Exhibit A ED0042614-PIP-II TTL Warm Control Valves specification.pdf

PIP-II Cryogenic Distribution System

ED0042614-PIP-II Tunnel Transfer Line

Warm Control Valves specification

PIP-II Cryogenic Distribution System ED0042614-PIP-II TTL Warm Control Valves specification

Fermi National Accelerator Laboratory 2

Document Approval

Signatures Required Date Approved

Originator: William Soyars, Vrushank Patel, Pratik Patel; CDS 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: Joseph Ozelis, PIP-II L2 for SRFCryo As in Teamcenter

Revision History

Revision Date Released Description

- As in Teamcenter Initial release

Fermi National Accelerator Laboratory 3

1. Introduction and Scope 4

2. Scope Error! Bookmark not defined.

3. General technical requirements 5

4. Valve specific technical requirements 7

5. Manufacturing, testing, and miscellaneous requirements. 8

6. Transportation and handling 10

7. Document deliverables 10

8. References 12

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1. Introduction

The Proton Improvement Plan II (PIP-II) is a particle accelerator being built as an upgrade of FNAL accelerator complex. The accelerator includes cryogenically cooled superconducting radio frequency cavities using liquid helium (He II) at 2 K. Warm Control Valves are needed to supply room temperature helium gas to the accelerator for controlling the cooldown and warm-up rates. This specification seeks proposals for the Warm Control Valves.

2. Acronyms and definitions

2.1. Acronyms

2.1.1. Technical acronyms

BC Bayonet Can

CDS Cryogenic Distribution System

CM Cryomodule (a proton beam accelerator cryogenic control valves)

CPP Cryogenic Process Piping

He Helium

HTTS, LTTS High Temperature Thermal Shield, Low Temperature Thermal Shield

MAWP Maximum Allowable Working Pressure

OEM Original Equipment Manufacturer

P&ID Piping and Instrumentation Diagram

PQR Procedure Qualification Record

TTL Tunnel Transfer Line

2.1.2. Organizational Acronyms

ANSI American National Standards Institute

ASME American Society of Mechanical Engineering

ASTM American Society for Testing and Materials

ISO International Organization for Standardization

PIP-II Proton Improvement Plan II

NIST National Institute of Standards and Technology

FNAL Fermi National Accelerator Laboratory

2.2. Definitions

AMBIENT

a term used to define nominal environmental conditions, unless otherwise specified, of atmospheric pressure

WARM CONTROL

VALVES

a term used to refer collectively to Warm Control Valve assemblies to be procured for installation on the Tunnel Transfer Line

OFFEROR An entity interested in submitting a proposal in response to this specification

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SUBCONTRACTOR

a term used to refer to the designer, fabricator, and supplier of the WARM CONTROL

VALVES

CODE

a term used to refer collectively to the various pressure safety standards to which the WARM CONTROL VALVES shall comply.

Linac a term that indicates a set of SRF cryomodules connected in series.

May a term which indicates that a provision is neither required nor prohibited

Steady State the nominal operating mode in which the WARM CONTROL VALVES operates at superfluid helium temperatures

Transient the mode in which the Linac is either cooling down or warming up and the WARM CONTROL VALVES operates in a range between 2 K and 300 K

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

Thermal Cycle a term that describes a temperature change experienced by a component equal to the difference between room temperature and the minimum design temperature of the component. It can apply to either the warming or cooling of a given component.

3. General technical requirements

3.1. The WARM CONTROL VALVES shall

3.1.1. Be top load type.

3.1.2. Have globe body pattern.

3.1.3. Have bellows spindle seal with backup sealing.

3.1.4. Have body integral weld-in flange.

3.1.5. Have Schedule 10S connections to process piping as specified in Table 4-1.

3.1.6. Be for helium service.

3.1.7. Have pneumatic diaphragm actuators, set to “fail-close” in the case of loss of actuator air supply pressure.

3.1.8. Have 1:100 equal percentage plug profile.

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3.2. Leak tightness

3.2.1. Maximum integral helium leak rates occurring during testing and operation of a cryogenic control valve shall not exceed the values presented in Table 3-1. Leak testing shall be performed at design pressure, room temperature, using helium gas as the fluid.

Table 3-1 Maximum acceptable leak rates at room temperature

Description Maximum Acceptable

Helium Rate

[Pa*m3/sec]

Welds, tube/pipe, forged material, bellows 1 x 10-9

O-ring seals 1 x 10-7

Seat tightness at maximum system pressure 1 x 10-5

3.3. Labelling

3.3.1. The valve body shall be etched to show serial number, size, class, body material, flow direction.

3.3.2. Valve serial number and tag/ID number shall be labeled on the valve bonnet and actuator. The tag/ID numbers will be provided by FNAL.

