DRAFT - SOW.pdf

D15-E455 SOW-01 Page 1 of 10

01Brookhaven National Laboratory Brookhaven Science Associates Collider Accelerator Department

Numberr:: D15-E450 Date: 12/24/2024 Revision: D

STATEMENT OF WORK

for the

NEW AGS QUAD AND SEXTUPOLE POWER SUPPLIES

Prepared by

Date

I. Marneris, Cognizant Engineer

Approved by

Approved by

J. Sandberg, Chief E.E.

W. Ng, Project Engineer

Approved by E. Bajon, Electrical Engineer

Approved by J. Funaro, Technical specialist

Approved by D. Passarello, Quality Assurance

1/24/2025

1/28/2025

1/28/2025

1/28/2025

1/29/2025

1/30/2025DRAFT

D15-E455 SOW-01 Page 2 of 10

1.0 SCOPE

This Statement of Work (SOW) is the basis for the procurement of three AC to DC converters (power supplies) used in the Alternating Gradient Synchrotron (AGS) accelerator at Brookhaven National Laboratory (BNL). The converters shall be configured as four quadrant (bipolar voltage, bipolar current) regulated pulsed power supplies which will power strings of, vertical and horizontal tune quad magnets, and sextuple magnets in the AGS ring. The AGS is part of the pre-injector that will serve the Relativistic Heavy Ion Collider (RHIC) at Brookhaven National Laboratory (BNL) managed by Brookhaven Science Associates (BSA).

The scope of work includes the engineering, design, manufacture, and delivery of the power supplies.

2.0 APPLICABLE DOCUMENTS

The following document and all referenced 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:

3.0 REQUIREMENTS

In accordance with the applicable specifications, referenced documents, and instructions as defined in this SOW, the Contractor shall be responsible for the material acquisition, fabrication methods, fabrication, assembly, tuning, testing, inspection, and delivery of the power supplies.

3.1 Contractor Responsibilities

3.1.1 Technical Performance

It is the Contractor’s responsibility to meet the technical performance as specified in BNL Technical Specification CAD-1340.

3.1.2 Tools/Fixtures/ Test Equipment/Facilities

The Contractor shall be responsible for supplying all materials, including (but not limited

to) the construction of all tools, jigs, fixtures, and test equipment as required to complete the manufacture, and testing of the power supply.

3.1.3 Materials

It is the Contractor’s responsibility to meet all material requirements as defined in the BSA Technical Specification CAD-1340

Number Title CAD-1340 Specification for the new AGS Quad and Sextupole power supplies

DRAFT

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3.1.4 Spare Parts/Special Tools

Special tools are not permitted without BSA written approval. Any special tools thus approved and then fabricated becomes the property of BSA. The special tools are to be delivered to BNL.

3.1.5 BSA Supplied equipment

One PSI (Power Supply Interface) One PSC (Power Supply Controller) test box which will interface the PSIs to the

Contractor’s computer through a USB port, Fiber optic cables to connect the PSIs and test box Software to control the test box and log data.

One waveform generator to generate the analog current reference.

Cables to connect the PSC to the PSI during factory testing Software to operate the PSC

3.2 Design and Manufacturing Requirements

3.2.1 Preliminary Design Review (PDR)

Three weeks after award of contract a preliminary design review shall take place at BNL.

Preliminary layout drawings and parts selections shall be reviewed.

3.2.2 Final Design Review (FDR) Report Requirements

The Contractor shall be responsible to develop the final design. Prior to the FDR, the Contractor shall prepare and submit a Final Design Report that includes the following ( for each model of the power supplies ) to be presented at the FDR Meeting: . The report shall include the following:

General Information:

The names and contact information of the contributors to the FDR report.

Detailed Design information:

Schematic and assembly drawings of the supply, drawn to scale where appropriate, showing basic configuration and all essential components.

Analysis of the performance and design margins of the system.

An estimate of the preliminary input power requirements and cooling water requirements if applicable.

The type of connections for water-cooling if applicable (refer to section 3.7.6 in the specification).

Calculations for designed and manufactured lifting components, proving that this requirement has been achieved.

Data sheets for standard catalog parts, such as lifting eyes, may be provided instead of calculations.

Expected leakage currents during prescribed high potential testing

3.2.3 Approval to Proceed

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Before proceeding BSA must approve in writing the Final Design Report, including any modifications introduced at the FDR . This includes but is not limited to ordering of material, changes in design, or changes in manufacturing processes.

3.3 Program Management

3.3.1 Management/Program Plan

Within two (2) weeks after award of contract, the Contractor must issue a program plan, which includes a milestone schedule defining the design validation, manufacturing, and testing phases in sufficient detail to allow regularly scheduled progress monitoring.

3.3.2 Progress teleconference

Within two (2) weeks after award of contract, bi-weekly (every two weeks) program technical and progress teleconferences 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, analyses, design reviews, value engineering, trouble-shooting, material status, resources, and manufacturing issues.

