HD Coldbox Steel Structure Procurement Specification 251021.pdf

Long-Baseline Neutrino Facility (LBNF) / Deep Underground Neutrino Experiment (DUNE) - US

LBNF/DUNE-US

HD Coldbox Steel Structure Procurement Specification Dated: October 21, 2025

HD Coldbox Steel Structure Procurement Specification

Long-Baseline Neutrino Facility (LBNF) / Deep Underground Neutrino Experiment (DUNE) - US Page ii

Version Control

Approvals for this document will be required from:

• FFDG Procurement: Spencer Keske, Procurement Specialist III

• FFDG Responsible Person: Justin Freitag, LBNF/DUNE-US, Staff Engineer

Table 1 Revision History

Revision Responsible Person

Date Description of Changes

0 Justin Freitag 04.03.2025 Original

Long-Baseline Neutrino Facility (LBNF) / Deep Underground Neutrino Experiment (DUNE) - US iii

Table of Contents

Version Control ............................................................................................................................................. ii

List of Figures ............................................................................................................................................... iii

List of Tables ................................................................................................................................................ iv

Acronyms and Abbreviations ....................................................................................................................... iv

1 Introduction

2 Component Description

3 Scope of Work

4 Pre-Award Submittals

5 Post-Award Submittals

6 Finished Materials Submittals

7 Delivery Time

8 Quality Control

8.1 Test Requirements

8.2 Source Inspections

8.3 Control of Nonconforming Equipment and Materials

8.4 Quality Control Plan

8.4.1 Purpose and Scope

8.4.2 Representatives and Responsibilities

8.4.3 Document Control

8.4.4 Fabricator QC Inspection and Test

8.4.5 SDWF Receipt Inspection

List of Figures

Figure 1 LBNF/DUNE-US Schematic Figure 2 Coldbox with door closed Figure 3 Coldbox with door removed Figure 4 Coldbox exploded view

Long-Baseline Neutrino Facility (LBNF) / Deep Underground Neutrino Experiment (DUNE) - US iv

List of Tables

Table 1 Revision History ................................................................................................................................ ii Table 2 HD Coldbox Assembly Reference Drawing/Specifications

Acronyms and Abbreviations

Acronym Definition

HD Horizontal Drift

APA Anode Plane Assembly

SURF Sanford Underground Research Facility

FFDG Fermi Forward Discovery Group

FNAL Fermi National Accelerator Laboratory

LBNF Long Baseline Neutrino Facility

DUNE Deep Underground Neutrino Experiment

I&I Installation and Integration

SDWF South Dakota Warehouse Facility

EDMS Engineering Data Management Service

FEA Finite Element Analysis

FEM Finite Element Model

QC Quality Control

FESHM Fermilab Environment, Safety and Health Manual

BOM Bill of Materials

PID Part Identifier

Customer FFDG/FNAL/Fermilab

HD Coldbox Steel Structure Procurement Specification Introduction

Long-Baseline Neutrino Facility (LBNF) / Deep Underground Neutrino Experiment (DUNE) - US 1

1 Introduction Under contract to the U.S. Department of Energy (DOE), the Fermi Forward Discovery Group, LLC (FFDG), is leading the Long-Baseline Neutrino Facility (LBNF) Project to enable a world-class program in neutrino physics. Specifically, the LBNF Project (https://lbnf-dune.fnal.gov) provides the infrastructure for the Deep Underground Neutrino Experiment (DUNE), which will consist of two large liquid argon-based neutrino detectors located nearly a mile underground at the Sanford Underground Research Facility (SURF) in Lead, SD. See Figure 1, LBNF/DUNE-US Schematic

The Far Detector & Cryogenics (FDC) subproject of LBNF/DUNE-US installs the cryostats, detectors, cryogenics and supporting infrastructure at the SURF laboratory.

