A.2_SOW_EIC_B1pF_Collar_Laminations.pdf

Electron-Ion Collider, Brookhaven National Laboratory

Doc No. EIC-MSG-SOW-023 Author: C. Runyan Effective Date: September 17, 2025 Review Frequency: N/A

SOW: EIC B1pF Collar Lamination Machining Revision: 02

STATEMENT OF WORK

for the

EIC B1pF Collar Laminations Quality Classification: A-3

Prepared By:

________________________________________ Date: __________________ Chris Runyan, Cognizant Engineer

Reviewed By:

Henry Hocker, SMD QA Representative

Jesse Schmalzle, Cognizant Engineer

Maggie Haviland, EIC Procurement Liaison Engineer

Chuck Schaefer, EIC ESH Manager

Angelika Drees, EIC Superconducting Magnets, Deputy System Manager

Bill Wahl, EIC Superconducting Magnets, System Manager

Approved By:

Michael Anerella, Acting SMD Division Director

Docusign Envelope ID: 49ADF099-3D27-451A-98D2-E93F7BDECDC4

9/17/2025

9/17/2025

9/17/2025

9/17/2025

9/18/2025

9/17/2025

9/17/2025

9/18/2025

REVISION HISTORY

Revision # Effective Date Summary of Change

00 11/14/2024 Initial Release

01 12/09/2024 Updated description in scope and background to specify procurement of prototypes

02 9/17/2025 Updated to require Contractor to utilize BSA-supplied material, updated testing of first articles to indicate performance of testing by BSA, updated Section 5 Deliverables

Table of Contents

LIST OF ACRONYMS

1 SCOPE

1.1 Background

2 APPLICABLE DOCUMENTS

3 REQUIREMENTS

3.1 Contractor Responsibilities

3.1.1 Technical Performance

3.1.2 Tooling/Fixtures/Test Equipment

3.1.3 Inspection

3.1.4 Materials

3.1.5 Government Furnished Material

3.2 Manufacturing Requirements

3.2.1 Technical Requirements

3.2.2 Dimensional Inspections

3.2.3 Test Coupons

3.2.4 Non-Conformance

3.2.5 First Article

3.2.6 Approval to Proceed

3.2.7 Manufacturing Sequence

3.3 Management

3.3.1 Program Plan

3.3.2 Progress Communications

3.3.3 Manufacturing/Inspection/Test Plan

3.3.4 Performance Reporting

3.3.5 “Witness” Points

3.4 Documentation and Data Management

3.4.1 Report/Documentation Format

3.4.2 End Item Documentation Package

3.4.3 Records

3.5 Environment, Safety and Health (ESH)

3.6 Marking and Serialization

3.7 Packaging and Shipping

3.8 Storage

4 QUALITY ASSURANCE

4.1 Quality System and Facility Access

4.2 Configuration Management

4.3 Responsibility for Subcontractor

4.4 Responsibility for Conformance

4.5 Measuring and Test Equipment (M&TE) Calibration

4.6 Inspections and Test Requirements

4.7 Repairs

4.8 Failure Reporting, Analysis and Corrective Action

4.9 Notification of Change to Design, Methods, or Processes

4.10 Material Traceability

5 DELIVERABLES

6 SCHEDULE

7 VALUE ENGINEERING

LIST OF ACRONYMS

ASME American Society of Mechanical Engineers BNL Brookhaven National Laboratory BSA Brookhaven Science Associates CMM Coordinate Measuring Machine EIC Electron-Ion Collider ESH Environment, Safety and Health IAW In Accordance With IEC International Electrotechnical Commission IR Interaction Region ISO International Organization for Standardization LE Lead End LH Left Hand MRP Material Requirements Planning M&TE Measuring and Test Equipment NIST National Institute of Standards and Technology NLE Non-Lead End PO Purchase Order QA Quality Assurance RH Right Hand SMD Superconducting Magnet Division SOW Statement of Work Tck Thick

Statement of Work for the EIC B1pF Collar Lamination Machining

1 SCOPE

This Statement of Work (SOW) will be the basis for the procurement of prototype Interaction Region (IR) Magnet Collar Laminations to be used at the Electron-Ion Collider (EIC) 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 EIC Project will design, build, and install the accelerator hardware for a new electron storage ring, an electron injector, and modifications to the hadron ring required to produce an electron-ion collider and infrastructure. It will include one interaction region, with an allowance for a second, and one detector. The facility is designed to meet requirements to ensure high reliability and availability for the user program.

