Facility Advisory Committee
LINAC Coherent Light Source Project
Conventional Facilities
Overview and Status
Scope, Schedule, and Budget
J. Albino
June 17, 2008
CF – Breakout Session 5
1
Jess Albino
albino@slac.stanford.edu
Beneficial Occupancy Dates
Central Utility Plant
JUL08
Undulator
Hall
JUL08
Beam
TransferJ
UL08
Near Experimental Hall
JUL08
Beam Dump
JUL08
Front End Enclosure
JUL08
Xray/Diagnostics
SEP08
Far Experimental Hall
SEP08
June 17, 2008
CF – Breakout Session 5
3
Jess Albino
albino@slac.stanford.edu
CONVENTIONAL FACILITIES
~90% Scope completed to date:
Beneficial Occupancy
Beam Transport Hall West (BTHwest)
Co-occupancy
Beam Transport Hall (BTH) to Near Experimental Hall (NEH)
Beam Transport Hall West upgrades
Natural Gas Line
New service line from Pacific Gas & Electric
Substation S522
Sector 20 (LCLS Injector Facility)
Magnet Measurement Facility
Beam Transport Hall Switchboard
Sector 21-30 AC Power Upgrade
June 17, 2008
CF – Breakout Session 5
4
Jess Albino
albino@slac.stanford.edu
Turner Construction
Contract
June 17, 2008
CF – Breakout Session 5
5
Jess Albino
albino@slac.stanford.edu
BTH Headhouse looking west
June 17, 2008
CF – Breakout Session 5
6
Jess Albino
albino@slac.stanford.edu
BTH Headhouse looking west
June 17, 2008
CF – Breakout Session 5
7
Jess Albino
albino@slac.stanford.edu
BTH looking east
June 17, 2008
CF – Breakout Session 5
8
Jess Albino
albino@slac.stanford.edu
BTH
looking east
into Undulator
UNDULATOR
MAGNET
STANDS
Hall
June 17, 2008
CF – Breakout Session 5
9
Jess Albino
albino@slac.stanford.edu
Electron Beam Dump
June 17, 2008
CF – Breakout Session 5
10
Jess Albino
albino@slac.stanford.edu
Near Experimental Hall
Subbasement looking west
June 17, 2008
CF – Breakout Session 5
11
Jess Albino
albino@slac.stanford.edu
Finishing the Final Floor Slab in X-ray Tunnel
June 17, 2008
CF – Breakout Session 5
12
Jess Albino
albino@slac.stanford.edu
Installing re-bar in the Far Experimental Hall
Far Experimental Hall
Far Experimental Hall south rib
Structural Shell
June 17, 2008
CF – Breakout Session 5
13
Jess Albino
albino@slac.stanford.edu
Construction Adit Backfilling
June 17, 2008
CF – Breakout Session 5
15
Jess Albino
albino@slac.stanford.edu
Backfill operation over Beam
Dump and FEE
June 17, 2008
CF – Breakout Session 5
16
Jess Albino
albino@slac.stanford.edu
BTH looking east
June 17, 2008
CF – Breakout Session 5
17
Jess Albino
albino@slac.stanford.edu
Surface Restoration in Research
Yard
June 17, 2008
CF – Breakout Session 5
18
Jess Albino
albino@slac.stanford.edu
Next 6 Months
CONSTRUCTION
Complete Site Grading
Complete Mechanical / Electrical / Plumbing installations
Complete Surface Restoration (curb and gutters, site drainage, etc.)
Complete Punch Lists
Turner / Conventional Facilities Commissioning
Close-out Trade Contracts
Close-out Turner Contract (before December 2008)
June 17, 2008
CF – Breakout Session 5
19
Jess Albino
albino@slac.stanford.edu
Next 6 Months (cont.)
ADMINISTRATION / DESIGN
Turner Claim
CF Staff Assignments
Design of Far Hall Hutches
Conceptual Design / prelim. cost estimate – Spring/Summer 08
Final Design / cost estimate – Fall/Winter 08
Construction – Complete by Nov 09
Design of Space Renovation for Offices
Design start in 2nd Quarter of Fiscal Year 2009.
