C. Statement of Work ED0047900 - Magnetic Shield.pdf

PIP-II HB650 CM3

- Procurement and Fabrication Specification -

Magnetic Shields

Author: J. Bernardini

Document Number: ED0047900 Rev -

PIP-II

Procurement and Fabrication Specification

Document Title: PIP-II HB650 CM3 - Procurement & Fabrication Specification - Magnetic Shields

Fermi National Accelerator Laboratory 2

Revision History

Author Revision Description of Change

J. Bernardini Rev - Initial Release

Table of Contents

1 Scope 3

2 Procurement Specification 3

2.1 Bidding Phase 3

2.2 Technical and Cost Evaluation Phase 4

2.3 Execution Phase and Hold Points 4

2.3.1 Hold Points 5

3 Fabrication Specification 6

3.1 Materials 7

3.2 Dimensional conformance 8

3.3 Fabrication Details 9

3.3.1 Cutting and Forming 9

3.3.2 Heat Treatment 9

3.3.3 Grinding and Snipping 9

3.3.4 Handling 9

3.4 Serial number stamping 9

3.5 Hardware 9

3.6 Quality controls 10

3.7 Shipping Plan 10

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1 Scope

This document describes the requirements necessary to specify, manufacture, and procure the assemblies

F10196665, F10141950, F10137913, F10193448 and F10111970. Manufacturer shall offer for acceptance fully fabricated assemblies, according to this document, associated drawings, and quality control specifications. Quantities are described in the Table 1.

Top Assembly Drawing Description Quantity F10196665, Rev C PROCUREMENT ASSY, HB650 GLOBAL MAG SHIELD 1 F10141950, Rev E KIT, STRONGBACK MAG SHIELD 1 F10137913, Rev B KIT, MAG SHIELD, COUPLER 6 F10193448, Rev B KIT, TUNER MOTOR MAG SHIELD 6 F10111970, Rev G ASSEMBLY, MAGNETIC SHIELD-650MHz-B92 6

Table 1: Top assembly drawings and quantities

The Manufacturer shall provide all materials necessary to fabricate complete deliverables. The

Manufacturer shall provide manufacturing engineering services required to generate internal shop drawings and all documentation needed to manage and support their suppliers. The Manufacturer shall provide all labor to supervise the manufacture of all components regardless of where these are made:

within the manufacturer’s plant or in a second facility or sub-contractor. The Manufacturer shall fabricate jigs and fixtures to ensure flange faces, ports, brackets, and other important components are maintained to specified tolerances. Any information of a proprietary nature must be identified in the bid response.

DAP Incoterm 2025 rules shall be applied as method of delivery (HTS code 8543.90.88.45).

2 Procurement Specification

2.1 Bidding Phase

Bidder shall provide Quotation including all costs to deliver the assemblies indicated in Table 1 at Fermilab.

In addition to quotation, the following documentation shall be provided:

a) Schedule that meets a lead time of 12 months starting from the date that the Fermilab Purchase

Order is awarded to the bidder running through fabrication, including hold points reported in

Table 2. Supporting documentation, to demonstrate that the bidder will deliver within the specified timeframe, is recommended.

b) Technical Proposal to demonstrate the ability of the bidder to deliver the assemblies with performance that meets or exceeds Fabrication Specification reported in section 3 of this document. The technical proposal shall include the magnetic shield material used by the bidder for these assemblies (see section 3.1). Example of past projects (within the last five years) that closely match the scope in complexity and value, and that best illustrate the bidder’s capability, Fermi National Accelerator Laboratory 4 experience, and performance will be considered for the technical evaluation. The Bidder shall disclose what part of the work, if any, will be sub-contracted.

c) Management Control Plan to demonstrate the ability to ensure the required quality standard (see section 3) throughout the entire execution of the project. Examples of documentation developed for past projects (within the last five years), which demonstrate the ability of performing inspection and testing will be considered for the technical evaluation.

All required documentation shall be organized with a table of contents and corresponding sections.

2.2 Technical and Cost Evaluation Phase

A Fermilab Purchase Order will be awarded to one bidder after that the proposals will have been evaluated by technical and cost evaluation teams.

2.3 Execution Phase and Hold Points

Upon Fermilab purchase order award, the Manufacturer shall assign a person responsible for the technical execution and Quality Control (QC) of the project, and a person responsible for the commercial follow-up, throughout the duration of the contract. They shall be able to communicate in English.