This SOW will be the basis for the procurement of Magnet Collar Laminations required for the B1pF prototype collaring assembly in the interaction region of the Electron-Ion Collider. The B1pF prototype magnet is being built to validate the design and uncover any uncertainties that would otherwise be found during construction.

2 APPLICABLE DOCUMENTS

In the event of a conflict between the Technical Documentation and this 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

Document Title

Revision

Hold or Witness Point

Dimensional Report (*)

SMD-EIC-RD2008.pdf

Procurement Specification, High Strength Non-Magnetic Austenitic Stainless Steel for EIC IR Magnet Collars

Rev B

RD64010521.stp B1pF Center Collar Rev B Note 1 Y

RD64010522.stp B1pF NLE Collar Rev C Note 1 Y

RD64010523.stp B1pF LE Collar Rev C Note 1 Y

RD64010524.stp B1pF Center End Collar LH Rev A Note 1 Y

RD64010525.stp B1pF Center End Collar RH Rev A Note 1 Y

RD64010527.stp B1pF LE End Collar Rev A Note 1 Y

RD64010529.stp B1pF NLE End Collar Rev A Note 1 Y

RD64010521.pdf B1pF Center Collar Rev B Note 1 Y

RD64010522.pdf B1pF NLE Collar Rev C Note 1 Y

RD64010523.pdf B1pF LE Collar Rev C Note 1 Y

RD64010524.pdf B1pF Center End Collar LH Rev A Note 1 Y

RD64010525.pdf B1pF Center End Collar RH Rev A Note 1 Y

RD64010527.pdf B1pF LE End Collar Rev A Note 1 Y

RD64010529.pdf B1pF NLE End Collar Rev A Note 1 Y

Collar_Layout_RD64010521.dxf Collar and Test Coupon Layout On Sheet for Straight Section Collars

Rev A

N

Collar_Layout_RD64010522.dxf Collar and Test Coupon Layout On Sheet for NLE Collars

Collar_Layout_RD64010523.dxf Collar and Test Coupon Layout On Sheet for LE Collars

ASME Y14.5 Dimensioning and Tolerancing Standard 2018 - -

*For Dimensional Report Formats: See section 3.4. For 1st articles, 100% inspection is required. For production articles, a sampling plan for contractor dimensional inspections shall be established IAW 3.3.3.

For note descriptions: See section 3.2.5.

3 REQUIREMENTS

In accordance with the applicable specifications, referenced documents, and instructions as defined in this SOW, the Contractor shall be responsible for manufacturing, inspecting, and delivering the B1pF Magnet Collar Laminations.

3.1 Contractor Responsibilities

3.1.1 Technical Performance

In accordance with this SOW 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 Magnet Collar Laminations. The Contractor shall ensure that the finished product meets the criteria in accordance with all referenced documents.

3.1.2 Tooling/Fixtures/Test Equipment

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 referenced documents.

3.1.3 Inspection

The Contractor shall be responsible for performing the dimensional and visual inspections throughout the machining process and maintaining records in compliance with this SOW.

3.1.4 Materials

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

3.1.5 Government Furnished Material

BSA shall supply materials in the form of either blanks or raw material to the Contractor.

The form of material shall be left up to the Contractor’s discretion as discussed in sections

3.2.3 and 3.2.7.

3.2 Manufacturing Requirements

3.2.1 Technical Requirements

Raw material shall be 10% minimum cold reduced 21-6-9 high strength austenitic steel, supplied by BSA and in accordance with SMD-EIC-RD2008.

3.2.2 Dimensional Inspections

Each component part shall meet the dimensional requirements of its respective drawing within the stated dimensional tolerance on the drawing. Any component part not meeting the stated dimensions, within stated tolerances, shall be rejected. Components which are oversized can be re-machined by the Contractor to bring them within the allowable tolerances. After re-machining, they must meet all of the requirements of this SOW.

First articles shall be inspected by BSA.

3.2.3 Test Coupons

Test coupons shall be cut from the provided sheets in designated areas shown in the layout document provided by BSA. Test coupons shall be extracted from each material thickness at specified intervals through the run, at the quantities specified in Section 5. Test coupons shall consist of:

3.2.3.1 Weld Test Coupon: 3.5” x 9” x Stock Sheet Thickness

3.2.3.2 2X Magnetic Test Coupons: 3.5” x 3.5” x Stock Sheet Thickness

3.2.3.3 2X Thermal Contraction Test Coupons: 2” x 2” x Stock Sheet Thickness

Proper traceability regarding which sheet each test coupon was cut from shall be maintained. Test coupons shall be labeled with the corresponding sheet serial number it was pulled from.

