Attachment (A) NSLSII-RF-SOW-SPC-002.pdf

Brookhaven National Laboratory Number: NSLSII-RF-SOW-SPC-002

Brookhaven Science Associates Version: 1

National Synchrotron Light Source II (NSLS-II) Effective: 13 MAR 2025

RF Cryogenic System – Helium Storage Tank

Statement of Work and Technical Specification

QA Category: A-3

Reviewed and Approved By:

William Gash NSLS-II Mechanical Engineer

James Rose NSLS-II RF System Group Leader

Robert Lee NSLS-II ES&H Manager

This information is controlled by the U.S. Department of Commerce Export Administration Regulations

15 CFR Parts 730-774 as EAR99 Technology.

Version 1 ii Brookhaven National Laboratory

VERSION CONTROL SHEET

VERSION DESCRIPTION DATE AUTHOR

1 First Issue 13 MAR 2025 W. Gash

MDC No. 1 – Added the Export Control disclaimer statement on the bottom of page 1.

28 MAR 2025 W. Gash

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Contents

1 Introduction and Overview

2 References

3 Requirements

3.1 Contractor Responsibilities

3.2 Design, Engineering, and Manufacturing Documentation

3.3 Pre-Production Meeting

3.4 Contractor Required Inspection and Testing

3.5 Progress Reporting

3.6 Documentation and Data Management

3.6.1 General Documentation Requirements

3.6.2 Drawing and Model File Format Requirements

3.6.3 End Item Documentation (EID)

3.7 Spare Parts

3.8 Environment, Safety and Health (ES&H)

3.9 Warranty

3.10 Shipping

4 Quality Assurance

4.1 Quality Assurance Requirements

4.2 Material Review Board (MRB) Authority

4.3 QA Flow-Down

5 Schedule / milestones

6 Deliverables

7 Value Engineering

8 Technical Specif ications

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Definitions/Acronyms

ASME American Society of Mechanical Engineers

BNL Brookhaven National Laboratory

BPVC Boiler and Pressure Vessel Certification

BSA Brookhaven Science Associates

CAD Computer Aided Design

EID End Item Documentation

ESH Environment, Safety, and Health

HST Helium Storage Tank

MRB Material Review Board

NSLS-II National Synchrotron Light Source II

QA Quality Assurance

PSI Pounds Per Square Inch

RF Radio Frequency

SOW/SPC Statement of Work/Technical Specification

NSLSII-RF-SOW-SPC-002: RF Cryogenic System – Helium Storage Tank Statement of Work and Technical Specification 1

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1 INTRODUCTION AND OVERVIEW

This Statement of Work and Technical Specification (SOW/SPC) is the basis for the procurement of the Helium Storage Tank (HST) for the RF Cryogenic system of the National Synchrotron Light Source II (NSLS-II) at Brookhaven National Laboratory (BNL). The Helium Storage Tank, hereafter will be referred to as the “HST”.

The cryogenic system used for cooling the superconducting RF cavities was installed during construction of the NSLS-II accelerator facility at BNL. Three (3) HSTs were included in the original cryogenic system installation.

Currently there is a requirement to add an additional HST, which will increase the helium storage capacity and enhance the performance of the existing cryogenic system. This additional HST will be built to the same specifications as the original (3) HSTs.

This document outlines the Contractor’s responsibilities and obligations necessary for completing the requirements as set forth herein.

2 REFERENCES

The following documents are an integral part of this document; the applicable revision level will be the latest that is in effect at the time of award or as stated herein:

Document Number Document Title

ASME Y14.5 Dimensioning and Tolerancing: Engineering Drawing and Related Documentation Practices

BNL-QA-101 BNL Supplier Quality Assurance Requirements

ASME BPVC Section VIII Division 1

ASME Boiler and Pressure Vessel Code

RF-CRY-TNK-0100 Helium Storage Tank – BNL Drawing

3 REQUIREMENTS

3.1 Contractor Responsibilities

The Contractor shall be responsible for the engineering, design, procurement of all materials, manufacturing, assembly, inspection/testing, and delivery of the HST. It is the Contractor’s responsibility to ensure that the HST complies with all the specifications, referenced documents, and instructions as referenced herein.

3.2 Design, Engineering, and Manufacturing Documentation

To ensure compliance with this document, and all referenced documents the Contractor shall provide the following documentation to BSA for review one (1) week prior to the Pre-Production Meeting.

• Pressure Vessel Design Calculations that conform to the 2015 edition of the ASME BPVC, Section VIII, Division 1, (the current edition of this code may be used with BSA concurrence).

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• Stress/deflection calculations and analyses for the lifting lugs using an engineering analysis technique approved by BSA. Calculations and analysis models/files shall be provided to BSA.

