Attachment C - Statement of Work.pdf

Electron-Ion Collider, Brookhaven National Laboratory

Doc No. EIC-IFD-SOW-016 Author: T. Nehring Effective Date: May 22, 2024 Review Frequency: N/A

SOW: Secondary Unit Substations for EIC Revision: 05

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STATEMENT OF WORK

for the

Secondary Unit Substations for EIC Quality Classification: A-2

Prepared By:

_________________________________ Date: __________________ Thomas C. Nehring, Group Leader, Electrical Power Systems

Reviewed By:

Dirul Nassar, Infrastructure Division Deputy Director

Edward Cheswick, Quality Assurance

Charles Schaefer, Group Leader, ESH

Maggie Haviland, Procurement Liaison Engineer

Approved By:

Charles Folz, Infrastructure Division Director

DocuSign Envelope ID: F4C06E4D-0829-40B1-8633-AD798E944C3F

5/22/2024

5/23/2024

5/23/2024

5/23/2024

5/23/2024

5/23/2024

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

DocuSign Envelope ID: F4C06E4D-0829-40B1-8633-AD798E944C3F

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REVISION HISTORY

Revision # Effective Date Summary of Change

00 October 19, 2023 Initial Release

01 (draft) November 1, 2023 Added applicable documents and references

02 (draft) December 20, 2023 Deliverables updated and attached revised specifications

03 January 18, 2024 Revise Unit Substation to be Skid Mounted

04 March 6, 2024 Added information on rigging and order for receipt of unit substations

05 May 22, 2024

Export control statement added to footer, applicable documents updated, ground-fault monitor equipment added, electrical safety updated, failure reporting updated, commissioning removed from scope

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Table of Contents

LIST OF ACRONYMS

1. SCOPE

1.1 Background

2. APPLICABLE DOCUMENTS

3. REQUIREMENTS

3.1 Vendor’s Responsibilities

3.1.1 Technical Performance

3.1.2 Special Parts & Tools

3.2 Design and Fabrication Requirements

3.2.1 Approval to Proceed

3.2.2 Fabrication and Test Requirements

3.2.3 Acceptance Test Procedures (ATP)

3.2.4 Shipping

3.2.5 Commissioning

3.3 Management

3.3.1 Program Plan

3.3.2 Progress Reporting

3.3.3 “Witness” Points

3.4 Documentation and Data Management

3.4.1 Report/Documentation Format

3.4.2 Engineering Drawing Practices

3.4.3 End Item Documentation Package

3.5 Environment, Safety and Health (ESH)

4. QUALITY ASSURANCE

4.1 Quality System and Facility Access

4.2 Configuration Management

4.3 Responsibility for Subcontractor

4.4 Responsibility for Conformance

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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

5. DELIVERABLES

6. SCHEDULE

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LIST OF ACRONYMS

ANSI American National Standards Institute ASME American Society of Mechanical Engineers ATP Acceptance Test Procedure BNL Brookhaven National Laboratory BSA Brookhaven Science Associates EIC Electron-Ion Collider ESH Environment, Safety and Health FOC Facility Operations Center HDR Architect/Engineer, under contract with Infrastructure Group IEEE Institute of Electrical and Electronics Engineers ISO International Organization for Standardization JHA Job Hazard Analysis kcmil kilo circular mils kV kilo-Volts kVA kilo-Volts-Amperes MFT Manufacturer’s Fabrication Time M&TE Measuring and Test Equipment NEC National Electrical Code NEMA National Electrical Manufacturers Association NFPA National Fire Protection Association NIST National Institute of Standards and Technology NRTL Nationally Recognized Test Laboratory PO Purchase Order QA Quality Assurance Qty Quantity SDS Safety Data Sheets SOW Statement of Work TBD To Be Determined UL Underwriters Laboratories V Volts

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Statement of Work for the Secondary Unit Substations for EIC

1. SCOPE

This Statement of Work (SOW) will be the basis for the procurement of skid-mounted secondary unit substations to be used at the Electron-Ion Collider (EIC) at Brookhaven National Laboratory (BNL) managed by Brookhaven Science Associates (BSA). This document outlines the Vendor’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.

