Exhibit A - ED0042515 - PIP-II TTL Interconnect Expansion Joints Specs.pdf

PIP-II Cryogenic Distribution System

TTL Interconnect Expansion Joints specification

Document number: ED0042515

PIP-II Cryogenic Distribution System ED0042515 TTL interconnect expansion joints specification

Fermi National Accelerator Laboratory 2

Document Approval

Signatures Required Date Approved

Originator: William Soyars and Vrushank Patel, PIP-II CDS Cryogenic Engineers As in Teamcenter

Reviewer: Ram Dhuley, PIP-II L3M and CAM for CDS As in Teamcenter

Reviewer: Matt Luedke, PIP-II Quality Assurance As in Teamcenter

Reviewer: Jeremy Nudell, PIP-II Project Engineer As in Teamcenter

Approver: Joe Ozelis, PIP-II L2 for SRFCryo As in Teamcenter

Revision History

Revision Date of Release Description of Change

- As in Teamcenter Original release

PIP-II Cryogenic Distribution System ED0042515 TTL Interconnect Expansion Joints specification

Fermi National Accelerator Laboratory 3

Table of Contents

Introduction

Subcontractor scope

Specific requirements for the axial expansion joints

General specifications for the axial expansion joints

Documentation deliverables

5.1 Offeror shall submit to FNAL the following items in English with the proposal. Information considered proprietary should be identified as such

5.2 The following items shall be submitted at the time of delivery to FNAL

PIP-II Cryogenic Distribution System ED0042515 TTL Interconnect Expansion Joints specification

Fermi National Accelerator Laboratory 4

Introduction

The Proton Improvement Plan II (PIP-II) is a particle accelerator being built as an upgrade of Fermilab accelerator complex. The accelerator includes cryogenically cooled superconducting radio frequency cavities using liquid helium. The modular Tunnel Transfer Line (TTL) delivers cryogens at various temperature levels to the accelerator. A series of interconnect axial expansion joints are needed to manage thermal contraction and allow interconnecting of the TTL modules. Four unique designs are called for in this specification.

Subcontractor scope

Table 3-1 shows the FNAL reference numbers for the axial expansion joints and their required quantities.

Table 2-1 Required quantity of axial expansion joints for PIP-II Tunnel Transfer Line (TTL)

Item FNAL reference number Description Quantity

1 F10227973 2” bellows 108

2 F10227974 3” bellows 27

3 F10227972 10” bellows 27

4 F10228252 32” bellows 27

Total quantity 189

Specific requirements for the axial expansion joints

Table 3-1 shows the allowed size, design and operating conditions, and the minimum required movements for the axial expansion joints.

Table 3-1 Specific requirements for the axial expansion joints

FNAL

reference number

Size of weld spools on both ends

Required overall length##

Design internal pressure

Minimum design metal temperature

Maximum design metal temperature

Minimum axial movement

Mounting tolerance, lateral#

F10227973 2” sch10 pipe 10” 24 bara / Vacuum

4 K 310 K 1.62” 1/8”

F10227974 3” sch10 pipe 10” 20 bara / Vacuum

4 K 310 K 1.62” 3/16”

F10227972 10” sch10 pipe 12.5”

4.1 bara / Vacuum

2 K 310 K 1.62” 1/2”

F10228252*+ 32” sch10 pipe 29” for 25 units; 27” for 2 units

1.5 bara / Vacuum

245 K 310 K 0.5” 1/2”

*This expansion joint will operate under vacuum with 1 atm external pressure during normal operation.

+ Bellow’s inner diameter shall not be less than spool’s inner diameter on both ends.

# For initial pipe fit up, addressing alignment tolerances ## Including convolutions and spools for welding to process lines

Table 3-2 shows the expected peak velocities and their estimated durations during certain operational events such as cooldown, flow during a pressure relieving, normal operation, etc.

PIP-II Cryogenic Distribution System ED0042515 TTL Interconnect Expansion Joints specification

Fermi National Accelerator Laboratory 5

Table 3-2 Peak velocity expected by the axial expansion joints during operational events

FNAL

reference number

Joint description

Internal fluid

Event Peak velocity expected during event

Duration of event

Flow direction during event

F10227973 2” bellows Helium gas Room temperature cooldown 14 m/s at 294 K, 2.7 bara ~hours Single

Pressure relief 15 m/s at 80 K, 24 bara 5 sec Bi-directional

F10227974 3” bellows Helium gas Accelerator device cooldown 45 m/s at 80 K, 1.3 bara ~1 min Single

F10227972 10” bellows Helium gas Pressure relief 2.2 m/s at 7 K, 4.1 bara 20 sec Bi-directional

Normal operation 6.5 m/s at 2 K, 0.03 bara Steady state Single

F10228252 32” bellows Vacuum Normal operation Not applicable Steady state Not applicable

Anchoring and guide model geometry for the process line expansion joints is depicted in Figure 3-1.

The anchor and guide positions are illustrated in Figure 3-2 with measurements in Table 3-3. The expansion joints shall resist instability (squirm).

