Exhibit A1 - PIP-II WFE Fluids Installation SOW.pdf

PIP-II Warm Front Ends Process Fluids Installation Statement of Work

Preparation Date: 01-Feb-2025 Date: 01-Feb-2025 Preparing Organization: AD/ACTD - MSD, PIP-II, FNAL Document Number: ED0040600 Rev A

ED0040600-PIP-II Warm Front Ends Fluids Installation Statement of Work

Fermi National Accelerator Laboratory 2

Document Approval Signatures Required Date Approved

Originator: M. Sadowski As in Teamcenter

Reviewer: C. Baffes As in Teamcenter

Reviewer: M. Ball As in Teamcenter

Reviewer: M. Geelhoed As in Teamcenter

Reviewer: T. DiGrazia As in Teamcenter

Reviewer: J. Nudell As in Teamcenter

Approver: J. Leibfritz As in Teamcenter

Revision History

Revision Date of Release Description of Change -- 2/1/20025 Initial Release A 7/14/2025 Addition of Section 3.6

Document Reference

Reference number

Document Name Document number

1 RFQ Cooling System Layout F10212106 2 PIP-II, WFE, Strut Brackets & Frame

Assembly for Cooling Manifold Assemblies

F10220981

3 PIP-II, LCW Pipe Assembly, Cryo Alcove

F10242943

Table of Contents

1 INTRODUCTION

1.1 LCW Manifolds for MEBT and LEBT

1.2 Chilled LCW Manifolds for Ion Source

1.3 RFQ Three Skid LCW System

2 ACRONYMS AND DEFINITIONS

2.1 Abbreviations

2.2 Definitions

3 DESCRIPTION OF WORK

3.1 General

3.2 LCW Manifolds for MEBT and LEBT

3.3 South LCW Manifold for MEBT – Girder 5

3.4 Chilled LCW Water Manifolds for Ion Source and LEBT

3.5 RFQ Three Skid LCW System

3.6 Rated Fire Barrier Penetration

3.7 Exceptions in the Assembly Drawings for PIPING installation work

4 APPLICABLE CODES AND STANDARDS

4.1 General

4.2 List of Codes and Standards

5 Fermi-Forward Provided MATERIALS and Equipment

6 Subcontractor Provided MATERIALS and Equipment

7 GENERAL REQUIREMENTS

7.1 Design Pressures and Temperatures

7.2 General Requirements

7.3 Summary of Responsibilities for Requirements

Fermi National Accelerator Laboratory 4

7.4 Work environment and Access Conditions

7.5 Safety Requirements

7.6 Waste disposal

8 CONSTRUCTION, FABRICATION, AND ASSEMBLY REQUIREMENTS

8.1 Welding

LCW Manifolds for MEBT and LEBT

Chilled LCW Water Manifolds for Ion Source and LEBT

RFQ Three Skid LCW System

8.2 Cleaning

8.3 Flanged piping joint assemblies

8.4 Drilling, coring, and anchoring

8.5 Structural Supports, Hangers, Brackets

8.6 VALVE Management

9 Acceptance tests

9.1 Inspection

9.2 Testing

10 Quality Control Plan

11 TIME-PHASED WORK

11.1 Phase Start Criteria

12 Documentation and Logistics Provided by FermiForward

12.1 Design documentation

12.2 Logistics

12.3 Field Conditions

13 SUBCONTRACTOR DOCUMENTATION

13.1 Subcontractor shall provide all documents as required by attached exhibits

Fermi National Accelerator Laboratory 5

13.2 Provided to FermiForward with offer

13.3 Provided to FermiForward prior to starting work

13.4 Provided during installation

1 INTRODUCTION

The Proton Improvement Plan-II (PIP-II) is Fermi National Accelerator Laboratory’s (FNAL) plan for providing powerful, high-intensity proton beams to the laboratory's research program which includes an 800 MeV superconducting linac.

In support of this program, the PIP-II project requires fluids systems delivering cooling water to various accelerator components.

This Statement of Work (SOW) document describes work required to install the Fluids Systems in the Warm Front End (WFE) section of the PIP-II Accelerator. This SOW has three major components:

• Installation of the Low Conductivity Water (LCW) manifolds for the Medium Energy Beam

Transport (MEBT) and Low Energy Beam Transport (LEBT)

• Installation of the Chilled Low Conductivity Water manifold for the Ion Source

• Installation and connection of piping for the RFQ Three Skid Low Conductivity Water

System

In this document, the vendor of the piping contract services shall be referred to as the

SUBCONTRACTOR; Fermi Forward Discovery Group, LLC shall be referred to as FermiForward;

and the term PIPING will refer to process piping fabricated or installed during this subcontract.

