A. ED0038433 PIP-II CDS TTL fabrication SoW.pdf

PIP-II

Statement of work

Document Title: PIP-II CDS TTL Fabrication Statement of Work

Document Number: ED0038433

Fermi National Accelerator Laboratory 1

PIP-II Cryogenic Distribution System Tunnel Transfer Line Fabrication Statement of

Work

Document Number: ED0038433 Rev B

Document Approval Date Approved

Originator Ram Dhuley, Vrushank Patel; PIP-II CDS engineers As in Teamcenter

Checker Ram Dhuley, PIP-II L3M and CAM for CDS As in Teamcenter

Checker Matthew Luedke, PIP-II Quality Assurance As in Teamcenter

Checker Jeremy Nudell, PIP-II Project Engineer As in Teamcenter

Approver Donato Passarelli, PIP-II L2M for SRFCryo As in Teamcenter

Revision History

Author Revision Date Description of Change

Ram Dhuley, Vrushank Patel As in Teamcenter Rev -- Initial Release

Ram Dhuley, Vrushank Patel As in Teamcenter Rev A - Minor formatting changes

Ram Dhuley As in Teamcenter Rev B - Change delivery terms from DDP –> DAP

Incoterms

Fermi National Accelerator Laboratory 2

1 INTRODUCTION

2 ACRONYMS AND DEFINITIONS

2.1 TECHNICAL ACRONYMS

2.2 ORGANIZATIONAL ACRONYMS

2.3 DEFINITIONS

3 TTL DESCRIPTION

4 STATEMENT OF WORK

4.1 FNAL SCOPE

4.2 SUBCONTRACTOR SCOPE

4.3 DELIVERY TERMS

5 PROJECT MANAGEMENT

5.1 BIDDING PHASE

5.2 TECHNICAL AND COST EVALUATION PHASE

5.3 EXECUTION PHASE

6 FABRICATION AND ASSEMBLY REQUIREMENTS

6.1 MATERIALS

6.2 DIMENSIONAL CONFORMANCE

6.3 CLEANLINESS

6.4 TUBE AND PIPE BENDING

6.5 WELDING

6.6 BRAZING

6.7 WELDED AND BRAZED JOINT REPAIR

6.8 MULTILAYER SUPERINSULATION (CRYOGENIC INSULATION) INSTALLATION

6.9 CONTROL VALVES INSTALLATION

6.10 BAYONET INSTALLATION

6.11 CRYOGENIC THERMOMETER INSTALLATION

6.12 LIQUID HELIUM LEVEL PROBE INSTALLATION

6.13 CARTRIDGE HEATER INSTALLATION

6.14 SPECIAL COMPONENTS AND CONSIDERATIONS

6.15 LABELING

6.16 HARDWARE

7 INSPECTION, EXAMINATION, AND FACTORY ACCEPTANCE TESTS

7.1 INSPECTION OF INCOMING FNAL PROVIDED MATERIAL AND EQUIPMENT

7.2 LEAK CHECKS

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7.3 PRESSURE TESTS

7.4 COLD LEAK TESTS

7.5 FACTORY ACCEPTANCE CRITERIA

8 SITE INSPECTION AND ACCEPTANCE TESTS

8.1 SITE INSPECTION

8.2 SITE ACCEPTANCE TESTS

9 QUALITY ASSURANCE AND QUALITY CONTROL

9.1 NON-CONFORMANCE MANAGEMENT

9.2 MODIFICATIONS MANAGEMENT

9.3 SUBCONTRACTOR’S QUALITY ASSURANCE PLAN (QAP)

9.4 SUBCONTRACTOR’S QUALITY CONTROL PLAN (QCP)

9.5 SUBCONTRACTOR’S MANUFACTURING INSPECTION PLAN (MIP)

10 SHIPPING AND HANDLING

10.2 CRATE HANDLING REQUIREMENTS

10.3 CRATE LABELING

10.4 SHIPPING SHOCK & VIBRATION MONITORING

10.5 MAXIMUM PERMISSIBLE SHOCK AND VIBRATION LOADS

10.6 CRATE ACCESS AND STORAGE

10.7 CRATE FABRICATION REQUIREMENTS

11 DOCUMENT DELIVERABLES DURING PROJECT EXECUTION PHASE

11.1 GENERAL

11.2 DOCUMENTS TO BE SUBMITTED TO FNAL PRIOR TO PURCHASING OF MATERIAL

11.3 DOCUMENTS REQUIRED AT THE MANUFACTURING READINESS REVIEW

11.4 DOCUMENTS REQUIRED AT THE SHIPPING READINESS REVIEW

Fermi National Accelerator Laboratory 4

1 Introduction

PIP-II is an upgrade of the Fermilab (in Batavia, Illinois, USA) accelerator complex that amongst other includes a new superconducting radiofrequency linear particle accelerator (linac). The PIP-II linac is kept at cryogenic temperatures using helium gas supplied by a Cryogenic Distribution System (CDS). The section of CDS located in linac tunnel is called Tunnel Transfer Line (TTL). The CDS TTL comprises 27 valve and bayonet boxes (called TTL MODULE) connected in series, spanning nearly 250 m length. Each TTL Module has a connection with warm manifold module (called TTL WARM MANIFOLD). Figure 1-1 depicts a representative section of the PIP-II CDS TTL.

Figure 1-1: 3 TTL Modules interconnected in series. The TTL has 27 such Modules. This view is only for representation purpose.

The details shown on the drawings of Table 4-1 shall be construed as govering.

The TTL Modules are named according to the linac cryomodule they supply cryogenic helium to. The names of TTL Modules, TTL Warm Manifolds, their quantity, and approximate length are given in Table

1-1.

