TRIUMF: Canada's national laboratory for particle and nuclear physics

Proposal : Engineering and construction management services for the Tri- University Meson Facility International Power and Engineering Consultants Ltd.; Canadian Bechtel Ltd. 1968

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I PEe TELEPHONE 685 - 5131 TELEPHONE 366. 352 1 =---..,., W . F . MI LES C.E .WHITE DIRECTOR AND GENERAL MANAGER INTERNATIONAL POWER AND EN G INEERI N G C ONSULTANTS LIMITED 570 DUNSMUIR STR E ET VANCOUVER 2 , B.C. CANADA SENIOR VICE - PRESIDENT C ANADIAN BECHTEL LIMITED 25 KING S TR E ET W E S T TO RONTO, O NTARIO PROPOSAL: ENGINEERING AND CONSTRUCTION MANAGEMENT SERVICES For The: Tri- University Meson Facility PRESENTED BY: INTERNATIONAL POWER AND ENGINEERING CONSULTANTS LTD. AND CANADIAN BECHTEL LTD. SD 68-34 (6485) Section 1 2 3 4 5 CONTENTS SUMMARY INTRODUCTION STATEMENT OF WORK TECHNICAL PLAN MANAGEMENT PLAN CAP ABILITIES DESCRIPTION SUMMARY This document pres ents a Joint Venture proposal for the development, engineering, construction, and testing of the Tri- University Meson Facility (TRIUMF) to be located at the University of British Columbia, by International Power and Engineering Consultants Limited (IPEC) and Canadian Bechtel Limited (CBL). The proposal, which is intended to be fully responsive to the needs of the University of British Columbia and its associates, includes a Statement of Work to be performed, Technical and Management Plans, and a Summary of IPEC-CBL back-ground and experience. IPEC-CBL is aware of the significant development work already perfo rmed by those associated with the TRIUMF project. The purpose of this proposal is to present a plan to translate the scientific concepts so developed into an operational facility. IPEC-CBL will furnish engineering, procurement, and construction management services required for completion of the TRIUMF project. The principal engineering offices will be located in Vancouver, B. C. The suggested plan is based upon experience growing out of the design and construction of many other complex, highly technical, extensive facilities and will provide a highly effective method of completing the TRIUMF project within the requirements of the TRIUMF Board. The IPEC-CBL proposal offers: • A staff experien.ced in the engineering and construction of cyclotrons, able to perform any and all phas es of the project under the direction of the TRIUMF Project Director • Control of costs, within an established budget, from inception of detailed design to completion of the facility • Continuous monitoring and intensive expediting of all activities to assure their accomplishment in conform-ance with a preestablished time schedule • Availability of an experienced technical and management staff for the direction of the work, thereby greatly reducing the University's need to recruit, select, train, and direct temporary personnel • Close inspection of the work to assure its completion in accordance with the design criteria and contract documents Section I INTRODUCTION International Power and Engineering Consultants Limited (IPEC) of Vancouver, British Columbia, and Canadian Bechtel Limited (CBL) of Toronto, propose to act as a Joint Venture (hereinafter referred to as IPEC-CBL) to provide engineering and construction management services for the Tri- University Meson Facility (TRIUMF) at the University of British Columbia. This proposal contains a Statement of Work and a Technical Plan, a Management Plan, and a Capabilities Description - personnel resumes for a typical staff, corporate services and related corporate experience of IPEC-CBL. Section 2 STATEMENT OF W ORK IPEC-CBL proposes to provide , under a single contract, engineering and construction management s e rvic e s for the d evelopment, design, engi-neering, procurement, fac ility construction-management, cyclotron as -sembly, testing, start-up operations, and personnel training for the TRIUMF project. This proposed approach w ill r e sult in a fully-engineered operational cyclotron and facility. Engineering for both th e facility and the cyclo-tron will be conducted concurrently. Thus, procurement of long - l e ad cyclotron items will b e made parallel w ith building construction per-mitting optimum interfacing of cyclotron and facility. Engineering will b e essentially completed prior to cyclotron installation, resulting in the lowest procurement and installation cost . Total cyclo-tron systems engineering will a llow procurement of individual systems and components on a competitive bid basis l a r gely in Canada. The cy-clotron systems w ill be engineered to utilize as many commercially available components a s possible to reduce requirements for stocking of r eplacement parts. Complete as-built enginee ring draw ings and specifications will facilitate cyclotron maintenance and training of TRIUMF personnel. The principal project functions will include: project administration and planning, technical services, construction manaJement and testing and start-up. 2.1 PROJECT ADMINISTRATION AND PLANNING 2.1.1 Administration IPEC-CBL will group together, as a project team, an administrative organization of personnel familiar with projects of this type to perform the functions necessary to provide a complete and operational facility. This organization will be under the direction of the IPEC-. CBL Project Manager. One of the first tasks will be the p reparation of a Project Scope and Procedures Manual to identify responsibilities, specify form and frequency of reports and other working documents, and determine the required approval procedures and document distribution. IPEC-CBL in association with the TRIUMF Director will prepare a Reference Design Criteria Document (RDCD). The RDCD will delineate the desired cyclotron specifications and will establish the basic specifications of each of the systems and sub-systems. The RDCD after approval b y both the IPEC-CBL and the TRIUMF Board will be the basis for the facility budget. Detail engineering will be bas ed on the approved RDCD. Deviation from this document will require approval of the TRIUMF Director. IPEC-CBL will prepare a list showing the capabilities of pre - qualified manufacturers, suppliers, and constructors in Canada and world-wide. This list of reference firm s will be the basis for subsequent equipment procurement and will permit the d esign of equipment compatible with the manufacturing capability of multiple firms to achieve maximum competitive bidding. 2.1. 