This document outlines the SUBCONTRACTOR’s responsibilities and obligations necessary for completing the PIPING based on the requirements as set forth herein and provides the technical description for fabrication and installation of the PIPING system for the PIP-II project.

1.1 LCW Manifolds for MEBT and LEBT

Figure 1 - Skids and RFQ Manifold

Figure 2 - All the manifolds

LCW Manifold for MEBT and LEBT is part of the WFE cooling system for PIP-II accelerator. The

LEBT manifold is located in the alcove next to the Ion Source Manifold, on the East side of the

MEBT Manifold RFQ Manifold

LEBT Manifold

Ion Source Manifold

MEBT South Manifold

RFQ Manifold

Intermediate Skid Vane Skid Wall Skid

High Bay Building, north from Wall and Vane Skids room. The Ion Source Manifold is mounted to the Unistrut assembly in that alcove. The MEBT Manifold is mounted on the east side wall of the tunnel along MEBT girders. LCW water comes from F37 Service Building pump room.

1.2 Chilled LCW Manifolds for Ion Source

Figure 3 - Ion Source Chiller

The Ion Source Chiller is a standalone low conductivity water system for cooling Ion Source. It is in the same room as the RFQ Intermediate Skid, on the East side of the High Bay Building, north of the Wall and Vane skids room. The Ion Source LCW manifold is mounted to the Unistrut assembly in that alcove above LEBT manifold.

1.3 RFQ Three Skid LCW System

The PIP-II RFQ Three Skid LCW System is a standalone system that provides water cooling solely to the PIP-II Radio Frequency Quadrupole (RFQ). The RFQ is located at the beginning of the PIP-

II accelerator beamline in the Warm Front End (WFE). LCW is distributed intricately to various sections of the vane and wall regions of the RFQ structure. One skid serves the wall circuits of

Ion Source Chiller the RFQ. A second skid serves the vane circuits of the RFQ. The third cooling skid serves as an intermediate skid distributing precisely tuned temperature controlled LCW to the other two skids upon request via a precision controller. The three cooling skids are located in alcoves on the ground floor east side of the PIP-II High Bay Building.

The major components of this system will be identified as follows:

• The Intermediate LCW Skid

• The Wall LCW Skid

• The Vane LCW Skid

• The RFQ LCW Manifolds

• Piping from Intermediate LCW Skid to Chilled Water Headers

• RFQ LCW Process Piping

Figure 4 – Interconnected Piping Layout

1.3.1 The Intermediate Skid

The RFQ Intermediate Skid will be in separate room North from the Wall and the Vane skids room.

Piping will run along the ceiling and through the concrete walls. See floor drawing F10212106.

Figure 5 - Intermediate Skid

1.3.2 The Wall Skid

The Wall skid will be with Vane skid in a separate room from the RFQ Intermediate Skid. Piping will go through the concrete wall. See floor drawing F10212106. Pipe connection is at the flange with Wall Manifold and RFQ Manifold.

Figure 6 - Wall Skid

1.3.3 The Vane Skid

The Vane skid will be in a separate room from the RFQ Intermediate Skid. Piping will go through the concrete wall. See floor drawing F10212106. Pipe connection is at the flange with Vane

Manifold and RFQ Manifold.

Figure 7 - Vane Skid

1.3.4 The RFQ Manifold

RFQ Manifold provides cooling for the RFQ. It is mounted on the RFQ frame, East from it. Piping are made of Copper Type K tube.

1.3.5 The Piping

The Interconnected piping system is a connection between Intermediate Skid, Wall Skid, Vane

Skid and RFQ Manifold. Pipes are made of Schedule 10 304 Stainless steel.

Figure 8, Figure 9 and Figure 10 show the general layout of the pipe route from the RFQ 3 Skid

LCW Cooling System to the RFQ water-cooled components.

