This is the first in a series of two articles about installing big machine research equipment in facilities. This article discusses the different categories of large-scale equipment and the challenges to consider during design and construction.

"Getting it right is important because the equipment is extraordinarily expensive and complex. There are design and installation issues that could not only lead to cost overruns and schedule delays, but also could result in the complete failure of a facility," says Russell Drinker, principal at Perkins + Will in San Francisco. "The equipment could cost as much as or more than the facility. If it is not operational when you open, you are going to be very sorry."

This type of equipment, as the name implies, is large, complex, and often serves as the driving force behind the design of a facility. It can be used for a variety of purposes, including applications in academics, manufacturing, or ramp-up facilities. It also applies to support equipment such as the robotic cage wash at the Stowers Institute for Medical Research in Kansas City, Mo. However, the challenges are distinct from those related to building-size equipment, such as the telescope at the W.M. Keck Observatory in Hawaii or linear accelerators.

Categories of Large-Scale Equipment

There are three basic categories of big machine research equipment: emerging technology, state-of-the-art, and state-of-the-industry. Emerging technology is often a prototype currently in design or in the process of being improved. Information about the equipment is not well documented because there are usually no other examples that can serve as a model for design or installation. It is considered high-risk from a design standpoint and atypical in its installation. The unshielded 7 Tesla Magnetic Resonance Imaging (MRI) machine is an example.

"Today's emerging technology is tomorrow's state-of-the-art technology," says Drinker.

With state-of-the-art equipment, there is a better understanding of the design and installation requirements because it has been thoroughly tested and put into practical use for its intended purpose. Although the equipment is being used in the industry, it still involves a high-risk design and an uncharacteristic installation. An unshielded cyclotron is an example. Cyclotrons are particle accelerators that generate radioisotopes that have been used for magnetic imaging procedures such as CT and PET scanning. Self-shielded cyclotrons are used for medical imaging, while unshielded cyclotrons are used for research.

Only two shielded cyclotrons were installed throughout the country in 1998, a time when it was an emerging technology. The number climbed to 12 in 2005, moving the equipment into the state-of-the-art category.

"That is still a relatively small number of installations nationwide for this kind of equipment," notes Drinker. "It is still high risk in terms of understanding the design requirements, but it has moved to a state-of-the-art technology where at least the experts understand what the issues are."

The term state-of-the-industry is used to describe equipment that is readily available, typical in its installation, and well documented. The design and installation requirements are considered a lower risk since the equipment is more familiar. The 1.5 and 3 Tesla MRIs are the current industry standard in imaging. More than 1,000 shielded MRIs were installed throughout the United States last year. However, there are only three of the emerging 7 Tesla MRIs in existence at this time.

Unique Design Challenges

"In order to design for this kind of equipment, it is important to have a process identified that helps you address the key issues," advises Drinker. "It is essential to start with how the equipment will be used."

Once the intended use is determined, there are many other questions that must be answered in order to create the best possible design and to ensure the proper installation. For instance, it is important to know how the equipment will be procured. Who will be the vendor? What is the purchasing arrangement? Is it part of a research grant?

Next, planners must understand how the project will be delivered and what construction method will be used. The answers to these questions will help determine what expertise will be necessary and who should comprise the project team. After the team is assembled, regulatory approvals and site issues must be addressed. Key facility design issues involve knowing what environmental considerations are needed for technical performance, what life safety measures must be implemented to protect people, what support equipment and space is needed, and what the operations requirements are.

Additional Considerations

Other issues that must be considered include height, code requirements, cost modeling, changing technology, and maintenance access. Height can be a significant constraint when installing this type of equipment. Sufficient vertical space must be available to accommodate the equipment and necessary mechanical support. Utilizing 3-D modeling provides a clear picture of how much space is available in the area where the equipment will be placed.

The design stage also takes into account the potential need to perform maintenance on big machines. For example, dedicated access space should be provided for MRIs, which require a lot of maintenance. Make sure an access hatch available in case an MRI magnet ever has to be removed. Flexibility in the facility design should also be provided to replace the cyclotron, if necessary. Access doors and corridors need to provide an opening wide enough to transport equipment, and the floor structure for the path of travel needs to be structurally designed to support the weight.

Making sure the building meets all regulatory requirements in order to receive the necessary permits is essential, as well.

"It really means meeting with the code officials at the beginning and understanding how the facility will be used," says Drinker. "In one case, county officials had never seen a six-foot thick concrete door and questioned how anyone would get out of that area in the event of an emergency. It took months to negotiate."

Planners should start their cost modeling long before there is a need to negotiate the regulatory permits. In fact, cost modeling should start on day one. Basic criteria are set for each piece of equipment and each space type, and then a cost estimate is made.

"We set targets by building systems and then we constantly estimate the cost," notes Drinker. "We don't wait until the end. We are continually tracking the new issues that come up and are looking for ways to offset those to reduce costs. The other variable is the amount that we carry for the contingency. On the MRI and cyclotron job at Stanford University, we advised the client to carry a 12 to 15 percent contingency. That was related to the fact that it was adjacent to an existing building and it was a major excavation. We had little space and didn’t know what issues we would find with existing footings. Most importantly, the MRI was still being designed and we had to allow for potential changes that might affect the layout and infrastructure requirements."

Potential changes in technology also must be figured into the overall design. Using an open ballroom setup can help accommodate new tools that researchers might use in the future. In this particular setup, all utilities can be distributed from above and brought to a point of connection in a nearby corridor. The main circulation system with all the primary process cooling water, gases, and other utilities can be changed to meet the requirements of a particular tool.

"An open ballroom design provides for a flexible facility that could easily be adapted for different kinds of tools with minimal cost," says Drinker.

All of these design and installation considerations are illustrated in three Perkins + Will projects: the Advanced Research & Technology (ART) Building at the University of Virginia, the Lucas Center Department of Radiology expansion project and the Mechanical Engineering Research Laboratory (MERL), both at Stanford University.

ART Building

Equipment installed at the ART Building in the Fontaine Research Park at the University of Virginia is state-of-the-industry. The shielded cyclotron and shielded 1.5 Tesla, 3 Tesla, and 7 Tesla MRIs are industry standards for magnetic imaging research.

"State-of-the-industry equipment is well documented and the requirements are well-known, but we still have to deal with the radiation and gauss line issues," says Rachel Lee, an associate at Perkins + Will. "Fortunately, at the UVA we have a relatively open site with a steep hill on one side."

The MRIs and cyclotron will be located in the basement next to the hill. A large buffer zone will be created for a service yard with access for the installation of the MRI and replacement, if necessary, in the future. The shielded MRIs, located in a room with standard walls and doors, can be located next to elevators and occupied areas.

"State-of-the-industry equipment does not impose a great demand on the building design and allows for a design that is highly adaptable to changing needs in the long term," notes Lee.

Next in This Series

The ART Building is an example of how designing and planning works with known requirements and documentation. Two Stanford University projects, the Lucas Center and the Mechanical Engineering Research Laboratory, demonstrate the challenges of working with emergent and state-of-the-art equipment. These issues are discussed in the next article.

By Tracy Carbasho

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