Exhibit A- ED0040980 SSR2 CM - VV and Strongback - Procurement and Fabrication Specification.pdf

PIP-II SSR2 Cryomodule

- Procurement and Fabrication Specification -

Vacuum Vessel and Strongback Tray

Author: J. Bernardini

Document Number: ED0040980 Rev -

Document Approval Date Approved

Originator J. Bernardini As in TC

Checker V. Roger As in TC

Approver M. Parise As in TC

PIP-II

Procurement and Fabrication Specification

Document Title:

PIP-II production SSR2 Cryomodule - Procurement and Fabrication Specification - Vacuum Vessel and Strongback Tray

Fermi National Accelerator Laboratory 2

Revision History

Author Revision Date Description of Change

J. Bernardini February 2025 Initial Release

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PIP-II production SSR2 Cryomodule - Procurement and Fabrication Specification - Vacuum

Fermi National Accelerator Laboratory 3

Table of Contents

1 Scope 4

2 Procurement Specification 4

2.1 Bidding Phase 4

2.2 Technical and Cost Evaluation Phase 5

2.3 Execution Phase and Hold Points 5

2.3.1 Hold Points 6

3 Fabrication Specification 7

3.1 Introduction 7

3.1.1 Materials 9

3.2 Dimensional conformance 10

3.3 Cleanliness 10

3.4 Welding 11

3.5 Leak check 11

3.6 Painting and Coating of F10239496, F10240570, F10150559, and F10239503 11

3.7 Serial number stamping 13

3.8 Hardware 14

3.9 Assembly 14

3.9.1 Traction test of the G11 Support Posts 15

3.9.2 Strongback Tray (F10239550) Insertion Test 15

3.10 Common and Design Parts to be procured 16

3.11 Design and Common Parts provided by FFDG 16

3.12 Quality controls 17

3.13 Shipping Plan 17

APPENDIX A: Technical datasheets of epoxy for vessel interior painting 18

APPENDIX B: Common Parts to be procured 22

APPENDIX C: Technical datasheets of High Emissivity Coating 23

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1 Scope

The Single Spoke Resonator Type 2 Cryomodule (SSR2 CM) is one of the five different types of cryomodules

(total of 23 units) that will constitute the PIP-II linear accelerator complex. The present specification is intended to inform the procurement, fabrication, and assembly of the vacuum vessel, strongback tray, and string assembly components for the SSR2 CM, in quantity indicated in Table 1.

Top Assembly Drawing Description Quantity

F10239491 PROCUREMENT ASSY, SSR1 VESSEL W/STRONGBACK 6

Table 1: Quantities and Top Assembly Drawing

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. The

Manufacturer shall fabricate jigs and fixtures to ensure flange faces, ports, brackets, and other important components are maintained to specified tolerances. Any information of a proprietary nature must be identified in the bid response.

FFDG is requesting that offerors provide firm-fixed pricing for DDP shipping (HTS code 8543.90.88.45) as part of their firm-fixed-price proposal to the RFP.

2 Procurement Specification

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

2.1 Bidding Phase

Bidder shall provide Quotation including all costs to deliver the assembly indicated in Table 1, along with the following documentation:

a) Schedule that meets a lead time of 18 months, starting from the date that the FFDG Purchase

Order is awarded to the Bidder running through fabrication, including hold points reported in

Table 2. Shipping batches will be defined at the time of the MRR. Supporting documentation, to demonstrate that the Bidder will deliver within the specified timeframe, is recommended.

b) Technical Proposal to demonstrate the ability of the Bidder to deliver the assembly with performance that meets or exceeds Fabrication Specification reported in section 0 of this

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Fermi National Accelerator Laboratory 5 document. The Bidder shall list the equipment that will be used for manufacturing, and shall disclose what part of the work, if any, will be sub-contracted.

c) Past experience including examples of past projects (within the last five years) that closely match the scope in complexity and value, and that best illustrate the bidder’s capability, experience, and performance.

d) Management Control Plan to demonstrate the ability to ensure the required quality standard (see section 0) throughout the entire execution of the project. Examples of documentation developed for past projects (within the last five years) to meet the pressure vessel codes of ASME B & PV VIII

Division I, 2021, and ASME section IX in terms of welding process, inspection and testing will be considered for the technical evaluation.

