Attachment A - Weld Inspection SOW.pdf

Attachment (A) P.O. Box 5000

Upton, NY 11973-5000 managed by Brookhaven Science Associates for the U.S. Department of Energy

Brookhaven Science Associates, LLC

STATEMENT OF WORK

Revision 1 -- July 15, 2026

I. TITLE: WELD INSPECTIONS

II. BACKGROUND

Brookhaven National Laboratory (BNL) is home to an extensive network of aging infrastructure including: a central steam facility, and a central chilled water facility each with a vast network of distribution piping. Brookhaven Science Associates (BSA) is under contract to operate and maintain this mission critical infrastructure. Due to the age of the equipment distribution piping fails from time to time resulting in the need for repairs that including welding.

BSA is seeking to hire a qualified vendor to inspect welds on an as-needed basis to inspect and document the quality of welds on this mission critical infrastructure.

III. SCOPE OF WORK

Under this Scope of Work (SOW), Brookhaven Science Associates (BSA) will contract with a firm employing qualified welding inspectors, as identified in the quality assurance section below, to perform visual inspections, and phased array ultrasonic testing of identified welds.

Welds may be present in one of two location typologies, confined spaces and non-confined space. This statement considers weld inspections in confined space and out of confined space as uniquely different due to the additional trainings, attendant, and equipment requirements, outlined below, required for confined space entry at BNL.

All work will be performed in accordance with this SOW and BSA safety requirements.

Work is expected to be performed during normal BNL working hours: Monday through Friday, 8:00 a.m. to 4:30 p.m. Work will not be permitted on nights, weekends, or holidays without prior written approval from the authorized BSA Technical Representative(s).

IV. TASKS, REQUIREMENTS & DELIVERABLES

The contractor shall perform weld inspections in two location typologies.

1) Inspections in non-confined spaces

The Contractor shall perform weld inspections in non-confined spaces such as mechanical rooms, utility corridors, pipe galleries, equipment yards, and other accessible areas identified by the BSA Technical Representative.

a. Site Coordination and Access

i) Contractor shall coordinate daily entry with the BSA Work Control Coordinator (WCC) and obtain an approved work permit prior to starting work.

ii) The Contractor shall verify that work areas are clear, accessible, and safe prior to conducting inspections.

b. Inspection Activities

i) Perform visual weld examinations in accordance with Section V as requested.

ii) Perform Phased Array Ultrasonic Testing (PAUT) as requested.

iii) Perform Shear Wave Ultrasonic Testing (UT) as requested.

iv) Perform Magnetic Particle Testing (MT) as requested.

v) Document all inspected welds, including photographs, identification numbers, and location references.

c. Safety Requirements

i) Personnel shall comply with all applicable BNL PPE and training requirements.

d. Deliverables

i) A complete inspection report for each weld inspected per Section V.

ii) Immediate notification to the BSA Technical Representative regarding any condition posing a safety or system-operational risk.

2) Weld Inspections in confined spaces

Weld inspections within confined spaces, such as manholes, vaults, crawl spaces, and utility pits, shall comply with the BNL Confined Space Entry Program and all applicable OSHA requirements.

a. Site Coordination and Access

i) Obtain a confined space entry permit approved by the BSA WCC. Follow all requirements.

ii) Follow the Job Hazard Assessment (JHA) specific to confined-space inspections.

iii) Ensure a trained attendant is present throughout entry.

b. Atmospheric Testing and testing

i) Perform pre-entry and continuous atmospheric testing using a calibrated four-gas meter.

ii) Provide power, lighting, and mechanical ventilation where not provided by BSA to ensure safe atmospheric and working conditions.

c. Inspection Activities

iii) Perform visual weld examinations in accordance with Section V, as requested.

iv) Perform Phased Array Ultrasonic Testing (PAUT) as requested.

v) Perform Shear Wave Ultrasonic Testing (UT) as requested.

vi) Perform Magnetic Particle Testing (MT) as requested.

vii) Document all inspected welds, including photographs, identification numbers, and location references.

viii)Protect existing utilities and ensure safe equipment placement in the confined space.

d. Safety & Personnel Requirements

i) Inspectors must have all training specified in Section VI.

ii) Maintain continuous communication with the attendant.

iii) Cease work immediately if hazardous conditions arise.

e. Deliverables

i) A full inspection report per Section V.

ii) Immediate notification to BSA if weld defects or hazards threaten safety or system integrity.

