Attachment A- Statement of Work for the HSR Main Arc Dipole and Quadrupole Power Supplies.pdf

Electron-Ion Collider, Brookhaven National Laboratory

Doc No. [Insert here] Author: [Insert here] Effective Date: [Insert here] Review Frequency: N/A

SOW: [Insert Title] Revision: 00

STATEMENT OF WORK

for the

HSR Main Arc Dipole and Quadrupole Power Supplies

Quality Classification: A-2

Prepared By:

__________________________________ Date: __________________

D. Prevosto, Electrical Engineer

Reviewed By:

K. Pandey, Electrical Engineer

S. Sankaran, Electrical Engineer

R.F. Lambiase, Principal Engineer

D. Bruno, Principal Electrical Engineer

C. Galdamez, EIC Procurement Liaison Engineer

C. Schaefer, EIC Environment Safety & Health Manager

C. Sullivan, EIC Quality Assurance

V. Ptitsyn, EIC HSR Performance Lead

_________________________________ Date: __________________

R. Feder, EIC TSD Deputy Director

J. Tuozzolo, EIC TSD Director

Approved By:

W. Halbig, EIC HSR Systems Manager, Deputy Division Director

This page intentionally left blank, to accommodate back-to-back printing.

REVISION HISTORY

Revision # Effective Date Summary of Change

00 Initial Release

Table of Contents

LIST OF ACRONYMS

1 SCOPE

1.1 Background

2 APPLICABLE DOCUMENTS

3 REQUIREMENTS

3.1 Contractor Responsibilities

3.1.1 Technical Performance

3.1.2 Tooling/Fixtures/Test Equipment

3.1.3 Spare Parts/Special Tools

3.1.4 Materials

3.1.5 Government Furnished Material

3.2 Engineering Design and Manufacturing Requirements

3.2.1 Detailed Design Requirements

3.2.2 NRTL Requirements

3.2.3 Acceptance Test Procedures (ATP)

3.3 Management

3.3.1 Program Plan

3.3.2 Progress Communications

3.3.3 Manufacturing/Inspection/Test Plan

3.3.4 Performance Reporting

3.3.5 “Witness” Points

3.4 Design Reviews

3.4.1 Preliminary Design Review Meeting

3.4.2 Final Design Review Meeting

3.5 Documentation and Data Management

3.5.1 Report/Documentation Format

3.5.2 End Item Documentation Package

3.5.3 Records

3.6 Software Requirements

3.6.1 Software Configuration Control

3.7 Environment, Safety and Health (ESH)

3.8 Marking and Serialization

3.9 Warranty

3.10 Packaging

3.11 Storage

4 QUALITY ASSURANCE

4.1 Quality System and Facility Access

4.2 Configuration Management

4.3 Inspections and Test Requirements

4.4 Repairs

4.5 Options

5 DELIVERABLES

6 SCHEDULE

7 VALUE ENGINEERING

LIST OF ACRONYMS

ABL As-Built Listing

ANSI American National Standards Institute

ASME American Society of Mechanical Engineers

ATP Acceptance Test Procedure

BNL Brookhaven National Laboratory

BSA Brookhaven Science Associates

COTS Commercial Off-The-Shelf

EIC Electron-Ion Collider

ESH Environment, Safety and Health

FDR Final Design Review

ISO International Organization for Standardization

MRP Material Requirements Planning

M&TE Measuring and Test Equipment

NEC National Electric Code

NFPA National Fire Protection Association

NIST National Institute for Standards and Technology

NRTL Nationally Recognized Test Laboratory

PDR Preliminary Design Review

PO Purchase Order

QA Quality Assurance

SOW Statement of Work

T&C Terms and Conditions

HSR Main Arc Dipole and Quad Power Supplies

1 SCOPE

This Statement of Work (SOW) will be the basis for the procurement of the Main Arc Dipole and

Quadrupole Power Supplies 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.

1.1 Background

The EIC Project will design, build, and install the accelerator hardware for a new electron storage ring, an electron injector, and modifications to the hadron ring required to produce an electron-ion collider and infrastructure. It will include one interaction region, with an allowance for a second, and one detector. The facility is designed to meet requirements to ensure high reliability and availability for the user program.

