Enclosure (1) Draft Contract 459871.pdf

Enclosure 1

Draft Contract 459871

BSA’s Contractual Representative

Overall Value Amount

Contract Type Contract Number

Ben Furlow $TBD Firm Fixed Price 459871

BROOKHAVEN NATIONAL LABORATORY

Brookhaven Science Associates

P.O. Box 5000

UPTON, L.I., N.Y. 11973-5000

Name and Address of Contractor

CONTRACT

This Contract (the "Contract") is between the party named above (the "Contractor"), and Brookhaven Science Associates, LLC. ("BSA"), the latter acting under Prime Contract with the United States of America (the "Government") represented by the United States Department of Energy ("DOE”).

I. SCOPE OF WORK

The Contractor shall be responsible for the manufacture, assembly, tuning, testing inspection and delivery, of the Collider Accelerator AGS Quad and Sextupole power supplies in accordance with Attachment (A) Brookhaven National Laboratory (BNL) Collider Accelerator Department Statement of Work (SOW), D15-E450, Revision D dated 12/24/2024, Attachment (B), Brookhaven National Laboratory Collider Accelerator Department Technical Specification for the New AGS Quad and Sextupole Power Supplies, CAD1370, Revision D, dated 12/24/2024, and Attachments (C) and (D) all incorporated herein.

A. Reports/Deliverables: The Contractor shall provide the deliverables noted in Section 6 of the referenced SOW.

B. Key Personnel

The personnel listed below are considered essential to the work being performed under this contract. Before removing, replacing, or diverting any of the listed personnel, the Contractor must: (1) Notify BSA’s contractual representative in writing; (2) submit justification (including proposed substitutions) in sufficient detail to permit evaluation of the impact on this contract; and (3) obtain BSA’s written approval.

The following individual(s) have been designated as “Key Personnel”:

Project Manager:

BSA retains the right to require removal of contractor personnel whose actions, while assigned to this contract, clearly conflict with BSA’s interests. The reason for removal shall be fully documented in writing by BSA. When such removal occurs, BSA and the Contractor shall mutually agree upon an expedient timeframe for assigning qualified replacement personnel to the resulting vacancy.

The list of personnel may, with the consent of the contracting parties, be amended from time to time during the course of the contract to add or delete personnel.

II. PERIOD OF PERFORMANCE:

This Contract shall be effective as of the date executed by BSA provided that the Contractor executes the Contract without exception or alteration. Delivery of all items shall be no later than 32 weeks after receipt of order (Actual date will be added here at time of Contract award).

III. FIRM FIXED PRICE AND PAYMENT:

A. Firm Fixed Price: In full consideration of the Contractor's performance hereunder BSA shall pay the Contractor the firm fixed price of TBD US Dollars ($00.00). The said sum shall constitute full compensation for all services and materials furnished hereunder.

B. Payment: Payment will be made upon receipt and approval of properly certified invoices.

Payment will be in accordance with the following milestone payment schedule:

Milestone Amount

Manufacturing/Inspection Plan $TBD

Final Design Report $TBD

Contractor Performed Acceptance Tests Complete – 1st Article $TBD

Delivery of Power Supply and End Item Documentation Package $TBD

TOTAL PRICE $__________

Payment terms are Net 30.

Invoices shall be directed to BSA’s Accounts Payable Section via electronic or regular mail.

Electronic invoice submittal is preferred by BSA. The Contractor shall make every effort to have systems in place that allow for electronic invoice transmittal. Invoices shall be submitted in PDF format, via e-mail, to apinvoices@bnl.gov .

Hard copy invoices, in duplicate, shall be directed to BSA's Accounts Payable Section, Contracts Division, Bldg. No. 400D.

The Contractor shall indicate the final invoice by clearly marking such invoice as "FINAL".

A copy of the final invoice must be submitted to BSA’s Contractual Representative.

C. Freight: Freight terms shall be FOB Destination Freight Prepaid, “DAP” Delivered At Place, Brookhaven National Laboratory, 98 Rochester Street, Upton, Long Island, New York.

mailto:apinvoices@bnl.gov

D. Labelling, Packing, and Notification Requirements:

More detailed instructions are available at https://www.bnl.gov/shipping/ or by emailing WarehouseOperations@bnl.gov.

Labeling Requirements

All shipments must comply with the following labelling requirements. Failure to do so may result in delayed payments. Labels must be placed on the upper left portion of the container when possible and contain:

Brookhaven National Laboratory Brookhaven’s Contract Number 98 Rochester St.

