installation global system

Beijing – Feb. 07 Global Design Effort 1

Installation Global System

F. AsiriW. Bialowons, T. Shidara

Acknowledgment: F. Peters, M. Munro, J. KimG. Aarons, C. Corvin, P. Rodriguez

Beijing-Feb. 07 Global Design Effort 2

ContentContent• IntroductionIntroduction

OverviewOverview• ScopeScope• MethodologyMethodology

Example – Installation of Main Example – Installation of Main Linac Linac ComponentsComponents

• RDR Installation Cost EstimateRDR Installation Cost Estimate• First-Cut ScheduleFirst-Cut Schedule• Future PlanFuture Plan

Toward EDRToward EDR

Installation Effort


Overview • Installation activities covers a large geographical area

– approximately 31 linear kilometers long which includes a complex network of about 72 km of underground tunnels at the depth of approximately 100m

• Requires the installation of – ~2,000 cryomodules, over 13,000 magnets and approximately

650 high level RF stations


Scope of Installation

• Covers all activities required to:– prepare, coordinate, integrate, and execute a detailed plan for

the complete installation of the ILC Technical Systems Components as well as associated site-wide logistics

• Includes all labor, materials and equipment required to;– receive, transport, situate, affix, accurately position,

interconnect, integrate, and checkout all components and hardware from a central storage or subassembly facility to its operational location within the Beam and Service tunnels

• Does not include:– fabrication, assembly, component quality control and

commissioning.• Elements of the installation system

– Range from complex subassemblies to single items– Highest stage of pre-assembly prior to installation– Components are to be bundled into installation kits, which

include all supports and hardware required to affix and interconnect the components in their operational


Working days per year

ContractYears3Cryomodule underground installation

Lab/ContractYears4Cryomodule handling & shipping

LabYears6Project engineering

LabYears8Project management

Installation rate: Three Cryomodules per day *

Installation time frame:

Contract 250

Number of Main Linac Cryomodules 1668

* 556 days @ max rate of Cryomodule installation, plus learning curve and interrupts.

Methodology- AssumptionMethodology- Assumption


Cost variables:• Number and size of equipment...• Distances to installation location and speed of transportation... • Man-hour estimates based on todays knowlege or general

experience... • Number of staff in each team needed per activity/function• Labor productivity ~ 75 %, 6 Hours of productivity per shift, due to

transport distances and dificulty in handling

Assumptions:• One ML section and associated services tunnel completely ready for joint

occupancy• One large and two small access shafts available during installation• ML installation periode of three years plus 1/2 year ramp up time• At least one installation zone occupied at a time, more zones as become

available• Installation rate: One Cryomodule unit & associated services / day

Benchmarked Cryomodule-Example


Cryomodule Installation- Example 9-8-9 Cavity Configuration

~ 12.7 Meter

Main LINACRTMLUndulatore- Sourcee* Boostere+ keep aliveDamping rings Total

1668 96 12 21 22 2 321853

Installation premise: Transport of single Cryomodule. Tunnel sections optimized into well defined areas. Personnel & low load traffic both directions. Heavy load traffic restriction, one direction only. Safety & communication systems ready to use. All in tunnel utilities provided by CF&S are complete and ready for tie-in.


Cryomodule Installation – Assumptions

BEAM TUNNELOccupancy During Installation

Ducts Long

Distance

Life Safety Systems

• Fire suppression• Fire detection sensor• Area lighting• Backup lighting• Life safety circuit conduits• Low O2 detection & alarm• Exit lighting• Fire controls & alarm• Communication systems• Emergency all stop• Fire pull station• Conveyance charging

BEAM TUNNEL Readiness at Joint Occupancy

WaveguideAlignment

Space

LINACArea


Methodology- ExampleMethodology- Example

Gas Return Pipe

40 K Pipe 4 K Pipe Cool down RF Power Coupler

RF Coupler Vacuum

Beam Pipe

2 K Pipe

80 K Pipe

4 K Pipe

2.2 K Pipe

40 K shield4 K shield

Module Connections

One of 556 Main Linac (RF) Unit ~ 38 Meter

Installation Sequence• Prepare tunnel section for installation…• Move, place, adjust and fix Cryomodule supports…• Move Cryomodules from access shaft to installation section… • Install, adjust, fix, and prepare section for Cryogenic & Beam Pipe connections…• Complete Cryogenic and Vacuum connections, leak check, then connect the Cryomodule sleeve coupling


Cryomodule ConnectionsPipe welding procedure e.g.:Prepare joints, tools, etc. 1. Place welding machine2. Check setup with one test run3. Execute welding procedure4. Remove welding machine5. Setup visual control monitor6. Execute control procedure 7. Remove control monitor8. Go to next pipe

