Attachment B - Statement of Work Acquisition of EIC Superconducting Type 2 Wire for Direct Wind Cable (Production) dated 8.1.2024.pdf

Electron-Ion Collider, Brookhaven National Laboratory

Doc No. EIC-MSG-SOW-007 Author: H. Hocker Effective Date: August 1, 2024 Review Frequency: N/A

SOW: Nb-Ti Type 2 Wire for EIC Interaction Region Direct Wind Coils (Production) Revision: 00

STATEMENT OF WORK

for the

Nb-Ti Type 2 Wire for EIC Interaction Region Direct Wind Coils (Production)

Quality Classification: A-3

Prepared By:

_________________________________ Date: __________________ H. Hocker, SMD Quality Assurance

Reviewed By:

________________________________ Date: __________________ M. Anerella, SMD Acting Division Director

B. Parker, SMD Cognizant Scientist

M. Kumar, SMD Cognizant Scientist

C. Schaefer, EIC ESH Manager

________________________________ Date: __________________ C. Galdamez, EIC Procurement Liaison Engineer

J. Zipper, EIC Quality Assurance Representative

Docusign Envelope ID: 21235481-2E8D-444E-9E49-0DDD8CA15758

8/2/2024

8/5/2024

8/2/2024

8/2/2024

8/2/2024

8/2/2024

8/2/2024

Approved By:

A. Drees, L2 EIC Interaction Regions & Detector Interface

H. Witte, L3, EIC Interaction Region

Docusign Envelope ID: 21235481-2E8D-444E-9E49-0DDD8CA15758

8/5/2024

8/5/2024

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

REVISION HISTORY

Revision # Effective Date Summary of Change

00 8/01/2024 Initial Release

Table of Contents

LIST OF ACRONYMS

1 SCOPE

2 APPLICABLE DOCUMENTS

3 REQUIREMENTS

3.1 Contractor Responsibilities

3.1.1 Tooling/Fixtures/Test Equipment

3.1.2 Materials

3.2 Manufacturing / Inspection Requirements

3.2.1 Unit Lengths

3.2.2 Spool Type

3.2.3 Spool Weight

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 Documentation and Data Management

3.4.1 Report/Documentation Format

3.4.2 End Item Documentation Package

3.4.3 Records

3.5 Environment, Safety and Health (ESH)

3.6 Packaging

4 QUALITY ASSURANCE

4.1 Quality System and Facility Access

4.2 Configuration Management

4.3 Responsibility for Subcontractor

4.4 Responsibility for Conformance

4.5 Measuring and Test Equipment (M&TE) Calibration

4.6 Inspections and Test Requirements

4.7 Repairs

4.8 Failure Reporting, Analysis and Corrective Action

4.9 Special Processes

4.10 Notification of Change to Design, Methods, or Processes

4.11 Material Traceability

5 DELIVERABLES

6 SCHEDULE

7 VALUE ENGINEERING

LIST OF ACRONYMS

ARO

ATP

After Receipt of Order Acceptance Test Procedure

BNL Brookhaven National Laboratory BSA Brookhaven Science Associates EIC Electron-Ion Collider ESH Environment, Safety and Health MRP Material Requirements Planning M&TE Measuring and Test Equipment NIST National Institute of Standards and Technology

PO

QA

SMD

SOW

Purchase Order Quality Assurance Superconducting Magnet Division Statement of Work

1 SCOPE

This Statement of Work (SOW) will be the basis for the procurement of production quantities of Niobium-Titanium (Nb-Ti) superconductor wire used to fabricate Direct Wind Coils for use in interaction region magnets 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. The total production quantity of wire will be 200,000 meters.

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 wire, as specified in this SOW, will be used to fabricate direct wind coils that will be used in the Interaction Region Magnets. Such cable, with its superconducting properties, is an essential element of the magnets for EIC.

