CEBAF Facilities 20-Year Plan: Infrastructure Upgrades for Reliability

Facilities 20 Year Plan Facilities is responsible for providing and maintaining infrastructure such as buildings, their utilities and other systems in support of CEBAF operations. This presentation will cover key items pertaining to providing CEBAF 20 more years of reliable Facilities Infrastructure.

Electrical Systems The UIM provided upgraded primary electric service feeds and the ability to back feed power during required service power outages. The project also upgraded the main communication lines to fiber optics.

Electrical Systems 1500 Kva Transformers Existing Program for replacing old transformers with reconditioned transformers 5 of 30 completed. Switchboards Purchase new switchboards Take the breakers from the old switchboards, have them reconditioned and then use them as spares for exiting units. Strategically purchase switchboards to have a full complement of spares Panel Board Reconditioning The plan is to purchase and install new chassis and breakers into each panel.

Electrical Systems 40 and 33 MVA, 15 kV Switchgear The 40 MVA switchgear is 30 years old and is in need of an upgrade and overhaul. A project has been developed and is awaiting funding to address this requirement. The 33 MVA switchgear is less than 3 years old and PMing on this for the next 20 years will largely only require breaker PM and testing at 7-10 year intervals. Once the 40 MVA switchgear is overhauled, it will be on the same 7-10 year schedule for breaker PM.

Electrical Systems Low Voltage Transformers A few low voltage transformers have begun to show signs that they are approaching the end of their life. Most are approximately 30 years old. The plan is to examine these transformers, while running at normal operational loads, and replace them on an as-needed basis. Most of these transformers can be easily purchased from local distributers with little advanced notice.

Electrical Systems Back-up / Standby Generators Life expectancy of standby generators is 20 to 30 years. We re halfway through the life cycle for most. Preventive Maintenance is performed on all standby generators. The program provides the required preventive maintenance and is able to identify issues and correct them prior to experiencing failures when the units are needed. A replacement program will need to be evaluated.

Mechanical Systems Cooling Towers The UIM and 12 GeV programs replaced/added the accelerator site cooling towers. o Upgrades included redundant pumps and backup towers and fans. Towers will support the operations for another 20 years at the current 12 GeV heat load levels. If additional cooling capacity is required (due to projects increasing heat generated), the projects will need to fund the increased cooling capacity. For example, Building 92 to support future experiments such as the Moeller Experiment.

Mechanical Systems Chilled Water Systems The UIM and recent projects have enhanced the cooling capacity of the chilled water systems. o An additional 800 ton chiller was added o System flow modifications were implemented to improve system reliability. o An additional heat exchanger was installed to increase cooling capacity up to 12 GeV heat load levels. o Pump and temperature control system modifications were implemented to improve system reliability and performance. Underground piping system is being evaluated to determine how to reduce the occurrence of leaks Miscellaneous small chilled water systems equipment (Injector, Counting House, Laser Room, and LERF) chilled water system chillers and pumps are nearing their service life and replacement projects need to be planned.

Mechanical Systems Service Building HVAC Service Building chilled water and direct expansion air conditioning systems are all functional. o The chilled water air handling units were installed in 2003 o With a 20/25 year life span - Replacement projects need to be evaluated A project to replace unitary controllers is being planned due to eventual obsolescence and parts unavailability.

Mechanical Systems Rack and Power Supply Fans All fans are currently operational and are replaced as required. Availability of replacement fans is becoming extremely difficult, FM engineering is assessing replacements using direct drive fans, no belt drive. LCW Modifications were implemented to increase heat rejection capacity to 12 GeV heat load levels. o All systems have backup pumps to minimize downtime due to pump related operational problems and failures. System controls and workstation software both need to be upgraded. North and South Access buildings - makeup water system improvements have been engineered. Most parts have been acquired and installation details are being addressed.

Mechanical Systems Improvements to the deoxygenation System Original deoxygenation system contactors (no longer in production) were replaced with current state of the contactors which are off the shelf replacement parts. South and North LINAC deoxygenation capacity was increased. Additional system enhancements were recently implemented and performance improvement effectiveness is being evaluated. Instrument and Compressed Air Systems Most compressed air systems have backup compressors or systems except the Hall D HDR System and the CHL2 System. Due to the critical nature of those systems, backup capacity should be installed. Since compressor equipment typically has an expected life of approximately 10 years, and most units are reaching or have exceeded this age. We have started a phased approach replacement project.

Civil Systems Domestic Water System A study was done of the domestic water system. Recommended isolation valve locations were identified to reduce the impact to accelerator operations when line breaks occur. Values have been installed to ensure redundant flow to the CHL as well as reduced impact to other areas in the accelerator. This program will need to continue until all recommended valves are installed Building Roofs Services buildings had their roofs re-coated in 2014 and are under warranty until 2024. - Prior to the end of the 10 year warranty period, the roofs will be re-coated to extend their serviceability for another 10 years. The Counting House roof was re-roofed in 2013 and is warranted until 2033. CHL is receiving a new roof this year. A roof condition assessment program was conducted in 2012 which provided FM Operations an understanding of all roof conditions on site. This condition assessment report has been and will continue to be used as the tool to plan roof replacement projects.

Civil Systems Tunnel Crack Repairs This is an ongoing program and needs to continue as additional cracks are identified in the tunnel. The challenge is the areas where accelerator equipment restricts the repairs from happening. Tunnel Penetrations Facilities has repaired some penetrations using an urethane grout. It has not perform as expected. A Test was done last week on a mock-up using a new product. All signs of the test show very favorable results. We need to further evaluate the product before we move forward on using it in the tunnel.

Civil Systems Roads Facilities has done an evaluations of the roads and has determined where the roads will have to be repaired/replaced with new asphalt, in addition, a complete overlay of accelerator roads will need to be done to support the next 20 years of CEBAF operations.

Closing Statements Facilities Operations are designed to support the current 12 GeV needs. If future initiatives require upgrades to capacities, or additional utilities, project designs will need to be created and funding will need to be obtained. Facilities established an in-house Operations group whose mission is to ensure proper operations and maintenance of facilities infrastructure. Preventive maintenance also increases efficiency of the equipment, thus reducing the likelihood of premature failures and therefore keeping the costs down especially when asked to provide 20 more years of CEBAF support. Facilities is working to establish funding profiles to support the next 20 years of CEBAF operations. This is additional funding to the current operational needs to support the Lab and CEBAF Operations.