3.2.4 Non-Conformance

BSA does not grant authority to the Contractor for disposition of non-conformances. In such case, BSA shall be immediately notified of the non-conformance and may ask for additional information for evaluation. No proposed repair shall be initiated without approval of BSA in writing. No repair shall be considered successfully accomplished without inspection and written approval by BSA. All repairs shall be at the expense of the Contractor.

3.2.5 First Article

The first articles, shall be manufactured and submitted to BSA along with the required documentation for approval before proceeding to the manufacture of the production run.

• Note 1 in Applicable Documents table in Section 2 – For each part number: BSA approval of quantity four (4) first articles each of RD64010521, RD64010522, RD64010523, RD64010524, RD64010525, RD64010527, RD64010529 (refer to deliverables table in Section 5) required prior to machining of remaining parts.

3.2.6 Approval to Proceed

Manufacturing of the parts shall not commence until written authorization has been received from BSA.

3.2.7 Manufacturing Sequence

Drawings or drawing next-assembly listings will establish a BSA-described sequence of manufacturing. Any variation from such sequence shall be considered a non-conformance as described elsewhere in this SOW.

3.2.7.1 Individual parts shall be machined from the supplied material and a minimum of fourteen (14) Collars shall be furnished from each sheet. If fourteen (14) Collars cannot be achieved, the Contractor must communicate number of Collars per sheet which can be achieved and submit written communication to and receive approval from BSA before proceeding.

3.2.7.2 Parts and test coupons shall be cut from the area interior to a ‘no-go’ border of all edges of the sheet to avoid areas of rolling which create thickness and flatness regions which are out-of-specification. The size of the region of each sheet which is acceptable to create parts and test coupons is the interior 22 in. x 116 in. This region shall be located central to the sheet to the Contractor’s best abilities.

3.2.7.3 The layout of part and test coupon location and orientation on each sheet will be provided by BSA. If the number of Collars per sheet is negotiated to be fewer than fourteen (14), then an alternative collar layout shall be agreed upon by both parties.

3.3 Management

3.3.1 Program Plan

Within one (1) week after award of contract, the Contractor shall deliver a detailed program plan outlining the following:

a) Management Structure - the management for the project shall be identified by name and contact information.

b) Point of Contact – a project representative shall be identified to be the primary point of contact with BSA for this project.

c) Schedule - a milestone schedule defining the manufacturing operations, inspection, and test and hold checkpoints. See Section 6 for additional significant milestones and proposed dates of accomplishment to be included in the milestone schedule.

3.3.2 Progress Communications

Within two (2) weeks after award of contract, bi-weekly program technical and progress telecommunications 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, material status, 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 two (2) 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 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, to designate selected manufacturing and/or inspection operations as “witness” points. Contractor shall provide BSA with ten (10) working days’ notice in advance of such witness points during the manufacturing and inspection cycle.

The BSA Technical Representative shall review and provide written approval prior to shipment.

3.4 Documentation and Data Management

3.4.1 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 defined 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 (BSA-identified FTP, DVD 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, IGES, IAM, or IPT.

3.4.2 End Item Documentation Package

The Contractor shall provide a documentation package for each shipment of the item(s) supplied, which consists of objective evidence of compliance with Purchase Order (PO) requirements. This documentation package shall be complete, legible, indexed, and traceable to the item supplied. The package shall be compiled and supplied to BSA. The BSA Technical Representative shall review and provide written approval of the package prior to shipment. All required documentation provided by the Contractor shall be provided in electronic copy. The package, which shall consist of all documentation identified in this SOW, shall include the following:

A) Certificate of Conformance:

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

Materials used are those which have been specified by BSA.

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.

All items delivered meet dimensional, alignment, cleanliness, and packing requirements.

B) Inspection Reports Copies of all required or necessary inspections.

C) Nonconformance Reports:

Copies of nonconformance reports dispositioned as “rework/repair” or “use-as-is”, and all BSA-approved deviation/waivers.

3.4.3 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.

3.5 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 and 3 of this

SOW.

3.6 Marking and Serialization

Each pallet shall be identified with at least the following data. Marking labels shall be applied so they are visible on the top surface of each pallet.

Part Number / Rev Letter BSA Purchase Order (PO) Number Manufacturer's Name Heat Number(s) Gross Weight (lb.)