To meet the schedule requirements, a group of new unit substations are being procured early to power new structures being built for the Election-Ion Collider. When the power to the building is energized, the Accelerator Groups can start their installation.

2. APPLICABLE DOCUMENTS

In the event of a conflict between the Technical Documentation and this SOW, the Vendor shall immediately notify the BSA Contractual Representative who shall in each instance work with BSA Engineering to determine which document takes precedence and advise the Vendor accordingly.

Failure to notify BSA of a document conflict shall not relieve the Vendor’s responsibility to ensure full compliance to all requirements.

The EIC unit substations shall be designed in accordance with all applicable federal laws, codes, and standards. In particular: American National Standards Institute (ANSI), National Electrical Manufacturers Association (NEMA), and Institute of Electrical and Electronics Engineers (IEEE) codes and/or standards applicable to 15 kilo-Volts (kV) rated switchgear, 480 Volts (V) switchgear and 13.8kV to 480V transformers with Apparent Power [kilo-Volts-Amperes (kVA)] ratings as indicated in the specifications and drawings, including all federal standards, codes, and references provided in the specifications.

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

Document Number Document Title

Specification 01 61 00 Common Products Requirements, May 7, 2024

Specification 01 78 23 Operations and Maintenance Data, May 21, 2024

Specification 26 11 16 Load Center Unit Substations, May 21, 2024, Addendum 5

Specification 26 23 00 Low Voltage Switchgear, May 7, 2024

Drawing E600 LLP One Line Diagram Schedules, 05/07/2024

Drawing E 601-01A LLP Unit Substation Oneline Diagram – Building 1001A, 05/07/2024

Drawing E 601-03A LLP Unit Substation Oneline Diagram – Building 1003A, 05/07/2024

Drawing E 601-04G LLP Unit Substation Oneline Diagram – Building 1004G, 05/07/2024

Drawing E 601-05T LLP Unit Substation Oneline Diagram – Building 1005T, 05/07/2024

Drawing E 601-06G LLP Unit Substation Oneline Diagram – Building 1006G, 05/07/2024

Drawing E 601-07A LLP Unit Substation Oneline Diagram – Building 1007A, 05/07/2024

Drawing E 601-09A LLP Unit Substation Oneline Diagram – Building 1009A, 05/07/2024

Drawing E 601-10D LLP Unit Substation Oneline Diagram – Building 1010D, 05/07/2024

Drawing E 601-10E LLP Unit Substation Oneline Diagram – Building 1010E, 05/07/2024

Drawing E 601-11A LLP Unit Substation Oneline Diagram – Building 1011A, 05/07/2024

Drawing E 601-12C LLP Unit Substation Oneline Diagram – Building 1012C, 05/07/2024

Drawing E 601-12D LLP Unit Substation Oneline Diagram – Building 1012D, 05/07/2024

Drawing E 602-06G LLP Unit Substation Oneline Diagram – Building 1006G, 05/07/2024

Drawing E 602-10D LLP Unit Substation Oneline Diagram – Building 1010D, 05/07/2024

Drawing E 602-10E LLP Unit Substation Oneline Diagram – Building 1010E, 05/07/2024

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ASME B30.26 Rigging Hardware

ASME BTH-1 Design of Below-the-Hook Lifting Devices, Design Category “A”

NFPA 70 National Electrical Code (NEC)

UL 508 Industrial Control Equipment

BNL-QA-101 Supplier Quality Assurance Requirements

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3. REQUIREMENTS

In accordance with the applicable specifications, referenced documents, and instructions as defined in this SOW, the Vendor shall be responsible for the shop drawings, fabrication, testing, and delivery of fifteen (15) Unit Substations, skid mounted, for outdoor use.

Successful Vendor shall provide comparable units to fabricators listed in the specifications.

3.1 Vendor’s Responsibilities

The Vendor is responsible for the preparation of shop drawings, fabrication of unit substations, shop testing and results (witnessed by BSA or their representative), delivery of unit substations, and documentation for operation and maintenance.

BSA will review the shop drawings and provide written approval prior to the start of fabrication. BSA will provide rigging to offload at BNL. Other installation contractors will be installing the unit substations and will coordinate startup.

