ED0043318 CMTF Power Supply Piping Installation Specification.pdf

PIP-II CMTF Power Supply Piping Installation Specification

Document number: ED0043318, Rev. A

Document Approval

Signatures Required Date Approved

Originators: Michael Hanson, Sr Fluids Engineer

Reviewer: Maurice Ball, BLDGI L3 Manager

Approver: Jerry Leibfritz, Linac Installation & Commissioning L2 Manager

Revision History

Revision Date of Release Description of Change

- June 2025 Initial Release for Review A July 2025 Revised to remove piping materials from scope

PIP-II CMTF Power Supply Piping Installation Specification, ED0043318

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Table of Contents

1 INTRODUCTION

2 SCOPE

3 ACRONYMS AND DEFINITIONS

3.1 Abbreviations

3.2 Organizational acronyms

3.3 Definitions

4 APPLICABLE CODES, DOCUMENTS, AND STANDARDS

4.1 General

4.2 List of Codes and Standards

5 GENERAL REQUIREMENTS

5.1 Design Pressures and Temperatures/Operating Conditions

6 MATERIALS

7 MATERIAL HANDLING/CLEANING

8 PIPE SUPPORTS

8.1 Structural Supports, Hangers, Brackets

9 CONSTRUCTION, FABRICATION, AND ASSEMBLY REQUIREMENTS

9.1 Welding

9.2 Inspection and Leak Testing

10 SUBCONTRACTOR DOCUMENTATION

10.1 Provided with offer

10.2 Provided prior to starting work

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1 INTRODUCTION

The Cryomodule Test Facility (CMTF) Power Supply Piping Installation will provide low conductivity water (LCW) to a set of five (5) radio frequency amplifiers as a part of the Proton

Improvement Plan II (PIP-II) Project. The piping system is located primarily on the mezzanine over the control room at the CMTF building and will connect with the existing LCW system there.

2 SCOPE

The scope for this installation specification is as follows:

• Installation of valves (supplied by FERMIFORWARD), instrumentation (supplied by

FERMIFORWARD) and all piping (supplied by FERMIFORWARD).

This document provides technical description for fabrication and installation of this new addition to the CMTF LCW System piping.

Along with general description and installation requirements, this specification includes the requirements for welding of stainless-steel piping and components. In addition to and/or reinforcement of the requirements of the Governing Code described below, this document specifies requirements and recommendations to ensure quality weld production. If conflicts arise between this specification and the Governing Code’s requirements, it SHALL be brought to the attention of the Fermilab engineering staff for evaluation.

3 ACRONYMS AND DEFINITIONS

3.1 Abbreviations

3.1.1 LCW – Low Conductivity Water

3.1.2 MAWP – Maximum Allowable Work Pressure

3.1.3 IPS – International Pipe Size

3.1.4 PQR – Procedure Qualification Record

3.1.5 WPQR – Welder Performance Qualification Record

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3.1.6 WPS – Welding Procedure Specification

3.1.7 NPT – National Pipe Thread

3.1.8 PSI – Pounds per Square Inch

3.1.9 PSIG – Pounds per Square Inch Gauge

3.1.10 P&ID – Process and Instrumentation Diagram

3.1.11 ES&H - Environment, Safety and Health

3.1.12 FESHM - Fermilab Environment, Safety and Health Manual

3.2 Organizational acronyms

3.2.1 ANSI – American National Standards Institute

3.2.2 ASCE – American Society of Civil Engineers

3.2.3 ASME – American Society of Mechanical Engineering

3.2.4 ASTM - American Society for Testing and Materials

3.2.5 ISO – International Organization for Standardization

3.2.6 UL – Underwriters Laboratory

3.3 Definitions

SUBCONTRACTOR

The piping contractor installing the PIPING system and all associated equipment

FF The buyer Fermi Forward Discovery Group, LLC

PIPING

The piping system defined within the scope this installation specification

CODE

A term used to refer collectively to the various pressure safety and other safety standards by which the DEVICE

SHALL comply

WPS Welding Procedure Specification

PQR Procedure Qualification Record

WPQ Welding Performance Qualification

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MAY

A term which indicates that a provision is neither required nor prohibited

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

4 APPLICABLE CODES, DOCUMENTS, AND STANDARDS

4.1 General

4.1.1 CAD INSTALLATION DOCUMENTS - The PIPING within the scope of this installation specification SHALL be built as shown on the following layout drawing documents:

▪ F10243791-LCW SUPPLY MANIFOLD, 650MHZ RF DISTRIBUTION ON

MEZZANINE, CMTF, PIP2

▪ F10243792-LCW RETURN MANIFOLD, 650MHZ RF DISTRIBUTION ON

MEZZANINE, CMTF, PIP2

Note: Many of the dimensions are shown as reference and field fitting may be necessary.

4.1.2 EQUIPMENT CUTSHEETS – FNAL shall provide cutsheets including installation instructions for all items purchased and supplied by FERMIFORWARD (valves, flowmeters, flow switches, pressure gages, etcetera). These will be provided for reference purposes only.

