Att1 RFP Appendix Detailed Scope description 2024Jan17.pdf

Project 6-7-9M MI-65 Evaporator Stack and Condensate Storage Design

Appendix Section – detailed description of scope

1. Section One: Ground Mount Exhaust - Scope of Work:

1.1 The pre-conditioning equipment (exhaust fan/heater/stack/appurtenances) is to be located on the west side of the MI-65 building adjacent to the existing evaporators.

1.2 Fermilab will provide geotechnical information/studies through existing documentation or FNAL will separately issue a construction contractor request for proposals for geotechnical studies and analysis.

1.3 This A/E to design the shallow foundations used to support the ground mounted exhaust equipment based on geotechnical recommendations provided by FNAL’s geotechnical contractor or assumptions to be verified by FNAL (such as FNAL’s qualified testing lab).

1.4 Design of the vertical stack and its anchorage to the foundation will be provided by the A/E through a stack manufacturer or other qualified A/E representative/personnel. A/E to coordinate their foundation design with the design and base reactions of the stack, as provided by their representative/personnel.

1.5 The vertical stack is assumed to be ground supported and free standing, without the need to be braced to the existing building in any way. Preliminary recommendations from a manufacture have confirmed this is possible. In the case that the stack would need to be braced to the building, that would require additional analysis by A/E and is excluded from this Scope of Work.

1.6 Deliverables: A/E to provide 30% structural drawings and specifications for the above-mentioned scope for FNAL review and preliminary 60% and final design drawings and specifications for the above-mentioned scope.

2. Section Two: Control Strategy - Scope of Work:

1.1 The control system for the MI-65 Stack Vapor Dispersion System shall include specifications for the following:

• Three existing evaporators providing tritiated vapor exhaust

• One new inline belt driven tube type exhaust fan.

• One new outside dilution air electric heater.

• One new outside air temperature element with an integral loop powered temperature indicating transmitter wired in series with a 4-20mADC surge suppressor. This shall be mounted outside on the north wall of the building under a 316 Stainless Steel, powder-coated white sunshield.

• One new loop powered outside air dew-point transmitter wired in series with a 4- 20mADC surge suppressor. This shall be mounted outside on the North wall of the building under a 316 stainless steel, powder-coated white sunshield.

• One new loop powered differential pressure indicating transmitter wired in series with a 4-20mADC surge suppressor. This shall be furnished with bleed / block valves for each sensing port. This shall be mounted to discharge header of the three existing evaporators.

the “High” side of the transmitter shall be vented to atmosphere, while the “Low” side of the transmitter shall be piped to the evaporator discharge header duct.

• One new loop powered differential pressure indicating transmitter wired in series with a 4-20mADC surge suppressor. This shall be furnished with bleed / block valves for each sensing port. This shall be mounted across the air filter on the outside dilution air duct. the “High” side of the transmitter shall be piped upstream of the air filter, while the “Low” side of the transmitter shall be piped downstream of the air filter.

• One new duct mounted air temperature element with an integral loop powered temperature indicating transmitter wired in series with a 4-20mADC surge suppressor. This shall be mounted upstream of the outside dilution air electric heater.

• One new duct mounted air temperature element with an integral loop powered temperature indicating transmitter wired in series with a 4-20mADC surge suppressor. This shall be mounted downstream of the outside dilution air electric heater.

• One new loop powered gauge pressure indicating transmitter wired in series with a 4- 20mADC surge suppressor. This shall be furnished with bleed / block valve for the sensing port. this shall be upstream of the new exhaust fan.

• One new 24VDC powered duct mounted thermal dispersion flow switch mounted downstream of the new exhaust fan.

• One new duct mounted air temperature element with an integral loop powered temperature indicating transmitter, wired in series with a 4-20mADC surge suppressor. This shall be mounted in the mixed air exhaust stack downstream of the new exhaust fan.

• One new loop powered duct mounted dew-point transmitter, wired in series with a 4- 20mADC surge suppressor. This shall be mounted in the mixed air exhaust stack downstream of the new exhaust fan.

• One new variable frequency drive installed in an enclosure (316 stainless steel, NEMA 4X with pad-lockable 3-point latch) with an integral flange-mounted disconnect switch and a 1000 VA control transformer (for feeding the safety interlock circuits) and local HIM (human interface module) mounted to the face of the enclosure.

• One new free standing control panel housing an Allen-Bradley ControlLogix PLC, managed Cisco switch, 19” PanelView Plus 7 HMI Display, DC redundant power supplies and miscellaneous control devices. A new license for the PLC programming software shall be furnished to the Owner.

