ED0004829---SPEC.pdf

LCLS-II Cryomodule Interconnect Internal Parts Kit, ED0004829, Rev. -

Fermilab Engineering Specification

LCLS-II Cryomodule Interconnect Internal Parts Kit

ED0004829, Rev. -

Rev. Date Description Originated By Checked By Approved By

- July 26, 2016 Initial release Yun He Tug Arkan Tom Peterson

Fermi National Accelerator Laboratory

P.O. Box 500 - Batavia, Illinois - 60510

CONTENTS

1. SCOPE

2. DESCRIPTION AND REQUIREMENTS OF EACH SUB-SYSTEM

2.1 HELIUM GAS RETURN INTERCONNECT PIPE

2.2 CRYOGENIC PIPING BELLOWS INSERTION

2.3 THERMAL SHIELD SHEETS

2.4 SPRING SUPPORT FOR THE BEAMLINE ABSORBER

3. GENERAL TECHNICAL REQUIREMENTS

3.1 DIMENSIONAL CONFORMANCE

3.2 MATERIALS

3.3 BELLOWS PARAMETERS AND PERFORMANCE

3.4 VACUUM INTEGRATION AND CLEANLINESS

3.5 WELDING

3.6 HELIUM LEAK CHECKING

3.7 LIQUID NITROGEN COLD SHOCK

3.8 PRESSURE TESTING

4. BIDDING PROCEDURE

4.1 PRE-OFFER DISCUSSIONS

4.2 ALTERNATIVE SOLUTIONS

4.3 SUBCONTRACTORS

5. MANUFACTURER FURNISHED MATERIALS AND SERVICES

6. QUALITY ASSURANCE

7. PREPARATION FOR SHIPMENT

8. DOCUMENTATION

1. SCOPE

The module interconnect internal parts kit (hereafter referred to as “Interconnect Kit”) is used for connecting the cryomodules to form the LCLS-II linac. This document describes the technical fabrication requirements, quality assurance, testing, packaging and documentation of the Interconnect

Kit. Manufacturer shall offer for acceptance fully fabricated and tested interconnect parts, according to this document and associated drawings.

The Interconnect Kit is shown in Figure 1, and the assembly drawing is F10056993. There are two kinds of the units, one standard and the other a short version named ECU. The major components are listed in Table 1.

Figure 1: Module interconnect internal parts kit

Table 1: Engineering drawings of the major components in the module Interconnect Kit

Drawing No. Description

Standard ECU

F10056993 Module interconnect internal parts, kit

1 F10030193 F10060191 Helium gas return interconnect pipe

2 F10030695, F10061937 F10060192 Cryogenic pipe bellows insertion

3 F10038024, F10038467, F10057784, F10057789

F10062190, F10062191

Thermal shield sheets

4 F10058710 N/A HOM absorber spring support

This Interconnect Kit will be used in a moderate to high vacuum service. The bellows assemblies will be used for cryogenic services and shall conform to the ASME B31.3 Process Piping code for Normal

Fluid Service, and they require vacuum leak checking and pressure testing.

2. DESCRIPTION AND REQUIREMENTS OF EACH SUB-SYSTEM

2.1 Helium gas return interconnect pipe

The material for the helium gas return interconnect pipe, shown in Figure 2, is stainless steel 316L.

This pipe is to be welded to adjacent pipes with semi-automatic orbital welder, the pipe GD&T circularity as specified on the drawing shall be met, and the pipe end should be square, burr free.

Figure 2: Helium gas return interconnect pipe

Due to the reliability issues associated with metal sulfur content differences across the joint when using orbital welding, it is required that the 316L stainless steel used on F10030193 and F10060191 should have Sulfur < 0.005%.

Table 2: Engineering drawings of the helium gas return interconnect pipe

Drawing No. Description

Standard ECU

F10030193 F10060191 Helium gas return interconnect pipe

2.2 Cryogenic piping bellows insertion

The cryogenic piping bellows will be compressed at the installation, and they will expand at cold due to the thermal contractions of the connecting pipes on both sides. The parameters of the bellows are listed in Table 3.

Table 3: Design parameters of the cryogenic piping bellows:

Description F10050694 F10060194

MAWP (differential pressure, inside to outside) 20 bar 20 bar

Operating temperature 2 K 2 K

Free length 173.2 mm 106.2 mm

Length at installation 153.2 mm 96.2 mm

Maximum axial stroke ±30 mm ±18 mm

Maximum lateral shift ±5 mm ±3 mm

Minimum fatigue cycles 1000 1000

The bellows insertion has external clam-shell covers for squirm restraint. They are slide-able with a 50 mm overlap, shown in Figure 3. The retaining collars are tack welded to the pipe stubs.

Figure 3: Cryogenic piping bellows insertion

The material for the cryogenic piping bellows insertion is stainless steel. Due to the reliability issues associated with metal sulfur content differences across the joint when using orbital welding, it is required that the 316L stainless steel used on F10030689 and F10061934 should have Sulfur < 0.005%.

