Attachment A2 -EX-10-ES00012 Rev 4 Technical Specification for a 90 Degree Extended Ver. and Shortened Ver. Utility Tray.pdf

Technical Specification for a 90 Degree, Extended Version, and Shortened Version Utility Tray

Doc Number: EX-10-ES00012

Revision: 04

AUTHOR:

Date

REVIEWERS:

UCNI Reviewing Official

APPROVER:

Technical Specification Number: EX-10-ES00012, Rev 4 Issued: See Approval Dates

90 Degree, Extended Version and Shortened Version Utility Tray

CHANGE HISTORY

REV. DESCRIPTION

REVISION

TYPE

Major Minor

01 Initial Issue ☐ ☐

02 Updated to reflect change in scope activities and new references. No rev bar shown.

03 Updated to reflect needed changes in testing requirements and specifications and the addition of the extended length version of the

Utility Tray.

04 Updated to reflect the addition of a shortened length version of the

Utility Tray.

PREVIOUS REVISION (2) AUTHORS AND APPROVERS

Author: Anna Strickland

Reviewers: Shane Carr

Darryl Dowling (UCNI RO)

Approver: Seth Wilder

PREVIOUS REVISION (3) AUTHORS AND APPROVERS

Author: Darryl Dowling

Reviewers: Shane Carr

Darryl Dowling (UCNI RO)

Approver: Seth Wilder

CONTENTS

1. INTRODUCTION

2. REFERENCE DOCUMENTS

3. ACRONYMS AND DEFINITIONS

4. GENERAL

4.1 Requirements

4.2 Design

5. DESCRIPTION

5.1 Utility Tray Source End Assembly

5.2 Utility Tray 45 Degree Assembly

5.3. Utility Tray Collection End Assembly

5.4 Extended Utility Tray Source End Assembly ……………………………………………………...18

5.5 Extended Utility Tray Removable Section Assembly ……………………………………………..22

5.6 Extended Utility Tray 1st 45 Degree Assembly ……………………………………………………22

5.7 Extended Utility Tray Mid Collection Area Assembly ……………………………………………23

5.8 Extended Utility Tray 2nd 45 Degree Assembly …………………………………………………...24

5.9 Extended Utility Tray Collection End Assembly ………………………………………………….25

5.10 Shortened Utility Tray Source End Assembly ……………………………………………………. 30

5.11 Shortened Utility Tray 30 Degree Assembly ……………………………………………………... 33

5.12 Shortened Utility Tray Collection End Assembly ………………………………………………... 34

6. UTILITES AND SERVICE DROPS

7. EQUIPMENT AND COMPONENT SUBSTITUTIONS

8. DOCUMENTATION

9. QUALITY ASSURANCE

10. INSPECTIONS AND TESTS

11. CLEANING & FLUSHING

12. WARRANTY

13. PACKING AND SHIPPING

14. DOCUMENT LIST

1. INTRODUCTION

This Specification defines the requirements for the design, procurement, materials, fabrication, assembly, testing, and shipment of a Utility Tray that will provide electrical service, cooling water, and compressed gases. The Utility Tray is designed as an integral part of a system used for production at the Oak Ridge National Laboratory (ORNL), hereafter referred to as the Company. The

Utility Tray design has three versions, a “90D Version”, an “Extended Version” and a “Shortened

Version”. The term “Utility Tray” is used to generically refer to each of the versions and the 90D

Version is the basic version, whereas the term “Extended Utility Tray” and “Shortened Utility Tray” details the requirements for those specific versions only.

2. REFERENCE DOCUMENTS

The Utility Tray fabrication shall conform to the requirements in the following documents.

Additional requirements are located in the General Project Specification, EX-00-ES00086. In the event of a conflict between the General Specification, Technical Specification, Statement of Work, or between either of these documents and a requirement in a specified code or standard, the Seller shall notify the Company’s TPO and PO. The TPO and PO will determine which document takes precedence and advise the Seller accordingly. Failure to notify the Company of any such conflict shall not relieve the Seller of any responsibility to meet all requirements.

Codes & Standards

• Applicable OSHA Standards and Regulations

• National Electric Code NFPA No 70-2020

• UL508A Edition 3 Industrial Control Panels

• ASME Building Services Piping Code B31.3-2020

• AWS Structural Welding Code - Steel AWS D1.1/D1.1M:2020

• AWS Structural Welding Code - Stainless Steel AWS D1.6/D1.6M:2017

• IPC/WHMA-A-620D Requirements and Acceptance for Cable and Wire Harness Assemblies

• ASME Section IX -2021 Welding, Brazing and Fusing Qualifications

• ASNT SNT-TC-1A Personnel Qualification and Certification in Nondestructive Testing

Project Documents

• EX-00-ES00086 General Project Specification

• See Section 14

3. ACRONYMS AND DEFINITIONS

ACRONYMS, ABBREVIATIONS, AND INITIALISMS

AISI American Iron and Steel Institute

ANSI American National Standards Institute

ASME American Society of Mechanical Engineers

ASNT American Society For Nondestructive Testing

AWS American Welding Society

BOM Bill of Materials

CAT Category

ACRONYMS, ABBREVIATIONS, AND INITIALISMS

EMT Electrical Metallic Tubing

ID Inside Diameter

IEEE Institute of Electrical and Electronics Engineers

IPC Institute for Printed Circuits

HV High Voltage

NEC National Electric Code

NEMA National Electrical Manufacturers Association

NFPA National Fire Protection Association

NPT National Pipe Thread

NRTL Nationally Recognized Testing Laboratory

OD Outside Diameter

ORNL Oak Ridge National Laboratory

OSHA Occupational Health and Safety Administration

P&ID Piping and Instrumentation Diagram

PDF Portable Document Format

PO Procurement Officer

POC Point of Contact

TPO Technical Project Officer

UL Underwriter Laboratories

WHMA Wiring Harness Manufacturer's Association

DEFINITIONS

COMPANY Oak Ridge National Laboratory

SELLER Provider of Goods or Services under this Contract (includes Seller contracted sub-suppliers)

4. GENERAL

4.1 Requirements

4.1.1 This document is technical in nature; all legal and procedural matters governing proposals and contract awards are covered in separate purchasing contracts and documents, as well as an accompanying Statement of Work document.

