD-3Site Preparation Const.Pre-cast Shield Wall

Const.Ring Bldg/CLOB/LOB

Bid & AwardConstruction1st Cluster ready for Accel. installationRing Bldg BO

CHW Plant ExpansionMech & Elect UtilitiesIntegrated Ctrl & Comm.Standard EquipmentCommissioning

Activity FY07 FY08 FY09 FY010 FY11 FY12 FY13


CF Risk Assessment

• Technical Challenges• Constructing massive concrete tunnel with reasonable economy• Achieving structural stability

• Minimizing vibration & differential settlement • Achieving thermal stability –

• Tight temperature constraints for tunnel• Assuring interior/exterior thermal gradients don’t affect beam

• Making tunnel available for accelerator installation in phases

• Risks• Cost & schedule sensitivity of achieving all of the above• Volatile material/construction markets• Detailed risk registry for CF will be prepared for final CDR

Documents

NSLS – II PAC Review