ED0036972-PIP-II CDS Tunnel Warm Piping Installation SOW.pdf

PIP-II CDS Tunnel Warm Piping Installation

Statement of Work

Preparation Date: 13-Dec-2024

Date: 13-Dec-2024

Preparing Organization: APSTD-Cryogenics, PIP-II, FNAL

Document Number: ED0036972

ED0036972-PIP-II CDS Tunnel Warm Piping Installation Statement of Work

Fermi National Accelerator Laboratory 2

Document Approval

Signatures Required Date Approved

Originator: W. Soyars As in Teamcenter

Reviewer: A. Martinez As in Teamcenter

Reviewer: M. Geelhoed As in Teamcenter

Reviewer: M. Luedke As in Teamcenter

Reviewer: J. Nudell As in Teamcenter

Reviewer: C. Baffes As in Teamcenter

Reviewer: R. Dhuley As in Teamcenter

Approver: J. Leibfritz As in Teamcenter

Revision History

Revision Date of Release Description of Change

-- 12-16-2024 Initial Release

Document Reference

Reference number

Document Name Document number

1 CDS Warm Piping in Linac Tunnel F10177204 http://pip-ii-doc-4053/

Table of Contents

1 INTRODUCTION

1.1 Vent-to-Atmosphere

1.2 Helium Low Pressure Return (Helium LP Return) Header

1.3 High Pressure Helium Supply

2 ACRONYMS AND DEFINITIONS

2.1 Abbreviations

2.2 Definitions

3 DESCRIPTION OF WORK

3.1 General

3.2 Exceptions in the Assembly Drawings for PIPING installation work

3.3 Weld count estimates

4 APPLICABLE CODES AND STANDARDS

4.1 General

4.2 List of Codes and Standards

5 MATERIALS

6 GENERAL REQUIREMENTS

6.1 General

6.2 Summary of Responsibilities for Requirements

6.3 Work environment and Access Conditions

6.4 Safety Requirements

6.5 Design Pressures and Temperatures

6.6 Flexibility

6.7 Waste disposal

7 CONSTRUCTION, FABRICATION, AND ASSEMBLY REQUIREMENTS

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7.1 Welding

7.2 Cleaning

7.3 Flanged piping joint assemblies

7.4 Drilling, coring, and anchoring

8 QUALITY CONTROL AND TESTS

8.1 Installation requirements

8.2 Acceptance Tests

8.3 Quality Control Plan

9 VALVES

9.1 Valves

9.2 Labelling

10 PIPE SUPPORTS

10.1 General

10.2 Ceiling supports and anchors

10.3 Wall mounted supports

10.4 Temporary supports

11 TIME-PHASED WORK

11.1 Start and Completion Dates

11.2 General

11.3 Section 2: Tunnel - HWR/SSR1/SSR2 Section

11.4 Section 3: Tunnel – LB650 Section

11.5 Section 4: Tunnel – HB650 Section and downstream relief lines

12 ITEMS PROVIDED BY FFDG

12.1 Design documentation

12.2 Material and parts

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12.3 Supports

12.4 Logistics

12.5 Tunnel Field Conditions

13 SUBCONTRACTOR DOCUMENTATION

13.1 Provided to FFDG prior to starting work

13.2 Provided during installation

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1 INTRODUCTION

The Proton Improvement Plan-II (PIP-II) is Fermi National Accelerator Laboratory’s (FNAL) plan for providing powerful, high-intensity proton beams to the laboratory's research program which includes an 800 MeV superconducting linac. In support of this program, the PIP-II project requires a new cryogenic distribution system (CDS). The Warm Piping System of CDS will provide room temperature helium gas to the PIP-II accelerator as well as recover and transport cold helium gas from the accelerator following a pressure relief event. This specification provides the basis for the piping installation contract for a portion of the CDS Warm Piping System. The scope of this specification shall be limited to the CDS Warm Piping system located in the accelerator tunnel.

In this specification, the vendor of the piping contract services shall be referred to as the

SUBCONTRACTOR; Fermi Forward Discovery Group, LLC shall be referred to as FFDG; and the term PIPING will refer to the Tunnel portion of CDS Warm Piping. This document outlines the

SUBCONTRACTOR’s responsibilities and obligations necessary for completing the PIPING based on the requirements as set forth herein and provides the technical description for fabrication and installation of the PIPING system for the PIP-II project.

The piping system described in this specification will reside within the PIP-II Linac Tunnel, see

Figure 1-1 for solid model view of where the piping is located. There are three distinct process lines. Helium Low Pressure Return (Helium LP Return), Vent-to-Atmosphere Header, Helium High

Pressure Supply (Helium HP Supply). See Figure 1-2 for a simple illustration of the piping’s function.

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Figure 1-1. View of PIP-II Linac tunnel with warm piping.

Figure 1-2. Illustration of function of warm piping system

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Figure 1-3. Representative View of Tunnel Warm piping main section, 1 of 24 locations illustrated.