2 Project Planning Scheduling. IPEC-CBL will prepare and implement a Critical Path Network (CPN), including development, design, detailed engineering, procurement, construction, testing, and start-up. Use of a CPN will assure that long lead-time items will be available when required for installation and if significant procurement delays do result, alternate installation plans may be implemented. The CPN will also identify which items require expediting. The CPN approach has been applied by both IPEC and CBL in other projects of similar magnitude and has resulted in the shortest possible completion time and the lowest cost for complex projects. Estimating and Cost Control. IPEC-CBL will prepare a budgetary cost estimate in accordance with the items identified in the RDCD. Subsequent cost forecasts will then be made a gainst the original budgetary estimates as engineering proceeds. If items are found to be in excess of the original budget estimate additional development engineering may be recommended to reduce the cost of these items. This procedure will allow regular and timely project cost control. Prior to initiation of cons truction of each major phas e of the facility, a definitive cost estimate will be prepared for the approval of the TRIUMF Director. These definitive cost estimates and subsequent cost forecasts will serve as a reference number for comparison with bids received from vendors. Estimating will be performed by experienced estimators who have worked on similar projects . Procurement Services. IPEC-CBL will receive tenders from rnanu-facturers and subcontractors and will make recommendation for award of contract; alternatively IPEC-CBL will award the necessary contracts with the approval of the TRIUM F Director. Purchase orders will be expedited by the procurement services of IPEC and CBL. Their expeditors are located at major facilities and areas throughoLlt the world. Inspection of conventional equipment and facilities will be made by the procurement groups of IPEC and CBL. Technical elements of the project requiring special analysis will be handled b y the IPEC-CBL engineering group. 2.2 Technical Services IPEC- CBL will coordinate or provide architectural services in the layout and design of the building to ensure that the cyclotron and beam transport system are properly installed. A local architect may be engaged so that the most qualified personnel will be available to assure that the facility conforms to architectural standards established by UBC. Substantial economies in structure can be accomplished through the proper selection of materials for the facility. IPEC-CBL will provide the engineering services necessary for the preparation of the plans and specifications of the cyclotron facility (i. e., buildings , utilities, etc.). The specifications will be prepared so that various elements of the facility will be procured on a competitive basis. IPEC- CBL will prepare detailed drawings and specifications for cyclo -tron components and subsystems; receive and evaluate tenders and recommend contract and subcontract awards; provide technical inspection of components and subsystems incorporated into the cyclo-tron; and provide technical assistance to the TRIUMF group for systems testing, cyclotron start-up, and personnel training. IPEC-CBL will prepare installation drawings for the cyclotron. IPEC-CBL will coordinate and monitor other organizations engaged in engineering and fabrication of elements of tIle cyclotron on a performance specifi ca -tion basis. IPEC-CBL is prepared 'LO monitoJ: and ~oordinate tb e work of project consultants. 2.3 Facility Construction Management and Cyclotron Assembly Construction Management will consist of the planning, direction, and coordination of contractors engaged in constructing separate portions of the project. It will include selection of appropriate construction methods; review and coordination of individual contrac.tor's construc-tion schedules, manning schedules, and forecasts; contract adminis-tration; authorization and negotiation of change orders; budgeting of funds and cost control and handling requests for extras; reviewing and establishing uniform labor policies including wage scales, working hours, and general working conditions; enforcement of good house-keeping; scheduling and arranging for inspection of work in progress and of completed work; monitoring adherence to draWings and specifica-tions; liaison with other construction representatives; approval and acceptance of contractor's work. Assembly of the cyclotron will be performed directly by IPEC-CBL because of the critical aspects of the assembly requirements. Personnel experienced in installation projects of this type are available on our staff and will be utilized. 2.4 Test, Start-up, and Personnel Training IPEC-CBL will perforITl final tests and prepare start-up procedures with the assistance of TRIUMF operation and ITlaintenance personnel and conduct a technical training pro graITl for d esignated TRIUMF personnel. Manuals for test procedures, operation, and ITlaintenance will be prepared by IPEC and CBL publications services to the speci-fication of the Client. Section 3 TECHNICAL PLAN 3.1 GENERAL The following Technical Plan describes the IPEC-CBL approach for engineering and construction management services for the TRIUMF project. The function of the project engineer construction manager will be to engineer and construct an operational facility based on the technical data developed at the UB C. To define clearly the project scope, the Technical Plan is broken down into five phases: Development Engineering, including technical consultant activities; Detailed Engineering; Procurement; Construc-tion Management; and Start-up and Training. A detailed discussion of each phas e is pr es ented below. 