Attachment A- Statement of Work for the ESR D1D3 Dipole Magnets (updated 6.08.2026).docx

STATEMENT OF WORK

for the Electron Storage Ring D1/D3 Dipole Magnets Quality Classification: A-3

Prepared By:

_____________________________________________ Date: __________________ George Mahler, Deputy Group Leader - Magnet Systems

Reviewed By:

_____________________________________________ Date: __________________ Racquel Lovelace, Technical Representative

_____________________________________________ Date: __________________ Eduardo Pereira, Quality Representative

_____________________________________________ Date: __________________ Chuck Schaefer, ESH Manager

_____________________________________________ Date: __________________ Marcel Romero, Procurement Liaison Engineer

_____________________________________________ Date: __________________ Joseph Tuozzolo, Technical Systems Division Director

_____________________________________________ Date: __________________ Sergei Nagaitsev, Technical Director

Approved By:

_____________________________________________ Date: __________________ Christoph Montag, Electron Storage Ring L2 Manager

REVISION HISTORY

Revisions to drawings numbers and configuration quantities.

Table of Contents

Electron-Ion Collider, Brookhaven National Laboratory

Electron-Ion Collider, Brookhaven National Laboratory

This information is controlled by the U.S. Department of Commerce Export Administration Regulations 15 CFR Parts 730-774 as EAR99 Technology.

This information is controlled by the U.S. Department of Commerce Export Administration Regulations 15 CFR Parts 730-774 as EAR99 Technology.

LIST OF ACRONYMS

SOW

Statement of Work

Statement of Work for the ESR D1/D3 Dipole Magnets

SCOPE

This Statement of Work (SOW) will be the basis for the procurement of Electron Storage Ring (ESR) D1/D3 Dipole Magnets to be used at the Electron-Ion Collider (EIC) at Brookhaven National Laboratory (BNL) managed by Brookhaven Science Associates (BSA). This document outlines the Contractor’s responsibilities and obligations necessary for completing the requirements as set forth herein.

Background

The Electron-Ion Collider (EIC) is a Nuclear Physics facility being built at the United States (U.S.) Department of Energy’s (DOE) Brookhaven National Laboratory (BNL). The EIC will create intense beams of relativistic energy electrons and ions in opposing particle storage rings that will be brought into collision in a large experimental detector. This will provide insight into the internal structure of protons and neutrons and the gluelike force that holds them together.

Conventional beam line accelerator magnets will be used to bend and focus high energy and high intensity electron beams in the EIC ESR. The ESR “ring” will be located in the existing Relativistic Heavy Ion Collider (RHIC) tunnel. The ESR will have a beam line circumference of 3,830 meters (2.4 miles).

The ESR will store the polarized electron beam for the EIC particle collisions for hours at various energies, depending on the science program, from 5 GeV to 18 GeV. Therefore, the ESR dipoles will operate at constant field/current. The magnets shall be fabricated with high quality laminated steel to provide high field quality. For production, there will be a requirement to shuffle the laminations from different heats to provide minimal differences in magnetic field strength from magnet to magnet because they are powered in a single series string.

APPLICABLE DOCUMENTS

In the event of a conflict between the Technical Documentation and this SOW, the Contractor shall immediately notify the BSA contract representative who shall in each instance determine which document takes precedence and advise the Contractor accordingly. Failure to notify the BSA contract representative of a document conflict shall not relieve the Contractor’s responsibility to ensure full compliance to all requirements.

The following documents and drawings are an integral part of the SOW; the applicable revision level will be the latest that is in effect at the time of award:

REQUIREMENTS

In accordance with the technical specification, referenced drawings (drawing references includes the model file), and instructions as defined in this Statement of Work, the Contractor shall be responsible for designing, manufacturing, inspecting, testing, and delivering the ESR D1/D3 Dipole Magnets.

The vendor will purchase all steel for D1/D3 magnets totaling 2,759 tons. The steel will be stored under required conditions identified in Technical Specification EIC-MSG-SPC-010.

