3. Enclosure 1, Attachment (A) SOW C-AD_Cyclo.pdf

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RFP 462624 - Power Control & Regulating System for AGS Motor Generator Set (Cycloconverter)
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462624
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This is a Statement of Work (SOW) for the procurement of a power controller/regulator system for the AGS (Alternating Gradient Synchrotron) Motor Generator Set at Brookhaven National Laboratory, managed by Brookhaven Science Associates (BSA). The document outlines comprehensive contractor responsibilities for designing, manufacturing, testing, installing, and commissioning a cycloconverter that controls input power to a 9 MW wound rotor induction motor driving a 95 MVA generator. The system must regulate power between 1 MW and 9 MW with repetition rates of one to six seconds, controlling both real and reactive power supplied by the utility while maintaining reactive power as close to zero as possible.

The contractor must conduct preliminary design review (PDR) at week 8 and final design review (FDR) at week 12 post-award, with delivery of equipment scheduled for week 85 and commissioning/testing completion by week 100. Key deliverables include detailed design documentation with five sets of schematic diagrams, cabinet layouts, parts lists, manufacturing schedules, preliminary test procedures, wiring schedules, and plumbing diagrams. The contractor is responsible for all manufacturing, inspection, testing, tooling, fixtures, transducers, sensors, controls, and specialized rigging equipment. Installation will be performed by BNL with contractor engineering support and inspection. The SOW mandates compliance with specification C-AD-1369, ASME B30.26 rigging standards, NFPA 70 electrical standards, and requires NRTL-approved auxiliary power supplies. Quality assurance includes documented quality systems, configuration management, M&TE calibration to NIST standards, and comprehensive failure reporting with corrective action procedures. Final inspection and acceptance testing at BNL must be completed within 120 days of equipment delivery, with contractor engineering staff on-site for approximately six weeks during system integration and commissioning.

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Brookhaven National Laboratory Number: D04-M-2409sow Brookhaven Science Associates Date: 2/20/2025

Collider Accelerator Department Revision: A

ECN#: N/A

C-AD SOW Template V2

STATEMENT OF WORK

for the

Power Control and Regulating System for the AGS Motor Generator Set

(Cycloconverter)

Prepared by

Approved by

Jon Sandberg/C-AD Chief Electrical Engineer

Approved by

Ioannis Marneris/AGS PS Group Leader

Approved by

Edward Bajon/Electrical Engineer

Approved by

Wolfram Fischer/C-AD Department Chair

Approved by

Rob Michnoff / Acting Division Head

David Passarello/ Configuration Management

3/25/2025

3/25/2025

3/25/2025

3/25/2025

3/25/2025

3/25/2025

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

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D04-M-2409sow Page 3 of 19

REVISION HISTORY

REV DESCRIPTION DATE AUTHOR ECN # APPROVED BY

A First Issue 01/24/2025 Jon Sandberg N/A See cover page.

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CONTENTS

1 SCOPE

2 APPLICABLE DOCUMENTS

3 REQUIREMENTS

3.1 Contractor Responsibilities

3.2 Design and Manufacturing Requirements

3.3 Management

3.4 Design Reviews

3.5 Documentation and Data Management

3.6 Software Requirements

3.7 Environment, Safety and Health (ESH)

3.8 Marking and Serialization

3.9 Packaging

4 QUALITY ASSURANCE

5 DELIVERABLES

6 SCHEDULE

7 VALUE ENGINEERING

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1 SCOPE

This Statement of Work (SOW) will be the basis for the procurement of a power controller/regulator to control the input power to a 9 MW wound rotor induction motor which drives a 95 MVA salient pole Generator. This Motor Generator Set will be used at the Alternating Gradient Synchrotron (AGS) at Brookhaven National Laboratory (BNL) managed by Brookhaven Science Associates (BSA). This document outlines the Contractor’s responsibilities and obligations necessary for completing the requirements as set forth herein.