Table 1-1 Details of the TTL Modules and Warm Manifolds

# TTL Module name Quantity Numerical Designation

1 HWR TTL Module 1 TTL Module 1

2 SSR-1 TTL Module 2 TTL Module 2-3

3 SSR-2 TTL Module 7 TTL Module 4-10

4 LB650 TTL Module 9 TTL Module 11-19

5 HB650 TTL Module 6 TTL Module 20-25

6 Extension TTL Module 1 TTL Module 26

7 Turnaround Can 1 TTL Module 27

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8 TTL Module Warm Manifold 25 TTL Warm Manifolds 1-25

9 Turnaround Can Warm Manifold 1 TTL Warm Manifold 27

2 Acronyms and Definitions

2.1 Technical acronyms

BC, TC Bayonet Can, Turnaround Can

CDS Cryogenic Distribution System

CM Cryomodule (a proton beam accelerator device)

CP Cryogenic Plant

CPP Cryogenic Process Piping

DVB Distribution Valve Box

DS Downstream, a direction from DVB to Turnaround Can (TC) toward Turnaround Can

ES External Support

FEA Finite Element Analysis

He Helium

HTTS, LTTS High Temperature Thermal Shield, Low Temperature Thermal Shield

MAWP Maximum Allowable Working Pressure

MDMT Minimum design metal temperature

MLI Multilayer Insulation

OEM Original Equipment Manufacturer

P&ID Piping and Instrumentation Diagram

PQR Procedure Qualification Record

ITL Intermediate Transfer Line

TTL Tunnel Transfer Line

US Upstream – a direction from Turnaround Can (TC) toward DVB

WPQ Welder Performance Qualification

WPS Welding Procedure Specification

WM Warm Manifold

2.2 Organizational acronyms

FFDG Fermi Forward Discovery Group, LLC

FNAL Fermi National Accelerator Laboratory

ANSI American National Standards Institute

ASCE American Society of Civil Engineers

ASME American Society of Mechanical Engineering

ASTM American Society for Testing and Materials

EJMI Expansion Joint Manufacturers Association

ISO International Organization for Standardization

PIP-II Proton Improvement Plan II

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NIST National Institute of Standards and Technology

2.3 Definitions

DEVICE A term used to refer to TTL Module, TTL Warm Manifold, or a combination of both

AMBIENT

a term used to define nominal environmental conditions, unless otherwise specified, of atmospheric pressure

OFFERER Entity submitting a responsive proposal for this project

SUBCONTRACTOR

a term used to refer to the fabricator, tester, and supplier of the system defined in this statement of work

CODE

a term used to refer collectively to the various pressure safety standards applicable to the system defined in this statement of work

FNAL a term used to refer to Fermi Forward Discovery Group, LLC

Fermilab a term used to refer to Fermilab National Accelerator Laboratory

Linac a term that indicates a set of SRF cryomodules connected in series

May a term which indicates that a provision is neither required nor prohibited

Steady State the nominal operating mode in which the system operates at superfluid helium temperatures

Transient the mode in which the system is either cooling down or warming up and operates in a range between 2 K and 300 K

Shall a term which indicates that a provision is a requirement

Should a term which indicates that a provision is recommended as good practice but is not a requirement

3 TTL description

All the HWR, SSR-1, SSR-2, LB650, and HB650 TTL Modules are functionally similar. Each TTL Module supplies cryogenic helium gas to (1) the downstream TTL Modules via main piping and (2) the corresponding cryomodule via branch piping. The second from last TTL Module called the Extension TTL

Module only supplies helium gas to its downstream module. It does not have branch piping. The last TTL

Module is called Turnaround Can whose purpose is to set the helium gas to return. The Turnaround Can also does not have branch connections.

Each TTL Module comprises of 6 main pipes and 5 branch pipes, as detailed in Table 3-1 shows the design and steady state operating parameters of the TTL process lines.

Table 3-1. All the cryogenic piping is enclosed in a thermal shield to reduce radiation heat loading. The piping as well as the thermal shield are housed in a vacuum vessel to reduce convection heat load on the internal cryogenic equipment. Flow control is established using control valves that penetrate the vacuum vessel and connect to the internal piping. Supply from a TTL Module to the corresponding cryomodule is

Fermi National Accelerator Laboratory 7 accomplished using bayonet type connections. These also penetrate the TTL vacuum vessel to connect to the internal piping. Finally, pressure relief piping is drawn from the branch lines that let out helium gas from the TTL Module in case the branch lines undergo excessive pressurization. The relief piping also penetrates the vacuum vessel. The three penetrating components (control valves, bayonets, and relief lines) are welded to the vacuum vessel and thermally intercepted to the thermal radiation shield, with certain exceptions.

The Extension TTL Module does not have penetrations. The Turnaround Can does not have bayonet penetrations but has controls valves and relief lines. The Turnaround Can also contains a phase separator

(an ASME pressure vessel) with heaters and helium liquid level sensors for regulating the returning flow of cryogenic helium. The CAD renderings in Figure 3-1 show the detailed views for a representative TTL

Module. Similarly, Figure 3-2 shows CAD renderings the Turnaround Can.

Warm Manifolds for the Bayonet Can TTL Modules and the Turnaround Can are depicted in Figure 3-3. All the Bayonet Can Warm Manifolds are functionally and geometrically similar while the Turnaround Can

Warm Manifold is distinct.

(a)

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(b)

(c)

Figure 3-1 Bayonet Can type TTL Module views of (a) vacuum vessel (b) thermal shield and supports (c) internal piping and supports. These views are only for representation purpose. The details shown on the drawings of Table 4-1 shall be construed as governing.

Fermi National Accelerator Laboratory 9

(a)

(b)

Fermi National Accelerator Laboratory 10

(c)

Figure 3-2 Turnaround Can views of (a) vacuum vessel (b) thermal shield and supports (c) internal piping and supports. These views are only for representation purpose. The details shown on the drawings of Table 4-1 shall be construed as governing.

Figure 3-3 Warm Manifold view of (left) TTL Module (Bayonet Can) (right) Turnaround Can. These views are only for representation purpose. The details shown on the drawings of Table 4-1 shall be construed as governing.

Fermi National Accelerator Laboratory 11

Figure 3-4 depicts a representative cross section of the TTL MODULE and lists details of the TTL process piping. All the TTL process piping falls under the Normal Fluid Service Category per ASME B31.3.

Figure 3-4 Representative cross section of the Tunnel Transfer Line (TTL). Dimensions are in mm. This view is only for representation purpose. The details shown on the drawings of Table 4-1 shall be construed as govering.

Table 3-1 shows the design and steady state operating parameters of the TTL process lines.