Figure 8 - The Piping System

Figure 9 - The Piping System, Side View

Figure 10 - The Piping System, Top View

2 ACRONYMS AND DEFINITIONS

2.1 Abbreviations

GTAW – Gas Tungsten Arc Welding

HA – Hazard Analysis

HP – High Pressure

LP – Low Pressure

LOTO – Lockout Tagout

PQR – Procedure Qualification Record

PPE – Personal Protective Equipment

WPQ – Welder Performance Qualification

WPS – Welding Procedure Specification

RFQ – Radio Frequency Quadrupole

Organizational acronyms

ASME – American Society of Mechanical Engineering

ASTM – American Society for Testing and Materials

AISC – American Institute of Steel Construction

BPVC – Boiler Pressure Vessel Code

DOE – Department of Energy

FFDG – Fermi Forward Discovery Group, LLC

Fermilab System Acronyms

ES&H – Environmental, Safety & Health

PIP-II – Proton Improvement Plan II

CHW - Chilled Water Headers

LCW – Low Conductivity Water

2.2 Definitions

CODE

a term used to refer collectively to the various pressure safety and other safety standards by which the PIPING system shall comply

FermiForward Fermi National Accelerator Laboratory (Fermi Forward Discovery Group, LLC)

LCW Low Conductivity Water may a term which indicates that a provision is neither required nor prohibited

PIPING the piping system defined here by this specification

PQR a Welding Procedure Qualification Record 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

SUBCONTRACTOR the piping subcontractor installing the PIPING system

WPS a Welding procedure specification

WPQ a Welder Performance Qualification record

Upstream Equal to Project North. Upstream refers to the linac beam direction, counter to beam toward source

Downstream Equal to Project South. Downstream refers to the linac beam direction, with beam toward target

3 DESCRIPTION OF WORK

3.1 General

3.1.1 The SUBCONTRACTOR shall furnish all labor, tools, materials (as noted), consumable items, and services necessary to install (handle, weld, fasten using nuts and bolts) all subject PIPING systems in strict accordance with this specification.

3.1.2 The SUBCONTRACTOR shall provide documentation as specified in Section 13 of this specification.

3.1.3 The assembly design was completed for installation in a site currently under construction. Some dimensions are shown as reference, and field fitting shall occur. Consequently, the SUBCONTRACTOR shall allow adequate provisions to perform field verification and field fitting.

3.2 LCW Manifolds for MEBT and LEBT

MEBT LCW Manifolds

3.2.1 The SUBCONTRACTOR shall install cantilever Strut Channel mounting arms for the

MEBT LCW Manifolds to existing Strut Channel embedded in the facility walls per drawing F10220981 sheet #2. When necessary, use appropriate anchors and mount unistrut brackets to the wall.

3.2.2 The SUBCONTRACTOR shall mount the MEBT LCW Manifolds to the Strut Channel mounting arms per drawing F10220981 sheet #2. Subcontractor shall use appropriate pipe clamps i.e. Cush-a-clamp.

3.2.3 The SUBCONTRACTOR shall adjust threaded interface section of the MEBT LCW manifolds to interface with the LCW headers. Note that there is a union each manifold, allowing the main run of the manifolds to be disconnected during this fitting task.

3.2.4 The SUBCONTRACTOR shall re-interface the MEBT LCW manifolds at the unions.

3.2.5 The SUBCONTRACTOR shall perform Preliminary Pneumatic Pressure Test (i.e.

“snoop test”) of all interfaces (including factory interfaces) of the MEBT LCW manifolds per the requirements of Section 9.0

3.2.6 Note that within the scope of this SOW, the SUBCONTRACTOR is not required to fill the MEBT LCW Manifolds with water.

Figure 11 – MEBT LCW Manifolds

3.3 South LCW Manifold for MEBT – Girder 5

MEBT South LCW Manifold

3.3.1 The SUBCONTRACTOR shall install cantilever Strut Channel mounting arms for the

MEBT South LCW Manifolds to existing concrete facility wall per drawing

F10242943. In this location, use appropriate anchors and mount unistrut brackets to the wall.

3.3.2 The SUBCONTRACTOR shall mount the MEBT South LCW Manifolds to the Strut

Channel mounting arms per drawing F10242943. Subcontractor shall use appropriate pipe clamps i.e. Cush-a-clamp.

3.3.3 The SUBCONTRACTOR shall interface section of the MEBT South LCW Manifolds to existing flanges on the North of the wall. Interface with the LCW headers.

3.3.4 The SUBCONTRACTOR shall install and field fit all other piping, supports and components per drawing F10242943. This includes both MEBT South LCW

Manifold piping and the connection to the LCW return header and supply header.

3.3.5 The SUBCONTRACTOR shall perform Preliminary Pneumatic Pressure Test (i.e.

“snoop test”) of all interfaces (including factory interfaces) of the MEBT South LCW

Manifolds per the requirements of Section 9.0.

3.3.6 Note that within the scope of this SOW, the SUBCONTRACTOR is not required to fill the MEBT South LCW Manifolds with water.