V. QUALITY ASSURANCE

1) Visual Inspection of Welds

Visual inspections shall be performed in accordance with ASME Section V, Article 9 – Visual Examination. All visual inspections will be post-weld inspections and should include inspection of:

a. Inspect size, contour, and finish of weld.

b. Look for surface discontinuities such as:

- Cracks

- Undercut

- Porosity

- Overlap

- Incomplete fusion

- Misalignment

- Excess reinforcement or concavity

The Acceptance Criteria for visual inspection of welds shall include:

a. Weld size and profile within tolerance

b. No visible cracks or incomplete fusion

c. Limited undercut, porosity, or overlap

d. Proper contour and blending with base metal

e. Smooth transitions with no sharp notches

2) Phased Array Ultrasonic Testing (PAUT)

All PAUT testing shall be performed in accordance with ASME Boiler and Pressure Vessel Code, Section 5 (ASME Section V): Nondestructive Examination:

a. Article 4, Ultrasonic Examination, General Requirements

b. Article 14, Phased Array Ultrasonic Examination

c. Mandatory Appendix VIII Calibration and validation requirements for advanced UT systems

Evaluate indications in accordance with the acceptance criteria of the applicable construction code (ASME Section I), the National Board Inspection Code (NBIC), and the approved repair procedure, as applicable. Cracks, lack of fusion, or incomplete penetration shall be rejectable regardless of length, other indications are rejectable based on wall-thickness-dependent length limits and must be described in the final test report.

3) Magnetic Particle Testing (MT)

a. All magnetic particle examinations shall be performed in accordance with the ASME Boiler and Pressure Vessel Code, Section V, Nondestructive Examination:

a. Article 7 – Magnetic Particle Examination

Examinations shall be performed using the continuous method unless otherwise approved by the Authorized Inspector. Surface preparation, magnetization technique, field strength verification, and examination procedures shall comply with ASME Section V requirements.

Indications shall be evaluated in accordance with the acceptance criteria specified by the applicable construction code or approved repair procedure. Linear indications determined to be cracks, seams, laps, or lack of fusion shall be rejectable. All rejectable indications shall be documented in the final examination report.

4) Ultrasonic Testing (UT) – Shear Wave

All ultrasonic examinations shall be performed in accordance with the ASME Boiler and Pressure Vessel Code, Section V, Nondestructive Examination:

a. Article 4 – Ultrasonic Examination, General Requirements

b. Mandatory Appendix I – Calibration Requirements (as applicable)

Shear wave examinations shall utilize angle beam search units (45°, 60°, or 70°, as appropriate) and shall be performed using procedures qualified in accordance with ASME Section V.

Indications shall be evaluated in accordance with the acceptance criteria specified by the applicable construction code or approved repair procedure. Cracks, lack of fusion, and incomplete penetration shall be rejectable regardless of size. Other indications shall be evaluated based on the applicable code acceptance criteria and shall be documented in the final examination report.

5) Report

Reporting requirements for each inspected well shall comply with Article 4, Article 14 and related Appendices. At minimum, the written report shall contain the following:

c. Procedure identification (qualified and approved per ASME Section V)

d. Date and time of the inspection

e. Identification of the component being inspected, provided by BSA project manager, and a photo of the component.

f. Examiner’s name, certification level, qualification documents, and employer

g. Equipment details including instrument make/model, transducer type, frequency, angle, and couplant.

h. Calibration data for the equipment, valid during the date/time of the inspection including the reference block ID, calibration date, sensitivity level, and reference reflector distance-amplitude curve (DAC) of time correct gain (TCG) data.

i. Technical parameters including scan angles, coverage, encoded vs manual, scan plane reference.

j. Indication data including location, by weld station or clock position, depth, length, and amplitude relative to reference.

k. Evaluations and acceptance reference, for example: Evaluated per ASME B31.1 344.6.2.

l. Disposition either Accept, Reject, or Rework/repair required.

m. Signatures for the examiner and Level III reviewer

Final reports shall be submitted in PDF format within five (5) business days.