Table 3-1 Details of the TTL MODULE process lines

Design parameters Steady state operation

Process line/component Design pressure MDMT Pressure Temperature

TTL MODULE [bar absolute] [K] [bar absolute] [K]

4.5 K Supply main line and branch lines 20 4.5 2.9 4.5

2 K Return main line and branch lines 4.1 2 0.03 3.8

Phase Separator 4.1 2 0.03 2

LTTS Return main line and branch lines 20 4.5 2.9 9

HTTS Supply main line and branch lines 24 40 18 40

HTTS Return main line and branch lines 24 40 18 80

Cooldown Return main line 20 4.5 1.1 80

HTTS - 40 - 80

Vacuum Jacket 1.5 245 0 298

TTL WARM MANIFOLD [bar absolute] [K] [bar absolute] [K]

Line connected to 4.5 K Supply 20 4.5 2.9 298

Line connected to 2 K Return 4.1 2 0.03 298

Line connected to LTTS Return 20 4.5 2.9 298

Line connected to HTTS Supply 24 40 18 298

Fermi National Accelerator Laboratory 12

Line connected to HTTS Return 24 40 18 298

4 Statement of work

4.1 FNAL Scope

4.1.1 In the Request for Proposal phase, FNAL shall provide:

4.1.1.1 This Statement of Work

4.1.1.2 Technical questionnaires

4.1.1.3 Approximate price list of components FNAL will supply for integration with the TTL. The

OFFEROR shall use this information for estimating the overall import expense into the

OFFEROR’s country.

4.1.1.4 Zipped PDF packages of production drawings of TTL MODULES and TTL WARM MANIFOLDS listed in Table 4-1.

Table 4-1: PDF packages containing component and assembly drawings information.

Zipped PDF package name

Contains components and assembly drawings of

QTY needed

1 F10226624 - HWR TTL Module HWR TTL Module (TTL Module 1) 1

2 F10227993 - SSR1 L1 TTL Module Regular SSR-1 TTL Module (TTL Module 2) 1

3 F10241220 - SSR1 L2 TTL Module Elongated SSR-1 TTL Module (TTL Module 3) 1

4 F10241168 - SSR2 L1 TTL Module Regular SSR-2 TTL Module (TTL Module 4-9) 6

5 F10241316 - SSR2 L2 TTL Module Elongated SSR-2 TTL Module (TTL Module 10) 1

F10235167 – LB650 L1 TTL Module

Regular LB650 TTL Module (TTL Module 11-15 & 17-18)

F10241319 – LB650 L1 VB TTL Module

Regular LB650 TTL Module with Vacuum Break (TTL Module 16)

8 F10241190 – LB650 L2 TTL Module Elongated LB650 TTL Module (TTL Module 19) 1

9 F10236416 – HB650 TTL Module HB650 TTL Module (TTL Module 20-25) 6

10 F10238278 – Extension TTL Module Extension TTL Module (TTL Module 26) 1

11 F10225452 – Turnaround Can Turnaround Can (TTL Module 27) 1

12 F10239078 – TTL Module Warm Manifolds

Bayonet Can TTL Module drawings (TTL Warm Manifolds 1-25)

13 F10239335 – Turnaround Can Warm Manifolds

Turnaround Can drawings (TC Warm Manifold)

4.1.2 During the project execution phase, FNAL shall supply components and documents to

SUBCONTRACTOR according to the (approximate) timetable shown in Table 4-2.

Fermi National Accelerator Laboratory 13

Table 4-2 Timeline and items that FNAL will supply to SUBCONTRACTOR for integration with TTL.

# Item Estimated ship-out from FNAL site

1 Blank template for bi-weekly status to be filled out by the SUBCONTRACTOR

1 week after Kick-Off Meeting

2 LTTS intercept thermal straps (see Paragraph

6.14.1 for details)

8 weeks prior to start of manufacturing

3 Female bayonet assemblies for TTL MODULE and straightness gauges

8 weeks prior to start of manufacturing

4 Flex hoses for TTL MODULE cryogenic piping 8 weeks prior to start of manufacturing

5 Manual valves for TTL WARM MANIFOLDS 8 weeks prior to start of manufacturing

Cryogenic instrumentation:

a. Cartridge heaters

b. Liquid helium level probes

c. Cryogenic thermometers

d. Cryogenic wiring and electrical feedthroughs

Will be shipped in 4 batches, each batch size commensurate with sensor requirement for the TTL Lot size shown in

Table Table 4-4. Each batch will be shipped out 8 weeks prior to the expected start of that TTL lot fabrication.

a. Breakout boxes and shorting connectors for electrical check out of the thermometers.

b. Reference values of thermometer resistance, heater resistance, level probe resistance, and blank check-out sheets

c. Electrical pin assignment documents for cryogenic instrumentation

d. Installation and check-out instructions for cryogenic instrumentation and feedthroughs.

With first batch of instrumentation

8 Cryogenic control valves

Will be shipped in 4 batches, each batch size commensurate with valves requirement for the TTL Lot size shown in

Table Table 4-4. Each batch will be shipped out 8 weeks prior to the expected start of that TTL lot fabrication.

Shock loggers for installation on shipping crates

8 weeks prior to start of manufacturing

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4.2 SUBCONTRACTOR Scope

4.2.1 The SUBCONTRACTOR shall provide all materials necessary to fabricate complete deliverables of Section 4.2. The SUBCONTRACTOR shall provide engineering services required to generate internal shop drawings (as deemed necessary), and all documentation needed to manage manufacturing and supporting their suppliers.

4.2.2 The SUBCONTRACTOR shall fabricate the 27 TTL MODULES and 26 TTL WARM MANIFOLDS based on

a. The component and assembly drawings provided by FNAL as described in Paragraph 4.1.1.3

b. Fermilab provided components listed in Paragraph 4.1.2.

4.2.3 The SUBCONTRACTOR shall provide all labor to assemble, test, and supervise the manufacture of all components regardless of where these are made within the SUBCONTRACTOR’s plant or in a second facility or sub-contractor.

4.2.4 The SUBCONTRACTOR shall design and fabricate jigs and fixtures to ensure ports, brackets, and other important components are maintained to specified tolerances. Any information of a proprietary nature must be identified in the bid response.

4.2.5 The SUBCONTRACTOR shall procure and fabricate all adapters for vacuum pumping, pressure tests, and cold leak tests. Any information of a proprietary nature must be identified in the bid response. All adapters shall be delivered to FNAL along with the DEVICE and shall become FFDG property.

4.2.6 The SUBCONTRACTOR shall complete and pass all cleanliness requirements, material certifications, dimensional checks, thermal shock tests, leak checks, pressure tests in strict adherence to the clauses in Section 7 and the document deliverables in Section 11.

