Exhibit A - ED0044582-A- ORBUMP Coil Assembly Fermilab SOW...pdf

ED0044582-A-PIP-II ORBUMP Coil Assembly SOW

Fermi National Accelerator Laboratory 1

PIP-II-ORBUMP Magnet ORBUMP Coil

Assembly Statement of Work

Document Number: ED0044582 Rev. A

Fermi National Accelerator Laboratory 2

Revision History

Revision Date of Release Description of Change

- November 2025 Initial Release A February 2026 Updated drawing revisions in Appendix B. Removed some references to drawing revisions throughout the document

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Table of Contents

1. INTRODUCTION

2. SCOPE AND DELIVERABLES

3. REQUIREMENTS/SPECIFICATIONS

3.1. MATERIAL REQUIREMENTS

3.2. BRAZING REQUIREMENTS

3.3. LEAD CLAMPING

3.4. MACHINING REQUIREMENTS

4. HOLD POINTS AND REVIEWS

5. DELIVERY SCHEDULE AND HOLD POINTS

6. REPORTING/MEETING REQUIREMENTS

7. QUALITY REQUIREMENTS

7.1. Documentation

8. ACCEPTANCE TESTING

8.1. SUBCONTRACTOR FACTORY ACCEPTANCE TESTING

8.2. FFDG SITE ACCEPTANCE TESTING

9. SERIALIZATION

10. WARRANTY

11. SHIPPING

12. BID EVALUATION CRITERIA

13. POST-AWARD MANUFACTURER’S EXCEPTION DOCUMENT

APPENDIX A

A.1 ACRONYMS

APPENDIX B

B.1 DRAWINGS

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1. INTRODUCTION

The Proton Improvement Plan Phase II (PIP-II) project will require a new 800 MeV Injection System to be installed in the reconfigured Long 11 straight section of the Fermilab Booster. The main components required to facilitate the injection process are the new Orbital Bump (ORBUMP) magnets. This statement of work establishes the requirements for the ORBUMP Coil assembly (Figure 1) which is a component of the PIP-II ORBUMP magnet.

Figure 1: ORBUMP Coil Assembly This Statement of Work (SOW) outlines the technical tasks and requirements for the Prospective Offerors (hereafter referred to as “The Subcontractor”), including reporting, documentation, scheduling, change management, deliverables, and communication with The Buyer, Fermi Forward Discovery Group (FFDG). These requirements must be fulfilled in accordance with Fermi National Accelerator Laboratory’s standards and guidelines as described in this SOW.

2. SCOPE AND DELIVERABLES

The primary scope of work covers ORBUMP coil fabrication, quality control (QC), and delivery for a build-to-print package inclusive of all associated and/or described work within this SOW as it relates to the ORBUMP Coil Assembly. The includes manufacturing of individual components, design and fabrication of a coil assembly brazing fixture, vacuum oven brazing, post-braze machining, and QC testing/inspections for one prototype and seven production ORBUMP Coil Assemblies.

The Subcontractor will be responsible for sourcing all necessary materials and tooling to fabricate the coils, as well as providing FFDG with comprehensive documentation on testing and material certification.

The Subcontractor will provide all shop facilities, manufacturing equipment, qualified shop personnel, engineering personnel, Quality Assurance (QA) inspection services, cleaning services, and packaging services for completing the scope of work defined in this SOW.

Table 1 provides a list of all contract deliverables, including documentation which is listed as required (AR). Only released drawings shall be used for fabrication. The Subcontractor must verify drawing versions with FFDG prior to the start of any manufacturing or fabrication. Upon completion of all deliverables stated in this SOW, the Subcontractor will transfer all developed unique tooling, including the brazing fixture, drawings and 3D models, to FFDG. One prototype coil will be delivered to FFDG first for Site Acceptance testing (SATs) outlined in Section 8.2. Upon Quality Assurance and testing completion, manufacturing and fabrication will begin on the remaining seven production ORBUMP Coil Assemblies.