Use:• 10 man-days per interconnect for cryogenic pipes and superconducting joints, Tom Peterson, 11/9/2006Tom Peterson, 11/9/2006• 7 man-days per connection for vacuum joints, 7 man-days per connection for vacuum joints, John Noonan, 11/9/2006John Noonan, 11/9/2006

Gas Return Pipe

40 K Pipe 4 K Pipe Cool down RF Power Coupler

RF Coupler Vacuum

Beam Pipe

2 K Pipe

80 K Pipe

4 K Pipe

2.2 K Pipe

40 K shield4 K shield

Cryomodule Installation – Assumptions


Activity of Cryomodule Unit (3 Modules) Installation underground

Staff Years Man Years

1 Cryo Module move inside tunnels 6 3 18

2 Floor drilling for supports 4 3 12

3 Support moving and placing 4 3 12

4 Support adjustment and fixing 2 3 6

5 Module installation, adjustment & readiness 5 3 15

6 Cryogenic connections, 8 cryogenic tubes / module 30 3 90

7 Vacuum connections, beam pipe & RF coupler vacuum 21 3 63

Daily personnel total 72216

Adjustment for productivity rate ( 25% ) 18 3 54

Number of FTE 90 270

Base of Installation Cost – 3 Cryomodules / Day


Main Linac Cross Section and Partial Plan Views


Installation at ML & Service Tunnel – Relative Evaluation

Subsystem installation underground Location Units % Assumptions1 Cryomodules ML* 1668 20 Optimized for installation

2 RF Power distribution system ML 1668 20 One unit per Cryo Module

3 Beam Lines: Magnets, supports, pipes etc. ML 10 Optimized for installation

4 Modulator & HV pulse transformer ST* 556 10 Container versions

5 Electronic racks and local control cable ST 556 10 Ready to go assembly

6 Klystron include shielding ST 556 5 Klystron on wheels

7 AC Power station & distribution ST 556 5 Container version

8 Cooling water station & distribution ST 556 5 Container version

9 Air condition system, fan, ducts etc. ST 556 5 Optimized for installation

10 Miscellaneous * * 10 From different sub systems

Installation underground 100

It take staff of (90) (100/20)=450 about three (3) years to install all ILC ML450x3x2000= 2,700,000 man-hours

* ML=Main Linac ST=Service Tunnel


Installation Cost Estimate Results


Status of WBS 1.7.3 Installation

Note;labor rate of 55 $US does not include overhead and profit Use labor rate of 70 $US to include for overhead and profit


Planning

Shaft 7 (9m DIA)

Shaft 11 (14m DIA) Shaft 3 (14m DIA)

Shaft 1.0 (9m DIA)

Shaft 1.2 (16m DIA)

Shaft 1.1 (16m DIA)

Shaft 2 (14m DIA) Shaft 4 (14m DIA)

Shaft 6 (9m DIA)

Shaft 10 (14m DIA)

Shaft 5 (14m DIA)

4.5 km4.5 km

Shaft 13 (9m DIA)

Shaft 12 (9m DIA)

RTML1.3 km

Underground Layout with Installation Access Shafts

Installation planning of the large and complex ILC machine requires the creation of 3-D computer models of all the major components as well as the underground works.


Installation Model for Main Linac Components in Underground Segment

Installation Rate- 3 Cryomodules per day


Installation Manpower Distribution

0

200

400

600

800

1000

0.0

1.0

2.0

3.0

4.0

5.0

6.0

7.0

8.0

Years

FTE

Day Shift (500)

Swing Shift (300)

Prep & Surface Xport (40)

Rec'v supplies/insp (30)

Eng. & Q&A (20)

Proj. Mgt (10)

JointOccupancy(T3)

Start ofConstruction(T0)

Installation Plan


FUTURE PLANNING

Refine the 3D drawings of the tunnel and insert brief overall drawings of the technical equipment and integrate with a time and motion software

Superimpose the surface warehouses, the staging assembly buildings and the elevator access shafts

Prepare alternate installation approach systems, to facilitate the best way to perform the installation

Evaluate elevator transport options for materials, to support installation activities

Design the main material transport system, for accelerator part movement, in the tunnel, then manufacture and test, a prototype vehicle

Check out utility access locations for an efficient installation Build a mockup of a tunnel section and using outline models of the

most difficult pieces of accelerator equipment to install, go through the installation procedures, to proof out the material handling equipment and fixtures/tooling to be used

The mockup could also be used as an installation training site and for the evaluation of safety procedures

Define support equipment required. This will include vacuum support equipment, such as leak checkers, materials handling equipment, fixtures, tooling, etc.


Major inputs required for the underground installation

• Basic civil engineering layouts of the facility, including surface building locations, access roads & tunnel layouts.