1.1 Background

The AGS contains a string of 240 magnets (0.75 Henries, 0.26 Ohms total load) which are continuously cycled from several hundred Amperes to 6150 Amperes D.C. with a repetition rate of from one to six seconds. In order to buffer the incoming A.C. power line from this large pulsating load, the D.C. (rectifier/inverter) power supply which energizes the AGS magnets is fed from a Motor Generator (MG) set. The input power drawn by the motor is controlled by an automatic power controller/regulator in the form of a cycloconverter feeding the motor’s wound rotor. The regulator controls the A.C. input power to the motor by dynamically controlling the motor rotor currents. This allows control of both the real and reactive power supplied by the utility. The reactive power is required to be as close to zero as possible for all cycles. The magnitude of the real power changes depending on the chosen Physics cycle but must remain constant throughout the chosen cycle. The input average power requirements can change between 1 MW and 9 MW. The input power is controlled by a cycloconverter and its associated electronics.

The operating parameters for the new power regulator and the existing power transformer are given in the Specification C-AD-1369, “Specification for the Power Control and Regulating System for the AGS Motor Generator Set (Cycloconverter)”. After award of contract no deviation from this document is permitted unless written approval is obtained from the Contract Specialist.

1.2 Definitions/Acronyms

A.C. Alternating Current AGS Alternating Gradient Synchrotron ASME American Society of Mechanical Engineers ATP Acceptance Test Procedure COTS Commercial Off The Shelf Cyclo Cycloconverter Power Regulator D.C. Direct Current FDR Final Design Review MG Motor Generator M&TE Measuring and Test Equipment NFPA National Fire Protection Association NRTL Nationally Recognized Test Laboratory PDR Preliminary Design Review

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PO Purchase Order

2 APPLICABLE DOCUMENTS

In the event of a conflict between the Technical Documentation and the SOW, the Contractor shall immediately notify the BSA Contractual Representative who shall in each instance determine which document takes precedence and advise the Contractor accordingly. Failure to notify BSA of a document conflict shall not relieve the Contractor’s responsibility to ensure full compliance to all requirements.

The following documents are an integral part of the SOW; the applicable revision level will be the latest that is in effect at the time of award:

Document Number Document Title spec_CAD-1369 Specification for the Power Control and Regulating System for the AGS Motor Generator Set (Cycloconverter)

ASME B30.26 Rigging Hardware

3 REQUIREMENTS

In accordance with the applicable specifications, referenced documents, and instructions as defined in this Statement of Work, the Contractor shall be responsible for designing, manufacturing, inspecting, testing, delivering, partially installing, and commissioning of the Cyclo.

The Cyclo must seamlessly interface with the existing motor, and it is therefor essential that the Contractor have documented experience with successfully building cycloconverters for machines of this class and size. The Contractor’s proposal shall enclude references for cycloconverters built for similar machines functioning in a similar manner.

3.1 Contractor Responsibilities

3.1.1 Technical Performance

In accordance with this SOW, BSA technical specification spec_CAD-1369, and all referenced documents, the Contractor shall furnish all equipment, materials, tools, facilities and labor to perform the work necessary to manufacture and test the Cyclo.

3.1.2 Tooling/Fixtures/Test Equipment

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The Contractor shall be responsible for supplying all materials, including (but not limited to) the construction of all tools, jigs, fixtures, and test equipment required to meet the requirements of this SOW and the specification.

3.1.3 The Contractor shall supply a description of rigging equipment need to unload, move, and install the supplied equipment. Any specialty rigging devices shall be supplied by the Contractor as agreed upon at the Final Design Review (FDR).

3.1.4 The Contractor shall supply calculations showing the expected heat rise for the chosen semiconductors.

3.1.5 If the Contractor proposes switching devices other than SCR’s it is the Contractor’s responsibility to provide documented proof that the proposed devices are properly protected. Such proof shall accompany the Contractor’s proposal.

3.1.6 If the Contractor proposes switching devices other than SCR’s it is the Contractor's responsibility to provide document proof of what the maximum dv/dt the motor rotor insulation will see and how that compares to acceptable values for similar insulation types. The existing insulation system of the motor rotor date to the late 1980’s.

3.1.7 The Contractor shall supply all transducers, sensors, local and remote operating controls, remote interface equipment, and ancillary equipment needed to manufacture, test, install and operate the power control system. System installation will be performed by BNL. System integration, commissioning, onsite testing, and initial turn on shall be a joint effort between the Contractor and

BNL.