3.2 PHASE I: DEVELOPMENT ENGINEERING A considerable amount of preliminary design has been performed by the TRIUMF Study Group. However, IPEC-CBL is prepared to under-take additional studies and model testing programs should this be required to define critical cyclotron parameters. During t h e development stag e of the pro gram, the basic ground rules for engineering and constructio~';. m anag ement of the fa c ility will be established. The results of development engineering will consist of specifications for the various elements of the facilit y based on theoretical and model studi es. It is anticipated that the basic physics parameters for the c y clotron will be established by the Client. However, IPEC-CBL will as sure that the specifications delineated are compatible from an engineering standpoint ; that a facility designed to these specifications can be constructed; and that special consideration is paid to meeting these specifications b y the capabilities of Canadian industry . IPEC-CBL will coordinate the development effort and will prepare the RDCD which will be bas ed on the model studies and theoretical phy sics per-formed b y the Client. Economic trade-offs will be developed during the development phas e to arrive at a design which will result in the lowest facility cost and short-est construction schedule consistent with per formance requirements. Detailed engineering will be bas ed on the RDCD. During the develop-ment phase and the preparation of the RDCD the work will be seg r ega-ted into individual Material Requisitions (MR's) which will later result in the preparation of bid packages correlated to the MR's. The M R identification w i ll also form the basis for budget and forecast estim ates. Additional consultants required for model and theoretical studies may b e under the direction of the IPEC-CBL Project Manag er at the dis c r etion of the Client. 3.3 PHASE II: DETAILED ENGINEERING In the detailed engineering phas e of the pro gram, engineering will be performed for the preparation of bid packages for the procurement of the cyclotron and its facilities. 3.3.1 Cyclotron and Beam Transport Detailed Engineering IPEC-CBL project engineering will be responsible for: • Development of performance specifications for systems, subsystems, and major components • Preparation of installation designs for mechanical systems including water, air, vacuum, etc. • Development of. cyclotron electrical distribution systems (one-line electrical) • Preparation of mechanical drawings and speci-fications necessary for procurement of the cyclotron mechanical equipment such as magnet systems, injection systems, RF systems, etc. • Development of instrumentation systems for machine operation and data analysis • Preparation of specifications for procurement • Preparation of control schemes, functional block diagrams and wiring schedules • Anal ys is of bids, and technical ins pection of sophisticated components • Preparation of system test and checkout procedures 3.3.2 Facilities Eng in eerin -{ IPEC-CBL project engineering will be responsib Ie for: • Site planning and coordination with the DBC site requirements • Architectural design coordination • Engineering and display models • Building mechanical system and subsystem design • Building shielding and cyclotron foundation r equir ements • • • 3.3.3 Procurement plans and specifications preparation Analysis of contractor tenders Auxiliary facilities (cooling tower, power sub-stations, etc.) design and specification Estimating A budgetary cost estimate will be prepared based on the RDCD. Subsequent cost forecasts will be made as engineering progresses and as actual bid data are received. A detailed cost analysis for the total project will be performed regularly or as requested by the Client. Estimating personnel also assist design engineers in the evaluation of alternative design approaches to determine the optimu m configuration within budget limitations. Anticipated m.aintenance costs will be considered as a factor in such evaluations. Capability to upgrade the facility for future requirements will be considered. 3.3.4 Codes and .standards The design and construction of all systems and assemblies for the TRIUMF project will be in accordance with the standard practices as established by the codes and standards of British Columbia and Canada. All drawings and specifications will be reviewed to ensure that thes e codes and standards are met. Equipment purchased outside Canada will be accepted if it meets codes and standards equal to Canadian standards. 3.3.5 TRIUMF Director Approval All drawings and specifications prepared for bid packages will be submitted to the TRIUMF Director to review and approve prior to is suance. After bids have been received and analyzed, a contractor or vendor will be s elected, s ubject to Client approval. 3.3.6 Test Specifications Vendor Shop Tests. Specifications for items procured on the basis of performance specifications shall be prepared by the vendors and approved by IPEC-CBL and the TRIUMF Group. Tests will be per-formed with simulated loads at the vendor shop prior to shipping, and may be witnessed by both TRIUMF and IPEC-CBL personnel. Equip-ment performance will be the basis for acceptance. Where detailed engineering drawings are prepared, they will be us ed to evaluate specification conformance :)n-Site Tests. Test specifications in this case will be prepared by IPEC-CBL and approved by the TRIUMF Group. The tests will be conducted on each system after installation, with equipment connected to the actual loads. Equipment performance will be the basis for final acceptance. 3.3. 7 Installation Procedures Installation procedures will be prepared to facilitate cyclotron assembly and maintenance. After systems are installed, these procedures will also serve as maintenance aids. In addition to cover-ing normal assembly sequences, the procedures will also provide detailed methods for such items as cleaning , leak testing , insulation resistance measurements, etc. 3.3.8 Bid Packages T ypically, bid packages will consist either of drawing s, specifications, or performance specifications to required guarantees. Where com-ponents and subsystems are purchased on the basis of vendor perform-ance specifications, vendor drawings will be reviewed before con-struction to ensure compatibility. 3.3.9 Changes and Modifications Changes and modifications may be required which will result in a deviation from the RDCD or in a purchase order change after a purchase order has been issued. Chang es may result either from technical or economic considerations. When a change is initiated b y e ither the TRIUMF Group or IPEC-CBL, it w i ll be analyzed and submitted with recommendations, a cost proposal for associated e n t:;ineering and construction, and an analysis o f i.ts effect on the schedule. If the change is appr.oved by the T R IUMF D i. rector, it will be inte grated into the system. 3.4 PHASE III: PROCUREMENT 3.4.1 General In order to complete the project at the lowest possible cost, it is imperative that all procurement activities, including selection of bidders, purchasing, expediting, and quality assurance, be performed by a procurement group highly experienced in these functions. IPEC-CBL, therefore, will use its own procurement personnel through the project. A Procurement Manager selected by IPEC-CBL will direct the project effort. Individual procurement actions will occur within the IPEC- CBL structure. 