4. SPEC_CAD-1372.pdf

SPEC_CAD-1372.DOCX Revision:B This information is controlled by the Page 1 of 15 U.S. Department of Commerce Export Administration Regulations

15 CFR Parts 730-774 as EAR99 Technology.

C-A Department Specification for the

Intercooler, Aftercooler and Utility Water-Helium Heat Exchanger Upgrades for Building 1005H Central Plant

_Pratik Patel________________________________

12/22/2025

Prepared by Pratik Patel / Cryogenic Engineer Sr., C-AD Date

_Yatming Than_____________________________

Approved by Yatming Than / Cryogenic Engineering GL, C-AD Date

_Russell Feder_____________________________

Approved by Russell Feder / Cryogenic Group Head, C-AD Date

_George Mahler________________________________

Approved by George Malher/Chief Mechanical Engineer Date

Jessica Paucar_______________________________

Approved by Jessica Paucar/QA Date

APPROVED

ELEC APPVL IN

W

INDCHILL

SPEC_CAD-1372.DOCX Revision:B This information is controlled by the Page 2 of 15

This page intentionally left blank, to accommodate back-to-back printing.

SPEC_CAD-1372.DOCX Revision:B This information is controlled by the Page 3 of 15

REVISION HISTORY

Date Rev. Change Notes By By Approved Approved Approved Approved

7/7/2025 A Initial Release P.Patel 10/20/2025 Y.Than R. Feder G.Malher P Jessica

12/22/2025 B Utility HX details added

P.Patel 12/22/2025 Y.Than R. Feder G.Malher P Jessica

SPEC_CAD-1372.DOCX Revision:B This information is controlled by the Page 4 of 15

This page intentionally left blank, to accommodate back-to-back printing.

SPEC_CAD-1372.DOCX Revision:B This information is controlled by the Page 5 of 15

Table of Contents

1 SCOPE

General background Definitions/Acronyms BSA Piping & Instrumentation Diagrams (P&ID) and General Arrangement drawings Compliance Codes

2 REQUIREMENTS

System description Intercooler Design Specifications Aftercooler Design Specifications Utility Heat Exchanger Design Specifications Helium Leak test requirements Galvanic protection and wall thickness margins Material of Constructions Cryoplant, B1005H, Description Piping Interfaces and Field Joint Closures

3 GENERAL REQUIREMENTS

Lifting Provisions Nameplate and Markers Vessel Supports Installation Instructions Seismic Design Condition Pressure vessel code analysis

SPEC_CAD-1372.DOCX Revision:B This information is controlled by the Page 6 of 15

15 CFR Parts 730-774 as EAR99 Technology.

1 SCOPE

This specification defines the technical requirements for three sets of Helium-Water heat exchangers that support the Relativistic Heavy Ion Collider (RHIC) and will support the Electron Ion Collider (EIC) Central Cryo Plant that is responsible for providing cooled helium to the RHIC/EIC at Brookhaven National Laboratory (BNL) managed by Brookhaven Science Associates (BSA). The scope of this procurement includes the design, fabrication, testing, delivery of three sets of heat exchangers, consisting of two sets of four vertically stacked heat exchangers—one skid for lower-pressure "intercoolers" and another for higher-pressure "aftercoolers," — and one heat exchanger that serves the utility compressor, (mainly used during startup and shutdown of the cryogenic system.) It is important to note that the removal of the old units is outside the scope of this procurement and will be performed by Brookhaven National Laboratory (BNL). Additionally, BNL will manage the integration of new heat exchangers, the fabrication and connection of supply and return piping as well as associated infrastructure.

General background The replacement effort for the helium-water heat exchangers outlined in this specification is necessitated by the aging units that were originally installed in the 1980s and have now reached the end of their operational life. These heat exchangers play a critical role in the Central Cryo Plant and provide the required temperature helium to ensure the future operation of the EIC. Due to their prolonged use for RHIC, the performance and reliability of the existing units have declined, in addition to an increased rate of helium leakage in the cryo plant, which is prompting the need for replacements to ensure the continued efficiency and safety of the cryogenic plant operations. The replacement units will be installed in the same location in the plant as the existing units utilizing the existing supply and returning water, helium and vacuum manifolds and piping.

