3. BNL_RHIC_CRYO_IX&AX_RFI_V3.pdf

RHIC Central Helium Plant Helium-Water Heat Exchanger Replacement Project

Intercooler and Aftercooler Replacement Project RFI Information Package Roberto Than, Pratik Patel, and Russell Feder Brookhaven National Lab Collider-Accelerator Division Cryo Group January 20, 2026

IntercoolersAftercoolers

Intercoolers Aftercoolers Typical "floating head" three-flange construction of current heat exchangers

This information is controlled by the U.S. Department of Commerce Export Administration Regulations 15 CFR Parts 730-774 as EAR99 Technology.

Outline

I. Project Introduction and Goals of the RFI

II. Introduction to Brookhaven National Lab

III. Intercooler and Aftercooler Mechanical Design

IV.Intercooler and Aftercooler Process Diagrams

Nine new helium-water shell-and-tube heat exchangers

Director’s Review of Injector Operations and RHIC R&R July 8-10, 2025

• The purpose of this project is to procure quantity nine (9) new helium-water shell-and-tube heat exchangers. The old heat exchangers currently cool compressed helium in the Relativistic Heavy Ion Collider (RHIC) central helium refrigeration plant at Brookhaven National Lab (BNL).

• Starting in 2026, the RHIC is shutting down to undergo a major upgrade. The machine will become the Electron- Ion Collider (EIC), coming back online in the mid 2030s. The RHIC central helium plant will become the EIC central helium plant, and these new replacement heat exchangers will be part of the helium refrigeration system for EIC.

• Four of the heat exchangers, the primary intercoolers, will operate at a helium inlet pressure of 4.5 bar and cool the helium from 405 K to 305 K at a mass flow rate of 1.13 kg/s each.

• Four of the heat exchangers, the primary aftercoolers, will operate at a helium inlet pressure of 16.7 bar and cool helium from 405 K to 305 K at a at a mass flow rate of 1.13 kg/s each.

• There is a single smaller aftercooler on the utility compressor skid. This aftercooler will operate at a helium inlet pressure of 17 bar and cool helium from 350 K to 308 K at a at a mass flow rate of .096 kg/s each.

• See Tech Spec "SPEC-CAD-1372" for all other design and fabrication parameters.

Nine new helium-water shell-and-tube heat exchangers

July 8-10, 2025

• There are additional important design requirements:

• The overall design should minimize helium leakage to outside air.

• Because the helium flow is part of a cryogenic plant cycle, the cross-stream leak rate must be zero. Delivered units will be required to be mass-spec leak checked to 10-9 Torr-L/s for the water to helium side leak rate.

• The heat exchangers must be engineered and fabricated to ASME BPVC Section VIII, and be U-stamped.

• The new units must fit into the same location and mate with the same water and helium plumbing as the original units. This requires helium to be on the tube-side and water to be on the shell-side of the heat exchanger units.

• Tech Spec "SPEC-CAD-1372" is the primary document for all design and fabrication requirements. A statement of work (SOW) that includes quality and management requirements will be included with the future Request For Proposal.

• The complete procurement will involve

• Fabrication and delivery of nine heat exchangers

• Preliminary and final design reviews and final design documentation, including all required engineering calculations.

• Final detailed fabrication drawings and material certs

• Test procedures review and a complete set of compliance testing results

• Vendor visit(s) to BNL to inspect the old heat exchangers in place

• BNL visits to the vendor for fabrication and testing progress hold points

Goals of the Request for Information (RFI)

July 8-10, 2025

The goals of this RFI are

1. Identify vendors that are qualified to participate in the future RFP and evaluate vendor capabilities and experience fabricating similar water-cooled gas-process heat exchanger

2. Collect budgetary cost and fabrication schedule estimates from potential vendors

3. Help potential vendors understand BNL procurement requirements, typical procurement timelines, and to answer questions about working with BNL

Introduction to BNL and the RHIC Helium Refrigeration Plant

Department of Energy National Labs

• The U.S. Department of Energy funds and directs the operations of 17 national labs

• Brookhaven National Lab (BNL) is part of the DOE Office of Science (the red labeled labs on this map)

• BNL is managed by Brookhaven Science Associates (BSA) which is a partnership between the DOE and Stony Brook University

• Office of Science | Department of Energy

• Brookhaven National Laboratory — a passion for discovery (bnl.gov)

• Stony Brook University, New York

This information is controlled by the U.S. Department of Commerce Export Administration Regulations 15 CFR Parts 730-774 as EAR99 Technology.

https://www.energy.gov/science/office-science https://www.energy.gov/science/office-science https://www.bnl.gov/world/ https://www.bnl.gov/world/ https://www.bnl.gov/world/ https://www.bnl.gov/world/ https://www.bnl.gov/world/ https://www.stonybrook.edu/ https://www.stonybrook.edu/

Brookhaven National Lab BNL is located in Upton, NY about 1.5 hours drive east of NYC on Long Island.