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Table 1: List of Contract Deliverables Item Quantity

ORBUMP Coil Assembly Prototype 1 ORBUMP Coil Assembly Production Units 7 Project Specific QC Plan 1 Material Certification Document(s) AR Subcontractor Factory Acceptance Test Report AR Visual and Dimensional Inspection Report AR Unique Tooling AR Discrepancy/Nonconformance Reports AR

3. REQUIREMENTS/SPECIFICATIONS

All dimensional tolerances, including brazing joint dimensions, bending radii, and post-machining profiles of the ORBUMP coil, shall conform to the following FFDG engineering drawings:

1. F10252560-A – Brazing Assembly ORBE Coil Assembly (geometric tolerances applicable to brazing and overall assembly).

2. F10120746-B – Coil Assembly, ORBE Magnet (geometric tolerances applicable to machined coil profiles after brazing).

The Subcontractor shall ensure compliance with these drawings and provide a Visual and Dimensional Inspection Reports as part of the deliverables. Any requests for deviations and/or exceptions shall be consistent with Clause 5 – CHANGES AND MODIFICATIONS as identified in the Terms and Conditions provided in the Request for Proposal (RFP) documents.

3.1. MATERIAL REQUIREMENTS

The brazed subcomponents of the ORBUMP Coil Assembly shall be made from OFHC C10200 copper alloy with an electrical conductivity of at least 100% conductive as per IACS standards. The coil assembly, subassembly, and subcomponents must be free of surface defects, damage, nicks, cuts, and scratches, ensuring the resistance of all coils constructed from it is equal within 1%. Material certifications shall be provided to FFDG all components.

The Lower Cooling Tube (F10120754) and Upper Cooling Tube (F10120746), made from OFHC C10200, will be provided by FFDG in minimum lengths of 100 meters of spooled tubing. There shall be no internal joints in the copper tubing used on each coil.

3.2. BRAZING REQUIREMENTS

Brazing of the ORBUMP Coil Assembly shall be completed via vacuum oven brazing according to AWS C3.6M/C3.6:2016-AMD2. All brazed joints must comply with Class A Joints as stated in the AWS specification. The subcomponents making up the ORBUMP Coil Assemblies shall be brazed simultaneously as one structure. Brazing of individual components outside of this process is not permitted. The Subcontractor is required to design and fabricate a vacuum oven brazing fixture to braze the ORBUMP Coil Assemblies as part of the deliverables for this SOW. The fixture shall hold the tolerances as shown in drawing F10252560 throughout the brazing process and subsequent cooling of the ORBUMP Coil Assembly. Prior to brazing, localized tack welding after application of brazing material is permitted. All locations and brazing application plans for tack welding shall be approved by FFDG.

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The brazing material shall be suitable for vacuum brazing, with all joints and connections brazed using Aufhauser Silver Alloy A-54N, A-50, or a FFDG-approved equivalent that contains at least 50% silver solder. After completing the brazing process, excess brazing alloy shall be mechanically removed to be flush with the surfaces of the assembly. The final stage of testing of the brazed joints is a non-invasive examination such as ultrasonic testing or equivalent that is approved by FFDG. The brazed joints must comply with the criteria outlined in AWS C3.6M/C3.6:2016-AMD2 for Class A Joints.

3.3. LEAD CLAMPING

The Lead Coil Bracket (F10234913) shall be assembled onto the Coil Assembly after brazing is complete prior to machining. It is permitted to slightly align the Top Conductor Bar while installing the Lead Coil Bracket in order to meet the tolerances outlined in drawing F10252560. The Lead Coil bracket shall remain assembled onto the Coil Assembly throughout the machining, Quality Assurance testing, and transport to FFDG.

3.4. MACHINING REQUIREMENTS

After brazing is complete, the ORBUMP Coil Assembly shall be machined to the dimensions and tolerances outlined in drawing F10120746. The process used to reach these tolerances, such as wire Electrical Discharge Machining, shall be approved by FFDG prior to machining.

4. HOLD POINTS AND REVIEWS

To ensure a proper understanding of the specifications within this SOW, the subcontractor and FFDG shall conduct the following program hold points and reviews. These are broken up categorically and include the deliverables for each. FFDG shall review and approve deliverables for the QC Review prior to shipment of the prototype coil. The Subcontractor is not permitted to ship the ORBUMP coils prior to approval of the deliverables for the QC Review Hold Point.

