Milestone Prediction and Risk Reportsafely and efficiently. Alpha Corporation believes that this...

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Readiness to Operate Milestone Achievement Prediction and Risk Report

For the Thomas Jefferson National Accelerator Facility Technology & Engineering Development Facility

(TEDF) Project �

January 10, 2012

Alpha Corporation 101 West Main Street, Suite 7100

Norfolk, Virginia 23510

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Table of Contents A.� Purpose ................................................................................................................................................. 2�B.� Mission Need ........................................................................................................................................ 2�C.� Project Preliminary Scope Baseline .................................................................................................... 3�D.� Milestone Achievement ........................................................................................................................ 4�

Introduction .............................................................................................................................................. 4�Submittal Contents ................................................................................................................................... 4�Review of Existing CPM Schedule .......................................................................................................... 5�Assessment ................................................................................................................................................ 6�Status and Logic Augmentation .............................................................................................................. 7�

Beneficial Occupancy Milestone ................................................................................................................. 8�

Recommendations .................................................................................................................................... 8�Risks – TED Facility ................................................................................................................................ 8�Risks – TLA Facility ................................................................................................................................ 9�

E.� Conclusions ........................................................................................................................................ 10�Appendix 1 – Longest Logical Paths to Predicted Milestones .............................................................. 11�Appendix 2 – Assessment Photographs ................................................................................................... 12�Appendix 3 – Hardcopy Assessment Forms ........................................................................................... 87�

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A. PurposeThe purpose of this report is to document the schedule predictions and field assessment by Alpha Corporation (“Alpha”) in the creation of the “Readiness to Operate Milestone Achievement Prediction and Risk Report” for the Technology and Engineering Development Facility (“TEDF”) project at the Thomas Jefferson National Accelerator Facility (“TJNAF”). Jefferson Science Associates, (“JSA”), requested Alpha provide an assessment for the construction of Jefferson Lab TEDF project to predict achievement dates of both the Beneficial Occupancy and Start of Operation of the new construction.

B. Mission Need TJNAF occupies a position of world leadership in the field of nuclear physics. This leadership is built upon the unique properties of the Continuous Electron Beam Accelerator Facility (“CEBAF”), as well as an outstanding array of experimental facilities and strong theoretical support. It is essential for the continuation of this world leadership that core competencies be maintained and enhanced in:

� Nuclear physics, including experimental, theoretical, and computational physics. � Accelerator science and technology, including radiofrequency superconductivity, high brightness, polarized electron beams, and cryogenics.

These core competencies enable TJNAF to deliver its mission, to perform a complementary role within the DOE laboratory system, and to attain its vision for scientific excellence and pre-eminence in the structure of nuclear building blocks, the structure of nuclei, and symmetry tests in nuclear physics. In addition to nuclear physics, TJNAF contributes to enabling technologies and emerging fields – photon science and electron-light ion colliders – including advanced radiofrequency superconductivity, 2K cryogenic engineering technology, photon science, advanced high power free electron lasers, energy recovering linacs, and electron-light ion collisions at ultra-high luminosity. These technologies support the ongoing research programs and projects at TJNAF which include 6-GeV, 12-GeV, and Free Electron Laser as well as other Doe national and international projects such as the Spallation Neutron Source, the Relativistic Heavy Ion Collider, and the Facility for Rare Isotope Beams.

This project is needed to support the ability of the laboratory to perform these core competency activities safely and efficiently. Alpha Corporation believes that this Milestone Achievement Prediction and Risk Report will enable TJNAF to pursue its vision of scientific excellence and pre-eminence in nuclear physics.

This project is needed to eliminate existing overcrowding, and improve workflow and productivity by co-locating the engineering and technical functions currently spread across the lab. It is needed to renovate the 1960's era Test Lab Building thereby providing efficient workflow, a safe and sustainable work environment, functional efficiencies, and removal of inadequate and obsolete work space, including the removal of dilapidated trailers.

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C. Project Preliminary Scope Baseline The facility occupies two sites that are currently under development. The footprint for the new Technology and Engineering Development (TED) facility is currently a wooded site adjacent to the north-west comer of the accelerator site. The new Test Lab Addition will be located on the south end of the Test Lab where there are currently two buildings; a small storage building and an acid processing building with associated roadways.

