446572 - Synopsis_DRAFT_Specification_SPEC-CAD_1365_REV B_11-26-2024.pdf

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C-A Department Technical SPEC-CAD_1365

Nov 26, 2024 Rev. B

Technical Specification for

3500 L liquid helium dewar with integrated subcooler and heater

Prepared by

Chintan Sheth_____________________________

Chintan Sheth / Cryogenic Engineering, C-AD

Date

11/26/2024

Approved By Pratik Patel__________________________ Date Pratik Patel/Cryogenic Engineering, C-AD 11/26/2024

Roberto Than_____________________________

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

Patrick Talty_______________________________ Approved by Patrick Talty, Cryogenics Eng. Controls & I, C-AD

Joseph Tuozzolo__________________________ Approved by

Joseph Tuozzolo / Chief M.E., C-AD

Frank Craner______________________________ Approved by Frank Craner / Safety, C-AD Date

Cindy Galdamez______________________________ Approved by Cindy Galdamez/ Configuration Engineering, C-AD Date

David Passarello______________________________ Date Approved by David Passarello / Quality Assurance, C-AD 11/26/2024

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REVISION HISTORY

Date Rev. Change Notes By By Approved Approved Approved Approved Approved

3/5/2024 A Initial Release C Sheth R. Than R. Feder

9/10/2024 B Updates process parameters; scope & subcooler design

P Patel R. Than R. Than R. Feder

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Table of Contents

1 SCOPE

1.1 General background

1.2 Definitions/Acronyms

1.3 Scope

2 APPLICABLE DOCUMENTS

2.1 BSA P&I Diagram, General Arrangement Drawings and Supporting Documents

2.2 Codes Compliance

3 REQUIREMENTS

3.1 System description

3.2 General Requirements:

3.3 Instrumentation:

3.4 Utilities Provided/Available in B912 for the Plant

3.5 Piping & Instrumentation Diagram and Instrumentations requirements

3.6 Subcooler

3.7 Heater

3.8 Cryogenic Valves

3.9 Piping Interfaces

3.10 Dewar Mechanical Design Requirements

3.11 Subcooler Mechanical Requirements:

3.12 Insulating Vacuum vessel:

Dewar Platform

3.13 Vacuum ports

3.14 Instrumentation

3.14.1 Temperature Sensors

3.14.2 Pressure Sensors and Gauges

3.14.3 Liquid Level Sensors

3.14.4 Dewar neck end shield intercept Mass Flowmeters

3.14.5 Vacuum Electrical Feedthroughs

3.14.6 Vacuum Sensors on Insulating Vacuum Volumes

3.15 Electrical feedthrough for helium pressure boundary

3.16 Instrumentation Junction box

All the pressure sensors, temperature sensors, level indicators and limit switches shall be terminated to junction box mounted on the dewar