1. Initial kickoff meeting to review requirements

2. Manufacturing Review Hold Point:

a. Material Certifications for Coil Assembly components

b. Updated Production Schedule

c. Project Specific QC Plan

d. Dimensional and visual inspection reports for Coil Assembly components

e. Review of tooling and processes to be used for fabrication of Prototype Coil

f. Review of tests to be completed after brazing of Prototype Coil

3. QC Review Hold Point:

a. Review of processes and lessons learned during Prototype Coil fabrication

b. Subcontractor Factory Acceptance Test Report

c. Visual and Dimensional Inspection Report

d. Delivery of prototype coil Subcontractor Factory Acceptance Tests are reviewed and approved followed by the FFDG Site Acceptance Tests

5. DELIVERY SCHEDULE AND HOLD POINTS

Table 2 below outlines the delivery schedule for the deliverables and hold points required by the contract for review and approval. The schedule shown is for reference only and represents number of weeks after

Fermi National Accelerator Laboratory 7 receipt of order (ARO) when the contract is awarded. The Subcontractor is requested to submit an updated production schedule for review and approval by FFDG as part of the deliverables for the Manufacturing Review Hold Point as stated in Section 4.

Table 2: Delivery Schedule and Hold Points

Description Weeks for Item ARO Kickoff Meeting 2 2 Manufacturing Review Hold Point 8 10 QC Review Hold Point 6 16 Subsequent Delivery of Production ORBUMP Coil Assemblies Along with Inspection Reports and Unique Tooling

14 30

Contract Closeout 4 34

6. REPORTING/MEETING REQUIREMENTS

The Subcontractor shall submit a written subcontract status report (in bullet form via email) to FFDG bi-weekly. Bi-weekly or monthly meetings shall also be held between the Subcontractor and FFDG on an as needed basis to discuss contract status. The Subcontractor shall provide access to the subcontractor’s manufacturing facility, which will include observation of the in-process fabrication and testing as described in this SOW, with 1 week’s written notice.

7. QUALITY REQUIREMENTS

The Subcontractor shall develop a Project Specific QC Plan for review by FFDG as part of the deliverables for this SOW. The quality control plan shall include:

• Description of equipment and testing/inspection methods planned to ensure requirements outlined in this SOW are met

• Description of documentation planned to communicate contract conformance to FFDG

• Description of nonconformance management process to be used

• Applicable training/qualifications required

As applicable, a Manufacturing Inspection Plan can be included to detail at which steps in manufacturing inspections shall occur as well as including any Hold Points listed in this SOW.

The Subcontractor is required to procure, build, and deliver items per the requirements listed in Section 2 and 3. The Subcontractor shall immediately notify FFDG of any conflict or ambiguity between the specifications, SOW and/or drawings prior to any work being performed or cost being incurred by FFDG.

In the event of a conflict, the order of precedence is as follows:

• Drawings

• Scope of Work

• Specifications

• General Terms and Conditions as identified in the RFP documents

• Subcontractor’s RFP response

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7.1. Documentation

The documentation required is considered a contract deliverable. Documentation deliverables are listed in Section 2, along with any documentation required to ensure that acceptance tests are successfully completed according to Section 8.

The following defines the requirement for the document deliverables outlined in Section 2:

• Project Specific QC Plan: The Subcontractor shall provide FFDG a project specific QC plan which includes, at a minimum, the requirements outlined in Section 7.

• Material Certification: Documentation stating the type of material, mechanical and chemical properties, lot or heat number, and the specifications the material complies with (i.e., ASME, ASTM, etc.) for each subcomponent. Material certification documents shall be provided to FFDG as soon as materials are received to ensure the materials are in compliance with the drawings/specifications.

• Subcontractor Factory Acceptance Test Report: The report shall include the results from the Factory Acceptance Tests outlined in Section 8.1.

• Visual and Dimensional Inspection Report: The production assemblies, weldments, and subcomponents shall be visually inspected. They must be free of damage, dirt, grease, oil, and chips. They must also be free of all sharp edges, corners, and burrs. The final production assemblies, weldments, and subcomponents shall conform to all dimensions, form, fit, and tolerances specified in the provided released drawings. The Subcontractor shall provide a summary of the visual inspection along with a dimensional inspection report for 100% of all assemblies, weldments, and subcomponents prior to shipment.

• Discrepancy/Nonconformance Reports: A document used to formally record and report a deviation or noncompliance from established drawings, specifications, or procedures.