3.3.3 Performance Reporting

Throughout the life of the contract, the Contractor shall supply an email by the fifth of every month to the BSA Technical Representative and Contractual Representative detailing progress through the prior month with respect to the program. This shall include fabrication progress, open items, problems, and recommended solutions.

3.3.4 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 within 2 weeks after award of contract.

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.

3.3.5 Witness Points

BSA reserves the right to designate selected manufacturing, inspection, and/or test operations as “witness” points. The Contractor shall provide the BSA with fifteen (15) working days’ notice in advance of reaching such witness points during the manufacturing and test cycle.

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3.4 Documentation and Data Management

3.4.1 Report/Documentation Format

All reports submitted shall include an introduction statement, body of the documents, and a conclusion. In the case of calculations, equations should be shown with values for each variable so the analysis can be reviewed. BSA reserves the right to request the Contractor to revise any documents to meet BSA’s requirements.

All documentation provided by the Contractor shall be in English.

The Contractor shall provide an electronic copy (email, plus either CD ROM or USB data storage device) of all documentation required by this SOW. Manufacturing drawing CAD files of all components and assemblies shall be in any of these formats:

STP, SAT, IGS, IAM, or IPT.

3.4.2 Drawing Dimension

All engineering 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 Contractor shall provide an electronic copy and three physical copies of the following documentation packages in accordance with the schedule set forth in this SOW. The End Item documentation package shall consist of all documentation identified in this Statement of Work and included the following:

a. 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.

b. Final test reports of all required or necessary inspections, examinations, and tests, properly validated by the Contractor’s authorized

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

d. Completed Travelers

e. Operations and Maintenance Manual - Shall include final parts lists, recommended spare parts lists, technical descriptions of the power supply operation and maintenance recommendations, detailed circuit descriptions, description of critical adjustments and potentiometer settings, and data sheets on gauges, meters, fuses, semiconductors, relays, valves, and other pertinent components. (Electronic format shall be approved by BSA Technical Representative)

f. Software Documentation - If programmable devices such as microcontrollers, programmable gate arrays, or PLCs are supplied with the power supply, the source code for the programmable components shall be delivered in paper and electronic forms.

g. Certificate of Conformance Materials used are those which have been specified by the BSA, and that the items delivered were produced from materials for which the Contractor has on

D15-E455 SOW-01 Page 6 of 10 file, reports of chemical or physical analysis, or any other equivalent evidence of conformance.

Processes used in the fabrication of items delivered were in compliance with the technical specification included as part of the PO/contract, or BSA approved procedures or specifications.

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

3.4.4 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 three (3) years, unless otherwise specified in the procurement documentation, after the completion of the Purchase Order / contract.

3.5 Design Review

3.5.1 Final Design Review (FDR) Meeting

A FDR meeting shall be held in accordance with the schedule in section 6 of this SOW.

The Contractor shall provide, no later than five (5) working days prior to the scheduled meeting, a draft FDR Report that meets the requirements set forth in section 3.2.1 herein.

This report shall be reviewed at the FDR, to be held at the Contractor’s facility or in videoconference (at the discretion of BSA), and shall cover all issues relating to the final design of the power supplies. The Contractor shall be responsible for maintaining and publishing the minutes of the FDR and shall also incorporate any agreed-to changes into the design report. FDR minutes are to be submitted within five (5) working days of the FDR for subsequent review and approval by BSA.

After written approval of the FDR report by BSA, the Contractor shall promptly begin manufacturing, testing, and delivery of the power supplies.

3.6 Environment, Safety, and Health (ES&H)

The Contractor shall design and build the power supplies in accordance with ES&H requirements in the appropriate specifications, codes, standards.

3.6.1 Electrical Safety.

All electrical distribution must be in accordance to U.S. standards. If international standards are referenced by the contractor, the use of those standards must be approved by BSA. All commercial off-the-shelf power supplies shall be approved by a Nationally Recognized Testing Laboratory (NRTL). All electrical equipment, material, and systems delivered to the site shall be certified, listed, or labeled by a Nationally Recognized Testing Laboratory (NRTL) as appropriate. The CE mark is NOT a recognized NRTL certification mark. (For listing of OSHA-recognized NRTLs, refer to http://www.osha.gov/)

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For electrical equipment, material and systems which no NRTL accepts, certifies, lists, labels or otherwise determines to be safe, the contractor shall determine the equipment to be safe for its intended use. The determination must be made on the basis of test data. The determination and test data documents shall be made available to BSA prior to or upon delivery for review and acceptance by the applicable BSA Contractual Authority Having Jurisdiction (AHJ).

3.7 Software Requirements

All control software provided under this contract shall be subject to review and approval by BSA. Source code shall be included with the deliverables.

3.6.1 Software Configuration Control

The Contractor shall have and maintain an effective software configuration management system. The Contractor's system shall establish requirements for placing software under configuration control, and provide for the positive identification of software and the control of all software baseline changes.