4.1.2 All drawings prepared by the Seller detailing modifications to Company provided drawings or to provide details omitted in the Company’s design drawings shall be reviewed and approved by the Company prior to fabrication.

4.1.3 The Seller shall fabricate, assemble, inspect, test, and ship the completed Utility Tray to the

Company’s facility.

4.1.4 Final acceptance of the Utility Tray shall occur after successful completion of all acceptance test as defined in the listed Specifications.

4.2 Design

The Company has designed the Utility Tray to provide the specific fit, form and function required to integrate with the system as defined in this Specification, design drawings and solid models.

All original drawings, as-built drawings, models, Bill of Materials (BOM) and related documents are the sole property of the Company and shall not be disseminated for reasons other than the fabrication, assembly, and testing of the Utility Tray. All changes in scope, fit, form or function must be submitted to the Company for approval in accordance with Section 5.2 of the General

Specification and documented on as-built drawings.

4.2.1 Solid models, drawings, schematics, etc. containing the assembly, sub-assemblies and individual components of the Utility Tray have been generated by the Company and will be provided to the Seller in zip file format. The 90D Utility Tray file is named UTILITY TRAY

90D.7z. The Extended Utility Tray file is named EXTENDED UTILITY TRAY 90D.7z.

The Shortened Utility Tray File is named SHORTENED UTILITY TRAY 60D.7z.

4.2.2 The top-level assembly and drawing defining the 90D Utility Tray design is EX-10-90000_90D

MASTER FACILITY TO MACHINE UTILITIES. The Extended Utility Tray design is

DX-10-90000_DEMIS MASTER FACILITY TO MACHINE UTILITIES. The Shortened

Utility Tray design is EX-10-60000_60D MASTER FACILITY TO MACHINE

UTILITIES. The assembly model and drawings were developed using SOLIDWORKS 2020

3D Design Software.

4.2.3 Bill of Materials are contained within the assembly and sub-assembly drawings for modeled components, with an additional BOM in an Excel spreadsheet format which includes

Instrumentation and Control or other components not modeled. In the event that a BOM item and the prints/solid models are discrepant with each other, the Seller is to notify the Company for resolution. The BOM for the 90D Utility Tray Panel D assembly file name is EX-10-

ES00029 Supplement – Panel D Bill of Materials. The BOM for the Extended Utility Tray

Panel D assembly file name is DX-10-ES00099 ES Supplement - DX Panel D Bill of

Materials. The BOM for the Shortened Utility Tray Panel D assembly file name is E1-10-

ES00102 ES Supplement – E1 Panel D Bill of Materials.

4.2.4 PDF instances of the drawings required to fabricate the Utility Tray and components, along with single line P&ID schematics of the electrical components, cooling water lines, and compressed gas lines, will be provided in an electronic drawing binder within the zip file referenced in Section 4.2.1. The name of the 90D Utility Tray file is EX-10-90000_MASTER

FACILITY TO MACHINE UTILITIES-DRAWINGS AND SCHEMATICS.pdf. The name of the Extended Utility Tray file is DX-10-00000_DEMIS MASTER FACILITY TO

MACHINE UTILITIES-DRAWINGS AND SCHEMATICS.pdf. The name of the

Shortened Utility Tray file is EX-10-60000_60D MASTER FACILITY TO MACHINE

UTILITIES-DRAWINGS AND SCHEMATICS.pdf.

4.3 Fabrication

4.3.1 The Utility Tray shall be fabricated according to this Specification and as detailed in the accompanying documents mentioned in Section 4.2.

4.3.2 Commercially procured equipment and components shall be selected and sized so that specifications of the original equipment manufacturer are not exceeded during normal operating conditions and shall be installed according to manufacturer’s recommendations.

4.3.3 All equipment provided by the Seller shall conform to applicable Occupational, Safety, and

Health Administration (OSHA) and National Electric Code (NEC) regulations which are in force at the time the contract is signed. Equipment must have a NRTL certification to U.S.

standards.

4.3.4 Bolting, threads, fasteners, piping, and electrical connectors shall be manufactured to applicable standards of the American National Standards Institute (ANSI), and shall, wherever possible, permit the use of ordinarily available tools. All specialty tools shall be provided by the Seller.

4.3.5 All fasteners shall be metric 18-8 stainless steel or metric grade 8.8 of medium-carbon steel unless otherwise specified in the drawing or spreadsheet BOM’s, using course thread specifications. Fasteners which are not specified in a drawing or spreadsheet BOM shall be metric 18-8 stainless steel and sized according to the mounting holes of the component it is supporting. All fasteners are required to have an appropriate anti-seize coating applied prior to assembly.

4.3.6 All piping connections shall be national pipe tapered (NPT) threaded fittings. Stainless steel tubing connections shall be imperial pipe size Swagelok stainless steel tube fittings. Copper water and compressed air lines shall utilize solder/braze connections except when connecting to other threaded components, in which case the joints shall be NPT threaded. In all cases, NPT threaded joints require suitable thread sealant in the form of tape and/or paste.

4.3.7 All solder/brazed joints shall be cleaned externally to remove any residual flux. Internal surfaces of solder/braze joints shall be cleaned & flushed per Seller provided plan as detailed in

Section 11 of this Specification.

4.3.8 Tubing shall be purchased, stored, and transported with end caps in place to exclude foreign matter and objects from the interior of the tubing. All tubing cuts shall be deburred and reamed to clean the cut surface and restore nominal ID to the tubing. This applies to both copper and stainless steel tubing.

4.3.9 Electrical cables shall not be spliced, including by in-line splices or by setting additional electrical boxes, enclosures, or terminal lugs beyond those called for in the drawing and schematic packages.