4.2.7 The SUBCONTRACTOR shall handle and transport the assembled and fully tested 27 TTL

MODULES and 26 TTL WARM MANIFOLDS to Fermilab site in strict adherence to the clauses in

Section 10.

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4.2.8 Table 4-3 lists the drawings that FNAL will provide for reference. These refer to the female bayonet assemblies, LTTS intercept thermal straps, and flex hoses. As these parts/assemblies will be provided to the SUBCONTRACTOR by FNAL, the SUBCONTRACTOR shall not be responsible for fabricating them. Additonally, the interconnects will be covered separately by

FNAL and are out of scope of this fabrication subcontract.

Table 4-3 List of items that are out-of-scope of fabrication.

Flex hoses Thermal straps Bayonet assemblies Interconnects

F10239315 F10239725 F10241450 F10214315 F10214946 F10214947 F10242574

F10240478 F10239769 F10141998 F09025578 F00257103 F10228296

F10240457 F10239712 F10142268 F10137517 F09025578 F10228253

F10239420 F10142282 F10142278 F10137517 F10228252

F10240480 F10142286 F10142925 F10142278 F10227974

F10240449 F10143550 F10142926 F10142925 F10227973

F10239529 F10147055 F10142927 F10142926 F10227972

F10239320 F10147056 F10142954 F10142927 F10227922

F10239312 F10148505 F10214945 F10142954 F10227889

F10240483 F10148636 F10214945 F10227812

F10240597 F10148637 F10227779

F10240541 F10167271 F10233807

F10244360 F10189231

F10240549 F10214292

F10240594 F10214293

Fermi National Accelerator Laboratory 16

4.3 Delivery terms

4.3.1 SUBCONTRACTOR shall be responsible for delivering the DEVICE to FNAL site. Delivered At

Place (DAP) per Incoterm 2020 shall be applied as method of delivery to FNAL site.

4.3.2 For components that FNAL will supply to SUBCONTRACTOR, SUBCONTRACTOR shall be responsible for clearing customs and import procedures at the receiving port of entry.

SUBCONTRACTOR shall include the expected cost of this administrative clearance in their response to FNAL Request for Proposal.

4.3.3 SUBCONTRACTOR shall deliver TTL Modules and TTL Warm Manifolds in 4 lots to FNAL site as detailed in Table 4-4.

Table 4-4 TTL delivery lot contents and delivery schedule.

Lot number Lot contents Required delivery to Fermilab site

1 a) TTL Module 1-4 (4 modules)

b) TTL Warm Manifolds 1-4 (4 modules)

Within 25 weeks from PO issue date

2 a) TTL Module 5-12 (8 modules)

b) TTL Warm Manifolds 5-12 (8 modules)

Within 35 weeks from PO issue date

3 a) TTL Module 13-20 (8 modules)

b) TTL Warm Manifolds 13-20 (8 modules)

Within 48 weeks from PO issue date

a) TTL Module 21-27 (7 modules)

b) TTL Warm Manifolds 21 – 25 and 27 (6 modules)

Within 65 weeks from PO issue date

5 Project Management

Purchase Order will be owned and managed by Fermi Forward Discovery Group, LLC (FNAL).

5.1 Bidding Phase

OFFEROR shall submit the following documents in English language with their proposal. Information considered proprietary should be identified as such.

5.1.1 Total cost to fabricate, test, and deliver to FNAL site all SUBCONTRACTOR scope of Section 4.

5.1.2 Completed questionnaires.

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5.1.3 Schedule showing main activities with 1-week granularity including

a. Hold points and milestones of Table 5-1

b. Deliverables of Table 4-4.

5.1.4 Lists of exceptions to this statement of work and reasoning for exception.

5.1.5 A technical proposal showcasing:

a. ASME B31.3 compliance strategy for the TTL MODULES and TTL WARM MANIFOLDS.

b. ASME BVPC compliance and stamp provision strategy for Phase Separator, a pressure vessel.

c. MLI installation procedure employed on prior systems built for liquid helium temperature service.

d. Leak test procedure using helium mass spectrometer employed on prior systems built for sub-atmospheric liquid helium service.

e. Installation and check out of cryogenic instrumentation used on piping/vessels built for liquid helium service.

f. Pressure test procedure in accordance with ASME employed on prior built systems.

g. Cold leak test procedure employed on prior systems built for sub-atmospheric liquid helium service.

h. Sample welding plan, WPS, examination, and acceptance testing procedures.

i. Sample shipping and handling plan.

5.1.6 Copy of OFFEROR Quality Assurance Plan (QAP).

5.1.7 OFFEROR company profile and experience document showcasing:

a. Company Organization Chart highlighting the key technical personnel and staffing level with skillset required for this project. Note that SUBCONTRACTOR shall immediately communicate to the FNAL changes in key personnel or qualified individuals.

b. Company profile showcasing workshop facilities.

c. 2 examples from within 10 years of prior successful supply of cryogenic valve boxes/transfer lines that resemble the current scope in scale, timeline, and technical requirements.

d. Sample Quality Control Plan (QCP) developed by OFFEROR for a prior project that resembles the current scope in scale, timeline, and technical requirements.

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5.2 Technical and Cost Evaluation Phase

5.2.1 FFDG will evaluate responsive proposals and award a subcontract to the best value offeror.

5.3 Execution Phase

5.3.1 Within 1 week of confirming FFDG’s subcontract award, SUBCONTRACTOR shall schedule a

Kick-Off Meeting (KOM) for initiating technical and commercial discussion between the technical and commercial representatives from FNAL and SUBCONTRACTOR. Action items from the meeting shall be addressed within the next 2 week.

5.3.2 At the KOM, SUBCONTRACTOR shall assign a person responsible for the technical execution and Quality Control (QC) of the project, and a person responsible for the commercial follow-up, throughout the duration of the contract. They shall be able to communicate fluently in

English.

5.3.3 Upon conclusion of the KOM, SUBCONTRACTOR shall provide a status report every two weeks on FNAL provided template. Also, a periodic meeting held by videoconference shall be set up at intervals negotiated at the KOM to discuss technical and commercial updates. The meetings will be held in English. However, FNAL representatives are always available to respond any time if questions will arise.