Figure 3-1 Model of the bellows used at interconnect points

Figure 3-2 Schematic of anchor and guide locations

PIP-II Cryogenic Distribution System ED0042515 TTL Interconnect Expansion Joints specification

Fermi National Accelerator Laboratory 6

Table 3-3 Anchor and guide locations

FNAL

reference number

Size of weld spools on both ends

L_exp joint, including both weld spools L1, inches L2, inches L3, inches

F10227973 (3 lines)* 2” sch10 pipe 10” 6.67 21.60 71.62

F10227973 (1 line) 2” sch10 pipe 10” 9.26 24.19 74.21

F10227974 3” sch10 pipe 10” 10.91 31.64 81.66

F10227972 10” sch10 pipe 12.5” 3.55 24.75 74.77

*Not expected to be worst-case for stability

General specifications for the axial expansion joints

The general specifications for all axial expansion joints are presented in Table 4-1.

PIP-II Cryogenic Distribution System ED0042515 TTL Interconnect Expansion Joints specification

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Table 4-1 General requirements for axial expansion joints

Sr. No. Item Item specification

1 Material

Both the flexible part and end pieces shall be made of stainless steel of the following grades:

• SS304L or SS316L: F10227973, F10227974, F10227972

• SS304 or SS316: F10228252

Bellows end-connection type, typical of both ends

• Butt-weld for F10227973, F10227974, F10227972. Include Weld-prep on both ends.

• Fillet weld for F10228252. (No Weld prep required)

Restraint and protective casing

• F10228252 (32” vacuum bellows) shall be equipped with integrated tie-rod assembly designed to withstand forces due to vacuum and pressure.

• F10228252 (32” vacuum bellows) shall have a removable external casing to protect the convolutions from external impact damage.

Minimum number of cryogenic operation cycles

• 1000 over 20 years.

• 4 Relieving events over 20 years.

Code requirement and standards

• The expansion joint will be installed on a piping system and therefore must comply with ASME B31.3 requirements for Normal Fluid Service.

• Quality Control, Weld Inspections, and Documentation shall meet ASME B31.3 requirements for Normal Fluid Service.

• The design of the bellows should be checked using EJMA standards: Stress state, buckling, and fatigue should be checked.

Maximum helium gas leak rate

Tested to demonstrate < 1 x 10-9 mbar-L/sec on a helium mass spectrometer leak detector, at a vacuum level < 1 x 10-4 mbar at room temperature.

7 Pressure Test Conduct test and provide pressure test certification in full compliance with ASME B31.3.

In-service gas purity requirements

• Design must ensure air and other impurities can be removed when expansion joint installed in high purity helium system.

• If internal liner/sleeves used in expansion joint, sleeves must allow gas-communication for the volume trapped between the sleeves and bellows with the main process flow.

Cleanliness requirements

Free of dirt, grease, oil, and chips. Clean and degrease to CGA 4.1 for oxygen service.

Shipping and handling requirements

Each axial expansion joint shall be capped on both the ends and individually bagged for shipment.

11 Labelling

• FNAL reference numbers of Table 3-1 shall be etched on the weld collar at both ends of each axial expansion joint.

• Overall length (27” or 29”) to be etched on each of F10228252.

PIP-II Cryogenic Distribution System ED0042515 TTL Interconnect Expansion Joints specification

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Documentation deliverables

5.1 Offeror shall submit to FNAL the following items in English with the proposal. Information considered proprietary should be identified as such.

Total cost to fabricate, test, and deliver all the axial expansion joints of Table 2-1 to FNAL site.

Delivery schedule.

Lists of exceptions to this specification and reasoning for exception.

Sample welding documentation including ASME WPS, PQR, WQR.

Technical details including at a minimum:

a. Calculations showing range of allowable axial expansion and lateral shift motion of each distinct axial expansion joints of Table 3-1.

b. Provide reference drawings showing

i. Overall length, OD, ID, of axial expansion joints.

ii. Details of end connection including weld preparation. This shall be suitable for making an ASME compliant weld.

iii. Drawings showing an approach to handling high velocity flow conditions as described in Table 3-2. Preference will be given to designs that meet or exceed the velocity handling requirement.

c. Full design allowance of motion, if more than the stated requirements.

d. Details on convolutions: number, thickness, number of plies.

e. Drawing showing approach to ensuring in-service helium purity and prevention of trapped cold fluid in sleeved and/or multi-ply bellows.

f. Analysis/verification showing that the proposed axial expansion joint is compatible with anchor and guides as described in Table 3-3.

PIP-II Cryogenic Distribution System ED0042515 TTL Interconnect Expansion Joints specification

Fermi National Accelerator Laboratory 9

5.2 The following items shall be submitted at the time of delivery to FNAL.

Final quality control reports including, but not limited to, helium leak check and ASME pressure test.

Completed manufacturing inspection plans.

Material certifications.

Nonconformances & their resolution.

Certificate of Compliance to ASME B31.3 – Normal Fluids Service.

Final welding documentation including ASME WPS, PQR, WQR.

Final detailed drawings of as-fabricated axial expansion joints.