• One local terminal box enclosure (316 Stainless Steel, powder-coated white, NEMA 4X with pad-lockable 3-point latch with 304 stainless steel combination breather drain) housing the local operator interface devices.

• One new loop powered current transmitter monitoring the current draw of the electric heater. This shall be mounted in the existing MCC (if present – if no MCC is present, this will be mounted in a small enclosure downstream of the disconnect of the heater).

• One new loop powered current transmitter monitoring the current draw of the variable frequency drive. This shall be mounted in the new VFD enclosure.

2.2 The newly proposed control system for the MI-65 Stack Vapor Dispersion System will not include furnishing the following equipment specifications:

• The FNAL supplied and installed Pulsar Weather Station.

• Uninterruptible Power Supply (UPS) and power conditioning for the new control panel.

2.3 The newly proposed control system for the MI-65 Stack Vapor Dispersion System will not include the following tasks:

• Any programming or hardware field modifications to any existing systems.

2.4 The newly proposed control system (PLC) for the MI-65 Stack Vapor Dispersion System shall be specified to interface the following:

• Three existing evaporators.

o This shall include “Initiate Exhaust System for Operation” command from the existing evaporator control panel to the new PLC control panel. Note: All modifications to the existing evaporators (both programming and field hardware modifications) to change the operation of the existing system to initiate this command will be done by the FNAL Controls Contractor.

o This shall include “System Ready” status from the new PLC enclosure to the existing evaporator control panel. Note: All modifications to the existing evaporators (both programming and field hardware modifications) to change the operation of the existing system to not start until this command is received will be done by the FNAL Controls Contractor.

o This shall include “Running” status from the existing evaporator control panel to the new PLC control panel.

• Interface and power (if needed) for all the new field instruments listed above.

• Interface with the FNAL Pulsar Weather Station and receive the following 4-20mADC signals.

o Wind Direction – Range: 0 to 360 degrees.

o Wind Speed – Range: 0 to 167 mph.

o Temperature – Range: -58 °F to +140 °F.

o Relative Humidity – Range: 0% to 100%.

o Barometric Pressure – Range: 8.85 inches Hg to 35.4 inches Hg.

o Precipitation Amount – Range: 0 inches to 3.940 inches.

o Precipitation Intensity – Range: 0 inches to 7.870 inches.

o Precipitation Type – Range: 0 to 255.

• Interface via 4-20mADC signals to the new outside dilution air electric heater.

• Interface with the new Variable Frequency Drive enclosure via 24VDC discrete I/O and 4- 20mADC analog I/O.

• Provisions will be provided for interface to the existing FNAL SCADA System. o An Ethernet RJ-45 port will be available on the new managed switch within the new PLC control panel.

o FNAL will be responsible for routing and installing the conduit and Category 6 cable from their existing SCADA switch to interface to the new managed switch within the new PLC control panel.

o The communication protocol for the new link shall be EtherNet/IP.

2.5 The newly proposed control scheme for the MI-65 Stack Vapor Dispersion System shall be specified to account for the following:

• Receive analog data from the existing FNAL weather station to enable and disable the operation of the existing evaporators. This control scheme will be determined through FNAL and A/E during the revised design phase of the project.

• Receive analog data from the new outside air temperature and dew-point sensors to stage the existing evaporators. This control scheme will be determined via internal coordination with A/E Process Mechanical during the revised design phase of the project.

• Automatic starting/stopping of the exhaust fan and ramping the speed of the exhaust fan.

This control scheme will be determined via internal coordination with A/E Process Mechanical during the revised design phase of the project.

• Starting/stopping and staging of the outside dilution air electric heater. This control scheme will be determined via internal coordination with A/E Process Mechanical during the revised design phase of the project.

2.6 Work performed by FNAL and not by A/E includes the following:

• Programming the new PLC.

• Programming the new HMI.

• Programming the new HIM.

• Programming the new VFD.

• Program modifications to any of the existing systems present at the site.

• Field hardware modifications to any of the existing systems and equipment present at the site.

• Factory testing of the new control panels, operator interface enclosures, VFD furnished and installed under this project.

• Performance testing of the new system installed under this project.

• Designing field modifications to any of the existing systems or equipment present at the site.

2.7 Additional items:

• The 100% design package will specify that the contractor will need to modify, test, and confirm code.

• Power requirements for the new control panel will be a 120VAC, 20 Amp circuit.