Upton, NY 11973 Box Number / Number of Boxes

Packing List Requirements

Every shipping container must include a packing list. The packing list must be clearly identified and affixed to a side of the shipping container. At a minimum, the packing list should contain the following information:

• Ship from company name and address

• Supplier contact name

• Supplier telephone number

• Ship to address as instructed by Buyer/Contracts Specialist

• Brookhaven’s Contract number

• Part number, description, quantity, unit of measure, and corresponding BNL Contract line number

Special Notification of Delivery

If a shipment is heavier than 3,000 lbs., longer than 8 feet in any direction, or has a high center of gravity, it will require rigging upon receipt and the shipper shall provide a minimum of 3 days’ advance notice of delivery to BNL’s Receiving Department via email to WarehouseOperations@bnl.gov. The shipper must obtain acknowledgement from BNL that delivery notification was received. Failure to contact BNL will result in delays during delivery and any resulting demurrage will be at the shipper’s expense.

Marking of Outer Package

Each shipping container (transport package) with a gross weight equal to or greater than 400 lbs. (180 kilograms) must be marked with the center of gravity location and gross weight on at least one side or end panel. It must also meet the requirements of the latest revision of ASTM Standard D 3951, Standard Practice for Commercial Packaging. This applies to any item shipped (originally packaged or repackaged) to BNL or other locations cited in the Contract.

https://www.bnl.gov/shipping/ mailto:WarehouseOperations@bnl.gov mailto:WarehouseOperations@bnl.gov https://www.astm.org/Standards/D3951.htm

Protection of Material and Equipment

The Contractor shall employ procedures which ensure adequate protection of material and equipment during shipment and while in storage. Such protection shall include special environmental packaging as necessary. All items shipped (originally packaged or repackaged) to BNL or other locations cited in the PO or Contract shall comply with the requirements for preservation, packaging, and marking as stated in the latest revision of ASTM Standard D 3951-10, Standard Practice for Commercial Packaging.

Unacceptable Packing Material

Do not use vermiculite as a packaging material inside any shipments to BNL unless required by shipping regulation. “Vermiculite” as defined in this specification means the hydrous, silicate mineral classified as a phyllosilicate that has been expanded by heating. Vermiculite used as a packaging material in shipments must be determined to be free of asbestos (<1% chrysolite, amosite, crocidolite, tremolite, anthophyllite, and actinolite). All shipments containing vermiculite must be accompanied by documentation stating that the vermiculite used is certified asbestos-free. This documentation must be affixed to the outside of the package.

Radioactive Shipments

Shipments to Brookhaven National Laboratory (BNL) containing radioactive material require pre-authorization prior to shipment. Contact the following staff in the Packaging & Transportation Group for instructions:

• Brett Fagan, Ext. 5645, bfagan@bnl.gov

• Kenneth Hansen, khansen2@bnl.gov

• Steven Woodburn, Ext. 3271, woodburn@bnl.gov

Ocean Shipments

Foreign shipments transported via ocean freight must use the 10+2 REQUIREMENTS Form (PDF). The form must be completed by the Contractor 72 hours before departure of the vessel. Send form to the following:

Interfreight Harmonized Logistics, Inc.

Fax: 516-371-6880 bnl@interfreight.net

Brookhaven National Laboratory WarehouseOperations@bnl.gov

Once the form is submitted to customs, an acceptance number will be provided. Freight will not be loaded onto a vessel without an acceptance number. Failure to submit the 10+2 form may result in fines. It is the Contractor's responsibility to make sure the 10+2 form is submitted 72 hours prior to the vessel sailing. BSA shall withhold payment from the Contractor's final invoice for any penalties incurred by BSA due to late or incorrect ISF filing by the Contractor.

https://www.astm.org/Standards/D3951.htm mailto:bfagan@bnl.gov mailto:khansen2@bnl.gov mailto:woodburn@bnl.gov https://www.bnl.gov/shipping/files/pdf/10-2-security-filing-bnl-interfreight.pdf mailto:bnl@interfreight.net mailto:WarehouseOperations@bnl.gov

IV. AUTHORIZED REPRESENTATIVES

A. BSA’s Technical Representative: XXXX of the Collider Accelerator department is BSA's

Technical Representative, hereunder. He shall act as liaison between BSA and the Contractor in technical matters only. He can be reached at XXX-XXX-XXXX (phone), (e-mail).