Contractor and BSA Responsibilities

The BSA/EIC Engineering group is responsible for the magnetic analysis and core and coil design of the D1/D3 dipole magnet to meet the ESR performance requirements and interfaces. The referenced specification control drawings and technical specification are the result of the magnetic design effort. The Contractor is responsible for the detailed magnet engineering design in accordance with the technical specification and drawings. The Contractor’s magnet design shall be reviewed and approved by the BSA technical representative in accordance with this SOW before proceeding with production of the first article production magnet.

First Article Magnet The Contractor is responsible for fabricating and assembling one (1) first article magnet (Drawing 2104M0000) that will verify the magnet’s conformance to this SOW, the technical specification, the referenced control drawings, the quality of the Contractor’s design and fabrication methods, and the conformance of the BSA/EIC magnetic design to the ESR performance requirements. The Contractor shall procure all materials and fabricate a first article magnet that shall be inspected and tested by the Contractor prior to shipping. BSA will inspect, test, and magnetically measure the first article magnet at no cost to the Contractor. After review of positive inspection, test, and measurement results, the magnets will be approved for production in writing by the BSA technical representative.

Production Magnets The Contractor shall fabricate and assemble five hundred forty-one (541) production magnets that will be inspected and tested by the Contractor prior to shipping. BSA will inspect, test, and magnetically measure the production magnets to verify the quality of each magnet at no cost to the Contractor again, after receiving. After review of positive inspection, test, and measurement results, the magnets will be accepted for installation by the BSA technical representative. The magnets will be installed by BSA. See table below for the number of magnets per configuration.

Technical Performance In accordance with this SOW, the technical specification, and the drawings, the Contractor shall furnish all equipment, materials, facilities, and labor to perform the work necessary to design, manufacture, test, and ship the ESR Dipole Magnets. The Contractor shall ensure that the resultant design and finished product meets the performance parameters and criteria in the technical specification and drawings.

Tooling/Fixtures/Test Equipment The Contractor shall be responsible for the design and fabrication of all tools, jigs, fixtures, and test equipment required to meet the requirements of this SOW, the technical specification, and the drawings.

Special Tools After completion of the magnet order, all special tooling developed specifically for the manufacturing, assembly, and/or testing of the magnets shall be carefully stored and maintained for a minimum of 3 years after contract completion. The BSA technical representative shall be notified in writing prior to disposing of any tooling or equipment required to manufacture, assemble or test the magnet.

Engineering Design and Manufacturing Requirements

The Contractor shall provide a complete design package, including but not limited to mechanical drawings for components, assemblies, and fixtures required for manufacturing and assembling the magnets, magnet assembly drawings, design analyses and reports, test plans and reports, inspection plans and reports, and quality assurance documentation.

Detailed Design Requirements The Contractor’s detailed design effort shall include but is not limited to the following considerations:

1. Magnet core structural design to assure that the laminated magnet cores have proper rigidity to meet the magnet interface drawing tolerance and specification requirements.

2. The magnet core design shall interface with the magnet core supports that securely hold the magnet to the support frame. The magnet core shall meet the tolerance requirements when secured by the support points defined by drawing 2104M0000.

3. The magnet design shall meet the lifting requirements in the technical specification. If a lifting frame is required to lift the magnet assembly, the Contractor shall design the lifting frame in accordance with the specification. A lifting frame shall be provided with the first article magnet.

4. The design of the coil support system that supports the coils without stress or deformation and the high voltage isolation requirements shall be in accordance with the magnet specification.

Detailed Analysis Requirements The Contractor shall perform analyses to ensure the ESR dipole magnets meet the requirements of the specification. Models and results shall be provided electronically in their native ANSYS or equivalent standard format, as well as in hard copy form to the BSA technical representative. The analyses shall include, but are not limited to:

1. Structural analysis of the magnet assembly, the coil support, cable termination assembly, etc. with interface to the girder assembly and the lifting requirements.

2. Electromagnetic analysis to determine forces for the magnet design and for proper coil support.

3. Thermal analysis for the coil support.

Project Communication and Management Progress Communications Within two (2) weeks after the award of contract, program technical and progress communications (via Zoom or MS Teams) between the Contractor and BSA shall be held at a mutually scheduled time on a bi-weekly basis. The discussions shall include the Contractor’s progress, technical and contractual questions, presentations of analysis or testing results, in process design reviews, value engineering, troubleshooting, material status, tooling status, resources, and manufacturing issues.