4.3.10 Conduits are specified as EMT. All conduit and cable tray cuts shall be deburred and cleaned.

5. DESCRIPTION

The 90D Utility Tray is designed as an integral part of the system, configured in a modified “L” 90-degree arrangement to closely mate with and provide electrical service, cooling water, and compressed gases to the system. The Utility Tray overall dimensions are approximately 37 inches wide X 203 inches along the first leg of the “L” and 180 inches along the second leg of the “L”, with a height of 9.5 inches over a majority of the tray surface. The Utility Tray is designed such that it can be fabricated off-site at the Seller’s facility in three primary sub-assemblies and transported to the

Company’s facility for installation. The three subassemblies are named Utility Tray Source End

Assembly, Utility Tray 45 Deg Assembly, and Utility Tray Collection End Assembly. Figures 1, 2 and 3 show the overall layout of the entire Utility Tray with general labeling of components.

The Extended Utility Tray is designed as an integral part of the system, configured in a modified “U” double 90-degree arrangement to closely mate with and provide electrical service, cooling water, and compressed gases to the system. The Utility Tray overall dimensions are approximately 37 inches wide x 231 inches along the first leg of the “U” and 318 inches along the width of the “U”, with a height of 9.5 inches over a majority of the tray surface. The Utility Tray is designed such that it can be fabricated off-site at the Seller’s facility in six primary sub-assemblies and transported to the

Company’s facility for installation. The six subassemblies are named Utility Tray Source End

Assembly, Utility Tray Removable Section Assembly, Utility Tray 1st 45 Deg Assembly, Utility Tray

Mid Collection Area Assembly, Utility Tray 2nd 45 Deg Assembly, and Utility Tray Collection End

Assembly. Figures 4, 5 and 6 show the overall layout of the entire Extended Utility Tray with general labeling of components.

The Shortened Utility Tray is designed as an integral part of the system, configured in a modified “V”

60-degree arrangement to closely mate with and provide electrical service, cooling water, and compressed gases to the system. The Utility Tray overall dimensions are approximately 37 inches wide X 175 inches along the first leg of the “V” and 118 inches along the second leg of the “V”, with a height of 9.5 inches over a majority of the tray surface. The Utility Tray is designed such that it can be fabricated off-site at the Seller’s facility in three primary sub-assemblies and transported to the

Company’s facility for installation. The three subassemblies are named Utility Tray Source End

Assembly, Utility Tray 30 Deg Assembly, and Utility Tray Collection End Assembly. Figures 7, 8 and 9 show the overall layout of the entire Utility Tray with general labeling of components.

Figure 1: 90D Utility Tray Isometric View

Figure 2: 90D Utility Tray with Services Noted, View 1

Figure 3: 90D Utility Tray with Services Noted, View 2

Figure 4: Extended Utility Tray Isometric View

Figure 5: Extended Utility Tray with Services Noted, View 1

Figure 6: Extended Utility Tray with Services Noted, View 2

Figure 7: Shortened Utility Tray Isometric View

Figure 8: Shortened Utility Tray with Services Noted, View 1

Figure 9: Shortened Utility Tray with Services Noted, View 2

Figure 10: 90D Utility Tray Source End Assembly

5.1 90D Utility Tray Source End Assembly

The 90D Utility Tray Source End Assembly, detailed in solid model and drawings EX-10-

90025_UTILITY TRAY, SOURCE END ASSEMBLY and shown in Figures 10, 11, 12 and 13 is the interface point between the entire Utility Tray Assembly and the facility utilities infrastructure where all the utility drops occur. This assembly has 7 major components consisting of a Platform

Frame, a pump tray, an assembly of three fused disconnects, an electrical enclosure named “Panel

D”, two receptacle assemblies and a Flow Switch Manifold Assembly. The overall assembly measures nominally 37 inches wide x 139 inches long with a 22.5° angle on one end and is designed as a 10 ft tall unit which is to be extended both in structure and utility functions to tie to the facility structure and facility utilities. The assembly includes removable fiberglass bar grates.

5.1.1 The Platform Frame is a welded assembly constructed of AISI 304 stainless steel and it supports the conduits, tubing, and fused disconnects to bring the electrical service, ethernet and fiber optic networks, cooling water, primary compressed air, auxiliary compressed air, nitrogen gas, argon gas and connection to the vacuum pump exhaust from the facility to the components.

It also supports the utility runs, the Flow Switch Manifold Assembly, and removable fiberglass bar grates.

5.1.2 The Pump Tray is a welded assembly constructed of AISI 304 stainless steel and it will support dry-type or oil-based vacuum pumps. The pump tray is free standing but located within the envelope of the Utility Tray Platform Frame. The vacuum pumps are not in the scope of this

Specification. The Pump Tray incorporates a lip and a drain feature to act as retention in case of an oil leak on a vacuum pump.

5.1.3 The Flow Switch Manifold Assembly provides supply and return cooling water manifolds with ten outlet ports each, shut off valves, and flow switches for connections to equipment. It also provides auxiliary compressed air capability via a manifold, pressure regulator, and quick disconnects.

5.1.4 Electrical Services consist of two circuits of 120/208V 100 amp 3 phase 4 wire, one circuit of

277/480V 40 amp 3 phase 4 wire, one circuit of 480V 40 amp 3 phase delta 3 wire, electrical enclosure Panel D, various electrical receptacles and a ground bar system.

5.1.4.1 All the line and load side wiring and connections, with the exception of Panel D and its load side circuits, will be installed by the Company and is outside the scope of this specification.

5.1.4.2 One 120/208V 3 phase circuit is routed to a fused disconnect and the load side is routed to

Panel D, with wiring installation included in the Utility Tray fabrication and testing. The final fused disconnect line side wiring installation will occur on-site by the Company, while the fused disconnect load side wiring, Panel D internal wiring and Panel D load side wiring to receptacles should be completed by Seller’s to facilitate testing.

5.1.4.3 Panel D is used as the distribution hub for all 120V and 208V electrical services along the entire Utility Tray. Wiring from Panel D is routed through the cable trays in the Utility Tray to corresponding receptacles. The layout, assembly and wiring of Panel D is detailed in drawings EX-10-00000_PANEL D ASSEMBLY and wiring schematic “EX-10-D00018

Single Line - Panel D and Utility Tray”. A supplemental Bill of Materials for Panel D components is detailed in “EX-10-ES00029 ES Supplement - Panel D Bill of Materials”.