Definitions/Acronyms ABL As-Built Listing ANSI American National Standards Institute ASME American Society of Mechanical Engineers ATP Acceptance Test Procedure NFPA National Fire Protection Association NRTL Nationally Recognized Test Laboratory BNL Brookhaven National Laboratory BSA Brookhaven Science Associate DOE Department of Energy ESH Environmental Safety Health FDR Final Design Review HASP Health And Safety Plan IEEE Institute of Electrical and Electronics Engineers ISO International Standards Organization LHe Liquid Helium NFPA National Fire Protection Association PDR Preliminary Design Review P&ID Piping & Instrumentation Diagram SOW Statement of Work

SPEC_CAD-1372.DOCX Revision:B This information is controlled by the Page 7 of 15

15 CFR Parts 730-774 as EAR99 Technology.

APPLICABLE DOCUMENTS

The following specifications, standards, and drawings form a part of this specification to the extent specified herein. General arrangement drawings are conceptual only and are not built-to print drawings. Unless otherwise specified, the issues of these documents shall be that in effect on the date of the solicitation or contract. In the event of a conflict between the Technical Specification document, the drawings and diagrams, and the Statement of Work document, the Contractor shall immediately notify the Brookhaven Science Associates (BSA) contract representative who shall determine which document takes precedence and advises the Contractor accordingly.

BSA Piping & Instrumentation Diagrams (P&ID) and General Arrangement drawings The following drawings give a general layout of the equipment and the piping and instrumentation diagrams for the system.

Document Number Document Title CA6000024 Compressor System Piping & Instrumentation Diagram CA6000025 Helium Plant Coldbox Piping & Instrumentation Diagram CA6000027 Cryogenic Distribution System Piping & Instrumentation

Diagram

BNL-8715-2008-IR Vacuum Systems Consensus Guidelines for DOE Accelerator Laboratories

3A995023 Intercooler Helium Compressor Station P&ID 3A995024 Aftercooler Helium Compressor Station P&ID 3a995021 Utility Compressor Station P&ID 31025043 Central Cryogenic Compressor System Aftercooler Skid 31025042 Central Cryogenic Compressor System Aftercooler Vessel 31025041 Central Cryogenic Compressor System Intercooler Skid 31025040 Central Cryogenic Compressor System Intercooler Vessel 31025046 Utility Compressor System Vessel

SPEC_CAD-1372.DOCX Revision:B This information is controlled by the Page 8 of 15

Compliance Codes The Contractor shall ensure that the project meets or exceeds the standards set forth in the listed codes and standards below. The Contractor shall use the latest version of these items when possible or indicate what version of the standard they shall be using. The Contractor shall have a copy of these items in the facility, particularly for the design standards and codes, and shall have a working knowledge of them for proper application in this project. The Contractor shall indicate any deviation from these standards and submit them for BSA approval before any work on the project is done. Any additional codes or standards the Contractor would like to apply to the design, shall also be submitted to BSA for written approval.

Codes and Standards

ASME BPVC Section VIII - Rules for Construction of Pressure Vessels, Division 1‚ Rules for Construction of Pressure Vessels Division 2‚ Alternative Rules

ASME BPVC Section IX - Qualification Standard for Welding and Brazing Procedures‚ Welders‚ Brazers‚ and Welding and Brazing Operators

ASME B31.3 Process Piping ASTM A269 Standard Specification for Seamless and Welded Austenitic Stainless-

S tee l Tubing for General Service ASTM A312 Standard Specification for Seamless, Welded, and Heavily Cold Worked

Austenitic Stainless-Steel Pipes TEMA Standards Tubular Exchanger Manufacturers Association AWS D1.1/D1.6 Structural and Stainless-Steel Welding ASME B30.26 Rigging Hardware

APPROVED

ELEC APPVL IN

SPEC_CAD-1372.DOCX Revision:B This information is controlled by the Page 9 of 15

15 CFR Parts 730-774 as EAR99 Technology.

2 REQUIREMENTS

System description A replacement helium water exchanger system consisting of three heat exchanger skids, one consisting of four vertically stacked intercoolers, the second consisting of four vertically stacked aftercoolers, and the third consisting of one smaller utility heat exchanger. The goals of the project are to 1) optimize the performance of the heat exchanger, 2) to minimize the leakage of helium by minimizing number of gasket/bolted joints, and 3) to ensure that the heat exchangers fit into the same location and mate with the same water and helium interface as the original heat exchangers.