5.3.4 Within 10 weeks from SUBCONTRACTOR confirmation of FFDG subcontract and before starting any fabrication/ procurement activity, the Manufacturing Readiness Review (MRR) shall be organized to allow FNAL reviewers to assess SUBCONTRACTOR’s level of preparation to proceed to the manufacturing and procurement phase. The recommendations from this review (if any) based on the presented material (see MRR deliverables in Table 5-1 and Section

11.2), shall be addressed within 2 weeks from the conclusion of the MRR.

5.3.5 Upon conclusion of the MRR, SUBCONTRACTOR shall proceed with the fabrication phase.

Quality Controls and Technical reports, as detailed in Table 5-1, shall be provided by

SUBCONTRACTOR to FNAL.

5.3.6 To reduce risks associated with full scale fabrication and assembly, SUBCONTRACTOR shall fully fabricate and test the first lot of TTL MODULES and TTL WARM MANIFOLDS prior to starting the assembly of subsequent lots. This ‘first lot’ build and test shall include:

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5.3.6.1 Fabricating all parts including piping runs, piping supports, thermal shield components, vacuum vessel components, external supports required to build modules in the first lot.

5.3.6.2 Installing thermometers on the piping and thermal shield following the installation procedure provided by FNAL, at locations as specified in the provided drawings.

5.3.6.3 Creating fully assembled Lot 1 TTL MODULES and TTL WARM MANIFOLDS by means of final welds as shown on the FNAL supplied drawings.

5.3.6.4 Checking straightness and vertical alignment of bayonets and control valve bonnets upon welding to process pipes and vacuum vessel to ensure they are within tolerance specified on

FNAL supplied drawings.

5.3.6.5 Welding pressure test caps to the ends of piping and vacuum vessel.

5.3.6.6 Leak checking all the piping circuits and vacuum vessel with Section 7.2.

5.3.6.7 Performing pressure test on each module in accordance with Section 7.3.

5.3.6.8 Performing cold leak test on each module in accordance with Section 7.4.

5.3.7 Any fabrication and/or assembly issues noticed during the first lot build and testing phase shall be addressed by SUBCONTRACTOR in close communication with FNAL. Any changes to the drawings shall be done upon written approval of FNAL. The issues and discrepancies shall be recorded and provided to FNAL on Non-Conformance reports in accordance with Section 9.1.

5.3.8 Production of the remaining TTL MODULES and TTL WARM MANIFOLDS shall begin only after the issues are resolved.

5.3.9 Hold Points

A Hold Point is defined as the moment in time when a process shall be halted to allow FNAL representatives to perform reviews and QCs deemed necessary. Table 5-1 lists the main hold points and associated documentation deliverables.

Table 5-1 Hold Points and Documentation Deliverables for hold points.

Hold Point

Description Deliverables When required

A Kick-off Meeting (KOM) – FNAL personnel at SUBCONTRACTOR premises

1) Resolution of action items from the meeting

2) Updated schedule

3) List of items to be purchased before MRR

As stated in Paragraph 5.3.1

B Manufacturing Readiness Review(s) (MRR) – remote over Zoom/Teams

As stated in Section 11.3 As stated in Paragraph 5.3.4

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C1

First lot in-process inspection

– FNAL personnel at SUBCONTRACTOR premises

1) Internal piping assembly welds

2) HTTS connection welds

3) Electrical checks of installed sensors

4) Internal piping leak check

5) MLI installation

QC report(s) After finishing assemblies as detailed on drawings.

C2

First lot factory acceptance test – FNAL personnel at SUBCONTRACTOR premises

1) Final dimensional checks

(linear, angular dimensions, etc. as shown on drawings)

2) Sensor electrical resistance checks

3) Leak check of vacuum vessel (Section 7.2)

4) Pressure test of process piping of TTL MODULE and TTL WARM MANIFOLD (Section 7.3)

5) Cold leak test of TTL MODULE (Section 7.4)

Factory Acceptance Test (FAT) report comprising the documents listed in

Section 7.

Within 1 week of FAT completion.

D1

FAT of Lot-2 – FNAL personnel at SUBCONTRACTOR premises

Factory Acceptance Test (FAT) report comprising the documents listed in

Section 7.

Within 1 week of FAT completion.

D2

FAT of Lot-3 – FNAL personnel at SUBCONTRACTOR premises

Factory Acceptance Test (FAT) report comprising the documents listed in

Section 7.

Within 1 week of FAT completion.

D3

FAT of Lot-4 – FNAL personnel at SUBCONTRACTOR premises

Factory Acceptance Test (FAT) report comprising the documents listed in

Section 7.

Within 1 week of FAT completion.

E Discrepancies / Nonconformities

Discrepancy/non-conformance report(s) As stated in Section 9.1.1

F1-F4 Shipping Readiness Review As stated in Section 11.4 Prior to shipping of Lots 1, 2, 3, 4 (see Table 4-4) after Steps

C2, D1, D2, and D3.

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5.3.10 Work Pause

A Work Pause is defined as the moment in time when all work shall be paused by

SUBCONTRACTOR upon (a) discovery of a discrepancy in FNAL provided documentation

(drawings, installation procedures) that prevents SUBCONTRACTOR from proceeding forward clearly, or (b) occurrence of a serious fault during fabrication or testing. SUBCONTRACTOR shall inform FNAL immediately after discovery/occurrence of such discrepancy/fault.

SUBCONTRACTOR shall resume work only after a resolution with the FNAL.

6 Fabrication and assembly requirements

6.1 Materials

6.1.1 Materials to be used in the fabrication of components are specified in the FNAL provided drawings. The use of any materials non-listed in the drawings is excluded by the present statement of work. Under exceptional conditions FNAL may approve other materials via a written request.

6.1.2 All materials and components used in construction of the DEVICE shall be new and suitable for the use for which they are intended.

6.1.3 All materials used in the DEVICE shall be traceable and documented, regardless of CODE requirements. Certified Mill Test Reports (CMTR) of all raw materials used to fabricate deliverables shall be provided to FNAL as part of the deliverables of the shipping readiness review. Electronic copies of materials certifications in PDF format shall be provided and shall include all processes and tests with grade and composition being clearly identifiable and traceable to the respective component.

6.1.4 All flanges and blanks used on the DEVICE shall conform to CODE requirements for appropriate fluid service category.

6.1.5 If the SUBCONTRACTOR procures components from a third-party vendor, the

SUBCONTRACTOR shall be responsible to prove that the materials and welds on those components meet compliance requirements.

