Attachment 2 - Statement of Work Direct Wind Oven Rev A. dated 5.31.24.pdf

Superconducting Magnet Division

BROOKHAVEN SCIENCE ASSOCIATES

Brookhaven Science Associates Upton NY 11973

Statement of Work Direct Wind Curing Oven Procurement

Revision A 05/31/24

Prepared By:

A.J. Marone Cognizant Engineer

Approval:

M. Anerella - Mechanical Engineering Head

P. Joshi Electrical Engineering Head

Henry Hocker - Quality Assurance Representative

Marteenio Samms ES&H

Revisions:

A Initial Release 05/31/24

Statement of Work Direct Wind Curing Oven Revision A 05/31/24

1 SCOPE

This Statement of Work (SOW) establishes the overall requirements for the procurement of the Coil Curing Oven for EIC IR Direct Wind Coils. This document responsibilities and obligations as set forth herein.

2 APPLICABLE DOCUMENTS and STANDARDS

2.1 NFPA 70 National Electric Code

2.2 In the event of a conflict between any of the procurement documents, the

Contractor shall immediately notify the BSA Contractual Representative who shall in each instance determine which document takes precedence and notify the Contractor accordingly. Failure to notify BSA of a document conflict shall not

3 GENERAL REQUIREMENTS

3.1 The oven shall be a high temperature oven to be used for the curing in an air atmosphere of coils comprised of niobium titanium superconductor. These coils shall be fabricated on stainless steel support tubes during curing and shall be instrumented with temperature sensors in critical areas. Coils of various lengths and diameters, and also tapered diameters, shall be supported during curing.

Temperature uniformity of the reaction fixture at 125 ºC, at 175 ºC, and at 225 ºC is critical and shall receive appropriate consideration in the detailed design of the oven and its control system.

3.2 Contractor Responsibilities

3.2.1 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 complete the contract.

3.2.2 Inspection: The Contractor shall be responsible for performing inspections and test throughout the assembly process and maintaining records in compliance with this

SOW.

3.2.3 BSA reserves the right to designate selected manufacturing, inspection, and/or manufacturing and test cycle. Contractor shall comply with any BSA required hold or witness points in the manufacturing process.

4 MANAGEMENT

4.1 Program Plan

Within two (2) weeks after award of Contract, the Contractor will deliver a detailed program plan which includes the following:

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

b. Point of Contact a project representative from the Contractor will be identified to be the primary contact with BSA for this project.

c. Schedule - a milestone schedule defining the material order, manufacturing, inspection, and assembly phases to allow for regularly scheduled progress monitoring. Identification of critical manufacturing operations, as well as inspection, test and hold checkpoints will be part of the schedule. In addition, the milestone schedule shall include the following significant milestones identifying proposed dates of accomplishment.

Significant Milestones Months

ARO

1 Contract Execution. 0

2 Contractor Submission of oven configuration drawing 2

3 Mechanical Completion of the oven 6

4 Factory Acceptance Testing of the oven 8

5 Oven shipment 9

6 Successful Commissioning 12

4.2 Progress Teleconference

Within two (2) weeks after award of Contract, monthly program technical and progress teleconferences and/or meetings between the Contractor and BSA will be held at a mutually scheduled time during all phases of manufacturing, technical and contractual questions, presentations of analysis or testing results, design reviews, value engineering, trouble shooting, material status, tooling status, resources, and manufacturing issues.

4.3 Performance Reporting

Throughout the life of the Contract, the Contractor will supply a written report by the fifth of every month to the BSA Technical Representative clearly detailing progress through the prior month with respect to the program. This will include milestone charts, detailed progress, open items, problems, recommended solutions, and risk mitigation.

5 PROPOSAL REQUIREMENTS

5.1 Any exceptions taken by the vendor to this SOW shall be submitted in writing to BNL at the time of proposal or before.

5.2

Any exceptions or qualifications to this specification. The seller may propose alternatives where cost, schedule and/or performance improvements may be realized.