Quantity

3.7 Packaging and Shipping

The Contractor shall be responsible for all packaging, crating, preparation for shipment, and shipping. The Contractor shall obtain BSA approval before selecting a shipper. The packaging shall be sufficient to ensure safe delivery of the items to BNL and meet the requirements of the Contractor-selected shipper. Stacks of laminations shall not exceed six inches high. Each stack of laminations shall be placed in its own box or crate. They shall be securely banded to pallets. Pallet weights shall not exceed 3,000 lb.

All first article shipments shall be via Air-Freight or expedited ground shipping, whichever delivery method is fastest. The remaining shipments can be shipped via ground. Contractor shall contact BSA procurement representative to review shipping logistics and costs prior to shipment.

BSA’s representative shall be notified five (5) days prior to shipment of the item. This notification shall be in the form of an e-mail message. The BSA representative will provide all shipping details upon request.

3.8 Storage

Parts shall be stored while awaiting testing or return to BNL in an area out of the elements and not subject to high levels of moisture.

4 QUALITY ASSURANCE

4.1 Quality System and Facility Access

The Contractor shall maintain and apply an effective and documented quality assurance system for the design, manufacture, and testing of all equipment provided. The system shall meet the requirements of the ISO-9001 Standard, “Quality Management Systems Requirements”, and shall provide the processes to ensure that each component produced for acceptance conforms to the requirements of this document and the applicable technical documentation. The Contractor shall supply the necessary documentation to demonstrate this compliance. Post-award surveys may be required and shall be supported by the Contractor. In addition, BSA representatives shall have access to the Contractor’s facility during agreed-upon fabrication, inspection and testing processes.

The Contractor shall provide ten (10) working days’ notice in advance of the agreed-upon witness points.

As set forth in BSA BNL-QA-101, “Brookhaven National Laboratory Supplier Quality Assurance Requirements,” as amended herein, forms a part of this statement of work. Specifically, this includes the following sections: 3.1.4, 4.4.3, 4.5, 4.10.1, 4.16, 4.19, 4.23, and 4.39

Proper traceability regarding which sheet each test coupon was cut from shall be maintained as noted in Section 3.2.3.

4.2 Configuration Management

The Contractor shall establish and maintain a configuration control system to assure that all end items are of the proper configuration, and that all approved configuration changes are incorporated at the specified effectivity points. Records verifying the configuration of each item shall be maintained for a minimum of five (5) years from the date of acceptance of the equipment by BSA.

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 flow down and impose applicable technical and quality assurance requirements upon their contractors and subcontractors. BSA reserves the right to disapprove, in writing, any contractor or 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 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 equipment conforms to prescribed requirements at no cost to the Contractor. BSA and/or their representative shall have the option to witness all of the tests defined in this SOW.

4.6.1 Final acceptance of the units shall take place following the successful completion of final testing at BNL.

4.6.2 First Article Acceptance

BSA’s acceptance of first article(s) is required prior to the production run. The first article(s) shall be identified as such, including the PO number/contract, part number, and part name.

After BSA Technical representative acceptance of first article(s), all of the remaining units required by the PO/Contract shall be produced by the Contractor and the Contractor’s suppliers using the same design, materials, processes, methods and tooling that were used to manufacture the approved first article(s). Any changes must have prior written approval from BSA.

4.7 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 the 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. In addition, the Contractor shall not use nonconforming materials via use-as-is disposition without written approval of BSA.

4.8 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.

4.9 Notification of Change to Design, Methods, or Processes

The Contractor shall immediately notify the BSA Technical Representative of any changes in fabrication methods, materials, work locations, equipment used, or processing from those used by the Contractor at time of Contractors quotation or offer to the BSA Procurement Representative, which resulted in the PO. This shall be done prior to the change being made. Contractor must receive written approval from BSA Procurement Representative prior to the change being made.

BSA reserves the right to require such analysis and testing to ensure that changes will not have a deleterious effect on delivered items.

4.10 Material Traceability

Materials used must be identified by material type, applicable specification and revision number, and be traceable to their lot and/or heat number(s). Traceability records shall be available for review by the BSA representative.