The Hadron Storage Ring (HSR) is formed by modifying the existing hadron ring, and its main arc dipole and quadrupole magnets are superconducting elements connected in series strings around the ring. The two power supplies covered by this specification will be used to supply and precisely regulate ramped current into superconducting magnet loads. One supply, Model A, for the main arc dipole circuit and one supply, Model B, for the main arc quadrupole circuit. The power supplies shall be installed at BNL in building 1004B.

2 APPLICABLE DOCUMENTS

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

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

Document Number Document Title

TBD Spec Number Technical Specification for the HSR Main Arc Dipole and Quadrupole

Power Supplies

BNL-QA-101

Brookhaven National Laboratory Supplier Quality Assurance

Requirements

ISO 9001 Quality Management Systems — Requirements

ASME B30.26 Rigging Hardware

ASME BTH-1 Design of Below-the-Hook Lifting Devices

IEEE 1202 IEEE Standard for Flame-Propagation Testing of Wire and Cable

UL 508 Standard for Industrial Control Equipment

3 REQUIREMENTS

In accordance with the applicable specifications, referenced documents, and instructions as defined in this Statement of Work, the Contractor shall be responsible for designing, manufacturing, inspecting, testing, and delivering the EIC HSR Main Arc Dipole and Quadrupole Power Supplies.

3.1 Contractor Responsibilities

3.1.1 Technical Performance

In accordance with this SOW, BSA technical specification XXX, and all referenced documents, the Contractor shall furnish all equipment, materials, tools, facilities and labor to perform the work necessary to manufacture and test the EIC HSR Main Arc Dipole and Quadrupole Power Supplies.

The Contractor shall ensure that the resultant design & finished product meets the performance parameters and criteria in accordance with BSA specification XXX and all other referenced documents.

3.1.2 Tooling/Fixtures/Test Equipment

The Contractor shall be responsible for supplying all materials, including (but not limited to) the construction of all tools, jigs, fixtures, test loads and test equipment required to meet the requirements of this SOW and the referenced technical drawings and specification(s).

The test load shall enable the testing of the power supply as required in section 4 of specification

XXX.

3.1.3 Spare Parts/Special Tools

Special tools are not permitted without BSA Technical Representative written approval. Any special tools thus approved and then fabricated shall become the property of BSA. The special tools shall be delivered to BNL with the end item.

3.1.4 Materials

The Contractor shall have an effective storage and age control system for items where acceptability is limited by the age or manner of storage of the item.

Suspect/Counterfeit Parts — Items furnished to BSA under this SOW shall not include suspect/counterfeit parts, nor shall such parts be used in performing any work covered by this

SOW whether on or off the BNL site. The Contractor shall:

• Verify the procurement source and associated certifying paperwork.

• Implement appropriate incoming inspection test methods to detect potential counterfeit parts and materials.

• Flow this requirement down to all sub-contractors and suppliers to prevent the inadvertent use of counterfeit parts and materials.

For more information refer to the following Department of Energy website:

https://www.energy.gov/ehss/suspectcounterfeit-and-defective-items-program

3.1.5 Government Furnished Material

In support of the Contractor's work, BSA will provide to the Contractor the following material to be used in the execution of this Contract:

• Controls Interface Test Box (Real time waveform generator)

The Contractor shall be responsible for the safe storage, handling, and use of all Government

Furnished Material from the time of receipt at the Contractor's facility until installation in the end item and shall return any unused or defective items to BSA.

3.2 Engineering Design and Manufacturing Requirements

3.2.1 Detailed Design Requirements

3.2.1.1 Preliminary Design Review (PDR) Report

The Contractor shall be responsible for providing a PDR report that reflects the state of the developed design. The PDR report shall consist of the following items to be addressed in detail and supported by preliminary calculations that shall be presented at the PDR for review and approval.