Figure 1-4 View of south end of PIPING.

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Figure 1-5 View of north end of PIPING.

1.1 Vent-to-Atmosphere

This is part of the relief pressure relief system. During worst case relieving event in linac, the

Vent-to-Atmosphere header transports cold helium gas from within the tunnel to the outside of the tunnel.

1.2 Helium Low Pressure Return (Helium LP Return) Header

During relieving events, the Helium LP Return delivers cold helium gas from within the tunnel to either be recovered by cryoplant system or relief outside via reliefs set at 6 psig. The Helium LP

Return header has additional function to deliver low pressure helium for maintaining purity of linac cryogenic systems that operate at sub-atmospheric conditions.

1.3 High Pressure Helium Supply

This header delivers room temperature high pressure helium gas (~250 psig), to the equipment in the linac tunnel. The warm helium gas is used in the linac for cryogenic system purification, and warmups and cooldowns of the linac sub-systems.

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2 ACRONYMS AND DEFINITIONS

2.1 Abbreviations

GTAW – Gas Tungsten Arc Welding

HA – Hazard Analysis

HP – High Pressure

LP – Low Pressure

LOTO – Lockout Tagout

PQR – Procedure Qualification Record

PPE – Personal Protective Equipment

WPQ – Welder Performance Qualification

WPS – Welding Procedure Specification

Organizational acronyms

ASME – American Society of Mechanical Engineering

ASTM – American Society for Testing and Materials

AISC – American Institute of Steel Construction

BPVC – Boiler Pressure Vessel Code

DOE – Department of Energy

FFDG – Fermi Research Alliance

Fermilab System Acronyms

ES&H – Environmental, Safety & Health

PIP-II – Proton Improvement Plan II

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2.2 Definitions

CODE

a term used to refer collectively to the various pressure safety and other safety standards by which the PIPING system shall comply

FFDG

Fermi National Accelerator Laboratory (Fermi Forward Discovery Group, LLC) may a term which indicates that a provision is neither required nor prohibited

PIPING the piping system defined here by this specification

PQR a Welding Procedure Qualification Record shall a term which indicates that a provision is a requirement should a term which indicates that a provision is recommended as good practice but is not a requirement

SUBCONTRACTOR the piping subcontractor installing the PIPING system

WPS a Welding procedure specification

WPQ a Welder Performance Qualification record

Upstream Equal to Project North. Upstream refers to the linac beam direction, counter to beam toward source

Downstream Equal to Project South. Downstream refers to the linac beam direction, with beam toward target

He helium

3 DESCRIPTION OF WORK

3.1 General

3.1.1 The SUBCONTRACTOR shall furnish all labor, tools, consumable items, and services necessary to install (handle, weld, fasten using nuts and bolts) the PIPING system in strict accordance with this specification.

3.1.2 The SUBCONTRACTOR shall provide documentation as specified in Section 0 of this specification.

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3.1.3 The PIPING shall be built as shown on the assembly drawings F10177204 – CDS

WARM PIPING, IN LINAC TUNNEL and associated subdrawings. The assembly design was completed for installation in a site currently under construction. Some dimensions are shown as reference, and field fitting shall occur. Consequently, the

SUBCONTRACTOR shall allow adequate time to perform field verification and field fitting.

3.1.4 The main portion of the piping, which consists of over 230 m of He HP Supply header, He LP Return header, and Vent-to-Atmosphere header, is illustrated in

Figure 3-1.

Figure 3-1. Representative section of the PIPING.

3.2 Exceptions in the Assembly Drawings for PIPING installation work

3.2.1 The assembly drawings are for the full, complete piping system. However, certain parts of the piping system with instrumentation and interfaces to future components will be installed later by FFDG.

3.2.2 The figures here in section 3.2 are for illustration only. Fabrication dimensions and details shall be taken from the indicated drawings.

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3.2.3 LP connect branches excluded from this PIPING installation is illustrated in Figure

3-2. This boundary will be marked on F10142875_BOUNDARY REFERENCE.pdf and

F10177365_BOUNDARY REFERENCE.pdf. A 2-inch pipe cap shall be welded at this boundary.

Figure 3-2. Excluded portion, LP branch connection for relief and guard, 1 of 25 locations.

3.2.4 HP supply branch excluded from this PIPING installation is illustrated in Figure 3-3.

This boundary will be marked on F10202904_BOUNDARY REFERENCE.pdf and

F10223548_BOUNDARY REFERENCE.pdf. A plastic pipe cover shall be placed on the ½” pipe opening.

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Figure 3-3. Excluded portion, Helium HP supply branch, 1 of 25 locations.

3.2.5 HP Supply branch at the turnaround excluded from this PIPING installation is illustrated in Figure 3-4. This boundary will be marked on F10145098_BOUNDARY

REFERENCE.pdf. A 1/2 inch blank off flange cap shall be installed at this boundary.