4.1.3 In the event of incompleteness, error or contradictions in FERMIFORWARD-supplied documents, drawings, or models, the SUBCONTRACTOR SHALL notify

FERMIFORWARD in writing to obtain directives.

4.1.4 In the event of contradictions between FERMIFORWARD supplied documents and governing code, FERMIFORWARD SHALL be informed at the earliest convenience and the problem SHALL be resolved in writing.

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4.1.5 If the SUBCONTRACTOR deems it necessary to observe additional governing codes and regulations, FERMIFORWARD SHALL be notified of this in writing.

FERMIFORWARD will notify the SUBCONTRACTOR in writing the outcome of this request.

4.1.6 The SYSTEM 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

4.2.1 The following list of codes in their latest edition, drawings and standards SHALL be applied to the engineering, design, fabrication, assembly and tests of the PIPING system and its components:

4.2.1.1 ASME B31.3 – Process Piping, Latest Edition

4.2.1.2 ASME B31.9 – Building Services Piping, Latest Edition

4.2.1.3 ASME Boiler and Pressure Vessel Code: Section VIII & IX, Latest Edition

4.2.1.4 AISC Manual of Steel Construction, Latest Edition

4.2.1.5 ASTM A380 Cleaning and De-scaling Stainless Steel Parts

4.2.1.6 FESHM 5031.1 Piping Systems

4.2.1.7 FESHM 5034 Pressure Vessel Testing

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5 GENERAL REQUIREMENTS

5.1 Design Pressures and Temperatures/Operating Conditions

5.1.1 Design conditions for LCW Piping system is as follows:

5.1.1.1 Design Pressure: 150 PSIG

5.1.1.2 Design Temperature: 200o F

5.1.1.3 Fluid: Clean filtered, low conductivity water

5.1.1.4 Temperature range: 60°F to 125°F; The Low Conductivity Water System will be considered a Category “D” Fluid Service when interpreting Code requirements

6 MATERIALS

6.1.1 All piping, fittings (tees, elbows, etc.), isolation valves, instrumentation, pipe hangers and hardware SHALL be supplied by the FERMI FORWARD.

6.1.2 All PIPING materials installed for this shall be:

▪ ASTM A312 Welded TP 304/304L SCH 40 for sizes 3/4” and under

▪ ASTM A312 Welded TP 304/304L SCH 10 for sizes 1” over.

▪ All socket welded fittings and o-lets shall be class 3000 ASTM A182

304/304L

▪ All butt-welded fittings shall be ASTM A403 WP304

6.1.3 The SUBCONTRACTOR SHALL supply all equipment, special tooling, scaffolding/manlifts, consumables, and perform all work and services necessary to fabricate, assemble, a fully functional PIPING suitable for long-term operation in accordance with this specification

6.1.4 Threaded fittings/joints SHALL be joined using both Loctite 7471 primer and

Loctite 569 thread sealant except where thread sealant could possibly foul operation of instrumentation (all gauges and sensors) where Teflon tape SHALL be used

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7 MATERIAL HANDLING/CLEANING

7.1.1 While handling PIPING, the SUBCONTRACTOR SHALL use only fabric slings. Use of chains or wire is not permitted.

7.1.2 It is the SUBCONTRACTOR's responsibility to maintain all PIPING sections, fittings and valves clean internally prior to installation and at every stage of installation.

7.1.3 No visible metal chip 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.

7.1.4 Weld spatter SHALL be removed by wire brushing using stainless steel brushes.

7.1.5 Cleaning agents SHALL be suitable for the material construction and will be neutralized if necessary. Any flammable materials use must meet the approval of

FRA.

7.1.6 During installation, open pipe ends SHALL be kept sealed with a cap, tape or equivalent material.

8 PIPE SUPPORTS

8.1 Structural Supports, Hangers, Brackets

8.1.1 LCW Piping SHALL be supported according to the attached installation drawings.

8.1.2 Weld joints SHALL avoid interfering with operation of any sliding or rolling points.

9 CONSTRUCTION, FABRICATION, AND ASSEMBLY REQUIREMENTS

9.1 Welding

9.1.1 All weld joint preparation and weld techniques SHALL be performed in accordance with Section VIII-Division 1 and IX of the ASME BPVC and/or Chapter V of the ASME

B31.3 code.

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9.1.2 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. Procedure Qualification Records (PQR) will be made available by the fabricator for approval by FERMIFORWARD before the welder begins work.

9.1.3 All welders must be qualified using an appropriate Welding Procedure

Specification (BPS).

9.1.4 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. Additionally, each welder will be required to weld one joint under the observation of a

FERMIFORWARD designated weld inspector. The welded joint must pass

FERMIFORWARD examination for the welder to be considered qualified.

9.1.5 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 this installation.

9.1.6 All welds SHALL be internally purged with welding quality argon gas during the time of welding and any post welding treatment.

9.1.7 The SUBCONTRACTOR SHALL supply and maintain in proper condition Argon gas purge oxygen monitor.

9.1.8 Welds that show evidence of a lack of proper purge SHALL not be accepted.

9.1.9 Joints will be brought to welding temperature in as short a time as possible without localized underheating or overheating.