• Thermal Calculations — including part numbers, ratings, and operating points o Cabinet Temperatures o Magnetic Temperatures o Semiconductor Temperatures

• Safe Lifting Capacity Analysis — Calculations to verify that the lifting components and the power supply frame are properly designed for safe lifting. The lifting calculations shall specify the hardware size and type, and the proper sling length and rating for lifting the power supply from calculations that define the estimated center of gravity and weight of the completed power supply assembly.

• Operating Points — Maximum voltage on the capacitors, the design voltages on the capacitors, and the maximum voltages on the semiconductors.

• Mechanical configuration — including dimensions, location of major components, and the control compartment.

• Schematic and assembly drawings of the supply, drawn to scale where appropriate, showing basic configuration and all essential components.

• A detailed block diagram of the power supply as part of the proposal and in the design review documentation.

• Analysis of the performance and design margins of the system, including ramp performance, current regulation accuracy, stability, and tracking against the commanded current reference.

• An estimate of the preliminary input power requirements and cooling water requirements.

• The type of connections for water-cooling, input power cables, output power cables, and control cables.

• The Contractor shall include in their proposal measures and procedures that demonstrate compliance with the pressure system requirements. Documentation supporting these requirements for all pressure components shall be included with each power supply shipped and shall include materials certifications, braze procedures and inspection reports, qualification of individuals performing brazing, component pressure rating or certification, and inspection and test reports.

• All electrical design concepts, including:

o Regulation — including current loop precision, voltage loop precision, bandwidth, and response to on and off load steps. The Contractor shall provide a complete current regulation system meeting the regulation, stability, and tracking requirements of the specification.

o Stored energy limiting — implementation and maximum energy to an arc.

o Control — including Programmable Logic Controller (PLC) communication and the current reference / status interface to BNL controls.

• A detailed manufacturing schedule, with milestones and staff assignments.

• Quench Protection Interface — design provisions for receiving quench link signals and executing protective actions specified response times

• Stored Magnetic Energy Management — analysis demonstrating the power supply is rated to safely handle the stored magnetic energy of the load (110.25 MJ for the HSR

Main Arc Dipole (Model A) and 17.15 MJ for the HSR Main Arc Quadrupole (Model

B)) under both normal operation and fault conditions including quench events.

• High Potential Testing — The design to provide sufficient voltage isolation to ground shall be described.

• Preliminary Acceptance Test Plan (ATP)

3.2.1.2 Final Design Review (FDR) Report

The Contractor shall be responsible for providing 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 Equipment in accordance with the applicable specifications and supporting documents as identified herein. 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

BSA.

• Summary of significant changes since the PDR

• Final detailed design information, including drawings, parts lists, and schematics

• Manufacturing Planning

• Environment, Safety, and Health (ESH) – description of personnel safety

• Final ATP

3.2.1.3 Approval to Proceed

The BSA Technical Representative must approve in writing the FDR Report, including any modifications introduced at the FDR, before the Contractor proceeds with ordering of material and components. Ordering long-lead-time materials and components prior to the approval of the Final

Design Review Report must be reviewed and approved in writing by the BSA Technical

Representative. The approval to proceed does not alter the requirements of the specification or

SOW in any way.

3.2.2 NRTL Requirements

All parts used in the power supply shall be listed by Underwriters Laboratories (UL) or equivalent

Nationally Recognized Testing Laboratory (NRTL). If any unlisted parts will be used, these shall be specifically called out in the proposal. The complete power supply shall be NRTL or equivalent agency certified with a field evaluation.

3.2.3 Acceptance Test Plan (ATP)

The Contractor shall provide an ATP that is in accordance with this SOW, BSA Technical

Specification [TBD — spec number], and all referenced documents noted herein. The ATP must be approved in writing by the BSA Technical Representative prior to use. The ATP shall ensure that all test requirements as defined in the Specification are achieved.

• Factory Acceptance Testing. BSA reserves the right to witness all factory acceptance testing prior to shipment.

• Specify documentation required at the completion of Factory and/or Site Acceptance testing.