3.1.8 The Contractor shall design all necessary circuitry that synthesizes and synchronizes the three rotor currents supplied by the cycloconverter to the motor rotor.

3.1.9 The Contractor shall provide a set of three phase overvoltage protection devices at the output of the cycloconverter. Presently this is being done with Selenium Rectifiers.

Selenium Rectifiers are preferred but the Contractor may propose alternative solution in their proposal. These protective devices shall limit the voltage to a safe value (<700 volts) and provide 24 volt alarm and trip contacts /signals when actuated. The trip settings on these devices shall be adjustable from 50% to 110 % of maximum voltage.

Firing of these devices shall engage the liquid rheostat and trip the cycloconverter off.

Contacts shall be provided to trip the old cycloconverter off as well. It is BNL intention to keep the old cycloconverter as a working backup for the new equipment. The Contractor shall describe this protective system in their proposal.

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3.1.10 Installation

BNL will supply all labor required to install the equipment purchased under this specification. The Contractor shall provide detailed recommendations on how best to install the equipment and engineering assistance and collaboration during this process.

The Contractor shall supply documentations including a point-to-point wiring schedule and recommended wire size list. The Contractor’s engineering staff will collaborate with the BNL engineering staff during this process as questions arise. The Contractor shall inspect the installation at least three times before the completion of the installation The Contractor shall supply complete installation instructions and equipment drawings necessary to install the delivered equipment prior to the delivery of the equipment to BNL. The supplied documentation shall include point to point wiring schedules including wiring type, water piping diagrams and flow requirements, required cabinet layouts which will be discussed with and approved by BSA during the FDR. In addition, rigging instructions including the size and weights of each piece of equipment shall be supplied.

The Contractor shall inspect the installation before the equipment is energized and be present for initial startup, commissioning, and final acceptance.

3.1.11 Spare Parts/Special Tools

If any special tools are required to properly install, operate or maintain this equipment they shall be supplied by the Contractor with the equipment.

The Contractor shall supply BSA with a list of recommended spare parts. BSA will decide upon the purchase of these spare parts under a separate contract.

3.1.12 Materials

The Contractor shall have an effective storage and age control system for items (such as epoxy) where acceptability is limited by the age or manner of storage of the item.

3.1.13 Government Furnished Material

In support of the Contractor’s work, BSA will provide the following material to be used in the execution of this Contract:

External cabling and external water piping necessary to install and operate the supplied equipment.

Standard rigging equipment needed to unload, move, and install the supplied equipment at BNL will be supplied by BSA however any specialty rigging equipment shall be furnished by the Contractor.

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3.2 Design and Manufacturing Requirements

3.2.1 Detailed Design Requirements are found in the Specification spec-CAD-1369

3.2.1.1 Preliminary Design Review (PDR) Report

The Contractor shall be responsible for providing a PDR report that reflects the state of the developed design. The PDR report shall consist of the following items to be addressed in detail and supported by preliminary calculations that shall be presented at the PDR for review and approval.

The Contractor shall submit to BNL a preliminary design including five (5) sets of schematic diagrams, cabinet outline drawings, control panel layouts, a parts list, a manufacturing schedule, and a preliminary test procedure.

3.2.1.2 Final Design Review (FDR) Report

The Contractor shall be responsible for providing an FDR report that reflects the state of the developing design as it evolved from the PDR. The Contractor shall be responsible for developing the overall design of the Equipment in accordance with the applicable specifications and supporting documents as identified herein.

The Contractor shall perform the tasks listed below, with the results to be included in the Final Design Review Report for review and approval in writing by

BSA.

The Contractor shall present a detailed design including five (5) sets of schematic diagrams, cabinet outline drawings, control panel layouts, a parts list, a manufacturing schedule, a preliminary wiring schedule including cable types, and a plumbing diagram. Electrical safety aspect of the equipment such as lock out tagout methods and arc flash reduction techniques should be discussed.

Installation , commissioning, and initial operations shall be discussed, and details finalized. This information shall be supplied at least three (3) weeks before the actual FDR to allow BSA to prepare for the meeting.

3.2.1.3 Approval to Proceed

BSA must approve in writing the Final Design Review Report, including any modifications introduced at the Final Design Review, before the Contractor proceeds with ordering of material and components. Ordering of long-lead-time materials and components prior to the approval of the Final Design Review Report must be reviewed and approved in writing by BSA.