3.4.2 Preferred Vendors Every effort will be made to obtain equipment from Canadian industries. If necessary , technical know-how and information on special manufac-turing techniques will be made availabl e to s elected Canadian firm.s. When Canadian suppliers are not available, procurement will be made in the United Kingdom, the United States , West Germany , Switzerland, Japan, or other countries, in accordance with Canadian import re gu-lations and consistent with project requirements. Based upon IPEC-CBL worldw;.de procurement experience and activities, a Preferred Vendors ~ist will be prepared to assur e that onl y the most competent companies, consistent with the desire to rnaximize participation of Canadian firms, are requested to submit proposals to perform the required work. This list will be subject to the approval of the TRIUMF Director. 3.4.3 Construction Contracts IPEC-CBL will recommend and/or award construction contracts required for the installation of the equipment, and construction of the facility, except for cyclotron and beam transport installation. All construction contracts will be under the d irection of the IPEC-CBL construction manager . 3.4.4 Bid Packages Bid packages will be submitted to pre-qualified vendors . Bid requests will be based on performance specifications and/or fabrication draw-ings. Emphasis will be placed on completing as much fabrication as possible at the vendor's shop. 3.4.5 Quality As surance Quality assurance requirements will be clearly spelled out in specifica-tions and on drawings. A quality assurance pro gram w ::'ll be initiated to ensure the reliability of des ign, fabrication, and installation of the cyclotron . The pro gram will verify that vendor and subcontractor components, subas s emblies, and s y stems meet all specifications and drawing requirements. Vendor processes and cOITlponents will be inspected as necessary in the vendor 1 S shop during the ITlanufacturing cycle by qualified personnel. No changes in design specifications will be allowed prior to approval by the TRIUMF Director. All changes will be properly docuITlented. 3.4.6 Schedule Control IPEC-CBL, with the backing of associated worldwide organizations, is in a favorable position to ITlonitor vendor contractual COITlITlitITlents. IPEC and CBL have resident inspectors and expediters in ITlany countries and in the shops of ITlany ITlajor ITlanufacturers. Therefore, vendor perforITlance can be readily and regularly checked, discrep-ancies noted iITlITled iately, and corrective action initiated proITlptly. The procureITlent schedule, together with the engineering schedule, will be controlled by a C ritical Path Network which can be continuously up-dated and checked by cOITlputer. Reports will be published and subITlitted to the TRIUMF Director ITlonthly or as requested. 3.5 PHASE IV: CONSTRUCTION MANAGEMENT IPEC-CBL proposes to furnish cOITlplete services for ITlanaging the facility construction and for erecting the cyclotron. These services also include checkout and testing of equipITlent, cOITlponents, and systeITls. 3.6 PHASE V: START-UP A ND TRAINING It is anticipated that prior to equipment installation and testing the TRIUMF organization will be expanded to include the engineers and technicians required to operate and maintain the facility . It is anticipated that the TRIUMF staff will participate in the equipment checkout program, in writing start-up and operational procedures, and in the cyclotron start-up. Experience has shown that "debugging" and testing with personnel who later will be in charge of the cyclotron operation provides the best possible training for them. Section 4 MANAGEMENT PLAN 4.1 PROJECT ORGANIZATION The IPEC-CBL Joint Venture for the TRIUMF project will have a Project Committee consisting of four members who will be the governing body of the Joint Venture. Two members will be appointed by IPEC and two by CBL. A project organization chart is shown in Figure 4-1. This Committee will report to the TRIUMF Director. The functions of this Committee will be: • To establish jointly with the Client the project scope, budget, and schedule • To review periodically the project status • To resolve with the Client all changes in contract scope that affect cost and schedule • To help resolve any outstanding contractual and technical problems • To provide the capabilities of the component organ-izations to the Project Manager A Project Manager will be appoin t ed b y the Project Committee who will be responsible to the TRIUMF P r oject Directo r . The Project Manag er within the context of the RDCD will be responsible for project direction, for organizing and directing all phases of the work, and for establishing the proper working relationship with TRIUMF' s planning, scientific, and engineering personnel. He will be the focal point fo r all client-contractor communications. The assignment of full project implementation responsibility to a s ingle individual ensures optimum utilization of manpower, effective inte r -facing of the accelerator and the facility, and minimum elaps ed time from initiation to engineering to start-up of the cyclotron. Consultants from IPEC, CBL, Bechtel Corporation, Allgemeine Electricitats Gesellschaft (AEG), and other or ganizations as required will report to the IPEC-CBL Project Manage r and will work closely with the TRIUMF staff and consultants on cyclotron preliminar y des i gn and lTIodel studies. Estimating and Scheduling, Project Administration, and Procurement supervisors will be assigned as permanent staff to the project, report-ing to the Project Manager. In charge of construction and er.gineering and also reporting directly to the Project Manager will b e : • The Resident Construction Engineer, who will adminis-ter Building Construction Contracts and supervis e all construction activities. A C y clotron Assembly Superintendent will report to the Resident Engineer. • The Project Engineer-C~; clotron will control all engineering work on c yclotron equi pment, shield-ing, beam transport, data systems, equipment test, start-up, and personnel training. • The Project Engineer-Facility will control all engineering work on facility, utilities and building design. IPEC-CBL will be responsible for the development and dissemination of basic design criteria, the approval of completed drawings for submittal to the Client, the preparation of specifications and purchase requisitions, and the analysis of vendor's quotations. The Project Engineers will be responsible for the Project