B. BSA’s Contractual Representative: Ben Furlow, telephone no. (631) 344-4070 bfurlow@bnl.gov (e-mail), is BSA's Contractual Representative. Any change or modification in the terms and conditions of this contract shall require the written approval of BSA's Procurement and Property Management Division’s Manager, or his designee.

C. Contractor’s Technical Representative: ________is the Contractor’s authorized Technical

Representative, hereunder. She/He shall act as point of contact between BSA and the Contractor in technical matters only. She/He can be reached at _______ (phone), _______ (e-mail).

E. Contractor’s Contractual Representative: _________ is the Contractor’s authorized

Contractual Representative, hereunder. She/He shall act as liaison between BSA and the Contractor. He can be reached at _______ (phone), _______________(e-mail).

V. PATENT CERTIFICATION

Upon contract expiration and completion of all work authorized under this contract, the Contractor shall complete and execute the Attachment (D) “Patent Certification” clearance form and forward it to the Contractual Representative. Failure to do so may result in the withholding of final payment or a portion thereof.

VI. GOVERNMENT PROPERTY

The Contractor shall submit a copy of its procedures for control of Government Property to the BSA Contractual Representative within 30 days after receipt of this Contract.

In support of the Contractor’s work hereunder, BSA has provided to the Contractor on a temporary basis the following Government Owned Property/Government Furnished Material:

- Power Supply Interface (PSI), Qty-1 Serial #0176, A-Tag #A80378

- Power Supply Controller (PSC) test box which will interface the PSIs to the Contractor’s computer through a USB port, Qty-1 A-Tag #A144639, no serial #

- Fiber optic cables to connect the PSIs and test box, Qty-1 *No serial numbers or property tags

- USB cable to connect the PSC to the Contractor-owned laptop, Qty-1 *No serial numbers or property tags

- Software to control the test box, PSC, and log data, Qty – 1 CD mailto:bfurlow@bnl.gov mailto:bodo.fritsche@ampegon.com

*No serial numbers or property tags

The Contractor shall maintain adequate property controls in accordance with the Article entitled, “Government Property” of the General Terms and Conditions of this Contract. At the conclusion of this Contract, the Contractor shall return any/all Government Property within 30 days.

VII. ADDITIONAL TERMS

The provisions of Brookhaven Science Associates, LLC General Terms and Conditions for Non- Commercial Items, Rev. 23.0 (May 2025) with the article titled: Rights in Data Facilities, Dear 970.5227-1 are incorporated herein and made a part hereof.

Article 22 entitled “Warranty” is modified to reflect a two (2) year warranty or the manufacturer’s warranty period, whichever is longer. The contractor shall warranty the equipment against failure and defects for a period of two (2) years or the manufacturer’s warranty period, whichever is longer, from delivery and final acceptance at BNL.

This Contract is issued pursuant to Brookhaven Science Associates General and/or Supplemental Terms and Conditions listed above, which are incorporated herein by reference. The complete text of these terms and conditions can be viewed at PPM | Terms and Conditions. Should the Contractor have any questions and/or not have access to these terms and conditions, contact the Buyer or Contracts Specialist immediately.

The following documents attached hereto and made a part hereof, contain additional provisions of this contract:

Attachment (A) Brookhaven National Laboratory (BNL) Collider Accelerator Department Statement of

Work (SOW), D15-E450, Revision D dated 12/24/2024

Attachment (B) Brookhaven National Laboratory Collider Accelerator Department Technical

Specification for the New AGS Quad and Sextupole Power Supplies, CAD1370, Revision D, dated 12/24/2024

Attachment (C) BNL Supplier Quality Assurance Requirements (BNL-QA-101) Dated 08/2024

Modified as delineated within the Statement of Work, D15-E450, listed herein as Attachment (A), Section 4 entitled Quality Assurance.

Attachment (D) Patent Certification; AMS-Form-032 (Revision 2.0 dated 9/23/24)

This Contract does not bind nor purport to bind the Government of the United States.

ACCEPTED:

BROOKHAVEN SCIENCE ASSOCIATES, LLC.

By: By:

Name: Name: ____Ben Furlow_________ https://www.bnl.gov/ppm/terms-and-conditions.php

Title: Title: Sr. Contracts Specialist

Date: Date:

Should you accept this Contract without exception or alteration, one copy of the Contract executed by both parties shall be returned to BSA's Contractual Representative. Should you take any exceptions or attempt to alter the Contract in any manner, BSA's execution thereof shall be null and void. Should you wish to take exception(s)/alteration(s), you shall notify BSA's Contractual Representative. BSA will consider the requested exception(s)/alteration(s) and notify you accordingly. No Contract shall exist unless and until such differences are resolved.