Description and drawings of the general arrangement of the oven and loading system.

Description of loading procedure.

Drawings of penetration ports and their closures.

Description of procedure for insertion of thermocouple wires through the ports and closing of ports to establish gas tight operating conditions.

Maximum power requirements.

Specification of temperature measurement system used by the control system.

Warrantee description

6 TECHNICAL REQUIREMENTS:

6.1 The design of the Coil Curing Oven shall include, but not necessarily be limited to the features, operating requirements and characteristics as specified herein. It shall be designed to best commercial practices and shall be constructed in a thoroughly workmanlike manner.

6.1.1 Operating temperature:

Desirable > 300 ºC Acceptable > 250 ºC

6.1.2 Temperature uniformity

Temperature uniformity of the working volume (including the thermal load mass) at 125 ºC, at 175 ºC, and at 225 ºC shall be as follows:

Desirable: +/- 3 ºC Acceptable: +/- 5 ºC

The use of fans to circulate the atmosphere within the oven in order to enhance temperature uniformity and to reduce the time delay at 225 ºC is acceptable.

6.1.3 Maximum time delay at 225 ºC:

This is the maximum time before the entire working volume (including the thermal load mass) shall be within the temperature uniformity range specified herein, at the end of a ramp to 225 ºC at 50 ºC/h with a thermal load mass of 700 Kg (122 Kg/m over 5.75 m length).

Desirable: < 2 hours Acceptable: < 3 hours

During this time period the temperature within the oven working volume may exceed the set point, but the load temperature shall not be permitted to overshoot the set point.

6.1.4 Temperature ramp-up rate:

Oven power shall be sufficient to ramp from 20 ºC to 225 ºC at specified rate with maximum load as follows:

Desirable: 200 ºC/h Acceptable: 100 ºC/h

6.1.5 Maximum load:

The load shall be a stainless steel tube supporting coils made of niobium titanium and copper, equal to or less than 700kg; 122 Kg/m over a 5.75m working length.

See also 6.1.9.2.

6.1.6 Working Volume:

This is the volume, in the center of the oven, where the temperature uniformity shall be maintained as specified herein. The door opening and internal oven dimensions shall be large enough to accommodate objects of this size with reasonable clearance for additional fixture supports, thermocouple wiring and plumbing as necessary. The seller shall specify the overall oven internal working dimensions and door opening size.

Length: 5.75 m Cross-section: 0.72 m x 0.72 m Shorter and smaller coils (e.g. 0.5m long, 0.05m diameter) will also be cured in this volume.

6.1.7 Oven And Retort/Reaction Fixture Atmospheres:

The oven shall have suitable gas penetrations to allow for venting the interior of the curing oven if needed and to provide access for the following. The seller shall specify the applicable oven components including, but not necessarily limited to the following:

o Oven sealing o Door sealing o Penetrations for thermocouple leads o Vent and overpressure protection provisions

The seller shall specify the selection of heating element materials as it applies to compatibility with the atmosphere within the oven.

The seller shall discuss oven venting and sealing provisions as required to prevent the intrusion of external, unheated air from degrading the temperature uniformity within the oven during the curing cycle. In addition, the seller shall discuss the adequacy of the proposed oven sealing scheme to provide sufficient sealing to enable an optional positive pressure inert gas (argon or nitrogen) purge of the atmosphere within the oven prior to and during curing if needed. Discussions may include, but not necessarily be limited to such pertinent factors as;

o The cost and schedule impact of providing enhanced sealing capability if required to enable positive pressure purging of the atmosphere within the oven o Estimated required purge gas flow rate as applicable o Effect of purge gas flow on temperature uniformity o Achievable internal oven pressure during purge o Control of the purge gas flow/pressure o Location of purge gas inlet and outlet connections

6.1.8 Control System:

The control system shall be network compatible and shall have supportable and patchable operating system, TBD. Possible system architecture is as follows: a controller with any operating system, connected via GPIB (or other dedicated connection) to a PC with Windows TBD.

