PIP-II F37 Building Low Conductivity Water (LCW) Pump Room Piping System Installation Specification

Document number: ED0042585, Rev. - B

Document Approval

Signatures Required Date Approved

Originators: Michael Hanson, Sr Fluids Engineer

Reviewer: Matt Slabaugh, BLDGI L3 Manager

Approver: Jerry Leibfritz, Linac Installation & Commissioning L2 Manager

Revision History

Revision Date of Release Description of Change

- May 2025 Initial Release for Review A January 2026 Issue for Bid B January 2026 Issue for Bid, added requirement for project specific QC plan

PIP-II F37 Low Conductivity Water Pump Room Piping System Installation Specification, ED0042585, Rev A

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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, ANCHORS, FOUNDATIONS

8.1 Structural Supports, Hangers, Brackets

8.2 Foundations, Bases, and Supports

9 CONSTRUCTION, FABRICATION, AND ASSEMBLY REQUIREMENTS

9.1 Welding

9.2 Inspection and Leak Testing

10 SUBCONTRACTOR DOCUMENTATION

10.1 Provided prior to starting work

10.2 Provided before completion of work

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1 INTRODUCTION

The F37 Low Conductivity Water (LCW) Piping System will be used for fluid temperature control of various pieces of equipment of the Proton Improvement Plan II (PIP-II) Project.

The pump room for the LCW Piping System will be located in the mechanical utility portion of the

F37 Building. The pump room will consist of two (2) 50 hp centrifugal pumps (1 in operation + 1 in standby), one (1) shell and tube heat exchanger, one (1) 250 gallon expansion reservoir tank, and a series of processing equipment (i.e. particulate filters, oxygen removal, and Deionization skid).

2 SCOPE

The scope for this installation specification is the pump room for the LCW Piping System located in the mechanical room of the F37 Building:

• Installation of all major LCW equipment (i.e. centrifugal pumps, shell and tube heat exchanger, and reservoir expansion tank) and connecting piping.

• Installation of all process loop equipment (i.e. deionization skid, particulate filter, dissolved oxygen removal skid)

• Installation and procurement of all process instrumentation and filters (i.e. pressure gages, flow transmitters, pressure transmitters, basket strainers, etcetera)

• Structural Supports for all piping and equipment, including foundation base for centrifugal pumps

• Supply of all piping and piping hardware (valves, flanges, gaskets, fitting, etcetera).

• Electrical Installation (excluding controls writing).

All in all, this installation specification document will refer to the installation of LCW piping, instrumentation, hardware, and processing equipment located in the mechanical room of the

F37 Building. This document provides description for fabrication and installation of this new LCW

System piping.

Along with general description and installation requirements, this specification includes the requirements for welding of 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

Fermi National Accelerator Laboratory 5 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 ICW – Industrial Cooling Water

3.1.3 MAWP – Maximum Allowable Work Pressure

3.1.4 IPS – International Pipe Size

3.1.5 PQR – Procedure Qualification Record

3.1.6 WPQR – Welder Performance Qualification Record

3.1.7 WPS – Welding Procedure Specification

3.1.8 GPM – Gallons Per Minute

3.1.9 mA – Milliampere

3.1.10 NPT – National Pipe Thread

3.1.11 PSI – Pounds per Square Inch

3.1.12 PSIG – Pounds per Square Inch Gauge

3.1.13 SCFM – Standard Cubic Feet Per Minute

3.1.14 VDC – Volts Direct Current

3.1.15 P&ID – Process and Instrumentation Diagram

3.1.16 ES&H - Environment, Safety and Health

3.1.17 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

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3.2.3 ASME – American Society of Mechanical Engineering

3.2.4 ASTM - American Society for Testing and Materials

3.2.5 EJMA – Expansion Joint Manufacturers Association

3.2.6 ISO – International Organization for Standardization

3.2.7 UL – Underwriters Laboratory

3.2.8 TEMA – Tubular Equipment Manufacturers Association

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

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

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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.

As these are 2D layout drawings and many of the dimensions are shown as reference and field fitting will be necessary.

F10170043- Sheet 01 through Sheet 28

4.1.2 EQUIPMENT SPECIFICATION DOCUMENTS – Equipment within the scope of this installation specification SHALL be specified and procured for installation as defined by the following document.

4.1.2.1 ED0042584 PIP-II LCW System Instrumentation Specification and Particulate

Filters

4.1.3 ELECTRICAL INSTALLATION DOCUMENTS – Electrical equipment, including wiring, conduit, cable trays, disconnects, MCC’s, VFD, etcetera, within the scope of this installation specification SHALL be specified by FNAL and procured for installation as defined by the following document.

4.1.3.1 ED0046270 – F37 LCW Electrical SOW

4.1.4 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.

4.1.5 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.

4.1.6 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.