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 in writing who shall 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 with 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

EIC-MSG-SPC-004 Technical Specification for Nb-Ti Type 2 Wire for EIC Interaction Region Direct Wind Coils

BNL-QA-101

Requirements Brookhaven National Laboratory Seller Quality Assurance

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 manufacturing, inspecting, testing, and delivering, the superconducting wire for the direct wind coils.

3.1 Contractor Responsibilities

In accordance with this SOW, BSA technical specification EIC-MSG-SPC-004, and all referenced documents, the Contractor shall furnish all materials, facilities, and labor to perform the work necessary to manufacture and test the wire. The Contractor shall ensure that the finished product meets the performance parameters and criteria in accordance with BSA specification EIC-MSG- SPC-004 and all other referenced documents.

3.1.1 Tooling/Fixtures/Test Equipment

In accordance with this SOW, BSA technical specification EIC-MSG-SPC-004, and all referenced documents, the Contractor shall be responsible for the engineering, design, construction, and maintenance of all tools, jigs, fixtures, and test equipment required to manufacture and test the wire.

3.1.2 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.

3.2 Manufacturing / Inspection Requirements

All work shall be in accordance with the specification EIC-MSG-SPC-004.

3.2.1 Unit Lengths

The unit lengths shall be as specified below, totaling 200 km.

Unit Length (m) Quantity of Units Total Wire Length (km) 5715 35 200

3.2.2 Spool Type

The spool type shall be specified by the Contractor and approved in writing by the BSA Technical Representative prior to use.

3.2.3 Spool Weight

The spool maximum weight shall be specified by the Contractor and approved in writing by the BSA Technical Representative prior to use.

3.2.4 Acceptance Test Procedures (ATP)

The Contractor shall provide an ATP that is in accordance with this SOW, the Specification, and all reference documents noted herein. The ATP shall be submitted to BSA for approval in writing thirty (30) calendar days prior to use. The ATP shall ensure that all test requirements as defined in the Specification are achieved. Once approved, any changes/revisions to the ATP shall be approved in writing by BSA prior to implementation.

3.3 Management

3.3.1 Program Plan

Within two (2) weeks after award of contract, the Contractor shall deliver a detailed program plan which includes the following:

a. Management Structure – the management for the project shall be identified by name and contact information.

b. Point of Contact – a project representative shall be identified to be the primary contact with BSA for this procurement.

c. Schedule – a milestone schedule defining the material order, manufacturing, inspection and assembly phases to allow for regularly scheduled progress monitoring. Identification of critical manufacturing operations, as well as inspection test and hold checkpoints shall be part of the schedule. In addition, the milestone schedule shall include the significant milestones identifying proposed dates of accomplishment as shown in Section 6 of this

SOW.

3.3.2 Progress Communications

Within two (2) weeks after award of contract, monthly program 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, 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 BSA in writing within one (1) month after award of contract. Once approved, and changes/revision must be approved by BSA in writing prior to implementation.

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.

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. Contractor shall provide BSA with ten (10) working days’ notice in advance of such witness points during the manufacturing and test cycle. The Contractor shall comply with any BSA required hold or witness points in the manufacturing process.

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

3.4 Documentation and Data Management

3.4.1 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 for specific items, such as vessel penetrations.

• 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.

3.4.2 End Item Documentation Package

The Contractor shall provide a documentation package for each shipment of the wire supplied, which consists of objective evidence of compliance with PO requirements. This documentation package shall be complete, legible, indexed, and traceable to the item supplied. The package shall be compiled and supplied to BSA. The BSA Technical Representative shall review and provide written approval of the package prior to shipment. All required documentation provided by the Contractor shall be provided in an electronic copy. The package shall consist of all documentation identified in this SOW, including the following:

3.4.2.1 Certificate of Conformance

With each shipment, the Contractor shall submit a Certificate of Conformance (C of C). In the case of drop shipment, a copy of the certificate shall be submitted to BSA at the time of shipment. The certificate shall include the title of and be signed by an authorized representative of the Contractor, and shall constitute a representation by the Contractor that:

i. Materials used are those which have been specified by BSA, and the items delivered were produced from materials for which the Contractor has on file, reports of chemical or physical analysis, or any other equivalent evidence of conformance of such items to applicable specifications.

ii. Processes used in the fabrication of items delivered are in compliance with the applicable specifications included as part of the contract or BSA approved procedures or specifications.