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

2.2 Technical and Cost Evaluation Phase

FFDG Purchase Order is awarded to one bidder after that the proposals will have been evaluated by technical and cost evaluation teams.

2.3 Execution Phase and Hold Points

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.

Within two weeks from FFDG purchase order award, a kick-off meeting shall be scheduled 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. Also, a monthly meeting held by videoconference shall be regularly scheduled to discuss technical and commercial updates. The meetings will be held in

English. However, FFDG representatives are always available to respond any time if questions will arise.

Within eight weeks from FFDG purchase order award and before starting any fabrication / procurement activity, the Manufacturing Readiness Review (MRR) shall be organized to allow FFDG reviewers to assess the Manufacturer’s level of preparation to proceed to the manufacturing and procurement phase.

Review’s recommendations (if any) based on the presented material (see MRR deliverables in Table 2), shall be addressed within two weeks from the conclusion of the MRR.

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Upon conclusion of the MRR, the Manufacturer will be allowed to proceed with the fabrication / procurement phase. Quality Controls (see section 3.12) and Technical reports, as detailed in Table 2, shall be provided by the Manufacturer to FFDG.

The readiness to ship the units shall be assessed through an appropriate review.

2.3.1 Hold Points

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.

Table 2 lists the main hold points and associated documentation deliverables for this project.

Hold Point

Description Deliverables When required

A Kick-off Meeting

Address action items from the meeting Within 2 weeks of contract award

B

Manufacturing Readiness Review(s) (MRR)

MDED (see section 3.2) Welding documentation (see section 3.4)

Common Parts to be procured Documentation (see section 3.10)

Detailed MIP and Travelers’ template (see section 3.12)

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

/ Procurement

C Traction Test of the G11

Support Post QC report(s) As specified in the MIP

D

Final Dimensional Check of the Strongback Tray

(with assembled support posts)

QC report(s) As specified in the MIP

E Final Dimensional Check of the Vacuum Vessel QC report(s) As specified in the MIP

F Pre-painting Leak Check of the Vacuum Vessel QC report(s) As specified in the MIP

G Painting Readiness

Review

Detailed plan describing which surfaces will be painted and which holes and surfaces will be masked off.

As specified in the MIP

H Strongback Insertion Test Technical Report (see section 3.9.2) As specified in the MIP

I Final leak check of the vacuum vessel QC report(s) As specified in the MIP

L Discrepancies /

Nonconformities Discrepancy report(s) As soon as identified

M Shipping Readiness

Review

Shipping Plan (see section 3.13) Final version of MIP

Final version of MDED Final version of Welding documentation

Discrepancy report(s) (If applicable) CMTRs (see sections 3.1.1) Visual Inspection Reports

Certificate of dimensional controls (see section 3.2)

Prior to shipping

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Leak Checking reports (see section 3.5)

Table 2: Hold Points and Documentation Deliverables for Fabrication Phase

3 Fabrication Specification

This section provides a technical introduction of the scope, assembly to be manufactured, quality controls, and shipping plan.

3.1 Introduction

FFDG engineering drawing packages listed in Table 1 shall be used for the complete parts list, including the hardware needed for assembling.

For the purpose of technical introduction, Table 3 lists ONLY the main subassemblies of top assembly

F10239491.

Item No. Name of sub-assembly Description

F10239492 Vacuum Vessel Assembly This assembly serves to house all the CM components which operate in a moderate to high vacuum service.

F10239500 Strongback Tray Assembly This assembly serves as the structure backbone of the coldmass.

F10142469 G11 Support Post

An assembly of a low thermal conductivity G11 fiberglass pipe and three stages of shrink-fit aluminum and stainless-steel discs and rings.

Assembly procedure in ED0014327.

FC0079396

Open Plain Linear Bearings

Pillow Blocks

Standard plain bearings which constitute the main interface between the Vacuum Vessel and

Strongback Tray assemblies. They allow the strongback to slide in and out of the vessel during the assembly process.