• Specifications, sourcing, and catalog cut sheets for all commercially purchased components.

• Manufacturing drawings and Part Lists if not embedded in the drawing.

• Manufacturing/Inspection/Test-Plan. The plan shall identify the manufacturing processes, inspections, and tests required to complete all efforts identified in this document.

• Manufacturing schedule (Gantt type chart) showing the timeline for each major activity necessary to meet the overall BSA schedule requirements shown in Section 5.

3.3 Pre-Production Meeting

A pre-production meeting by video conference between the Contractor and BSA shall be held in accordance with the schedule set forth herein, at a mutually agreed upon time.

The required documentation shown in Section 3.2 shall be presented by the Contractor at the pre-production meeting to validate compliance with this document and all referenced documents.

Upon written approval from BSA the design shall be considered “locked”, and no changes are permitted to the design, materials, processes, methods, or component-level substitutions, without written approval by BSA. BSA approval of the Contractor’s documentation does not relieve the Contractor’s responsibility for meeting the specifications, requirements, and referenced documents listed herein. Ordering of materials and components prior to BSA approval are done solely at the Contractor’s risk and responsibility .

3.4 Contractor Required Inspection and Testing

The Contractor shall inspect and test the HST at the Contractor’s facility to demonstrate full compliance to the requirements, specifications, and referenced documents listed herein. BSA reserves the right to witness the final inspection and hydrostatic pressure test at the Contractor’s facility.

3.5 Progress Reporting

Within two (2) weeks after award of contract, bi-weekly progress reports shall be emailed to the BNL technical representative. If additional information is needed, a conference call or video conference meeting between the Contractor and BSA shall be held at a mutually agreed upon time.

3.6 Documentation and Data Management

3.6.1 General Documentation Requirements

▪ All documentation provided by the Contractor shall be in English.

▪ Electronic documents other than drawings can be furnished in PDF format.

▪ All Contractor drawings shall:

Be formatted in accordance with ASME Y14.5 or equivalent (requires written approval by BSA)

Have views shown in third-angle projection

Have a separate parts list if not embedded in the drawing

Be provided to BSA in electronic format as defined below.

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3.6.2 Drawing and Model File Format Requirements

The Contractor shall provide and maintain, as well as have the capability to receive and send, CAD files of all components or assemblies in the following formats:

▪ 2D formats: AutoCAD 2D drawings (.DWG format).

▪ 3D solid model formats: IPT (preferably), IAM, STP or SAT.

▪ IGES files and surface models are not acceptable.

3.6.3 End Item Documentation (EID)

At a minimum, the Contractor shall provide an electronic copy and one hard copy of the EID package in accordance with the schedule set forth in this document. The EID package for the HST shall consist of the following documentation:

▪ ASME Form U-1, Manufacturer’s Data Report

▪ Name plate rubbing or photo

▪ Paint safety data sheet

▪ Manufacturer warranty statement

▪ Final (as-built) manufacturing drawings

▪ Material certification for all parts.

▪ Source inspection documents for all major items purchased by the Contractor (source inspections would be those conducted at a subcontractor to the Contractor)

▪ Dimensional inspection report per the HST design

▪ Radiographic inspection reports

▪ Hydrostatic pressure test report

▪ HST interior surface cleanliness inspection report (performed after hydrostatic pressure testing)

3.7 Spare Parts

The Contractor shall provide BNL with the specifications and sourcing information for the manway flange and gasket.

3.8 Environment, Safety and Health (ES&H)

The Contractor shall design and build the HST in accordance with ES&H requirements in the appropriate specifications, codes, standards, and other documents listed herein.

3.9 Warranty

The Contractor shall provide a warranty for the HST, against failure and defects for a minimum period of 2 years (24 months) from final acceptance of the HST at BNL.

3.10 Shipping

• After the HST has been cleaned and tested, all openings shall be sealed with metal flanges and metal plugs and the HST shall be purged and pressurized with dry nitrogen to an internal pressure of 15 PSI.

• The HST shall be properly braced and cushioned so that it will not shift during handling and shipment.

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• The Contractor shall arrange transportation services with a specialized truck carrier. A drawing of the BNL on-site access tunnel is supplied for reference to determine the type of truck necessary for delivery to the BNL site.

• The HST shall be delivered to:

Brookhaven National Laboratory

Central Receiving Department

98 Rochester Street

Upton, New York 11973

• BNL requires a minimum of five (5) business days’ notice prior to the date and time of the carrier’s arrival at the BNL site.

• The BNL receiving department hours of operation are Monday through Friday between 9:00AM and 3:00PM Eastern Time zone.