5 DELIVERABLES

The Contractor shall supply the following:

Quantity Part Number Description Due Calendar Weeks After Award

BSA

Approval

1 - Program Plan 1 Y

1 - Progress Reporting 2 Y

1 - Manufacturing/Inspection/Test Plan 2 Y

1 RD64010521 First Article B1pF Center Collars 6 Y

41 RD64010522 First Article B1pF NLE Collars 6 Y

41 RD64010523 First Article B1pF LE Collars 6 Y

41 RD64010524 First Article B1pF Center End Collars RH 6 Y

41 RD64010525 First Article B1pF Center End Collars LH 6 Y

41 RD64010527 First Article B1pF LE End Collars 6 Y

41 RD64010529 First Article B1pF NLE End Collars 6 Y

13512 RD64010521 B1pF Center Collars 162 N

406 RD64010522 B1pF NLE Collars 16 N

554 RD64010523 B1pF LE Collars 16 N

793 RD64010524 B1pF Center End Collars RH 163 N

703 RD64010525 B1pF Center End Collars LH 163 N

50 RD64010527 B1pF LE End Collars 16 N

38 RD64010529 B1pF NLE End Collars 16 N

1 every 30 sheets - Weld Test Coupon: 3.5” x 9” for .1125” Thk

Material 13 Y

2 every 30 sheets - Magnetic Test Coupons: 3.5” x 3.5” for .1125”

Thk Material 13 Y

2 every 30 sheets

- 2” x 2” Thermal Contraction Test Coupons for .1125” Thk Material

6 Y

1 every 30 sheets - Weld Test Coupon: 3.5” x 9” for .090”

Thk Material 16 Y

2 every 30 sheets - Magnetic Test Coupons: 3.5” x 3.5” for .090” Thk

Material 16 Y

2 every 30 sheets

- 2” x 2” Thermal Contraction Test Coupons for .090” Thk Material

6 Y

1 - End Item Documentation Package IAW SOW - -

1) First article Collar Laminations to be completed first. Production to halt until BSA approval of first article Collars.

2) Quantity 128 RD64010521 to be delivered by calendar week 13 after award.

Remainder of parts to be delivered by calendar week 16 after award.

3) Quantity 10 RD64010525 and Quantity 10 RD64010524 to be delivered by calendar week 13 after award. Remainder of parts to be delivered by calendar week 16 after award.

6 SCHEDULE

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

Significant Milestones Calendar Weeks After Award

1 Contract Execution 0 2 Contractor Receipt of Material from BSA 2 3 Submittal of Manufacturing/Inspection/Test plan 2

4 BSA Receipt of collar lamination 1st Article Items (1 of 1 hold and witness points) 6

5 BSA Approval of collar lamination 1st Article Items (1 of 1 hold and witness points) 8

6 BSA Receipt of a minimum of Quantity 128 RD64010521, Quantity 10 RD64010524, and Quantity 10 RD64010525 13

7 Completion of Production Articles /Submission of End Item Documentation Package 15

8 BSA Authorization to Ship 16

7 VALUE ENGINEERING

The Contractor is encouraged to make recommendations for changes that might lead to an improvement in performance, reliability, quality, safety, or reduction in cost. 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.

STATEMENT OF WORK

for the

EIC B1pF Collar Laminations

Quality Classification: A-3

Prepared By:

________________________________________ Date: __________________

Chris Runyan, Cognizant Engineer

Reviewed By:

________________________________________ Date: __________________

Henry Hocker, SMD QA Representative

________________________________________ Date: __________________

Jesse Schmalzle, Cognizant Engineer

________________________________________ Date: __________________

Maggie Haviland, EIC Procurement Liaison Engineer

________________________________________ Date: __________________

Chuck Schaefer, EIC ESH Manager

________________________________________ Date: __________________

Angelika Drees, EIC Superconducting Magnets, Deputy System Manager

________________________________________ Date: __________________

Bill Wahl, EIC Superconducting Magnets, System Manager

Approved By:

________________________________________ Date: __________________

Michael Anerella, Acting SMD Division Director

Electron-Ion Collider, Brookhaven National Laboratory

Doc No. EIC-MSG-SOW-023

Author: C. Runyan

Effective Date: September 17, 2025

Review Frequency: N/A

SOW: EIC B1pF Collar Lamination Machining

Revision: 02

2 National Synchrotron Light Source II

Electron-Ion Collider, Brookhaven National Laboratory

Doc No. EIC-MSG-SOW-023

Author: C. Runyan

Effective Date: September 17, 2025

Review Frequency: N/A

SOW: EIC B1pF Collar Lamination Machining

Revision: 02

Version n 10 of 8 nnMon2009

Brookhaven National Laboratory

REVISION HISTORY

Revision #

Effective Date

Summary of Change

11/14/2024

Initial Release

12/09/2024

Updated description in scope and background to specify procurement of prototypes

9/17/2025

Updated to require Contractor to utilize BSA-supplied material, updated testing of first articles to indicate performance of testing by BSA, updated Section 5 Deliverables