This assembly must meet the ASME B31.3 Process Piping code for Normal Fluid Service. They shall be leak checked, cold shocked and pressure tested in accordance to sections 3.6, 3.7 and 3.8. The piping bellows insertion is to be welded to adjacent pipes with automatic orbital welder, the GD&T circularity of the pipe ends as specified on the drawings shall be met, and they should be square, burr free.

Table 4: Engineering drawings of the cryogenic piping bellows insertions:

Drawing No. Description

Standard Line E ECU

F10030695, F10061937 F10060192 Cryogenic pipe bellows insertion, assembly

F10030687 F10061938 F10060193 Weldment, interconnect bellows

F10030689 F10061934 Same Cuff Bellows

F10050694 Same F10060194 Bellows

F10060355 Same Same Flange, Large OD

F10060403 Same Same Flange, small OD

F10039413 Same Same Plate, attachment

F10050082 Same F10060196 Cover, small OD

F10050148 Same F10060382 Cover, large OD

2.3 Thermal shield sheets

The thermal shields are made from aluminum AL 1100-H14 sheets, with the upper sheet being ¼” thick and the lower sheet being 1/8” thick, shown in Figure 4. These sheets will be connected to adjacent module thermal shields. To avoid bolting hole fit-up problems at the cryomodule installation stage, it is important to maintain the shield shape and bolt-hole patterns as shown in the drawings.

Figure 4: Thermal shield sheets

Table 5: Engineering drawings of the interconnect thermal shield sheets:

Drawing No. Description

Standard ECU

F10038024

F10038467

F10057784

F10057789

F10062190

F10062191

Thermal shield sheets

2.4 Spring support for the beamline absorber

The spring support, shown in Figure 5, serves to support the beamline absorber.

Figure 5: Spring support of the beamline absorber

Table 6: Engineering drawings of the spring support for the beamline absorber:

Drawing No. Description

F10058710 Beamline absorber spring support, kit

F10059462 Plate attachment

F10059510 Clip

F10059531 Special bolt

F10059537 Modified washer

3. GENERAL TECHNICAL REQUIREMENTS

3.1 Dimensional conformance

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

In the drawings, the metric system of units is used as the primary dimensions. Stated in square brackets, are the dimensions in US system of units. The drawings supplied as part of this request for proposal (RFP) are to be considered near-final release. Minor modifications will be done by Fermilab during the RFP open period, and a final set of drawings will be given to the Manufacturer at the time a contract is awarded.

3.2 Materials

The material used in the fabrication shall conform to the specifications in associated drawings. It is the responsibility of the Manufacturer to ensure that ALL materials used are traced to the stated specification.

Due to the reliability issues associated with metal sulfur content differences across the joint when using orbital welding, it is required that the 316L stainless steel used on F10030193, F10060191, F10030689 and F10061934 should have Sulfur < 0.005%.

3.3 Bellows parameters and performance

The dimensions of the bellows specified in the drawings are for reference only. The Manufacturer shall ensure the parameters for the bellows are met as those specified in the drawings. The

Manufacturer shall provide the bellows data sheet according to the design calculations per Standard of the Expansion Joint Manufacturers Association (EJMA) 9th Edition. Number of convolutions are to be set by the Manufacturer in accordance with ASME or EJMA standard.

In order to meet these parameters, a bellows structure with two-layer or “Ω-profile” corrugation is acceptable. For the two-layer structure, two venting holes are required on the outer layer for preventing virtual leak, and they should be made at the last stage shortly before welding.

Bellows shall be hydroformed with an even pitch and height and have no cracks, holes, pits, dents, or other visible flaws that would render the bellows useless for cryogenic vacuum use. Circumferential welds joining one convolution to another are not permitted. All designs and values are subject to

Fermilab’s approval.

3.4 Vacuum integration and cleanliness

This Interconnect Kit will be used in a moderate to high vacuum service. Proper cleaning eliminates contamination to the vacuum space or leaks in the welds. Before any welding, all parts must be degreased with soap and water, followed by a thorough deionized water rinse. Parts shall be protected at all stages of fabrication for the cleanliness.

3.5 Welding

All welding process, inspection and testing of the cryogenic pipes must be in accordance to the ASME

B31.3 Process Piping code for Normal Fluid Service. All welders shall be qualified to the ASME BPVC section IX. The welding filler material for stainless-to-stainless joint shall be ER308.

Weldment must be free of dirt, grease, oil and chips. The Manufacturer shall ensure that no entrapped gases, fluxes, pits, cracks, or like imperfections are left in the heat affected zones. All fillet welds shall be smooth for cosmetic appearance. Post cleaning of welds with a wire brush only is acceptable (prior to final leak checking) and required to leave the surface in a bright finish condition with no trace of solvent residue.