The work outlined in the Conceptual Design Report dated July 2008 forms the preliminary basis for establishing the performance parameters. The Conceptual Design provides for new construction of between 90,000 and 120,000 square feet, including the new TED facility and an addition to the Test Lab building. The project will also renovate about 90,000 square feet in the existing Test Lab building in the future. The Conceptual Design includes removal of between 9,000 and 22,000 square feet of inadequate and obsolete work space including the removal of dilapidated trailers.

The scope of the project includes design, site work (including parking, fence, and gate relocation), construction of new facilities, renovation of the Test Lab building, commissioning, building demolition, and removal of trailers. The new facilities will consist of laboratories, equipment rooms, offices, and support space. In addition to the technical work space and high-bay space, the facilities will include offices for researchers, small group conference rooms, equipment areas, restrooms, circulation space and needed supporting infrastructure.

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As stated in Critical Decision 2, the TEDF Project is located on the TJNAF site and will provide modern, 21st century technical work space, high-bay space, office space, and associated space for support functions. The design of the facility will emphasize more open, collaborative environments and flexibility to respond to future mission changes. The scope of the project includes design, site work (including fence, parking, and gate relocation), construction of new facilities, renovation of the Test Lab building, commissioning, building demolition, and removal of trailers. The new facilities will consist of laboratories, equipment rooms, offices, and support space. In addition to the technical work space and high-bay space, the facilities will include offices for researchers, small group conference rooms, equipment areas, restrooms, circulation space, and needed supporting infrastructure. The key performance parameters for the project are:

� Construction of a new 65,000 to 80,000 gsf Technology and Engineering Development (TED) building.

� Construction of a new 25,000 to 40,000 gsf Test Lab building Addition.

� Renovation of the Test Lab building (approximately 90,000 gsf).

� Demolition of 7,000 to 10,000 gsf of inadequate and obsolete work space in and adjacent to the Test Lab building, and 2,000 to 12,000 gsf of dilapidated trailers.

D. Milestone Achievement

�Introduction�In an effort to accurately predict defined milestones provided by the Owner, Alpha conducted a field assessment in conjunction with its normal monthly schedule review. In order to maximize the assessment time, Alpha initially investigated the Project specifications and records and interviewed management personnel. This was undertaken to determine reported progress, highlight pre-requisites to both the Beneficial Occupancy Milestone and the Start of Operations and to buttress any logical changes Alpha considered in predicting dates.

Submittal�Contents�Alpha received and reviewed the following schedule files, authored by the Construction Manager, from the Owner for execution of this task:

� JLAB-19B, in Oracle/Primavera Project Management (“P6”) format

� JLAB-23, in P6 format

� JLAB-24, in P6 format

� Construction Manager’s six week look-ahead schedule in excel format

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Alpha also reviewed the following Project correspondence providing background about the nature and status of the project:

� Technical Specifications – TEDF TWO, Ewing Cole Project Number 20080400

� Critical Decisions CD-0 through CD-3

� Project Execution Plan

� Preliminary Fire/Life Safety Report, by W.G. Carson, P.E.

Review�of�Existing�CPM�Schedule�Alpha has utilized a number of contemporaneous project documents in the evaluation of the existing CPM scheduling practices and work product of the Construction Manager on the Project. Alpha was first engaged by the Owner to evaluate the scheduling practices and schedule work product of the Construction Manager in the summer of 2011 in conjunction with the transmission of the “JLAB-19B” schedule. The following were the recommendations provided by Alpha at that time:

1. There are seven (7) activities with no predecessors, and seven (7) activities with no successors. Alpha suggests that all activities other than the Start and Finish Milestones have both predecessor and successor activities. Missing relationships will not allow the Critical Path Method (“CPM”) network to calculate accurately.

2. The Critical Path (“CP”), defined as the longest path, contains five (5) activities (0.28% of the total activities). This amount of activities on the CP is inconsistent with the type of Project and it is driven by a task dependent activity of Building 58 Addition with OD of 200 days, Activity #A000-6L22 “PHASE 2 GENERAL CONDITIONS (INCLUDING BONDS & INS) – TLA.” This activity appears to be a cost-carrying activity designed to allow appropriate billing of the activity rather than an activity that models any scope of work that would affect the planning and control. It is not appropriate for the CP to be driven by this type of activity. Removal of the relationships that force this activity onto the CP and the use of a more scope-of-work-oriented logic would help to provide a better network which would then more correctly calculate a legitimate and appropriate CP.

3. There are the four (4) activities with unsatisfied constraints in the schedule. Alpha suggests tying these activities to a predecessor or successor wherever possible. This again will enable the CP to calculate correctly. We recommend restricting the use of constraints wherever possible as they can adversely affect the network calculations unless applied appropriately.