Scope and Procedures Manual; development and maintenance of engineering schedules; and estimating, reporting, forecasting, and controlling engineering manhour requirements. Civil Struct. I TRIUMF CONSULTANTS I IPEC-CBL CONSULT ANTS I PROJECT ADMINISTRATION ~ PROJECT ENG. FACILITY I Elec. Mech. Draft. Mech. TRIUMF BOARD TRIUMF IPEC-CBL DIRECTOR COMMITTEE IPEC-CBL PROJECT MANAGER ESTIMATING & SCHEDULING PROJECT ENG. CYCLOTRON Elec. Instr. Contr. FIGURE 4-1 Draft. Quality Assurance I PR OC UR EMENT I RESIDENT CONSTR. ENGINEER Bldg. Constr. I Cyclotron Assembly Su pe rintendent Section 5 IPEC-CBL CAPABILITIES DESC RIPTION AVAILAB LE STAFF IPEC-CBL will draw personnel as required from existing staff of International Power and Engineering Consultants Limited in Vancouver, Canadian Bechtel Limited offices throughout Canada, and from the worldwide offices of Bechtel Corporation. This reservoir of experienced specialists will provide IPEC-CBL with flexible capability in all the major engineering disciplines and in the support-ing areas of estimating, procurement, and management of construc-tion. In general the IPEC-CBL design staff for the fa cility will be largely drawn from IPEC and CBL. The design staff for the cyclotron will be largely drawn from the Bechtel Corporation and in particular ke y engineers from the Scientific Development Department. The S cientific Development Department, with over 80 engineers and physicists, was responsible for the Texas A&M University 88 -inch variable energy cyclotron whic}. has been successfully completed on schedule and on budget. SPECIAL RESOURCES Computer Services IPEC-CBL will draw on computer services available in the International Power and Engineering Company Limited and Bechtel Corporation facilities. Both of thes e companies have been applying computer technology to engineering and design since 19 55 . Machine time will be available from existing contract services in Vancouver and from Bechtel's GE 625 in San Francisco. Alternatively UBC's own computer machine availability would be utilized . Currently, over 550 scientific, engineering, and administrative programs are available for use. These include several critical path scheduling programs as well as design pl;"ograms for stress analysis, piping network pressure analyses, determination of multigroup neutron diffusion, slope stability analysis, EHV radio interference analysis, piping flexibility analysis, and a program for developing isometric drawings from model takeoff points. IPEC-CBL would also have available through a consulting agreement with AEG the following computer programs which can be used for TRIUMF beam dynamics analysis: POL 2. This program is designed to determine the optimum magnetic field for a machine when the following parameters are given: machine dimensions; kind of particle; maximum energy; number of sectors; magnet gaps; ion frequency; average magnetic field along the last orbit; and axial number of betatron oscillations per turn (or spiral angle as a function of radius). By means of a two-dimensional solution of the pot ential theor f , rnagneti ,: fi eld correction requirements are determined in such a . way t hat deviation fr om the a verage isochronous field will remain within the allowable limits. The program is also used to specify the optimum steel con-fi g uration, i. e., the configuration of the pole plates. POL 3. This program, a modification of P O L 2, provides a step- by- step solution for the total magnetic field. DEPOL. This program allows study of the degree of depolarization of polarized ions in a given magnetic field. RUKU. With RUKU, it is possible to accomplish numerical integration of the motion e quations. Time-dependent electric fields, used to simulate the ion beam in the c y clotron, permit analysis of beam behavior under field errors and various resonance conditions. S EA. Although primarily intended to allow analysis of the beam orbit by a sharp-edge approximation method, SEA is also useful in determining beam extraction requirements. QUAL. This program develops the beam phas e spac e characteristics so that extracted beam quality ma y be studied. MFB. The MFB computer program is used to a naly z e the magnetic field under saturated iron conditions. Bechtel Laboratories Bechtel maintains a rnetallurgical laboratory equipped and staffed to evaluate fabrication techniques and determine env ironment service characteristics of metals. Principal investigations conducted include studies of corrosion and materials and coatings. A new laborator y facilit y is engaged in deve lopment of industrial applications of micro-w a ve power and RF components. AEG Facilities The Nuclear Energy Division of AEG has extensive facilities for the construction and testing of accel erator models. Thes e can be utilized by IPEC-CB L in d i rect support to the T R IUMF project. The accompanying brochure entitled "ACCE L ERATORS, Development/ Design / E n gineering / Construction" describes in g reate r d etail thes e AEG facilities and capabilities. APPLICABLE EXPERIEN C E The following projects are indicative of IPEC-CBL experience in a pplicable complex assignments: Nuclear Research and Service Facilities Bechte l sta ff capabilities in the design of nuclear research facilities ar e demonstrated by successful design work on the M a terials Testing A ccelerator (MTA), the Texas A&M Variable Energ y C y clotron (TAMVEC), H o t Cells, Reactor - in - Flight Test Facilities, larg e a nd complex spac e simulation chambers for testing nuclear rocket engines and components, the SNAP-8 test facilit y , and the General Electric V a llecitos Atomic Laboratory . These pr o jects were cond ucted under a variety of c ontractual relation-ships, including cost - plus, target-price, and fixed-price. In addition to normal design, engineering, and construction, se rvices pr o vided included site inv estigation and selection, maste r planning, system a naly sis a nd selection of optimum plant size, a nd rev iew of m a nufacturing capabilities and recommendation of suitable suppliers for fac i lity s y stems . The advanced nature of these facilities a lso required specialized capabilities in cryogenics, shielding, control and instrumentation, hazards analy sis, and r emote handling . Texas A&M Cyclotron (TAMVEC) Respons ible for engineering and construction services for the T exas A &M Variabl e Ene rgy Cyclotron (TAMVEC), Bechtel completed engineer-ing and installation in June, 1967, and an internal beam was achieved in August. This particle accelerator is one of the highest energy