8. ACCEPTANCE TESTING

8.1. SUBCONTRACTOR FACTORY ACCEPTANCE TESTING

The Subcontractor shall provide a Certificate of Conformance prior to shipment of the ORBUMP Coil Assemblies, which documents the completion of all deliverables and conformance with the specifications stated in this SOW. FFDG reserves the right to assign technical or procurement specialists to witness Subcontractor Factory Acceptance Testing to verify compliance with the specifications stated in this

SOW.

The following tests shall be conducted at the Subcontractor facility as part of their Factory Acceptance Testing:

• Non-Invasive Brazed Joint Test. All non-invasive testing must comply with AWS C3.6M/C3.6:2016-AMD2 for Class A Joints. The total measured void, or unbonded area, of the joint shall not exceed 15% of the total joint area. The width of the largest void or unbonded area as measured parallel to the joint width shall not exceed 60% of the total joint width. Any such void that is wider than 40% of the width of the joint shall extend no closer to either edge of the joint than 20% of the joint width.

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• Resistance Measurement. The ORBUMP Coil Assembly Ohmic resistance shall be measured and recorded to four significant figures (i.e., X.XXX or XXX.X), at 22ºC ± 3ºC (72ºF ± 5ºF), using standard equipment approved by FFDG. The ORBUMP Coil Assembly Ohmic resistance readings shall be within ±10% of the average across all coils.

• Hydrostatic Test. The Lower Cooling Tube (F10120754) and Upper Cooling Tube (F10120918) shall be filled with clean, filtered water and pressurized to 24.1 Bar (350 PSI). The cooling tubes shall be isolated from the pressure source for a period of 30 minutes and any pressure changes shall be recorded on the Coil Data Sheet. The coil shall show no evidence of external leakage or internal pressure drop.

• Hydraulic Flow Test. Each water branch of the coil shall be tested for water flow in Liters/min

(gallons per minute) at a pressure differential of 3.45 Bar (50 PSI) ± 5% for the Upper Cooling Tube (F10120918) and 3.17 Bar (46 PSI) ± 5% for the Lower Cooling Tube (F10120754). Only clean, filtered water shall be used with a temperature range of 15 ºC to 27 ºC (60 Fº to 80 Fº).

The estimated water flow for each cooling branch is 6.06 L/min (1.6 GPM) ± 10% at the pressure differentials listed. Any coil whose water flow rate exceeds ± 5% of the average rate for all the coils produced or does not meet the flow rate specified by the buyer shall be rejected.

8.2. FFDG SITE ACCEPTANCE TESTING

Upon receipt of the ORBUMP Coil Assemblies, FFDG will conduct a visual inspection identical to the one outlined in Section 7.1. A dimensional inspection will also be conducted. The geometric positions and profile tolerances outlined in drawing F10120746 will be measured. Testing will be conducted on the Hydraulic flow, hydrostatic pressure, and Ohmic resistance identical to the tests outlined in Section 8.1 will be conducted.

9. SERIALIZATION

Each coil must be stamped or laser engraved with a unique serial number. This information shall be displayed in the location specified in Figure 2. The serial number must include the following:

• ORBUMP-X-XX-XXXX

Where X is the sequential number of coils manufactured (i.e., the prototype is ‘1’) along with XX and XXXX is the month and year of manufacturing. All texts shall be 6.35 mm (0.25”) high.

Figure 2: Location of stamped or laser engraved marking

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Throughout the manufacturing process, all material shall be clearly identified to indicate their inspection and test status, as well as the specific assembly in which each part is used. Identification may be maintained through the supplier’s use of tags, routing cards, or other equivalent means.

10. WARRANTY

Contract deliverables shall be free of manufacturing defects for a period of 12 months after component delivery.

11. SHIPPING

The Subcontractor is responsible for proper packing and/or crating of each ORBUMP Coil Assembly.

Standard shipping methods and practices shall be used. All items shall be packaged to protect them from shipping and weather damage. Prior to storage, the magnet water passages should be flushed with clean, filtered water and drained. They should then be blow dried with clean, filtered, and oil free compressed air. The outlets of cooling pipes shall be protected with suitable plastic or rubber caps.

Coils shall be covered by waterproof shrouding and shall be cushioned and blocked to prevent damage by impact. Particular attention should be paid to the protection of the profiled middle features of the coils and power terminals.

