A. SOW ED0045002 - SSR2 Global Magnetic Shield.pdf

PIP-II SSR2 Cryomodule

- Procurement and Fabrication Specification -

Global Magnetic Shield

Author: V. Roger

Document Number: ED0045002 Rev -

Document Approval Date Approved

Originator V. Roger As in TC

Checker J. Bernardini As in TC

Approver M. Parise As in TC

Contents 1 Scope 3

2 Procurement Specification 3

2.1 Bidding Phase 3

2.2 Technical and Cost Evaluation Phase 4

2.3 Execution Phase and Hold Points 4

3 Fabrication Specification 6

3.1 Introduction 6

3.2 Dimensional conformance 7

3.3 Fabrication Details 7

3.4 Serial number stamping 8

3.5 Hardware 8

3.6 Assembly 8

3.7 Magnetic Flux Measurements 9

3.8 Quality controls 10

3.9 Shipping Plan 10

1 Scope

The Single Spoke Resonator Type 2 Cryomodule (SSR2 CM) is one of the five different types of cryomodules (total of

25 units) that will constitute the PIP-II linear accelerator complex. The present specification is intended to inform the procurement, fabrication, and assembly of the Global Magnetic Shields for the Production SSR2 CM, in quantity indicated in Table 1.

Top Assembly Drawing Description Quantity

F10240910, Rev - PROCUREMENT ASSY, SSR2 GLOBAL MAGNETIC SHIELD 6

F10182640, Rev A KIT, TUNER MOTOR MAG SHIELD 32

Table 1: Quantities and Top Assembly Drawing

The Manufacturer shall provide all materials necessary to fabricate complete deliverables. The Manufacturer shall provide manufacturing engineering services required to generate internal shop drawings and all documentation needed to manage and support their suppliers. The Manufacturer shall 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.

FFDG is requesting that offerors provide firm-fixed pricing for DDP shipping (HTS code 8543.90.88.45) as part of their firm-fixed-price proposal to the RFP.

2 Procurement Specification

Purchase Order will be owned and managed by Fermilab Research Alliance (FFDG).

2.1 Bidding Phase

Bidder shall provide Quotation including all costs to deliver and assemble the assembly indicated in Table 1 at Fermilab.

In addition to quotation, the following documentation shall be provided:

a) Schedule that meets a lead time of 12 months for the first unit and less than 24 months for the other units, starting from the date that the FFDG Purchase Order is awarded to the bidder running through fabrication, including hold points reported in Table 2. Supporting documentation, to demonstrate that the bidder will deliver within the specified timeframe, is recommended.

b) Technical Proposal to demonstrate the ability of the bidder to deliver the assembly with performance that meets or exceeds Fabrication Specification reported in section 0 of this document. The technical proposal shall include datasheets showing physical and magnetic properties of the shield proposed material, so that it’s conformance with ASTM A753 Type 4 can be assessed. Example of past projects (within the last five years) that closely match the scope in complexity and value, and that best illustrate the bidder’s capability, experience, and performance will be considered for the technical evaluation. The Bidder shall disclose what part of the work, if any, will be sub-contracted.

c) Management Control Plan to demonstrate the ability to ensure the required quality standard (see section 0) throughout the entire execution of the project. Examples of documentation developed for past projects (within the last five years), which demonstrate the ability of performing inspection and testing will be considered for the technical evaluation.

All required documentation shall be organized with a table of contents and corresponding sections.

2.2 Technical and Cost Evaluation Phase

An FFDG Purchase Order will be awarded to one bidder after that the proposals will have been evaluated by technical and cost evaluation teams.

2.3 Execution Phase and Hold Points

Upon FFDG purchase order award, the Manufacturer 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 in English.

Within two weeks from FFDG purchase order award, a kick-off meeting shall be carried out to initiate technical and commercial discussion between the technical and commercial representatives from FFDG and the Manufacturer.

Action items from the meeting shall be addressed within one week.

Upon conclusion of the kick-off meeting, FFDG expects to receive bi-weekly a status report via e-mail (FFDG will provide a template) from the manufacturer. Also, a monthly meeting held by videoconference shall be regularly scheduled to discuss technical and commercial updates (FFDG reserves the right to increase the frequency of the meetings). The meetings will be held in English. However, FFDG representatives are always available to respond any time if questions will arise.

Within eight weeks from FFDG purchase order award and before starting any fabrication / procurement activity, the

Manufacturing Readiness Review (MRR) shall be organized to allow FFDG reviewers to assess the Manufacturer’s level of preparation to proceed to the manufacturing and procurement phase. The review’s recommendations (if any) based on the presented material (see MRR deliverables in Table 2), shall be addressed within two weeks from the conclusion of the MRR.