• As listed in the End Item Documentation. And agreed upon at the FDR

3.3 Management

3.3.1 Program Plan

Within 4 weeks after award of contract, the Contractor shall deliver a detailed program plan which includes a milestone schedule defining the design validation, manufacturing, inspection, and testing phases in sufficient detail to allow regularly scheduled progress monitoring.

3.3.2 Progress Communications

Within 4 weeks after award of contract, monthly technical and progress telecommunications and/or meetings between the Contractor and BSA shall be held at a mutually scheduled time. The discussions shall include the Contractor's progress, technical and contractual questions, presentations of analysis or testing results, design reviews, value engineering, troubleshooting, material status, tooling status, resources, and manufacturing issues.

3.3.3 Manufacturing/Inspection/Test Plan

A manufacturing/inspection/test plan shall be developed which identifies the manufacturing processes required to complete all efforts as identified in this SOW. The plan shall be submitted for review and approval by the BSA Technical Representative within 6 weeks after award of contract and a minimum of sixty (60) calendar days prior to the performance of work.

The plan may be a single document or may make use of existing travelers or other suitable planning and control documents. It shall address the Material Requirements Planning (MRP), and at a minimum include manufacturing, inspection, and test steps including identification of critical manufacturing operations and parts/subassemblies showing integrated flow into the end item(s). If the Contractor does not have an MRP system in place, then details for purchasing all raw materials, shop loading (by work center), and a schedule for manufacturing all components and assemblies through packaging and shipping shall be provided by the Contractor.

The power supplies shall be fully tested at the Contractor's plant to ensure complete compliance with BSA Technical Specification [TBD —spec number]. All facilities shall be provided by the

Contractor at their plant for testing of the power supplies as stated in the specification. Three (3) weeks before these tests, the Contractor shall provide the acceptance test procedure to the BSA

Technical Representative for approval. Included in this procedure shall be test data sheets and interlock check out lists. Final tests at the Contractor's plant shall be witnessed by BSA prior to shipment.

The BSA technical representative shall have access to the Contractor's facility during fabrication and testing. The Contractor shall provide fifteen (15) working days' notice for a domestic

Contractor and forty-five (45) working days for a foreign Contractor in advance of the test date so that BSA can make the necessary travel arrangements.

3.3.4 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 and Contractual 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.

3.3.5 “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

BSA with fifteen (15) working days' notice for a domestic Contractor and forty-five (45) working days for a foreign Contractor in advance of such witness points during the manufacturing and test cycle.

3.4 Design Reviews

3.4.1 Preliminary Design Review Meeting

A PDR meeting shall be held in accordance with the schedule set forth in section 6 herein, to ensure compliance with this SOW and applicable specifications. The Contractor shall provide, no later than ten (10) working days prior to the scheduled meeting, a draft PDR Report that shall consist of the requirements set forth in section 3.2.1.1. The contents of this report shall be reviewed at the PDR to be held at the Contractor's facility. At BSA's discretion this could become a teleconference. 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, both of which shall be submitted within ten (10) working days of the PDR for subsequent review and written approval by the BSA Technical Representative.

The Contractor shall provide BSA with fifteen (15) working days' notice for a domestic Contractor and forty-five (45) working days for a foreign Contractor in advance of the design review.

3.4.2 Final Design Review Meeting

An FDR meeting shall be held in accordance with the schedule set forth in section 6 herein, to ensure compliance with this SOW, applicable specifications, and to obtain BSA approval 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 in section 3.2.1.2. The findings of the FDR Report shall be reviewed at the FDR to be held at the

Contractor's facility and shall cover all pertinent issues relating to the final detailed design of the

Equipment. At BSA's discretion this could become a teleconference. 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 BSA within ten (10) working days of the FDR for subsequent review and approval.

The Contractor shall provide BSA with fifteen (15) working days' notice for a domestic Contractor and forty-five (45) working days for a foreign Contractor in advance of the design review.

The FDR shall be held within ten (20) weeks after receipt of order and prior to the start of fabrication. Documentation for the FDR shall be submitted to BSA in electronic form, using standard file formats, and having all details clearly readable.