Figure 12- MEBT South LCW Manifold

Existing headers

MEBT South Manifold

LEBT LCW Manifolds

3.3.7 The SUBCONTRACTOR shall mount the LEBT LCW Manifolds to the Strut Channel support frame per drawing F10220981 sheet #1.

3.3.8 The SUBCONTRACTOR shall adjust threaded dog-leg section of the LEBT LCW manifolds to align the manifolds’ flanges with the flanges of the LCW header

3.3.9 The SUBCONTRACTOR shall interface the LEBT LCW manifolds to the LCW header at the flanged interfaces.

3.3.10 The SUBCONTRACTOR shall perform Preliminary Pneumatic Pressure Test (i.e.

“snoop test”) of all interfaces (including factory interfaces) of the LEBT LCW manifolds per the requirements of Section 9.0

3.3.11 Note that within the scope of this SOW, the SUBCONTRACTOR is not required to fill the LEBT LCW Manifolds with water.

Figure 13 – LEBT LCW Manifolds

3.4 Chilled LCW Water Manifolds for Ion Source and LEBT

3.4.1 The SUBCONTRACTOR shall mount the Chilled Ion Source LCW and LEBT LCW

Manifolds to the Strut Channel support frame per drawing F10220981 sheet #1.

3.4.2 The SUBCONTRACTOR shall perform Preliminary Pneumatic Pressure Test (i.e.

“snoop test”) all interfaces (including factory interfaces) of the Chilled Ion Source

LCW and LEBT LCW manifolds per the requirements of Section 9.0.

3.4.3 Note that within the scope of this SOW, the SUBCONTRACTOR is not required to connect or fill the Chilled Ion Source LCW and LEBT LCW with water.

Figure 14 – Chilled Ion Source LCW and LEBT LCW

3.5 RFQ Three Skid LCW System

3.5.1 Prior to the work described here, the RFQ itself, the RFQ manifolds, and the RFQ’s three skids will have been installed and anchored within the facility. Through-wall penetrations required for the piping will have been already cored.

3.5.2 The SUBCONTRACTOR shall install all other piping, supports and components per drawing F10212106. This includes both RFQ Process Piping and the connection between the Intermediate Skid and the Chilled Water Headers.

3.5.3 The SUBCONTRACTOR shall perform Preliminary Pneumatic Pressure Test (i.e.

“snoop test”) all piping system interfaces per the requirements of Section 9.0.

3.5.4 Note that within the scope of this SOW, the SUBCONTRACTOR is not required to fill any portion of the RFQ Three Skid LCW System with water.

3.5.5 An estimated number of welds by size and type for RFQ 3 piping are shown in Table

3-1. This table is intended only as an aid for estimation. The actual number of welds may vary during actual field installation. Drawings shall be reviewed for more detailed information.

Table 3-1 Sizes and Estimated Quantities of Welds: RFQ System Piping

Weld type Size Qty.

Pipe to pipe buttweld 3" 51 Pipe to pipe buttweld 2.5" 84 Pipe to pipe buttweld 2" 6 Pipe to pipe buttweld 1.5" 44 Pipe to pipe buttweld 1” 32 Pipe to pipe buttweld 0.5” 10

Figure 15 – RFQ Three Skid LCW System

3.6 Installation of Fire Barrier

Four piping runs of the RFQ Three Skid System will penetrate a rated fire wall between the highbay and the south fluids alcove. The SUBCONTRACTOR shall install fire barriers in these penetrations per the details below.

Figure 16 – Penetration Fire Barrier Detail

Figure 17 – Wall between highbay and south fluids alcove requiring penetration fire barriers

Figure 18– Locations in south fluids alcove requiring penetration fire barriers

3.7 Exceptions in the Assembly Drawings for PIPING installation work

3.7.1 The assembly drawings are for the full, complete piping system. However, within the scope of this SOW, the following described components will not be installed:

• N/A - none

4 APPLICABLE CODES AND STANDARDS

4.1 General

4.1.1 In the event of conflict between drawings and the written specification, the written specification shall be the governing document.

4.1.2 In the event of incompleteness, error or contradictions in FermiForward-supplied documents or drawings, the SUBCONTRACTOR shall notify FermiForward in writing at the earliest convenience to obtain directives.

4.1.3 If the SUBCONTRACTOR deems it necessary to observe additional governing codes and regulations, FermiForward shall be notified of this in writing. FermiForward shall notify the SUBCONTRACTOR in writing of the outcome of this request.