Upon conclusion of the MRR, the Manufacturer will be allowed by FFDG to proceed with the fabrication / procurement phase. Quality Controls (see section 3.8) and technical reports, as detailed in Table 2, shall be provided by the

Manufacturer to FFDG.

The readiness to ship the unit shall be assessed through an appropriate review.

2.3.1 Hold Points

A Hold Point is defined as the moment in time wherein the process needs to be stopped in order to allow a FFDG representative to perform reviews and QCs deemed necessary.

Table 2 lists the main hold points and associated documentation deliverables for this project.

Hold Point

Description Deliverables When required

A Kick-off Meeting

Address action items from the meeting Within 2 weeks of contract award

B

Manufacturing Readiness Review(s) (MRR)

MDED (see section 3.2) Detailed MIP and Travelers’ template (see section 3.8)

Within 8 weeks from FFDG purchase order award and before starting any Fabrication

C Discrepancies /

Nonconformities Discrepancy report(s) As soon as identified

D Shipping Readiness

Review

CMTRs (see sections 3.1.1) Final version of MIP

Final version of MDED Discrepancy report(s) (If applicable)

Installation report(s) (see section 3.6) QC Reports (see section 3.8)

Shipping Plan (see section 3.9)

Prior to shipping

E Assembly at Fermilab and

Magnetic Field Measurements

Magnetic Flux Measurements report(s) (see section 3.7)

After receipt of the assembly at Fermilab

Table 2: Hold Points and Documentation Deliverables for Fabrication Phase

3 Fabrication Specification

This section provides a technical introduction of the scope, assembly to be manufactured, quality controls, and shipping plan.

3.1 Introduction

The PIP-II SSR2 CM adopts a global magnetic shield, which is bolted to a support frame welded inside the vacuum vessel. The global magnetic shield is composed of body segments, end caps, and vertical and horizontal covers as shown in Figure 1, Figure 2, and Figure 3.

Figure 1: F10240910, SSR2 CM Global Magnetic Shield, cryogenic side (dimensions are in mm)

Figure 2: F10240910, SSR2 CM Global Magnetic Shield, instrumentation side

Figure 3: F10156588, SSR2 CM Global Magnetic Shield, Strongback mount

FFDG engineering drawing package (top assembly F10240910) shall be used for the complete parts list.

3.1.1 Materials

Materials used in F10240910, and F10182640, are specified in the referenced drawings. The use of any materials not listed in the drawings is excluded by the present specification. Under exceptional conditions FFDG may approve other materials upon a written request. The Manufacturer is allowed to substitute 3mm thick with 1/8’’ thick material, provided that FFDG will be notified of such change and will give written approval.

Certified Mill Test Reports (CMTR) of all raw materials shall be provided to FFDG as part of the deliverables of the shipping readiness review (see Table 2). These material certifications shall include all processes and tests with grade and composition being clearly identifiable and traceable to the respective component.

If the vendor obtains components from a subcontractor, the vendor is responsible to prove that the materials for the components meet compliance requirements.

3.2 Dimensional conformance

All drawings referenced shall be used by the Manufacturer for configuration control and dimensional conformance.

Dimensional variances and overall envelope configuration shall be maintained within specified tolerances. The final validation of dimensional conformance will be installation of the global magnetic shield inside the SSR2 CM vacuum vessel, as detailed in Section 3.6 of this document.

The drawings supplied as part of this request for proposal are to be considered near-final release. The final set of drawings (latest revisions), including minor modifications that might occur during the bidding phase, will be given to the Manufacturer at the time of the kick-off meeting.

The Manufacturer may decide to use the drawings provided by FFDG for fabrication, or to produce its own drawings.

Any change or deviation from the set of drawings provided by FFDG shall be listed in a Manufacturer’s Drawings

Exception Document (MDED). FFDG will have to provide a written approval to the MDED before the Manufacturer can proceed to the next step. FFDG 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.

3.3 Fabrication Details

3.3.1 Cutting and Forming

The material shall be formed via normal sheet metal operations. Laser cutting and water jet cutting of the flat stock and rolling to final size is permitted.

3.3.2 Heat Treatment

After forming, the shields shall be annealed and processed accordingly to optimize the magnetic properties. The heat treatment batch number and other critical information for each part of the shield assemblies shall be recorded and be traceable to the part and serial numbers.

3.3.3 Grinding and Snipping

Before annealing, grinding and snipping are permissible to create a better fit with mating parts. No metal work is permitted once the annealing process has been completed.

3.3.4 Handling

Before and after annealing, white cotton gloves shall be worn to prevent cosmetic defects from dirty hands and skin oils. The magnetic permeability of the shield material can be degraded significantly by mechanical stress and shock during handling, packing and transportation, so proper handling procedures must be established and clearly stated.