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

3.4.2.2 Final Inspection and Test Reports

Final test reports of all required and 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.

i. Material Test Certificates: Copies of material test reports for specified materials, showing physical and chemical properties.

ii. Nonconformance Reports: Nonconformance reports identified as “rework / repair” or “use-as-is” and all BSA approved deviation / waivers shall be provided.

iii. Chemical and Physical Test Report: One copy of the actual chemical and physical test report(s) for each heat, batch or lot shall accompany each shipment. Test reports shall list the actual parameters tested, the acceptable limits for each parameter, and shall contain the actual readings taken during the test.

3.4.3 Records

The Contractor shall retain objective evidence, including records, of the inspections and tests performed in the course of manufacturing, testing, inspecting, preserving, packaging, and preparation for shipment of procured items. These records shall be made available to BSA for review upon request. These records shall be maintained for a minimum of one (1) year, unless otherwise specified in the procurement documentation, after the completion of the Purchase Order (PO)/Contract.

3.5 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.

3.6 Packaging

The wire shall be shipped on spools as defined in section 3.2.2 and 3.2.3 herein. In preparation for shipping, the wire shall be covered or wrapped for protection against weather elements, dust, and damage to projections, shock loads, impacts, and rubbing. The wire spools shall be properly braced and cushioned within the packing so that they will not shift during handling and shipment.

BSA’s representative shall be notified five (5) days prior to shipment of the item. This notification shall be in the form of an e-mail message. The BSA representative will provide all shipping details upon request. The container shall be appropriately labeled with the listing of contents, destination, gross weight, location of center of gravity, purchase order/Contract number, and contact information. Each container shall have G-force shock indicators. Each container shall be palletized and include provisions to permit access for a forklift to lift the container.

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 advance of the agreed-upon witness points.

As set forth in BSA Form BNL-QA-101, “Brookhaven National Laboratory Supplier Quality Assurance Requirements,” as amended herein, forms a part of this statement of work. Specifically, this includes the following sections: 1, 2, 3, 3.1, 3.1.2, 3.2–3.22, 4.0, 4.1, 4.2, 4.3, 4.4 as modified below, 4.4.1, 4.4.2, 4.4.3, 4.5 as modified below, 4.6 as modified below, 4.7, 4.7.1, 4.7.2, 4.7.3, 4.10, 4.10.1, 4.10.2, 4.10.4, 4.13, 4.15, 4.16, 4.19, 4.22, 4.23, and 4.39.

Clause 4.4: Manufacturing/Inspection/Test Plan, is modified as follows: four weeks prior to performance of work, the Supplier shall submit for the Buyer’s approval a Manufacturing/Inspection/ Test Plan for the item(s) to be produced.

Clause 4.5: “Witness” Points, is modified as follows: The supplier shall provide BNL with ten (10) working days’ notice in advance of reaching such witness points during the manufacturing and test cycle of each item.

Clause 4.6: Test and Inspection Procedures, is modified as follows: The supplier shall submit to BSA test and inspection procedures for approval (30) calendar days prior to use.

4.2 Configuration Management

The Contractor shall maintain a system of process sheets, shop travelers, or equivalent means to define the sequence of manufacturing, inspection, and test activities to be performed. Flow sheets, or equivalent, shall be provided for sign-off by designated inspection personnel at specified inspection and test points, including, as required, reinspection and re-test points, to assure completion as well as proper sequencing of required manufacturing operations.