3.4. Operating environment and lifetime

3.4.1. The control valves shall operate in an indoor environment.

3.4.2. The control valve bellows shall be designed for 10,000 cycles full open to full closed at nominal pressure.

3.4.3. Pneumatic actuators shall be suitable for instrument air pressure range of 4.2 bar(g) ≤ P

≤ 6 bar(g)

3.4.4. The valves shall be constructed using materials that can withstand lifetime radiation dose of 1e5 Gy without degradation or valve performance deterioration.

3.5. Service experience requirements

3.5.1. SUBCONTRACTOR shall have previously provided actuators using Siemens controls per section4.3.1.

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4. Valve specific technical requirements

4.1. Details of Control Valves on TTL Bayonet Cans (TTL-BC) are given in Table 4-1.

Table 4-1 Warm Valves for TTL-BC (nn = 1-25 unless specified otherwise)

FNAL Tag ID PV-nn70 PV-nn71 PV-nn72

Process line HP Helium Supply HTTS temp control 4.5K circuit temp control

Connecting pipe [inch] ½” ½” ½”

Connecting pipe schedule 10S 10S 10S

Pipe design pressure [bara] 24 24 24

MDMT 244 K 244 K 244 K

Nominal operating Temperature 293 K 293 K 293 K

Valve stem material SS SS SS

Requested Cv 6 6 0.5

Quantity 25 25 25

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4.2. Additional scope

4.2.1. Spare seal kits and tooling required to remove bullet and valve seat (if applicable) for each valve size.

4.3. Other technical requirements

4.3.1. Pneumatic diaphragm actuators on the valves shall be suitable for installation test pressure per ASME for the pressure ranges indicated in Table 4-1.

4.3.2. The control valve seals, actuator, and positioner shall be suitable for use in a high radiation environment.

4.3.2.1. The valve Static seal material should be EPDM and seat seal material should be PEEK. Alternatives may be proposed, their use is subject to FNAL written approval.

4.3.2.2. Actuator air thread sealing should use Loctite 580 for thread sealing. Alternatives may be proposed, their use is subject to FNAL written approval. Teflon PTFE or other materials not suitable in radiation environment shall not be used.

4.3.2.3. The SUBCONTRACTOR shall identify any plastic or polymer-based components, and any low thermal conductivity materials used on the tunnel valves, and they shall be suitable for service in radiation environment.

4.3.1. The control valve actuators shall use an i-p positioner with external analog electronics mounted remotely outside via SIPART PS2 19” drawer with PROFIBUS-PA communication. The control valves shall use the following positioner:

4.3.1.1. Siemens SIPART PS2 6DR5910 with external analog electronics in rack. This component shall be provided by the SUBCONTRACTOR integrated with the CONTROL VALVE assembly. The component shall have readback provision that shows current position of the valve.

4.3.1.2. The external 19” rack for positioner electronics (A5E00250503) will be procured by FNAL separately and is not in the scope of this procurement.

5. Manufacturing, testing, and miscellaneous requirements.

5.1. CODE requirements

5.1.1. All WARM CONTROL VALVES shall be built and tested in full compliance with ASME

B31.3.

5.2. Quality Assurance

5.2.1. The SUBCONTRACTOR shall have a current certification to ISO 9001 requirements.

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5.2.2. The WARM CONTROL VALVES shall be designed and manufactured in accordance with the SUBCONTRACTOR’s Quality Assurance Plan (QAP).

5.2.3. The QAP shall comprise training and qualification records of personnel and/or procedures for the performance of certain special processes. These include, but are not limited to welding, heat treatment, non-destructive examination, helium mass spectrometer leak check, and others as may be required by this specification or by the nature of the process or product.

5.3. Leak tightness testing

5.3.1. Leak testing shall be done in accordance with the following standards as applicable

5.3.1.1. ASTM E493 Testing for Leaks Using the Mass Spectrometer Leak Detector in the Inside-Out Testing

Mode

5.3.1.2. ASTM E498 Testing for Leaks Using the Mass Spectrometer Leak Detector in the Tracer Probe Mode

5.3.1.3. ASTM E499 Testing for Leaks Using the Mass Spectrometer Leak Detector Probe Mode

5.4. Cleanliness

5.4.1. The control valves shall be thoroughly cleaned of all foreign substances including, but not limited to, scale, spatter, flux, oil, grease, and dust.