Figure 3-4 Excluded portion, Helium HP supply at turnaround, 1 location.

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3.2.6 For the 10-inch piping at far southern end of PIPING, subassemblies provided by

FFDG and excluded portion is illustrated in Figure 3-5. This boundary will be marked on F10228356_BOUNDARY REFERENCE.pdf and F10174816_BOUNDARY

REFERENCE.pdf.

Figure 3-5. Excluded portion, He LP Return 10” piping at southern end.

3.3 Weld count estimates.

3.3.1 An estimated number of welds by size and type for process piping are shown in

Table 3-1. Next, estimated welds by size and type for structural elements are shown in Table 3-2. These tables are intended only as an aid for estimation. The actual number of welds may vary during actual field installation. Drawings shall be reviewed for more detailed information.

Table 3-1 Sizes and Estimated Quantities of Welds: Process piping

Weld type Size Qty.

Pipe to pipe buttweld 10" 11

Pipe to pipe buttweld 8" 168

Pipe to pipe buttweld 4" 125

Pipe to pipe buttweld 2" 41

Pipe to pipe buttweld 1” 6

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Pipe to pipe buttweld 0.5” 182

Weldolet weld to pipe 2” 26

Weldolet weld to pipe 1” 2

Weldolet weld to pipe 0.5” 26

Table 3-2 Sizes and Estimated Quantities of Welds: Structural

Weld type Size Qty. Location

Linear fillet weld 3/16 fillet weld x 2” long 296 Unistrut to Ceiling plates at roller locations

Linear fillet weld 3/16 fillet weld x 14” long 48 Future Relief support pipe

Linear fillet weld 1/8 fillet weld x 3” long 96 Future Relief support unistrut

Linear fillet weld ¼” fillet skip weld, 1.75” – 3.5” x 12” long 96 Side plates to Ceiling plates and pipe at anchor location

Linear fillet weld 1/8” fillet skip weld, 1.75” – 3.5” x 12” long 96 Pipe reinforcement at anchors

4 APPLICABLE CODES AND STANDARDS

4.1 General

4.1.1 In the event of conflict between drawings and the written specification, the written specification shall be the governing document.

4.1.2 In the event of incompleteness, error or contradictions in FFDG-supplied documents or drawings, the SUBCONTRACTOR shall notify FFDG in writing at the earliest convenience to obtain directives.

4.1.3 If the SUBCONTRACTOR deems it necessary to observe additional governing codes and regulations, FFDG shall be notified of this in writing. FFDG shall notify the

SUBCONTRACTOR in writing of the outcome of this request.

4.1.4 The PIPING and its subcomponents shall be designed to comply with all applicable requirements of the CODE, documents and standards listed in this specification.

4.2 List of Codes and Standards

Health and safety applicable regulations

• 10 CFR 851 - DOE Worker Safety and Health Program

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• Illinois rules of the road apply at Fermilab Site

The following list of codes in their latest edition, drawings and standards shall be applied to the fabrication, assembly and testing of the PIPING system and its components:

• ASME B31.3 Process Piping

• ASME B31.9 Building Services Piping

• AISC Manual of Steel Construction

• ASTM A380 Cleaning and De-scaling Stainless Steel Parts

5 MATERIALS

5.1.1 FFDG shall provide all PIPING materials and hardware, for example: pipe, fittings, supports, expansion joints, flange bolting, flange gaskets, hardware for supports, etc.

5.1.2 All piping and PIPING components will be stainless steel (Type 304/L) or (Type

316/L).

5.1.3 The tunnel ceiling will have embedded structural carbon steel plates. These are used to provide support and anchoring of the 8” Vent-to-Atmosphere Header and the 8” (including a section of 10”) Helium LP Return Header. PIPING supports will be welded to this structure by the SUBCONTRACTOR as shown in F10177204.

5.1.3.1 At roller locations, carbon steel unistruts will be welded to the ceiling plate.

5.1.3.2 At anchor points, stainless steel plates will be welded to the ceiling plate.

5.1.4 All materials used in pressure containing piping components will conform to the required CODE material requirements for the appropriate fluid service category and operating temperature range.

5.1.5 All fittings, flanges, and blanks will conform to CODE requirements for the appropriate service category.

5.1.6 All piping will be provided in general lengths of 20 feet.

5.1.7 All piping, fittings and hardware will be staged at the job site for SUBCONTRACTOR use.

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5.1.8 From the time that the materials are released to the SUBCONTRACTOR until the final acceptance of the work is performed, all costs for the replacement of materials lost or damaged become the responsibility of the SUBCONTRACTOR.

5.1.9 Any excess material supplied by FFDG remains the property of FFDG and shall be returned upon completion of the work.

6 GENERAL REQUIREMENTS

6.1 General

6.1.1 The SUBCONTRACTOR shall supply all equipment, special tooling, consumables, and perform all work and services necessary to fabricate, assemble, a fully functional PIPING system suitable for long-term operation in accordance with this specification.