New York City

Brookhaven National Lab

JFK airport

Newark airport RHIC Cryo Central Plant

East 1005 office building

LHe storage

Compression Expansion

Cooling towers

Oil separation

NSLS-II

AGS

BNL

New York City RHIC Cryo Central plant Bldg 1005

RHIC Cryo Central plant Bldg 1005

Building 1005H

• Helium gas compression

• Oil processing and separation systems

• Helium purification system

Building 1005R

• Helium refrigeration and liquefaction

• Cold box vacuum systems

Building 1005S

• Cryo control room (CCR)

• Central computer control systems

• Operations offices and shops

Helium gas storage

• 47 tanks storing 26,000 LHe gallons equivalent

Building 1006B

• Typical cryo service building at 2, 4, 6, 8, 10, and 12

• EIC Project Warm and cold gas distribution

• Central Plant Upgrades Local PLC control systems

Cooling Tower #7

The Central Helium Processing Plant The heart of RHIC/EIC helium processing and pumping is at building 1005

From 1006B helium is divided and circulated through the blue and yellow RHIC rings

Helium is pumped to and from 1006B and 1005R through long cryogenic distribution system.

Director’s Review of Injector Operations and RHIC R&R July 8-10, 2025 This information is controlled by the U.S. Department of Commerce Export

Relativistic Heavy Ion Collider (RHIC) Cryo-plant

This information is controlled by the U.S.

Department of Commerce Export Administration Regulations 15 CFR Parts 730-774 as EAR99 Technology.

The Electron-Ion Collider Project

• In 2026 RHIC will shut down and BNL will start a project to transform RHIC in to the Electron-Ion Collider (EIC).

• The Central Helium Plant that cooled RHIC for 25 years will undergo repairs and upgrades to service EIC.

• EIC will start operations in the early 2030s.

• Electron-Ion Collider (EIC)

The RHIC central helium plant at the 5:00 position becomes the EIC central helium plant.

This information is controlled by the U.S. Department of Commerce Export Administration Regulations 15 CFR Parts 730-774 as EAR99 Technology.

https://www.bnl.gov/eic/ https://www.bnl.gov/eic/ https://www.bnl.gov/eic/ https://www.bnl.gov/eic/

Intercooler and Aftercooler Layout and Design

Photographs of the Intercooler and Aftercooler Stacks

Intercoolers

Intercoolers

Aftercoolers

Aftercoolers

Typical Flange Configuration

IntercoolersAftercoolers

IntercoolersAftercoolers

3D CAD Models of the Intercooler and Aftercooler Stacks The project involves removing the eight old heat exchangers and installing eight new units in the same place using the same supply and return piping interfaces.

Viewing the intercoolers and aftercoolers from above

3D CAD Models of the Intercoolers and Aftercoolers In Building 1005

1st Stage Compressors

2nd Stage Compressors

Utility Compressor Intercooler and Aftercooler Units

Intercooler Shell and Port Design Dimensions

Intercooler Stack Assy Design Dimensions

Aftercooler Shell and Port Design Dimensions

Aftercooler Stack Assy Design Dimensions

Process Diagrams

1005H Helium Compressor System Diagram 1st Stage

Compression Helium

Intercoolers 2nd Stage

Compression Helium

Aftercoolers Oil Removal Equipment

Flow to Refrigerator• This process flow diagram shows helium flow only in building 1005H. The primary helium flow is from left (A) to right (B) in the diagram.

• The intercooler and aftercooler stacks are shown as simple boxes in this diagram

This information is controlled by the U.S. Department of Commerce Export Administration Regulations 15 CFR Parts 730-774 as EAR99 Technology.

1005H Gas Management Control Screen Diagram

• This is a snapshot of the Gas Management control screen in our control room.

• Typical helium pressure (blue), temperature (green), and flow (olive) data from RHIC are shown. Helium and cooling water flow rates for EIC will be higher.

• Cooling water parameters and heat exchanger performance details for the intercooler and aftercooler are not shown.

This information is controlled by the U.S. Department of Commerce Export Administration

Simplified T-s diagram for the RHIC helium process

July 8-10, 2025

Simplified T-s diagram for the RHIC Central Helium Plant

Aftercooler Temperature Step

Intercooler Temperature Step

1st Stage Compression

Helium Intercoolers

2nd Stage Compression

Helium Aftercoolers

Oil Removal Equipment

Flow to Refrigerator

This information is controlled by the U.S. Department of Commerce Export Administration Regulations 15 CFR Parts 730-774 as EAR99 Technology.

Intercoolers P&ID There are three flows

1. Helium

2. Water

3. Oil Drainage

This information is controlled by the U.S. Department of Commerce Export Administration

Aftercoolers P&ID There are three flows

1. Helium

2. Water

3. Oil Drainage

This information is controlled by the U.S. Department of Commerce Export Administration

Utility Compressor

Aftercooler HX Information

Utility Compressor Skid P&ID Diagram

Helium-Water Aftercooler

This information is controlled by the U.S. Department of Commerce Export Administration

Utility Compressor Aftercooler Heat-exchanger Drawing

UT skid and UT skid aftercooler photos here BOS-HATTEN INC.

BUFFALO, N.Y.

SERIAL 821 696 83

NATL. BD. 2965

{U}

S/W SHELL TUBES

DES.PRESS: 150 FV & 400

TEST PRESS. 225 600

DES. TEMP 250F 250F

KOCH PROCESS SYSTEM

CUST. PO 516602

ITEM AC2394

UT HX Aftercooler

UT HX Aftercooler Head

Creo CAD model view of UT Skid

UT HX Aftercooler 6 5/8" OD X 13' 4" long