ED0048302 - MLI SSR PROD CM - PROC AND FAB SPECS.pdf

MLI PROD SSR Cryomodule - Procurement & Fabrication Specifications

Document number: ED0048302

Document Approval

Signatures Required Date Approved

Author/Owner: V. Roger X

Reviewer: J. Bernardini Concurrence in TC

Approver: M. Parise Concurrence in TC

Revision History

Revision Date of Release Description of Change

- 06/11/2026 Initial Release.

PROD SSR2 Cryomodule

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Contents

1. Introduction

2. Scope

3. Alternative solutions

4. Procurement Specification

5. Technical management

6. Technical requirements

7. Quality assurance

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1. Introduction

1.1 PIP-II Project

The Proton Improvement Plan II, or PIP-II, is an essential enhancement to the Fermilab accelerator complex, powering the world’s most intense high-energy neutrino beam on its journey from Illinois to the Deep Underground Neutrino Experiment in South Dakota – a distance of 1,300 kilometers (800 miles). DUNE scientists will use neutrinos to answer some of the most profound questions about our universe. In addition, over the next 50 years, PIP-II will drive a broad physics research program, delivering scientific breakthroughs and likely to reveal surprising answers to questions that are not yet contemplated.

1.2 Subject of this Technical Specification

The present specification is intended to inform the procurement and fabrication of the MLI for the production SSR2 Cryomodules, in quantity indicated in Table 1. This specification concerns the Multi-Layer Insulation (MLI) blankets installed on the High Temperature Thermal Shield (HTTS) and on the cavities. The MLI consists essentially of 10 or 30 layers of superinsulation as specified on drawings.

Table 1: Quantities and Top Assembly Drawing Top Assembly Drawing Description Quantity

F10180804 MLI, SSR SIDE PORT COVER 3

F10180832 MLI, SSR2 TOP PORT 3

F10180833 MLI, SSR SIDE PORT 3

F10180834 MLI, SSR2 TOP PORT COVER 3

F10180835 MLI, SSR COLD MASS ENDS US 3

F10180836 MLI, SSR2 UPR COLDMASS 3

F10180837 MLI, SSR2 STRONGBACK ASSY 3

F10193321 MLI, SSR COLD MASS ENDS DS 3

F10221237 MLI SLEEVE, SSR VESSEL WINDOW 16

F10220260 INSULATION, SSR SSR SUPPORT POST TUBE 32

F10181697 MLI, SSR2 CAVITY 17

In order to ease the handling, the superinsulation will be composed of several blankets as specified in chapter

5.1. The MLI blankets will be prefabricated with a specified thickness.

The Manufacturer shall provide all materials necessary to fabricate complete deliverables. The Manufacturer shall provide manufacturing engineering services required to generate internal shop drawings and all documentation needed to manage and support their suppliers. The Manufacturer shall provide all labor to assemble, test, and supervise the manufacture of all components regardless of where these are made: within the manufacturer’s plant or in a second facility or sub-contractor. Any information of a proprietary nature must be identified in the bid response.

Delivered Duty Paid (DDP) Incoterm 2020 rules shall be applied as method of delivery.

2. Scope

The invitation to offer concerns the manufacture and delivery to Fermilab of MLI blankets. Step file of the MLI with the thermal shield and with the cavities will be provided.

The bidder is invited to submit an offer for the supply of materials as well as the manufacture of the MLI blankets as described in this specification.

The supply shall include:

• Detailed design of the MLI blankets (will be reviewed and approved by Fermilab before manufacturer proceed with procurement and fabrication)

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• The procurement of all necessary raw materials and components

• The manufacture of MLI blankets

• The establishment, implementation, and maintenance of a documented Quality Assurance Plan (QAP), fulfilling all the requirements of this specification, see chapter 6.

• The supply of all materials certifications and records of inspection, tests and measurements carried out within the scope of this specification, in a format agreed with Fermilab.

3. Alternative solutions

If the bidder finds that any part of this specification is difficult, or costly to meet, the bidder is free to propose an alternative solution, provided that the deviations from this specification, together with the reasons, are clearly indicated in the offer. Alternative solutions shall be submitted to Fermilab for final approval prior to the start of the production.

Such alternative solutions shall always be made in addition to the basic offer. The basic offer shall comply fully with the original specification.

4. Procurement Specification

The Purchase Order will be owned and managed by Fermi Forward Discovery Group (FFDG).