3.4 Serial number stamping

Supplier shall permanently etch a serial number on each component. The serial number shall follow the following alphanumeric format:

Part# Revision CM# Sequence#

Part number and revision number shall be the ones indicated in FFDG drawings, if no revision is indicated in the drawing, symbol “-“ shall be used. CM number is 2 for the 1st unit and 3 for the 2nd unit , … The sequence number shall increase from 01 to the number of repeated components in the assembly.

3.5 Hardware

The Manufacturer shall supply to FFDG the hardware listed in the provided drawings. Quantities are the ones listed in the part list of drawings plus 25% of spares, up to a limit of 30 spares for each item. Hardware material is the one listed in the part list of drawings, please note that SSB88 is SS 316L. The hardware shall be properly packed and labeled to be easily identifiable during assembling of the global magnetic shield at Fermilab.

3.6 Assembly

It is required that the Manufacturer perform or provide oversight assembling the global magnetic shield at Fermilab.

Cost associated with the assembling of the global magnetic shield shall be clearly stated in the proposal. FFDG drawings, with exceptions listed and approved in the MDED, shall be used as reference for configuration and dimensional conformance control.

The upper magnetic shield body segments shall be bolted on the frame welded to the SSR2 vacuum vessel shell, top hat, and side port, as shown in Figure 4.

Figure 4: Global Magnetic Shield bolted into SSR2 vacuum vessel

The lower portion of the magnetic shield shall be bolted on the SSR2 strongback as shown in Figure 5.

Figure 5: SSR2 Global Magnetic Shield on Strongback

Installation details of the fasteners, such as torque values, shall be specified by the vendor and communicated to FFDG, which will have to provide approval.

3.7 Magnetic Flux Measurements

The global magnetic shield is designed so that the magnetic flux generated by all surrounding components is less than

15mG into a 600 mm diameter ideal cylinder drawn around the axis of the shield, for its entire length.

After assembling the global magnetic shield at Fermilab, the manufacturer shall measure the magnetic flux into the

600 mm ideal cylinder for the entire length of the magnetic shield.

The magnetic flux measurements shall take place after the strongback and magnetic shielding have been fully installed.

Orientation shall match that of final assembly. The access provided by the 8 lower ports will allow for the gauge to be inserted for measurements. The magnetometer shall be a flux-gate-type gaussmeter G93 or equivalent. Readings shall be taken in the vertical plane, horizontal plane, and axial plane. Non-magnetic tooling should allow for the accurate positioning of the sensor at a height 240± 5mm above the strongback surface, as shown in Figure 6. Additional measurements should be performed at beamline height of 520±5mm and a lower height such as 120±5mm.

Figure 6: Measurement Height, Centered Horizontally

Any tooling needed to perform magnetic flux measurements shall be provided by the Manufacturer at its own expense.

FFDG will provide a STEP file of the global magnetic shield that the Manufacturer can use to design the tooling needed to perform magnetic flux measurements.

The Manufacturer should communicate to FFDG the extent to which they are able to perform this procedure, along with any eventual deviation from it. FFDG should provide approval for any deviation from this procedure.

Results shall be collected in a report which has to be submitted to FFDG for approval. Cost associated with the measurement of the magnetic flux shall be clearly stated in the proposal.

3.8 Quality controls

The Manufacturer shall prepare a project specific Manufacturing and Inspection Plan (MIP) for FFDG’s approval. The

MIP shall list the sequence of manufacturing steps, as well as the associated inspections:

- Visual inspections.

- Dimensional inspections.

- Magnetic flux measurements.

The Manufacturer shall develop quality control procedures and tests to guarantee that the project will be in full conformance with the FFDG’s specifications. If during inspections a discrepancy occurs, which affect the final product, the supplier shall generate a Discrepancy Report (DR) and obtain FFDG’s approval before proceeding to the subsequent step.

The Manufacturer shall maintain records of all inspections and tests in the form of Quality Reports (i.e., electronic travelers).

The MIP shall be made available for FFDG’s reviews and approval before the Manufacturing Readiness Review (MRR), as also indicated in Table 2.

3.9 Shipping Plan

The Manufacturer shall ship each component properly packed to ensure that damage is not incurred during shipment, in accordance with transportation industry standards. This shall include weather protection and shock protection. The vendor shall propose a shipping configuration to FFDG, and FFDG shall approve prior to any shipments.

Recommendations include foam, bubble wrap, and other vibration/shock reducing materials to be used as packing material, and for components to be shipped in hard-side crates to reduce the risk of damage. Each package shall be labeled with a tag identifying the serial number of the shield component(s) contained inside. Sizing shall be such that handling is facilitated and weight limitations imposed by the transportation industry can readily be met.

All deliverables including documentation shall be catalogued and offered for acceptance to FFDG by the Shipping

Readiness Review, as detailed in Table 2.