Figure 1 LBNF/DUNE-US Schematic

During the installation of LBNF DUNE HD the active detectors (APAs) require a cold test cycle to verify all components are operating properly in cryogenic conditions. A custom fabricated enclosure is required to house the components while cold gaseous nitrogen flows through the enclosure to create the cryogenic environment for cold cycles. The coldbox will be constructed of 304 stainless steel with both welded and bolted connections. These enclosures will be lined internally with foam insulation to prevent the external surface from cooling to the point where condensation would form. To support the LBNF/DUNE installation schedule, (2) coldboxes of identical construction, with the option of a third are needed. Each coldbox represents a 14m tall insulated stainless-steel structure that will hold the fully assembled APA units while they are cooled to 90K(+40,-0). This technical specification document defines the requirements for the steel enclosures without the foam insulation. The coldbox steel structures will be delivered in multiple pieces that will be transported and assembled by FFDG underground.

2 Component Description A coldbox steel structure consists of stainless steel (SS 304) subassembly plates welded with internal and external stiffener ribs welded to both faces of the main shell frame. The coldbox subassemblies will be bolted together and then the internal flanges will be field welded to provide the airtight seal. The field https://lbnf-dune.fnal.gov/

HD Coldbox Steel Structure Procurement Specification Scope of Work

Long-Baseline Neutrino Facility (LBNF) / Deep Underground Neutrino Experiment (DUNE) - US 2 welding is not included in this procurement. There will be stub columns welded to the upper inner ribs, which will support a monorail for a trolley supporting the APA’s to roll into the coldbox and rest while being cold cycled. There are several roof penetrations with pipe feedthroughs of various diameters. The figures below represent a single unit of the (2) identical coldboxes, with alternate additive scope of a third which shall be supplied by the fabricating vendor. (Insulating materials are not included in this procurement.)

Figure 2 Coldbox with door closed

Figure 3 Coldbox with door removed

Figure 4 Coldbox exploded view

3 Scope of Work The vendor shall procure all materials, fabricate, assemble, test, package, and deliver the complete products as shown in Figure 2 Coldbox with door closed. FFDG shall provide vendor with detailed contractual drawings of all components and assemblies. The main contractual detailed drawing number that contains this assembly is listed in Table 2 below. The BOM in this drawing contains all relevant components that make up this assembly with their material and quantities specified. All tolerances shown on drawing shall be achieved.

Long-Baseline Neutrino Facility (LBNF) / Deep Underground Neutrino Experiment (DUNE) - US 3

Table 2 HD Coldbox Assembly Reference Drawing/Specifications

Assembly Name Drawing Number Part Identifier (PID) Quantity

TOP LEVEL COLDBOX

ASSEMBLY

COLDBOX-ASSEMBLY D-086-002-00001-0000#1 2+1

QUADRANT1 COLDBOX-QUAD-1 D-086-002-00002-0000# 2+1

QUADRANT2 COLDBOX-QUAD-2 D-086-002-00003-0000# 2+1

QUADRANT3 COLDBOX-QUAD-3 D-086-002-00004-0000# 2+1

QUADRANT4 COLDBOX-QUAD-4 D-086-002-00005-0000# 2+1

DOOR HALF TOP COLDBOX-DOOR-HALF-TOP D-086-002-00006-0000# 2+1

DOOR HALF BOTTOM COLDBOX-DOOR-HALF-BOT D-086-002-00007-0000# 2+1

MONORAIL SUBASSEMBLY COLDBOX-MONORAIL-

ASSEMBLY

D-086-002-00008-0000# 2+1

All components must be packaged to ensure materials will conform to specifications upon shipment, delivery, and storage.

The vendor shall:

• Procure and fabricate the materials to realize (2) identical HD coldbox steel structure assemblies, with alternate additive scope of a third at the time of procurement.

• Perform dry fit of completed assemblies to ensure bolted parts mate properly.

• Develop any specialized tooling and procedures required to realize and handle the HD coldbox structure assemblies.