6.1.2 The SUBCONTRACTOR shall perform all drilling/coring of holes for piping penetrations of the Vent-to-Atmosphere and Helium LP Return headers at the north end of the tunnel. This allows PIPING weldment F10225877 (behind the wall in Figure 6-2) to be installed for interfacing the PIPING to the future surface piping.

Layout drawing F10232815 shows the location of required cored holes leading out of tunnel. This is show in model in Figure 6-2 and schematically in Figure 6-2. The wall is 24 inch thick concrete. See 7.4 for further requirements for Drilling and

Coring.

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Figure 6-1 Model showing core drilling locations at north end of tunnel.

Figure 6-2 Illustration of core drilled holes needed for piping penetrations at north end of tunnel. Layout fully defined in F10232815.

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6.1.3 At the south end of the tunnel, the PIPING connects to pipe runs that will be in place at the east wall. See Figure 6-3. No core drilling is required here as the interfacing piping will already be in place at the time of PIPING system installation.

Figure 6-3 Image of PIPING connection, south end of tunnel.

6.1.4 FFDG shall be available to perform in-process and/or radiographic weld inspections/examinations for CODE compliance.

6.1.4.1 FFDG shall be responsible for coordinating independent radiographic inspections and the cost for these services.

6.1.5 FFDG shall perform all pressure testing in coordination with the SUBCONTRACTOR per FFDG requirements.

6.1.6 The SUBCONTRACTOR shall repair any welds that fail inspections or qualification tests.

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6.1.7 The SUBCONTRACTOR may fabricate subassemblies at their home shop with FFDG written approval. It is the responsibility of the SUBCONTRACTOR to verify all field dimensions. When fabricating at their home shop, recognize that assembly design was completed for installation in a site currently under construction. Some dimensions are shown as reference, and field fitting shall occur. The

SUBCONTRACTOR shall allow FFDG representatives to visit the SUBCONTRACTOR home shop to inspect any work at their site. The SUBCONTRACTOR shall sign out all piping materials taken off the Fermilab site.

6.2 Summary of Responsibilities for Requirements.

6.2.1 See Table 6-1 Task Responsibilities Summary.

Table 6-1 Task Responsibilities Summary.

TASK OR ITEMS SUBCONTRACTOR FFDG

Purchasing of all materials for the PIPING system. X

Purchasing of all consumables including weld gas. X

Purchasing subassemblies comprising expansion joints (flex hoses at branch connection, axial bellows along main run) X

Purchasing of all support and anchor hardware. X

Assembling and installing supports X

Fabricating and installing PIPING as shown in drawings F10177204 and sub-drawings.

X

Coordinating independent radiography weld inspections for CODE compliance as required and the cost for such services.

X

Performing any in-process weld inspections for CODE compliance. X

Performing pressure testing. X

Repairing any welds that fail inspection or pressure tests. X

Drilling/coring holes in the tunnel walls as detailed in F10232815 for piping penetrations.

X

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Providing of man-lifts, scaffolding, other equipment to perform work at elevated heights, and lifts, cranes, and other equipment to deliver piping materials to elevated heights.

X

Providing mobile fall protection systems for persons working at elevation, if required.

X

Completing all required FFDG safety training. X

Fabricating instrumentation subassemblies and their installation.

(Not in scope of this specification, see 3.2) X

6.3 Work environment and Access Conditions

6.3.1 The PIPING installation work will be in an underground tunnel.

6.3.2 The PIPING installation work will be at elevated levels above the tunnel floor. The tunnel ceiling is 13.5 ft above the floor.

6.3.3 The PIPING installation area will be time-phased for access. The full tunnel length will be divided into three different sections for access. See Section 11 TIME

PHASED WORK for details.

6.3.4 At the time of PIPING installation at a given section, the tunnel will be mostly empty except for cable tray and utility infrastructure. The SUBCONTRACTOR will have priority access to all areas of the tunnel during installation. Other work may be going on nearby, but the PIPING installation work will take priority.

6.3.5 Cable trays will be installed prior to PIPING installation. The main North-South cable tray runs will not interfere with the PIPING work. However, there will be 29

East-West cable tray cross-overs that are expected to interfere with PIPING installation. See Figure 6-4. These cable trays are also shown in Figure 12-1. The

SUBCONTRACTOR shall remove these trays for PIPING installation. The

SUBCONTRACTOR shall re-install these trays at conclusion of the work.

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Figure 6-4 Cable tray cross-overs for removal and installation

6.4 Safety Requirements

6.4.1 SUBCONTRACTOR employees will be required to complete Fermilab General

Contractor Training. The SUBCONTRACTOR shall allocate one half day to complete the training.

6.4.2 The SUBCONTRACTOR shall provide proof of Fall Protection training and implement fall protection protocols as required.