4 GENERAL REQUIREMENTS

4.1 Materials

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4.2 Brazed joints

4.3 Multi-Layer Insulation

4.4 Bellows and Braided Flexible Metal Line

4.5 Vacuum Spaces, Vacuum pump-out Valve, Vacuum gauging, and Getter System

4.5.1 Vacuum Getter System

4.6 Vacuum Relief Requirements

4.6.1 Vacuum Vessel Relief Requirements

4.7 Valves

4.7.1 Radiation or Sub-atmospheric Operation

4.8 Purge, Relief, and Instrumentation Branch Lines

4.8.1 Instrument/purge lines

4.8.2 Purge and Instrumentation Valves

4.9 Safety Pressure Relief Devices

4.9.1 Relief valves

4.9.2 Rupture Disk

4.10 Lifting Lugs

4.11 Nameplate and Markers

4.12 Instrumentation and Equipment Protection

4.13 Earth Electrical Ground connection

4.14 Vessel Supports

4.15 Installation Instructions

4.16 Seismic and Transport Design Condition

4.17 Construction/Layout/Location Requirements

5 VERIFICATION/ANALYSES

5.1 Valve sizing

5.2 Pressure vessel code analysis

5.2.1 Dewar with subcooler and heater

5.3 Pressure relief devices analysis

Structural design

5.4 Lifting lug analysis

5.5 Piping Connections

5.5.1 Analysis Requirements

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1 SCOPE

This specification defines the technical requirements for a 3500 liters liquid helium dewar with an integrated subcooler and heaters, and associated equipment to be used at the building 912 Superconducting Radio Frequency (SRF) Cryomodule Test Facility at the Collider Accelerator Department at Brookhaven National Laboratory (BNL) managed by Brookhaven Science Associates (BSA). The liquid helium dewar shall be designed and fabricated by the Contractor and installed by BSA with Contractor engineering support in building 912 (B912). The Contractor shall fabricate and assemble the subcooler and heaters inside the liquid helium dewar and install any BSA provided items on/in the dewar.

1.1 General background

The BNL Collider Accelerator Division Cryogenic Engineering Group is involved with a project to provide upgraded liquid helium processing and delivery services for future SRF testing. The upgrade involves purchasing and installing a new high capacity liquefier unit, purifier, subatmospheric systems, valve boxes and other required equipment. A new 3500 liter storage dewar containing an integrated subcooler is needed to mate with the new liquefier system to store and distribute cold helium.

1.2 Definitions/Acronyms

ABL As-Built Listing ANSI American National Standards Institute ASME American Society of Mechanical Engineers ASTM American Society for Testing and Materials BNL Brookhaven National Laboratory BSA Brookhaven Science Associate CGA Compressed Gas Association DOE Department of Energy FDR Final Design Review LHe Liquid Helium MLI Multi-Layer Insulation OSHA Occupational Safety Health Administration P&ID Piping & Instrumentation Diagram SOW Statement of Work SRF Superconducting Radio-Frequency

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1.3 Scope

This specification covers the following systems and equipment included in this Dewar procurement:

1. 3500 liters liquid helium dewar with integrated subcooler and heater units.

a. Process design data is included, and the Contractor can size and design the exchanger to fit the dewar according to their manufacturing capability. A proposed subcooler design is also given in this technical specification to build/manufacture to Subcooler. The Subcooler design will be provided by BSA, fabrication drawings will be in Contractor scope.

b. Redundant set of 1 Kw Heater will be provided by BSA, mounting method and installation of this inside the Dewar shall be in Contractor’s scope. Cryogenic temperature sensors are also provided by BSA to be installed inside the dewar in the liquid bath space and on tubing in the insulating vacuum space.

2. Dewar installation support during BSA installation

3. Dewar testing and commissioning at BNL

2 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 build-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 in each instance determine which document takes precedence and advise the Contractor accordingly.

2.1 BSA Piping and Instrumentation Diagrams, (P&ID) General Arrangement Drawings and Supporting Documents

The following drawings gives a general layout of the equipment and the piping and instrumentation diagrams for the system. Document BNL-8715-2008-IR provides typical design guidelines regarding the vacuum systems for DOE Accelerator Laboratories and the Fastner Inspection document describes the guidelines for inspection of counterfeit and defective fasteners.

Document Number Document Title CA6000026 Rev D 3500L Liquid Helium Storage Dewar/Subcooler Piping &

Instrumentation Diagram (P&ID)

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

CA6000062 Sub-cooler Details and Design Fastener Inspection Suspect/Counterfeit & Defective Fastner Inspection

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2.2 Codes Compliance

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 CGA S-1.3 CGA S-1.3, Pressure Relief Device Standards – Part 3 – Stationary Storage

Containers for Compressed Gases 29 CFR 1910 OSHA General industry Regulations & Standards

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3 REQUIREMENTS

3.1 System description

The liquid helium storage dewar along with heater and subcooler will be designed, manufactured, and supplied to BNL. This dewar will be integrated with a new helium liquefier plant, cryogenic distribution system and an old 250W piston cylinder plant. The co-axial cryogenic transfer line from the dewar to the cryoplant will be provided by BNL. The Contractor shall provide the interface requirements for the dewar side for the co-axial cryogenic transfer line and other components as described in referenced documents.