3.1.1 Technical Performance

In accordance with this SOW, the BSA-contracted Architect/Engineer’s (HDR’s) ‘Construction Document – Project Manual’, including Specification 26.11.16 and Specification 26.23.00, and all referenced documents, the Vendor shall furnish all equipment, materials, tools, facilities, and labor to perform the work necessary to manufacture and test the unit substations. The Vendor shall provide a design as specified for the unit substations that meets the performance parameters and criteria and include all associated documentation.

All unit substations shall have high resistance grounding of the neutral system.

3.1.2 Special Parts & Tools

If not already included with the unit substations, the Vendor shall provide the following:

• Racking devices (Qty. 3, total) for all 15kV breakers, if required

• Hoists for 480V breakers (Qty. 1 per unit substation)

• Racking devices (Qty.1 per unit substation) for 480V breaker, if required

• Dielectric Covers for Grounding Ball Studs, removable with lineman’s insulated tool

• Test paddles for test block associated with relay testing, etc. (Qty. 3 of each kind), if required

• Spare Pressure/Vacuum gauge for transformer (Qty. 3)

• Spare Liquid Level gauge for transformer (Qty. 3)

• Spare fuses (Qty. 10 of each size)

• Spare compartment heaters (Qty. 10 of each size)

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• Rigging attachments for hoisting, lifting, or jacking of equipment

The Vendor shall provide a list of any additional recommended spare parts and their pricing.

3.2 Design and Fabrication Requirements

The Vendor shall prepare shop drawings for review and written approval by BSA.

Drawings shall have sufficient details to allow BSA to determine the product to be fabricated. At a minimum, the drawings shall include plan views, elevations, enclosure dimensions, bus details for matching equipment to equipment, simplified one-lines, bus details for terminating cables (need sufficient height for terminating 2 sets of 1000 kilo circular mils (kcmil), 133% cable, bottom fed), access windows in the skid and primary breaker floor for incoming feeder entry, ‘hi-hats’, or other means, for load cables to exit out the top of the 480V switchgear compartments, ground pads for ‘grounding’ equipment and bonding shield wire from 15kV cable, ‘ground balls’ for maintenance and safety, panel front views, tables for data (e.g. breaker ratings, control voltages, nameplates, etc.), high resistance ground system, ground-fault monitor equipment with monitoring capable of transmitting alarms to the BNL Facility Operations Center (FOC), breaker handling equipment, heaters controlled for condensation and winter heating and control wiring diagrams.

The Vendor shall provide two (2) sets of initial shop drawings for review by BSA. An electronic copy of the drawings shall also be provided.

The Vendor shall provide three (3) sets of final shop drawings for review and written approval by BSA. The Vendor shall also provide two (2) copies on electronic media.

3.2.1 Approval to Proceed

BSA must approve in writing the shop drawings before the Vendor proceeds with ordering of material and components. This includes an initial submission for review and comment, followed by a final version(s) for approval for fabrication.

3.2.2 Fabrication and Test Requirements

The Vendor shall follow all standards, codes, and regulations cited in the specifications, at a minimum. The Vendor shall follow their quality assurance program. Standard Factory Inspection and Acceptance Tests shall be performed in accordance with IEEE C37.09, IEEE C57.12.00, and IEEE C37.13.1.

3.2.3 Acceptance Test Procedures (ATP)

The Vendor shall provide an ATP that is in accordance with this SOW and all reference documents noted herein. The ATP must be approved in writing by BSA prior to use. The ATP shall ensure that all test requirements as defined in the

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3.2.4 Shipping

BSA will coordinate with the Vendor to facilitate groups of unit substations being tested and shipped. The schedule (Section 6) suggests 3 to 4 shipments. BSA will be responsible for coordination and cost of all “Rigging” and “Off-loading” activities associated with the delivery of the equipment.

3.2.5 Commissioning

Commissioning is not included in the scope of work for this Statement of Work.

3.3 Management

3.3.1 Program Plan

To be provided at the time of award of contract, the Vendor shall deliver a detailed program plan which includes a milestone schedule defining the design validation and approval, fabrication, testing plan and approval, and testing phases and approvals in sufficient detail to allow regularly scheduled progress monitoring.

3.3.2 Progress Reporting

The Vendor shall provide monthly status reports, starting two (2) weeks following the planned start of fabrication, indicating progress and any variances from planned fabrications.