4. There are two (2) activities completed , Activity #A000-3U4C23 “Fire Sprinkler Demand Increase (PCO 109) - Simplex - Bldg 58 Addn,” and Activity #A000-3U4C33 “Fire Sprinkler Demand Increase (PCO 109) - Mortenson - Bldg 58 Addn,” which worked out-of-sequence. These activities and the work progressing as predecessors and successors should be monitored carefully. Out-of-sequence work can cause inaccuracies to the schedule if it is not carefully monitored and the changes on the project are not responded to.

5. The Schedule did not account for adverse weather day planning in each of the calendars. Based on scheduling best practices a specific number of adverse weather days should be built into a construction schedule so that the project may be completed on time. These adverse weather days can be gathered from the National Oceanic and Atmospheric Administration (NOAA) research in the project location. In addition, the Schedule did not apply the Asphalt Calendar existing in the file to the asphalt activities so those activities are planned to proceed as if there are no

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restrictions on paving. This needs to be corrected to reflect the appropriate available times for paving.

6. There are the 35 task construction dependent activities, which are in progress and not started that exceed 20 workdays of Original Duration (“OD”). Actual start dates are needed for activities in progress. Activity durations should be limited to 20 workdays. Consider breaking the activities into smaller more detailed activities.

Based on Alpha’s monthly review of the Contractor schedule updates and agreement with Jefferson Lab the previously identified recommendations have been addressed.

�Assessment�

Alpha made a series of site assessments of the status of the TEDF and TLA Project Facilities between January 5, 2012 and January 12, 2012, through physical walk-through tours of the facilities. Alpha conducted its assessment with scope specific teams who toured the facilities. These assessors were split into architectural and mechanical/electrical groups for the specific assessment of discrete scopes of work. These teams evaluated reported progress, photographed potential deficiencies and reported general project status for use in predicting future work. These photos can be found in Appendix two attached to this report.

Reported Schedule Progress, and any changes found during assessment, includes the following specifics:

TED Facility

� Above Ceiling rough in complete

� Interior Stud framing 99% complete

� Painting and Finishes are ongoing

� Ceramic Tile is complete in the bathroom and ongoing in the café

� Ceiling grid ongoing

� Light installation ongoing

� Diffuser installation is ongoing

� Electrical Wire pulling and rough in 98% complete (Assessment yields 90-95% complete.)

� Pressure Service piping ongoing

� Electrical Panel wiring and hookup currently ongoing.

� Electrical devices ongoing

� Fire Alarm Devices ongoing

� Permanent Power completed

� Exterior veneer currently 98% complete (Assessment yields 85-90% complete)

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� Curtainwall installation 98% complete

� Storefront and punch window installation complete

� Metal panel installation 98% complete

� Unistrut open ceilings 98% complete

� Interior finishes started

� Elevator is functional, powered and under temporary construction use.

TLA Facility

� 2nd floor ductwork complete � Duct insulation 80% � Pressure service piping ongoing � Electrical wire pull and equipment ongoing � AHU and fans set � Plumbing and pressure service piping ongoing � AHU 5 and 6 providing conditioned air to clean rooms � Clean room access floor completed � Clean room plenum installed � Electrical rough in ongoing � Fire alarm rough in is ongoing

Alpha, in the course of its assessment, found that reported percentages complete in the managers monthly CPM schedule are, for the most part, accurate. Prescribed remaining durations were also investigated and changed where observed percentage complete departed from reported percentage complete.

�Status�and�Logic�Augmentation�Alpha utilized the assessed completion percentages in conjunction with revised logic introduced by Alpha into the existing Project schedule, to predict, as accurately as possible, the remaining work to be completed in advance of completion milestones defined by the Owner. This logic augmentation included:

� Breaking existing Life Safety activities’ logical successor ties to Punchlist and Closeout and tied these activities into a newly created Beneficial Occupancy milestone as a successor.

� Revising Remaining Durations to match reported progress in the Construction Manager’s six week look-ahead schedule.

� Introducing activities that represented the Life Safety Commissioning fragmentary network (“fragnet”) necessary prior to achievement of the Beneficial Occupancy milestone.

� Tying of multiple logical interdependences, i.e. the inability to complete Testing and Balancing with an unsealed building.

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A third party commissioning agent will be engaged to review design documents to ascertain performance and operational test requirements for all major building systems. A commissioning plan to test and evaluate system performance both individually and collectively as compared to approved design criteria will be prepared and completed prior to the start of building construction. Functional performance tests will be established and all designated systems will be tested against the performance criteria. Results will be recorded, and corrective actions initiated if required.