The following table summarizes the major equipment that is included in the procurement:

Major item grouping 1 Four ‘Intercooler’ Helium Water Heat Exchangers 2 Four ‘Aftercooler’ Helium Water Heat Exchangers 3 One Utility Helium Water Heat Exchanger 4 Intercooler Skid Structure (optional) 5 Aftercooler Skid Structure (optional)

Intercooler Design Specifications

Fluid Properties Units Helium [Tube Side] Water [Shell side]

Inlet Temperature [K] 405 303 Outlet Temperature [K] 305 314 Inlet Pressure [bar] 4.5 2.6 Outlet Pressure [bar] 4.3 2.5 Mass flow Rate [kg/s] 1.13 12.72 Volume Flow Rate [m3/s] 1.66 0.012 Average Density [kg/ m3] 0.61 994 Average Specific Heat [J/kg-K] 5193 4179 Thermal Duty [Q] [W] 585000

Shell (water) Tube (Helium) Design Pressure 10.34 bar Full Vacuum & 10.34 bar Test Pressure (1.5x

DP)

15.5 bar 15.5 bar

Design Temperature 408 K 408 K

Intercooler Heat Exchanger Design Construction

Intercooler General Configuration

APPROVED

ELEC APPVL IN

SPEC_CAD-1372.DOCX Revision:B This information is controlled by the Page 10 of 15

15 CFR Parts 730-774 as EAR99 Technology.

• Type: Shell-and-tube heat exchanger

• Shell:

o Two-pass shell with a longitudinal baffle (TEMA Type F)

• Front End Head:

o TEMA Type B or equivalent, bonnet with integral cover.

• Tube Sheet: Directly welded to the Front-End Head o Bolted Flanged Connection between Tube Sheet and Shell (Water Interface Only)

• Tube Bundle:

o U-Tube bundle – with Forward end tube-sheet welded to Front End Head o Removeable with Front End Head

• Rear End Head:

o TEMA Type M welded cap design

Piping Interfaces

i. Water (Shell Side):

1. There shall be two sets of water inlets and outlets configured as shown in Attachment 1 (Intercooler outline drawing).

2. One set will support standard direction flow, and the second set will support counter direction flow.

3. Water inlet and outlet piping shall be 3” schedule 40 pipe.

ii. Helium (Tube Side):

1. There shall be one helium inlet and one outlet in the channel portion of the heat exchanger as shown in Attachment 1.

2. Helium inlet and outlet piping shall be 10” schedule 40 pipe.

iii. Ports:

1. Each water and helium supply and return shall have a ½” – 3000# NPT and ¾” – 3000 NPT port as specified in Attachment 1.

2. There shall be a ½” -3000# NPT port on the bottom surface of the Front-End Head to function as an oil drawing as specified in Attachment 1.

3. There shall be four 2”-3000# NPT ports in the shell housing located as specified in Attachment 1.

Aftercooler Design Specifications

Inlet Temperature [K] 405 303 Outlet Temperature [K] 305 314 Inlet Pressure [bar] 16.7 2.6 Outlet Pressure [bar] 16.5 2.5 Mass flow Rate [kg/s] 1.13 12.72 Volume Flow Rate [m3/s] 0.44 0.013 Average Density [kg/ m3] 2.28 994 Average Specific Heat [J/kg-K] 5193 4179

APPROVED

ELEC APPVL IN

SPEC_CAD-1372.DOCX Revision:B This information is controlled by the Page 11 of 15

Thermal Duty [Q] [W] 585000

Design Pressure 10.34 bar Full Vacuum & 20.6 bar

Test Pressure (1.5x

DP)

15.5 bar 31 bar

Aftercooler Heat Exchanger Design Construction

Aftercooler General Configuration

• Type: Shell-and-tube heat exchanger

• Shell:

o Two-pass shell with a longitudinal baffle (TEMA Type F)

• Front End Head:

o TEMA Type B or equivalent, bonnet with integral cover.