6.4.3 The SUBCONTRACTOR shall submit a signed and dated Hazard Analysis (HA) for all scope including work at heights above 6 feet, which are required to meet the following criteria:

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6.4.3.1 If applicable, the SUBCONTRACTOR shall prioritize use of 100% fall protection systems that requires minimal user input (e.g., Self-Retracting Lifeline System

(SRL) connected to an attachment point approved by the form manufacturer) over dual lanyard systems. If dual lanyards are deemed the best equipment for the task, documentation of that analysis shall be reviewed and approved by

FFDG ES&H personnel.

6.4.3.2 Explicitly identified and documented acceptable tie-off points necessary for each element of work.

6.4.3.3 Fall protection rescue plans that have been crafted and are incorporated into the HA.

6.4.3.4 Daily inspection of Personal Protective Equipment and mechanical equipment.

6.4.3.5 Ensure the knowledgeable supervisor communicates the HA, both verbally and in writing, to all workers in a consistent manner. This is especially important for workers new to the PIP-II site.

6.4.3.6 Workplans and HAs will require a 3-day DOE review and approval before work may commence. FFDG subject matter expert (SME) reviews of the HA will also be required. The SUBCONTRACTOR shall allocate sufficient time for HA preparation and review.

6.4.4 For any work using SUBCONTRACTOR supplied equipment such as a scissor lift, articulating lift, etc., the SUBCONTRACTOR shall supply proof of training.

6.4.5 If required, FFDG shall provide a certified crane operator for use of building overhead cranes. The SUBCONTRACTOR shall not be authorized to operate the building overhead cranes.

6.4.6 For any work with a crane supplied by the SUBCONTRACTOR, the

SUBCONTRACTOR shall submit operator training records and lifting documentation to FFDG for approval.

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6.4.7 The SUBCONTRACTOR shall have proper PPE as outlined in the approved hazard analysis. Specifically, the use of safety helmets/hard hats will be required in situations that include but not limited to crawling under equipment, climbing ladders, exposed work with safety line, etc. The use of safety helmets shall be covered as PPE in the Hazard Analysis.

6.5 Design Pressures and Temperatures

6.5.1 The PIPING system design consists of design temperatures and pressures as presented in Error! Reference source not found..

Table 6-2 Process Piping Design Pressure and Temperature.

Circuit Circuit Description Design Pressure Minimum Design

Temperature

Helium HP Supply and its branches

Helium High Pressure Supply header and branches

23 barg 245 K

Helium LP Return

Helium Low Pressure Return header and branches

1 barg 20 K

Vent to Atm.

Header

Relief header 1 barg 20 K

6.6 Flexibility

6.6.1 The FFDG design in drawings F10177204 and sub-drawings allow for thermal contraction due to ambient and process temperature changes. Support, guide, and anchor positions are also shown on these drawings.

6.6.2 FFDG will provide supports, guides, and anchor hardware that supports and compensates for this motion.

6.7 Waste disposal

6.7.1 The SUBCONTRACTOR shall separate and dispose of waste separately:

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6.7.1.1 A general waste container will be made available by FFDG.

6.7.1.2 Disposal of discarded metal parts will be performed in a separate bulk container/pallet and will be managed by FFDG.

6.7.1.3 Hazardous substances shall be managed in a separate disposal area and managed by FFDG.

6.7.1.4 Upon demobilization, the SUBCONTRACTOR shall perform a site cleanup.

7 CONSTRUCTION, FABRICATION, AND ASSEMBLY REQUIREMENTS

7.1 Welding

7.1.1 All weld joint preparation and welding techniques shall be performed in accordance as required by Section VIII-Division 1 and IX of the ASME BPVC and/or

Chapter V of the ASME B31.3 code.

Table 7-1 ASME Piping Code Categories.

Circuit Piping Type Applicable ASME code Weld preparation and techniques

Helium HP Supply Compressor helium discharge B31.3 Normal Fluid Service B31.3 Chapter V

Helium LP Return Compressor helium suction B31.3 Normal Fluid Service B31.3 Chapter V

Vent to Atm. Header Vent-to-Atmosphere Relief header

B31.9 Building Services B31.9 Chapter V

7.1.2 The SUBCONTRACTOR shall conduct the tests required to provide a Procedure

Qualification Record (PQR) for each Welding Procedure Specification (WPS) as required by Section VIII-Division 1 and Section IX of the ASME BPVC and/or

Chapter V of the ASME B31.3 code.

7.1.3 The SUBCONTRACTOR shall conduct the tests required to qualify each welder to a

Welder Performance Qualification (WPQ) as required by Section VIII-Division 1 and

IX of the ASME BPVC and/or Chapter V of the ASME B31.3 code.