Table 3: List and descriptions of main sub-assemblies.

The vacuum vessel assembly consists of a cylindrical shell, anchored to the floor with bottom supports, and equipped with lugs for lifting purposes. The vessel shell is closed at the upstream and downstream side with endcaps, which host viewports and access ports. The vessel has got ports for input RF power couplers, access, instrumentation, vacuum pump-out, and safety relief. The main components of SSR2 vacuum vessel are shown in Figure 1 and Figure 2.

The vacuum vessel provides a structural support for the strongback tray, which can slide in the vessel by means of a system of rails and plain linear bearings. The strongback tray can be locked to the vessel with a central lock-out stud accessible from the outside. Eight G11 support posts and two stiffening elements are bolted to the strongback tray, as shown in Figure 3 and Figure 4.

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Figure 1: F10239492, Vacuum Vessel Cryogenic Side

Figure 2: F10239492, Vacuum Vessel Instrumentation Side

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Figure 3: F10239491, Vacuum Vessel with Strongback Tray Section View

Figure 4: F10239500, Strongback Tray

3.1.1 Materials

Materials are specified in the referenced drawings. The use of any materials non-listed in the drawings is excluded by the present specification. Under exceptional conditions FFDG may approve other materials upon a written request. Exceptions for hardware materials are specified in section 3.8.

Certified Mill Test Reports (CMTR) of all raw materials used to fabricate deliverables shall be provided to

FFDG as soon as materials are received and as part of the deliverables of the shipping readiness review

(see Table 2). Electronic copies of materials certifications in PDF format shall be provided and shall include all processes and tests with grade and composition being clearly identifiable and traceable to the respective component.

If the vendor obtains components from a subcontractor, the vendor is responsible to prove that the materials and welds for the components meet compliance requirements.

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3.2 Dimensional conformance

All drawings referenced shall be used by the Manufacturer for configuration control and dimensional conformance. Dimensional variances and overall envelope configuration shall be maintained within specified tolerances.

The drawings supplied as part of this request for proposal are to be considered near-final release. The final set of drawings (latest revisions), including minor modifications that might occur during the bidding phase, will be given to the Manufacturer at the time of the kick-off meeting.

The Manufacturer may decide to use the drawings provided by FFDG for fabrication, or to produce its own drawings. Any change or deviation from the set of drawings provided by FFDG shall be listed in a

Manufacturer’s Drawings Exception Document (MDED). FFDG will have to provide a written approval to the MDED before the Manufacturer can proceed to the next step. FFDG is not accountable for any change in the drawings not listed in the MDED. The MDED can be revised and approved throughout the entire duration of the project.

CMM reports shall be produced for the following parts:

- F10142469 and subcomponents: SSR CAVITY/SOLENOID SUPPORT POST (before and after traction test, as specified in ED0014327).

- F10128129: SSR2 ALIGNMENT PLATE.

- F10144914: WLDMT, SSR SOLENOID SUPPORT.

- F10135011: SOLENOID SUPPORT PLATE.

Dimensional control reports, with the use of a laser tracker system, shall be generated for the following components:

- F10239496: SSR2 PROD VESSEL FINAL MACHINING.

- F10239503: SSR2 PROD TRAY STIFFENER.

- F10239501: SSR2 PROD STRBK TRAY, FINAL MACHINED.

- F10239500: SSR2 PROD STRONGBACK TRAY ASSY.

CMM and dimensional control reports shall be made available by the time of the shipping readiness review, as detailed in Table 2.

3.3 Cleanliness

The interior of the vacuum vessel shall be bead or sand blasted to remove all rust and foreign material.

Before any welding or painting (as specified in drawings), all parts must be degreased with soap and water, followed by a thorough DI water rinse. Parts shall be protected at all stages of fabrication for the cleanliness. Protective caps must be installed during fabrication to help protect sealing surfaces. All threads shall be cleaned and checked with go/no-go gauges before shipment.

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3.4 Welding

All weld joints shall conform to types and sizes called out on drawings provided by FFDG, unless otherwise listed in the MDED approved by FFDG.