4.1.4 The PIPING 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

Health and safety applicable regulations

• 10 CFR 851 - DOE Worker Safety and Health Program

• Illinois rules of the road apply at Fermilab Site

The following list of codes in their latest edition, drawings and standards shall be applied to the fabrication, assembly and testing of the PIPING system and its components:

• ASME B31.3 Process Piping o The subject piping systems will be considered a Category “D” Fluid Service when interpreting Code requirements

• ASME B31.9 Building Services Piping

• AISC Manual of Steel Construction

• ASTM A380 Cleaning and De-scaling Stainless Steel Parts

5 Fermi-Forward Provided MATERIALS and Equipment

5.1.1 FermiForward shall provide the following materials and equipment

Table 5-1 Process Piping Design materials and equipment.

System/Component Drawing and BOM # (if applicable)

Condition provided by FermiForward

LCW Manifolds for MEBT and LEBT

LCW Manifold for LEBT F10217562

Add installation drawing

Delivered to

Subcontractor

Staging Area

LCW Manifold for MEBT F10213595 Delivered to

Subcontractor

Staging Area

South LCW Manifold for

MEBT

F10218275 Delivered to

Subcontractor

Staging Area

Existing LCW Header F10220981 sheet #3 zone C6

Installed High Bay

Building

Chilled Water Manifold for LEBT

Chilled Water

Manifold for LEBT

F10217562 Delivered to

Subcontractor

Staging Area

RFQ 3 Skid LCW System

RFQ Vane Skid F10209559 Located, Anchored, Connected to

Electrical Power

RFQ Wall Skid F10209560 Located, Anchored, Connected to

Electrical Power

RFQ Intermediate Skid F10210120 Located, Anchored, Connected to

Electrical Power

RFQ Manifold F10212555,F10212679, F10212741,F10213207

Located, connected to RFQ

Flow Control Valves FC0119043

Item 43

Delivered to

Subcontractor

Staging Area

Static Mixers FC0118012, FC0118013

Item 41, Item 42

Delivered to

Subcontractor

Staging Area

Control Box F10219690

Item 12

Delivered to

Subcontractor

Staging Area

Flow Control Valve FC0117965

Item 40

Delivered to

Subcontractor

Staging Area

Flow Meters FC0117883, FC0117884

Item 38, Item 39

Delivered to

Subcontractor

Staging Area

5.1.1 From the time that the materials and equipment are released to the

SUBCONTRACTOR 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.

5.1.2 All noted materials and equipment will be staged at the job site for

SUBCONTRACTOR use.

5.1.3 Any excess material supplied by FermiForward remains the property of

FermiForward and shall be returned upon completion of the work.

6 Subcontractor Provided MATERIALS and Equipment

6.1.1 Except as identified in Section 5, all piping, fittings, valves, hardware and materials shall be supplied by the SUBCONTRACTOR.

6.1.2 All PIPING materials provided by the SUBCONTRACTOR for this installation shall be

ASTM A312 Stainless Steel Pipe Specification Schedule 10, 304L Stainless Steel

Seamless Pipe. (seamless preferred but not required).

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

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

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

6.1.5 Ball Valves:

½” and 1 ½” FNPT, 3 piece, 2way, full port flow, UHMWPE seal and seats, 316SS body, ball, and stem with locking handle, Manufacturer: Inline series 302F or approved equal.

6.1.6 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 GENERAL REQUIREMENTS

7.1 Design Pressures and Temperatures

7.1.1 For all subject piping systems, the following design conditions apply:

• Fluid: Clean filtered, process water LCW

• The subject piping systems will be considered a Category “D” Fluid Service when interpreting Code requirements

7.1.2 The PIPING system design consists of design temperatures and pressures as presented in the following table:

Table 7-1 Process Piping Design Pressure and Temperature.

Requirement # PARAMETER DESCRIPTION VALUE T- ED0012655-A002 Design Pressure 150 psig T- ED0012655-A003 Discharge Pressure 105 psig T- ED0012655-A004 Suction Pressure 15 psig T- ED0012655-A005 Supply Temperature 95⁰F +/- 1⁰F T- ED0012655-A006 Delta T (ΔT) 17 F⁰ T- ED0012655-A009 Side Stream Particulate

Filtration 5 micron

T- ED0012655-A010 Resistivity 4 MOhm*cm T- ED0012655-A011 Oxygen Removal Levels ≥ 20 PPB

7.2 General Requirements

7.2.1 The SUBCONTRACTOR shall supply all equipment, special tooling, consumables, and perform all work and services necessary to fabricate, assemble, a fully functional PIPING system suitable for long-term operation in accordance with this specification.