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7.1.4 The SUBCONTRACTOR shall maintain records in accordance with paragraph UW-

48 Section VIII-Division 1 of the ASME BPVC for all welders and welding operators working on the PIPING system.

7.1.5 All stainless-steel welding performed on piping shall utilize the Gas Tungsten Arc

Weld (GTAW) process using weld quality argon gas for the inert shield. Carbon steel welding shall utilize any process selected by the SUBCONRACTOR that meets

Code requirements.

7.1.6 All stainless-steel welds shall be internally purged with weld quality argon gas during the time of welding and post welding treatment. Oxygen levels shall be less than 1% as read by a TOPAC oxygen meter or equivalent.

7.1.7 Stainless-steel welds that show evidence of a lack of purge will not be accepted and shall be repaired by the SUBCONTRACTOR.

7.1.8 All welding shall be performed in such a manner that the weld surface is smooth and free of irregularities. No visible metal chips or foreign material shall be detectable within any component of the PIPING system. All external surfaces in the weld area shall be cleaned of heat tint, slag, and other deposits. No mechanical process shall be used to achieve a smooth appearance.

7.1.9 No production welding shall be performed on the PIPING system until all WPS, PQR, and WPQ documents have been qualified in accordance with ASME BPVC

Section VIII-Division 1 paragraphs UW-28 and UW-29 and Section IX of the ASME

BPVC and submitted to and approved by FFDG.

7.1.10 The SUBCONTRACTOR shall supply weld maps which identify each weld and name of welder performing the weld. This applies to piping covered by B31.3.

7.1.11 At the conclusion of each workday, the SUBCONTRACTOR shall attach removable caps on all open piping ends to maintain cleanliness. FFDG shall provide the removable caps.

7.1.12 Acceptance tests

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• Random radiographic examination according to the CODE for 5% of all butt welds shall be coordinated by FFDG using an independent subcontractor.

It is the SUBCONTRACTOR’S responsibility to repair any welds that fail a radiographic exam.

• If a weld fails radiography, it is the SUBCONTRACTOR’S responsibility for costs incurred for any subsequent radiographic examinations required by the CODE. This includes radiographic examination of additional welds due to the progressive sampling clause of the CODE. All radiographic examinations shall be coordinated by FFDG.

• In-Process Inspection according to the CODE may be substituted for radiographic examination at the discretion of FFDG. The SUCONTRACTOR shall allow access to FFDG to perform In-Process Inspection as required.

7.2 Cleaning

7.2.1 FFDG shall provide initially clean piping material and components. It is the responsibility of the SUBCONTRACTOR to maintain this cleanliness throughout the fabrication process, as described below:

• Cleaning agents shall be suitable for the materials of construction and shall be neutralized if necessary.

• Each assembly shall be cleaned to provide an inner surface of all pipes and tubes free of grease, flux, moisture, dirt, and other foreign materials by vapor degreasing or suitable wash. Surfaces shall be visibly inspected and wiped down with a white cloth. To be considered free of contamination, no discoloration shall appear on the white cloth.

• After cleaning, each section shall be blown dry with clean dry air until no visual moisture remains.

7.2.2 All pipe sections, fittings and valves shall remain clean internally at every stage of installation by the SUBCONTRACTOR. No visible metal chips or foreign material shall be allowed to remain inside any component of the piping system including, but not limited to, scale, spatter, flux, and grease. At the end of each shift, open pipe ends shall be kept sealed with a cap, tape, or equivalent material.

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7.2.3 Weld spatter shall be removed by wire brushing using only stainless-steel brushes.

7.2.4 The SUBCONTRACTOR shall ensure all piping, fittings, and component interiors stay clean and dry while awaiting installation.

7.3 Flanged piping joint assemblies

7.3.1 The SUBCONTRACTOR shall treat all flanged assembly sealing faces carefully and is responsible for any scratches or damage that cause leaks.

7.3.2 Special flanges such as CF flanges and double o-ring machined flanges may be expected at certain interfaces. At the work start milestone, the SUBCONTRACTOR shall receive instructions on how to prepare and fasten the specific connections.

7.3.3 Copper-based anti-seize LOCTITE LB 8065 shall be used in the interface between stainless steel bolts and nuts and shall be provided by the FFDG.

7.4 Drilling, coring, and anchoring

7.4.1 The SUBCONTRACTOR shall perform any concrete drilling and coring operations with the precautions specified in FESHM 4195 Special Toxic Hazards – Silica including but not limited to worker respiratory protection and dust management via wet slurry or HEPA vacuums.

8 QUALITY CONTROL AND TESTS

8.1 Installation requirements

8.1.1 During installation, FFDG will perform spot checks to verify the PIPING complies with 7.2 cleanliness requirements. The SUBCONTRACTOR shall correct any cleanliness non-conformities before finalizing the affected piping circuit.

8.2 Acceptance Tests

8.2.1 Random radiographic examination according to the CODE shall be coordinated by

FFDG using an independent subcontractor. It is the SUBCONTRACTOR’s responsibility to repair any welds that fail a radiographic exam.

