A. SOW ED0041991 Rev C.pdf

Statement of Work for the Design of the PIP-II

Laserwire Magnets

Preparation Date: 24 February 2025

Date: 24 February 2025

Preparing Organization: AD/MSD/Instrumentation, FNAL

Document Number: ED0041991

Statement of Work

Fermi National Accelerator Laboratory 2

Document Approval

Signatures Required Date Approved

Originator: Dakota Krokosz As in Teamcenter

Reviewer: Randy M Thurman-Keup As in Teamcenter

Approver: Victor Scarpine As in Teamcenter

Revision History

Revision Date of Release Description of Change

- 2/24/2025 Date of Creation.

A 4/29/2025 Updated quantity of production units.

B 5/15/2025 Updated terminology, QC requirements, and deadlines.

C 9/29/2025 Update images and drawing package to reflect changes in the design.

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Table of Contents

1. INTRODUCTION

2. SCOPE

3. READINESS REVIEWS, HOLD POINTS, AND PROGRESS MONITORING

4. REQUIREMENTS

5. DOCUMENTATION REQUIRED FOR PROPOSAL AND MILESTONES

6. DELIVERY AND ACCEPTABILITY TESTING

6.1. DOCUMENTATION TO BE SUPPLIED PRIOR TO SHIPMENTS

6.2. CONFORMANCE AND ACCEPTANCE

6.3. PACKAGING AND SHIPPING

APPENDIX A

A.1 ACRONYMS AND DEFINITIONS

Fermi National Accelerator Laboratory 4

1. INTRODUCTION

The PIP-II particle accelerator will be the new heart of Fermilab, featuring a brand-new, 800-MeV, leading-edge superconducting linear accelerator. Its high intensity proton beam will power a broad range of particle physics experiments for decades to come and maintain Fermilab’s leadership as one of the world’s premier particle physics laboratories. PIP-II will enable the most intense high-energy neutrino beam for the laboratory’s flagship project— the Long Baseline Neutrino Facility and Deep Underground Neutrino Experiment (LBNF/DUNE).

This Statement of Work (SOW) provides details on technical tasks and requirements for prospective subcontractors such as reports, documentation, schedule, change management, deliverables, and communication with FNAL regarding the PIP-II Laserwire magnets.

2. SCOPE

The primary scope of work covers the fabrication, quality control, testing, and delivery for a build-to-print package of the PIP-II laserwire magnets (FNAL DWG #F10254388) as shown in Figure 1. The scope of this document is limited to Table 1 which outlines the list of contract deliverables including documentation of the PIP-II Laserwire magnet. Electronics, cables, and surrounding components are not included in the scope of this work. Only released drawings shall be used for fabrication.

Figure 1: Laserwire Magnet Pair

Coil

Terminal Block

Coil supports

Yoke

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Table 1: Table of Deliverables

Item Drawing

Number

Revision Quantity Notes Delivery Date

1.1

F10254388 - 1 A single First Article (This unit will be used for production after testing concludes)

April 30th , 2026

1.2

F10254388 - 14 Additional Production units* December 31st ,

1.3 N/A - 1 Tooling and tooling Drawings

shall be delivered to FNAL with end of production batch.

December 31st , An offeror must submit the following items to be considered responsive:

1) Unit pricing for milestones 5.1–5.8, and unit pricing for milestones 5.9-5.11.

* The Offeror shall provide pricing for a first article and subsequent production. If deemed acceptable, FNAL will approve the fabrication of the production units.

P LEASE NOTE: FFDG reserves the right to award or to not award the production units, whatever is deemed to be in the best interest of FNAL.

2) The Offeror shall provide evidence of prior experience (at a minimum, 5 years) with magnet fabrication, materials, and procedures. This would include providing, with your submission a minimum of (3) three references/projects of similar size and scope.

3) The Offeror shall provide with their submission detailed written information on all materials, material properties, and bulk materials to be used.

4) The Offeror shall provide with their submission, a detailed quality assurance plan. At a minimum, the plan shall include the methods to be used to verify material properties, find defects, flaws, test procedures, and criteria for rejecting parts.

5) The Offeror shall provide a production schedule, including the proposed timeline for first article development, and, if awarded, the full production schedule. If FNAL awards the full production subcontract, all production items must be completed no later than April 30th, 2026.

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3. READINESS REVIEWS, HOLD POINTS, AND PROGRESS MONITORING

FNAL reserves the right to be present, or to be represented by an organization of its choice, to witness any manufacturing step carried out at the subcontractor’s or his subcontractor’s premises. The subcontractor shall assign a person responsible for the technical execution of the sub-contract and its follow-up, a person responsible for the commercial follow-up as well as a person responsible for the Quality Control (QC), throughout the duration of the contract.