5.5. Testing and inspection

5.5.1. All inspections, examinations, and tests shall be documented in a Manufacturing

Inspection Plan (MIP). If SUBCONTRACTOR is not familiar with a MIP, FNAL can provide guidance, examples, and/or template.

5.5.2. The SUBCONTRACTOR shall pressure test all WARM CONTROL VALVES in accordance with ASME B31.3.

5.5.3. Control valve function shall be checked for stroke movement, actuator, and positioner indication.

5.5.4. All inspection, examination, and test reports shall be fully documented and provided to

FNAL.

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6. Transportation and handling

6.1.1. The WARM CONTROL VALVES shall be packed adequately for shipment to prevent any damage during transit to the FNAL site in Batavia, Illinois, USA.

6.1.2. The WARM CONTROL VALVES shall be crated to be readily handled with a forklift truck and shall have suitable lifting attachments for use with an overhead crane.

7. Document deliverables

7.1. The following items shall be submitted in English with the proposal. Information considered proprietary should be identified as such.

7.1.1. Total cost to fabricate, test, and pack for shipment to FNAL site fully functional Warm

Controls valves ready for installation.

7.1.2. Pricing for shipment to deliver to FNAL. (See “Subcontractor Form for Pricing-

Shipments”) shall be provided in the following option.

7.1.2.1. Incoterms 2020 DAP Fermilab

7.1.1. As option, pricing for spare parts option if offered. (See “Subcontractor Form for Pricing-

Spare Part Options”.)

7.1.2. Delivery schedule listing main activities of this project.

7.1.3. Lists of exceptions to this specification and reasoning for exceptions.

7.1.4. Technical details of the offered WARM CONTROL VALVES covering:

7.1.4.1. ASME B31.3 compliance strategy

7.1.4.2. Drawings and step files of the following:

• Process piping connection interface

7.1.4.3. Details of materials to be used for constructing the WARM CONTROL VALVES

7.1.4.4. All other requirements stated in Section 3 and Section 4 of this specification.

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7.1.1. A copy of QAP that demonstrates OFFEROR’S capability to satisfy requirements of paragraph 5.2.

7.1.2. Sample welding plan, WPS, examination, and acceptance testing procedures.

7.1.3. Sample packaging and shipping plan. The sample shall serve as illustration of the packing and shipping solutions to be used for this proposal.

7.1.4. OFFEROR profile highlighting the key technical personal, staffing level, and workshop facilities.

7.1.5. OFFEROR examples within the last 10 years of providing control valves that resemble this proposal. (See “Subcontractor Technical Questionnaire” document.)

7.1.6. OFFEROR completed “Technical Questionnaire”, “Subcontractor Form for Pricing-

Shipments”, “Subcontractor Form for Pricing- Spare Part Options”, and other documents provided by FNAL with this Technical Specification.

7.2. The following items shall be submitted to FNAL in English at the time of manufacturing start

7.2.1. Mill certification reports for all raw materials used in the construction of WARM

CONTROL VALVES. Reports shall be clearly identified with the WARM CONTROL

VALVES part number(s) for which the material was used and show cast or heat numbers, chemical analysis, and mechanical properties.

7.2.2. Certificates of compliance (in lieu of mill certification reports) for commercial items such as weld rods, electrodes, and fasteners.

7.2.3. Copies of the WPQ, WPS, and PQR for each welder and welding procedure utilized in welding operations.

7.2.4. Qualification documents of all technical personnel performing the required examinations and inspections of materials, in-process fabrications, non-destructive tests, and acceptance tests.

7.2.5. Final version of Manufacturing Inspection Plan (MIP) including work instruction for meeting the requirements of Section 5.4.

7.2.6. Final drawings and step files of items given in paragraph 7.1.4.2 if modifications were made.

7.2.7. Final transportation and handling plan.

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7.3. The following items shall be submitted in English at the time of delivery to FNAL

7.3.1. Final quality control reports including, but not limited to, leak check and pressure test reports with name and qualification of the person(s) performing tests.

7.3.2. Completed MIP.

7.3.3. Nonconformances & their resolution.

7.3.4. Instructions for initial uncrating/unpacking and handling upon delivery to FNAL.

7.3.5. Certificate of Compliance for the WARM CONTROL VALVES stating compliance with

ASME B31.3.

8. References

There are no sources in the current document.