Alpha statused the latest submitted schedule for both the TLA and TED facilities, after implementing the previous steps and the following Milestone predictions and risks are the result of those calculations. The multiple Longest Paths to these milestones can be graphically observed in Appendix 1 attached to this report.

Beneficial Occupancy Milestone

As stated in the Project Execution Plan (“PEP”), Beneficial Occupancy may occur prior to the completion of all of the commissioning and punch list items but all building Life Safety systems must be operational prior to any occupancy. A readiness assessment will be completed when the construction is complete, prior to occupancy. Training of the TJNAF Facilities Management staff on the use of all building equipment and systems will be performed as the equipment and systems become operational. This training is part of regular operating costs and not part of the project costs. At the point of Beneficial Occupancy the responsibility for the operation and safety of the facility will transfer to the TJNAF Facilities Management and Logistics Division (FM&L). The laboratory, not this project, will be responsible for relocating all personnel and program equipment into the Technology and Engineering Development Facility and for their transition to operations costs.

Recommendations�

Based on present contractor resource predictions, and Alpha’s assessment and analysis of the current schedule, as enumerated above, Alpha provides the following recommendations for predictions of beneficial occupancy:

� TLA Facility: March 2, 2012� TED Facility: February 24, 2012

�Risks�–�TED�Facility�

As noted above, the current schedule is shown as missing significant scope, primarily related to closeout procedures required for Beneficial Occupancy. Due to the nature of work at this point in the Project, all

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potential factors could become critical delays without constant monitoring vigilance. The missing scopes of work pose high risks of failing to achieve predicted dates, as these items are not presently being tracked in the submitted Project schedule. Alpha notes the following risks that need to be monitored:

� Missing scope for the emergency power generator – The interface between the power for emergency lighting and life safety must be monitored as this is a direct influence on the ability to achieve Life Safety Commissioning.

� Egress into and out of stairways and doorways are integral to completion of Life Safety. � Duct Smoke Detectors must be operational to achieve completion of Life Safety. � Testing and debugging of Fire Alarm devices individually and as a system must proceed as

planned. � Sprinkler System Certification must be achieved. � Door Hardware must be installed to achieve Life Safety completion. � Missing interim milestones for monitoring and tracking progress. (NFPA-13 Contractors

statement to initiate Fire and Life safety commissioning).

Risks�–�TLA�Facility�

The TLA facility addition shares of the same Risk concerns as the TED facility for impacts in achieving the Beneficial Occupancy Milestone. The added amount of work on the schedule, in a variety of scopes in a more confined area than the TED facility necessitates a higher threshold of complexity which must be managed. The risks include:

� Duct Smoke Detectors must be operational to achieve completion of Life Safety. � Testing and debugging of Fire Alarm devices individually and as a system must proceed as

planned. � Sprinkler System Certification must be achieved. � If the Clean rooms are going to utilize any hazardous chemicals during the interim period

between Beneficial Occupancy and final Project Completion, all safety devices (i.e. safety showers, eye washes, etc. must be installed and operational) to achieve Beneficial Occupancy. As currently planned, these hazardous substances will not be in use in the period between Beneficial Occupancy and Project Completion and therefore are not required before achieving the interim milestone. Any change to this plan will require extra time to achieve.

� The array of scopes to be prosecuted is more varied than the TED Facility. Mechanical and electrical scopes must be coordinated to a higher degree. The risk of subcontractor performance delaying the entire schedule is higher at this facility than the predominantly finish scopes and mechanical/electrical completion at the TED facility.

� The confined spaces of scope concentration makes physical coordination of subcontractor work a major risk on the TLA as well.

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E. Conclusions

The purpose of this report is to document the schedule review and field assessment by Alpha Corporation in the creation of the “Readiness to Operate Milestone Achievement Prediction and Risk Report” for the TEDF project at the TJNAF. JSA requested Alpha provide an assessment for the construction of Jefferson Lab Technical TEDF and TLA located in Newport News, Virginia to predict achievement dates of both the Beneficial Occupancy and Start of Operations.

Based on correction of the current deficiencies in the existing Project CPM networks and the physical assessment by Alpha teams onsite, including management personnel interviews, the prediction for achievement of the Beneficial Occupancy Milestone is February 24th, 2012, for the TED Facility and March 2nd, 2012, for the TLA Facility. Alpha further predicts Start of Operations for the TED and the TLA Facilities for March 15th, 2012.