3.3.3 “Witness” Points BSA reserves the right to designate selected inspection, and/or test operations as “witness” points. Vendor shall provide BSA with fifteen (15) working days’ notice in advance of such witness points during the fabrication and production testing.

The BSA Technical Representative shall review test results 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 substation name, breaker positions, etc.

• All documentation provided by the Vendor shall be in English.

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

• The Vendor shop drawings shall be in one of these formats: PDF or DWG.

3.4.2 Engineering Drawing Practices

All Vendor-generated drawings shall be in accordance with ASME Y14.100, Engineering Drawing Practices. All dimensions and tolerances shall be U.S.

Customary units with metric (SI) units as a secondary notation.

3.4.3 End Item Documentation Package

The Vendor shall provide with the end item documentation package: two (2) electronic copies 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:

a. Final Inspection and Test Reports: Final test reports of all required or necessary inspections, examinations, and tests, properly validated by the Vendor’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.

b. Nonconformance Reports: Nonconformance reports identified as “rework / repair” or “use-as-is” shall be provided.

c. As-Built Drawings, as well as 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.

d. Maintenance and Operations Manuals.

e. Certificate of Conformance

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

• Materials used are those which have been specified by BSA, and that the items delivered were produced from materials for which the Vendor has on file, reports of chemical or physical analysis, or any other equivalent evidence of conformance, where necessary.

• Processes used in the fabrication of items delivered followed the SOW or BSA approved procedures or specifications.

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

3.5 Environment, Safety and Health (ESH)

The Vendor 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.

• Fire The Vendor shall ensure that any electrical equipment or wiring minimizes combustibility using flame-resistant materials.

• Vendor Work on Site at BNL (When requested) A Job Hazard Analysis (JHA) shall be developed for all tasks performed on site which includes the job steps, hazards and controls associated with the Equipment and installation. Safety Data Sheets (SDS) shall be submitted to BSA for approval prior to the start of work. Vendors performing work on site at BNL will be required to participate in the BNL work planning process as described in the Work Planning and Control Subject Area.

• 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 must conform to U.S. standards, must comply with National Fire Protection Associates (NFPA) 70 and shall be certified, listed, or labeled by a Nationally Recognized Testing Laboratory (NRTL) as required by NFPA 70.

If electrical work is being performed at BNL, all work must be performed only by qualified electrical workers. Vendor employees performing work with exposure to an electrical hazard must meet the qualification requirements in BSA’s Electrical Safety Subject Area.

All electrical connections ≥50V shall be covered to comply with UL 508 so that all uninsulated charged surfaces protect workers from the hazards of electrical shock. The use of Plexiglas® is not allowed; Lexan® may be used. In the event that the installation of a

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Lexan® barrier is required, the equipment manufacturer shall be contacted by the Vendor and written permission of the modification be obtained from the manufacturer.

4. QUALITY ASSURANCE

4.1 Quality System and Facility Access

The Vendor 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 Vendor shall supply the necessary documentation to demonstrate this compliance. Post-award surveys may be required and shall be supported by the Vendor.

In addition, BSA representatives shall have access to the Vendor’s facility during agreed-upon fabrication, inspection and testing processes. The Vendor shall provide fifteen (15) 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, 3.1.4, 3.2–3.22, 4.0, 4.1, 4.2, 4.3, 4.4, 4.4.1–4.4.3, 4.5 as modified below, 4.6, 4.7, 4.7.1, 4.10, 4.10.1, 4.10.2, 4.10.3, 4.10.4, 4.13, 4.14 as modified below, 4.16, 4.19, 4.21, 4.34, and 4.39. With each Component delivered, the Vendor shall supply to BSA a Certificate of Conformance, in accordance with Section 4.16 of BNL QA-101.

Clause 4.5: “Witness” Points, is modified as follows: The Vendor shall provide BNL fifteen (15) working days’ notice in advance of reaching such witness points during the manufacturing and test cycle of each item.

Clause 4.14: Source Inspection/Surveillance, is modified as follows: Items to be delivered require inspection, test, or surveillance by the Buyer’s representative at the Supplier’s facility. Fifteen (15) working days’ notice, for acceptance inspections and tests, shall be given by the Vendor to the Buyer to permit scheduling of source inspection.