Within two weeks from award, a kick-off meeting shall be scheduled to initiate technical and commercial discussion between the representatives from FNAL and the subcontractor. Bi-weekly updates by e-mail shall be delivered to

Fermilab’s designated point of contact. FNAL representatives will always be available to respond any time if questions shall arise.

Before starting any fabrication / procurement activity, the Manufacturing Readiness Review (MRR) shall be organized to allow FNAL reviewers to assess the subcontractor’s level of preparation to proceed to the manufacturing and procurement phase; Manufacturing and Inspection Plan (MIP) shall be presented by the subcontractor at this time. Steel for the yoke fabrication shall not be machined until all the MRR’s recommendations have been addressed and FNAL has provided a written approval. Review’s recommendations (if any) based on the presented material shall be addressed within two weeks from the conclusion of the MRR. Upon conclusion of the

MRR, the subcontractor will be allowed by FNAL to proceed with the fabrication / procurement phase.

A hold point is defined as the moment in time, usually at the end of a fabrication, processing, or quality control step, wherein the process needs to be stopped in order to allow the FNAL representative to review documentation, monitor the progress, and perform additional QCs where deemed necessary. Acceptance of the supply shall be given by FNAL only after the delivered supply is deemed to be in conformity with the contract including documentation referred to in this specification, all tests specified have been successfully completed and all tests or other certificates have been submitted to FNAL.

Below, in Table 2, please find the Hold Points and expected duration. If your duration differs, please provide proposed durations in your response.

Table 2: Hold Points

Hold

Point

Description Deliverables Notes Expected

Duration

Hold

Point 1

Manufacturing

Readiness

Review

Vendor provides manufacturing drawing package.

Vendor provides updated schedule.

----- 6 Weeks

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Hold

Point

Description Deliverables Notes Expected

Duration

Hold

Point 2

Vendor QC of the first article

F10254388

QC according to

Table 4

Generate and deliver QC report to

FNAL per batch.

Hold occurs after assembly of the first article magnet pair, after the QC has been completed. Vedor QC is to be done per batch. Testing shall be done on 100% of the quantity being delivered to

FNAL.

4 Weeks

Hold

Point 3

FNAL QC of the first article

F10254388

FNAL will install and check fitment of the first article into the laserwire system.

QC according to

Table 4

Document required changes of the first article.

Approval and acceptance of first article.

Hold occurs after shipment of chamber batch to FNAL.

FNAL QC shall be performed on 100% of the quantity per batch being received by the vendor.

4 Weeks for First

Article

Hold

Point 4

Vendor QC of production quantity

QC according to

Table 4

Generate and deliver QC report per batch.

Hold occurs after assembly of the chamber batch, after the

QC has been completed.

Vendor QC is to be done per batch. Testing shall be done on 100% of the quantity being delivered to FNAL.

1 Week per magnet pair

Hold

Point 5

FNAL QC of production quantity

QC according to

Table 4

Approval and acceptance of production quantity per batch.

Hold occurs after shipment of chamber batch to FNAL.

FNAL QC shall be performed on 100% of the quantity per batch being received by the vendor.

1 Week per magnet pair

4. REQUIREMENTS

Table 3 lists technical requirements for the PIP-II Laserwire magnets. The subcontractor may request modifications to facilitate fabrication or improve performance. Any requested deviations shall be clearly indicated, discussed, and be subject to written approval by FNAL. Alternative design standards to those required below shall be proposed for review and approval by FNAL prior to implementation. Any modifications are pursuant to FermiForward General

Terms and Conditions included herein.

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Table 3: Technical Requirements

Requirement # Requirement Statement

4.1 The coils shall be made from 10 AWG copper magnet wire.

4.2 The magnet coil shall be 9 layers with 473 turns.

4.3 The copper coil shall be made from OFHC C10200 copper alloy with electrical conductivity of 100% IACS per ASTM B188.

4.4 The copper shall be free of surface defects, damage, nicks, cuts, and/or scratches.

4.5 Uniformity of the conductor shall be such that the resistance of all coils constructed from it shall be equal to ±1%.

4.6 Finished coils shall be vacuum impregnated with epoxy and cured. FNAL shall approve of the epoxy recipe as well as the curing cycle. Unsupported epoxy volumes greater than

1.59mm (1/16”) shall not be allowed.