The FDR documentation shall include all electrical schematic drawings, including all schematics of printed circuit boards, mechanical assembly drawings, a manufacturing schedule, an acceptance test procedure, and parts lists. This documentation shall be submitted to BSA at least ten (10) working days prior to the FDR.

Agreement shall be reached during the FDR not only on the drawings and material submitted, but also on the Contractor's manufacturing plan, preliminary test procedure and schedule. Components and materials shall also be reviewed at this time. The results of the FDR shall be documented by the Contractor and submitted to the BSA Technical Representative for approval.

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, tooling, or component-level substitutions, without written approval by BSA.

3.5 Documentation and Data Management

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

The Contractor shall provide an electronic copy (BSA-identified FTP, DVD or USB data storage device) of all documentation required by this SOW. Contractor manufacturing drawing Computer-

Aided Design files of all components and assemblies shall be in one of these formats: STP, SAT, IGES, IAM, or IPT.

Electrical schematic formats shall be Mentor Graphics or equivalent subject to approval by the

BSA Technical Representative.

3.5.2 End Item Documentation Package

The Contractor shall provide with the end item documentation package an electronic copy and three (3) physical copies of the following documentation in accordance with the schedule set forth in this SOW. The End Item documentation package shall consist of all documentation identified in this SOW and include the following:

• Manufacturing Travelers: Manufacturing Travelers that include documentation of visual and dimensional inspections and materials shall be provided. A traveler shall accompany each power supply through production. The traveler shall contain critical settings, including torque requirements for bolted connections, for the power supply and shall serve as a history of its production. A copy of each traveler shall be supplied to the BSA

Technical Representative.

• Final Inspection and Test Reports: Final test reports of all required or necessary inspections, examinations, and tests, properly validated by the Contractor's authorized personnel shall be recorded and compiled in a measurement and test report and be supplied to BSA. The BSA Technical Representative shall review and provide written approval prior to shipment.

• Nonconformance Reports: Nonconformance reports identified as "rework / repair" or "use-as-is" shall be provided.

• A listing of the as-built configuration of each delivered item; this may be defined by the use of drawing numbers and revisions, unique parts lists, or other such means of positive identification. Parts must be identified by the commercial part number.

• Operating Manual: Three (3) sets of bound design and operations manuals shall be shipped with the equipment. An electronic version shall be included as part of the End Item

Documentation Package. It shall include final parts lists, recommended spare parts lists, technical descriptions of the power supply operation and maintenance recommendations, detailed circuit descriptions, description of critical adjustments and potentiometer settings, and data sheets on gauges, meters, fuses, semiconductors, relays, valves, and other pertinent components.

• Certificate of Conformance: The Contractor shall provide a Certificate of Conformance that certifies the following:

o Components used were produced from materials for which the Contractor has on file, reports of chemical or physical analysis, or any other equivalent evidence of conformance.

o Processes used in the fabrication of items delivered were in compliance with the

SOW or BSA approved procedures or specifications.

o The items as delivered comply with all applicable drawings, specifications, deviations/waivers, and other requirements of the procurement documentation.

• Reliability, Maintainability, and Obsolescence Management Plan: The Contractor shall provide a Reliability, Maintainability, and Obsolescence Management Plan for the power supply system. The plan shall be submitted in accordance with the project document submittal schedule and shall be subject to review and approval by the BSA Technical

Representative. At a minimum, the plan shall include:

o Identification of critical components and assemblies whose failure could result in loss of power supply operation.

o Identification of credible failure modes, including single-point failures and common-cause failures.

o Identification of components having limited operating life, limited shelf life, known aging mechanisms, or elevated obsolescence risk.

o Recommended preventive and predictive maintenance activities and maintenance intervals.

o Recommended spare parts, complete spare assemblies, and special maintenance tools.

o Estimated repair or replacement times for major components and assemblies.

o Recommended criteria for refurbishment, replacement, or retirement of equipment.

o Identification of proprietary hardware, software, firmware, communication interfaces, and diagnostic tools required to maintain the equipment.

o Description of the process for notifying BNL of component discontinuance, loss of manufacturer support, or other conditions affecting long-term equipment support.