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8.2.2 All piping pressure tests shall be done by FFDG. Tests will be conducted in accordance with Fermilab ES&H requirements.

8.2.3 The PIPING system shall be pneumatically tested with nitrogen gas at the following pressures, see Table 8-1.

Table 8-1. Process Piping Pressure Tests.

Circuit Description Design Pressure

[bara]

Test Pressure

[bara] Test Type

Helium HP Supply 24 26.4 Pneumatic pressure test

Helium LP Return 2 2.1 Leak test

Vent to Atm. Header 2 NA NA

* Soap bubble solution test at low pressure # Soap bubble solution test at design pressure

8.2.4 All joints shall show no indication of any gas leak when tested with a soap bubble solution (LEAK-TEC or equivalent).

8.2.5 The SUBCONTRACTOR shall be responsible for repairing any leaks or failed radiographically examined welds.

8.3 Quality Control Plan

8.3.1 The SUBCONTRACTOR shall develop a Quality Control (QC) Plan for review by FFDG prior to the start of installation. The quality control plan shall include:

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8.3.1.1 Description of equipment and testing/inspection methods planned to ensure requirements outlined in this SOW are met.

8.3.1.2 Description of documentation planned to communicate contract conformance to FFDG.

8.3.1.3 Description of nonconformance management process to be used.

8.3.1.4 Applicable training/qualifications required.

8.3.1.5 Description of receiving inspections and how cleanliness will be maintained for

FFDG provided components.

8.3.2 The Quality Control Plan information should be presented at the Kickoff Meeting at the start of the contract. The information shall be presented prior to the start of installation work.

9 VALVES

9.1 Valves

9.1.1 Manual valves are defined in the Parts List for drawings listed below. Valves shall be provided by FFDG and installed by the SUBCONTRACTOR. Subassemblies using manual valves are:

9.1.1.1 He HP Supply, south end: F10228356.

9.1.1.2 He HP Supply, branches: F10175088, F1016667 and F10224104.

9.1.2 The SUBCONTRACTOR shall take appropriate precautions when welding near valves to prevent overheating of valve seals. The SUBCONTRACTOR shall follow the manufacturer instructions to protect the valve internal parts from welding damage.

9.2 Labelling

9.2.1 FFDG is responsible for final labelling of valves.

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10 PIPE SUPPORTS

10.1 General

10.1.1 FFDG shall supply pipe support materials, i.e., clevises and lengths of threaded rod, Unistrut pieces, roller hangers, etc.

10.1.2 The SUBCONTRACTOR shall install all the pipe supports and make welded or bolted connections to tunnel building interfaces as detailed in 10.1.3.

10.1.3 Specific support and anchoring details are shown on drawings F10177204.

Anchoring locations are shown on drawing F10177232 and sub-drawings.

10.1.4 Pipe welds shall be located to avoid interfering with the operation of any sliding or rolling points.

10.2 Ceiling supports and anchors.

10.2.1 Embedded plates in the tunnel ceiling are used for supporting the 8 inch LP Return and Vent piping at key locations where these lines will interface with other linac cryogenic systems. These either provide fixed support or roller support for the piping. Schematically, fixed (F) and roller (F) support locations are shown in Figure

10-1. There are 12 fixed ceiling plate locations and 16 roller ceiling plate locations.

Figure 10-1 Schematic of 8 inch pipe support style (Fixed or Roller) from embedded ceiling plates

10.2.2 The welding for supports at the embedded plates involves welding stainless steel pieces (Unistrut and vertical side plates) to carbon steel (embedded ceiling plate).

Some of the installed, embedded plates is shown in Figure 10-2. The plates are 48 inches x 42 inches.

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Figure 10-2 Embedded plate in ceiling of linac tunnel.

10.2.1 An illustration of the PIPING with the structural welds at the embedded ceiling plates is shown in Figure 10-3.

Figure 10-3. A view of locations with structural welds to the ceiling plates

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10.3 Wall mounted supports

10.3.1 The 2” HP supply will be supported from Unistrut braces mounted into wall-embedded Unistrut channels.

Figure 10-4 Supports for 2" HP Helium line

10.4 Temporary supports

10.4.1 Temporary supports, such as pipe stands, shall be provided for the HP branch lines at 26 locations. The pipe stands will be provided by FFDG.