4.2 Configuration Management

The Vendor shall establish and maintain a configuration control system to assure that all end items 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 three (3) years from the date of acceptance of

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

4.3 Responsibility for Subcontractor

It is the responsibility of the Vendor 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 Vendor is responsible for providing items which conform to the requirements of the Purchase Order (PO)/Contract regardless of any assessments, surveillances, inspections and/or tests by BSA or its representatives at either the Vendor’s or BSA’s facility. The Vendor 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 Vendor 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 Vendor 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 Vendor shall be responsible for the performance of all inspections and tests specified herein. Except as otherwise specified in the PO/Contract, the Vendor 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 assure that Equipment conforms to prescribed requirements at no cost to the Vendor. BSA and/or their representative shall have the option to witness all of the tests defined in this SOW.

The systems shall be tested by the Vendor at the Vendor’s facility, the Vendor’s subcontractor’s facility, or a pre-approved BSA collaborator prior to shipment, using an

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ATP (as noted in Section 3.2.3) generated by the Vendor and approved in writing by BSA.

BSA or its designee retains the right to witness all testing.

4.7 Repairs

If failures occur or repairs are required to an assembly or any component during manufacturing, transportation 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 written approval by BSA. No repair shall be considered successfully accomplished without inspection and written approval by BSA. All repairs shall be at the expense of the Vendor. In addition, the Vendor shall not use nonconforming materials via:

“use-as-is" disposition without written approval of BSA.

4.8 Failure Reporting, Analysis and Corrective Action

The Vendor shall maintain a failure reporting, analysis, and corrective action system which shall, at 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 and shall be provided within two (2) working days.

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5. DELIVERABLES

The Vendor shall supply the following:

Item Deliverable Due BSA Approval

1 Program Plan At award of contract Yes

2 Initial Shop Drawings for review 8 weeks after award of contract, or as determined at contract award

No

3 Final Shop Drawings for review and approval As set forth in contract Yes

4 Progress Reporting 2 weeks after the planned start of fabrication/ monthly thereafter No

5 Acceptance Test Procedure (ATP), for review and approval

8 weeks prior to start of factory testing Yes

6 Factory Witness Testing Notify BSA 4 weeks in advance No

Acceptance Test Procedure (ATP) Factory Witness Testing Documentation, for review and approval

As set forth in contract

Yes; BSA Approval following each inspection including testing reports

8 Installation Instructions 4 weeks prior to first delivery No 9 Delivery of equipment As set forth in contract Yes

10 End Item Documentation As set forth in contract Yes

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6. SCHEDULE

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

No. Task Milestone Date

1 Prepare Shop Drawings 8 weeks after award of contract

Planned Start of Fabrication Time (start date to be indicated at time of contract award)

TBD

Fabrication (duration to be indicated at time of contract award)

Manufacturer’s Fabrication Time (MFT): First group of unit substations. (First shipment not to exceed approximately 2.25 years, total shipment within 3 additional months)

Following Factory Testing, Group 1 delivery including special parts & tools (plus recommended parts /tools if purchased) (B-1005T, Subst-1005TA; B-1012D, Subst-1012B, B- 1003A, Subst-1003A; B-1001A, Subst-1001A; B- 1009A, Subst-1009A)

4 weeks after start of MFT

Following Factory Testing, Group 2 delivery (B- 1006G, Subst-1006E, B-1006G, Subst-1006F, B-1101, Subst-1101A, B-1010D, Subst-1010C)

8 weeks after start of MFT

6 Start of Commissioning Group 1 (for information only) 10 weeks after start of MFT

Following Factory Testing, Group 3 delivery (B- 1010D, Subst-1010D, B-1010E, Subst-1010E, B- 1010E, Subst-1010F)

12 weeks after start of MFT

Continue Commissioning Group 2 (for information only)

14 weeks after start of MFT

Following Factory Testing, Group 4 delivery, if needed (B-1004G, Subst-1004G; B-1007A, Subst-1007A, B- 1012C, Subst-1012C)

14 weeks after start of MFT

Continue Commissioning Group 3 (& 4 if needed, for information only)

16 weeks after start of MFT

3.5 Environment, Safety and Health (ESH)