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4.1.7 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

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

5.1.2 Design conditions for ICW Piping system is as follows:

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5.1.2.1 Design Pressure: 150 PSIG

5.1.2.2 Design Temperature: 200o F

5.1.2.3 Fluid: Industrial Cooling Water, pond water

5.1.2.4 Temperature range: 32°F to 105°F; The Industrial Cooling Water System will be considered a Category “D” Fluid Service when interpreting Code requirements

6 MATERIALS

6.1.1 All equipment, components and instrumentation, including equipment described above in Section 4.1.2 SHALL be supplied by the SUBCONTRACTOR.

6.1.2 All piping, fittings (tees, elbows, etc.), isolation valves, and hardware SHALL be supplied by the SUBCONTRACTOR.

6.1.3 All piping, fittings (tees, elbows, etc.), and hardware must conform to ASME/ANSI

Process Piping B31.3 Code Standard for Category D Fluid Service category.

6.1.4 All piping, fittings (tees, elbows, etc.), shall be buttweld for sizes 2” and greater and socket welded for sizes under 2”.

6.1.5 All pipe for the LCW system 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.

6.1.6 All pipe for the ICW system shall be

ASTM A53 Type E Grade B SCH 40 for all sizes

6.1.7 All isolation valves installed for this installation will be as specified below:

6.1.8 Ball Valves

6.1.8.1 ¼” through 1 ½” FNPT, 3 piece, 2 way, full port flow, UHMWPE seal and seats, 316SS body, ball, and stem with locking handle, Manufacturer: Inline series

302F or approved equal

6.1.9 Butterfly valve

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6.1.9.1 8” through 24”: Lug type, ductile iron body epoxy coated, 150 psi pressure rating, buna-n seat material, stainless steel shaft and disk, including a chain operated gear mechanism.

6.1.9.2 2” through 6”: Lug type, ductile iron body epoxy coated, 150 psi pressure rating, buna-n seat material, stainless steel shaft and disk, 10-position locking lever

6.1.10 The SUBCONTRACTOR SHALL supply all equipment, special tooling, 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

6.1.11 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

7 MATERIAL HANDLING/CLEANING

7.1.1 All PIPING, fittings (tees, elbows, etc.), and hardware SHALL be delivered in new and undamaged condition and SHALL be inspected/examined by the

SUBCONTRACTOR at the installation site and cleaned free of dirt, oil, and debris before installation.

7.1.2 All PIPING, fittings, and hardware SHALL be kept clean and dry with ends capped while awaiting installation or during storage.

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

7.1.4 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.

7.1.5 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.

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

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7.1.7 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.

7.1.8 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.

7.1.9 Any excess material supplied by FERMIFORWARD remains the property of the

FERMIFORWARD and SHALL be returned upon completion of the work.

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

8 PIPE SUPPORTS, ANCHORS, FOUNDATIONS

8.1 Structural Supports, Hangers, Brackets

8.1.1 LCW and ICW Piping in the Utility Plant SHALL be supported according to installation drawings.

8.1.2 For details on supports refer to section 23 05 29 of document 230529-1.

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

8.1.4 Pipe and structural support material and hardware SHALL be appropriate and compatible for supporting schedule 10, 304L stainless steel seamless pipe.

8.2 Foundations, Bases, and Supports

8.2.1 Furnish and install foundations, bases, and supports according to the installation drawings as shown on F10170043.

8.2.2 Centrifugal pump discharge and suction piping SHALL be properly and adequately supported to avoid any load or stress on the centrifugal pump casing or volute by the piping system.

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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.

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.

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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.

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

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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 In-process examination comprises examination of the following:

9.2.1.3.1 Joint preparation and cleanliness

9.2.1.3.2 Preheating

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

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

9.2.1.3.5 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 Contractor shall perform in service hydrotest on F37 LCW system per ASME B

31.3 345.1(a).

9.2.2.4.2 The total volume of clean deionized water to be used is estimated at 2,000

Gallons. Contractor shall make arrangements to provide this.

9.2.2.4.5 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.

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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 prior to starting work

10.1.1 The SUBCONTRACTOR SHALL furnish copies of the WPQ and PQR’s for each welder performing work on the piping system ten (10) working days prior to the start of welding.

10.1.2 The SUBCONTRACTOR SHALL furnish copies of all WPS’s that will be used in execution of the work.

10.1.3 The SUBCONTRACTOR SHALL furnish copies of all MTR’s for all piping components that will be used in execution of the work.

10.1.4 The SUBCONTRACTOR SHALL provide drawings/datasheet/documentation as required in the equipment specification for review/comment/approval on all equipment prior to start of fabrication.

10.1.5 The SUBCONTRACTOR SHALL provide a project specific QC plan, this is an addition to providing evidence of a corporate Quality Assurance during the bidding process

10.2 Provided before completion of work

10.2.1 The SUBCONTRACTOR SHALL furnish copies of the following documents before the project is deemed complete by FNAL

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Final documentation packages for all equipment purchased. Specific requirements for final documentation packages can be found in the respective equipment specifications

Redlined drawings of the installed system

Hydrotest reports and all NDE reports required per this specification and the equipment specifications.

Datasheets and drawings for all instrumentation

3.3 Definitions