• Preliminary outline drawings of the various pieces of equipment to be installed in the tunnel. These details should include mechanical, electrical & utility equipment requirements.

• Details of the physical locations of all pieces, of equipment to be placed in the tunnel.

• Location of all utility connections in the tunnel.• Cryogenic system connection box locations, in the tunnel. • Develop flow charts, showing the typical sequence of events, per

major equipment item, in the installation process. • Approximate schedule of facility completion, plus delivery dates &

sequence of equipment deliveries to the site.• An inventory control system that incorporates input data, output

data & documentation.• Safety/emergency features in the tunnel & on the surface.• Details of the quality & quantity of local labor available, to support

the installation.


FUTURE PLANNING

• There are a series of long lead items that must be addressed, before the installation can commence. These are:– Warehousing capacity– Tunnel transportation for equipment &

personnel– Materials handling requirements for the tunnel– Utility requirements & locations including cryo

box locations in the tunnel.– Data processing, including inventory control &

scheduling.


FUTURE PLANNING

• Warehousing:– Based on a preliminary installation schedule, a

warehouse capacity requirement can be established & thus the specs for the warehouse itself, can be developed.

– Significant materials handing equipment, will also be required, to support the warehousing activities.

– Installation staging area requirements, can also be considered, at the same time.

– External contract warehousing, is an alternative approach that can also be considered, for use.

– As an alternative to permanent buildings, temporary buildings can be considered, as a possibly less expensive solution, to provide adequate warehouse buildings, for the installation years


FUTURE PLANNING

• Tunnel Transportation for Equipment & Personnel :– As the transportation lengths are relatively long, specialized

materials handling equipment will be required for both equipment & personnel.

– Depending on the amount of traffic, some form of guidance system, may be required to control the transportation movement & thus avoid any potential damage, to the accelerator equipment.

• Equipment Transportation: – The major options are battery or electrically driven vehicles.

With the use of fast battery chargers, the down time for battery powered trucks, has become much shorter, but they still have their productivity limitations. A bus bar powered system, may be required to provide adequate equipment delivery, for scheduling requirements.

• Personnel Transportation: – This system will use separate equipment. Several types of

commercial equipment are available, to provide this service. Some relatively minor modifications to the equipment, may be required.


FUTURE PLANNING

Data Processing:• An inventory control system to cover, receiving,

scheduling, installation planning & documentation reproduction, will be required. This type information should be readily accessible, at many points on the site.

• Quick part data identification, can enhance our ability, to perform the installation. Several types of part identification equipment are available, including RFID, Data Matrix & Bar Coding; these should be evaluated regarding the site requirements, as some of them need relatively expensive writers & readers, plus some vendors, may not have this capability


Added Values

• Centralized information database– Sharing and synchronization of records, files

• Easy and fast communication• Better-informed planning decisions from

– Operation optimization• Feasibility study with resource loaded production plan• Global optimization

– Interference detection• Physical interferences detection• Work space conflicts detection• Analysis of the severity of the interferences and conflicts

• Real-time tracking and reporting– Status check for individual equipment

• Fabrication, transit, storage, sub-assembly, installation• Comparison between planned and actual


Application of Virtual Design & Construction Technologies

3D model(AutoCAD)

4D model / interference check

(NavisWorks)

Scheduling(Primavera)

IntegratedCentral

4D Database(Enterprixe)

Mobile Server

FabricatorJob Site

Mobile Technology

Operation Optimization

Discrete event simulation

(Strobscope)

Database Technology

Transporter

4D Technology (3D CAD + schedule)


Integration of VDC database

• Information included in the database– 3D geometry of the equipment to be installed– Installation schedule (i.e., sequence, duration)– Manufacturer information– Status: manufactured, received, stored,

assembled, installed– Location (i.e., x, y, z)– Labors needed– Predecessors (i.e., equipment list that need to

be installed before)– Requirement for clearance during installation


FUTURE PLANNING

• Installation G.S.– Goal: to produce an integrated Installation

process for the ILC Baseline in full cooperation with other regions Set-up and manage an installation data base

in FY 07 that can be expanded in a full pledged program thru FY 08 and FY 09

Estimate: FY 07;1.5 FTE and ~ $100K M&S (contract)FY 08; 2 FTE and ~ $200K M&S (contract)FY 09; 2 FTE and ~ $200K M&S (contract)


FUTURE PLANNING

• Miscellaneous Considerations• Some possible conflicts in multi country projects are: • Part Drawing Views Procedure: Is different, from the

USA, in the rest of the world. Drawing procedures are also different.

• Metric & Inch Designs: Used in the same project, can breed costly errors

• Standards: Mechanical, electrical & material standards can also differ.

• Date Number Sequence of Numbers: Is different in the rest of the world, from the USA.

installation global system

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