sector-focused cyclotrons in the world. Funds for construction were provided by the Atomi c Ene rgy Commission. TAMVEC, located at the Cyclotron Institute at Texa 3 A &M, College Station, Texas , is s imilar to the 88 -inch cyclotron completed in 1963 at Lawrence Radiation Laboratory at the Uni-versity of California, Berkeley. Protons, deuterons, and alpha particles can be accelerated to hi gh energi es (60, 65, and 1 30 Me V , respectively) for basic research in such fields as physics, chernistry, biology, and medicine. The magn e t w e i ghs ov er 270 tons o Each time the particle completes one half a revolution, it receives an e l ectrostatic "kick" of 70 KeV. After about 350 revolutions, the particle will have reached its maximmn energy at about 40 inches radius. At this time it is e l ectrostatically deflected out of the rnachine into the beam transport system. Materials Testing Accelerator (MTA) Bechtel's experi ence in the design and construction of accelerators began with preliminary design w ork in 1950 on a large accelerator for the manu-facture of plutonium. At this time a project was initiated by the Atomic Energy Commission and California Research and Development Corpora-tion (CR &D) to apply the e l ectronuclear process for manufacturing pluto-nium in what was to be a $427, 000, 000 facility at Weldon Springs, Missouri. The first stage of the project was design and construction at Livermore, California, of a giant linear acce l erator (Mark I Materials Testing Accel-erator . ) Overall TAMVEC Vi e w, Looking Toward B e am Port . After doing site and vessel work on the Mark I, which went into opera-tion in 1952 as a full-scale prototype of the front end of the final device, Bechtel Corporation was appointed general contractor for the Weldon Springs facility. As such, the Company performed over one million dol-lars worth of engineering, including es sential completion of the equip-ment layout, power supply requirements and design, and mechanical de-sign of the accelerator and supports. Fast Reactor Test Facility (FARET) Bechtel prepared designs for the Argonne National Laboratory Fast Re-actor Test Facility (FARET). The plan called for a reactor capable of investigating the neutronics of large, dilute fast reactors and the per-formance capability of various potential fast reactor fuels. Facility design included the three-bay reactor building which houses the reactor; radioactive and nonradioactive reactor cooling systems; and the cell, vault, and reactor cavity with their individual gas cooling systems, fuel transfer facilities, and auxiliary systems. The cell, vault, and cavity provide containment; controlled inert argon gas or air atmospheres; and biological shielding for the reactor and all radioactive systems. Allied Chemical Corporation During the past two years Bechtel, under contract to Allied Chemical Corporation, has conducted numerous engineering studies related to a spent nuclear fuel plant capable of processing up to five metric tons of uranium daily. The work began with an estimate and conceptual design for an aqueous proces s facility, and subsequently included a compara-tive evaluation of aqueous and fluoride volatility processes. Other studies involved capital cost vs capacity, site selection criteria, anal-ysis of satellite facilities, and design optimization of specific plant areas. At present Bechtel is preparing a safety analysis report for presentation to the AEC as part of a request for a construction license. ." Fast Reactor Test Facility (F ARET) Experimental B reeder Reactor No. I Experimental Breeder Reactor No. I In 1949 Bechtel constructed Experimental Breeder Reactor No. I (EBR.-l) at the U. S. Atomic Energy Commission National Reacto r Testing Station, Arco, Idaho. This is a liquid-me tal-cooled, e nriched-uranium-fue l e d fast reactor surrounded by a blanket containing depleted uranium. The reactor was desi gned to demonstrate for the first time the e x p e rimental practicability of creating more fissionable materials than are consumed during operation. In addition, EBR-I was used in the first successful application of nuclear-reactor-generated heat to the generation of e lec-tric power. Vallecitos Atomic Laboratory Vallecitos Atomic Laboratory is the large st privately financed nuclear re-search facility in the United States. The laboratory, engineered and constructed by Bechte l for General Electric in 1957, includes a develop-mental power reactor, an experimental physics lab, and a radioactive materials facility. Nuclear equipment development programs and studies for atomic power reactors are conducted at this facility. Development work for the Dresden Reactor was performed here. Hot Cells Bechte l has performe d engineering design work and construction for three hot cell facilities which are currently in use for nuclear research and development. The General Electric Company hot cells at Vallecitos Atomic Laboratory, discussed above, were the first constructed by Bechtel. Bechtel respon-sibility began with site selection and continued through construction. The -.r Hot Cell, Vallecitos Atomic Laboratory Vallecitos Boiling Water Reactor adaptation of the basic Vallecitos Hot Cell design by other companies in -dicates the validity of Bechtel's original concepts . The second hot cell facility was built at the John Jay Hopkins Laboratory, La Jolla, California, for General Atomic, a division of General Dynamics. It consists of a high-le vel cell, a low-level cell, and a metallographic cell, along with the necessary supporting areas for hot-cold changes, health physics, dark room mock-ups, offices, underwater storage, and decontamination facilities. Atomics International subsequently retained Bechtel to design and con-struct a hot cell facility at its Field Test Laboratory near Los Angeles. Vallecitos Boiling Water Reactor This reactor, the first privately owned commercial nuclear power plant, was engineered and constructed by Bechtel for the owners - General Electric Company and Pacific Gas and Electric Company. Used to test new reactor designs at the Vallecitos Laboratory, the reactor is also a thermal source for generation of electricity distributed over the PG & E transmission system. SNAP-8 Test Facility, U. S. Atomic Energy Commission Bechtel designed the nuclear power supply test facility located in the Santa Susana Mountains north of Los Angeles. This facility permits on-the-ground, 10, ODD-hour, unattended operation of a 600-kwt power supply for use in space. The complex includes an aluminum-lined , shielded vacuum tank 70 feet in diameter and 