3.2 General Requirements:

Sr.

No.

Feature Comments

1. Capacity 3500 Liters

2. Length / Diameter < 96”

3. Circular base and forklift lifting provision

4. Lifting lugs Eng calc;

5. Material of construction helium vessel

SS 304/304L

6. 2 electrical heaters 1kW each with electrical feedthrough:

BSA will provide electrical feedthrough and Contractor will install. Heaters will be installed at BNL by BSA

7. Sub-cooler BSA will provide design.

Fabrication details and drawings by Contractor

8. Safety relief valves Contractor scope

9. Switch-over valve for primary reliefs Contractor scope

10. Rupture disk Contractor scope

11. Cooldown return line valve Contractor scope, CryoComp C2041-M21

He ½”Tube

12. Cooldown return line interface Tube weld

13. Subcooler-In female bayonet Contractor scope, PHPK Helium ½”Tube

14. Subcooler-out female bayonet Contractor scope, PHPK Helium ½”Tube

15. Coaxial LHe/VHe transfer line

Interface Contractor scope, Radial gland seal coupling, BSA will provide jacket diameter

16. LHe in/out draw female bayonet Contractor scope PHPK He ½”Tube size

17. Cryogenic isolation valve subcooler inlet Cryocomp C2043-M21 Y-pattern

18. Cryogenic isolation valve subcooler outlet

Contractor scope C2043-M21 Y-pattern ½”Tube

19. Cryogenic isolation valve liquid draw line

Contractor scope C2043-M21 Y-pattern ½”Tube

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20. Cryogenic isolation cooldown return Cryocomp

Vacuum ports & Valves:

Sr. No. Feature Comments

1. 4.5”-Conflat flange and 2.5” bellows stem & metal seat vacuum valve Contractor scope

2. 2.75”-Conflat flange and 1” bellows stem & metal seat vacuum valve

Contractor scope

3. Vacuum volume relief device Contractor scope

4. TC vacuum gage port isolation valve Contractor scope

3.3 Instrumentation:

Sr.

No.

Instrumentation Comments

1. Neck intercept local Flow meter Contractor scope

2. Super conducting level sensor Contractor scope

3. Liquid Level Differential pressure level sensor with 4-20mA output Local Gage readout of Liquid Level Differential pressure level sensor

Contractor scope

4. Pressure gauges BSA will provide and Contractor will install

5. Electrical Feed through helium boundary for temperature sensors

BSA will provide and Contractor will install

6. TC Vacuum gauge Contractor scope

7. Redundant Diode temperature sensors BSA will provide and Contractor will install

8. Electrical Feed through vacuum boundary BSA will provide and Contractor will install

9. Neck intercept parallel remote flow-controller BSA will provide and Contractor will install

10. Pressure Transmitters BSA will provide Contractor will install

11. Pirani Gauge BSA scope and installed at BNL

12. Cold cathode Gauge BSA scope and installed at BNL

3.4 Utilities Provided/Available in B912 for the Plant

The following utilities shall be used for the 3500 L liquid helium storage dewar. Components shall be designed to be compatible with these specifications. Exceptions shall require review and approval by the BSA technical representative. B912 is a non-airconditioned tall industrial building with 40 Ton overhead crane with a hook height of 21 ft. Electrical 120V/1-phase is available in B912 and shall be provided and used for the dewar components systems. Heater power and controls will be provided by BSA.

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3.5 Piping & Instrumentation Diagram and Instrumentations requirements The 3500 L liquid helium storage dewar shall have temperature and pressure sensors throughout to allow proper operation, troubleshooting, and maintenance of the system. The dewar will be connected to a new cryogenic plant and an old cryoplant. Contractor scope items are delineated on diagram

CA6000026.

3.6 Subcooler

A conceptual subcooler design will be provided by BSA shown in dwg. CA6000064 and CA6000065. The subcooler assembly shall be mounted as low as possible in the helium reservoir.