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

1/30/2025

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

D15-E455 SOW-01 Page 3 of 10

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

D15-E455 SOW-01 Page 4 of 10

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.

D15-E455 SOW-01 Page 5 of 10

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/)

D15-E455 SOW-01 Page 7 of 10

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.

D15-E455 SOW-01 Page 8 of 10

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

D15-E455 SOW-01 Page 10 of 10

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 - 1st Article 31 weeks ARO Yes 9 Delivery of equipment Date of Delivery (Article 2 of 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 - 1st Article 31 weeks 9 Delivery of Power Supply, and End Item documentation package 32 weeks

01Brookhaven National Laboratory Brookhaven Science Associates Collider Accelerator Department

Number: CAD 1370 Date: 12/24/2024 Revision: D

SPECIFICATION

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 J. Funaro, Technical specialist

Approved by

Approved by

E. Bajon Project Engineer

D. Passarello, Quality Assurance

1/24/2025

1/28/2025

1/28/2025

1/28/2025

1/29/2025

1/30/2025

“This technology contains information subject to U.S. Government Export Control in accordance with the Export Administration Regulations (EAR), 15 CFR Parts 730-744. Export of these data to any foreign country or disclosure of these data to any non-U.S. person may be a violation of federal law.”

New AGS Quad and Sextuple supplies

1.0 SCOPE

This specification, in conjunction with other documents, defines the performance, design requirements, construction, materials, quality assurance, inspection, testing, and packaging of ten, AC to DC converters (power supplies).

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 quadrupole magnets, and sextuple magnets at Brookhaven National Laboratory (BNL). All supplies must regulate the current at 0 Amps. These three fully assembled and tested units will be installed and interfaced to remote control computers by Brookhaven Science Associates (BSA).

2.0 APPLICABLE DOCUMENTS

2.1 Standards from the following organization form a part of this specification to the extent specified herein. Unless otherwise specified, the versions of these documents that are in effect on the date of the solicitation or contract apply. Any exceptions requested by the Contractor must be approved in writing by BSA before being implemented.

Institute of Electrical and Electronic Engineers (IEEE) International Electrotechnical Commission (IEC) National Electrical Manufactures Association (NEMA)

The following documents are to be used as standards in the design and manufacture of the power supplies.

Number Title Code of Federal Regulations Title 29, Section 1910

OSHA General Industry Safety and Health Regulation and Standards

NEMA SG-5, Indoor Power Switch Gear IEEE 383 Vertical Flame Test IEC 478-3 Level C Reference levels of conducted electromagnetic interference (EMI) IEC 1000-4-4 Level 2 Electrical fast transient/burst immunity test IEC 1000-4-6 Level 2

NFPA70

ANSI/IEEE C57

Immunity to conducted disturbances, induced by radio-frequency fields

NEC

Distribution and Power Transformers

3.0 REQUIREMENTS: POWER SUPPLY PERFORMANCE & DESIGN CHARACTERISTICS

3.1 Specification Data Sheet

Detailed electrical requirements and parameters for these power supplies are listed in the Specification Data Sheets attached as Appendix A1 and A2 of this specification.

3.2 Topology/lifetime

The topology of the supplies shall be current regulated four quadrant AC to DC converters.

The incoming 480-volt line will be converted to DC by a voltage regulated AC to DC converter in the front end of the power supply. These power supplies shall be designed to operate continuously for periods of up to a year and shall have a life expectancy of 20 years.

3.2.1 Cooling: The power supplies shall all be quoted as water cooled units.

3.3 Output Requirements

3.3.1 Basic Description - The power supplies shall be switch-mode configured as four quadrant (bipolar voltage, bipolar current) pulsed supplies, current regulated with an inner voltage regulated loop. The voltage reference of this voltage loop should be calculated from the power supply current reference electronically, following the equation V=Lm*dI/dt+I*R.