Within two weeks from Fermilab purchase order award, a kick-off meeting shall be carried out to initiate technical and commercial discussion between the technical and commercial representatives from

Fermilab and the Manufacturer. Action items from the meeting shall be addressed within one week.

Upon conclusion of the kick-off meeting, Fermilab expects to receive bi-weekly a status report via e-mail from the manufacturer. Also, a monthly meeting held by videoconference shall be regularly scheduled to discuss technical and commercial updates (Fermilab reserves the right to increase the frequency of the meetings). The meetings will be held in English. However, Fermilab representatives are always available to respond any time if questions will arise.

Within eight weeks from Fermilab purchase order award and before starting any fabrication / procurement activity, the Manufacturing Readiness Review (MRR) shall be organized to allow Fermilab reviewers to assess the Manufacturer’s level of preparation to proceed to the manufacturing and procurement phase. The review’s recommendations (if any) based on the presented material (see MRR deliverables in Table 2), shall be addressed within two weeks from the conclusion of the MRR.

Upon conclusion of the MRR, the Manufacturer will be allowed by Fermilab to proceed with the fabrication / procurement phase. Quality Controls (see section 3.6) and technical reports, as detailed in

Table 2, shall be provided by the Manufacturer to Fermilab.

The readiness to ship the unit shall be assessed through an appropriate review.

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2.3.1 Hold Points

A Hold Point is defined as the moment in time wherein the process needs to be stopped in order to allow a Fermilab representative to perform reviews and QCs deemed necessary.

Table 2 lists the main hold points and associated documentation deliverables for this project.

Hold Point Description Deliverables When required

A Kick-off Meeting Address action items from the meeting Within 2 weeks of contract award

B Manufacturing

Readiness Review(s) (MRR)

MDED (see section 3.2) Detailed MIP (see section 3.6)

Within 8 weeks from Fermilab purchase order award and before starting any Fabrication / Procurement

C Discrepancies / Nonconformities Discrepancy report(s) As soon as identified

D Shipping

Readiness Review

Material certifications (see section 3.1) Final version of MDED

QC Reports including discrepancy reports (see section 3.6) Shipping Plan (see section 3.7)

Prior to shipping

Table 2: Hold Points and Documentation Deliverables for Fabrication Phase

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3 Fabrication Specification

This section provides a technical introduction of the scope, assemblies to be manufactured, quality controls, and shipping plan.

Introduction

The PIP-II HB650 Cryomodule adopts a global magnetic shield bolted to the inner side of the vacuum vessel, and a strongback magnetic shields bolted on the top of the strongback. These shields are operating at room temperature.

Figure 1: F10196665 C, Procurement assembly HB650 global magnetic shield

Figure 2: F10141950 E, Strongback Magnetic Shield

The PIP-II HB650 Cryomodule adopts a local magnetic shield around each cavity. These cavities will be operated at 2K.

Figure 3: F10193448, HB650 CM Tuner motor magnetic shield

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Figure 4: F10111970, HB650 CM Cavity magnetic shield

3.1 Materials

Materials are specified in the referenced drawings. The use of any materials not listed in the drawings is excluded by the present specification. Under exceptional conditions FFDG may approve other materials upon a written request. The Manufacturer is allowed to substitute 3mm thick with 1/8’’ thick material, and 1.5 mm thick with 1/16’’ thick material provided that FFDG will be notified of such change and will give written approval.

Certified Mill Test Reports (CMTR) of all raw materials shall be provided to FFDG as part of the deliverables of the shipping readiness review (see Table 2). These material certifications shall include all processes and tests with grade and composition being clearly identifiable and traceable to the respective component.

If the vendor obtains components from a subcontractor, the vendor is responsible to prove that the materials for the components meet compliance requirements.

Magnetic shields for cavities (F10111970) and tuner motors (F10193448) must be fabricated from

Cryoperm10, Amumetal 4K (A4K), Cryophy, or an equivalent material that is specially prepared to have high permeability over a wide range of temperatures. Suitable performance is illustrated in Figure 5. The relative magnetic permeability of the completed shields, after installation in the cryomodule, must exceed

10 000 over the temperature range 1.6 K < T < 300 K. Note that this value for relative permeability is the minimum requirement after all mechanical and handling procedures have been completed and is based on the assumption that the permeability will be degraded significantly by mechanical stress and shock.

Material certifications shall be required as part of the acceptance criteria.