• Verify components and assemblies conform to specifications, including following the code outlined in:

− AISC Design Guide 27, Structural Stainless Steel − ANSI/AISC 370 Specification for Structural Stainless-Steel Buildings − ASTM A320 Stainless Steel Bolting for Low-Temperature Service

− ANSI Y14.5M-1994

− Structural Welding Codes: ANSI/AWS D1.1/D1.6

1 “#” shall represent 1-3 for each of the (3) coldbox assembly item numbers.

Long-Baseline Neutrino Facility (LBNF) / Deep Underground Neutrino Experiment (DUNE) - US 4

• Accommodate hold/witness points during the fabrication and testing process to allow designated FNAL personnel to perform or witness important steps as necessary. Hold/witness points may include:

− Dry fitting of assemblies once fabrication has completed.

− Load bearing beam load test.

• Provide required documentation with sufficient advance (2 weeks) time to allow for feedback and acceptance from FNAL prior to start the fabrication of the components.

• Package and ship completed product components such that the products conform to specifications.

Additional details of this scope are described below:

• Each coldbox shall be constructed of (4) sub level assembly quadrants and (2) sub level assembly halves for the door. The (4) quadrants and (2) door pieces shall bolt together as a dry fit at the vendor premises to form the overall coldbox top level assembly.

• All components will be constructed with 304 Stainless Steel unless otherwise noted.

• Cold box quadrants and door halves shall be of welded construction with internal and external rib plates.

• Handling limitations shall be provided by customer. This is to ensure excessive stresses/deformations are not introduced during manufacturing, assembly, shipping, and storage.

• Main skin of each coldbox quadrant will be constructed of 1/4” thick stainless steel plate with dimensions as provided on customer reference drawings.

• External ribs shall be constructed of 1/4” thick stainless steel plate unless otherwise specified with dimensions as provided on customer reference drawings.

• Internal ribs shall be constructed of 3/8” thick stainless steel plate unless otherwise specified with dimensions provided on customer reference drawings.

• Ribs shall be slotted to key into one another as shown on customer reference drawings.

• Internal and external rib plates shall have intermittent fillet welds unless otherwise specified as shown on customer reference drawings.

• All bolts, washers, nuts shall be provided by the contractor as designated on customer provided drawings. (2x) Twice the quantity as shown on the drawings shall be provided as extra contingency.

• All fabricated assemblies shall be marked in a conspicuous location with a part identifier (PID) as outlined in the table above.

• All components shall be free of oils, solvents, lubricants, etc. Cleaning procedure shall be proposed by manufacturer and approved by FFDG.

• The vendor shall not make any cost-intensive changes without consulting the stakeholders, including the Technical Representatives and authorized personnel.

HD Coldbox Steel Structure Procurement Specification Pre-Award Submittals

Long-Baseline Neutrino Facility (LBNF) / Deep Underground Neutrino Experiment (DUNE) - US 5

4 Pre-Award Submittals The following information is requested with the quotation and this information will be used in evaluating the proposal from each offeror.

• Offeror’s proposed manufacturing plan including:

− Offeror’s proposed fabrication method for the HD coldbox structure assembly and all features.

− Offeror’s proposed fabrication method for all other components in this HD coldbox structure assembly.

− Offeror’s proposed assembly method and plan for dry fit of the HD coldbox structure subassemblies.

− Locations of fabrication, assembling and testing site to be performed.

• Documentation detailing any proposed exceptions to the specifications and drawings provided by FNAL.

• Offeror’s proposed material procurement, fabrication, testing, and delivery schedule including schedule milestones.

• Offeror’s list of experience with other projects like this project, particularly with large stainless steel welded materials. The offeror must demonstrate that they have experience manufacturing complex assemblies which conform to the tolerances specified and maintain tolerances during/after welding. Experience with fabricating equipment used in cryogenic systems and low-pressure vessels should also explicitly be cited.