• The existing chain link fence is for human safety in the event of a leak (not for the control system)

• The interface to the existing SCADA should be located in the electronics room (FNAL will perform field connections and run conduit)

• The weather station will be furnished by FNAL

• The system will specify an interface to the weather station (external enable contact)

2.8 Deliverables:

• Specifications for the above features will be included in A/E design.

2. Section three: Transformer design and placement – Scope of Work

3.1 Building MI-65 does not have natural gas service consequently the pre-conditioning equipment will be served by direct electric resistance heaters. The heaters and associated elements of the new building are estimated to be in excess of 500KW.

3.2 Review of the existing MI-65 electrical plans indicates that the existing conventional power 750KVA transformer will need to be upgraded/replaced with a new 1500KVA transformer (size to be confirmed by design A/E and FNAL). FNAL is in possession of a refurbished 1500KVA transformer, all efforts will be made to utilize this transformer as the replacement to the existing 750KVA unit.

3.3 FNAL requests that the A/E provide 30% construction design drawings and one lines to serve the new dispersion system (exhaust and heaters) and storage tank building with the new 1500KVA transformer prior to proceeding with 60%/100% design. This new transformer will serve the current loads (mainly MI-65) on the existing 750KVA transformer plus the new exhaust system and the new storage tank building. This includes panels and overcurrent protection.

3.4 The location of the new replacement transformer should take into account the layout of the existing electric power yard that is in close proximity to the MI-65 facility. FNAL requests that the high-side of the new MI-65 transformer be connected to the existing 13.8kV switchgear.

3.5 The high-side (13.8kV) of the new transformer would have fuse protection and not a circuit breaker. The fuse protection will be included with the transformer. The primary wire service from the distribution switchgear will be upgraded as required. The secondary side will include new circuit breakers to serve the existing building, the new building and the exhaust system.

Conduit additions and reconfiguration will be required to serve the existing and new loads.

3.6 FNAL notes that the capacity of the new transformer is currently to be determined. The exact capacity of the new transformer will be based on A/E’s analysis of the new dedicated demand of the dispersion heater/exhaust system and the existing current loads. It is very desirable to use the refurbished 1500KVA transformer in current possession of Fermilab.

3.7 The new transformer will be three phase, pad mount, 13.8kV/480V/277V, delta-wye ground.

3.8 Temporary power service to MI-65 during new transformer installation will be evaluated as a part of this design scope.

3.9 Deliverables: Specifications for the above features will be included in A/E’s preliminary design.

3. Section Four: Minimum 15,000 Integrated Condensate Storage - Scope of Work:

3.1 As a result of the previously conducted CFD study, it was determined that to accomplish complete evaporation of the projected annual condensate stream during the identified optimal weather conditions a minimum storage volume of 15,000 gallons would be required at MI-65.

The storage volume design is to consider a ground mounted enclosure on the west side of the MI-65 building adjacent to the existing evaporators and ground mount exhaust and pre-conditioning equipment. The storage volume design will be fully integrated into the evaporation systems controls and monitoring to operate automatically with minimal personnel intervention.

3.2 A/E to design the shallow foundations used to support the storage system equipment within the new building described below, based on geotechnical recommendations provided by FNAL’s geotechnical contractor or assumptions to be verified by FNAL (such as FNAL’s qualified testing lab).

3.3 Design of the storage system shall consider a minimum of two tanks each capable of holding 67% of required 15,000 gallon volume capacity. The design shall consider freeze prevention of the tank(s) and the interconnected piping whether in the building or the transfer piping to MI-65. Full volume secondary containment shall be provided and tertiary containment protection from spills and overflow to recapture or direct spills to surface water/pond rather than ground water.

3.4 Design shall consider the storage system to be the primary point of discharge from the NuMI Target Hall pumps. Design shall include pumps, all interconnecting piping and valving

(isolating or automated) to result in a complete operating system. Consideration to circulate and mix the entire condensate volume and to ensure neutralization of the nitric acid component of the condensate by the existing NaOH injection shall also be included. This could include the need for an additional parallel NaOH neutralization system.

3.5 Design of control and monitoring system shall include monitoring of all pertinent temperatures, pressures, valve positions, pumps, tank levels, etc. System control shall include optimal movement of condensate between tanks to properly maximize evaporator operation.

3.6 A/E to conduct a meeting within six weeks of project start to present/review preliminary pumping, piping configuration and controls and monitoring design of the storage system.

Fermi requires notice of this presentation two weeks prior so that appropriate Fermilab Accelerator Division Controls personnel along with the tritium management group can be scheduled to attend. An example of a similar control/monitoring system can be provided to A/E to facilitate basis of design and costing.