Contractor shall prepare manufacturing drawings and submit to the BSA for approval. The Contractor is responsible for manufacturing method. Only after approval can the Contractor manufacture the subcooler. Contractor shall submit installation plan for BSA’s review and approval. After BSA’s approval, the subcooler shall be installed inside the dewar. The process requirements are given below to allow the Contractor to propose an alternate design for the subcooler exchanger.

Table 3.6.1 Process Requirements

Loading Mode Location Flow g/s Temperature

K Pressure bar

Bath Pressure

Bar

Bath Pressure

K 100%

Liquefaction Inlet 10 6.0 3.5 1.25 4.45

Outlet 10 4.57 3.45 1.25 4.45

100% Refrigeration

Inlet 45 4.8 3.5 1.25 4.45 Outlet 45 4.57 3.3 1.25 4.45

A UA margin of 20% shall be added after exchanger sizing.

Subcooler Coil The subcooler can be constructed as a wound coil inside the dewar submerged to as low as possible.

Material is stainless steel 304/304L Tubing: 0.625 inch OD x 0.035 inch wall.

Table 3.6.2 Subcooler Coil

Length Ft

Tube diameter Inch OD

Wall thickness inch

95 0.625 0.035

3.7 Heater

BSA to install heaters onsite after the receipt of the liquid helium dewar. BSA to remove the shipping support/fixture prior to installation of the heaters.

3.8 Cryogenic Valves

Manual Helium temperature cryogenic valves shall be provided for the subcooler inlet and outlet circuits and for the liquid draw line and for the cooldown return line. The valve model number are listed in Table 3.2. There shall be a relief for subcooler exchanger circuit set for the design pressure of the subcooler.

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3.9 Piping Interfaces

In order to interface the dewar to cryogenic distribution system and plant coldbox, the Contractor shall provide female bayonet connections and the radial gland seal interface to the co-axial transferline from the plant coldbox, as mentioned in Table 3.2. The Contractor shall also provide all required o-rings if the o-ring groove is on the Contractor side’s flange. Mating components or adapters for any non-US flange or fittings interfaces for other connections such as vacuum, shall be provided.

3.10 Dewar Mechanical Design Requirements

Pressure vessels shall be designed and manufactured in accordance with ASME BPVC VIII Div-1 or 2 and shall be U-stamped. Design parameters for the dewar and its subsystems are as follows:

Helium Vessel MAWP 65 PSI differential at 100°F MDMT -452°F at MAWP MAEWP 15 PSI full vacuum at 100°F

Interconnecting piping shall be seamless ASTM 304L or ASTM 316L stainless steel pipe or tube shall be designed and manufactured in accordance with ASME B31.3 Process Piping.

3.11 Subcooler Mechanical Requirements:

Subcooler tubing shall be dual grade stainless steel 304/304L. Piping shall be designed and manufactured in accordance with ASME B31.3 Process Piping. The coil windings shall be supported with a fixture to set the centerline to centerline spacing at 1.5 inches. The support fixture shall allow the coil to contract during cooldown.

Subcooler MAWP 150 PSI differential at 100°F MDMT -452°F at MAWP MAEWP 15 PSI full vacuum at 100°F

3.12 Insulating Vacuum vessel:

Vacuum vessel shall be made of stainless steel 304 and does not require to be ASME U-stamped.

Vacuum Vessel MAWP 14.7 PSI differential at 100°F MDMT -20°F at MAWP MAEWP 14.7 PSI full, vacuum at 100°F

Dewar Platform The Dewar shall have a platform for all around access to the top interface plate / dewar neck and transfer line penetrations (for example locate all three penetrations on one side), with full OSHA Regulation 1910 compliance, including a hand railing and ladder.

3.13 Vacuum ports

Vacuum ports and valves shall be provided by Contractor per requirements given in vacuum ports and valves table items 1 and 2.