Reliability-related failures identified during design, manufacturing, factory acceptance testing, site acceptance testing, commissioning, or the warranty period shall be documented. The Contractor shall provide failure investigation reports, root-cause analyses, corrective actions, and recommendations for updates to maintenance procedures and spare parts provisions.

3.5.3 Records

The Contractor shall retain objective evidence, including records, of the inspections and tests performed during manufacturing, testing, inspecting, preserving, packaging, and preparation for shipment of procured items. These records shall be made available to BSA for review upon request.

These records shall be maintained for a minimum of five (5) years, unless otherwise specified in the procurement documentation, after the completion of the Purchase Order (PO)/Contract.

3.6 Software Requirements

All software provided under this Contract shall be subject to review and approval by BSA. Source code shall be included with the deliverables.

3.6.1 Software Configuration Control

The Contractor shall have and maintain an effective software configuration management system.

The Contractor's system shall establish requirements for placing software under configuration control and provide for the positive identification of software and the control of all software baseline changes.

3.7 Environment, Safety and Health (ESH)

The Contractor shall design and build all equipment in accordance with ESH requirements in the appropriate specifications, codes, standards, and other documents listed in section 2 of this SOW.

• Pressure Safety

• Fire

▪ The Contractor shall ensure that any electrical equipment or wiring minimizes combustibility by the use of flame-resistant materials.

▪ All cables to be installed in a cable tray shall be rated for Cable Tray use. The cable shall have the TC (Tray Cable) and NRTL markings. If a Contractor elects to use a cable not marked for Tray Cable use, then the Contractor shall use a cable that will meet IEEE 1202 or equivalent approved by BSA in writing. BSA shall approve the use of all non NRTL marked tray cables in advance of the Contractor ordering the cable.

▪ All other cables shall be Low Smoke Zero Halogen (LSZH)

• Material Handling

▪ Lifting hardware must meet BSA safety requirements, and as such shall be designed according to ASME B30.26, “Rigging Hardware”, and ASME BTH-1 (Design of

Below-the-Hook Lifting Devices, Design Category “A”).

• Electrical Safety

▪ All electrical equipment, material, and systems delivered to BNL shall be certified, listed, or labeled by a Nationally Recognized Testing Laboratory (NRTL). The CE mark is NOT a recognized NRTL certification mark. (For a listing of OSHA-recognized NRTLs, refer to http://www.osha.gov/)

▪ For electrical equipment, material, and systems which are not NRTL listed, the

Supplier shall determine the equipment to be safe for its intended use. The determination must be made on the basis of test data. The determination and test data documents shall be made available to BSA prior to or upon delivery for review and acceptance by the applicable BSA Authority Having Jurisdiction (AHJ).

▪ All electrical connections ≥50 volts shall be covered to comply with UL 508 so that all uninsulated charged surfaces protect workers from the hazards of electrical shock. Plexiglas® is not allowed; Lexan® may be used. Electrical insulation must be Low Smoke, Zero Halogen and Fire Retardant.

3.8 Marking and Serialization

Where labeling is required, the position of serialization and/or labeling of the identification number/nameplate shall be agreed upon between the Contractor and BSA Technical

Representative prior to acceptance of final design.

3.9 Warranty

All elements of these power supplies shall be covered by a warranty against material and manufacturing failure. The warranty period shall be for a minimum period of at least two (2) calendar years from the final acceptance test date.

3.10 Packaging

In preparation for shipping, the power supplies shall be covered or wrapped for protection against weather elements, dust, and damage to projections, shock loads, impacts, and rubbing. The units shall be delivered in undamaged conditions to BNL. All water circuits shall be blown free of any water prior to packaging to prevent damage during shipping or storage under freezing conditions.