VI. SITE SAFTY REQUIREMENTS

Training for team members assigned to this scope of work shall be completed within 30 days of contract award. Following the 30 day grace period, the contractor shall have at least one team member trained and approved by BSA to perform any welding inspection defined in this statement of work, for the duration of the contract term.

Minimum requirements for BSA approval are as follows:

a. All Contractor employees are required to obtain a Contractor access badge through the Guest User and Visitor Center (GUV) and be approved by their host and the GUV Center on an annual basis.

b. All Contractor workers performing work at the BNL site are required to take Contractor Vendor Orientation (CVO) annually. The orientation class is a 90-minute class offered three times a week, currently it can be scheduled to take remotely Wednesday and Friday mornings, the schedule is subject to change.

c. All contractor work, including inspection services performed at BNL is considered permitted work by BSA policy. To obtain a work permit the contractor will work with the BSA Work Control Coordinator (WCC) to complete a Job Hazard Assessment

(JHA).

- At minimum the selected contractor can expect to complete two JHA’s one for inspections inside of buildings and plants, the other for inspections that take place inside of confined spaces including but not limited to utility manholes.

d. The inspectors shall, at minimum, provide document training evidence of the following competencies:

For inspections taking place in non-confined spaces:

- Asbestos Awareness

For inspections taking place in confined spaces:

- Confined Space Entry

- Asbestos Awareness

- Fall Protection

- Four Gas Meter

There are areas of campus that may require advanced BNL specific training. It is recommended the contractor include the following training efforts as line-item costs per employee, so they can be billed if BSA deems them required for a specific inspection:

- Lock-out Tag-out Affected Employee (HP-OSH-151A-W) - This is a four-hour training course, with an exam at the end, that must be taken on site

- General Employee Radiological Training (TQ-GERT) – This is a 90-minute training that may be taken remotely.

- Barricade Training (TQ-Barricades) – This is a 30 minute course offered on-line

The Contractor may submit an approved training class certification to prove that workers are competent in all other training areas identified in the JHA, including but not limited to confined space, fall protection, four gas meter, etc. BSA has the sole discretion of approving such classes.

e. The Contractor is expected to provide all personal protective equipment identified in the JHA to ensure the Contractor’s employee can safely work on the task assigned.

f. All tools required to safely execute work shall be provided by the Contractor.

g. Contractor must comply with all BNL site access protocols, safety procedures, and PPE requirements.

h. All personnel must be badged to enter and have all the necessary training deemed by the facility project manager and the Energy and Utilities (EU) safety representative to execute the permitted work.

VII. INSPECTOR QUALIFICATION REQUIREMENTS

a. The selected vendor shall ensure that all personnel performing Phased Array Ultrasonic Testing (PAUT) of welds are qualified and certified in accordance with a written practice prepared and maintained by the selected vendor in conformance with ASNT SNT-TC-1A, and ASNT CP-189. The written practice shall be made available for review by BSA prior to commencement of work.

b. Personnel performing PAUT shall hold, at a minimum, Level II certification in Ultrasonic Testing (UT) with documented PAUT-specific training and examination.

Only personnel certified to Level II or higher may independently perform, interpret, and report PAUT examinations. All certifications shall be current at the time of testing.

c. The selected vendor shall designate an NDE Level III, certified in Ultrasonic Testing, who shall:

- Approve all PAUT procedures prior to use.

- Verify the adequacy of calibration and examination techniques; and

- Review and sign examination reports when required.

d. Inspectors shall be located within 50 miles of Brookhaven National Laboratory, and able to respond to a request for inspection services within 2 business days.

VIII. SIGNATURE AND DATE

____________________________ July 15, 2026 Benedetto Schiraldi