The Contractor shall establish and maintain a configuration control system to assure that the wire has 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, 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 Responsibility for Subcontractor

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

4.4 Responsibility for Conformance

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

4.5 Measuring and Test Equipment (M&TE) Calibration

The Contractor shall calibrate any M&TE used in the fulfillment of the PO/Contract requirements against certified standards that are traceable to national standards such as the National Institute of Standards and Technology (NIST), or an international standard, or a physical constant. The Contractor shall notify BSA of any condition found during the calibration, servicing or repair of measuring and test equipment that can affect the end item requirements.

4.6 Inspections and Test Requirements

Unless otherwise specified in the PO/Contract, the Contractor shall be responsible for the performance of all inspections and tests. The wire 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 3.2.4) generated by the Contractor and approved in writing by BSA. 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 and/or their representative shall have the option to witness all the tests defined in this SOW.

BSA reserves the right to re-perform any of the inspections and/or tests set forth in this document or referenced specifications deemed necessary to assure that it conforms to prescribed requirements at no cost to the Contractor. Final acceptance of the wire shall take place following the successful completion of final inspection and testing at BNL. The time period for the final testing at BNL shall be within 90 days after receipt of the units at BNL.

4.7 Repairs

If failures occur 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.

4.8 Failure Reporting, Analysis and Corrective Action

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

4.9 Special Processes

Processes (e.g., bonding, plating, chemical machining, chemical coating, chemical cleaning, precision cleaning, heat treating, or waste processing) that either cannot be verified non-destructively or require a unique (special) non-destructive test / inspection (e.g., radiographic inspection, ultrasonic testing) shall be performed in accordance with detailed written procedures.

These procedures shall specifically describe the exact manner in which the processes are to be performed. Additionally, the following requirements apply as selected:

• Copies of special process procedures shall be made available on request for review by the BSA Representative.

• At least sixty (60) calendar days prior to use on items deliverable to BSA, the Contractor shall submit to BSA copies of all applicable process procedures for review and approval.

Revisions or changes to BSA approved special process procedures must be submitted to BSA for review and approval prior to implementation.

• The Contractor shall, prior to use, qualify the procedures / specifications, facilities, equipment, and personnel that will be used for the performance of special processes. Only those personnel who have been qualified to perform a specific special process shall be used to perform that process. Records of such a qualification shall be available to the BSA representative upon request.

4.10 Notification of Change to Design, Methods, or Processes

The Contractor shall immediately notify BSA of any changes in fabrication methods, materials, work locations, equipment used, or processing from those used by the Contractor at the time of the Contractors quotation or offer to BSA, which resulted in the PO. This shall be done prior to the change being made. The Contractor must receive written approval from BSA Procurement Representative prior to the change being made. BSA reserves the right to require such analysis and testing to ensure that changes will not have a deleterious effect on delivered items.

4.11 Material Traceability

Materials used must be identified by material type, applicable specification, and revision number, and be traceable to their lot and/or heat number(s). Traceability records shall be available for review by the BSA representative.

5 DELIVERABLES

The Contractor shall supply the following:

Item Deliverable Due BSA Approval

1 Program Plan 2 weeks after award of contract Yes 2 Technical and Progress Reporting 2 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 1 Month after award of contract Yes 5 Delivery of spools As set forth in contract Yes 6 End Item Documentation As set forth in contract Yes

6 SCHEDULE

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

Significant Milestones Months ARO

1 Contract Execution 0

2 First program progress teleconference 0.5

3 Submittal of manufacturing/inspection/test plan 1

4 Start of quantity production 2

5 Completion of quantity production 7

6 End item documentation submittal 7.5

7 Approval to ship 8

8 Quantity shipment 8

7 VALUE ENGINEERING

The Contractor is encouraged to make recommendations for changes that might lead to an improvement in performance, reliability, quality, or reduction in cost. Where it appears, a substantial improvement will result from the use of materials 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.

3.4.3 Records