5.1.4.4 The receptacle assemblies from Panel D provide access to 120V 20 amp circuits, 208V 15 amp single phase circuits, a 208V 30 amp single phase circuit, 208V 20 amp 3 phase circuits, and 208V 20/30 amp 3 phase circuits. All 208V circuit wiring within Panel D and run through the Utility Tray to receptacles is to be rated for 30A. All 208 V receptacles are standardized to 30A versions, though some breaker sizes are lower than this. This is to allow for easier updating of individual circuit amperage in the future if/as needed. Receptacle types and locations along the Utility Tray are found in wiring schematic “EX-10-D00018 Single

Line Diagrams – Panel D and Utility Tray”.

5.1.4.5 The ground bar system is provided as a means of grounding equipment and structures along the length of the Utility Tray that are not grounded by other means. The ground bar system extends to all three primary Utility Tray sub-assemblies.

5.1.5 Though not a part of this Specification, signal and communication cables are also routed through the primary cable tray and small channel trays to equipment which will be installed adjacent to the Utility Tray.

5.1.6 Fluid Services consist of distilled cooling water supply and return at up to 80 psig, primary compressed air at up to 100 psig, auxiliary compressed air at up to 100 psig, nitrogen gas at up to 100 psig, argon gas at up to 10 psig, and vacuum pump exhaust at slightly negative pressure relative to atmospheric.

Figure 11: 90D Utility Tray Source End Utility Drop Identification View 1

Figure 12: 90D Utility Tray Source End Utility Drop Identification View 2

Figure 13: 90D Utility Tray Source End Utility Drop Identification View 3

Figure 14: 90D Utility Tray 45 Degree Assembly

5.2 90D Utility Tray 45 Degree Assembly

The 90D Utility Tray 45 Degree Assembly, detailed in solid model and drawings EX-10-

90024_UTILITY TRAY, 45 DEGREE ASSEMBLY and shown in Figure 14, provides the structure to route utilities from the Utility Tray Source End Assembly through a 90 degree bend to the Utility Tray Collection End Assembly and to support a Magnet Electronics Rack. This assembly has three major components consisting of the 45 Degree Platform Frame, the Dipole

Water Manifold Assembly, and an Electronics Rack Support Plate. The Magnet Electronics Rack is outside the scope of this Specification. The overall assembly measures nominally 37 inches wide x 89 inches long with a 22.5° angle on each end. The assembly also includes removable fiberglass bar grates.

5.2.1. Platform Frame: See Section 5.1.1 for a general description.

5.2.2. The Flow Switch Manifold Assembly includes supply and return cooling water manifolds with three outlet ports each, shut off valves, and flow switches for connections to equipment.

5.2.3. The Electronics Rack Support Plate provides a base for supporting the Magnet Electronics

Rack.

5.2.4. Electrical Services to receptacles and all fluid services are continued from the Utility Tray

Source End to the Utility Tray Collection End. Though not a part of this Specification, signal and communication cables are also routed through the primary cable tray and small channel trays to equipment which will be installed adjacent to the Utility Tray by the Company.

Figure 15: 90D Utility Tray Collection End Assembly

5.3. 90D Utility Tray Collection End Assembly

The 90D Utility Tray Collection End Assembly, detailed in solid model and drawings EX-10-

90026_UTILITY TRAY, COLLECTION END ASSEMBLY and shown in Figure 15, provides the structure to route utilities from the Utility Tray 45 Degree to the final locations on the

Collection End Assembly. This assembly has five major components consisting of the Collection

End Platform Frame, a pump tray, the Collector Water Manifold Assembly, and two receptacle assemblies. The overall assembly measures nominally 37 inches wide x 116 inches long with a

22.5° angle on one end. The assembly also includes removable fiberglass bar grates.

5.3.1 Platform Frame: See Section 5.1.1 for a general description.

5.3.2 Pump Tray: See Section 5.1.2 for a general description.

5.3.3 Flow Switch Manifold Assembly: See Section 5.1.3 for a general description.

5.3.4 Electrical Services to receptacles and all fluid services are continued from the 45 Degree Utility

Tray Source Assembly to the utility termination locations. Though not a part of this

Specification, signal and communication cables are also routed through the primary cable tray and small cross trays to equipment which will be installed adjacent to the Utility Tray by the

Company.

Figure 16: Extended Utility Tray Source End Assembly

5.4 Extended Utility Tray Source End Assembly

The Extended Utility Tray Source End Assembly, detailed in solid model and drawings DX-10-

00025_UTILITY TRAY, SOURCE END ASSEMBLY and shown in Figures 16, 17, 18 and 19 is the interface point between the entire Utility Tray Assembly and the facility utilities infrastructure where all the utility drops occur. This assembly has 7 major components consisting of a Platform

Frame, a pump tray, assemblies of three fused disconnects, an electrical enclosure named “Panel

D”, two receptacle assemblies and a Flow Switch Manifold Assembly. The overall assembly measures nominally 37 inches wide x 139 inches long with a 22.5° angle on one end and is designed as a 10 ft tall unit which is to be extended both in structure and utility functions to tie to the facility structure and facility utilities. The assembly includes removable fiberglass bar grates.

5.4.1 Platform Frame: See Section 5.1.1 for a general description.

5.4.2 Pump Tray: See Section 5.1.2 for a general description.

5.4.3 Flow Switch Manifold Assembly: See Section 5.1.3 for a general description.

5.4.4 Electrical Services consist of one circuit of 120/208V 125 amp 3 phase 4 wire, one circuit of

120/208V 100 amp 3 phase 4 wire, two circuits of 277/480V 40 amp 3 phase 4 wire, one circuit of 480V 40 amp 3 phase delta 3 wire, electrical enclosure Panel D, various electrical receptacles and a ground bar system.

5.4.4.1 All the line and load side wiring and connections, with the exception of Panel D and its load side circuits, will be installed by the Company and is outside the scope of this specification.

5.4.4.2 The 120/208V 125A 3 phase circuit is routed to a 200A capacity, 125A fused disconnect and the load side is routed to Panel D, with wiring installation included in the Utility Tray fabrication and testing. The final fused disconnect line side wiring installation will occur on-site by the Company, while the fused disconnect load side wiring, Panel D internal wiring and

Panel D load side wiring to receptacles should be completed by Seller’s to facilitate testing.

