HEX Preliminary Design Review Beamline Infrastructure Chris Stebbins

HEX Preliminary Design Review: Beamline Infrastructure Chris Stebbins NSLS-II Project Engineer and CAM for WBS 7. 05. 04 April 26, 2018 1

Outline • • Beamline Infrastructure Scope Schedule Hutches Mechanical Utilities Electrical Utilities EPS PPS Risk 2

HEX Beamline Infrastructure Scope • • Level 4 Level 3 3 Similar project structure has previously been implemented on ABBIX, NEXT, and BDN. Horizontal organization provides ability to manage HEX alongside other ongoing projects at NSLS-II.

WBS 7. 05. 04. 01 Hutches Scope: • • • Design, specification, procurement, fabrication, assembly, installation, and testing of the required radiological enclosures All necessary hoist, air handling equipment, fans, labyrinths, doors, windows, and lights. Construction oversight Filing of as-built drawings and preparation for the IRR. Concrete hutch F is part of the conventional construction, but the hutch doors (with door frames) and labyrinth covers etc are part of the hutch contract (like HXN, but lead). h Hutc *Image courtesy of Mike Lucas E h Hutc C FOE h Hutc tch D Hu B am D F utch H 4 stre n w o

WBS 7. 05. 04. 02 Mechanical Utilities Scope: • • • Design, specification, procurement, fabrication, assembly, installation, & testing of beamline mechanical utilities. Structural utility support pylons and L-brackets, Equipment racks (including heat exchangers and all mounting provisions) De-ionized (DI) water system. with appropriate flow/temperature instrumentation. Process chilled water system. Gaseous nitrogen and compressed air systems. Exhaust system for experimental needs. Liquid nitrogen distribution system (including all service points, facility interfaces, emergency shutoff system, phase separators, etc). Filing of as-built drawings, safety reviews, oversight, and preparation for the IRR. HEX Mechanical Utilities has same scope, but larger scale than previous beamlines • 11 equipment racks • 5 hutches with DI water provisions • LN 2 service in 4 hutches, including satellite building 5 Typical Mechanical Utilities Layout Typical Installation in an FOE at NSLS-II

WBS 7. 05. 04. 03 Electrical Utilities Scope: • • Design, specification, procurement, fabrication, assembly, installation, and testing of beamline electrical utilities. Installation of cable trays, conduits, utility power cables, power outlets, boxes and circuit breaker panels. Provisioning of power to equipment racks. Installation of all conduit and boxes for the Oxygen Deficiency Hazard (ODH) system inside the hutches. UPS system for the beamline Wiring up and testing of hutch smoke detectors. Installation of the beamline SAF monitors and conduit. Electrical inspections, as-built drawings and preparation for the IRR. 6 Typical schematic for beamline power distribution

WBS 7. 05. 04 EPS Scope: • • Design, specification, procurement, fabrication, assembly, installation, and testing. Includes PLC, wiring, custom sensors, water leak detection systems inside the hutches, and integration of the rack smoke alarms. Installation and testing of cables & connectors to interface to the various water flow sensors, temperature sensors and the vacuum pump and gauge controllers used on the beamline (particularly in the white/pink beam sections). Development and implementation of PLC software Development of interface screens for EPICS Control System Filing of as-built drawings and preparation for the IRR. HEX EPS has same scope, but larger scale than previous beamlines • ~100 thermocouple sensors distributed throughout the beamline. • EPS DI water located in 3 hutches Beamline EPS user interface (CSS) screen shown in EPICS 7

WBS 7. 05. 04. 05 PPS • • • Design, specification, procurement, fabrication, assembly, installation, & testing of beamline PPS Dual chain safety-rated PLC architecture (two manufacturers) Status of PPS functions available on local HMI and EPICS Redundant critical device configuration Doors and labyrinths monitored by redundant and diverse switches Interface to photon shutters & water flow circuits Tie-in to storage ring and front end Interior warning – revolving beacons and sirens Detailed interface control drawing provided for requirements HEX has same scope, but larger scale than previous beamlines • 6 hutches • 8 doors • 5 labyrinths • 5 hutches with PPS water • 4 photon shutters • 1 PPS aperture Recent design improvements & experience 8 have reduced costs Bench assembled PPS pane

Risks within WBS 7. 05. 04 Risk Code Cost $100, 000 $50, 000 Risks Prob 0. 10 0. 05 $10, 000 $50, 000 0. 03 0. 05 $100, 000 0. 10 Late completion of infrastructure $100, 000 Additional scope needed to complete central branch $20, 000 PPS work is more complex than anticipated $40, 000 Insufficient DI water flow rate available $10, 000 Insufficient electrical capacity for SB from the LOB $50, 000 Changes to NSLS-II or BNL safety requirements $100, 000 Failure to agree new standard for door actuation before bid $10, 000 • HEX 0412 Underestimated effort or underestimated scope 0. 10 0. 20 0. 10 0. 01 $300 Use O/T or consultant $2, 500 1 month of 6 person standing $10, 000 army $4, 000 2 weeks of 2 electricians $4, 000 2 people for 1 month $2, 000 $5, 000 $1, 000 0. 10 $1, 000 HEX 0401 HEX 0402 HEX 0403 HEX 0404 HEX 0405 Risk Description Underestimated effort or underestimated scope Accident and injury Limited availability of specialized effort (eg workforce reduction) * Late optics design changes impact infrastructure Late completion of satellite building delays infrastructure start HEX 0406 HEX 0407 HEX 0408 HEX 0409 HEX 0410 HEX 0411 Most significant risks: • • Notes Value $10, 000 $2, 500 Mitigated by using experienced personnel to develop requirements and by using actuals from previous projects to inform HEX project on labor needs. Late start and late completion of beamline infrastructure scope can lead to “standing army” costs and delays in the overall construction schedule. • Mitigation: Redirect utilities installation labor to HEX hutches that are completed inside Building 740. • Mitigation: Can reschedule activities to start in parallel with other activities to catch up on schedule (example: start PPS installation prior to completion of utilities installation is completed) 9

Summary • HEX infrastructure WBS is well understood; scope is based on similar work that was previously completed at NSLS-II and scaled to meet the needs of HEX. • Detailed technical specifications will be developed in preparation for the HEX Final Design Review • Costing was performed with experienced CAMs, Scientists, and Engineers who are familiar with this work. Actuals from past projects were used to inform HEX costs. • Infrastructure schedule was developed with integrated project team. • Risks have been identified and assessed. Mitigations have been developed to minimize any effects on the overall project. • Project is well-positioned for success. 10