• Tube Sheet: Directly welded to the Front-End Head o Bolted Flanged Connection between Tube Sheet and Shell (Water Interface Only)

• Tube Bundle:

o U-Tube bundle – with Forward end tube-sheet welded to Front End Head o Removeable with Front End Head

• Rear End Head:

o TEMA Type M welded cap design

Piping Interfaces

i. Water (Shell Side):

1. There shall be two sets of water inlets and outlets configured as shown in Attachment

2. (After cooler outline drawing)

2. One set will support standard direction flow, and the second set will support counter direction flow.

3. Water inlet and outlet piping shall be 3” schedule 40 pipe.

ii. Helium (Tube Side):

1. There shall be one helium inlet and one outlet in the channel portion of the heat exchanger as shown in Attachment 2. (aftercooler outline drawing)

2. Helium inlet and outlet piping shall be 10” schedule 40 pipe.

SPEC_CAD-1372.DOCX Revision:B This information is controlled by the Page 12 of 15

15 CFR Parts 730-774 as EAR99 Technology.

iii. Ports:

1. Each water and helium supply and return shall have a ½” – 3000# NPT and ¾” –

3000 NPT port as specified in attachment 2.

2. There shall be a ½” -3000# NPT port on the bottom surface of the Front-End Head to function as an oil drawing as specified in attachment 2.

3. There shall be four 2”-3000# NPT ports in the shell housing located as specified in attachment 2.

Note: The suitable TEMA type heat exchanger mentioned in the specification document shall be considered by supplier.

The supplier shall minimize bolted/flanged connections.

Utility Heat Exchanger Design Specifications

Inlet Temperature [K] 350 303 Outlet Temperature [K] 308 315 Inlet Pressure [bar] 17 2.6 Outlet Pressure [bar] 16.9 2.4 Mass flow Rate [kg/s] 0.096 0.42 Volume Flow Rate [m3/s] 0.039 0.0004 Average Density [kg/ m3] 2.4 993.7 Average Specific Heat [J/kg-K] 5193 4179 Thermal Duty [Q] [W] 20943

Design Pressure 10.34 bar Full Vacuum & 20.6 bar

Test Pressure (1.5x

DP)

15.5 bar 31 bar

Utility Heat Exchanger Design Construction

General Configuration

• Type: Shell-and-tube heat exchanger

• Shell:

o Two-pass shell with a longitudinal baffle (TEMA Type F)

• Front End Head:

o TEMA Type B or equivalent, bonnet with integral cover.

• Tube Sheet: Directly welded to the Front-End Head

APPROVED

ELEC APPVL IN

SPEC_CAD-1372.DOCX Revision:B This information is controlled by the Page 13 of 15

15 CFR Parts 730-774 as EAR99 Technology.

o Bolted Flanged Connection between Tube Sheet and Shell (Water Interface Only)

• Tube Bundle:

o U-Tube bundle – with Forward end tube-sheet welded to Front End Head o Removeable with Front End Head

• Rear End Head:

o TEMA Type M welded cap design

Piping Interfaces

i. Water (Shell Side):

1. There shall be one water inlet and outlet configured as shown in Attachment 3(Utility HX drawing).

2. Water inlet and outlet piping shall be 1” schedule 40 pipe.

ii. Helium (Tube Side):

1. There shall be one helium inlet and one outlet in the channel portion of the heat exchanger as shown in Attachment 3 (utility HX drawing).

2. Helium inlet and outlet piping shall be 2” schedule 40 pipe.

iii. Ports:

1. Each helium and water supply and return shall have a ½” – 3000# NPT and ¾” – 3000 NPT port as specified in attachment3.

2. There shall be a ½” -3000# NPT port on the bottom surface of the Front-End Head to function as an oil drawing as specified in attachment 3.

Note: For details, kindly refer to the Utility HX drawing number 31025046

Note: The suitable TEMA type heat exchanger mentioned in the specification document shall be considered by supplier.

The supplier shall minimize bolted/flanged connections.

Helium Leak test requirements

1. 1st test: Leak to external side (air): 1E-5 Torr-L/s with a charge of 10 bar in the helium tubes.

External sniff sensitivity is only 1E-5. Alternate tests can also be done together with no.2.

Mass spec on the helium tube side and spray external (air side) boundaries followed by test no.2

2. 2nd test: stream to stream leak check (internal leak) 1E-9 Torr-L/s with a helium charge of 2 bar in the shell (water) side with mass spec pumping on the tube side. (need to weld pipe caps on helium pipe).

(If the skid is shut down and the helium is lower than water pressure: water leak to helium)

Galvanic protection and wall thickness margins

ELEC APPVL IN

SPEC_CAD-1372.DOCX Revision:B This information is controlled by the Page 14 of 15

15 CFR Parts 730-774 as EAR99 Technology.

The water side exchanger pressure boundaries shall have a minimum 1/8” thickness margin for corrosion and erosion thinning. The water side boundary shall also have a sacrificial anode protection that can be easily accessed for replacement.