Program Plan Within three (3) weeks after award of contract, the Contractor shall deliver a detailed program plan which includes a milestone schedule for the first article magnet program. It shall include the magnet design effort, the design validation through design reviews as defined in this SOW, material procurement, fabrication of tooling, fixtures, and magnet components, parts inspection and testing, magnet assembly, inspection, testing and delivery. The program plan shall be sufficient in detail to allow progress monitoring.

Performance Reporting Throughout the life of the contract, the Contractor shall 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 shall include milestone charts, detailed progress, open items, problems, recommended solutions, and risk mitigation.

“Witness” Points BSA reserves the right, after review of the Contractor Manufacturing Plan, to designate selected manufacturing, inspection, and/or test operations as “witness” points. The contractor shall provide the BSA technical representative with ten (10) working days’ notice in advance of such witness points during the manufacturing and test cycle.

Manufacturing/Inspection/Test Plan The Contractor shall develop and provide a Manufacturing/Inspection/Test Plan which identifies the manufacturing processes required to complete the individual magnet assemblies. The plan shall include manufacturing, inspection, and test steps with identification of critical manufacturing operations for parts and subassemblies showing integrated flow into the complete ESR dipole magnet assemblies. The Manufacturing/Inspection/Test Plan shall address shop loading (by work center). It shall include a schedule for manufacturing all components, inspection and testing components, assembling the magnets, final acceptance testing, and shipping.

The plan shall address Material Requirements Planning (MRP). The plan shall provide details for purchasing all raw materials, hardware, and other commercial off-the-shelf components. The contractor shall perform all inspections and tests required to assure that the magnets meet the requirements of the technical specification and associated documents. The plan shall provide for material, procured component, and manufactured parts inspection and traveler acceptance documentation which will be part of a completed magnet Quality Assurance (QA) documentation.

The Manufacturing/Inspection/Test Plan shall include acceptance tests in the technical specification as well as the “Magnet Assembly Inspection Data Sheet” and the “Coil Inspection Data Sheet”. The plan is required for the first article and production magnets fabrication efforts.

Design Reviews and Production Review

In addition to the bi-weekly progress communication the Contractor is responsible for holding formal preliminary and final design reviews as defined in this SOW. The reviews shall be at the Contractor’s site and the BSA technical representative shall have the option to attend in person and/or via Zoom or MS Teams. The reviews provide for formal communication on design progress and design approval. Approval of Contractor designs and processes by the BSA technical representative does not relieve the Contractor’s responsibility to meet the requirements of this SOW, technical specification, or drawings unless approved by BSA.

Preliminary Design Review (PDR) The PDR shall be held in accordance with the schedule set forth in section 6 herein, to ensure compliance with this SOW, applicable specifications, and interface control drawings. The PDR meeting and associated PDR report shall include at a minimum the following items to be addressed in detail and supported by preliminary calculations that shall be presented at the PDR for review and approval.

· General information and outline of magnet design progress.

· Detailed design information, including drawings, parts lists, engineering analyses.

· Design concerns, documented requests for deviations from the requirements in this SOW, the technical specification, and the associated drawings.

· Design verification plan and report

· Preliminary Manufacturing/Inspection/Test Plan

· Program Plan and Schedule Update for Completion of Design and Fabrication of the First Article Magnet.

Preliminary Design Review (PDR) Report The Contractor shall provide, no later than ten (10) working days prior to the scheduled PDR meeting, a draft PDR Report. The contents of this report shall be reviewed at the PDR. The Contractor PDR report shall reflect the state of the developed design.

Preliminary Design Review Meeting The Contractor shall be responsible for maintaining and submitting the minutes of the PDR and shall also incorporate any agreed-to changes into the final comprehensive PDR Report. The final report shall be submitted within ten (10) working days of the PDR meeting. The PDR report shall be reviewed and approved by the BSA technical representative.

Final Design Review (FDR) The FDR shall be held in accordance with the schedule set forth in section 6 herein. The FDR shall ensure compliance with this SOW, applicable specifications, and interface control drawings. The FDR meeting and associated FDR report shall include at a minimum the items listed in 3.4.2.1 to be addressed in detail and supported by preliminary calculations that shall be presented at the FDR for review and approval.