3.2.2 Manufacturing Requirements

Manufacturing requirements and testing requirements are described in the Specification, spec_CAD-1369.

3.2.3 Acceptance Test Procedures (ATP)

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The Contractor shall provide an ATP that is in accordance with this SOW, the Specification, and all reference documents noted herein. The ATP must be approved in writing by BSA prior to use. The ATP shall ensure that all test requirements as defined in the Specification are achieved. This test plan shall include factory acceptance testing and acceptance testing at BNL under the direct supervision of the Contractor’s Engineering staff.

All testing shall be fully document by the Contractor and delivered to BNL upon acceptance of the equipment.

3.3 Management

3.3.1 Program Plan

Within six (6) weeks after award of contract, the Contractor shall deliver a detailed program plan which includes a milestone schedule defining the design validation, manufacturing, inspection, testing, installation and commissioning phases in sufficient detail to allow regularly scheduled progress monitoring.

3.3.2 Progress Teleconference

Within eight (8) weeks after award of contract, bi-weekly program technical and progress teleconferences and/or meetings between the Contractor and BSA shall be held at a mutually scheduled time. The discussions shall include the Contractor’s progress, technical and contractual questions, presentations of analysis or testing results, design reviews, value engineering, trouble shooting, material status, tooling status, resources, and manufacturing issues.

3.3.3 Manufacturing/Inspection/Test Plan

A manufacturing/inspection/test plan shall be developed which identifies the manufacturing processes required to complete all efforts as identified in this SOW. The plan shall be submitted for review and approval by BSA within eight

(8) weeks after award of contract.

The plan may be a single document or may make use of existing travelers or other suitable planning and control documents. It shall address the Material Requirements Planning (MRP), and at a minimum include manufacturing, inspection, and test steps including identification of critical manufacturing operations and parts/subassemblies showing integrated flow into the end item(s).

If the Contractor does not have an MRP system in place, then details for purchasing all raw materials, shop loading (by work center), and a schedule for manufacturing all components and assemblies through packaging and shipping shall be provided by the Contractor.

3.3.4 Performance Reporting

Throughout the life of the contract, the Contractor shall supply a written report by the fifth of every month to the BSA technical representative and contractual representative clearly detailing progress through the prior month with respect to

D04-M-2409sow Page 12 of 19 the program. This shall include milestone charts, detailed progress, open items, problems, recommended solutions, and risk mitigation.

3.3.5 “Witness” Points BSA reserves the right, after review of the Contractor Manufacturing Plan, to designate selected manufacturing, inspection, and/or test operations as “witness” points. Contractor shall provide BSA with fifteen (15) working days’ notice in advance of such witness points during the manufacturing and test cycle.

3.4 Design Reviews

3.4.1 Preliminary Design Review Meeting

A PDR meeting shall be held in accordance with the schedule set forth in section 6 herein. To ensure that the requirements are compliant with this SOW and applicable specifications, the Contractor shall provide, no later than ten (10) working days prior to the scheduled meeting, a draft PDR Report that shall consist of the requirements set forth in section 3.2.1.1. The contents of this report shall be reviewed at the PDR to be held at the Contractor’s facility in video conference format. BNL may either choose to attend the PDR in person or attend virtually.

The Contractor shall be responsible for maintaining and submitting the minutes of the PDR and shall also incorporate any agreed-to changes into the final comprehensive PDR Report, both of which shall be submitted within ten (10) working days after the PDR for subsequent review and written approval by BSA.

3.4.2 Final Design Review Meeting

A FDR meeting shall be held in accordance with the schedule set forth in section 6 herein. The Contractor shall provide, no later than fifteen (15) working days prior to the scheduled meeting, a draft FDR Report that shall consist of the requirements set forth in section 3.2.1.2. The findings of the FDR Report shall be reviewed at the FDR to be held in person at BNL and shall cover all pertinent issues relating to the final detailed design of the Equipment. The Contractor shall be responsible for maintaining and submitting minutes of the FDR and shall also incorporate any agreed-to changes into the final comprehensive FDR Report, both of which are to be submitted to BSA within fifteen (15) working days after the FDR for subsequent review and approval. After written approval of the FDR report by BSA, the Contractor shall promptly begin manufacturing the Equipment.