7.2.2 FermiForward shall be available to perform in-process weld inspections/examinations for CODE compliance.

7.2.3 FermiForward shall perform all pressure testing in coordination with the

SUBCONTRACTOR per FermiForward requirements.

7.2.4 The SUBCONTRACTOR shall repair any welds that fail inspections or qualification tests.

7.2.5 The SUBCONTRACTOR may fabricate subassemblies at their home shop with

FermiForward written approval. It is the responsibility of the SUBCONTRACTOR to verify all field dimensions. When fabricating at their home shop, recognize that assembly design was completed for installation in a site currently under construction. Some dimensions are shown as reference, and field fitting shall occur. The SUBCONTRACTOR shall allow FermiForward representatives to visit the

SUBCONTRACTOR home shop to inspect any work at their site. The

SUBCONTRACTOR shall sign out all piping materials taken off the Fermilab site.

7.3 Summary of Responsibilities for Requirements.

7.3.1 See Table 6-1 Task Responsibilities Summary.

Table 7-2 Task Responsibilities Summary.

TASK OR ITEMS SUBCONTRACTOR Fermi

Forward

Providing equipment as described in Section 5.1.1 X

Purchasing of all other materials for the PIPING system. X

Purchasing of all consumables including weld gas. X

Purchasing of all support and anchor hardware. X

Assembling and installing supports X

Fabricating and installing PIPING as described herein X

Performing low pressure pneumatic tests X

Performing any in-process weld inspections for CODE compliance.

X

Performing pressure testing. X

Repairing any welds that fail inspection or pressure tests. X

Providing of man-lifts, scaffolding, other equipment to perform work at elevated heights, and lifts, cranes, and other equipment to deliver piping materials to elevated heights.

X

Providing mobile fall protection systems for persons working at elevation, if required.

X

Completing all required FermiForward safety training. X

Filling systems with water X

Powering chillers and skids X

Circulating water through systems X

7.4 Work environment and Access Conditions

7.4.1 The PIPING installation work will be in the lower level of the PIP-II Highbay Building

7.4.2 Other work will be going on nearby, in parallel with SUBCONTRACTOR’s work.

FermiForward shall coordinate space and access to ensure that work described here may proceed efficiently.

7.5 Safety Requirements

7.5.1 SUBCONTRACTOR employees will be required to complete Fermilab General

Contractor Training. The SUBCONTRACTOR shall allocate one half day to complete the training.

7.5.2 The SUBCONTRACTOR shall provide proof of Fall Protection training and implement fall protection protocols as required.

7.5.3 The SUBCONTRACTOR shall submit a signed and dated Hazard Analysis (HA) for all scope including work at heights above 6 feet, which are required to meet the following criteria:

7.5.3.1 If applicable, the SUBCONTRACTOR shall prioritize use of 100% fall protection systems that requires minimal user input (e.g., Self-Retracting Lifeline System (SRL) connected to an attachment point approved by the form manufacturer) over dual lanyard systems. If dual lanyards are deemed the best equipment for the task, documentation of that analysis shall be reviewed and approved by FermiForward ES&H personnel.

7.5.3.2 Explicitly identified and documented acceptable tie-off points necessary for each element of work.

7.5.3.3 Fall protection rescue plans that have been crafted and are incorporated into the HA.

7.5.3.4 Daily inspection of Personal Protective Equipment and mechanical equipment.

7.5.3.5 Ensure the knowledgeable supervisor communicates the HA, both verbally and in writing, to all workers in a consistent manner. This is especially important for workers new to the PIP-II site.

7.5.3.6 Workplans and HAs will require a 3-day DOE review and approval before work may commence. FermiForward subject matter expert (SME) reviews of the HA will also be required. The SUBCONTRACTOR shall allocate sufficient time for HA preparation and review.

7.5.4 For any work using SUBCONTRACTOR supplied equipment such as a scissor lift, articulating lift, etc., the SUBCONTRACTOR shall supply proof of training.

7.5.5 If required, FermiForward shall provide a certified crane operator for use of building overhead cranes. The SUBCONTRACTOR shall not be authorized to operate the building overhead cranes.

7.5.6 For any work with a crane supplied by the SUBCONTRACTOR, the

SUBCONTRACTOR shall submit operator training records and lift documentation to FermiForward for approval.

7.5.7 The SUBCONTRACTOR shall have proper PPE as outlined in the approved hazard analysis. Specifically, the use of safety helmets/hard hats will be required in situations that include but not limited to crawling under equipment, climbing ladders, exposed work with safety line, etc. The use of safety helmets shall be covered as PPE in the Hazard Analysis.

