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CF Status Update


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CF Status Update

  1. 1. CF Status Update Marty Fallier Conventional Facilities Division Director Conventional Facilities Advisory Committee Review November 9-10, 2009
  2. 2. Outline <ul><li>Progress & Events Since Last Review (March 10, 09) </li></ul><ul><ul><li>Begin Ring Bldg construction </li></ul></ul><ul><ul><li>Accelerated elements of the Ring Bldg schedule </li></ul></ul><ul><ul><li>Award & issue NTP for all construction contracts (except LOBs) </li></ul></ul><ul><ul><li>Award all pre-purchased equipment contracts </li></ul></ul><ul><ul><li>Begin LOB design 1 year early </li></ul></ul><ul><ul><li>Executed LOB design, contractor outreach and prepare RFP </li></ul></ul><ul><ul><li>Experience 1 st construction site injuries </li></ul></ul><ul><li>Scope Status - Project Change Requests - PCRs </li></ul><ul><li>EVMS Status </li></ul><ul><li>Cost Status & Schedule Status </li></ul><ul><li>Risks </li></ul><ul><li>Issues </li></ul><ul><li>Action Items (separate PDF file) </li></ul>
  3. 3. Progress <ul><ul><li>Started Ring Bldg Construction (CP-2) – </li></ul></ul><ul><ul><ul><li>NTP March 25 th , construction start April 15 th </li></ul></ul></ul><ul><ul><ul><li>Adopted revised phasing plan accelerating Injection and RF Bldgs – no added cost </li></ul></ul></ul><ul><ul><ul><li>Mobilization went smoothly until an injury occurred </li></ul></ul></ul><ul><ul><ul><ul><li>Carpenter fell from step ladder fracturing heel bone 4/25 </li></ul></ul></ul></ul><ul><ul><ul><li>Instituted changes in field safety presence as a result </li></ul></ul></ul><ul><ul><ul><ul><li>Discussed in detail in Steve Hoey’s presentation </li></ul></ul></ul></ul><ul><ul><ul><li>Construction progressed ahead of baseline until combination of bad weather and adopting Torcon “Early Finish” schedule as baseline was done in July 09 </li></ul></ul></ul><ul><ul><ul><li>Ring Bldg has since regained most of schedule and baseline has been revised to be more realistic </li></ul></ul></ul>
  4. 4. Progress cont’d Photo From BGRR Stack 9-21-09 Vehicle Tunnel SR Tunnel Wall Forms SR Tunnel Slab Status of construction Site at FY09 End
  5. 5. Progress cont’d Photo From BGRR Stack 11-5-09 Vehicle Tunnel SR Tunnel Wall Forms SR Tunnel Slab SR Tunnel Walls Column Footings Ring Bldg Progress from month to month is substantial Monthly billing is ~$4M - $5M
  6. 6. Progress cont’d <ul><ul><li>Awarded Balance of Construction Contracts – </li></ul></ul><ul><ul><ul><li>Awarded Electrical Substation (CP-3) July 17 th </li></ul></ul></ul><ul><ul><ul><li>Awarded Chilled Water Plant Expansion (CP-4) July 1 st </li></ul></ul></ul><ul><ul><ul><li>Awarded Chilled Water Piping (CP-5) August 28 th </li></ul></ul></ul><ul><ul><li>Net bid results of three CP’s were within $10k of baseline </li></ul></ul><ul><ul><li>Awarded balance of pre-purchased equipment contracts </li></ul></ul><ul><ul><ul><li>All awarded on or ahead of schedule </li></ul></ul></ul><ul><ul><ul><li>Delivery of equipment for each procurement running about 2-3 months ahead of schedule </li></ul></ul></ul>
  7. 7. Progress cont’d <ul><li>ARRA funds enable advance of LOB design, procurement & construction </li></ul><ul><ul><ul><li>Perform design in FY09 instead of FY10 </li></ul></ul></ul><ul><ul><ul><li>Start construction in FY10 instead of 12 </li></ul></ul></ul><ul><ul><ul><li>Complete construction FY12 ~16 months early </li></ul></ul></ul><ul><ul><li>Enables procurement during favorable market and early occupancy by beamline staff during beamline construction </li></ul></ul><ul><ul><li>Creates some potential contractor coordination issues </li></ul></ul><ul><ul><ul><li>Have worked closely with Torcon to minimize impacts </li></ul></ul></ul><ul><ul><li>A/E Design nearly complete </li></ul></ul><ul><ul><li>Held contractor informational meeting – more scheduled </li></ul></ul><ul><ul><li>RFP to DOE for approval – expect release in early-mid Dec </li></ul></ul>