Upon written approval of the FDR report the design is to be considered “frozen” and no changes are permitted to the design, materials, processes, methods, and tooling, or component-level substitutions, without written approval by BSA.

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3.5 Documentation and Data Management

3.5.1 Report/Documentation Format

All reports submitted shall include an introduction, body of the documents, and a conclusion. Large documents shall include a table of contents. For calculations, equations shall be shown with values for each variable, so the analysis can be reviewed. Diagrams shall be included for clarity and labels shall be consistent with design drawings for specific items.

All documentation provided by the Contractor shall be in English.

The Contractor shall provide an electronic copy (email, plus either CD ROM or USB data storage device) of all documentation required by this SOW.

Contractor manufacturing drawing Computer-Aided Design files of all components and assemblies shall be in one of these formats: STP, SAT, IGS, IAM, or IPT.

3.5.2 Engineering Drawing Practices

All Contractor-generated engineering drawings shall be in accordance with ASME Y14.100, Engineering Drawing Practices. All dimensions and tolerances shall be U.S. Customary units with metric (SI) units as a secondary notation.

3.5.3 End Item Documentation Package

The Contractor shall provide with the end item documentation package an electronic copy and five (5) physical copies of the following documentation packages in accordance with the schedule set forth in this SOW. The End Item documentation package shall consist of all documentation identified in this SOW and include the following:

a. Manufacturing Travelers: Manufacturing Travelers that include documentation of visual and dimensional inspections, materials, cleaning procedures, vacuum bake-outs, etc. shall be provided.

b. Final Inspection and Test Reports: Final test reports of all required or necessary inspections, examinations, and tests, properly validated by the Contractor’s authorized personnel shall be recorded and compiled in a measurement and test report and be supplied to BSA.

c. Material Test Reports: Copies of material test reports for specified materials, showing physical and chemical properties.

d. Nonconformance Reports: Nonconformance reports identified as “rework / repair” or “use-as-is” shall be provided

e. A listing of the as-built configuration of each delivered item; this may be defined by the use of drawing numbers and revisions, unique parts lists or other such means of positive identification

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f. Certificate of Conformance The Contractor shall provide a Certificate of Conformance that certifies the following:

Materials used are those which have been specified by the BSA, and that the items delivered were produced from materials for which the Contractor has on file, reports of chemical or physical analysis, or any other equivalent evidence of conformance.

Processes used in the fabrication of items delivered were in compliance with the SOW or BSA approved procedures or specifications.

The items as delivered comply with all applicable drawings, specifications, deviations/waivers and other requirements of the procurement documentation.

g. Wiring schedules including wire type

h. A Complete set of as built drawings bothe electronic and hard copy.

3.5.6 Records

The Contractor shall retain objective evidence, including records, of the inspections and tests performed in the course of manufacturing, testing, inspecting, preserving, packaging, and preparation for shipment of procured items. These records shall be made available to BSA for review upon request.

These records shall be maintained for a minimum of three (3) years, unless otherwise specified in the procurement documentation, after the completion of the Purchase Order (PO)/Contract.

3.6 Software Requirements

All control software provided under this contract shall be subject to review and approval by BSA. Source code shall be included with the deliverables in electronic formate. The exact formate of the code to be agreed upon at the PDR.

3.6.1 Software Configuration Control

The Contractor shall have and maintain an effective software configuration management system. The Contractor's system shall establish requirements for placing software under configuration control and provide for the positive identification of software and the control of all software baseline changes.

3.6.2 Software Review

Software designed by the Contractor shall be validated through independent technical review. The Contractor shall document review activities, including comments and resolutions of comments. Contractor software designs and review documentation shall be subject to review and approval by BSA at the FDR

3.6.3 Software Validation

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The Contractor shall test and verify computer software developed or modified to fulfill the requirements as set forth herein. The validation testing shall be accomplished by a comparison of test results with those from other verified software, or by a comparison with results from analytical solutions or BSA-approved alternatives.