4.1 Bidding Phase

The bidder shall provide a Quotation including all costs to deliver the items indicated in Table 1. The quotation shall be itemized so that the cost associated with each subassembly listed in Table 1 is clearly identified. In addition to quotation, the following documentation shall be provided:

a) Schedule that meets a lead time of 12 months, starting from the date that the FFDG Purchase Order is awarded to the bidder running through fabrication. Shipping batches will be defined at the time of the kick off meeting. Supporting documentation, to demonstrate that the bidder will deliver within the specified timeframe, is required.

b) Technical Proposal to demonstrate the ability of the bidder to deliver the assembly with performance that meets or exceeds the specification requirements reported in this document. Examples of past projects (preferably within the last five years) that closely match the scope of this procurement in complexity and value, and that best illustrate the bidder’s capability, experience, and performance will be considered for the technical evaluation. The scope of this procurement includes sewing many Velcro and ensuring that all blanket interfaces are designed to avoid thermal shorts. Past projects shall highlight this.

c) Management Control Plan to demonstrate the ability to ensure the required quality standard (see section

7) throughout the entire performance of the project. Examples of documentation developed for past projects (preferably within the last five years) will be considered for the technical evaluation.

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

4.2 Technical and Cost Evaluation Phase

The FFDG Purchase Order will be awarded to one bidder after proposals will be evaluated by technical and cost evaluation teams.

4.3 Execution Phase

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

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Within two weeks from FFDG purchase order award, a kick-off meeting shall be carried out to initiate technical and commercial discussion between the technical and commercial representatives from FFDG and the Manufacturer. Action items from the meeting shall be addressed within one week.

Upon conclusion of the kick-off meeting, FFDG expects to receive bi-weekly a status report via e-mail (FFDG will provide a template) from the manufacturer. FFDG representatives are always available to respond any time if questions will arise.

5. Technical management

5.1 Contact person

The manufacturer shall assign a person to be responsible for the order and all contacts with Fermilab throughout the duration of the order.

5.2 Manufacturing program

The manufacturer shall submit to Fermilab within two weeks of notification of the order, a written program detailing the manufacturing, including hold points listed in Table 2.

Hold Point

Description Deliverables When required

A Kick-off Meeting

Address action items from the meeting

Within 2 weeks from FFDG purchase order award and before starting any Fabrication

/ Procurement

B

Manufacturing Readiness Review(s)

(MRR)

Manufacturing drawings Detailed Manufacturing and Inspection Plan (MIP) and

Travelers’ template Material certificates

Within 8 weeks from FFDG purchase order award and before starting any Fabrication

/ Procurement

C Shipping

Readiness Review

Final version of MIP Final version of Manufacturing Drawings

Discrepancy report(s) (If applicable) Final version of material certificates

Visual Inspection Reports Digital photos of the final products

Prior to final delivery

Table 2: Hold points and documentation deliverables

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

6. Technical requirements

6.1 MLI blanket design

• Using the .stp CAD file F10231731, manufacturer will design pre-made MLI blankets to cover the thermal shield. To ease the handling, the superinsulation will be composed of several blankets as described in Figure 1 (the upper part can be also composed of several blankets connected with Velcro). The blankets F10180804, F10180832, F10180833, F10180834, F10180835, F10180836, F10180837, F10193321, F10220260 shall have Velcro connecting them together.

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Figure 1: MLI over the thermal shield & G11 tube

Velcro needs to be sewed to F10220260 in order to be connected to the lower face of F10144593 and to F10180837 (Figure 2). Velcro shall be provided by the manufacturer in order for Fermilab to glue them on the blue ring F10144593. As specified on the drawing F10220260, the number of MLI layers is different at the bottom and top, such design is done to reduce the heat loads. The innermost layer of F10220260 shall be long enough to be connected with Velcro both to the blue ring – F10144593 (Figure 2) and to the innermost layer of F10180837.

Figure 2: Details about the interface in between F10220260 & F10180837

Upper part, F10180836

Lower part, F10180837

Top part, F10180832

Top part cover F10180834

Side part cover, F10180804

Side part, F10180833

Endcap part – Downstream, F10193321

Endcap part – Upstream, F10180835

G11 tube, F10220260

F10220260

F10180837

Blue ring - F10144593

5 layers

30 layers

Sleeve, F10221237

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Figure 3: Details of the Velcro connection

• F10221237 are not connected to any other blankets.

• Using the .stp CAD files F10181736, manufacturer will design pre-made MLI blankets to cover the cavities. To ease the handling, the superinsulation will be composed of 3 blankets.

SSR2 cavity with the MLI F10181697

Step file F10181736

The blankets shall have pre-cuts. The location and size of these pre-cuts can be determined using the .stp files and drawings. Fermilab drawings are for reference only. The manufacturer shall submit to Fermilab their own drawings for approval prior to proceed to manufacturing. The manufacturer shall ensure that the blankets have a low profile meaning that once assembled, the total thickness shall be no more than 10 mm thick for 30 layers.

The manufacturer shall submit manufacturing drawings for approval at the time of the MRR, as detailed in Table 2. Drawings shall include details about Velcro (position and number of connections) and schematics on how each blanket-to-blanket connection will be made.

