NSLS II PAC Review Conventional Facilities Marty Fallier

NSLS – II PAC Review Conventional Facilities Marty Fallier Director for Conventional Facilities National Synchrotron Light Source – II Project October 27, 2006 1 BROOKHAVEN SCIENCE

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 2 BROOKHAVEN SCIENCE

Conventional Facilities WBS 3 BROOKHAVEN SCIENCE

Building Program 4 BROOKHAVEN SCIENCE

NSLS II Site Plan NSLS CLOB CFN Conf. Center Service Bldg Typ 4 Future JPsi RFLINAC AREA uest Future G House Ring Bldg Underpa ss 5 LOB Typ 4 Loading BROOKHAVEN SCIENCE

Ring Building Concept • 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 6 BROOKHAVEN SCIENCE

Section at CLOB 7 BROOKHAVEN SCIENCE

Ring Building Section at LOB 8 BROOKHAVEN SCIENCE

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 9 BROOKHAVEN SCIENCE

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 2 nd 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 10 BROOKHAVEN SCIENCE

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 • 2 nd floor viewing gallery overlooking experimental floor • Bridge to electrical mezzanine and control room & RF/LINAC areas • Close Proximity to future: • JPSI Building • Guest house 11 BROOKHAVEN SCIENCE

1 st Floor Plan – CLOB 12 BROOKHAVEN SCIENCE

2 nd Floor Plan - CLOB 13 BROOKHAVEN SCIENCE

3 rd Floor Plan – CLOB 14 BROOKHAVEN SCIENCE

CLOB & Ring Building 15 BROOKHAVEN SCIENCE

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 16 BROOKHAVEN SCIENCE

LOB & Experimental Floor Arrangement 17 BROOKHAVEN SCIENCE

Lab-Office Building 18 BROOKHAVEN SCIENCE

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 19 BROOKHAVEN SCIENCE

Utility Support for Beamlines • Services provided at each Beamline include: • Electric Power Panel at Ratchet Wall, 7595 k. W/Cell, 120/208 V • Cooling Water Supply and Return • HVAC Supply Air, Central Exhaust • Compressed Air, LN 2, GN 2 • DI Cooling Water (Copper and Aluminum systems) by Accelerator Group 20 BROOKHAVEN SCIENCE

Utility Support 21 BROOKHAVEN SCIENCE

Conventional Facilities Organization Director Conventional Facilities Marty Fallier Conventional Facilities Deputy Director TBD Design A/E T-I, I, III TBD [C] Design A/E Subconsultants [C] Construction Manager Agent CM – TBD [C] Site Prep Contractor [C] Precast Contractor [C] [M] – Matrixed [C] - Contracted Ring Bldg Contractor [C] CHW Contractor [C] Conventional Facilities Engineering Staff & WBS Managers Plant Engineering ECS Support Team Commissioning Contractor J. Mills [M] TBD [C] CF Project Architect TBD PE Project Architect T. Mc. Evaddy [M] CF Civil/Struct. Engr. TBD PE Civil/Struct. Engr. T. Joos [M] CF Mech. Engineer TBD PE Mech. Engineer G. Leskody [M] CF Elect. Engineer TBD 22 PE Sr Mech. Engineer C. Channing [M] PE Trade Shop Support – Various PE Elect. Engineer [M] D. Danseglio [M] BROOKHAVEN SCIENCE

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 23 and construction BROOKHAVEN SCIENCE

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 24 BROOKHAVEN SCIENCE

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 TII • Enables reduction in Ring bldg construction duration • Reduces risk associated with existing site conditions • Provides more time to 25 deal with unforeseen earthwork BROOKHAVEN SCIENCE

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 & LN 2 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 26 BROOKHAVEN SCIENCE

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 & 27 BROOKHAVEN SCIENCE

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 28 BROOKHAVEN SCIENCE

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 BROOKHAVEN SCIENCE 29

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-3 A • CD-3 B • Site Preparation contract • HD Shield Wall Pre-cast contract • Ring/CLOB/LOB Building Contract • Chilled Water Plant Expansion Contract • Standard Equipment 30 BROOKHAVEN SCIENCE

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 31 BROOKHAVEN SCIENCE

Schedule Activity FY 07 FY 08 FY 09 FY 010 FY 11 FY 12 FY 13 Title I Design CD-2 Title II Design CD-3 Site Preparation Const. Pre-cast Shield Wall Const. Ring Bldg/CLOB/LOB Bid & Award Construction 1 st Cluster ready for Accel. installation Ring Bldg BO CHW Plant Expansion Mech & Elect Utilities Integrated Ctrl & Comm. Standard Equipment Commissioning 32 BROOKHAVEN SCIENCE

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 33 BROOKHAVEN SCIENCE