Material of Constructions

Shell (Water fluid): The material shall be recommended by supplier as per Industrial standard code requirements. Carbon steel or Stainless steel are acceptable.

Tube (Helium fluid): The material shall be recommended by Supplier as per Industrial standard code requirements. Copper/Ni (90/10) is acceptable.

Cryoplant, B1005H, Description B1005H is a non-air-conditioned tall industrial building with 10 Ton overhead crane with a hook height of 91 ft. The building has a two high rollup door with dimensions 12 ft wide x 14 ft and 10 ft wide x 10 ft

Piping Interfaces and Field Joint Closures

• The input and output connections to the heat exchangers shall be stubs with weld preps as identified in the outline drawings of Intercooler and Aftercooler and Utility HX.

• All weld preps shall conform to ASME B31.3 and ASME Section IX to ensure proper welding quality and compatibility with facility piping.

• BNL will be responsible for making all final piping connections between the facility supply and returns to the heat exchange units.

3 GENERAL REQUIREMENTS

Lifting Provisions Lifting lugs are required for all heat exchangers. The lugs shall be mounted to the exterior vessel or as requested by BSA for installation purposes. If applicable, the Contractor shall provide the appropriate number of lugs to allow for the safe transition of the vessel from the vertical to horizontal position and vice versa. This should include at least 2 lugs at the top of the vessel and at least 1 at the bottom. Lugs shall be mounted to allow them to have full and proper travel when attached to the lifting device. Lifting equipment shall meet the requirements of ASME B30.26 Rigging Hardware.

Lugs shall be located to distribute the load uniformly. Lifting lug stress/structural calculation shall be provided for the lug and weld to BSA as specified in the accompanying Statement of Work (SOW).

A weld inspection and sign-off of the lug attachment welds is required. The design limit shall be at least a safety factor of 4 relative to the yield value of the material. Each individual lug shall be able to hold the full weight of the section. The Center of Gravity (CG) mark shall be permanently marked on the shell.

Nameplate and Markers All intercooler, aftercooler and utility heat exchangers shall have a nameplate, mounted on the external surface for identification. The following information shall be contained on the nameplate:

APPROVED

ELEC APPVL IN

SPEC_CAD-1372.DOCX Revision:B This information is controlled by the Page 15 of 15

15 CFR Parts 730-774 as EAR99 Technology.

1. Nameplate with design ratings, ASME/National Board

2. Serial number

3. Contractor's name and address

4. Weight of assembly

Pressure vessels shall have at least 2 markings to indicate the Center of Gravity (CG) of the vessel.

The markings should be placed to make a clear designation as to where the CG is based on the positions of the lifting lugs.

Vessel Supports The Intercooler and Aftercooler vessels shall be supported by legs from the bottom of the vessel with bolt patterns as specified in outline drawing Intercooler and Aftercooler. Two of each unit type shall be fitted with additional support feet on the top of the vessel for stack mounting, as specified in outline drawing Intercooler and Aftercooler. Each support leg shall have a minimum strength to support 3 times the entire weight of the entire vessel divided by the number of legs. The Utility Heat exchanger vessel shall be supported by legs from the bottom of the vessel with bolt patterns as specified in outline drawing 31025046. The supports shall be able to resist corrosion for the effective life of the product or at least 30 years. This can mean the use of corrosion resistant materials or a surface coating such as paint. Dissimilar materials connected to each other shall be reviewed for the potential for galvanic corrosion. The vessel support shall have provision for forklift and pallet jack forks to move the vessel into its final location. At a minimum, a flat surface shall be provided 4” above the ground level to rest the forks safely under the vessel without tipping.

Installation Instructions The Contractor shall provide all information to BSA for items that require assembly on site. Such information would include drawings and procedures detailing sequence of installation, lifting procedures, details on hardware safety during installation, and torque rating for all fasteners. The instructions shall be in a report outline format, listing the order of installation at each subsequent step. The instructions should be clear since they should be used to generate safety procedures for the installation. The instructions shall be used to review physical access to parts of the design as well as aspects not fully captured in general arrangement drawings.

Seismic Design Condition Equipment location: Sea level Seismic Zone: Long Island NY. Use 0.25G for design Vessel elevation: At ground level

VERIFICATION/ANALYSES

Pressure vessel code analysis Heat exchangers shall meet ASME BPVC Section VIII Div 1 or 2 code, and U stamped as listed below.