Table of Contents

LIST OF ACRONYMS 6

1 SCOPE 7

1.1 Background 7

2 APPLICABLE DOCUMENTS 7

3 REQUIREMENTS 8

3.1 Contractor Responsibilities 8

3.1.1 Technical Performance 8

3.1.2 Tooling/Fixtures/Test Equipment 9

3.1.3 Inspection 9

3.1.4 Materials 9

3.1.5 Government Furnished Material 9

3.2 Manufacturing Requirements 9

3.2.1 Technical Requirements 9

3.2.2 Dimensional Inspections 9

3.2.3 Test Coupons 9

3.2.4 Non-Conformance 10

3.2.5 First Article 10

3.2.6 Approval to Proceed 10

3.2.7 Manufacturing Sequence 10

3.3 Management 11

3.3.1 Program Plan 11

3.3.2 Progress Communications 11

3.3.3 Manufacturing/Inspection/Test Plan 11

3.3.4 Performance Reporting 12

3.3.5 “Witness” Points 12

3.4 Documentation and Data Management 12

3.4.1 Report/Documentation Format 12

3.4.2 End Item Documentation Package 12

3.4.3 Records 13

3.5 Environment, Safety and Health (ESH) 13

3.6 Marking and Serialization 13

3.7 Packaging and Shipping 14

3.8 Storage 14

4 QUALITY ASSURANCE 14

4.1 Quality System and Facility Access 14

4.2 Configuration Management 15

4.3 Responsibility for Subcontractor 15

4.4 Responsibility for Conformance 15

4.5 Measuring and Test Equipment (M&TE) Calibration 15

4.6 Inspections and Test Requirements 15

4.7 Repairs 16

4.8 Failure Reporting, Analysis and Corrective Action 16

4.9 Notification of Change to Design, Methods, or Processes 16

4.10 Material Traceability 17

5 DELIVERABLES 17

6 SCHEDULE 18

7 VALUE ENGINEERING 19

Electron-Ion Collider, Brookhaven National Laboratory

Doc No. EIC-MSG-SOW-023

Author: C. Runyan

Effective Date: September 17, 2025

Review Frequency: N/A

SOW: EIC B1pF Collar Lamination Machining

Revision: 02

LIST OF ACRONYMS

ASME

American Society of Mechanical Engineers

BNL

Brookhaven National Laboratory

BSA

Brookhaven Science Associates

CMM

Coordinate Measuring Machine

EIC

Electron-Ion Collider

ESH

Environment, Safety and Health

IAW

In Accordance With

IEC

International Electrotechnical Commission

IR

Interaction Region

ISO

International Organization for Standardization

LE

Lead End

LH

Left Hand

MRP

Material Requirements Planning

M&TE

Measuring and Test Equipment

NIST

National Institute of Standards and Technology

NLE

Non-Lead End

PO

Purchase Order

QA

Quality Assurance

RH

Right Hand

SMD

Superconducting Magnet Division

SOW

Statement of Work

Tck

Thick

Statement of Work for the EIC B1pF Collar Lamination Machining

SCOPE

This Statement of Work (SOW) will be the basis for the procurement of prototype Interaction Region (IR) Magnet Collar Laminations to be used at the Electron-Ion Collider (EIC) 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 EIC Project will design, build, and install the accelerator hardware for a new electron storage ring, an electron injector, and modifications to the hadron ring required to produce an electron-ion collider and infrastructure. It will include one interaction region, with an allowance for a second, and one detector. The facility is designed to meet requirements to ensure high reliability and availability for the user program.

This SOW will be the basis for the procurement of Magnet Collar Laminations required for the B1pF prototype collaring assembly in the interaction region of the Electron-Ion Collider. The B1pF prototype magnet is being built to validate the design and uncover any uncertainties that would otherwise be found during construction.