Final Design Review Report The Contractor shall provide an FDR report that reflects the state of the developed design as it evolved from the PDR. The Contractor shall be responsible to develop the overall design of the ESR dipole magnets in accordance with the applicable specifications and supporting documents. The Contractor shall perform the tasks listed below, with the results to be included in the Final Design Review Report for review and approval in writing by the BSA technical representative.

· General information and outline of magnet design effort.

· Summary of significant design changes since the PDR.

· Detailed design information, including models, drawings, parts lists, and engineering analyses.

· First article Magnet Production Program plan with schedule through to testing and shipping.

· Production Magnet Manufacturing plan with production rate and schedule.

· Manufacturing/Inspection/Test Plan final for First article and Production Magnets.

· Program Plan and Schedule Update for Completion of Design and Fabrication of the First Article Magnet.

Final Design Review Meeting The FDR meeting shall be held in accordance with the schedule set forth in section 6 herein, to ensure compliance with this SOW, technical specification, interface control drawings (and model), and to obtain approval from the BSA technical representative to proceed to the production phase. The Contractor shall provide, no later than ten (10) working days prior to the scheduled meeting, a draft FDR Report that shall consist of the requirements set forth herein. The findings of the FDR Report shall be reviewed at the FDR meeting and shall cover all pertinent issues relating to the final detailed design of the ESR D1/D3 dipole magnets.

The Contractor shall be responsible for maintaining and submitting minutes of the FDR meeting and shall also incorporate any agreed-to changes into the final comprehensive FDR Report, both of which are to be submitted to the BSA technical representative within ten (10) working days of the FDR for subsequent review and approval. After written approval of the FDR report by the BSA technical representative, the Contractor shall promptly begin manufacturing the ESR dipole magnets. Upon written approval of the FDR report the design is to be considered “frozen” and no changes are permitted to the design, materials, processes, methods, and tooling, or component-level substitutions, without written approval by the BSA technical representative.

Approval to Proceed with First Article Fabrication The BSA technical representative must approve in writing the Final Design Review Report, including any modifications introduced at the Final Design Review, before the Contractor proceeds with ordering of material and components. The BSA technical representative may approve in writing ordering of long-lead-time materials and components prior to the approval of the Final Design Review Report to expedite schedule.

Manufacturing Readiness Review (MRR) After first article testing by the Contractor and testing and magnetic measurement by BSA, the Contractor shall hold a manufacturing readiness review for the production quantities. The Contractor shall provide, no later than ten (10) working days prior to the scheduled meeting, a draft of the final Production Magnet Manufacturing Plan and the Manufacturing/Inspection/Test Plan for review. The MRR shall include:

· Discussion of lessons learned from manufacturing by the Contractor and opportunities for value engineering improvements or cost savings.

· Inspection, test, and magnetic measurements results provided by BSA.

· Any modifications that may be needed and negotiated to improve the magnet design.

· Updates to the Production Magnet Manufacturing Plan with production rate and schedule.

· Update to the Manufacturing/Inspection/Test Plan final for production Magnets.

Manufacturing Readiness Review Report The Contractor shall be responsible for maintaining and submitting minutes for the MRR meeting and shall also incorporate any agreed-to changes into the final comprehensive MRR Report, both of which are to be submitted to BSA within ten (10) working days after the MRR for subsequent review and approval. After written approval of the MRR report by the BSA technical representative, the Contractor shall promptly begin the process for manufacturing the ESR dipole magnets.

Documentation and Data Management Report/Documentation Format

· All reports submitted shall include an introduction, body of the documents, and a conclusion. Large documents shall include a table of contents. For calculations, equations shall be shown with values defined for each variable so the analysis can be reviewed. Diagrams shall be included for clarity and labels shall be consistent with design drawings for specific items.

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

· The Contractor shall provide an electronic copy of all documentation required by this SOW. Contractor manufacturing drawing Computer-Aided Design files of all components and assemblies shall be in a mutually agreed format.

Engineering Drawing Practices All Contractor-generated engineering drawings shall be in accordance with ASME Y14.100, Engineering Drawing Practices. All dimensions and tolerances shall be U.S. Customary units with metric (SI) units as a secondary notation.