All weld joints shall be performed using the following welding filler materials:

- Carbon steel to carbon steel: E70XX

- Stainless steel to stainless steel: ER308

- Carbon steel to stainless steel: ER309

All welding process, inspection and documentation shall be performed and developed in accordance with related pressure vessel codes of ASME B&PV section VIII Division I, 2021.

All welders shall be qualified to the ASME B&PV section IX, 2021.

The Manufacturer shall ensure that no entrapped gases, fluxes, pits, cracks, or like imperfections are left in the heat affected zones. All fillet welds shall be smooth for cosmetic appearance.

Post cleaning of welds with a wire brush only is acceptable (prior to final leak checking) and required to leave the surface in a bright finish condition with no trace of solvent residue.

3.5 Leak check

Helium leak testing at room temperature shall be used to verify that assembly, subassemblies, and components (when specified on drawings) are suitably leak-tight at all stages of fabrication and assembly.

The allowable leakage rates are indicated on drawings (when applicable). Leak testing should be performed with a calibrated Helium Mass Spectrometer Leak Detector (HMSLD), according to ISO 20485 or equivalent standard.

No painting (external or internal) is allowed before leak check is completed and approved by FFDG representatives.

The completed Vacuum Vessel Assembly shall be made available to FFDG for inspection before, during, or after final leak checking (prior to painting). Advanced notice shall be provided to FFDG for travel arrangements.

A final leak check shall be performed on the assembled vacuum vessel with strongback tray, as detailed in F10239491.

3.6 Painting and Coating of F10239496, F10240570, F10150559, and F10239503

After the assembly has passed final leak checking, the carbon steel surfaces and stainless-steel nozzles of

F10239496 and F10240570 shall be painted with a rust preventative primer. The exterior shall be painted with a rust preventative primer, color Lamborgini Giallo Orion Metallic (or equivalent) and jet black (RAL

9005) as detailed in drawing F10239496. The interior shall be painted with low vapor pressure vacuum compatible rust preventative epoxy paint, color white (RAL 9003). Both interior and exterior paints must

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Fermi National Accelerator Laboratory 12 be lead free, have good adhesion to the metal surfaces, and must be solvent resistant. Once completed, the vessel shall always remain dry. Before starting any painting process, a Painting Readiness Review shall be conducted as an hold point listed in Table 2.

All sealing surfaces and threaded areas shall be masked as also specified on drawings prior to painting.

In addition, the next figures show inside of tubes, faces, holes, and threads that shall be masked off during the painting.

Figure 5: SSR2 Vacuum Vessel, Cryogenic Connections

Figure 6: SSR2 Vacuum Vessel, Bottom plates

Figure 7: SSR2 Vacuum Vessel, Coupler ports

The bottom surface of the strongback (F10150559) and the I-beams (F10239503) shall be sand blasted and coated with high emissivity coating Aremco HiE-Coat_840-M, as specified on drawings. Heat curing up to 500 K for 60 minutes is required after the coating is applied to dry off chemically retained water.

Included with this package are technical datasheets for interior primer, interior paint finishing recommendations, and high emissivity coating.

Holes on these plates shall be masked off during painting

No epoxy on these faces and threaded holes

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3.7 Serial number stamping

Supplier shall permanently etch a serial number on each subassembly. The serial number shall follow this alphanumeric format:

Part# Revision CM# Sequence#

Part number and revision number shall be the ones indicated in FFDG drawings, if no revision is indicated in the drawing, symbol “-“ shall be used. CM number is 1 for items included in the 1st SSR2 vessel and should increment for the subsequent vessels. The sequence number shall increase from 01 to the number of repeated components in the assembly.

The etched serial number shall be placed consistently on the location shown in Figure 8, Figure 9, Figure

10, and Figure 11.

Figure 8: Downstream flange of the vacuum vessel to be etched (revision letter shall be latest revision)

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Figure 9: End flanges to be etched (revision letter shall be latest revision)

Figure 10: Top flange of the support post to be etched (revision letter shall be latest revision)

Figure 11: Strongback tray to be etched, downstream side (revision letter shall be latest revision).