4.0 QUALITY ASSURANCE REQUIREMENTS

4.1 Quality System and Facility Access

The Contractor shall maintain a documented quality assurance system, which provides the processes to ensure that each component produced for acceptance conforms to the requirements of this document and the applicable technical documentation. The quality system shall be available for review. BSA representatives shall have access to the contractor’s facility during agreed upon fabrication, inspection, and testing processes.

4.2 Configuration Management

The Contractor shall establish and maintain a system to assure that all end items are of the proper configuration, and that all approved configuration changes are incorporated at the specified affected points. The Contractor shall immediately notify the BSA Contractual Representative of any significant changes (those that may affect form, fit, function, reliability, safety, or interchangeability) in product design, fabrication methods, material or processing from those used by the Contractor at time of Contract which resulted in the purchase order.

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.

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4.3 Responsibility for Subcontractors and Vendors

It is the responsibility of the Contractor to flow down all applicable technical and quality requirements to their subcontractors and vendors. The Contractor shall identify and define the role and level of experience of all subcontractors and suppliers three (3) weeks prior to the manufacturing plan review. BSA reserves the right to disapprove, in writing, any subcontractors or vendors.

4.4 Responsibility for Conformance

The Contractor is responsible to provide items which conform to the requirements of the purchase order/contract regardless of any assessments, surveillances, inspections and/or tests by BSA or its representatives at either Contractor’s or BSA’s facility. BSA reserves the right to request failure analysis and corrective action for non-conforming articles or items submitted or supplied to BSA. Contractor is responsible for notifying the BSA Contractual Representative of any recalls or alerts associated with this purchase order/contract.

4.5 Measuring and Test Equipment (M&TE) Calibration

The Contractor shall calibrate any M&TE used in the fulfillment of the purchase order 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 specified herein. 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 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 supplies and services conform to prescribed requirements at no cost to the Contractor. BSA and/or their representative shall have the option to witness all of the tests defined in this

SOW.

4.6.1 First Article Acceptance

One +/-700 A, +/-300 V power supply shall be designated the first article. The first article shall be identified as such, including the PO number/contract, part number, and part name. The first article shall be built and tested at the Contractors facility before production of the remaining units commences. This unit shall meet all the specifications described in the specification Number: CAD 1340.

After BSA Technical representative acceptance of the first article all the remaining units required by the PO/Contract shall be produced by the Contractor and the Contractor’s suppliers using the same design, materials, processes, methods and tooling, scaled for the appropriate power levels, that were used to

D15-E455 SOW-01 Page 9 of 10 manufacture the approved first article(s). Any changes must have prior written approval from BSA.

4.7 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.

4.8 Rework and Repairs

If failures occur or repairs are required 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 mode(s) and proposals for repair. Proposals for repair shall include adequate information for evaluating the repair, testing the effectiveness of 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 accomplished without inspection and approval by BSA. All repairs shall be at the expense of the Contractor

5.0 PACKAGING

5.1 All units and parts of this equipment shall be properly packaged and delivered in undamaged condition to BNL. All water circuits shall be blown free of any water prior to packaging to prevent damage during shipping or storage under freezing conditions. When traveling by road.

5.2 The Power Converters shall be packaged individually, suitable to their dimensions and intended applications.

5.3 The Power Converters shall be shipped on pallets which allow access for a fork lift to lift the converter.

5.4 The packaging shall be appropriately labeled listing the destination, gross weight, location of the center of gravity, and contract order number

5.5 Each converter shall have a G-force indicator.

6.0 DELIVERABLES

Item

Deliverable

Due

BSA

Approval Required

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1 Program Plan 2 weeks ARO Yes 2 Technical & Progress Teleconference 2 weeks ARO/bi-weekly thereafter No 3 Performance Reports 5th of every month of the contract Yes 4 Manufacturing/Inspection Plan 5 weeks ARO Yes 5 Draft FDR Report 7 weeks ARO Yes 6 Final Design Report 9 weeks ARO Yes 7 Acceptance Test Procedures 4 weeks prior to scheduled testing Yes 8 Acceptance Test Report As set forth in contract Yes 9 Delivery of equipment As set forth in contract Yes 10 End Item Documentation Package With delivery of equipment Yes

7.0 SCHEDULE

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

8.0 VALUE ENGINEERING

Contractor is encouraged to make recommendations for changes that might lead to an improvement in performance, reliability, quality, safety, or reduction in cost. Simplicity in operation, ease of maintenance, and an improvement in the performance and reliability of the specific functions beyond the requirements of this specification are objectives, which shall be considered. Where it appears that a substantial improvement in simplicity of design, performance, and ease of maintenance or reliability will result from the use of materials, parts and processes other than those specified, then 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 and, if approved, authorized in writing.

Item Milestone Calendar

ARO

1 Manufacturing/Inspection Plan 5 weeks 2 Final Design Review 8 weeks 8 Contractor Performed Acceptance Tests Complete 31 weeks 9 Delivery of Power Supply, and End Item documentation package 32 weeks