  8. 8. Progress cont’d <ul><li>First Construction Accidents/Injuries </li></ul><ul><ul><li>Progress in the sense that we need to learn from these events to prevent recurrence </li></ul></ul><ul><ul><li>2 DART cases and one reportable plus several first aid cases to date </li></ul></ul><ul><ul><li>Each is an opportunity to improve the safety program and reduce possibility of recurrence </li></ul></ul><ul><li>Numerous corrective actions have been implemented </li></ul><ul><li>Draft investigation report is topic of discussion/review </li></ul><ul><ul><li>Steve Hoey & Ray Costa presentations later today </li></ul></ul><ul><li>We welcome your comments & recommendations on how these events can be used to further improve the construction safety program </li></ul>
  9. 9. FY09 Goals & Milestones <ul><li>Complete Bid and Award of Major Contracts for: </li></ul><ul><ul><li>Electrical Substation Expansion - Done </li></ul></ul><ul><ul><li>Chilled Water Plant Expansion - Done </li></ul></ul><ul><ul><li>Chilled Water Piping - Done </li></ul></ul><ul><ul><li>Owner Furnished Equipment - Done </li></ul></ul><ul><li>Complete Readiness of Construction Mgt Team - Done </li></ul><ul><li>Begin successful execution of construction contracts: </li></ul><ul><ul><li>Ring Building earthwork completed and start concrete & utilities - Done </li></ul></ul><ul><ul><li>Begin Chilled Water Plant foundations - Done </li></ul></ul><ul><ul><li>Begin Electrical Substation - Done </li></ul></ul><ul><ul><li>Begin CHW Piping - Done </li></ul></ul><ul><li>Confirm LOB design plan & execute detailed design- underway </li></ul>
  10. 10. EVMS Status - Cost & Schedule <ul><li>Cost Assessment: Cumulative cost variance $+24k on~$43M or 0% On budget - CPI =1.00 </li></ul><ul><li>Schedule Assessment: Cumulative schedule variance $-3,811k on ~$46.8M or -8.1% - Slightly behind schedule SPI =0.92 </li></ul>Data up to Sept 30, 09
  11. 11. EVMS Status - Variance Analysis <ul><li>Cost Variance - None </li></ul><ul><li>Schedule Variance WBS 1.5 – aggregate – ($3.81M) </li></ul><ul><ul><li>Ring Bldg variance (-$1.3M or -5.4%) </li></ul></ul><ul><ul><ul><li>Contractor early finish schedule for steel fabrication is most of this </li></ul></ul></ul><ul><ul><ul><li>Some utility work and submittals account for balance </li></ul></ul></ul><ul><ul><ul><li>None affect critical path and contractor is making up ground </li></ul></ul></ul><ul><ul><li>Chilled Water Plant Expansion (-$1.8M variance) </li></ul></ul><ul><ul><li>Electrical Substation (-$0.2M) </li></ul></ul><ul><ul><li>Chilled Water Piping (-$0.2M) </li></ul></ul><ul><ul><ul><li>All 3 contracts scheduled for on-time completion </li></ul></ul></ul><ul><ul><ul><li>Baseline profile for these contracts did not reflect reasonable cost plan </li></ul></ul></ul><ul><ul><ul><li>PCR required to adopt contractor schedule/cost profile as baseline for each </li></ul></ul></ul><ul><ul><ul><li>PCR to be processed in October 09 </li></ul></ul></ul>
  12. 12. Scope Status – Project Changes PCRs <ul><li>Approved changes since last CFAC 3/10/09 </li></ul>
  13. 13. Scope Status – Project Changes PCRs <ul><li>Changes in preparation for near term </li></ul><ul><ul><li>*Pending LOB bid results in 2QFY10 </li></ul></ul>
  14. 14. Costs – Management & Engineering
  15. 15. Costs - Construction <ul><li>As Part of FY10 Work planning Process EAC is being reevaluated and will be corrected for Oct 09 data </li></ul><ul><li>Bulk of VAC is pending PCR for LOB scope, A/E LOB re-design fee & post bid addendum costs </li></ul>