5.4.4.3 Panel D is used as the distribution hub for all 120V and 208V electrical services along the entire Utility Tray. Wiring from Panel D is routed through the cable trays in the Utility Tray to corresponding receptacles. The layout, assembly and wiring of Panel D on the Extended

Utility Tray is detailed in drawings DX-10-00000_PANEL D ASSEMBLY and wiring schematic “DX-10-D00092-00 Electrical Single Line Diagrams - Panel D and Utility Tray”.

A supplemental Bill of Materials for Panel D components is detailed in “DX-10-ES00099 ES

Supplement - DX Panel D Bill of Materials”.

5.4.4.4 Receptacle Assemblies from Panel D: See Section 5.1.4.4 for a general description.

Receptacle types and locations along the Extended Utility Tray are found in wiring schematic

“DX-10-D00092-00 Electrical Single Line Diagrams - Panel D and Utility Tray”.

5.4.4.5 Ground Bar System: See Section 5.1.4.5 for a general description. The ground bar system extends to all six primary Utility Tray sub-assemblies.

5.4.5 Signal and Communication Cables: See Section 5.1.5 for a general description.

5.4.6 Fluid Services: See Section 5.1.6 for a general description.

Figure 17: Extended Utility Tray Source End Utility Drop Identification View 1

Figure 18: Extended Utility Tray Source End Utility Drop Identification View 2

Figure 19: Extended Utility Tray Source End Utility Drop Identification View 3

Figure 20: Extended Utility Tray Removable Section Assembly

5.5 Extended Utility Tray Removable Section Assembly

The Extended Utility Tray Removable Section Assembly, detailed in solid model and drawings

DX-10-00076_UTILITY TRAY, REMOVABLE SECTION ASSEMBLY and shown in Figure

20, provides the structure to route utilities from the Utility Tray Source End Assembly to the

Utility Tray 1st 45 Deg Assembly through a short straight path. This assembly has one major component consisting of the Removable Section Platform Frame. The overall assembly measures nominally 37 inches wide x 43 inches long with a 22.5° angle on each end. The angled ends of the Platform Frame are parallel. The assembly also includes removable fiberglass bar grates.

5.5.1. Platform Frame: See Section 5.1.1 for a general description.

5.5.2. Electrical Services to receptacles and all fluid services are continued from the Utility Tray

Source End to the Utility Tray 1st 45 Deg Assembly. Though not a part of this Specification, signal and communication cables are also routed through the primary cable tray and small channel trays to equipment which will be installed adjacent to the Utility Tray by the Company.

Figure 21: Extended Utility Tray 1st 45 Degree Assembly

5.6 Extended Utility Tray 1st 45 Degree Assembly

The Utility Tray 1st 45 Degree Assembly, detailed in solid model and drawings DX-10-

00029_UTILITY TRAY, 1st 45 DEGREE ASSEMBLY and shown in Figure 21, provides the structure to route utilities from the Utility Tray Removable Section Assembly through a 90 degree bend to the Utility Tray Mid Collection Area Assembly. This assembly has two major components consisting of the 1st 45 Degree Platform Frame and the Dipole Water Manifold

Assembly. The overall assembly measures nominally 37 inches wide x 63 inches long with a

22.5° angle on each end. The assembly also includes removable fiberglass bar grates.

5.6.1. Platform Frame: See Section 5.1.1 for a general description.

5.6.2. Flow Switch Manifold Assembly: See Section 5.2.2 for a general description.

5.6.3. Electrical Services to receptacles and all fluid services are continued from the Utility Tray

Removable Section Assembly to the Utility Tray Mid Collection Area. Though not a part of this Specification, signal and communication cables are also routed through the primary cable tray and small channel trays to equipment which will be installed adjacent to the Utility Tray by the Company.

Figure 22: Extended Utility Tray Mid Collection Area Assembly

5.7. Extended Utility Tray Mid Collection Area Assembly

The Extended Utility Tray Mid Collection Area Assembly, detailed in solid model and drawings

DX-10-00026_UTILITY TRAY, MID COLLECTION AREA ASSEMBLY and shown in Figure

22, provides the structure to route utilities from the 1st Utility Tray 45 Degree Assembly to the 2nd

Utility Tray 45 Degree Assembly and to provide utility drops on the assembly. This assembly has five major components consisting of the Mid Collection Area Platform Frame, a pump tray, the Mid Collection Area Water Manifold Assembly, and two receptacle assemblies. The overall assembly measures nominally 37 inches wide x 190 inches long with a 22.5° angle on one each end. The assembly also includes removable fiberglass bar grates.

5.7.1 Platform Frame: See Section 5.1.1 for a general description.

5.7.2 Pump Tray: See Section 5.1.2 for a general description.

5.7.3 Flow Switch Manifold Assembly: See Section 5.1.3 for a general description.

5.7.4 Electrical Services to receptacles and all fluid services are continued from the 1st 45 Degree

Utility Tray to the 2nd 45 degree Utility Tray and to the utility termination locations. Though not a part of this Specification, signal and communication cables are also routed through the primary cable tray and small cross trays to equipment which will be installed adjacent to the

Utility Tray by the Company.

Figure 23: Extended Utility Tray 2ndt 45 Degree Assembly

5.8 Extended Utility Tray 2nd 45 Degree Assembly

The Utility Tray 2nd 45 Degree Assembly, detailed in solid model and drawings DX-10-

00028_UTILITY TRAY, 2nd 45 DEGREE ASSEMBLY and shown in Figure 23, provides the structure to route utilities from the Utility Tray Collection Area Assembly through a 90 degree bend to the Utility Tray Collection End Assembly. This assembly has three major components consisting of the 2nd 45 Degree Platform Frame, the Dipole Water Manifold Assembly, and an

Electronics Rack Support Plate. The Electronics Rack is outside the scope of this Specification.

The overall assembly measures nominally 37 inches wide x 89 inches long with a 22.5° angle on each end. The assembly also includes removable fiberglass bar grates.