7.5.8 Additional safety requirements are given in Exhibit A form 013100 – Environment, Safety, and Health Requirements

7.6 Waste disposal

7.6.1 The SUBCONTRACTOR shall separate and dispose of waste separately:

7.6.1.1 A general waste container will be made available by FermiForward.

7.6.1.2 Disposal of discarded metal parts will be performed in a separate bulk container/pallet and will be managed by FermiForward.

7.6.1.3 Hazardous substances shall be managed in a separate disposal area and managed by

FermiForward.

7.6.1.4 Upon demobilization, the SUBCONTRACTOR shall perform a site cleanup.

8 CONSTRUCTION, FABRICATION, AND ASSEMBLY REQUIREMENTS

8.1 Welding

8.1.1 All weld joint preparation and welding techniques shall be performed in accordance as required by Section VIII-Division 1 and IX of the ASME BPVC and/or

Chapter V of the ASME B31.3 code.

Table 8-1 ASME Piping Code Categories.

Circuit Applicable ASME code Weld preparation and techniques

LCW Manifolds for MEBT and LEBT

B31.3 Category “D” Fluid

Service

B31.3 Chapter IX

Chilled LCW Water Manifolds for Ion

Source and LEBT

B31.3 Category “D” Fluid

Service

B31.3 Chapter IX

RFQ Three Skid LCW System

B31.3 Category “D” Fluid B31.9 Chapter IX

8.1.2 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.

8.1.3 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.

8.1.4 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 the PIPING system.

8.1.5 All stainless-steel welding performed on piping shall utilize the Gas Tungsten Arc

Weld (GTAW) process using weld quality argon gas for the inert shield. Carbon steel welding shall utilize any process selected by the SUBCONRACTOR that meets

Code requirements.

8.1.6 All stainless-steel welds shall be internally purged with weld quality argon gas during the time of welding and post welding treatment. Oxygen levels shall be less than 1% as read by a TOPAC oxygen meter or equivalent.

8.1.7 Stainless-steel welds that show evidence of a lack of purge will not be accepted and shall be repaired by the SUBCONTRACTOR.

8.1.8 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 system. All external surfaces in the weld area shall be cleaned of heat tint, slag, and other deposits. No mechanical process shall be used to achieve a smooth appearance.

8.1.9 No production welding shall be performed on the PIPING system until all WPS, PQR, and WPQ documents have been qualified in accordance with ASME BPVC

Section VIII-Division 1 paragraphs UW-28 and UW-29 and Section IX of the ASME

BPVC and submitted to and approved by FermiForward.

8.1.10 The SUBCONTRACTOR shall supply weld maps which identify each weld and name of welder performing the weld. This applies to piping covered by B31.3.

8.1.11 At the conclusion of each workday, the SUBCONTRACTOR shall attach removable caps on all open piping ends to maintain cleanliness.

8.2 Cleaning

8.2.1 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.

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

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

8.2.4 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.

8.2.5 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.

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

8.2.7 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.

8.2.8 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.

8.2.9 Any excess material supplied by FRA remains the property of the FRA and SHALL be returned upon completion of the work.

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

8.3 Flanged piping joint assemblies

8.3.1 The SUBCONTRACTOR shall treat all flanged assembly sealing faces carefully and is responsible for any scratches or damage that cause leaks.

8.3.2 Copper-based anti-seize LOCTITE LB 8065 shall be used in the interface between stainless steel bolts and nuts.

8.4 Drilling, coring, and anchoring

8.4.1 The SUBCONTRACTOR shall perform any concrete drilling and coring operations with the precautions specified in FESHM 4195 Special Toxic Hazards – Silica including but not limited to worker respiratory protection and dust management via wet slurry or HEPA vacuums.

8.5 Structural Supports, Hangers, Brackets

8.5.1 MEBT LCW system Unistrut as specified.

8.5.2 LEBT/Ion Source LCW Manifold frame as specified.

8.5.3 The SUBCONTRACTOR shall determine and implement appropriate support for RFQ.

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

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

8.6 VALVE Management

8.6.1 Valve Installation

8.6.1.1 Manual valves are defined in the Parts List for the RFQ 3 Skid LCW System F10220106.

8.6.1.2 The SUBCONTRACTOR shall take appropriate precautions when welding near valves to prevent overheating of valve seals. The SUBCONTRACTOR shall follow the manufacturer instructions to protect the valve internal parts from welding damage.