9.1.10 The clearance between surfaces to be joined by welding SHALL be no larger than necessary to allow complete capillary distribution of the filler metal. Additionally, the material SHOULD be complete free of burrs.

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9.1.11 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.

9.1.12 Sensitive equipment (e.g. cable) must be protected from the heat by the use of heat blankets and shielding where possible.

9.1.13 Shielding will be used to prevent scorch marks on wall, cabinets, etc.

9.1.14 At the conclusion of each workday, the SUBCONTRACTOR SHALL provide and mount removable caps on all open piping ends to maintain cleanliness.

9.1.15 All external surfaces in the weld area will be left in a condition suitable for subsequent inspections (visual, bubble, or hydrostatic pressure tests).

9.1.16 The residual soot and/or scale will be removed by stainless steel wire brush or scouring pad.

9.2 Inspection and Leak Testing

9.2.1 Inspection

9.2.1.1 As stated in ASME B31.3 [p. 75, Ref. 7.1], not less than 5% of all welded joints will be examined by in-process examination.

9.2.1.2 The joints to be examined will be selected to ensure that the work of each welder making the production joints is included.

9.2.1.3 The joints to be examined will be selected to ensure that the work of each welder making the production joints is included.

9.2.1.4 Fit-up, joint clearance, and internal alignment prior to joining

9.2.1.5 Variables specified by the joining procedure, including filler material, position, flux, brazing temperature, proper wetting, and capillary action

9.2.1.6 Appearance of the finished joint

9.2.2 Testing

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9.2.2.1 All pressure testing of piping within the scope of this installation specification shall be performed according to FESHM 5031.1 Piping Systems and FESHM

5034 Pressure Vessel Testing

9.2.2.2 Pressure testing SHALL be performed under the oversight of Fermilab Test

Coordinator or designated Fermilab qualified person and witnessed by

Fermilab ES&H representative as required by FESHM 5034 Pressure Vessel

Testing

9.2.2.3 Preliminary Pneumatic Pressure Test

9.2.2.3.1 A low pressure preliminary test using compressed air at 12 PSIG SHALL be performed by the SUBCONTRACTOR prior to hydrostatic testing to locate major leaks by the SUBCONTRACTOR’s testing agency

9.2.2.3.2 A 15 PSIG pressure relief device and pressure gauges SHALL be installed directly to the system which SHALL be visible to the operator throughout the duration of the test.

9.2.2.3.3 The test pressure shall be maintained for not less than 2 hours. All joints and connections SHALL be examined for leaks using liquid leak detection solution (e.g. SNOOP®)

9.2.2.3.4 If leaks are found, the air pressure SHALL be vented from the piping system. The SUBCONTRACTOR SHALL be responsible for appropriate repairs and/or additions. The piping SHALL be retested via pneumatic test until no leakage is found or until waived by Fermilab Test Coordinator or

Fermilab qualified person.

9.2.2.4 Hydrostatic Pressure Test

9.2.2.4.1 In preparation for the Hydrostatic Pressure Test, the LCW piping system shall be filled with clean deionized water by the SUBCONTRACTOR.

9.2.2.4.2 The total volume of clean deionized water to be used is estimated at

10,000 Gallons.

9.2.2.4.3 A hydrostatic pressure test SHALL be performed according to ASME B31.3

– Process Piping, under the oversight of Fermilab Test Coordinator or designated Fermilab qualified person and witnessed by ES&H representative and according to Fermilab FESHM 5034 - Pressure Testing

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9.2.2.4.4 If leaks are found, the hydrostatic pressure SHALL be relieved from the piping system. The SUBCONTRACTOR SHALL be responsible for appropriate repairs and/or additions. The piping SHALL be retested via hydrostatic pressure test until no leakage is found or until waived by

Fermilab Test Coordinator or Fermilab qualified person.

9.2.2.5 Test Start-Up – Centrifugal Pump Operation and System Flow Commissioning

9.2.2.5.1 Upon successful completion and final acceptance of both Preliminary

Pneumatic Pressure Test and Hydrostatic Pressure Test, the

SUBCONTRACTOR shall witness the “bumping” of the LCW centrifugal pumps to ensure proper impeller rotation.

9.2.2.5.2 The piping system and valves will be configured for “Pump Room Only” closed loop circuit operation. The SUBCONTRACTOR shall witness centrifugal pump turn on and commissioning of “pump room” closed loop circuit operation.

10 SUBCONTRACTOR DOCUMENTATION

10.1 Provided with offer

10.1.1 The SUBCONTRACTOR SHALL furnish copies of the WPS utilized in welding operations on the piping system with the bid.

10.1.2 The SUBCONTRACTOR SHALL furnish copies of the PQR utilized in welding operations on the piping system with the bid.

10.2 Provided prior to starting work

10.2.1 The SUBCONTRACTOR SHALL furnish copies of the WPQ for each welder utilized in brazing operations on the piping system ten (10) working days prior to the start of welding.