Lm is the magnet inductance; R is the magnet resistance plus the cable resistance. The voltage loops of all supplies shall be able to be switched out, if necessary, such that the power supplies will only run with current loops. Also, all power supplies should be able to run with the voltage loops and current loops at the same time, being able to set the voltage reference of each loop to 0 volts, or to the calculated voltage reference. These voltage reference should be very stable to 50 ppm or better, so that they do not affect the current stability of the supplies as specified. Each current output shall follow a reference waveform provided by BSA; as such they shall generate a variety of pulses at different voltages and currents. The pulse duration for each of these current levels varies. To ensure Insulated Gate Bipolar Transistors (IGBT) current sharing, each IGBT pack shall have its own current loop.

The power supplies shall be rated to run continuously at the maximum rated current. (DC operation). Also, the power supplies shall be rated to run at the maximum current for 2 sec at a repetition rate of one pulse every 3 sec, or run at the maximum current for 3 sec at a repetition rate of one pulse every 5 sec. The output current of the power supplies will be bipolar. Some of the power supplies will see a back EMF (electromotive force) of as high as +/-40 volts. Table 1a displays the power supply ratings and the maximum back EMF for some of the supplies. More details about the power supply ratings are defined in the Specification Data Sheet (appendix A1).

3.3.2 Magnet stored energy-The power supply design must consider the stored energy in the magnet loads. This energy must be controlled when the power supply turns off, so it does not damage the IGBT’s or the dc link capacitor bank. During any output current ramp down, the energy from the load will transfer back to the capacitor bank. If the current reference quickly goes to zero, the voltage on the capacitor bank may increase to a value which could be destructive to the capacitor bank. Therefore, a crowbar resistor must be included to clamp the voltage to a safe level. A circuit in the power supply shall monitor the DC bus voltage and if it increases above the safe operating value the crowbar resistor shall be switched into the circuit and the input contactor shall open. In the case where the input circuit breaker opens under full load conditions, the crowbar circuit must automatically engage or there must be sufficient holdup in the control power to detect the absence of the three-phase input and to turn on the crowbar circuit.

3.3.2 Typical wave forms-. Figure 2 displays a typical magnet current and voltage wave form for any of the supplies. The current rise time and fall time is defined in the Specification Data Sheet (appendix A1).

Table 1a. Power supply ratings

Figure 1: Block diagram of power supplies with back EMF are connected

0 0.5 1 1.5 2 2.5 Time (s)

-100

-200

Imag_ver Vmag_vert

Figure 2: Typical wave form of magnet current and voltage for supplies.

3.3.2 Repeatability, accuracy of the magnet current

The parameters for the current repeatability and accuracy are specified in Appendix A1.

3.3.2.1 Repeatability: The magnet current shall be repeatable during the flat top within 0.01% of the power supply current rating. This repeatability shall include drift with time, temperature drifts, current ripple, noise, input line disturbance and random errors.

3.3.2.2 Absolute Accuracy: The measured output current shall be within +/- 0.25% of its current reference value.

3.4 Control and Instrumentation Interface

3.4.1 General Interface Requirements

Each power supply shall be controlled by one BSA Power Supply Interface (PSI) chassis. The PSI’s shall be provided by BSA and mounted by the Contractor in the power supply control cubicle. All statuses and interlocks shall interface to a PSI. A description of this interface, as well as operational states, is given in Appendix B.

Each PSI is a 1U chassis designed for a standard 19-inch rack. The depth is approximately 9 inches. The connectors for the two electrical cables (analog and digital) are located on the rear surface of the chassis. The connectors for the two fiber optic cables (transmit and receive) are on the front panel.

In addition to the PSIs BSA will supply a test controller for the PSIs, the fiber optic cables between the PSIs and the test controller, and the software to control each power supply and to log its read backs and statuses. The Contractor shall provide mounting space within the control compartment of each power supply to mount the PSI, the cables between the PSI and the power supply, means for the fiber optic cables to exit the cabinet (if mounted internally) and standard 120 VAC outlets to power the PSI.

3.4.2 Remote Control and Monitoring

The analog reference, the analog read backs, the digital command bits, and the digital status bits all interface through the PSI. Each PSI shall control the Current reference, and receive the Current Readback, Magnet Voltage Read back, Current error, Current reference readback and all Commands and Status to and from the Power supply. The input impedance of all PSIs analog inputs is 10 kOhms +/- 2%

3.4.2.1 Analog references

The magnet current reference shall be a 0 to +/-10-volt signal corresponding to 0 to +/- maximum output current A, See Table 1.