The power supplies shall be properly braced and cushioned so that they will not shift during handling and shipment. The method of shipping shall be specified and approved by BSA one month prior to delivery. The power supplies shall be labeled with the destination, gross weight, location of center of gravity, purchase order/Contract number, and contact information. Each power supply shall have G-force shock indicators. The power supplies shall be shipped via air ride trucks. Provisions shall be included to lift the power supplies with forklifts. Each power supply should ship with all required components for operation at a schedule agreed upon with the BSA

Technical Representative.

3.11 Storage

The storage air temperature is 10 °C to 40 °C.

4 QUALITY ASSURANCE

4.1 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 all equipment provided. 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 advanced 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, select between 3.1.1 to 3.1.4 , 3.2 to 3.8, 3.21, 3.22, 4.0, 4.1, 4.2, 4.3 , 4.4 , select one or more between 4.4.1 to 4.4.3, 4.5, 4.6, 4.7, select between 4.7.1 to 4.7.3 as applicable, 4.10, select between 4.10.1 to 4.10.4 as applicable, 4.11, 4.13, 4.14, 4.16, 4.18, select one or more between 4.18.1 to 4.18.4, 4.19, 4.21, 4.34, and 4.39.

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 and that the BSA Technical Representative shall review and provide written approval prior to shipment.

BNL-QA-101 Clause 4.39 “Records” is amended to require the Contractor to maintain records for a minimum of five (5) years.

4.2 Configuration Management

The Contractor shall establish and maintain a configuration control system to ensure that all power supplies 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 equipment by BSA. The Contractor shall immediately notify the BSA Contractual 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 for consideration. Changes in configuration may be made by the Contractor only with the written approval of BSA.

4.3 Inspections and Test Requirements

Unless otherwise specified in the PO/Contract, the Contractor shall be responsible for the performance of all inspections and tests specified herein. Except as otherwise specified in the

PO/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 referenced specifications where deemed necessary to ensure that Equipment conforms to prescribed requirements at no cost to the Contractor. BSA and/or their representative shall have the option to witness all of the tests defined.

The systems shall be 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 an ATP (as noted in section 3.2.3) generated by the Contractor and approved in writing by BSA. BSA or its designee retains the right to witness all testing. Final acceptance of the units shall take place following the successful completion of final testing at BNL. The time period for the final testing at BNL shall be within 90 days after receipt of the units at BNL.

4.4 Repairs

If failures occur or repairs are required to an assembly or any component during manufacturing or testing that affects form, fit, function, reliability, safety, or interchangeability, the process shall stop and BSA shall be immediately notified. BSA 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 approval of BSA. No repair shall be considered successfully accomplished without inspection and written approval by BSA. 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 of BSA.

4.5 Options

The Contractor shall include in the proposal the option to commission the power supplies at a BNL designated facility by completing the full ATP.

5 DELIVERABLES

The Contractor shall supply the following:

Item Deliverable Due

BSA

Approval

1 Program Plan 4 weeks after award of contract Yes

2 Technical and Progress Reporting 4 weeks after award of contract/ monthly thereafter No

3 Performance reports 5th of each month after receipt of

Program Plan No

4 Manufacturing/Inspection/Test Plan 6 weeks after award of contract Yes

5 Draft Preliminary Design Review Report 10 working days prior to PDR Yes

6 Final Preliminary Design Review Report 10 working days after PDR Yes

7 Draft Final Design Review Report 10 working days prior to FDR Yes

8 Final Final Design Review Report 10 working days after FDR Yes

11 End Item Documentation As set forth in schedule Yes

12 Delivery of Equipment As set forth in schedule Yes

6 SCHEDULE

The following schedules are for planning purposes only. Schedule requirements set forth in the

Contract will take precedence.

Milestone Calendar weeks after award

Preliminary Design Review 12 Weeks ARO

Final Design Review 20 Weeks ARO

Delivery of End Item Documentation 120 Weeks ARO

Delivery of Equipment to BNL (Main Quadrupole PS) 173 Weeks ARO

Delivery of Equipment to BNL (Main Dipole PS) 186 Weeks ARO

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 design and manufacture and an improvement in the performance and reliability beyond the requirements of this specification are objectives which shall be considered in the Main Arc Dipole and

Quadrupole Power Supplies. 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 BSA for review.