3.14 Instrumentation

3.14.1 Temperature Sensors

Redundant diode temperature sensors will be provided by BSA. Mounting and installation shall be

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done by Contractor as per direction given by BSA. The hard mount shall be silver brazed to the component and/or mechanical stacked with an indium washer to ensure good thermal contact as to minimize thermal surface contact resistance. Possible configurations include, but not limited to, a contoured copper pad that is brazed to the component surface. The sensor shall have a mechanical fastening feature to ensure a good compression using a screw fastener or mechanical clamp. Sensor mounts shall be approved by BSA prior to use. Thermal isolation pads (provided by BSA) will be mounted walls of the dewar to act as a thermal break between the outside feedthroughs and temperature sensors. See below.

Figure 1 Thermal Isolation Pad

External temperature sensor wires leaving the isolation pads will need to be adequately labeled and wrapped around a hook on a 2.75” conflate flange provided by BSA. See below.

Figure 2 2.37" Conflat flange with hook

3.14.2 Pressure Sensors and Gauges

Local pressure gauges shall be provided by the Contractor to indicate the pressure. Pressure transmitters will be provided by BSA. Contractor shall also provide parallel taps with isolation valves to install pressure transmitters. The pressure transmitters require a special fitting interface.

3.14.3 Liquid Level Sensors

Superconducting Level Insertion type superconducting level sensor shall be purchased and installed by the Contractor per BSA’s instructions. The liquid level shall be measured continuously during operations. The Contractor shall provide the mounting design and mounting system for the level probes. The Contractor shall install the level probe connection that meets the pressure and temperature requirements for the vessel. The Contractor shall verify that the probe can be inserted into the vessel in its final installation location.

Differential Pressure Level Transmitter and local readout A local liquid inventory gage (Differential Pressure Indicator) and a differential pressure transmitter with signal output of 4-20 mA shall be provided by Contractor for the liquid level indication in

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addition to the superconducting level sensor. The local gauge and the transmitter shall be pressure rated to the design pressure of the helium vessel.

3.14.4 Dewar neck end shield intercept Mass Flowmeters

Contractor shall provide a standard flow meter for local display. Contractor shall also provide additional parallel taps with isolation valves to install BSA Mass flow meter for Dewar neck flow measurement.

3.14.5 Vacuum Electrical Feedthroughs

Location of the feedthroughs shall allow for easy access to facilitate repair or replacement. Feed through shall be provided by BSA and installed by Contractor. The electrical feedthroughs for the temperature sensors shall be mounted on a 2.75” Conflat flange set.

3.14.6 Vacuum Sensors on Insulating Vacuum Volumes

Cold Cathode and Pirani gauges shall be provided by BSA. Contractor shall provide a 2.75” conflat flange and isolation valve as the interface for installation of Cold Cathode and Pirani gauges.

The Contractor shall install their own thermal conductivity vacuum gauge and isolation valve for testing.

3.15 Electrical feedthrough for helium pressure boundary

Electrical feed through for the heater shall be provided by BSA and installed by Contractor as per directions provided by BSA.

3.16 Instrumentation Junction box

All the pressure sensors, temperature sensors, level indicators and limit switches shall be terminated to junction box mounted on the dewar.

4 GENERAL REQUIREMENTS

This section specifies general requirements for the procurement of the dewar along with its sub-systems. Not everything may necessarily apply to a specific procurement, thus can just be designated as not applicable. To ensure proper field installation, the dimensions on the drawings shall be followed. They are specified to ensure such items as proper mating for pipe ends, avoiding interferences, and structural support locations. The selection of specific components and materials for the final design shall minimize heat leak, cool-down cold-mass, and fluid flow resistance.

The Contractor is responsible for the manufacturing drawing and fabrication of this system. All aspects of the Contractor proposed design shall be reviewed and approved by BSA prior to beginning fabrication. The Contractor shall have the responsibility for all aspects of the final design, such as: thermal and mechanical performance, safety, reliability, quality, ease of installation and assembly, etc., in accordance with this specification. The Contractor is responsible for showing that the design meets all analytical requirements through the use of hand calculations, computer simulations, and code calculations which shall be documented in reports submitted to BSA.