4.7 The yoke shall be manufactured from 1006 carbon steel.

4.8 A terminal block shall be mounted to the outer face of the yoke.

5. Quality Assurance and Milestones

The subcontractor shall plan, establish, implement, and adhere to a documented quality assurance program that fulfills all the requirements described in this SOW. In addition to the requirements of Section 4, the subcontractor may propose any internationally recognized design standard, subject to prior written approval by FNAL. The subcontractor shall state their intended method of design including applicable codes as part of their proposal. FNAL reserves the right to disapprove and exclude the use of certain codes or standards. Any information in the documentation that is considered proprietary should be marked as such.

5.1. Equipment Calibration Records

The subcontractor shall maintain records of all equipment used to fabricate, test, and measure all components delivered to the Company. The subcontractor must ensure that all equipment is calibrated in accordance with the equipment manufacturer’s specifications and is traceable to the U.S. National Institute of Standards and Technology or equivalent standards laboratory. The records shall contain the equipment name, model number and serial number if applicable, the calibration date, the applicable calibration procedures, and the serial numbers of the calibration standards. All equipment used must be traceable to the serial numbers of the samples and final components

5.2. Warranty

The manufactured components shall be warranted for 12 months after final acceptance at the Company’s Site.

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Table 4: QA Tests

QC Test Description

QC Test #1 Hipot testing between coils and the core.

QC Test #2 Measure DC resistance.

QC Test #3 Measure Inductance.

QC Test #4 Ring test to 100 volts. (Observing the coils oscillatory response to detect shorted turns in a winding).

Table 5: Key Milestones

Milestone Description

5.1 Kickoff meeting between FNAL and Vendor within 2-weeks of sub-contract award date.

5.1.a Status updates will be held every 2 weeks until delivery of first article.

5.2 Vendor to complete fabrication design proposal based on FNAL print package, fabrication prints are to be sent to FNAL for review when complete.

5.2.a FNAL must approve all dimensional deviations from reference design

5.3 Pre-production fabrication starts after this approval

5.3.a Completion of Pre-Production magnet pair and QC at vendor (FNAL reserves the right to observe critical QC stages at the subcontractor).

5.5 Vendor delivers first article to FNAL.

5.6 FNAL evaluates quality, cleanliness, fitment, and performance of first article.

5.7 FNAL meets with vendor to dictate any changes if required.

5.8 FNAL provides approval of first article and proceed with production of additional units.

5.9 After QC acceptance by FNAL, vendor delivers additional units agreed upon in bid package.

5.10 FNAL evaluates quality, cleanliness, fitment, and performance of production units.

5.11 FNAL provides acceptance of production units.

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6. DELIVERY AND ACCEPTABILITY TESTING

The subcontractor is required to procure, build, test, and deliver items per Section 4. All phases of fabrication shall be in accordance with the documents provided by the subcontractor and conform to the specifications in Section 4 above. Any conflict or ambiguity in the document(s) shall be brought to the attention of the FNAL procurement representative prior to any work being done or cost being incurred by FNAL.

6.1. DOCUMENTATION TO BE SUPPLIED PRIOR TO SHIPMENTS

1. For each magnet assembly the subcontractor shall provide a Certificate of Conformance that includes the following, this shall be provided at hold points 2 and 4:

a. Reports of QC inspections as defined in the Table 1 deliverables. The reports shall be delivered to

FNAL upon completion of the QC hold point, before the next hold point is reached. Approval of the hold point will not be given by FNAL if all reports are not delivered.

b. Parts to be assembled and packaged to assure no contamination from foreign materials, metal chips, or other contaminates.

c. Packaging shall be sufficient to protect parts from damage during shipment.

2. Traceability information from raw materials to finished magnets.

a. Non-conformance reports.

b. Material certifications.

6.2. CONFORMANCE AND ACCEPTANCE

1. Acceptance tests performed at FNAL will include:

a. Measurements for dimensional conformance.

b. Visual inspection of coils to ensure they’re free of scratches, deformations, and other defects.

c. Resistivity and magnetic field measurement to ensure the absence of electrical shorts.

6.3. PACKAGING AND SHIPPING

The subcontractor is responsible for the packing and where specified by FNAL for the transport to Fermilab of each.

In all cases, the subcontractor shall ensure that the equipment is delivered to Fermilab or to any other location without damage and any possible deterioration in performance due to transport conditions. The contractor shall comply with professional regulations in matter of packing and shipping.

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APPENDIX A

A.1 ACRONYMS AND DEFINITIONS

FNAL Fermi National Accelerator Lab

FFDG Fermi Forward Discovery Group

MIP Manufacturing and Inspection Plan

MRR Manufacturing Readiness Review

PIP-II Proton Improvement Plan Phase 2

RFI Request For Information

RFP Request For Proposal

SOW Statement of Work