4 QUALITY ASSURANCE

The Contractor shall maintain and apply an effective QA program for the design, manufacture, inspection and testing of all equipment provided. The equipment shall comply with the requirements of the ISO-9001 Standard, “Quality Management System Requirements.” The Contractor shall supply the necessary documentation to demonstrate this compliance. Pre-award and post-award surveys may be required and shall be supported.

4.1 Quality Assurance Requirements

As set forth in BSA Form BNL-QA-101, “Brookhaven National Laboratory Supplier Quality Assurance Requirements,” as amended herein, forms a part of this statement of work. Specifically, this includes the following sections: 1, 2, 3.0, 3.1, 3.1.2, 3.2 to 3.8, 4.0, 4.1, 4.2, 4.10.4, 4.29.

4.2 Material Review Board (MRB) Authority

Unless, and until Material Review Board (MRB) authority has been requested and received, the Contractor shall be restricted to dispositions of rework, scrap, and return-to-vendor; i.e., the Contractor shall not use nonconforming materials via unique or standard repair processes, nor via use -as-is-dispositions.

The Contractor shall not delegate MRB authority to suppliers without the prior knowledge and written approval of BSA.

BSA may delegate MRB Authority to the Contractor, when requested by the Contractor. Such request shall be accompanied by 1) the Contractor’s procedure for the identification, evaluation, disposition, and control of nonconformances; and 2) the resumes of personnel to be assigned as MRB members.

All nonconformances requiring MRB action shall be documented and sent to the BNL technical representative within five (5) working days of the decision.

4.3 QA Flow-Down

The Contractor shall ensure a proper and complete flow-down of all applicable QA requirements to its suppliers and sub-tier suppliers.

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5 SCHEDULE / MILESTONES

The following schedule is for planning purposes only. Schedule requirements as set forth in the contract will take precedence.

SCHEDULE IN WEEKS AFTER AWARD OF CONTRACT

Submittal of the Design, Engineering, & Manufacturing documentation (Section 3.2) 6

Pre-Production Meeting & BSA approval of the Contractor documentation (Sect ion 3.3) 7

Procurement of Materia ls (after BSA approval of the Contractor documentat ion) 8

Start fabrication of the HST 9

The HST has been fabricated, inspected, tested, and ready for shipment 25

Receipt of the EID, and acceptance of the HST at BNL 26

6 DELIVERABLES

The Contractor shall supply the following:

Item Deliverable Due Approval

Required

1 Design, Engineering, & Manufacturing Documentation (Section 3.2)

6 weeks after award of contract Yes

2 Pre-Production Meeting (Section 3.3) 1 week after BSA receives the Item #1 documentation from the Contractor

No

3 Progress Reports (Section 3.5)

2 weeks after award & bi-weekly thereafter No

4 Receipt of the EID package (Section 3.6.3) With delivery of the HST Yes

5 Delivery of the HST at BNL As set forth in the contract Yes

7 VALUE ENGINEERING

The Contractor is encouraged to make recommendations for changes that might lead to an improvement in performance, reliability, quality, safety, or reduction in cost. Simplicity in operation, ease of maintenance, and an improvement in the performance and reliability of the specific functions beyond the requirements of this SOW/SPC are objectives which shall be considered in the production of each component type. Where it appears a substantial improvement in simplicity of design, performance, ease of maintenance or reliability will result from the use of materials, parts and processes other than those specified, it is desirable that their use be investigated. When investigations point to advantages that may be realized, the recommendation for change shall be presented to BSA for review and, if approved, authorized in writing. An equitable agreement will be negotiated between BSA and the Contractor to share the savings of any recommended change that is approved and implemented.

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8 TECHNICAL SPECIFICATIONS

This section of the SOW/SPC document defines the technical specifications for the HST.

• The HST design, inspection/testing, and associated manufacturing drawings shall conform to the 2015 edition of the ASME BPVC, Section VIII, Division 1 (the current edition of this code may be used with BSA concurrence).

• The HST shall be code stamped by a certified ASME pressure vessel manufacturer.

• HST Configuration: Horizontal

• Ultra-Pure Helium (99.9995% purity) will be stored in the HST. Any debris or corrosion on the interior surfaces will degrade the quality of the helium and performance of the system. There shall be no corrosion (zero corrosion allowance) on any of the HST internal and external surfaces.

• HST Capacity: 30,000-gallon

• Maximum Working Pressure: 250 PSI at 140o F

• HST Outside Dimensions: 10’ 11-7/8” Diameter x 46’ 8-7/8” in length

• Full vacuum service is not required during system operation, however when the HST is being prepared for service, a vacuum down to 0.1 milli-bar is required for cleaning to remove contamination. The HST shall meet this requirement.