Baseline Change RequestBCR Title: EBD New 6 Ton Bridge Crane InstallationBCR #: N/A

Presenter’s Name: Robert Law

CCB Presentation Date:

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BCR Summary

This BCR entails the requirement for a new 7 ton motorized chain hoist &

bridge crane system to be installed in EBD Area to efficiently, safely and

timely facilitate the removal and/or installation EBD system activities as

follows:• Removal of (2) existing LCLS dumps shielding with combined weight of

approximately 92 tons (57 tons for South dump; 35 tons for North dump)• Installation of LCLS-II new dumps shielding with combined weight of

approximately 408 tons (204 tons each for both North and South dumps)

including 90 plates weighing 2 tons/plate, • Relocation / Installation of EBD hard & soft beam lines components /

devices including (3) permanent magnets, and (2) dump slugs with

shielding coffins weighing between 5 and 6 tons each.• Installation of over 200 new shielding components for both hard & soft

beam lines components / devices.

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BCR Form

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• Background

In Electron Beam Dump (EBD) housing there are (2) monorail

cranes on the North and the South sides. Each rail starts with a

short piece and finishes with short piece assumable 20.5’ each .

The middle section is a long rail assumable 41’ long.

The two crane rails are parallel ( field verified). Distance between

rails is 98.5”. The distance from South and North walls to the South

and North rails center is 39.25”.

Both cranes have lifting capacity of 5 tons (10,000 lbs) each. Based

on current SLAC crane records, only the South monorail crane has

anchored fixture for crane certification with quadrennial certification

date of November 1, 2011.

Refer to Figures 1 & 2 for existing monorail cranes arrangement.

Background, Problem, Solution

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• Background (Continued)

Background, Problem, Solution (Continued)

BEAM

Monorail crane rails - 41’ EBD Housing End

Figure 1: Existing monorail crane rail view from the South side

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• Background (Continued)

Background, Problem, Solution (Continued)

Figure 2: Existing monorail cranes view downstream

Monorail crane rails - 98.5” apart

EBD Housing 177”W X 150”H

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• Problem- Relocation of (3) permanent magnets in EBD will be a challenge since

the current crane rails do not fully align with both North and South

beam lines as shown in Figure 3.- New beam lines after the BYD magnets are not parallel to each other

and to the existing crane rails. Existing cranes will cover very limited

service areas as shown in Figure 4.- Existing shielding was put in the pit with forklift when there was no

East wall in the housing and there were no obstructions on the North

side.- New dump will have two similar beam lines on the North and South

sides with very limited space between them and forklift access will be

either unsafe or not feasible.

Background, Problem, Solution (Continued)

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• Problem (Continued)- New shielding will be much larger than the existing ones in magnitude

of more than 4 (total combined new dumps shielding quantity will be

about 408 vs total existing dumps shielding quantity of 92. The

average single shielding plate weighs about 2 tons. Besides new

shielding, there will be over 200 new shielding components to be

installed for both hard & soft beam lines components / devices.

- A single heaviest device to be lifted, the dump slug with shielding coffin

required by RP, weighs between 5 to 6 tons.

Background, Problem, Solution (Continued)

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• Problem (Continued)

Background, Problem, Solution (Continued)

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• Problem (Continued)

Background, Problem, Solution (Continued)

Figure 4: Top view of existing cranes coverage areas

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• Solution- Install a new 7 ton motorized chain hoist / trolley and bridge crane

system in EBD Area using existing monorail crane rails to meet

EBD System’s crane capacity and space dimensions requirements

as outlined in Figures 5 & 6.- The new crane system will provide the required coverage area as

shown in Figure 7.- Installing shielding and beam lines components / devices with the

new bridge crane will be safer, reduce potential worker injury,

equipment damage, and maintain the project’s fast paced

installation schedule.- The entire EBD Area will be modified and the installation of the new

crane system will not impact EBD system installation schedule.

Background, Problem, Solution (Continued)

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• Solution (Continued)

Background, Problem, Solution (Continued)

Figure 5Crane upgrade requirements:- Single hoist rail;- Capacity – 6t Min;- Dim “A” – 10” Min;- Dim “B” – 160” Min;- Dim “C” – 118” Min

Existing rails

Ceiling

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• Solution (Continued)

Background, Problem, Solution (Continued)

Figure 6Crane upgrade requirements(continued):- Dim “D” – 920” min;- Dim “E” – 30” Max;

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• Solution (Continued)

Background, Problem, Solution (Continued)

New bridge crane coverage area

Figure 7: Top view of new bridge crane coverage area

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• Alternative Solutions Considered- No new crane: Material handling equipment access for

shielding, beam lines components / devices installation works

in EBD Area will be seriously affected in terms of logistics,

cost and schedule. Inadequate available crane capacity to lift

heaviest object will be a problem. - Different shielding design to meet RP requirements will be a

challenge in terms of cost and schedule.- Option to install a new 7 ton manual hoist / trolley and

motorized bridge crane system vs the current proposed 7 ton

motorized hoist / trolley and bridge crane is currently being

considered as another option to lower first cost.

Background, Problem, Solution (Continued)

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Technical Review

• EBD installation bi-weekly meetings have been held for

several months to plan Accelerator and Photon System

installations.

• The group has concluded that a modified crane is

required to:

• Install the heavier objects like shielding and dump slug.• Facilitate remotely removing a radioactive dump slug in the

event this will be required.

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Summary of Cost/Schedule Changes

• For new proposed 7 ton motorized hoist/trolley and motorized bridge crane system:- Total Construction Cost: $223k- Total Estimated Cost: $235k- Installation to start after December 17, 2016 (LCLS short downtime)- No change to current construction schedule

• For new alternate 7 ton manual hoist/trolley and motorized bridge crane system:- Total Construction Cost: $184k- Total Estimated Cost: $196k- Installation to start after December 17, 2016 (LCLS short downtime)- No change to current construction schedule

• For no new crane option

- Total Construction Cost Increase: $600k (ROM)

- Total Estimated Cost Increase: $700k (ROM)

- Construction schedule delay (short downtime): ~ 25 days

- Construction schedule delay (long downtime): ~ 35 days

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Impact of not approving

• Material handling equipment access for shielding, beam lines

components / devices installation work in EBD Area will be

seriously affected in terms of logistics, cost and schedule.

Inadequate available crane capacity to lift heaviest object will be

a problem.

• Design of a temporarily installed lifting device capable of

moving 2-6 ton objects in a restricted area will be challenging

and likely result in a less safe working environment.

• If the dump slug ever needs to be removed, radiation exposure

time is expected to be longer relative to having a crane design

optimized for this purpose.

• Increased risk relative to safety, hardware damage, and

schedule.

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Stakeholder Review

• Stakeholder Input Received- PMCS group: Updating P6- System Managers and CAMs: Infrastructure Systems, Photon

Systems, and Accelerator Systems have been working together

on this.- ES&H: Reviewed details with Jim Healy. Jim provided feedback

indicating that installing shielding and devices by crane will be

safer, reduce potential worker injury, equipment damage, and

maintain the project’s fast paced schedule.

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Documents Updated

• If approved, the following will be updated:• Applicable ICD and RDS• eCAM Book• BOE’s

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What else should we know?

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Questions?

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