APPLICABLE DOCUMENTS

In the event of a conflict between the Technical Documentation and this 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

Document Title

Revision

Hold or Witness Point

Dimensional Report (*)

SMD-EIC-RD2008.pdf

Procurement Specification, High Strength Non-Magnetic Austenitic Stainless Steel for EIC IR Magnet Collars

Rev B

RD64010521.stp

B1pF Center Collar

Rev B

Note 1

Y

RD64010522.stp

B1pF NLE Collar

Rev C

Note 1

Y

RD64010523.stp

B1pF LE Collar

Rev C

Note 1

Y

RD64010524.stp

B1pF Center End Collar LH

Rev A

Note 1

Y

RD64010525.stp

B1pF Center End Collar RH

Rev A

Note 1

Y

RD64010527.stp

B1pF LE End Collar

Rev A

Note 1

Y

RD64010529.stp

B1pF NLE End Collar

Rev A

Note 1

Y

RD64010521.pdf

B1pF Center Collar

Rev B

Note 1

Y

RD64010522.pdf

B1pF NLE Collar

Rev C

Note 1

Y

RD64010523.pdf

B1pF LE Collar

Rev C

Note 1

Y

RD64010524.pdf

B1pF Center End Collar LH

Rev A

Note 1

Y

RD64010525.pdf

B1pF Center End Collar RH

Rev A

Note 1

Y

RD64010527.pdf

B1pF LE End Collar

Rev A

Note 1

Y

RD64010529.pdf

B1pF NLE End Collar

Rev A

Note 1

Y

Collar_Layout_RD64010521.dxf

Collar and Test Coupon Layout On Sheet for Straight Section Collars

Collar_Layout_RD64010522.dxf

Collar and Test Coupon Layout On Sheet for NLE Collars

Collar_Layout_RD64010523.dxf

Collar and Test Coupon Layout On Sheet for LE Collars

ASME Y14.5

Dimensioning and Tolerancing Standard

*For Dimensional Report Formats: See section 3.4. For 1st articles, 100% inspection is required. For production articles, a sampling plan for contractor dimensional inspections shall be established IAW 3.3.3.

For note descriptions: See section 3.2.5.

REQUIREMENTS

In accordance with the applicable specifications, referenced documents, and instructions as defined in this SOW, the Contractor shall be responsible for manufacturing, inspecting, and delivering the B1pF Magnet Collar Laminations.

3.1 Contractor Responsibilities

3.1.1 Technical Performance

In accordance with this SOW 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 Magnet Collar Laminations. The Contractor shall ensure that the finished product meets the criteria in accordance with all referenced documents.

3.1.2 Tooling/Fixtures/Test Equipment

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 referenced documents.

3.1.3 Inspection

The Contractor shall be responsible for performing the dimensional and visual inspections throughout the machining process and maintaining records in compliance with this SOW.

3.1.4 Materials

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

3.1.5 Government Furnished Material

BSA shall supply materials in the form of either blanks or raw material to the Contractor. The form of material shall be left up to the Contractor’s discretion as discussed in sections 3.2.3 and 3.2.7.

3.2 Manufacturing Requirements

3.2.1 Technical Requirements

Raw material shall be 10% minimum cold reduced 21-6-9 high strength austenitic steel, supplied by BSA and in accordance with SMD-EIC-RD2008.

3.2.2 Dimensional Inspections

Each component part shall meet the dimensional requirements of its respective drawing within the stated dimensional tolerance on the drawing. Any component part not meeting the stated dimensions, within stated tolerances, shall be rejected. Components which are oversized can be re-machined by the Contractor to bring them within the allowable tolerances. After re-machining, they must meet all of the requirements of this SOW.

First articles shall be inspected by BSA.

3.2.3 Test Coupons

Test coupons shall be cut from the provided sheets in designated areas shown in the layout document provided by BSA. Test coupons shall be extracted from each material thickness at specified intervals through the run, at the quantities specified in Section 5. Test coupons shall consist of:

3.2.3.1 Weld Test Coupon: 3.5” x 9” x Stock Sheet Thickness

3.2.3.2 2X Magnetic Test Coupons: 3.5” x 3.5” x Stock Sheet Thickness

3.2.3.3 2X Thermal Contraction Test Coupons: 2” x 2” x Stock Sheet Thickness

Proper traceability regarding which sheet each test coupon was cut from shall be maintained. Test coupons shall be labeled with the corresponding sheet serial number it was pulled from.

3.2.4 Non-Conformance

BSA does not grant authority to the Contractor for disposition of non-conformances. In such case, BSA shall be immediately notified of the non-conformance and may ask for additional information for evaluation. No proposed repair shall be initiated without approval of BSA in writing. No repair shall be considered successfully accomplished without inspection and written approval by BSA. All repairs shall be at the expense of the Contractor.

3.2.5 First Article

The first articles, shall be manufactured and submitted to BSA along with the required documentation for approval before proceeding to the manufacture of the production run.