4.1 Materials

All internal lines and vacuum jackets (including weld attachments) shall be constructed of dual graded Type 304/304L, austenitic Stainless Steel as per ASTM A-312 or ASTM 269. In addition, all internally pressurized piping and vacuum jackets shall be of a welded construction. Contractor shall identify all materials of construction during the conceptual design review. All other cryogenic

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components such as valves, flexible hose, bayonets, etc., shall be constructed of cryogenic engineering industrial standard 304L or 316L Series Stainless Steel. Application of epoxies or other similar materials shall be rated for cryogenic service, specified in the proposal, and used only upon written approval of BSA. When building assemblies or components of dissimilar materials, the Contractor shall review the interfaces to remove or minimize the effects of any potential galvanic corrosion.

4.2 Brazed joints

For copper to copper and copper to stainless steel, brazed joints are needed. These joints are typically susceptible to damage from thermal shock due to the difference in the material’s thermal expansion coefficients. The Contractor shall ensure these joints are properly secured in their design and shown not to be stressed in their piping and structural analysis. When such joints are to be used, they shall be fully thermally cycled at least 5 times from room temperature to 80K. After the temperature cycling, the joints shall be helium mass spectrum leak checked to verify that there were no manufacturing defects. The Contractor shall provide photographs, indicating the time elapsed, for each thermal cycle as well as results of the leak checking in a single report. Equivalency reports from a component Contractor shall be considered by BSA, in lieu of such testing if the Contractor can show that their testing exceeds the requirements listed.

4.3 Multi-Layer Insulation

All process piping shall be individually wrapped with MLI (Multi-Layer Insulation). Blanket or spiral wrapped construction is acceptable and shall be consistent with liquid helium temperature applications MLI design shall be adequate for low heat leak liquid helium temperature applications with sufficient layers to insulate the surface of the helium vessel consistent with the liquid helium applications. This is to minimize the heat flux for the case of loss of insulating vacuum to air (to an MLI insulated helium vessel). needed to use the minimum heat flux value of 6,000 W/m2.

4.4 Bellows and Braided Flexible Metal Line

Flexible sections, both process flow and vacuum space, are required as part of the final design, and all flexible hoses shall meet ASME B31.3 requirements.

Braided flexible lines shall be supplied with Contractor’s pressure/temperature ratings technical data sheet. Bellows and braided flexible lines shall be designed to handle external pressure (vacuum inside with pressure outside) as specified in the requirements section of this specification.

4.5 Vacuum Spaces, Vacuum pump-out Valve, Vacuum gauging, and Getter System The self-contained, static vacuum space shall contain a pump-out valve, pressure relief valve, and a conflat flange. The vacuum spaces shall each contain an appropriate getter system that shall remove residual gases, moisture, and hydrogen. A list of each size Vacuum Seal-Off /Valve Operators used shall be supplied to BSA.

4.5.1 Vacuum Getter System

Contractor shall provide the appropriate gettering system for a static insulating vacuum system for liquid helium dewar application..

4.6 Vacuum Relief Requirements

4.6.1 Vacuum Vessel Relief Requirements

Relief of insulating vacuum vessel volume shall have a vacuum rated ASME UV relief, or ASME

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UD stamped burst disc (FIKE Axius disc, XL holder assembly G with O-ring groove, critical leakage design version) or one or more MDC 420033 BDA-275-ASME. To prevent accidental release of a burst disc, a pressure relief device shall be provided to vent well below the set point of the burst disc.

Alternatively, relief plates held onto the flange by gravity/vacuum and guarded from flying away can be used if they lift cleanly and provide a clean opening. To guard against the projectile hazard, the lift plate shall be attached by a stainless-steel chain. The lift plate shall be designed to prevent accidental lifting from bumping into it. Upon BSA approval, the lift plate can be used in place of an ASME rated device.

4.7 Valves

4.7.1 Radiation or Sub-atmospheric Operation

Valves used as part of any sub-atmospheric circuit shall be a bellows sealed stem type design.