5.8.1. Platform Frame: See Section 5.1.1 for a general description.

5.8.2. Flow Switch Manifold Assembly: See Section 5.2.2 for a general description.

5.8.3. Electronics Rack Support Plate: See Section 5.2.3 for a general description.

5.8.4. Electrical Services to receptacles and all fluid services are continued from the Utility Tray Mid

Collection Area Assembly to the Utility Tray Collection End Assembly. Though not a part of this Specification, signal and communication cables are also routed through the primary cable tray and small channel trays to equipment which will be installed adjacent to the Utility Tray by the Company.

Figure 24: Extended Utility Tray Collection End Assembly

5.9. Extended Utility Tray Collection End Assembly

The Utility Tray Collection End Assembly, detailed in solid model and drawings DX-10-

00019_UTILITY TRAY, COLLECTION END ASSEMBLY and shown in Figure 24, provides the structure to route utilities from the 2nd Utility Tray 45 Degree Assembly to the final locations on the Collection End Assembly. This assembly has five major components consisting of the

Collection End Platform Frame, a pump tray, the Collector End Water Manifold Assembly, and two receptacle assemblies. The overall assembly measures nominally 37 inches wide x 134 inches long with a 22.5° angle on one end. The assembly also includes removable fiberglass bar grates.

5.9.1 Platform Frame: See Section 5.1.1 for a general description.

5.9.2 Pump Tray: See Section 5.1.2 for a general description.

5.9.3 Flow Switch Manifold Assembly: See Section 5.1.3 for a general description.

5.9.4 Electrical Services to receptacles and all fluid services are continued from the 2nd 45 Degree

Utility Tray Assembly to the utility termination locations. Though not a part of this

Specification, signal and communication cables are also routed through the primary cable tray

Figure 25: Shortened Utility Tray Source End Assembly

5.10 Shortened Utility Tray Source End Assembly

The Shortened Utility Tray Source End Assembly, detailed in solid model and drawings EX-10-

60025_UTILITY TRAY, SOURCE END ASSEMBLY and shown in Figures 25, 26, 27 and 28 is the interface point between the entire Utility Tray Assembly and the facility utilities infrastructure where all the utility drops occur. This assembly has 8 major components consisting of a Platform

Frame, a pump tray, assemblies of three fused disconnects, an electrical enclosure named “Panel

D”, two receptacle assemblies and two Flow Switch Manifold Assemblies. The overall assembly measures nominally 37 inches wide x 151 inches long with a 15° angle on one end and is designed as a 9 ft tall unit which is to be extended both in structure and utility functions to tie to the facility structure and facility utilities. The assembly includes removable fiberglass bar grates.

5.10.1 Platform Frame: See Section 5.1.1 for a general description.

5.10.2 Pump Tray: See Section 5.1.2 for a general description.

5.10.3 Flow Switch Manifold Assembly: See Section 5.1.3 for a general description.

5.10.4 Electrical Services consist of two circuits of 120/208V 100 amp 3 phase 4 wire, one circuit of

277/480V 30 amp 3 phase 4 wire, one circuit of 480V 40 amp 3 phase delta 3 wire, electrical enclosure Panel D, various electrical receptacles and a ground bar system.

5.10.4.1 All the line and load side wiring and connections, with the exception of Panel D and its load side circuits, will be installed by the Company and is outside the scope of this specification.

5.10.4.2 One of the 120/208V 100A 3 phase circuits is routed to a 100A capacity, 100A fused disconnect and the load side is routed to Panel D, with wiring installation included in the

Utility Tray fabrication and testing. The final fused disconnect line side wiring installation will occur on-site by the Company, while the fused disconnect load side wiring, Panel D internal wiring and Panel D load side wiring to receptacles should be completed by the Seller to facilitate testing.

5.10.4.3 Panel D is used as the distribution hub for all 120V and 208V electrical services along the entire Utility Tray. Wiring from Panel D is routed through the cable trays in the Utility Tray to corresponding receptacles. The layout, assembly and wiring of Panel D on the Shortened

Utility Tray is detailed in drawings EX-10-00000_PANEL D ASSEMBLY and wiring schematic “E1-10-D00100 EMIS E1 PANEL-D AND UTILITY TRAY ELECTRICAL

SINGLE LINE DIAGRAMS ”. A supplemental Bill of Materials for Panel D components is detailed in “E1-10-ES00102 ES Supplement – E1 Panel D Bill of Materials”.

5.10.4.4 Receptacle Assemblies from Panel D: See Section 5.1.4.4 for a general description.

Receptacle types and locations along the Shortened Utility Tray are found in wiring schematic “E1-10-D00100 EMIS E1 PANEL-D AND UTILITY TRAY ELECTRICAL

SINGLE LINE DIAGRAMS”.

5.10.4.5 Ground Bar System: See Section 5.1.4.5 for a general description. The ground bar system extends to all three primary Utility Tray sub-assemblies.

5.10.5 Signal and Communication Cables: See Section 5.1.5 for a general description.

5.10.6 Fluid Services: See Section 5.1.6 for a general description.

Figure 26: Shortened Utility Tray Source End Utility Drop Identification View 1

Figure 27: Shortened Utility Tray Source End Utility Drop Identification View 2

Figure 28: Shortened Utility Tray Source End Utility Drop Identification View 3

Figure 29: Shortened Utility Tray 30 Degree Assembly

5.11 Shortened Utility Tray 30 Degree Assembly

The Shortened Utility Tray 30 Degree Assembly, detailed in solid model and drawings EX-10-

60024_UTILITY TRAY, 30 DEGREE ASSEMBLY and shown in Figure 29, provides the structure to route utilities from the Utility Tray Source End Assembly through a 60° bend to the

Utility Tray Collection End Assembly and to support a Magnet Electronics Rack. This assembly has three major components consisting of the 30 Degree Platform Frame, the Dipole Water

Manifold Assembly, and an Electronics Rack Support Plate. The Magnet Electronics Rack is outside the scope of this Specification. The overall assembly measures nominally 37 inches wide x 56 inches long with a 15° angle on each end. The assembly also includes removable fiberglass bar grates.

5.11.1. Platform Frame: See Section 5.1.1 for a general description.

5.11.2. The Flow Switch Manifold Assembly includes supply and return cooling water manifolds with three outlet ports each, shut off valves, and flow switches for connections to equipment.

5.11.3. The Electronics Rack Support Plate provides a base for supporting the Magnet Electronics

Rack.