• Offeror’s proposed QC/QA plan for the HD coldbox structure assemblies. The techniques to be employed to verify that the product will satisfy requirements and specifications should be explicitly identified.

• Offeror’s proposed plan for packaging, shipping, and handling of the HD coldbox structure assemblies including appropriate secured clamps/straps/fixtures to prevent unintended motion and damage during transport.

• Offeror’s equipment list including shop space, machine tools, inspection equipment and other equipment for performing fabrication, assembly, and testing.

• Offeror’s quotes for the entire assembly.

5 Post-Award Submittals The Subcontractor shall comply with the following requirements once subcontract award has been made.

• Attend a remote conference kickoff meeting, to discuss project requirements, technical requirements, review schedule for deliverables.

• Vendor shall provide material specifications and fabrication drawings for review prior to start of fabrication. The vendor provided drawings shall be the same or like the FFDG detailed drawings they receive with all relevant tolerances specified since this is a build-to-print

HD Coldbox Steel Structure Procurement Specification Finished Materials Submittals

Long-Baseline Neutrino Facility (LBNF) / Deep Underground Neutrino Experiment (DUNE) - US 6 fabrication. Any modification(s) or inconsistencies thereof MUST be communicated to FFDG for review, resolution, and approval prior to fabrication.

− Note that products shall conform to all dimensions, form, fit, and tolerances specified in the FFDG contractual detailed drawings.

• Vendor shall provide timely updates on status of design, material procurements, fabrication, and delivery schedule, per milestones specified in the pre-award submittal.

• Complete fabrication and conduct a test fit prior to shipment to site. Customer site visit for test fit inspection prior to shipment.

• Incorporated load bearing beam shall be load tested and certified prior to delivery.

6 Finished Materials Submittals The Subcontractor shall provide documentation certifying that the material is a specified. The vendor shall provide documentation on each component as follows:

• Certifications and copies of materials test report for the main structural stainless-steel elements according to section A3.1 of ANSI/AISC 370

• Certifications and copies of manufacturer’s test report for the fasteners according to section A3.3 of ANSI/AISC 370

• Copies of manufacture’s certification for the welding consumables according to section A3.6 of

ANSI/AISC 370

• Manufacturer’s product data sheets or catalog data for welding filler metals and fluxes to be used. The data sheets shall describe the product, limitations of use, recommended or typical welding parameters, and storage and exposure requirements, including baking, if applicable

• Welding procedure specifications (WPS) or documentation of prequalified welding procedure specifications (PWPS)

• Procedure qualification records (PQR) for WPS that are not prequalified in accordance with

AWS D1.6/D1.6M

• Welding personnel performance qualification records (WPQR) for the stainless steel alloy and WPS and continuity records

• QC manual that shall include, as a minimum:

− Material control procedures − Inspection procedures − Nonconformance procedures

• QCI (Quality Control Inspector) qualifications

• Fabricator NDT personnel qualifications

• Report detailing the dry fitting of the assemblies

• Dimensional inspection of the Coldbox: report demonstrating compliance with the tolerances indicated on the drawings shall be provided

HD Coldbox Steel Structure Procurement Specification Delivery Time

Long-Baseline Neutrino Facility (LBNF) / Deep Underground Neutrino Experiment (DUNE) - US 7

• Report detailing the load bearing beam load test

• Nonconformance Reports that have been dispositioned as Use As Is or Repair, that contain a technical justification for the disposition assuring the material meets its form, fit and function despite not meeting the specification and drawing requirements. These Nonconformance Reports’ dispositions shall have been approved by the Project prior to their implementation.

7 Delivery Time All coldbox components shall be delivered to the FDC SDWF location within 6 months of the date of signature of the procurement contract.

South Dakota shipping address:

Dakota Warehouse 1313 E. Saint Patrick St.

Rapid City, SD 57701

A deviation from this delivery date would need to be negotiated at the time the contract is signed. A delivery in batches can be negotiated with FFDG.