3.4.2.2 Read Backs to the PSI’s.

a) Measured Load Current – A 0 to +/-10 Volt signal indicating the measured load current shall be sent to the PSI. +/- 10 volts shall indicate +/- maximum output current A, See Table 1, and be accurate to +/- 0.25 % of the actual current value. The repeatability of this signal shall be +/- 50 ppm.

b) Measured Load Voltage – A -10 to +10-volt signal indicating the voltage across the load shall be sent to the PSI. +/-10 volts shall indicate +/-maximum output voltage V and shall be accurate to +/- 0.5 %, See Table 1,

c) Current Error – This represents regulation error and is:

Ierror = 50 X (set point current – measured current)

This signal shall be accurate to ± 0.1% and shall have a scale factor of ± 10 Volts = ± 10 Amps. Its bandwidth shall not be less than 10KHz. It shall be sent to the PSI.

d) Current reference. This is a buffered wrapped around version of the analog current reference. This shall be accurate to ± 0.25%, and shall have the same scale factor as the current reference. It shall be sent to the PSI.

3.4.2.3 Commands

The transition between states in response to commands is shown in Appendix B.

a) OFF – This command puts the power supply in the OFF state from any previous state. The capacitor bank crowbar resistor shall be engaged in this state.

b) STANDBY – This command has two functions. If there are no faults, this command puts the power supply into the STANDBY state from any previous state. This command shall also function to clear latched faults. If the faults clear, the power supply will them be put into the STANDBY state. If the faults do not clear, the power supply shall remain in the FAULT state.

c) ON – This command puts the power supply into the ON state, but only from the STANDBY state. The capacitor bank crowbar shall be disengaged.

3.4.2.4 Status Bits

a) Modes – ON, OFF, STANDBY, FAULT

b) LOCAL / REMOTE

c) Faults – Individual faults. The faults to be indicated shall be stated in the Seller’s proposal.

d) Interlocks – The interlocks described by section 3.4.4 are to be monitored.

3.4.3 Local Control and Monitoring

3.4.3.1 Monitoring

3.4.3.1.1 Analog Signals - Analog representations of the current reference, voltage reference, output voltage, output current, current error, pre-regulated output voltage shall be brought out to separate buffered isolated BNC connectors on the front panel. The scale factors for this monitoring shall be 10 Volts for full scale output for monopolar signals and +/- 10 Volts for bipolar signals. The accuracy of this representation shall be better than ±0.5%. The bandwidth of the of the current reference, output voltage, output current, current error, pre-regulated output voltage shall be 10KHz. These monitoring signals shall be active in both Local and Remote modes.

3.4.3.1.2 Measured Load Current – A 0 to +/-10 Volt buffered signal indicating the measured load current shall be supplied to a front panel BNC. +/-10 volts shall indicate +/- maximum output current A and be accurate to +/- 0.25 %.

3.4.3.1.3 Measured Load Voltage – A -10 to +10 volt buffered signal indicating the power supply output terminal voltage shall be connected to a front panel BNC.

+/-10 volts shall indicate +/- maximum output voltage V and be accurate to +/-

0.5 %.

3.4.3.1.4a Current reference –A buffered version of the analog current reference, used for a diagnostic. It shall be connected to a front panel BNC. +/- Ten volts shall indicate +/- maximum output current A, and be accurate to +/-

0.25 %.

3.4.3.1.4b Voltage reference –A buffered version of the calculated analog voltage reference, used for a diagnostic. It shall be connected to a front panel BNC. +/-Ten volts shall indicate +/- maximum voltage reference V, and be accurate to +/- 0.25 %.

3.4.3.1.5 Current Error – A current error signal where: Ierror = 50 * (set point current – measured current). This signal shall be accurate to 0.1% and shall have a scale factor of ± 10 Volts equals ± 10 Amps. It shall be connected to a front panel

BNC.

3.4.3.1.6 Modes and Status Indicators – All modes and status bits described in Appendix B, and interlocks described in paragraph 3.4.4, shall be annunciated by front panel LEDs.

3.4.3.2 Local Control

3.4.3.2.1 Local / Remote switch - A covered front panel switch shall be used to go from Local mode to Remote mode. Switching the mode to either Local or Remote when the supply is on shall place the power supply in the Standby mode.

3.4.3.2.2 Operating Mode Switches –OFF, STANDBY, and ON switches shall be on the front panel. STANDBY and ON shall only be active when the unit is in the local mode, but OFF shall be active in either the local or remote mode.

3.4.3.2.3 Current amplitude adjustment – In the local mode, the regulated current shall be controlled by an analog reference to a BNC input, or by an internal dc…