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6.1.6 All components constructed of carbon steel shall be painted with rust-preventative industrial grade base coat primer with a surface coat of rust-preventative gloss enamel, color blue.

6.1.7 The materials listed in Table 6-1 are explicitly prohibited.

Table 6-1 Materials explicitly prohibited for use.

All greases, except for Apiezon and Dow-Corning vacuum greases

All glues, except Loctite 243 (non-wicking type), Loctite 290 (wicking type), GE Varnish

All plastics and epoxy composites, except G10, G11, Kapton, ASTM type 303 or equivalent, free cutting stainless steel

Silicon or Sulphur based machining lubricants when machining any components (only water-soluble machining lubricants are permitted)

Teflon

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6.2 Dimensional conformance

6.2.1 All drawings referenced shall be used by the SUBCONTRACTOR for configuration control and dimensional conformance. Dimensional variances and overall envelope configuration shall be maintained within specified tolerances.

6.2.2 SUBCONTRACTOR may decide to use the drawings provided by FNAL for fabrication, or to produce its own drawings. Any change or deviation from the set of drawings provided by FNAL shall be listed in a SUBCONTRACTOR’s Drawings Exception Document (MDED). FNAL shall provide a written approval to the MDED before the SUBCONTRACTOR can proceed to the next step.

6.2.3 FNAL is not accountable for any change in the drawings not listed in the MDED. The MDED can be revised and approved throughout the entire duration of the project.

6.3 Cleanliness

6.3.1 Before any welding, all parts must be degreased with soap and water, followed by a thorough deionized water rinse. The inside of all pipes and fitting shall be cleaned and fully dry blown with clean air until no visual moisture remains. Parts shall be protected at all stages of fabrication for the cleanliness. The soap shall be Diversey™ Speedball™ Heavy Duty Spray

Cleaner. The SUBCONTRACTOR may choose an equivalent soap upon written approval from

FNAL.

6.3.2 Each component and subassembly shall be thoroughly cleaned of all foreign substances including, but not limited to, scale, spatter, flux, and grease after every stage of fabrication.

6.3.3 Cleaning agents shall be suitable for the materials of construction and shall be neutralized if necessary.

6.3.4 Weld spatter shall be removed by wire brushing using stainless steel brushes after visual inspections are completed. The use of pickling paste is EXPLICITLY PROHIBITED.

6.3.5 Each sub-assembly shall be cleaned to provide an inner surface of all pipes and tubes free of grease, flux, moisture, dirt, and other foreign materials by vapor degreasing or suitable wash.

Surfaces shall be visibly inspected and wiped down with a white cloth. To be considered free of contamination, no discoloration shall appear on the white cloth.

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6.3.6 After cleaning, each sub-assembly shall be blown dry with clean dry air until no visual moisture remains.

6.4 Tube and pipe bending

6.4.1 Tube and pipe bending shall be performed in accordance with ASME B31.3 requirements.

6.4.2 All bends shall be free of kinks, cuts, and abrasions.

6.4.3 Tubes and pipes shall remain circular within ASME B31.3 requirements after bending.

6.4.4 Vendor may substitute tube bends for fittings where desirable, provided that mechanical strength is not compromised. This is subject to FNAL written approval.

6.5 Welding

6.5.1 General welding requirements

6.5.1.1 All weld joints shall conform to types and sizes called out on drawings provided by FNAL, unless otherwise listed in the MDED approved by FNAL.

6.5.1.2 All welding performed on cryogenic piping shall utilize the Gas Tungsten Arc Weld (GTAW) process using welding quality argon gas for the inert shield.

6.5.1.3 All stainless-steel welds shall be internally purged with weld quality argon gas during the time of welding and post welding treatment. Oxygen levels shall be less than 0.01% by volume as read by a TOPAC oxygen meter or equivalent.

6.5.1.4 Welds that show evidence of a lack of purge such as discoloration shall not be accepted. Figure

6-1 displays welds that are unacceptable.

Figure 6-1 Unaccptable welds of stainless steel as determined visually based on discoloration.

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6.5.1.5 All welding shall be performed in such a manner that the weld surface is smooth and free of irregularities. No visible metal chips or foreign material shall be detectable within any components. All external surfaces in the weld area shall be cleaned of heat tint, slag, and other deposits. No mechanical process or filler materials shall be used to achieve a smooth appearance.

6.5.1.6 The SUBCONTRACTOR shall ensure that no entrapped gases, fluxes, pits, cracks, or like imperfections are left in the heat affected zones. All fillet welds shall be smooth for cosmetic appearance. Post cleaning of welds with a wire brush only is acceptable (prior to final leak checking) and required to leave the surface in a bright finish condition with no trace of solvent residue. When cleaning stainless steel surfaces the wire brushes shall have stainless steel bristles and those wire brushes shall only be used on stainless steel surfaces.

6.5.1.7 Any evidence of residual flux shall require SUBCONTRACTOR to reclean the affected area.

6.5.1.8 Welding instructions for control valves and bayonets are specified on FNAL provided drawings.

6.5.1 Welder and Weld Procedure qualification

6.5.1.1 All weld joint preparation and welding techniques utilized in Weld Procedure Specification (WPS) shall be done in accordance with Section VIII-Division 1 and IX of the ASME BPVC and/or Chapter

V of the ASME B31.3 code.

6.5.1.2 The SUBCONTRACTOR shall conduct the tests required to provide a Procedure Qualification

Record (PQR) for each Welding Procedure Specification (WPS) as required by Section VIII-Division

1 and IX of the ASME BPVC and/or Chapter V of the ASME B31.3 code.

6.5.1.3 The SUBCONTRACTOR shall conduct the tests required to qualify each welder to a Welder

Performance Qualification (WPQ) as required by Section VIII-Division 1 and IX of the ASME BPVC and/or Chapter V of the ASME B31.3 code.

6.5.1.4 ASME BPVC VIII Div. 1 UHA-51(a)(3)(-a) can be used on vessels and piping to fulfil impact testing requirements.

6.5.1.5 The SUBCONTRACTOR shall maintain records in accordance with paragraph UW-48 Section VIII-

Division 1 of the ASME BPVC for all welders and welding operators.