8 Quality Control The Subcontractor is responsible for all activities necessary to manage, control, and document work to ensure compliance with the Subcontract documents. The Subcontractor’s responsibility includes ensuring adequate Quality Control services are provided for work accomplished on- and off-site by their organization, suppliers, sub-tier subcontractors, technical laboratories, and consultants.

The work activities include submittal management, testing and inspection, and all other functions relating to the requirement for quality manufacturing. The Subcontractor shall implement a Quality Control program and designate a quality responsible person(s) to achieve these goals.

Subcontractors shall maintain an adequate inspection system and perform such inspections as will ensure that the work called for by the subcontract conforms to contract requirements. The Inspectors shall be qualified to perform the type of inspections being performed. The Subcontractors shall maintain complete inspection records and make them available to the LBNF/DUNE Project for review.

The Subcontractor will be required to submit its Company Quality Assurance Program with its proposal.

The Subcontractor’s quality program shall meet an applicable nationally recognized standard such as ISO 9001, ASME, etc. The Subcontractor’s welding program shall meet applicable nationally recognized such as ASME, AWS, etc. utilizing qualified welders, Weld Procedure Specifications and Weld Qualification Records. Nondestructive Examination personnel shall be qualified in accordance with ASNT-TC-1A.

The shipping/packaging plan will be submitted with the proposal to verify that the packaging will facilitate transport down the shaft. This primarily is a verification that any cross bracing for stability will not exceed the envelope required to fit in the shaft and that the lifting point are free.

HD Coldbox Steel Structure Procurement Specification Quality Control

Long-Baseline Neutrino Facility (LBNF) / Deep Underground Neutrino Experiment (DUNE) - US 8

8.1 Test Requirements

Tests shall be identified as individual activities in the specifications. The Customer shall identify critical tests (e.g., x-rays, dye penetrant tests) that must be included as schedule activities. Subcontractors are required to perform any sampling and testing required under the Subcontract.

When reporting on test results, the Subcontractor must cite applicable Subcontract requirements, tests and the analytical procedures used. Actual results must be provided and include a statement that the item tested or analyzed conforms to specified requirement(s). An authorized Subcontractor representative shall certify test results by signing the test report.

The coldboxes will be test assembled at the factory to ensure all the pieces fit together and the tolerance on the door will enable the box to be sealed. The Subcontractor shall provide 14 days’ notice to the Customer prior the performance of the test assembly and arrange for an FFDG in person visit.

8.2 Source Inspections

The Customer will perform interim inspections as part of its source surveillance efforts. As applicable, a list of non-conformances may be developed as a result of this inspection. Each deficiency noted as nonconformances shall reference the applicable specification paragraph, Drawing No., etc., from which the deficiency stems. Any items noted deficient during the inspections shall be corrected in timely manner and shall be accomplished within the time slated for completion of the entire work, or any increment thereof if the project is divided into increments by separate completion dates. The QC Manager shall ensure that all items on this list are corrected prior to notifying the LBNF/DUNE Project that a "Final" inspection can be scheduled.

A Final inspection will be formally scheduled. The QA Manager, other primary Subcontractor management personnel, and Customer Project representatives will attend this inspection.

At least 14 days prior to the final inspection, notice shall be given to Customer Procurement stating that all items previously identified to the Subcontractor as being unacceptable, along with all the remaining work performed under the contract, will be complete and acceptable by the date of the final acceptance inspection.

This Final Inspection will occur at the vendor premises to verify that all QC documents are available, and the fabricated coldboxes meet the dimensional tolerances. This will include collecting welder certification, material certification, weld inspection, dimensional tolerance verification and reporting.