· Note 1 in Applicable Documents table in Section 2 – For each part number: BSA approval of quantity four (4) first articles each of RD64010521, RD64010522, RD64010523, RD64010524, RD64010525, RD64010527, RD64010529 (refer to deliverables table in Section 5) required prior to machining of remaining parts.

3.2.6 Approval to Proceed

Manufacturing of the parts shall not commence until written authorization has been received from BSA.

3.2.7 Manufacturing Sequence

Drawings or drawing next-assembly listings will establish a BSA-described sequence of manufacturing. Any variation from such sequence shall be considered a non-conformance as described elsewhere in this SOW.

3.2.7.1 Individual parts shall be machined from the supplied material and a minimum of fourteen (14) Collars shall be furnished from each sheet. If fourteen (14) Collars cannot be achieved, the Contractor must communicate number of Collars per sheet which can be achieved and submit written communication to and receive approval from BSA before proceeding.

3.2.7.2 Parts and test coupons shall be cut from the area interior to a ‘no-go’ border of all edges of the sheet to avoid areas of rolling which create thickness and flatness regions which are out-of-specification. The size of the region of each sheet which is acceptable to create parts and test coupons is the interior 22 in. x 116 in. This region shall be located central to the sheet to the Contractor’s best abilities.

3.2.7.3 The layout of part and test coupon location and orientation on each sheet will be provided by BSA. If the number of Collars per sheet is negotiated to be fewer than fourteen (14), then an alternative collar layout shall be agreed upon by both parties.

3.3 Management

3.3.1 Program Plan

Within one (1) week after award of contract, the Contractor shall deliver a detailed program plan outlining the following:

a) Management Structure - the management for the project shall be identified by name and contact information.

b) Point of Contact – a project representative shall be identified to be the primary point of contact with BSA for this project.

c) Schedule - a milestone schedule defining the manufacturing operations, inspection, and test and hold checkpoints. See Section 6 for additional significant milestones and proposed dates of accomplishment to be included in the milestone schedule.

3.3.2 Progress Communications

Within two (2) weeks after award of contract, bi-weekly program technical and progress telecommunications 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, material status, 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 two (2) 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 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, to designate selected manufacturing and/or inspection operations as “witness” points. Contractor shall provide BSA with ten (10) working days’ notice in advance of such witness points during the manufacturing and inspection cycle.

The BSA Technical Representative shall review and provide written approval prior to shipment.

3.4 Documentation and Data Management

3.4.1 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 defined 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 (BSA-identified FTP, DVD 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, IGES, IAM, or IPT.

3.4.2 End Item Documentation Package

The Contractor shall provide a documentation package for each shipment of the item(s) supplied, which consists of objective evidence of compliance with Purchase Order (PO) requirements. This documentation package shall be complete, legible, indexed, and traceable to the item supplied. The package shall be compiled and supplied to BSA. The BSA Technical Representative shall review and provide written approval of the package prior to shipment. All required documentation provided by the Contractor shall be provided in electronic copy. The package, which shall consist of all documentation identified in this SOW, shall include the following:

A) Certificate of Conformance:

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

· Materials used are those which have been specified by BSA.

· 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.

· All items delivered meet dimensional, alignment, cleanliness, and packing requirements.

B) Inspection Reports

Copies of all required or necessary inspections.

C) Nonconformance Reports:

Copies of nonconformance reports dispositioned as “rework/repair” or “use-as-is”, and all BSA-approved deviation/waivers.

3.4.3 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.

3.5 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 and 3 of this SOW.

3.6 Marking and Serialization

Each pallet shall be identified with at least the following data. Marking labels shall be applied so they are visible on the top surface of each pallet.

· Part Number / Rev Letter

· BSA Purchase Order (PO) Number

· Manufacturer's Name

· Heat Number(s)

· Gross Weight (lb.)

· Quantity

3.7 Packaging and Shipping

The Contractor shall be responsible for all packaging, crating, preparation for shipment, and shipping. The Contractor shall obtain BSA approval before selecting a shipper. The packaging shall be sufficient to ensure safe delivery of the items to BNL and meet the requirements of the Contractor-selected shipper. Stacks of laminations shall not exceed six inches high. Each stack of laminations shall be placed in its own box or crate. They shall be securely banded to pallets. Pallet weights shall not exceed 3,000 lb.

All first article shipments shall be via Air-Freight or expedited ground shipping, whichever delivery method is fastest. The remaining shipments can be shipped via ground. Contractor shall contact BSA procurement representative to review shipping logistics and costs prior to shipment.