5.11.4. Electrical Services to receptacles and all fluid services are continued from the Utility Tray

Source End to the Utility Tray Collection End. Though not a part of this Specification, signal and communication cables are also routed through the primary cable tray and small channel trays to equipment which will be installed adjacent to the Utility Tray by the Company.

Figure 30: Shortened Utility Tray Collection End Assembly

5.12. Shortened Utility Tray Collection End Assembly

The Shortened Utility Tray Collection End Assembly, detailed in solid model and drawings EX-

10-60026_UTILITY TRAY, COLLECTION END ASSEMBLY and shown in Figure 30, provides the structure to route utilities from the Utility Tray 30 Degree Assembly to the final locations on the Collection End Assembly. This assembly has five major components consisting of the Collection End Platform Frame, a pump tray, the Collector Water Manifold Assembly, and two receptacle assemblies. The overall assembly measures nominally 37 inches wide x 92 inches long with a 15° angle on one end. The assembly also includes removable fiberglass bar grates.

5.12.1 Platform Frame: See Section 5.1.1 for a general description.

5.12.2 Pump Tray: See Section 5.1.2 for a general description.

5.12.3 Flow Switch Manifold Assembly: See Section 5.1.3 for a general description.

5.12.4 Electrical Services to receptacles and all fluid services are continued from the 30 Degree Utility

Tray Source Assembly to the utility termination locations. Though not a part of this

Specification, signal and communication cables are also routed through the primary cable tray

6. UTILITES AND SERVICE DROPS

General information regarding the electrical and fluid utility and service drops are detailed in Table 1 and Table 2. Specific utility service locations in the Utility Tray, receptacle locations, flow switch locations, etc. are provided in the drawing packages.

UTILITY TRAY DROP GENERAL INFORMATION

UTILITY DROP TYPE CONDUIT OR

TUBE SIZE

DESCRIPTION

Power Supply Receptacle EMT 3/4 277/480V 40A 3Ph 4W

[277/480V 30A 3Ph 4W] HV Transformer Disconnect, Line and Load EMT 3/4 480V 40A 3Ph Delta 3W

Cabinet Power Disconnect, Line and Load EMT 1-1/4 120/208V 100A 3Ph 4W

Panel "D" Disconnect, Line and

Load EMT 1-1/4 (1-1/2) [1-1/4] 120/208V 100A 3Ph 4W

(120/208V 125A 3Ph 4W)

[120/208V 100A 3Ph 4W]

CAT-6A Cable EMT 3/4 Ethernet Cable, Qty 2 cables for

VOIP & ORNL LAN

Fiber Optic Cable EMT 3/4 Fiber Optic OM4-12 Fiber for

Control System

Ground Cable EMT 3/4 1” Copper/Tinned Flat Braid

FTCB 1550 w/ PB50 Lugs

Cooling Water Supply and

Return Copper Type L 2" Nom OD x .07 Wall 60 - 80 psig supply, 20 gpm nom, 30 gpm max

(25 gpm nom, 30 gpm max)

[20 gpm nom, 30 gpm max]

Primary Compressed Air 316 SS Tubing .50 OD x .049 Wall 90-100 psig, regulated to 80 psig, 10 SCFM max

Auxiliary Compressed Air Copper Type L 1" Nom OD x .05 Wall 90 - 100 psig, 50 SCFM max

Argon Gas 316 SS Tubing .50 OD x .049 Wall 5 psig nom, 10 psig max,

1.5 SCFM (40,000 SCCM) max

Nitrogen Gas 316 SS Tubing .50 OD x .049 Wall 60 psig nom, 100 psig max, 2 SCFM max

Vacuum Pump Exhaust Wire Reinforced PVC

Flex Tubing

2.00 ID x .2 Wall Atmospheric Discharge to

Toxic Exhaust System

Table 1: Utility Tray Drop General Information - Extended Utility Tray Specific Requirements provided in parenthesis (); Shortened Utility Tray Specific Requirements provided in brackets []

ELECTRICAL CIRCUIT GENERAL INFORMATION

UTILITY DROP QTY RECEPTACLE /

DISC SPECS

SERVICE

Power Supply Receptacle 1

(2)

[1]

Meltric

DSN60 63-64043-375-843

(480V 60A 3P, G)

[Meltric

DSN30 63-34043-375-843

(480V 30A 3P, G)]

277/480V 40A 3Ph 3W

[277/480V 30A 3Ph 3W]

HV Transformer Disconnect, Line and Load 1 Fusible 600V 60A 3P SN disconnect switch, Square D H362N

480V 40A 3Ph Delta 3W

Cabinet Power Disconnect, Line and Load 1 Fusible 240V 100A 3P SN disconnect switch, Square D H323N

120/208V 100A 3Ph 4W

Panel "D" Disconnect, Line and

Load 1 Fusible 240V 100A (200A) 3P SN disconnect switch, Square D H323N (VH324N)

120/208V 100A 3Ph 4W

(120/208V 125A 3Ph 4W)

Convenience Receptacles 12

(18)

[14]

NEMA 5-20R 120V 20 Amp

Power Receptacles 13

(22)

[17]

NEMA L6-30R (2P, G) 208V 1Ph 15/30 Amp

Power Receptacles 2

(1)

[1]

NEMA L15-30R (3P, G) 208V 3 Ph 30 Amp

Power Receptacles 7

(9)

[5]

Meltric

DSN30 63-34163-375-843

(208V 30A 3P, G)

208V 3 Ph 15/20 Amp

Table 2: Utility Tray Electrical Circuit General Information – Extended Utility Tray Specific

Requirements provided in parenthesis (); Shortened Utility Tray Specific Requirements provided in brackets []

7. EQUIPMENT AND COMPONENT SUBSTITUTIONS

Equipment, components, and materials have been chosen for specific fit, form, and function to ensure performance and interface with components within the Utility Tray and to the overall System. In many cases, a specific vendor or manufacturer’s item can be substituted if the substitute item has the same fit, form and function along with performance parameter. Allowances and restrictions for substitution of components are detailed in Table 3. All substitutions which require Company approval shall be requested from the Company’s POC or designee in writing, either hard copy or email, by requesting a seller deviation using form ORNL-313. See the GS for additional instructions.