4.8 Purge, Relief, and Instrumentation Branch Lines

4.8.1 Instrument/purge lines

The heat leak budget for independent instrument/purge lines is 0.1 W.

4.8.2 Purge and Instrumentation Valves

All the valves shall have metallic bellow stem seal. Where purge valves are required, they shall be globe or needle valves with manual handles to offer flow control. All the connections from valve to tubing shall be welded joints. Instrumentation valves shall be used to isolate sensors so that they can be replaced during operation. All valves need to be selected to handle the maximum pressure in the line.

4.9 Safety Pressure Relief Devices

The Contractor shall refer to CGI S-1.3, for capacity and sizing of the relief device. The Contractor may use other calculations, which shall be approved by BSA. The listed afore-mentioned standards’ results shall be shown, and the more conservative value shall be selected.

4.9.1 Relief valves

All reliefs shall be ASME UV stamped reliefs. For reliefs with an inlet connection equal to or larger than 1 inch, the reliefs may be an Anderson Greenwood series 80 style if the minimum set pressure is applicable to this series. For reliefs smaller than 1-inch inlet size, the reliefs can be Anderson- Greenwood or Crosby, or Flowsafe microbody relief, Leser, Circle Seal, or equivalent as approved by BSA in writing. The relief device outlet ports shall have a means of connection to a pipe so that discharge can be piped to outside of the building. An ANSI flange is preferred, but others can be considered with prior notification. These reliefs shall be plumbed as to fully drain any condensation that develops and prevent dripping onto other components. The outlet of any relief shall be placed such that it does not pose a hazard to any personnel in the area during a relief event. The relief placement and vent direction shall be sent to BSA for approval.

4.9.2 Rupture Disk

Rupture disks shall be ASME UD stamped disks. The discharge side of the holder shall have a pipe extension to divert the charge 2 ft higher than highest point of the dewar assembly.

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4.10 Lifting Lugs

If lifting lugs are required, the Contractor shall provide the appropriate number of lugs to allow for the safe transportation of dewar by crane. This should include at least 3 lugs at the top. Lugs shall be mounted to allow them to have full and proper travel when attached to the lifting device. 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).

Analysis shall be provided per section 5.5. A weld DPT NDE shall be carried out. The design limit shall be at least a safety factor of 3 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 dewar.

4.11 Nameplate and Markers

The Dewar shall have a nameplate, suitable for outdoor service, mounted on the external surface for identification. The following information shall be contained on the nameplates:

1. Contractor's name and address

2. Vacuum Vessel nameplate with design conditions.

3. ASME U Name plate of the ASME stamped vessel with duplicate on outside of Dewar

4.12 Instrumentation and Equipment Protection

The Contractor shall ensure that all items have some form of protection to prevent accidental knocking or loading from human error. Items such as, but not limited to, sensors, valves, and flanges shall be designed to prevent accidental human error loads, either by keeping such components out of typical work paths or using supplemental guards. Such guards, as a minimum, s h a l l be simple sheet metal U-shapes welded over the components to prevent accidental damage.

The components shall be reviewed once the layout is complete and items that require protection shall be identified. BSA reserves the right to make the final decision on the items that shall need protection.

4.13 Earth Electrical Ground connection

A stud or tapped hole shall be provided on leg/support welded to the vacuum shell to allow bolting of an electrical ground tie-in. Equipment Grounding terminal shall conform to NEC 250.126, connector option (3): A green pressure wire connector. The terminal shall be marked with informational note symbol figure 250.126. Paint shall be removed radially 0.5” from the hole. At a minimum, a ¼”-20 UNC stud with at least 1” length shall be provided. Electrical continuity shall be maintained in all parts attached to the ground connection. If not, additional earth ground connections shall be provided.

4.14 Vessel Supports

The vessel shall be supported by Circular base forklift lifting provision. The Circular base shall have a flat surface so that they can be bolted to the concrete floor. Circular base shall have a minimum strength to support 3 times the entire weight of the entire vessel. 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.