3.7 Design consideration shall include a separate enclosure to house the storage tank.

Enclosure design shall include adequate space for the tanks and associated electrical, piping and other appurtenances. Allowance for system expansion of one additional tank (total of three 10,000 gallon tanks) shall be included. Spatial consideration shall be given to exiting and adequate maintenance access of all associated equipment in the enclosure. Enclosure design shall be slab on grade/shallow foundation and comply with current building codes and enclosure elements as required by the Fermi Engineering Manual. Enclosure design shall include HVAC to provide a year round conditioned environment. Winter minimum of 60F and a summer maximum of 80F. All interconnected piping between MI65 and the new enclosure shall be protected from freezing.

4.8 Deliverables: A/E to provide architectural, structural, mechanical and electrical 30% design drawings for the above-mentioned scope prior to the 60% and final design drawings.

4. Section Five: New building for Storage Tanks - Scope of Work:

4.1 A new separate building will be required to house the storage tank system. The design shall include adequate space for the tanks and associated electrical, piping and other appurtenances. Allowance for system expansion of one additional tank (total of three 10,000 gallon tanks) shall be included. Spatial consideration shall be given to exiting and adequate maintenance access of all associated equipment in the building. Building design shall be slab on grade/shallow foundation and comply with current building codes as required by the Fermi Engineering Manual. Building design shall include HVAC to provide a year round conditioned environment. Winter minimum of 60F and a summer maximum of 80F. All interconnected piping between MI65 and the new building shall protected from freezing. Three (3) concepts shall be presented within six (6) weeks for FNAL to make selection for final directions of building. Building plans, elevations, and/or 3-D sketches shall be presented to FRA for discussion.

4.2 A/E shall provide a building design that shall comply with all governing Codes (FESHM 1071). A/Es shall provide a comprehensive code analysis for all disciplines (including NFPA) per the Design Guides. The enclosure shall be in compliance with IBC & NFPA, including, but not limited to height, area, and separation requirements. Minimum utilities and fire protection systems shall be in accordance with the enclosure use group. A/Es shall assess and provide any required building systems to comply with the Codes and to serve the controls equipment monitoring the storage tanks.

4.3 Fermilab will provide geotechnical information/studies to A/E through existing documentation or FNAL will separately issue a construction contractor request for proposals for geotechnical studies and analysis.

4.4 Deliverables: A/E to provide architectural, structural, mechanical and electrical 30% design drawings for the above-mentioned scope prior to the 60% and final design submissions.

5. Section Six: Fermi Radiological Work requirements – Scope of Work

5.1 To comply with the Fermi Radiological Work requirements all design and contractor fabrication will need to be done in accordance with the most recently published version of

ASME B31.3., in addition to FESHM 5031.1 Piping Systems, FESHM 5031.5 Low Pressure

Vessels (Fermilab ESH Manual) and FRCM (Fermi Radiological Control Manual) CHAPTER 3

Conduct of Radiological Work. Portions of this work from the latter FNAL specific standards will be provided by Fermilab.

5.2 A/E to design all systems to meet ASME B31.3 Normal fluid service, including Bonding

Procedure Specifications (BPS) and Welding Procedure Specifications (WPS). These specifications will outline the ASME B31.3 requirements for fabrication, assembly and erection of piping, worker qualifications/certifications, pressure and leak test procedures and inspections.

• A/E to include P&ID (piping and instrumentation diagram) schematics of the system along with a VIE (valve, instrumentation and equipment) list.

• A/E to provide all ASME B31.3 required design calculations, including stress calculations for loading conditions.

• DFMEA (Design Failure Mode Engineering Analysis) will be produced by Fermilab.

• A technical requirements report will be produced by Fermilab in accordance with

ASME B31.3 Normal fluid service, EN13480, FESHM 5031.1, FESHM 5031.5 and FRCM

CHAPTER 3 CONDUCT OF RADIOLOGICAL WORK.

• Preliminary engineering notes for the piping and the storage vessel will be created by

A/E on Fermilab provided forms and the notes will be reviewed by Fermilab.

• Fermilab will produce an ORC (Operational Readiness Clearance) process.

5.3 A/Es shall provide a design that complies with all related FRA codes, including the radiological codes, The work shall be in accordance with the Fermilab Radiological Control Manual (FRCM) (https://publicdocs.fnal.gov/cgi-bin/ListBy?topicid=91 ).

5.4 Deliverables: A/E to incorporate the above into the drawings and specifications .

https://publicdocs.fnal.gov/cgi-bin/ListBy?topicid=91