8.6.2 Valve Labelling

8.6.2.1 FermiForward is responsible for final labelling of valves.

9 Acceptance tests

9.1 Inspection

9.1.1 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. Check ASME category D vs normal fluid service

9.1.2 The joints to be examined will be selected to ensure that the work of each welder making the production joints is included.

9.1.3 In-process examination comprises examination of the following:

• Joint preparation and cleanliness

• Preheating

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

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

• Appearance of the finished joint

9.2 Testing

9.2.1 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 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

9.2.3 Preliminary Pneumatic Pressure Test

9.2.3.1 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

9.2.3.2 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.

9.2.3.3 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®)

9.2.3.4 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.

9.2.4 Hydrostatic Pressure Test

9.2.4.1 A hydrostatic pressure test SHALL be performed according to ASME B31.3 – Process

Piping, under the oversight of Fermilab Test Coordinator or designated Fermilab qualified person and witnessed by ES&H representative and according to Fermilab

FESHM 5034 - Pressure Testing

9.2.4.2 A 150 PSIG pressure relief valve and pressure gauges SHALL be installed directly to the system which SHALL be visible to the operator throughout the duration of the test.

9.2.4.3 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.

9.2.5 Test Start-Up

9.2.5.1 N/A for this Statement of Work

10 Quality Control Plan

10.1.1 The SUBCONTRACTOR shall develop a Project Specific Quality Control (QC) Plan for review by FermiForward prior to starting work (Notice to Proceed). The quality control plan shall include:

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

10.1.1.2 Description of documentation planned to communicate contract conformance to

FermiForward.

10.1.1.3 Description of the nonconformance management process to be used.

10.1.1.4 Applicable training/qualifications required.

10.1.1.5 Description of receiving inspections and how cleanliness will be maintained for

FermiForward provided components.

10.1.2 The Quality Control Plan information should be presented at the Kickoff Meeting at the start of the contract. The plan shall be finalized prior to the start of work.

11 TIME-PHASED WORK

11.1 Phase Start Criteria

11.1.1 This effort is NOT expected to require phased starts. I.e., all areas are equipment are expected to be available at Notice to Proceed.

12 Documentation and Logistics Provided by FermiForward

12.1 Design documentation

FermiForward will provide access to the following design documentation

• Top level drawings as shown in reference Table 2 .

• 3D model in STEP format upon request

• 3D model in Navisworks .nwd format upon request

12.2 Logistics

FermiForward will provide access to the following equipment and areas:

• Loading dock at High Bay Building

• Work area adjacent to installation footprint

• AC power (utility 120VAC, welding 480VAC 3ph) in interior work areas. AC power is

NOT provided in exterior areas of Section 1.

12.3 Field Conditions

While the work of this subcontract is ongoing, the SUBCONTRACTOR will have priority but NON-

EXCLUSIVE access to the work areas. The SUBCONTRACTOR shall:

• Preserve safe aisleways for the transport of personnel and materials through the work area

• Implement appropriate protective equipment (e.g. weld screens) to protect personnel transiting through the work area or in adjacent areas

• Notify Fermilab Task Manager in advance of any need for more stringent access restrictions (e.g. exclusion of personnel from the work area during critical equipment lifts)

• Make reasonable accommodations for other nearby work

13 SUBCONTRACTOR DOCUMENTATION

13.1 Subcontractor shall provide all documents as required by attached exhibits.

• 010010 General Requirements

• 013100 ES&H Requirements

• 013300 Submittals o Shop drawings are not expected for this project. However, any deviations from the FermiForward-provided design shall be documented in redlines as described in Section 1.4 of the 013300 Submittals Document

• 014100 Quality Requirements o Note that a Project Specific Quality Control Plan is required prior to starting work (Notice to Proceed).

13.2 Provided to FermiForward with offer

13.2.1 The SUBCONTRACTOR SHALL furnish copies of the WPS utilized in welding operations on the piping system with the bid.

13.2.2 The SUBCONTRACTOR SHALL furnish copies of the PQR utilized in welding operations on the piping system with the bid.

13.3 Provided to FermiForward prior to starting work

13.3.1 The SUBCONTRACTOR SHALL furnish copies of the WPQ for each welder utilized in welding operations on the piping system ten (10) working days prior to the start of welding.

13.4 Provided during installation

13.4.1 For consumable items such as weld rods, electrodes, and fasteners, certificates of compliance shall be supplied.

13.4.2 Weld maps as required in section 7.1.10.

4.2 List of Codes and Standards