4.15 Installation Instructions

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The Contractor shall provide all information to BSA for items that require assembly on site. Such information includes drawings and procedures detailing sequence of installation, lifting procedures, welding purge paths, details on hardware safety during installation, and torque rating for all fasteners.

For installation of electrical and control panels and junction boxes, all necessary installation and wiring diagrams shall be provided. The instructions shall be in a report outline format, listing the order of installation in each subsequent step. The instructions shall be clear since it shall be used to generate safety procedures for the installation. The instruction shall be used to review the physical access to parts of the design as well as aspects not fully captured on general arrangement drawings.

For instance, MLI is typically not included in a 3D model, however its presence requires specific precautions and procedures when welding to prevent fires through sparks or heat conduction. A preliminary copy of the installation instructions shall be submitted to BSA before the Final Design Review (FDR).

4.16 Seismic and Transport Design Condition

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

4.17 Construction/Layout/Location Requirements

The Contractor shall provide envelope 3-D models or 2D drawings of the Dewar including subcooler

5 VERIFICATION/ANALYSES

5.1 Valve sizing

The Contractor shall provide minimum sizes for the following valves.

Valve Cv Subcooler Inlet 2.5 Subcooler Outlet 2.5 Liquid draw 2.5

5.2 Pressure vessel code analysis

Vessels and heat exchangers shall meet ASME BPV VIII Div 1 or 2 code and be U stamped as listed below. Documents shall be submitted for each item and submitted as stated in the SOW

CA6000049SOW.

If this is an existing design, a certificate stating that the vessel has been engineered and manufactured per relevant ASME code, the U-stamped plate information, and form U-1A and associated quality documents shall be submitted per SOW CA6000049SOW.

5.2.1 Dewar with subcooler and heater

1. Dewar: ASME BPVC VIII Div.1/2,

2. Subcooler Coil: ASME B31.3; or Subcooler exchanger: if size is greater than 6 inches diameter: ASME BPVC VIII Div.1/2

3. Vacuum vessel design shall follow at a minimum BNL-8715-2008-IR Vacuum Systems

Consensus Guidelines for DOE Accelerator Laboratories.

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5.3 Pressure relief devices analysis

Pressure relief analysis shall include the following items.

1. Criteria for and duty rating calculation for each volume protected by relief (s)

2. The mass flow rate for each relief using the CGA S-1.3 indicated in the specification.

3. The selected relief device’s manufacturer and model number with its specification information added to the appendix of the report or in the drawings.

Structural design

The Contractor shall submit the G-force information that the dewar has been designed to for shipping purposes and the shipping supports that will be used.

For overseas shipment the following design loads shall be followed:

The system shall be designed to handle the following transportation / seismic loads:

Transportation Seismic Forward 1g 0.25g Backward 1g 0.25g Sideway/ Lateral 1g 0.25g Downward 3g 0.25g Upward 2g 0.25g

5.4 Lifting lug analysis

If applicable the lifting lug analysis shall include the following items.

1. Rigging method

2. Criteria for each type of lug and material yield value

3. Design limit and full weight capacity sizing

4. A summary table indicating the calculated stress and the safety factor for each loading case

5.5 Piping Connections

Where the piping model shall need to interface with existing pipelines and provide connections for future systems, the ends of the piping provided shall be assumed to be fixed anchors in the analysis model. The fixed anchor assumption shall apply unless a more realistic case can be determined or where an interface boundary condition is given by BSA. Vessel interfaces shall be modeled as well as vessel supports to accurately represent stresses and displacements. If separate models are created for each segment, then the Contractor shall ensure consistency between interfacing components. BSA shall have final approval of all piping constraints applied to the model.

5.5.1 Analysis Requirements

The piping analysis shall meet ASME B31.3 latest version.

For a simple single line small diameter route between 2 points, an isometric sketch with size and wall thickness can be submitted for review. For a line that ties together at more than 2 locations to other lines, a pipe flexibility analysis is required.

The Contractor shall perform the Piping flexibility/stress analysis per the design code, rating and conditions for the piping specified.

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