The blankets shall have pre-cuts. The location and size of these pre-cuts can be determined using the .stp files and drawings. Fermilab drawings are for reference only. The manufacturer shall submit to Fermilab their own drawings for approval prior to proceed to manufacturing. The manufacturer shall ensure that the blankets have a low profile meaning that once assembled, the total thickness shall be no more than 10 mm thick for 30 layers.

The manufacturer shall submit manufacturing drawings for FFDG approval at the time of the MRR, as detailed in Table 2. Drawings shall include details about Velcro (position and number of connections) and schematics on how each blanket-to-blanket connection will be made.

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6.2 MLI blanket assembly

Blankets shall consist of “n” layers of reflective films, interleaved with “n-1” layers of spacers, where “n” is specified on applicable drawings accompanying this specification.

The reflective films and the spacers shall be assembled either by stitching using polyester thread and/or pin tags and/or by ultrasonic welding.

The outside layer of each blanket shall be protected by a microfiber glass net (e.g. Vitrulan®) or by a reinforced reflective film with a thickness of 12 µm to 25 µm, in order to ease its handling.

If the latter is used it must be aluminized on the outer surface of the blanket and perforated (see 5.3) and shall have an integrated spacer between this protective layer and the first reflector film.

The protective covering shall be fixed to the blankets by stitching.

For ease of mounting of the blankets, they shall be equipped with Velcro® fasteners made of polyamide (Nylon 6.6). The drawings introduce a baseline solution in which the Velcro® fastener is stitched to the edges of the blankets through the whole set of layers while not reducing the packing factor. The Velcro® fasteners shall be assembled on the cold inner side of the blankets when possible.

6.3 Perforation

The reflective films shall be perforated with open areas of minimum 0.05% and maximum 0.15% of their total area, to ease the evacuation of the MLI enclosed areas. The perforation holes should not be on the same position from one layer to another.

6.4 Material

The base material of the reflectors shall be polyester (polyethylene terephthalate PET) film aluminized 2 sides.

The base material of the spacers shall be polyester net (tulle) or microfiber glass fabric (eg Vitrulan) http://www.vitrulan.com/

7. Quality assurance

7.1 General

The manufacturer shall demonstrate the quality control is of a sufficient level. The manufacturer’s quality assurance system shall comply with the requirements of ISO 9001. Fermilab prefers that the contractor have a certification by an accredited institution.

The manufacturer must plan, establish, implement and maintain a documented quality assurance program that fulfills all the requirements described in this specification and drawn up according to his quality assurance system. In particular, the quality assurance program shall include :

• Contact person

• Manufacturing program

• Design approval

• Quality control of reflector material

• Quality control of spacer fabric

• Dimensional checking of MLI blankets

• Certificates and records

• Packing / release for dispatching

• Shipping to Fermilab

• Acceptance post-delivery http://www.vitrulan.com/

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7.2 Quality control

In particular, the manufacturer shall be responsible for the quality control of:

• The reflector material and, in particular, the cleanliness of the polyester film (corona treatment)

• The thickness of the aluminum (Al) coating and its adhesion to the film

• The spacer fabric (material properties, specific weight etc.)

• The dimensions of the assembled MLI blankets

7.3 Certificates of records

The manufacturer shall deliver the test certificates and records resulting from the quality control, carried out by either the subcontractors or the manufacturer. Each production should be certified to customer’s specification. All specified tests and measurements carried out during all stages of production, from raw material procurement up to delivery and installation, must be recorded in a specific file called the "traveler".

The certification is the responsibility of the manufacturer and shall accompany each blanket.

7.4 Applicable documents

In his offer the manufacturer shall give reference to any international, national or industrial standards or codes related to the trade and which the manufacturer and/or its subcontractors will apply for checking the performance of the equipment, in particular, with respect to the thickness and the adhesion of the aluminum (Al) coating on the reflective films (polyester film).

7.5 Handling during assembly

The blankets must be handled under clean conditions using clean cotton gloves such that they are protected from airborne pollution of any kind by a plastic sheet cover maintained in place until its installation is complete. No deposit, including fingerprints, on the aluminized surfaces will be accepted.

The manufacturer is required to protect each blanket against damage from 1) shipping, 2) self-weight compaction, 3) mineral contamination, and 4) weather.

7.6 Packing and transport to Fermilab

Each blanket should be independently wrapped in a plastic cover and label with Fermilab drawing ID. All blankets must be packaged such as to ensure that the MLI blankets are delivered without damage and any possible deterioration in performance due to transport conditions, and ensure safe and efficient handling, transport and delivery to Fermilab. Each box shall be equipped with humidity indicator, which is sufficient to prove that the relative humidity during the storage and the transportation at all time has not exceeded 65%.

7.7 Rejection of Materials for Non-Compliance with Specifications

Non-compliance with the specification contained in this document without a written waiver of the specification from the requisitioner or his representative having signature authority is cause for rejection of the materials for procurement.