Vigilance in monitoring the enumerated Critical Path risks will serve to ensure timely completion matching these predicted dates.

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Appendix 1 – Longest Logical Paths to Predicted Milestones

Longest Path through Beneficial Occupancy & Start of Operations Milestones for the TED Facility.

Longest Path through Beneficial Occupancy & Start of Operations Milestones for the TLA Facility.

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Appendix 2 – Assessment Photographs

Mechanical and Electrical areas of Concern:

1. 8-inch stormwater riser located at Column 2.7/D.8 – cleanout does appear completely accessible at enclosure.

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2. HVAC cabinets – temporary filters are dirty / need cleaning, or are missing.

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3. “Mysterious slab opening – southeast corner of Hall D Techs Room 1546

4. Incomplete condenser water piping insulation – TED Building roof – also – is the heat tracing energized / operational?

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5.

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Exhaust Fan on TED Building roof – gooseneck / rain cap not installed.

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Through-roof pipe penetrations not sealed – potential roof leaks

West Exterior Elevation – Metal Soffit Installation

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West Exterior Elevation – Brick/Metal Screen Wall

West Exterior Elevation – Portico Metal Soffit Installation

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North/West Exterior Elevation - Sitework

West Exterior Elevation – Portico Metal Soffit Installation

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East Exterior Elevation – Brick Screen Wall

East Exterior Elevation – North Connection

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South Exterior Elevation

South/East Exterior Elevation

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South Exterior Elevation

Corridor Area D 2nd Floor – TED F

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Stair 6 2nd Floor – TED F

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Conference Room 2nd Floor – TED F

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Fitness Room 2nd Floor – TED F

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Window Sills for Corridor 2nd Floor – TED F

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Womens Room 2nd Floor – TED F

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Womens Room 2nd Floor – TED F

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Mens Room 2nd Floor – TED F

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Area A – TED F

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Area A 2nd Floor No Fire Extinguisher – TED F

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Lobby Wall 2nd Floor – TED F

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Lobby 2nd Floor – TED F

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Corridor Area A 2nd Floor – TED F

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Corridor Area A 2nd Floor – TED F

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Document Control Room Area A 2nd Floor – TED F

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Pantry Area A 2nd Floor – TED F

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Offices Area A 2nd Floor – TED F

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Mens Room Area A 2nd Floor – TED F

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Area B 2nd Floor – TED F

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Area B 2nd Floor – TED F

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Stair 7 2nd Floor Area B – TED F

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Stair 7 2nd Floor Area B – TED F

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Cryo Break Room 1st Floor Area B – TED F

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Window Sills in Storage Room 1st Floor Area B – TED F

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Floor Prep Corridor Area B 1st Floor – TED F

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SSG/VME 1st Floor Area A/B – TED F

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LPTS/LLRF 1st Floor Area B – TED F

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General Purpose Test Area 1st Floor – TED F

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Lobby 1st Floor Area A – TED F

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Vacuum Assembly Shop 1st Floor Area A – TED F

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Corridor 1st Floor Area A – TED F

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Corridor 1st Floor Area A – TED F

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North Link – TED F

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Roof Screens North View – TED F

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Northwest View of Roof – TED F

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Cryo FAB High Bay Area C – TED F

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Solar Panels – TED F

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West Exterior Elevation – TED F

West Exterior Elevation – TED F

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North Exterior Elevation – TED F

Production Clean Room – TLA

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R&D Clean Analytical –TLA

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Production Clean Room / R&D Clean Room - TLA

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R&D Chem Clean Room - TLA

R&D Chem Clean Room Fire Sprinkler- TLA

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R&D Chem Clean Room - TLA

R&D Chem Clean Room Empty Conduit- TLA

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R&D Chem Clean Room Life Safety - TLA

R&D Clean Room Air Duct – TLA

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Production Clean Room Gas and Electrical Outlets- TLA

R&D Clean Room Raised Access Floor – TLA

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Water Chem Room – TLA

Water Chem Room - TLA

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Gown Room Sink Hookup - TLA

Gown Room Fire Sprinkler and Electrical Conduit- TLA

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Acid Chemistry Room – TLA

Acid Chemistry Room Electrical Conduit – TLA

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Acid Chemistry Room – TLA

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Water Chem Room Base Coating – TLA

Water Chem Room w/o Base Coating – TLA

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Appendix 3 – Hardcopy Assessment Forms

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