End Item Documentation Package The Contractor shall provide the end item documentation package in electronic form for each magnet shipped. The End Item documentation package shall consist of all documentation identified in this SOW and include the following:

· Manufacturing Travelers in accordance with the Manufacturing/Inspection/Test Plan.

· Final Inspection and Test Reports in accordance with the Manufacturing/Inspection/Test Plan.

· For a complete list of documents required for the End-Item Documentation Package reference BNL-QA-101 Clause 4.10.

Records The Contractor shall retain objective evidence, including records, of the inspections and tests performed in the course of manufacturing, testing, inspecting, preserving, packaging, and preparation for shipment of the magnets. These records shall be made available to BSA for review upon request. These records shall be maintained for a minimum of three (3) years, unless otherwise specified in the procurement documentation, after the completion of the Contract.

Environment, Safety and Health (ESH)

The Contractor shall design and build the ESR D1/D3 dipole magnets in accordance with ESH requirements in the specification, codes, standards, and other documents listed in Section 2 of the technical specification.

QUALITY ASSURANCE

Quality System and Facility Access

The Contractor shall maintain and apply an effective and documented quality assurance system for the design, manufacture, and testing of the dipole magnets. The system shall meet the requirements of the ISO-9001 Standard, “Quality Management Systems Requirements”, and shall provide the processes to ensure that each component produced for acceptance conforms to the requirements of this document and the applicable technical documentation. The Contractor shall supply the necessary documentation to demonstrate this compliance. Post-award surveys may be required and shall be supported by the Contractor. In addition, BSA representatives shall have access to the Contractor’s facility during agreed-upon fabrication, inspection and testing processes. The Contractor shall provide ten (10) working days’ notice in advance of the agreed-upon witness points.

As set forth in BSA Form BNL-QA-101, “Brookhaven National Laboratory Supplier Quality Assurance Requirements,” as amended herein, forms a part of this SOW. Specifically, this includes the following sections: 1, 2, 3, 3.1, 3.1.2, 3.2 to 3.8, 3.11, 3.21, 3.22, 4.0, 4.1, 4.2, 4.3,4.4, 4.4.1, 4.4.2, 4.4.3, 4.5, 4.6, 4.7, 4.7.1, 4.7.3, 4.10, 4.10.1, 4.10.2, 4.10.3, 4.10.4, 4.11, 4.13, 4.14, 4.16,4.18, 4.18.2, 4.18.3, 4.19, 4.21, 4.34, and 4.39. With each Component delivered, the Contractor shall supply BSA a Certificate of Conformance, in accordance with section 4.16 of BNL-QA-101.

BNL-QA-101 Section 2.0 Definitions use the terms Buyer and Seller. In the context of this SOW Buyer is referred to as “BSA” and Seller is referred to as “Contractor”.

BNL-QA-101 Clause 4.5 “Witness Points” is amended to require the Contractor to provide BSA with ten (10) working days’ notice in advance of reaching such witness points during the manufacturing and test cycle of each item.

Configuration Management The Contractor shall establish and maintain a configuration control system to assure that all magnets are of the proper configuration, and that all approved configuration changes are incorporated at the specified effectivity points. Records verifying the configuration of each item shall be maintained for a minimum of five (5) years from the date of acceptance of the dipole magnets by BSA. The Contractor shall immediately notify the BSA technical representative of any significant changes (those that may affect form, fit, function, reliability, safety, or interchangeability) in design, fabrication methods, material or processing.

For changes in configuration, a request for change approval shall be submitted to BSA technical representative for consideration. Changes in configuration may be made by the Contractor only with the written approval of the BSA technical representative.

Responsibility for Subcontractor

It is the responsibility of the Contractor to flow down and impose applicable technical and quality assurance requirements upon their contractors and subcontractors. BSA reserves the right to disapprove, in writing, of any contractor or subcontractor.

Responsibility for Conformance

The Contractor is responsible to provide magnets which conform to the requirements of the Contract regardless of any assessments, surveillances, inspections and/or tests by BSA or its representatives at either the Contractor’s or BSA’s facility. The Contractor is responsible for notifying the BSA technical representative of any recalls or alerts associated with this Contract.