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Figure 5: Curves for Cryoperm10 and for Amumetal 4K, Both are Acceptable for Magnetic Shield Use.

3.2 Dimensional conformance

All drawings referenced shall be used by the Manufacturer for configuration control and dimensional conformance. Dimensional variances and overall envelope configuration shall be maintained within specified tolerances.

The drawings supplied as part of this request for proposal are to be considered near-final release. The final set of drawings (latest revisions), including minor modifications that might occur during the bidding phase, will be given to the Manufacturer at the time of the kick-off meeting.

The Manufacturer may decide to use the drawings provided by Fermilab for fabrication, or to produce its own drawings. Any change or deviation from the set of drawings provided by Fermilab shall be listed in a

Manufacturer’s Drawings Exception Document (MDED). Fermilab will have to provide a written approval to the MDED before the Manufacturer can proceed to the next step. Fermilab is not accountable for any change in the drawings not listed in the MDED. The MDED can be revised and approved throughout the entire duration of the project.

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3.3 Fabrication Details

3.3.1 Cutting and Forming

The material shall be formed via normal sheet metal operations. Laser cutting and water jet cutting of the flat stock and rolling to final size is permitted.

3.3.2 Heat Treatment

After forming, the shields shall be annealed and processed accordingly to optimize the magnetic properties. The heat treatment batch number and other critical information for each part of the shield assemblies shall be recorded and be traceable to the part and serial numbers.

3.3.3 Grinding and Snipping

Before annealing, grinding and snipping are permissible to create a better fit with mating parts. No metal work is permitted once the annealing process has been completed.

3.3.4 Handling

Before and after annealing, white cotton gloves shall be worn to prevent cosmetic defects from dirty hands and skin oils. The magnetic permeability of the shield material can be degraded significantly by mechanical stress and shock during handling, packing and transportation, so proper handling procedures must be established and clearly stated.

3.4 Serial number stamping

Supplier shall permanently etch a serial number on each component. The serial number shall follow the following alphanumeric format:

Part# Revision CM# Sequence#

Part number and revision number shall be the ones indicated in Fermilab drawings, if no revision is indicated in the drawing, symbol “-“ shall be used. CM number is 1. The sequence number shall increase from 01 to the number of repeated components in the assembly.

An example is provided for component F10115763, Rev B. Since 3 equal components are to be manufactured, the serial number on each component of the 1st unit shall be:

• F10115763 B 1 01

• F10115763 B 1 02

• F10115763 B 1 03

3.5 Hardware

The Manufacturer shall supply to Fermilab the hardware listed in the provided drawings. Quantities are the ones listed in the part list of drawings plus 25% of spares, up to a limit of 30 spares for each item.

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Hardware material is the one listed in the part list of drawings. The hardware shall be properly packed and labeled to be easily identifiable during assembling of the magnetic shield at Fermilab.

3.6 Quality controls

The Manufacturer shall prepare a project specific Manufacturing and Inspection Plan (MIP) for Fermilab’s approval. The MIP shall list the sequence of manufacturing steps, as well as the associated inspections:

- Visual inspections.

- Dimensional inspections.

The Manufacturer shall develop quality control procedures and tests to guarantee that the project will be in full conformance with the Fermilab’s specifications. If during inspections a discrepancy occurs, which affect the final product, the supplier shall generate a Discrepancy Report (DR) and obtain Fermilab’s approval before proceeding to the subsequent step.

The Manufacturer shall maintain records of all inspections and tests in the form of Quality Reports (i.e., electronic travelers).

The MIP shall be made available for Fermilab’s reviews and approval before the Manufacturing Readiness

Review (MRR), as also indicated in Table 2.

3.7 Shipping Plan

The Manufacturer shall ship each component properly packed to ensure that damage is not incurred during shipment, in accordance with transportation industry standards. This shall include weather protection and shock protection. The vendor shall propose a shipping configuration to Fermilab, and

Fermilab shall approve prior to any shipments. Recommendations include foam, bubble wrap, and other vibration/shock reducing materials to be used as packing material, and for components to be shipped in hard-side crates to reduce the risk of damage. Each package shall be labeled with a tag identifying the serial number of the shield component(s) contained inside. Sizing shall be such that handling is facilitated and weight limitations imposed by the transportation industry can readily be met.

All deliverables including documentation shall be catalogued and offered for acceptance to Fermilab by the Shipping Readiness Review, as detailed in Table 2.