3.8 Hardware

The Manufacturer shall provide to FFDG the hardware (bolts, nuts, washers, seals, rod-ends) in quantities listed in the part list of drawings plus 20% for each item. Quantities and materials are the ones listed on drawings, please note that SSB88 is SS 316L. The hardware shall be properly packed and labeled to be easily identifiable during assembling of the components at Fermilab.

3.9 Assembly

It is required that all parts shall be assembled per drawings provided by FFDG at Manufacturer’s premises prior to delivery.

Unless specified on drawings, all the fasteners shall be torqued to their recommended values depending on their sizes and materials, listed in Table 4.

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Size Torque (N∙m) Bolt & Nut Material

Association

M4x0.7 1.9 SS/SB

M4x0.7 1.7 BR/SS

M5x0.8 2.6 SS/SB

M6 x 1 6.8 SS/SB

M8 x 1.25 14.1 SS/SB

M8x1.25 12.4 BR/SS

5/16-18 14.1 SS/SB

M10 x 1.5 27.1 SS/SB

M12 x 1.75 48.6 SS/SB

M16 x 2 118.6 SS/SB

Table 4: Torque requirements (N∙m) for the fasteners

FFDG may request the Manufacturer to use Loctite in some bolted connections. Those connections will be identified by FFDG and communicated to the Manufacturer during the execution phase.

Silicone bronze (SB) hardware in assembly may be substituted with CuNi2Si alloy or with silver plated hardware. The substitution shall be communicated and approved by FFDG before its implementation.

3.9.1 Traction test of the G11 Support Posts

All the assembled G11 Support Posts (F10142469) shall undergo a vertical traction test in tension, as specified in Appendix B of ED0014327. To successfully pass the test, each support post shall sustain a load of 5,000 kg for at least 5 minutes. The following tests results shall be collected and reported:

1. Vertical dimension of the post before the test, the measurement shall comply with step 2 of

ED0014327, Appendix B.

2. Maximum load and time at maximum load.

3. Repeated measurement of the vertical dimension of the post with the same accuracy and in the same conditions as in step 1.

Appendix B of ED0014327 shall be the reference for this test. The traction test should be performed in presence of FFDG representatives. Advanced notice shall be provided to FFDG for travel arrangements.

3.9.2 Strongback Tray (F10239550) Insertion Test

The Strongback Tray shall be inserted into the vacuum vessel by using the rails and the open plain bearings. A series of insertion and removal tests shall be performed to validate the functional behavior of the assembly in presence of FFDG representatives. The following tests results shall be collected and reported:

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1. Weight of the Strongback Tray.

2. Force needed to move the Strongback Tray across the open plain bearings (FC0079396) for its entire length.

The completed Vacuum Vessel Assembly and Strongback Tray Assembly shall be made available to an

FFDG representative for inspection. Advanced notice shall be provided to FFDG for travel arrangements.

3.10 Common and Design Parts to be procured

The common parts are components available on the market from one or multiple suppliers. In the bill of material of FFDG drawings, the common parts are the ones with drawing number starting with letters

‘’FC’’ (example FC0079396).

The following common parts are available at one supplier only:

- FC0079396: PNC (INCH) OPEN PLAIN LINEAR BEARING PILLOW BLOCK.

- FC0083028: ROD END BEARING, LH THREAD, 10MM X M10 X 1.5.

- FC0083207: ROD END BEARING, RH THREAD, 10MM X M10 X 1.5.

The Manufacturer shall procure those parts from the suppliers specified in Appendix B.

The following design parts shall be procured by the Manufacturer from the supplier specified in

Appendix B:

- F10166424: Low Profile Support 1.

- F10166425: Low Profile Support 2.

- F10166426: Low Profile Support 3.

- F10166451: Shaft 1.

- F10166452: Shaft 2.

- F10166465: Low Profile Shaft Assembly.

Documentation of the procured parts listed in this section shall be sent to FFDG for approval, as detailed in Table 2.

3.11 Design and Common Parts provided by FFDG

FFDG will provide the following design parts to the Manufacturer:

- F10158991: WASHER, LWR MAG SHIELD (used in F10239500).