12. BID EVALUATION CRITERIA

This is a best value trade off source selection. This process permits tradeoffs among cost or price and non-cost factors and allows FFDG to accept other than the lowest priced proposal. All evaluation factors other than cost or price, when combined, are significantly more important (approximately equal to or significantly less important) than cost or price. Award shall be made to the supplier who is deemed responsible by FFDG, whose proposal conforms to the solicitation's requirements, and is judged to represent best value to FFDG. FFDG intends to award without discussions. The Subcontractors are required, at a minimum, to submit information regarding these topics as outlined below as part of their proposal during the Request for Proposals process.

1. PRICE

2. TECHNICAL PROPOSAL

a. Infrastructure and Capabilities: Subcontractors are to include their in-house infrastructure related to this specific job including, but not limited to, manufacturing and fabrication capabilities as well as their general quality assurance program and equipment.

b. Fabrication Experience: Subcontractors are to include past construction experience for similar fabrication, and quality assurance done on their premises.

c. Schedule: Subcontractors are to include a computer-generated Gantt chart (or similar) showing all activities and detailed schedules to provide all deliverables including delivery of the ORBUMP Coil Assemblies.

13. POST-AWARD MANUFACTURER’S EXCEPTION DOCUMENT

If the Subcontractor requests a post-award change to the contract requirements (specifications, drawings, etc.), the Subcontractor shall provide to FFDG a Manufacturers Exception Document (MED). This

Fermi National Accelerator Laboratory 11 document shall list all proposed changes. When drawings are affected, each drawing change shall be listed and include the drawing number, changed drawing values, and drawing location. FFDG must sign and return the MED prior to implementing changes. All changes shall be pursuant to and consistent with Clause 5 – CHANGES AND MODIFICATIONS as identified in the Terms and Conditions provided in the Request for Proposal documents.

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APPENDIX A

A.1 ACRONYMS

PIP-II Proton Improvement Plan Phase II ORBUMP Orbital Bump SOW Statement of Work FFDG Fermi Forward Discovery Group QC Quality Control AR As Required MRHP Manufacturing Readiness Hold Point ARO After Receipt of Order

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APPENDIX B

B.1 DRAWINGS

Number Name of Drawings Revision

F10120746 COIL ASSEMBLY, ORBE MAGNET B

F10252560 BRAZING ASSEMBLY, ORBE COIL ASSEMBLY A

F10120748 CONDUCTOR BAR 2, COIL, ASSEMBLY, ORBE MAGNET B

F10120750 JUMPER 1, COIL, ASSEMBLY, ORBE MAGNET B

F10120751 JUMPER 2, COIL, ASSEMBLY, ORBE MAGNET B

F10120754 COOLING TUBE, LOWER, COIL ASSEMBLY, ORBE MAGNET B

F10120880 BRIDGE PLATE, JUMPER TO LEAD, COIL ASSEMBLY, ORBE

MAGNET

B

F10120918 COOLING TUBE, UPPER, COIL ASSEMBLY, ORBE MAGNET B

F10194787 COVER PLATE, UPPER COIL, ORBE MAGNET B

F10194798 LEAD PLATE UPPER COIL, ORBE MAGNET B

F10194949 KEY, NON LEAD END TOP, ORBE COIL ASSEMBLY B

F10194950 KEY RECTANGLE, ORBE COIL ASSEMBLY B

F10198942 KEY, LEAD END TOP, ORBE MAGNET B

F10199554 LEAD ROD - COIL ASSEMBLY, ORBE MAGNET B

F10203322 KEY FILLER, COIL ASSEMBLY, ORBE MAGNET B

F10209598 CONDUCTOR BAR 1, COIL ASSEMBLY, ORBE MAGNET B

F10209699 CLAMP, ROUND, SHORT, COIL ASSEMBLY, ORBE MAGNET B

F10209700 CLAMP, ROUND, LONG, COIL ASSEMBLY, ORBE MAGNET B

F10211519 CLAMP, ROUND, MINI, COIL ASSEMBLY, ORBE MAGNET B

F10234913 LEAD COIL BRACKET, ORBE MAGNET A

F10234932 LOWER CLAMP, COIL BRACKET -

F10234952 UPPER CLAMP, COIL BRACKET -