  16. 16. Schedule
  17. 17. Risks <ul><li>Construction safety program must be effective </li></ul><ul><ul><li>Safety program enhancements after most recent injury must be maintained and developed further </li></ul></ul><ul><li>Potential for field changes during construction </li></ul><ul><ul><li>Site related changes nearly retired, only design related remain </li></ul></ul><ul><ul><li>Added potential for changes due to LOB & Ring contractor interface </li></ul></ul><ul><li>Potential for design changes from ASD & XFD </li></ul><ul><ul><li>Thus far, only very minor changes with exception of larger LOBs </li></ul></ul><ul><li>Risks for procurement of balance of CF scope partially retired </li></ul><ul><ul><li>CHW Plant & Pipe, Elect Substation, Elect Equip - Done($16M) </li></ul></ul><ul><ul><li>LOB procurement remains – ($~40M+ for larger LOBs) </li></ul></ul><ul><li>No new risks foreseen </li></ul>
  18. 18. Look Ahead <ul><li>Ring Building contractor </li></ul><ul><ul><li>Improved safety performance, ramp-up concrete and utility installation, expedite submittals, prepare for steel delivery and erection </li></ul></ul><ul><li>Electrical Substation Expansion </li></ul><ul><ul><li>Begin ductbank installation and B603 modifications </li></ul></ul><ul><li>Chilled Water Plant Contractor </li></ul><ul><ul><li>Install foundations, pipe headers, steel & equipment submittals </li></ul></ul><ul><li>Chilled Water Piping </li></ul><ul><ul><li>Defer mobilization to 3/15/10, order & deliver piping & components </li></ul></ul><ul><li>Electrical equipment vendors </li></ul><ul><ul><li>Prepare for in-process inspections and equipment delivery </li></ul></ul><ul><li>LOB Design and Construction </li></ul><ul><ul><li>Prepare bid-issue bid set </li></ul></ul><ul><ul><li>Submit draft RFP: for DOE review </li></ul></ul><ul><ul><li>Continue contractor outreach </li></ul></ul>
  19. 19. Issues <ul><li>Ring Building Contract </li></ul><ul><ul><li>Torcon must maintain excellent safety performance </li></ul></ul><ul><ul><li>Torcon has implemented plan to regain schedule </li></ul></ul><ul><ul><li>Torcon slow on submittal of pricing proposals for ECN’s (management currently focused on improving safety) </li></ul></ul><ul><ul><li>Utility conflicts have been resolved and utility submittals need to catch up </li></ul></ul><ul><li>PCR’s in preparation for newly awarded contracts </li></ul><ul><ul><li>Need to incorporate CHW Plant Expansion, CHW Piping and Elect Substation contractors cost plans into baseline for accurate performance assessment </li></ul></ul><ul><ul><li>PCRs for field changes and ECN’s need to be processed once acceptable proposals are received. </li></ul></ul><ul><li>Advancing LOB Design & Construction </li></ul><ul><ul><li>LOB RFP advancing more slowly than expected however, coordination of LOB contractor with Ring contractor limits start of LOB construction to no earlier than 7/1/10 – thus no impact if awarded in March 10. </li></ul></ul>
  20. 20. Conclusions <ul><ul><li>CF activities are on budget and close to on-schedule </li></ul></ul><ul><ul><ul><li>Will be back on schedule when contracts are incorporated </li></ul></ul></ul><ul><ul><ul><li>Working with Torcon to get back on early finish schedule </li></ul></ul></ul><ul><ul><li>Maintaining a “best in class” construction safety program remains a key objective </li></ul></ul><ul><ul><li>Construction proceeding well </li></ul></ul><ul><ul><ul><li>Contractor and subcontractors are technically proficient and quality is very good </li></ul></ul></ul><ul><ul><li>Balance of CF procurements (except LOBs) are in place or nearly so – cost results are within baseline </li></ul></ul><ul><ul><li>LOB design nearing completion and release for proposals when RFP is approved </li></ul></ul>