3.6 Helium leak checking

All welds of the cryogenic piping shall be leak checked with a calibrated Helium Mass Spectrometer

Leak Detector (HMSLD). The leak test shall be carried out with the volume of the assembly unit being evacuated by a high vacuum pump and with a helium spray outside. No leak shall be detectable on the most sensitive scale of a helium leak detector with a minimum sensitivity of 1x10-9 mbarliter/sec. The leak detector calibration shall be checked daily with a calibrated leak before the measurements.

The Manufacturer shall provide flanges or end caps for leak checking. Bellows MUST BE properly restrained with the two connecting rods during leak checking to ensure no damage occurs to the bellows.

3.7 Liquid nitrogen cold shock

After the preliminary leak check, the cryogenic piping bellows weldments shall be cold shocked and followed by sequential helium leak checking. The cold shocking shall be carried out with the weldments immersed in a liquid nitrogen bath until the temperature of the part reaches liquid nitrogen temperature. Then take the parts out, warm to room temperature, and repeat for two more cold shocks. Afterwards, perform helium leak checking.

3.8 Pressure testing

The cryogenic piping bellows insertion shall be pressure tested consistent with a 20 bar MAWP.

Bellows MUST BE properly restrained during the pressure test to ensure no damage occurs to the bellows. The Manufacturer shall provide flanges or end caps for pressure testing.

4. BIDDING PROCEDURE

4.1 Pre-offer Discussions

The manufacturers are free to contact Fermilab and discuss details of the technical specification before making an offer. In particular, Fermilab wishes to ensure that no doubt exists as to the interpretation of this specification.

4.2 Alternative Solutions

If the manufacturer finds that any part of this specification is difficult, or costly to meet, he is free to propose an alternative solution, provided that the deviations from this specification, together with the reasons, are clearly indicated in the offer. Such alternative solutions shall always be made in addition to the basic offer. The basic offer shall comply fully with the original specification.

4.3 Subcontractors

In his offer, the manufacturer shall declare any sub-contractors he intends to use in the event of a contract.

5. MANUFACTURER FURNISHED MATERIALS AND SERVICES

The Manufacturer shall provide all materials, personnel and associated facilities necessary to fabricate, inspect and test the Interconnect kits. The Manufacturer shall provide the manufacturing engineering services to generate internal shop drawings and documentation needed to manage and support their suppliers. The Manufacturer shall fabricate jigs and fixtures to ensure all components are maintained to specified tolerances.

6. QUALITY ASSURANCE

The Manufacturer shall prepare a project specific Quality Assurance Plan, including the leak checking procedure, for Fermilab’s approval.

The Manufacturer shall maintain records of all inspections and tests. This information shall be made available for inspection to any Fermilab technical representative.

Fermilab reserves the right to have free access to the relevant manufacturing facilities, including any subcontractor’s premises, to have its technical representatives witness any manufacturing steps, tests, and inspections. Any information of a proprietary nature must be identified in the bid response. The parts will be inspected again and tested at SLAC prior to final acceptance.

7. PREPARATION FOR SHIPMENT

The Manufacturer shall ship the Interconnect Kits properly packed, to ensure that damage is not incurred during shipment. This shall include weather protection and the closure of all open pipes with protection caps. The bellows should be restrained to approximately their free length for shipping.

Packaging and shipping plan should be reviewed by Fermilab prior to shipment. All deliverables including documentations and loose items shall be catalogued for acceptance to SLAC at the time of

Interconnect Kits delivery. The package shall be prominently marked with the part number and revision level.

8. DOCUMENTATION

A project specific Quality Assurance Plan (QAP) must be provided within 4 weeks of contract award.

A production timeline that meets our delivery schedule for fabrication, starting from time of award running through F.O.B. shall be provided as part of the bid package. Following Fermilab’s approval of timeline and contract award, it is the responsibility of the Manufacturer to comply with the term of the contract and meet dates specified in the timeline.

Certified Mill Test Reports (CMTR) of all raw materials used to fabricate deliverables shall be provided upon Interconnect Kits delivery. These material certifications shall include all processes and tests with grade and composition being clearly identifiable. Copies of the travelers, inspection and test reports listed in Table 7 shall be provided to Fermilab or SLAC with delivery.

Table 7: Submittals that the Manufacturer shall supply to Fermilab or SLAC:

No. Description When required Approval

1 Project specific QAP Within 4 weeks of contract award Required

2 Production timeline Within 4 weeks of contract award Required

3 Welding procedure specification Within 4 weeks of contract award Required

4 Welding procedure qualification record Within 4 weeks of contract award Required

5 Welder performance qualification Within 4 weeks of contract award Required

6 Certificate of dimensional control Prior to delivery -

7 Leak checking reports Prior to delivery -

8 Packaging and shipping plan Prior to delivery -

9 CMTRs/travelers/inspections/test reports With delivery -

For submittals that require Fermilab’s approvals, the Manufacturer shall wait for the approval notice before continuing fabrication activities.