6.5.1.6 No production welding shall be performed until all WPS, PQR, and WPQ documents have been qualified in accordance with ASME BPVC Section VIII-Division 1 paragraphs UW-28 and UW-29 and Section IX of the ASME BPVC and approved by FNAL.

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6.5.2 Weld Inspection, Examination, and Testing

6.5.2.1 SUBCONTRACTOR shall supply a weld map or weld tracking system to FNAL that identifies each weld and tracks which welder performed each weld. The template for the weld map shall be provided to FNAL for approval prior to the start of fabrication. A copy of the completed weld map shall be provided to FNAL once fabrication is complete.

6.5.2.2 Examination of the welds shall be performed by qualified inspectors according to ASME B31.3

Chapter VI. SUBCONTRACTOR shall provide FNAL inspector/examiner qualification records along with all reports including visual inspections and radiographic tests as required by ASME B31.3.

6.5.2.3 In addition to code requirements, the vendor shall inspect interior of all pipe welds with a borescope, when possible. Pictures will be part of the welding documentation to be provided to

FNAL.

6.5.2.4 SUBCONTRACTOR shall maintain records of each completed weld inspection, examination, and test required by the ASME codes. The templates for the inspection, examination, and test report forms shall be provided to FNAL for approval prior to the start of fabrication. Completed inspection, examination, and testing reports shall be provided to FNAL once fabrication is complete.

6.5.2.5 Each weld inspection, examination, or test report shall include the weld identification number used by the weld map.

6.6 Brazing

6.6.1 General brazing requirements

6.6.1.1 Brazing is prohibited on pressure retaining components viz. process pipes and vacuum vessel and load bearing components viz. internal piping anchors.

6.6.1.2 Brazed joints shall be used for connecting flexible thermal straps to the HTTS. Brazing shall able be used in the construction of thermal straps where end-connectors are attached with the flexible braid. Details are provided in FNAL drawings.

6.6.1.3 SUBCONTRACTOR shall use braze filler metal(s) and flux(s) as indicated on FNAL drawings. The use of other metals or fillers is prohibited unless approved by FNAL in writing.

6.6.1.4 SUBCONTRACTOR shall provide a flux removal and cleaning procedure covering all brazed joints to FNAL for approval prior to the start of fabrication.

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6.6.1.5 All brazes shall be made fill and flush, 100% of braze joints must be inspected to ensure joints have uniform fill without excessive braze material or underfill. Pictures will be part of the brazing documentation to be provided.

6.6.2 Brazer & Brazing Procedure Qualification

6.6.2.1 Brazed joints on the thermal shield that fall out of the scope of the ASME codes are not required to have BPS, BPQR, and BPQ qualification documentation. However, SUBCONTRACTOR shall ensure that all brazers have sufficient training and experience to perform the brazing work and that all industry best practices for brazing are followed.

6.6.3 Brazing Inspection, Examination, & Testing

6.6.3.1 Brazed joints on the HTTS that fall out of the scope of the ASME codes are not required to have inspection, examination, or test reports. However, all brazed joints shall be visually examined by

SUBCONTRACTOR. Defective joints found during visual examination shall be repaired and/or recleaned.

6.7 Welded and Brazed joint repair

6.7.1 Defective joints found during visual examination by SUBCONTRACTOR and in photographs by

FNAL shall be repaired/recleaned by SUBCONTRACTOR. The SUBCONTRACTOR shall record defective joints as Non-Conformance in accordance with Section 9.1.

6.7.2 Any failure that is correctable by simple re-welding or re-brazing may be undertaken without prior direct contact with FNAL. Any leak that is repaired shall be fully documented in a Non-

Conformance Report and submitted to the FNAL Technical Representative.

6.7.3 SUBCONTRACTOR shall provide a written procedure for identifying, recording, and repairing welds that have failed any inspection, examination, or test to FNAL for approval prior to the start of fabrication.

6.7.4 SUBCONTRACTOR shall provide a weld repair report to FNAL upon completion of fabrication for all welds which have failed an inspection, examination, or test.

6.8 Multilayer superinsulation (cryogenic insulation) installation

6.8.1 Two-sided aluminized polyester film with appropriate spacer material shall be used for multilayer superinsulation (MLI), subject to the following requirements:

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6.8.1.1 Two-sided aluminized, minimum 400 Angstroms each side, Mylar film shall be used for multilayer superinsulation (MLI)

6.8.1.2 Reemay Spunbonded Polyester, Type 2250 (0.50 oz/yd2, 2.2 dpf) may be used as a spacer material.

6.8.1.3 The use of Dexter paper as a spacer is specifically excluded for use in the DEVICE.

6.8.2 The SUBCONTRACTOR shall obtain written approval from FNAL for the choice of MLI and spacer material to be used in the DEVICE. To meet this requirement, the SUBCONTRACTOR shall share the MLI specifications from their supplier for FNAL review and written approval prior to finalizing purchase of MLI.

6.8.3 MLI layer number and layer density on each component/sub-assembly shall be applied in strict accordance with the details on shown the component/sub-assembly drawings. One layer of two-sided aluminized Mylar and one layer of spacer represent a single layer of MLI.

6.8.4 The MLI layer density by default shall be ≤ 25 layers/cm, unless stated differently on a drawing. Spiral half overlapped wrapping of MLI should be utilized. Where spiral wrapping is impractical as determined by mutual agreement between SUBCONTRACTOR and FNAL, blankets of no more than five layers of MLI may be applied, with no one layer of aluminized

Mylar directly adjacent to another layer of aluminized Mylar. Additional ten (10) layered MLI blankets shall be used to reach the total number of layers required. The edges of MLI blankets shall be symmetrically located to reduce the number of edges in any one region.

6.8.5 At corners, penetrations, and other joints, the edges of MLI (whether individual or in blankets) shall be formed by overlapping layers.

6.8.6 Table 6-2 shows the general minimum number of MLI layers that shall be applied on the cryogenic process piping and HTTS, unless noted otherwise on drawings.

6.8.7 Spiral half overlapped wrapping of MLI should be utilized. Where spiral wrapping is impractical as determined by mutual agreement between SUBCONTRACTOR and FNAL, blankets of no more than five layers of MLI may be applied, with no one layer of aluminized Mylar directly adjacent to another layer of aluminized Mylar. Additional ten (10) layered MLI blankets shall be used to reach the total number of layers required. The edges of MLI blankets shall be symmetrically located to reduce the number of edges in any one region.