3.7 Environment, Safety and Health (ESH)

The Contractor shall design and build all equipment in accordance with ESH requirements in the appropriate specifications, codes, standards, and other documents listed in Section 2 of this SOW such as:

Pressure safety Fire Contractor Work on Site at BNL Material Handling: Any lifting hardware supplied by the Contractor must meet BSA safety requirements, and as such shall be designed according to ASME B30.26, “Rigging Hardware.”

Electrical safety All electrical distribution equipment shall be in accordance to U.S. standards, and must comply with NFPA70 (2020). All commercial off-the-shelf (COTS) auxiliary power supplies shall be approved by a Nationally Recognized Testing Laboratory (NRTL) – see this link for approved certification marks;

http://www.osha.gov/dts/otpca/nrtl/nrtlmrk.html.

In the event the equipment cannot be NRTL approved, exceptions must be approved in writing by BSA and the Contractor shall determine the equipment to be safe for the intended use. The determination must be documented and approved by a trained BSA inspector upon delivery to BNL.

All exposed uninsulated electrical connections ≥50 volts shall be covered to comply with U.L. Standard 508 so that workers are protected from the hazards of elecrical shock from all uninsulated charged surfaces. Plexiglas is not allowed; Lexan® may be used. Electrical insulation must be Low Smoke, Zero Halogen, and Fire Retardant.

3.8 Marking and Serialization

Where labeling is required, the position of serialization and/or labeling of the identification number/nameplate shall be agreed upon between the Contractor and BSA prior to acceptance of final design.

3.9 Packaging

In preparation for shipping, all supplied equipment shall be covered or wrapped for protection against weather elements, dust, and damage to projections, shock loads i.e. G-shock measurements, impacts, and rubbing. The supplied equipment shall be properly

D04-M-2409sow Page 16 of 19 braced and cushioned within the packing so that it will not shift during handling and shipment. Crates shall be marked with their center of gravity. The method of shipping will be specified by BSA one month prior to delivery.

4 QUALITY ASSURANCE

4.1 Quality System and Facility Access

The Contractor shall maintain a documented quality assurance system, which provides the processes to ensure that each component produced for acceptance conforms to the requirements of this document and the applicable technical documentation. The quality system shall be available for review. BSA representatives shall have access to the Contractor’s facility during agreed upon fabrication, inspection and testing processes. These agreed upon witness points shall be determined during the FDR. The Contractor shall provide fifteen (15) working days’ notice in advanced of the agreed upon witness points. BNL reserved the right to visit and inspect the Contractors facilities anytime during fabrication and testing upon giving the Contract fifteen

(15) working days’ notice before such visits.

4.2 Configuration Management

The Contractor shall establish and maintain a system to assure that all end items are of the proper configuration, and that all approved configuration changes are incorporated at the specified affected points. Records shall be maintained verifying the configuration of each item. The Contractor shall immediately notify the BSA Contractual Representative of any significant changes (those that may affect form, fit, function, reliability, safety, or interchangeability) in design, fabrication methods, material or processing.

For changes in configuration, a request for change approval shall be submitted to BSA for consideration. Changes in configuration may be made by the Contractor only with the written approval of BSA.

4.3 Responsibility for Subcontractor

It is the responsibility of the Contractor to impose applicable technical and quality requirements upon their subcontractors. BSA reserves the right to disapprove, in writing,of any subcontractor.

4.4 Responsibility for Conformance

The Contractor is responsible to provide items which conform to the requirements of the PO/Contract regardless of any assessments, surveillances, inspections and/or tests by BSA or its representatives at either the Contractor’s or BSA’s facility. The Contractor is responsible for notifying the BSA Contractual Representative of any recalls or alerts associated with this PO/Contract.

4.5 Measuring and Test Equipment (M&TE) Calibration

The Contractor shall calibrate any M&TE used in the fulfillment of the PO/Contract requirements against certified standards that are traceable to national standards such as the National Institute of Standards and Technology (NIST), or an international standard, or a

D04-M-2409sow Page 17 of 19 physical constant. The Contractor shall notify BSA of any condition found during the calibration, servicing or repair of measuring and test equipment that can affect the end item requirements.