7.1 Substitution of equipment and components for items detailed in Table 3 as “No Restriction” may be performed without Company approval and must be documented in as-built BOM.

7.2 Substitution of all equipment and components for items detailed in Table 3 as “Upon Approval” must be approved in writing by the Company.

7.3 Substitution of all equipment and components for items detailed in Table 3 as “No Substitution” will not be approved by the Company unless there are severe supply chain or design/safety issues which can’t be reasonably overcome.

7.4 Substitution of any equipment or component other than bolts and fasteners shall occur across all

Utility Tray builds which are occurring under a single contract and must be documented by the

Seller on as-built drawings and/or BOM’s. Sales sheets or cut sheets shall be provided to the

Company for items which require Company approval.

Table 3: Equipment and Component Substitution Allowances

7.5 Tubing, fittings, and valves for the water system and manifold assemblies are configured into tight assembly and operating spaces so substitution for these items must be performed with careful consideration of component dimensions.

EQUIPMENT AND COMPONENT SUBSTITUTION ALLOWANCES

Manufacturer/Vendor Item Class Substitution Restrictions

B-Line Framing Channels, Channel Nuts, Hardware

Company Approval

Burger and Brown

Engineering

Fluid Manifold No Substitution

Corning Fiber Optic Cassette Housing No Substitution

DW: Dwyer Flowmeter No Substitution

Eaton Cable Tray Company Approval

Hilti Anchors No Restrictions

LK: Kurt Lesker Vacuum Equipment No Restrictions

Meltric Power Receptacles No Substitution

NG: Norgren Pressure Regulator No Restrictions

MC: McMaster Carr Bar Grating Company Approval

MC: McMaster Carr Hose Quick Disconnects No Substitution

MC: McMaster Carr Valves, Tube Fittings Company Approval

MC: McMaster Carr All Others No Restrictions, any vendor or manufacturer

MSC: MSC Industrial Brass Valves Any Vendor, but Manufacturer or model change requires Company Approval

SCE: Electrical Enclosure No Substitution

SMC: SMC Corp Flow Switches No Substitution

SQD: Square D Disconnect Switch Company Approval

SP: Storm Power Insulators, Stand-offs No Substitution

SW: Swagelok Valves, Quick Disconnects, Tube and

Pipe Fittings

No Substitution

SW: Swagelok 1" and 2" Braided Flex Hose Company Approval

SW: Swagelok Tubing Company Approval, 304SST or 316SST

Acceptable

UNI-Unistrut Framing Channels, Channel Nuts, Hardware

Company Approval

8. DOCUMENTATION

8.1 The Seller shall provide the following documentation for approval by the Company as defined in the Submittal Schedule included with the SOW. All documentation shall be provided in English.

The submittal schedule summarizes all required documentation and identifies the referenced specification section which can provide details on what is expected. It also provides information regarding document format, when the document is needed, & if approval to proceed is required.

Additional information and documentation submittal requirements can be found in the General

Project Specification, EX-00-ES00086.

• Fabrication drawings used by the Seller to fabricate the Utility Tray

• All As-built drawings prepared by the Seller

• Any additional design drawings and solid models required for fabrication and assembly of the system

• Dimensional Inspection Plan

• Material Certificates for all fabricated steel components and all weld material

• Wiring Schematics / Detailed Electrical Drawings

• Bill of Material

• Specification Sheets of major component parts (as defined by the BOM)

• Welding Documentation

• Inspection & Test Procedures

• Cleaning & Flushing Plan

• Inspection & Test Reports

• Shipping Plan

8.2 Modifications required to the Utility Tray shall be submitted in writing for Company approval prior to modifications being implemented, and as-built drawings shall be provided (red-lines of

Company drawings are acceptable).

8.3 Substitutions of equipment and components which require Company approval according to

Section 7.0 shall be approved by the Company in writing prior to substitutions being implemented. The Seller shall provide a copy of the manufacturer’s documentation, including mechanical drawings, manuals, schematics and parts lists, to enable Company evaluation of the substitution request. Components will be identified by manufacturer, part number and quantity on applicable prints. U.S. domestic parts are recommended.

9. QUALITY ASSURANCE

The Seller shall assure the quality of this equipment by complying fully with all the requirements of this specification, related drawings, and those defined in the General Project Specification.

9.1 All electrical components must be listed by a Nationally Recognized Testing Laboratory (NRTL) or be inspected and certified by a trained electrical inspector. The Seller shall submit a plan for certification of non-listed electrical equipment to the Company for review and approval. The

Seller shall include the cost of obtaining this certification in the cost of the Utility Tray.

9.2 All panels shall be assembled to the UL-508A standard and appropriately marked/labeled with a

NRTL certification. All wiring/cables shall be labeled in accordance with UL-508A and include

“FROM/TO” designation. Each outlet shall be labeled with feed breaker “CB-xx”. Cables routing from Panel D to outlets along tray shall be labeled at 3ft intervals.

9.3 All tubing runs shall be labeled according to applicable ASME Process Piping Code B31.3 using standard color schemes and label sizes.

9.4 All cabling and piping routing shall be performed as close to modeled and drawings as possible, which maximizes area for personnel accessing various components. No sharp edges should be exposed, especially where cabling could come in contact. No adhesive zip tie mounts are permitted.

10. INSPECTIONS AND TESTS

Acceptance tests shall include verification of each of the following items, at a minimum, as per respective parameters listed elsewhere in this equipment specification. Test and Inspection procedures shall be provided to the Company for review and approval prior to performance of the test or inspection. The Seller shall provide the power supplies and any other ancillary items needed for testing at the Seller’s facility.

10.1 Electrical component and circuit testing shall include verification of screw lug tightness and circuit continuity checks for each circuit phase leg, neutral and ground connection of receptacles.

Additional verifications after connection to power feeds shall include appropriate voltage readings line to line, line to neutral, neutral to ground, and line to ground for all receptacles on a breaker-by-breaker basis, with results of all measurements and breaker size observation supplied in table format. Phase rotation checks shall be performed for all 3 phase outlets as well.

10.2 Cooling water supply and return line testing shall include static pressurization using distilled water according to the conditions set forth in Table 4.