11 TIME-PHASED WORK

11.1 Start and Completion Dates

The piping work is separated into three sections based on the availability of the components, interfacing systems, and physical facility envelope. The SUBCONTRACTOR may combine and coordinate work in multiple sections or may work in a single section as conditions permit. The sections do not necessarily need to be installed in numerical order. The s descriptions and start constraints for each section of the machine is given in

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11.1.1 Table 11-1:

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Table 11-1. Tunnel Warm Piping Sections Time phased work description

Section Start Constraint Comments

1: Tunnel Warm

Piping-

HWR/SSR1/SSR2

Section

Conventional Facility

Tunnel Handoff (to column line L18) +1 month

Interfaces for 10 cryomodules

2: Tunnel Warm

Piping – LB650

Section

Conventional Facility

Tunnel Handoff (to column line L26) +1 month

Interfaces for 9 cryomodules

3: Tunnel Warm

Piping – HB650

Section and downstream relief lines

Conventional Facility

Tunnel Handoff (to end of

Linac Tunnel) +1 month

Interfaces for 6 cryomodules + turnaround can, downstream relief runs

Figure 11-1 Warm Piping Sections

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Figure 11-2 Work Areas for Warm Piping Sections

11.2 General

11.2.1 The main components of the tunnel warm piping system consist of the following:

• Warm piping 8 inch headers o Vent-to-Atmosphere o Low Pressure Return o Helium low pressure guard and relief collector, branch connections.

• Helium high pressure supply o 2 inch header o GHe supply, branch connections.

• Piping supports.

11.2.2 All parts are expected to be available at the start of the contract.

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11.3 Section 2: Tunnel - HWR/SSR1/SSR2 Section

11.3.1 In F10177232 for LP He Return and Vent Piping, this is Section A-D.

11.3.2 In F10177347 for HP He Supply, this is section A-F.

11.3.3 See Figure 11-2 for the areas available for installation in Phase 2.

11.4 Section 3: Tunnel – LB650 Section

11.4.1 In F10177232 for LP He Return and Vent Piping, this is Section D-G.

11.4.2 In F10177347 for HP He Supply, this is section G-L.

11.4.3 See Figure 11-2 for the areas available for installation in Phase 3.

11.5 Section 4: Tunnel – HB650 Section and downstream relief lines

11.5.1 In F10177232 for LP He Return and Vent Piping, this is Section G-N.

11.5.2 In F10177347 for HP He Supply, this is section M-V.

11.5.3 See Figure 11-2 for the areas available for installation in Phase 3.

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12 ITEMS PROVIDED BY FFDG

12.1 Design documentation

• Piping assembly drawing pdf for F10177204, supporting sub-drawings.

• 3D model in STEP format upon request

12.2 Material and parts

• Stainless steel pipe for helium lines in 20 ft. sections in appropriate sizes

• Flanges, fittings, fasteners, gaskets, valves, expansion joint assemblies, etc.

• Hand valves

• Solenoid valves (excluded from this installation specification)

• Pressure indicators and transducers (excluded from this installation specification)

• Flexhoses

• Axial bellows

12.3 Supports

Supports supplied by FFDG, installed by SUBCONTRACTOR

• Clevises and threaded rods

• Roller supports and threaded rods

• Unistrut in standard lengths (to be cut by the SUBCONTRACTOR as needed)

• Miscellaneous support hardware including stainless-steel plates, nuts, bolts, and washers.

• Plates for anchor locations.

• Temporary Pipe stands for HP He branches at conclusion of project (see Error! R eference source not found.)

Supporting elements installed by FFDG

• Carbon steel plates embedded in the tunnel ceiling at predetermined locations

• Unistrut channels embedded in the tunnel ceiling at predetermined locations

• Unistrut channels embedded in the tunnel ceiling at predetermined locations

• Unistrut channels embedded in the east wall at predetermined locations

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12.4 Logistics

FFDG will provide access to the following equipment and areas:

• Exterior material lay-down area (as requested by SUBCONTRACTOR)

• Loading dock at High Bay Building

• Work area adjacent to Warm Piping installation footprint

• AC power (utility 120VAC, welding 480VAC 3ph) in interior (Section 2, 3, 4) work areas.

AC power is NOT provided in exterior areas of Section 1.

12.5 Tunnel Field Conditions

While the work of this subcontract is ongoing, the SUBCONTRACTOR will have priority but NON-

EXCLUSIVE access to the work areas. The SUBCONTRACTOR shall:

• Preserve safe aisleways for the transport of personnel and materials through the work area

• Implement appropriate protective equipment (e.g. weld screens) to protect personnel transiting through the work area or in adjacent areas

• Notify Fermilab Task Manager in advance of any need for more stringent access restrictions (e.g. exclusion of personnel from the work area during critical equipment lifts)

• Make reasonable accommodations for other nearby work

This work will occur early in the installation of the PIP-II accelerator, and before the majority of other technical equipment installation. Cable trays, water and air piping, and AC electrical distribution systems will be installed, as shown in representative Figure 12-1.

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Figure 12-1. Representative Tunnel condition at start of Warm Piping installation work

13 SUBCONTRACTOR DOCUMENTATION

13.1 Provided to FFDG prior to starting work

13.1.1 This is defined in document 010010_General Requirements.

13.2 Provided during installation

13.2.1 For consumable items such as weld rods, electrodes, and fasteners, certificates of compliance shall be supplied.

13.2.2 Weld maps as required in section 7.1.10.