Measuring and Test Equipment (M&TE) Calibration The Contractor shall calibrate any M&TE used in the fulfillment of the 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 the BSA technical representative of any condition found during the calibration, servicing or repair of measuring and test equipment that can affect the end item requirements.

Inspections and Test Requirements Unless otherwise specified in the Contract, the Contractor shall be responsible for the performance of all inspections and tests required in the technical specification. Except as otherwise specified in the Contract, the Contractor shall utilize facilities suitable for the performance of the inspection and test requirements specified herein, which are acceptable to BSA. BSA reserves the right to re-perform any of the inspections and/or tests set forth in this document or technical specification when deemed necessary to assure that the ESR D1/D3 dipole magnets conform to prescribed requirements at no cost to the Contractor. The BSA technical representative shall have the option to witness all tests defined in this SOW or the technical specification.

Test and Inspection

Steel Testing Requirements

The steel supplied by the Contractor will be sample tested by BSA. The Contractor shall supply a sample set for each steel heat. The dimensions of the sample piece, quantity required, and other requirements are provided in specification EIC-MSG-SPC-010. Samples of material distributed throughout each heat of material shall be provided to BSA for magnetic property testing.

One week prior to each shipment, the Contractor shall notify the BSA technical representative and supply all records of inspection, test results and specimens for the tests as required in specification EIC-MSG-SPC-010. The BSA technical representative will communicate to the Contractor the disposition of the supplied steel coil delivery. Steel shall not be used for production until testing is completed and approved by the BSA technical representative. Contractor shall supply material certification prior to shipment, indicating contract and identification of the specification to which the material conforms. Contractor shall be responsible for certification validity.

Magnet Testing Requirements The magnets shall be inspected and tested by the Contractor at the Contractor’s facility, the Contractor’s subcontractor’s facility, or a pre-approved BSA collaborator prior to shipment, using the Manufacturing/Inspection/Test Plan defined in this SOW. The BSA technical representative retains the right to witness all inspections and tests. Final acceptance of the magnets shall take place following the successful completion of final testing and magnetic measurement at BNL. The time period for the final testing at BNL shall be within 90 days after receipt of the magnets at BNL.

First Article Acceptance BSA’s acceptance of first article magnet is required prior to the production run. The first article shall be identified as such, including the contract, part number, and part name.

After BSA technical representative acceptance of first article magnet, all remaining magnets required by the Contract shall be produced by the Contractor and the Contractor’s suppliers using the same design, materials, processes, methods, and tooling that were used to manufacture the approved first article. Any changes must have prior written approval from the BSA technical representative.

Repairs If failures occur or repairs are required to a magnet assembly or any component during manufacturing or testing that affects form, fit, function, reliability, safety, or interchangeability the process shall stop and the BSA technical representative shall be immediately notified. The BSA technical representative at their discretion may ask for retesting, additional review and evaluation to determine root causes, analyses of failure modes(s) or proposals for repair. Proposals for repair shall include adequate information for evaluating the repair, testing the effectiveness of the repair, and methods to prevent damage to the existing work. No proposed repair shall be initiated without the approval of the BSA technical representative. No repair shall be considered successfully accomplished without inspection and written approval by the BSA technical representative. All repairs shall be at the expense of the Contractor. In addition, the Contractor shall not use nonconforming materials via use-as-is disposition without written approval from the BSA technical representative.

Failure Reporting, Analysis and Corrective Action

The Contractor shall maintain a failure reporting, analysis, and corrective action system which shall, as a minimum, evaluate, analyze, and correct failures occurring during end-item acceptance testing and inspection. The results of all failure evaluations and analyses shall be documented and available for review by the BSA technical representative.

DELIVERABLES

The Contractor shall supply the following:

SCHEDULE

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

VALUE ENGINEERING

The Contractor is encouraged to make recommendations for changes that might lead to improvements in performance, reliability, quality, safety, or reduction in cost. Simplicity in design and manufacturing and an improvement in the performance and reliability beyond the requirements of this SOW and the technical specification are objectives which shall be considered in the dipole magnet design. Where it appears a substantial improvement in simplicity of design, performance, 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 the BSA technical representative for review.