Construction complete 3rd Quarter of Fiscal Year 2010
June 17, 2008
CF – Breakout Session 5
20
Jess Albino
albino@slac.stanford.edu
Schedule
Delays
Waterline breaks
Lab Operations
Undulator Hall slab
Saturated Soils at storm drain
NEH waterproofing (delayed other trades)
Late delivery of elevator for NEH
Productivity issues with electrical trade contractor; misc. steel
Resolution of trade contract scope of work (AIC Painting: Seismic bracing)
Weather Contingency
Winter 2006: below average (good)
Winter 2007: about average (minor impact)
100-year storm in January 2008
Schedule Mitigation
Re-sequencing of activities
Additional work force for electrical installations
System modifications to allow work to proceed (water valves)
June 17, 2008
CF – Breakout Session 5
21
Jess Albino
albino@slac.stanford.edu
Cost to Go at WBS Level 3
(as of APR08)
$M, Burdened, Escalated
1.09 Conventional Facilities
TEC Estimate
to Complete
Contingency %
Contingency
Total Estimated Cost (TEC)
27.32
28.3%
7.72
1.09.01 System Management & Integration
5.20
14.6%
0.76
1.09.02 Title 1 & Title 2 Conventional Facilities
0.0
0
0
22.12
31.5%
6.96
1.09.03 Construction-T3 Conventional Facilities
1.09.03 – includes FEH hutches and space renovation construction
estimates
June 17, 2008
CF – Breakout Session 5
24
Jess Albino
albino@slac.stanford.edu
Integrated Safety Management
Define Work
Trade Contractor
Task Plan
Analyze Hazards
Job Safety Analysis – reviewed and approved by Safety
Pre-Task Meeting – conducted by foreman/crew members
Develop Controls
Personal Protective Equipment
Special Tools / Training
Safety Oversight
Perform the Work
Zero Accidents
Stop and Evaluate Changes in the Work or Controls
Work within Pre-task plan
Obtain Feedback and Improve
Safe Performance Observations
Monthly Safety Meetings
Safety Recognition Programs
Elicit feedback from the crews through direct communication
June 17, 2008
CF – Breakout Session 5
25
Jess Albino
albino@slac.stanford.edu
PROJECT SAFETY EXPERIENCE
29 March 2008
DART Rate
Total Project Hours
1.73 M Hours worked
5
4.5
LCLS Collaboration
1.27 M Hours worked
2 DART Incidents
4
4.6
TCCo
3.5
None in past 24 months
LCLS
Contractors
LCLS
Collaboration
Total Project
3
LCLS Sub-Contractors
2.5
108 K Hours worked
No Injuries
2
1.5
TCCo
348 K Hours Worked
8 DART Incidents
DOE Goal
1
0.5
0
1.2
0
0.3
0.6
Project To Date
Note: Injury rates based on 200 K hours (100 man years) of effort.
June 17, 2008
CF – Breakout Session 5
26
Jess Albino
albino@slac.stanford.edu
CONVENTIONAL FACILITIES
Project (Turner) Safety Performance History
LCLS Prepares for Field Work to begin
Safety Record as part of selection process
Site Safety and Health Plan
Driving home the message
Result: Procedural Violations
Actions
Stand Down of Construction Activities
Review of Approval Process for field work
Review of Project safety statistics – Analyze Hazards / Define Controls inadequate
Check/correction of existing documentation
Turner Construction “in full swing”
Data points indicate rising trends (near misses)
Paperwork trivialized by CM/GC and trade contractors
Result: Injury to Concrete Pump Operator
Actions:
Stand Down of Construction Activities
CM/GC and trade Personnel changes / fines levied
Letter to Turner Corporate
Joint Safety Stewardship Committee established
June 17, 2008
CF – Breakout Session 5
27
Jess Albino
albino@slac.stanford.edu
CONVENTIONAL FACILITIES
Safety Performance (continued)
Turner Construction “over the hump”
Injury rate increases (DART rate above national average)
Turner personnel and trade personnel changes / fines levied
Tunnel contractor begins to de-mobilize
Result: Serious injuries (shoulder and hand)
Actions:
Work Activity stopped.
Trade personnel changes made
Safety statistics reviewed – Perform the Work inadequate
Letter to Turner Corporate
Plan for joint observation and monitoring of the work planning and execution
prepared.
Review of JSA / Pre-task meeting notes
Attendance at each Pre-task meeting (Turner augmented by CF UTRs)
Monitoring Specific trade contractors or activities for safe work practices
We own Safety. It is our obligation to complete the project injury
free!
June 17, 2008
CF – Breakout Session 5
28
Jess Albino
albino@slac.stanford.edu
Issues (and Mitigation)
Site Security and Safety
Safety Statistics
Re-emphasis on Safe Work
November 20, 2007 Stand-down
Safety Stewardship
Additional Staff defined and constantly evaluated
Construction Delays
Site Conditions – Saturated soils
Waterproofing Cut-and-cover structures
Above average precipitation
June 17, 2008
CF – Breakout Session 5
29
Jess Albino
albino@slac.stanford.edu
Issues (and Mitigation) cont.
Technical Systems Construction Tolerances
Undulator Hall tunnel invert slab
Clearance zones for follow-on work
Integration management and site walks
Disputes and Claims
Known Claims
Request for Arbitration = $4.5M
Request for Equitable Adjustment = $ 1.5M
Total / Percent of May08 EAC = $6 / $88 = 6.8%
June 17, 2008
CF – Breakout Session 5
30
Jess Albino
albino@slac.stanford.edu
Summary
Good Progress - Beneficial Occupancy of BTH to NEH
is imminent.
Staff replenished after key personnel left the project.
Emphasis on cost control - continue to critically review
change requests
Interface with DOE, SLAC, Tech. Systems, CM/GC to
get buy in on procedures
Increased visibility of Line Management show
promising return with respect to safety.
Co-occupancy successful and relatively seamless.
June 17, 2008
CF – Breakout Session 5
31
Jess Albino
albino@slac.stanford.edu
End of presentation
June 17, 2008
CF – Breakout Session 5
32
Jess Albino
albino@slac.stanford.edu