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6.8.8 At corners, penetrations, and other joints, the edges of MLI (whether individual or in blankets) shall be formed by overlapping layers.

Table 6-2 General minimum number of MLI layers required on the TTL Module process piping and HTTS.

Surface of Number of MLI Layers

4.5 K Supply 20

2 K Return 20

LTTS return 20

HTTS Supply 20

HTTS Return -

HTTS 50

Cooldown Return 20

6.8.9 For any external penetrations such as cryogenic control valves, bayonets, relief lines, and instrumentation conduits, MLI shall be tapered from a single layer at room temperature to the maximum number of layers at the cold end. Figure 6-2 depicts MLI tapered wrapping.

Figure 6-2 Illustration of tapered MLI installation on a penetrating component (cryogenic control valve, relief lines, bayonets).

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6.8.10 No edge of an inner layer of aluminized Mylar shall touch any layer more than ten (10) layers farther out in the wrapping. No other forms of thermal shorts in the insulation shall be accepted.

6.8.11 Application techniques shall follow the procedures and principles above to minimize heat transfer through gaps, exposed edges, and shorts.

6.8.12 Burned or singed insulation materials shall not be accepted.

6.8.13 Fiberglass or other shielding materials shall be used by SUBCONTRACTOR to prevent damage to materials during welding or other operations. No such materials shall be left in the assembly except with FNAL written approval.

6.8.14 Insulation materials shall not plug, block, or inhibit any vacuum vessel ports.

6.9 Control Valves installation

6.9.1 FNAL will supply control valves to SUBCONTRACTOR for installation on the TTL MODULES.

Figure 6-3 shows a representative control valve.

Figure 6-3 Representative cryogenic control valve that will be provided by FNAL.

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6.9.1 All recommended installation methods and requirements from the cryogenic valve manufacturer shall apply. Instructions for assembly and disassembly of the valves will be provided by FNAL to SUBCONTRACTOR at the time of Kick-off Meeting (KOM).

6.9.2 The stem must be taken apart from the valve assembly before welding the bonnet at the vacuum jacket weld interface, process piping interfaces, and thermal intercept connection ring. SUBCONTRACTOR shall follow the assembly/disassembly instructions to remove the stem. SUBCONTRACTOR shall exercise caution during removal of valve stem from the valve bonnet. The valve stem must be gently pulled straight out of the bonnet, without bending sideways during the pulling operation.

6.9.3 The valve bonnet (housing) shall be welded to the internal pipework such that the connection welding process does not deform the valve body and does not deteriorate the valve seal.

6.9.4 Thermal intercepts shall be brazed to the intercept rings on valve bonnet as indicated on FNAL provided drawings. MLI shall be applied on the valve bonnet as specified in Section 6.8.

6.9.5 The valve stem must be installed back on the bonnet after completing all the welds.

SUBCONTRACTOR shall follow the assembly/disassembly instructions to install back the valve stem. SUBCONTRACTOR shall exercise caution during re-insertion of valve stem into the valve bonnet. The valve stem must be gently inserted straight into the bonnet, without rubbing the stem against the bonnet inner wall.

6.9.6 SUBCONTRACTOR shall provide FNAL with a completed checklist demonstrating that all cryogenic control valves were successfully actuated after completion of welding activities.

6.9.7 Thermal intercept connection specific to control valves as well as MLI application instructions with regards to tapered layers are shown on FNAL provided drawings.

6.10 Bayonet installation

6.10.1 FNAL will supply bayonets to the SUBCONTRACTOR for installation on the TTL MODULES.

Figure 6-4 shows representative bayonets.

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Figure 6-4 Representative bayonet assemblies that will be provided by FNAL.

6.10.1 The larger bayonet assembly (shown to the right in Figure 6-4) will be provided by FNAL without the manual valve. FNAL will supply square o-rings to seal the flange joint on the larger bayonet. SUBCONTRACTOR shall be responsible for procuring the blank flange and hardware

(nuts, bolts, washers) needed to make the flanged connection for leak check and pressure test.

The smaller bayonet (shown to the left in Figure 6-4) will be provided by FNAL including the manual valve.

6.10.2 Bayonet “straightness” gauges will be provided by FNAL as depicted in Figure 6-5. The gauge is used to check any deformation of the bayonet pipe resulting from welding to vacuum jacket or process pipes.

Figure 6-5 Insertion tool for checking straightness of bayonets.

6.10.1 SUBCONTRACTOR shall perform pre-installation interference/straightness tests and helium leak check on each FNAL supplied bayonet. A record of this test shall be submitted to FNAL within one month of receipt of the bayonets and prior to installation on the TTL MODULES.

6.10.2 The bayonet shall be welded to the internal pipework such that the connection welding process does not deform the bayonet body and does not deteriorate the valve seal.

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6.10.3 The bayonet manual valve shall be removed during welding of the female bayonet to the vacuum cuff to prevent damage to the valve seal. The valve shall be re-installed on the bayonet after welding.

6.10.4 SUBCONTRACTOR shall perform post-installation interference/straightness tests on each FNAL supplied bayonet using the straightness gauge. A record of this test shall be submitted to the

FNAL prior to delivery of the TTL MODULES.

6.10.5 Thermal intercept connection specific to bayonets as well as MLI application instructions with regards to tapered layers are shown on FNAL provided drawings.

6.11 Cryogenic thermometer installation

6.11.1 FNAL will provide Platinum and Cernox thermometer assemblies for installation on TTL

MODULE piping and thermal shield. Sample assemblies are pictured in Figure 6-6.

6.11.2 Table 6-3 lists the items required to install the thermometers. Substitution of certain items is acceptable but is subject to written approval from FNAL.

Figure 6-6 An example of thermometer assemblies provided by FNAL (left) Cernox (right) Platinum.

6.11.1 The thermometers shall be installed during the specific assembly step as identified on the drawings provided by FNAL.

6.11.2 IMPORTANT: SUBCONTRACTOR shall install thermometers following the step-by-step procedure in strict accordance with the FNAL supplied document.

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6.11.3 The mounted thermometers can get damaged during subsequent pipe welding operation due to excessive heating or AC electrical frequencies involved with the welding processes. The mounted thermometers shall be handled according to the following:

6.11.3.1 Prior to welding, every thermometer on the piping sub-assembly to be welded shall be individually shorted by plugging in to the shorting connector…