- F10161778: SPACER RING, SUPPORT POST MAG – SHIELD (used in F10239500).

- F10161777: DISC, SUPPORT POST MAG – SHIELD (used in F10239500).

The Manufacturer is responsible for all costs associated to import / export the shipment of parts provided by FFDG.

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3.12 Quality controls

The Manufacturer shall prepare a project specific Manufacturing and Inspection Plan (MIP) for FFDG’s approval. The MIP shall list the sequence of manufacturing steps, as well as the associated inspections:

- Visual inspections.

- Dimensional inspections.

- Leak checks.

- Magnetic permeability measurements.

The Manufacturer shall develop quality control procedures and tests to guarantee that the project will be in full conformance with the FFDG’s specifications. If during inspections a discrepancy occurs, the supplier shall generate a Discrepancy Report (DR) and obtain FFDG’s approval before proceeding to the subsequent step.

The magnetic permeability of Stainless Steel components shall be measured when specified on drawings prior and after machining. A magnetic permeability higher than 1.02 is a discrepancy, and as such it shall be reported to FFDG before proceeding to the following manufacturing steps.

The Manufacturer shall maintain records of all inspections and tests in the form of Quality Reports (i.e., electronic travelers).

The Manufacturer shall provide documentation detailing the weld assurance program. Welding documentation shall be developed in accordance with related pressure vessel codes of 2021 ASME B&PV section VIII, Division I, and ASME section IX.

The MIP and Welding Documentation shall be made available for FFDG’s reviews and approval by the

Manufacturing Readiness Review (MRR), as also indicated in Table 2.

3.13 Shipping Plan

The Manufacturer shall ship the vacuum vessel, with the strongback tray in place and properly locked, and magnets and cavities alignment kits assembled on the support posts, as in drawing F10239491. The

Manufacturer shall ship the entire assembly properly packed, to ensure that damage is not incurred during shipment, in accordance with transportation industry standards. This shall include weather protection and the closure of all open pipes with test plugs or removable caps. Protective caps must be installed during shipping to help protect sealing surfaces. Sizing shall be such that handling is facilitated and weight limitations imposed by the transportation industry can readily be met.

All deliverables including documentation shall be catalogued and offered for acceptance to FFDG by the

Shipping Readiness Review.

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APPENDIX A: Technical datasheets of epoxy for vessel interior painting

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APPENDIX B: Common Parts to be procured

The common part FC0079396: PN20C, PLBLK 1.250 OPN COMP (used in F10166413), shall be procured from PBC Linear (https://www.pbclinear.com/), and it is highlighted in the product catalog shown in Figure

12.

Figure 12: Open Plain Linear Bearings - PN20C (FC0079396 – PNC (INCH) OPEN PLAIN LINEAR BEARING PILLOW BLOCK)

The Manufacturer shall procure the parts listed in section 3.10 from the specified supplier only.

Documentation of the parts to be procured parts shall be submitted to FFDG for approval, as detailed in

Table 2.

Parts FC0083027 and FC00832028 shall be procured from IGUS (link), parts number are KARM-10-MH and KALM-10-MH, respectively.

https://www.pbclinear.com/ https://www.igus.com/chainflex/bulk-cables?utm_campaign=a-cf-cf&utm_source=ppc&utm_campaign=US+-+Chainflex+(Brand+Terms)&utm_term=igus%20cable&utm_medium=ppc&utm_source=adwords&hsa_kw=igus%20cable&hsa_mt=b&hsa_grp=83220875471&hsa_tgt=kwd-299037623670&hsa_net=adwords&hsa_cam=7237701973&hsa_ver=3&hsa_acc=2997300550&hsa_src=g&hsa_ad=391439601318&gad_source=1&gclid=CjwKCAiAqrG9BhAVEiwAaPu5zo_lgRin7pL4dqTmBWnUy-MEz_3chbFxE6wdD2Do5-7TFEDkwHdF8BoCGTkQAvD_BwE

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APPENDIX C: Technical datasheets of High Emissivity Coating

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