The control system shall provide for both manual and automatic control

The temperature measuring system shall have an absolute accuracy of +/- 1ºC from 125 ºC through 225 ºC.

The temperature measuring system shall have a minimum sensitivity of 0.1 ºC

The control system shall provide for control of a minimum of 4 independent zones (depending on zone division of heaters suggested by the seller in order to meet temperature uniformity requirements specified herein)

The control system shall allow change of set-point temperature during operation.

The control system shall allow displaying, recording and remote viewing of 20 temperature sensors.

The control system shall allow use of external (user supplied) temperature sensors for multiple control loops.

The control system shall allow for the use of advanced control schemes including cascade, rate limits, real-time mathematical functions, etc.

The control system shall have sufficient non-volatile memory to store all temperature recordings at 1 minute intervals over a 20 day period.

The control system shall store programs and settings through indefinite power outages.

An over-temperature interlock shall be provided.

The control system shall have the capability of alarming on any out-of-specification condition.

A discrete output shall be provided for alarm conditions capable of driving a small relay.

If an internal circulation system is employed, system operational status indicators shall be provided.

6.1.9 Other:

6.1.9.1 Loading System: The seller shall propose a loading system to facilitate moving the load into and out of the oven. The oven shall be top loaded. The detailed design of this system shall be capable of safely operating with maximum loads as specified herein.

6.1.9.2 Load supports: Coils to be cured shall be supported by the ends only.

Supports shall be at an infinitely variable spacing between 0.4m and 5.75m, either on rails or equivalent. The supports shall be adjustable to accommodate diameters from 0.05m to 0.72m. Each support shall have a weight supporting capacity of 350Kg.

6.1.9.3 Penetrations: The oven shall be provided with penetration ports for thermocouple wires and various gas pipes. The ports shall be configured and located to facilitate connection of coil-mounted thermocouples after insertion of the coil into the oven.

o Penetrations shall be provided for up to 16 thermocouple pairs.

o Penetrations shall be provided for gas inlet and outlet pipes as needed.

o Suitable closures for unused ports shall be provided.

o In addition, if the optional capability to purge the atmosphere within the oven is selected for implementation, the oven shall be provided with gas inlet and outlet connections as appropriate.

6.1.9.4 Documentation: The following documentation shall be provided by the seller:

o User manuals (including instructions for start-up, operation, maintenance and troubleshooting) for the oven and control system o Complete as-built drawings including wiring diagrams o Control system source files if applicable o Copies of reports of all required inspections and tests o Recommended spare parts list

6.1.9.5 Power requirements: Power supplied shall be 480 VAC, 3 phases, 4 wire, 60 Hz.

6.1.9.6 Safety:

The oven shall meet all applicable OSHA requirements as well as all applicable federal, state and local codes.

The oven shall be listed by an OSHA approved Nationally Recognized Testing Laboratory (NRTL).

The oven shall not contain asbestos or asbestos containing material.

6.1.9.7 Installation/Operation: The seller shall provide detailed instructions for installation and operation of the oven at Brookhaven National Laboratory, Upton, NY, including but not limited to an operation manual, utilities interface drawing, and engineering drawings.

7 OPTIONS:

The seller shall quote the following options:

On site start-up service at Brookhaven National Laboratory (seller support of first item production run) Description and costs of service and maintenance options Requirement to continue to operate normally on an external generator (customer supplied) subsequent to an unplanned power outage occurring at any point in the heat treat cycle.

Ability to maintain a positive pressure argon purge of the atmosphere within the oven prior to and during the heat treat cycle (see 3.7)

8 Packaging and Shipping:

8.1 Contractor shall be responsible for all packaging, crating, and preparation for shipment. The packing shall be sufficient to ensure safe delivery of the items to BNL and meet the requirements of the selected shipper.

8.2

This notification shall be in the form of an e-mail message. The BSA representative will provide all shipping details upon request.