35 feet high. Within the test vault is a large-capacity, SNAP - 8 Test Facility Nuclear Fuel Services, Fuel Reprocessing Plant remotely controlled manipulator and television system and the associated experimental equipment necessary to set up a full-scale, complete test of SNAP-8. Heat is transferred by radiation to the walls of the facility at pressures as low as 0.01 atmospheres; and the capability for remote disassembling, repair, packaging, and shipping of used radioactive equip-ment is provided. Nuclear Fuel-Services - Spent Fuel Reprocessing Plant Bechtel Corporation was responsible for engineering, procurement, and construction of the nuclear fuel reprocessing plant for Nuclear Fuel Ser-vices. The plant consists of facilities for receiving fuel elements in casks; handling and storage of elements in a pool ; mechanical processing for re-moval of extraneous material, and dissolving and conditioning for feed preparation; extraction of product values and wastes; handling and ship-ping of products; and storage of wastes. Auxiliary facilities include utilities, laboratories, and offices. The plant reproces ses atomic fuel elements used in nuclear research to produce heat for electrical power generation. Operations are carried on a 24-hour-per-day, seven-day-per -week basis. Fuel elements are stored underwater at a minimum depth of 11 feet and are handled by remote control. REPRESENTATIVE PROJECTS University of Toronto, Medical Sciences Building Under the project management services of Bechtel, a new major Medical Sciences Building is being designed and constructed for the University of Toronto. This building, devoted to medical teaching and research, will contain approximately 500,000 square feet of floor area . Its lo cation on the main campus and close to the Ontario Provincial Legislative · I o ~ o '"' o f:-l ~ Q) u ~ o U til Buildings and Queen l s Park area - presents many problems, since the building must harmonize with its surroundings. The mechanical features to be incorporated in the building are varied and complex. There will be areas that must be made free of vibration, dust, germs, light, sound, and electrical interference. Some experiment s undertaken in the building will be carried out at sub-zero temperatures, others in tropical heat. Certain rooms will require negative air pres-sure to prevent the spread of odors or infection; others will require posi-tive pre ssure to maintain sterile conditions. Literally hundreds of fume hoods will be exhausting air continuously from all parts of the building. Some types of scientific equipment will weigh tons and require specially reinforced floors; other types will be so delicate that they can only be operated under controlled conditions of temperature and humidity. Great Canadian Oil Sands Limited (GCOS) The first major steps in developing the Athabasca oil sands deposits in Northern Alberta have been undertaken by Great Canadian Oil Sands LiInited. Bechtel furnished all proces s design, detailed engineering, procurement, construction, and overall project management services for this $240 million project . Previously, Bechtel designed and constructed a test plant to prove the economic and technical feasibility of the process for removing oil from the sands. Construction work began in the SUmIner of 1964 and was completed in the spring of 196 8. The work force hit a peak of approximately 2000 during the course of the project. Development of the project required construction of temporary living fa-cilities for construction personnel, and the building of new roads to the site, including a l550-foot bridge across the Athabasca River. The com-pleted plant will handle 100,000 tons of oil sands per day and produce 45,000 barrels of synthetic crude oil per day. The facilities included large, heavy-duty, bucket-wheel excavators, a high-speed conveyor syste1l1, an extraction plant, processing units, a steam plant, electric generating facilities, and a pipeline from the proj-ect to the Edmonton area. Asbestos Corporation Limited, Quebec-Asbestos Hill Project Bechtel is providing project management" for construction of the Asbestos Hill project for Asbestos Corporation Limited, near Deception Bay, Ungava, Quebec. This major project involves the construction of a recovery plant capable of producing asbestos fiber from ore initially obtained by open-pit mining and later by underground mining. Associated facilities include crushing, milling, power generation, warehousing, and maintenance shops. The project requires building a townsite for approxi1l1ately 1100 people, with such related facilities as water supply and sewage disposal, an access road, an airport, and complete harbor facilities. Iron Ore Company of Canada, Iron Ore Concentrating and Pelletizing Plant Bechtel provided design engineering and construction management for the Iron Ore Company of Canada's $200 million iron ore development in Labrador. This project, located in the isolated Wabush Lake area, required the develop1l1ent of complete townsite facilities, an access railroad, and an airport. REPRESENTA TIVE NUCLEAR POWER PLANTS Owner and Description Philadelphia Electric Company, Peach Bottom I, 2, and 3 - 2170 Mw(e) Duke Powe r Company, Ocone e 1, 2, and 3 - 2517 Mw(e) Florida Power and Light Company, Turkey Point 3 an d 4, 1442 Mw(e) Wisconsin Michigan Power Company, Point Beach 1 and 2 - 910 Mw( e ) Consumers Power Company, Palisades - 700 Mw (e) Boston Edison Company, Pilgrim I - 625 Mw( e ) Northt>rn States Power Company, Monticello - 471 Mw(e) Rochester Gas and Electric Company, Ginna - 420 Mw(e) Southern California Edison Company, San Onofre - 429 Mw(e) Government of India Tarapur 1 and 2 - 380 Mw( e) Commonwealth Edison Company, Dresden -l 202 Mw(e) Union Electrica Madrilena, Zo rita, 160 Mw(e) Consumers Public Power District and Atomic Energy Comlnission, Hallam - 76 Mw(e) Consumers Power Company, Big Rock Point - 72 Mw(e) E = Engineering P = Procurement Scope EPC E (Consul-ting) EPC EPC EPC EPC EPC PC EPC EPC EC E (Consul-ting) E EPC Location P e nnsylvanla South Carolina Florida Wisconsin Michigan Massachusetts Minnesota New York California India Illinois Spain Nebraska Michigan C = Construction , L ... ~ ..... _ .