4.6 Inspections and Test Requirements

Unless otherwise specified in the PO/Contract, the Contractor shall be responsible for the performance of all inspections and tests specified herein. Except as otherwise specified in the PO/Contract, the Contractor shall utilize facilities suitable for the performance of the inspection and test requirements, specified herein, which are acceptable to BSA. BSA reserves the right to re-perform any of the inspections and/or tests set forth in this document or referenced specifications where deemed necessary to assure that supplies and services conform to prescribed requirements at no cost to the Contractor. BSA and/or their representative shall have the option to witness all the tests defined in this SOW.

4.7 Rework and Repairs

If failures occur or repairs are required to an assembly or any component during manufacturing or testing that affects form, fit, function, reliability, safety, or interchangeability the process shall stop and BSA shall be immediately notified. BSA at their discretion may ask for retesting, additional review and evaluation to determine root causes, analyses of failure modes(s) or proposals for repair. Proposals for repair shall include adequate information for evaluating the repair, testing the effectiveness of repair, and methods to prevent damage to the existing work.

No proposed repair shall be initiated without approval of BSA. No repair shall be considered successfully accomplished without inspection and written approval by BSA. All repairs shall be at the expense of the Contractor.

4.7 Failure Reporting, Analysis and Corrective Action

The Contractor shall maintain a failure reporting, analysis, and corrective action system which shall, as a minimum, evaluate, analyze, and correct failures occurring during end-item acceptance testing and inspection. The results of all failure evaluations and analyses shall be documented and available for review by the BSA Contractual Representative.

4.8 Final Inspection

4.8.1 For the purposes of warranty, final inspection is defined as the successful completion of commissioning and acceptance testing at BNL to substantiate compliance with the specification. After the installation phase the Contractor shall participate in the system testing, integration and commissioning of the equipment at BNL. BNL engineers and technicians will do hands on commissioning of the equipment under the direction of engineers from the Contractor. It is anticipated that the Contractor engineers will be at the BNL site for a period of approximately six weeks. The Contractor will state in their proposal the best estimate of the time required for system integration and commissioning at BNL, and the proposed number of personnel required for these tasks

4.8.2 Final commissioning and acceptance testing at BNL will be within 120 days of equipment delivery to BNL.

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5 DELIVERABLES

The Contractor shall supply the following:

Item Deliverable Due BSA Approval

1 Program Plan 6 weeks after award of contract Yes 2 Technical and Progress Reporting 8 weeks after award of contract/

Bi-weekly thereafter No

3 Performance reports 5th of each month after receipt of Program Plan No

4 Manufacturing/Inspection/Test Plan 8 weeks after award of contract Yes 5 Draft Preliminary Design Review Report 10 working days prior to PDR Yes 6 Final Preliminary Design Review Report 10 working days after PDR Yes 7 Draft Final Design Review Report 15 working days prior to FDR Yes 8 Final Design Review Report 15 working days after FDR Yes 9 BSA review of FDR 25 working days after FDR Yes 10 Delivery of equipment As set forth in contract Yes 11 End Item Documentation As set forth in contract Yes

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6 SCHEDULE

The following schedules are for planning purposes only. Schedule requirements set forth in the contract will take precedence.

Milestone Calendar weeks after award

Preliminary Design Review 8 Final Design Review 12 Wiring schedules complete and delivered to BNL 50 Equipment fabrication complete 77 Factory Tests complete 81 Delivery of Equipment to BNL 85 Installation and wiring complete 94 Commissioning and testing at BNL 100 Delivery of End Item Documentation 104

7 VALUE ENGINEERING

7.1 The Contractor is encouraged to propose alternate solutions for the power regulating system that would lead to an improvement in performance, reliability, quality, safety, or reduction in cost. Such justifications shall accompany the Contractor’s proposal and shall be evaluated by BNL. Acceptance of the Contractor’s proposal by BNL shall not limit the Contractor’s responsibility to satisfy all requirements of this specification. Simplicity in operation, ease of maintenance, and an improvement in the performance and reliability of the specific functions beyond the requirements of this specification are objectives which shall be considered in the production. Where it appears a substantial improvement in simplicity of design, performance, ease of maintenance or reliability will result from the use of materials, parts and processes other than those specified, it is desirable that their use be investigated. When investigations point to advantages that may be realized, the recommendation for change shall be presented to BSA for review.

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