9 QUALITY ASSURANCE

9.1 Qualification Tests

9.1.1 Test requirements: The oven shall pass qualification/acceptance testing at the installation at Brookhaven National Laboratory. Testing shall demonstrate as a minimum all applicable requirements set forth in this specification. Testing shall be performed by the seller and witnessed by BNL representatives. Before testing shall begin, the seller shall submit a written Acceptance Test Procedure (ATP) to BNL for approval. Once approved, changes must be approved by BNL prior to implementation.

One cure cycle shall be performed during the qualification test utilizing a dummy mass of up to 4 meter length and 490 Kg mass. (provided by Brookhaven National Laboratory).

The cure cycle shall consist of the following :

o Ramp to 125 ºC at 100 ºC/h minimum ramp rate, o Hold for 1 hour, o Ramp to 175 ºC at 100 ºC/h minimum ramp rate, o Hold for 1 hour, o Ramp to 225 ºC at 100 ºC/h minimum ramp rate.

o Hold for 1 hour.

o Cool-down to room temperature at maximum rate (all heaters off).

A minimum of 16 temperature sensors shall be placed in the working volume and on the thermal load by Brookhaven National Laboratory. All temperatures shall be recorded during the complete thermal cycle.

All requirements as set forth in this specification shall be met for acceptance, including, but not limited to:

o Temperature uniformity inside the working volume at 125 ºC, at 175 ºC, and 225 ºC.

o Maximum time delay at 225 ºC.

o All features of the control system.

Conformance to the requirements of this specification shall be demonstrated by observation, inspection, calculation, test, etc. as applicable.

9.2 Quality System and Facility Access: The Contractor shall maintain a documented quality assurance system which provides the processes to ensure that each component produced for acceptance conforms to the requirements of this document and the applicable technical documentation. BSA representatives shall

9.3 Records: The Contractor shall retain objective evidence, including records, of the inspections and tests performed in the execution of this SOW. These records shall be made available to BSA for review upon request. These records shall be maintained for a minimum of one (1) year, unless otherwise specified.

9.4 Certificate of Conformance: The Contractor shall provide a Certificate of Conformance. The certificate shall include the title of and be signed by an authorized representative of the company, and shall constitute a representation by the contractor that:

The items as delivered comply with all requirements of the procurement documentation.

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

9.5 Responsibility for Subcontractors: It is the responsibility of the Contractor to impose applicable technical and quality requirements upon their subcontractors.

9.6 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.

9.7 Responsibility for Inspections and Tests: Unless otherwise specified in the contract or purchase order, the Contractor shall be responsible for the performance of all inspections and tests specified herein. Acceptance or approval of material during the course of manufacture shall not be construed as a guarantee of its acceptance in the finished product. BSA reserves the right to re-perform any of the inspections and/or tests set forth in this document were deemed necessary to assure that supplies and services conform to prescribed requirements at no cost to the contractor.

9.8 Warranty: The delivered unit shall be covered by a warranty against material and manufacturing faults. The warranty shall be for a period of at least one calendar year from the date the unit is shipped. The Contractor shall specify in detail the warranty period and its provisions in their proposal. Acceptance under the provisions specified herein shall not relieve the Contractor from the responsibility of ensuring that the item delivered to BSA complies with all requirements of the contract or purchase order.

10 DELIVERABLES

10.1 Curing Oven As describe in this SOW (section 7)

10.2 Certificate of Conformance IAW Section 9.4

10.3 End Item Documentation Package,

10.3.1 The package shall be compiled and supplied to BSA. The BSA Technical

Representative shall review and provide written approval of the package prior to component shipment.

10.3.2 All required documentation provided by the Contractor shall be in English and may be provided in electronic or paper copy.

10.4 The package, which shall consist of all documentation identified in this SOW, will include the following:

a) Dimensional Inspection Report: All dimensions shown on vendor drawing approved by BSA prior to fabrication.

b) All documentation necessary for compliance with this SOW

c) Results of all performance tests.

d) All system and component drawings

e) All wiring diagrams