~ .... ~ r;",' , f,j , \ . } j" .' ,n l<" !, ,~ . , " " !,-~ l .": • • J :' {t.' ,','" • ! , .. ~ ~-... -----,-,-- ;_._-San Onofre Nuclear Generating Station, San Clern.ente, Calif. Peace River Hydro-Electric Project IPEC is responsible for feasibility and planning studies, design engineering and construction inspection for the British Columbia Hydro and Power Authority's approximately $700 million Peace River Hydro-Electric Project. The largest component of the Peace River Project is Portage Mountain Development. At this site diversion of the Peace River was accomplished through three 48-foot internal diameter, horseshoe shaped, concrete lined tunnels, each approximately 2280-feet in length. The W .A. C. Bennett Darn (formerly Portage Mountain Darn) is a zoned rolled earthfill structure some 600-feet high, 6700-feet long at the crest, 2600-feet wide at the base and utilizes 57,000,000 cubic yards of fill material. Extensive soils exploration and stability analysis programs were carried out in connection with the earthfill darn. The 200 mile long reservoir, when full, will impound some 60,000,000 acre-feet of water. The underground powerhouse at Portage Mountain is 890-feet long, 65-feet wide, l40 - feet high and with the associated draft tubes, manifolds, tailraces, and penstocks required over 1 million cubic yards of underground rock excavation. When completed the powerhouse will contain ten generators and Francis turbines of 2,390,000 KV A total capacity. The power intake structure includes ten concrete towers each about l80-feet high with an operating deck on top. The design of this structure included a thorough seismic loading analysis based on the most advanced methods of determining dynamic responses. The spillway is a concrete lined channel 2800-feet long and 100-feet wide at the invert. Discharged water will pas s through nine slide gates, each 6-feet wide by 8-feet high, and under three radial gates, each 50-feet wide by 6l-feet high. Approximately 1 million cubic yards of concrete will have been PORTAGE MOUNTAIN DEVELOPMENT SHOWING ASSEMBLED TURBINE. SHAFT AND RUNNER INSTALLATION PORTAGE MOUN TArn DEVELOPMENT - UNDERGROUND POWERHOUSE SHOWrnG STATOR BEING INSTALLED placed for the first stage of the develpment, much of it being highly stressed or otherwise critical mass concrete. Commercial power from the first three generating units at Portage Mountain Development is scheduled to be generated in the fall of 1968. Unique features of the electrical design are the static excitation, braking resistors power bypass, and the development of the concept of solid state relaying. Power from the Peace River Project will ultimately be delivered to the main load centre, some 600 miles distant, by means of three 500 kv transmission lines. The first of these lines, together with intermediate and terminal switching stations, is scheduled to be placed in operation in the fall of 1968. Feasibility studies have been completed for a second generating station on the Peace River at Site 1 about 12 miles downstream from Portage Mountain Development. These studies envisage the installation of six generating units, operating at a head of 134-feet, and developing 915, 000 KVA. Burrard Thermal Generating Station - Vancouver Responsible for the planning, engineering design, procurement services, and supervision of construction of a 900 MW (6 x 150 MW hydrogen cooled units) plant in Vancouver, No.5 unit presently under construction to be in service in 1968. The design of this plant is on a unit connected basis, e. g. one boiler, turbine, generator, unit step up, and unit auxiliary transformation, with each overall unit operating at critical limits with respect to temperature, pressure, and speeds, requiring a rapid sensing of failure, or condition that may require failure and a fast acting protection system to prevent or minimize damage. The protective and interlock schemes designed together with the provision of automatic control of the boilers, the automatic start-up facilities designed for the turbines, the automatic data processing and the alarm system incorporated into the programs have been successful in provid-ing safe protection for the units. Burnaby Mountain System Control Centre Responsible for the design of the system control centre for British Columbia Hydro and Power Authority's electrical network. This centre is located at Burnaby Mountain, Vancouver, and is adjacent to the Simon Fraser University and the design was required to conform to the architectural concept of the campus. This centre will be the prime control point for the electrical network in British Columbia by means of automated remote control linked by micro-wave to all major installations. A significant part of this centre is a data logger and computer complex which provides automatic and instantaneous correlation of all system functions. Gas Turbine Plant - Port Mann Responsible for the planning, engineering design, and supervision of construction of the Port Mann Gas Turbine Power Station which is one of the largest of its kind in the world. It contains four double shaft turbo sets, without air preheating, with inter cooling and with a total output of 108 MW. The cOITlplete power-plant is autoITlatically controlled froITl the ITlain load dispatching centre approxiITlately 15 ITliles distant. The gas turbines can be started up froITl there, brought up to load and switched off without the pres ence of any operating staff in the power station. Since the plant is located in a residential district the air intake ducts and exhaust stacks are fitted with silencers whi c h appreciably diITlinish the nois e. Since the plant operates without any supervisory staff, a safe and cOITlplete autoITlatic supervisory systeITl had to be designed. Vancouver Island HVDC Link Responsible for the design and supervision of construction of the AC terITlinal facilities at the Arnott and Vancouver Island TerITlinal Stations, and associated with ASEA Sweden in the design of the extra high voltage DC switchyards at thes e locations. In this cOITlplex, electrical energy is accepted at A:::-nott at 230 kv AC where it is converted to ± 260 kv DC for delivery to the Vancouver Island TerITlinal Station. There inversion to 230 kv AC occurs. A unique feature of this installation is the operation of the DC cables in parallel with the existing AC cables. Of special interest is the screening of the valve halls a t both terITlinal buildings designed by IPEC. This screening reduces the radio inter-ference eITlanating froITl these halls to below 1 ITlicrovolt, at 1 ITlega cycle, at a distance of l500-feet. LOW-PRESSURE COMBUSTION CHAMBER REGULATING VALVE CUBICLE .~ .. HIGH-PRESSURE COMBUSTION CHAMBER HIGH-PRESSURE COMPRESSOR STARTING MOTOR ' HIGH-PRESSURE TURBINE GAS TUR BINE PLANT EXHAUST STACK PRESSURE TURBINE LOW-PRESSURE COMPRESSOR SPEED INCREASER GENERATOR 


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