8.3 Control of Nonconforming Equipment and Materials

When the Subcontractor identifies equipment or material as nonconforming to the specifications and/or drawing requirements, the nonconforming condition shall be documented, segregate the nonconforming item, disposition the nonconforming condition, perform the applicable corrective action and verify that it has been performed and close out the nonconformance once the disposition has been verified as being satisfactorily completed. Dispositions of Accept as Is and Repair will require approval by the LBNF/DUNE Project personnel. For Accept as Is and Repair dispositions a technical justification shall be provided

Long-Baseline Neutrino Facility (LBNF) / Deep Underground Neutrino Experiment (DUNE) - US 9 showing that although the equipment will not meet the specification requirements, it still meets its intended form, fit and function. Rework and Scrap dispositions do not require LBNF/DUNE Project approval since the reworked item is brought into compliance with the specifications and/or drawings and the scrapped items are removed from the fabrication. A list of Nonconformances shall be maintained for review by the LBNF/DUNE Project.

8.4 Quality Control Plan

8.4.1 Purpose and Scope

8.4.1.1 Purpose

The purpose of this Quality Control Plan is to describe the methods for controlling product and process variation to produce quality parts that meet the requirements of the DUNE Experiment.

Section 0 of this plan outlines the inspections and tests necessary to validate that deliverables will work according to specifications.

The inspections and tests outlined here and detailed in referenced procedures will ensure that coldboxes will be functioning as required as the elements of the detector are tested in the coldboxes.

8.4.1.2 Scope

The Coldbox for the Horizontal Drift (HD) represent structures used to run cold tests on APA prior to their being installed inside the HD cryostat. The Coldboxes are constructed of large stainless-steel plates which form the main Coldbox shell, with welded stiffener plates on the interior and exterior for structural rigidity and stability.

• Ensure coldboxes are fabricated and tested in accordance with this document and the specification.

• Ensure the Coldboxes are installed and commissioned in accordance with this document and the specifications.

8.4.2 Representatives and Responsibilities

8.4.2.1 Project Engineer, FFDG

Responsibilities:

• Oversee inspection and tests for quality performance,

• Provide periodic assessment of fabrication field inspection, oversight, testing, commissioning, and acceptance.

• Interface with LBNF/DUNE QA Manager on Consortia QA/QC related matters.

• Review inspection and test data for accuracy and completeness.

8.4.2.2 Coldbox Quality Assurance Representative, FFDG

Responsibilities:

• Oversee the Subcontractors for Quality performance.

• Review inspection and test data for accuracy and completeness.

Long-Baseline Neutrino Facility (LBNF) / Deep Underground Neutrino Experiment (DUNE) - US 10

• Check certifications of delivered materials and equipment, spot check workmanship, observe testing procedures.

• Ensure complete upload of required test data

• Make or arrange for inspections to be performed by the Project.

• Interface with the Subcontractor’s QC Manager on project QA/QC related matters.

• Review rework items list, testing plan and log, etc.

• Maintain and monitor issues and actions document.

8.4.3 Document Control

Documents are periodically updated, usually prompted by a review deadline. Coldbox QC Inspection and Test Requirements

8.4.4 Fabricator QC Inspection and Test

The Fabricator shall notify the Project 14 days prior to the performance of the witness and hold points identified below to allow the Project to attend these inspections and tests.

8.4.4.1 Description

1. Dimensional Inspection of the steel pieces

2. Flatness measurements of the chamfered edges that will be welded during installation.

3. NDE of all welds performed during fabrication.

4. Fit-up Test of the Cold Box components (Witness Point)

5. Load Bearing Beam Load Test (Witness Point)

6. Final Inspection to verify packaging of the Cold Box components and review QC Documentation prior to shipment. (Hold Point)

8.4.4.2 Location(s)

Fabricator’s Facility

8.4.4.3 Justification

Ensure Coldbox fabrication meets the specification and drawing requirements.

8.4.4.4 Data to FFDG

The Fabricator shall provide the following QC Documentation prior to shipment:

• Certified Material Test Reports for the stainless steel and fasteners showing chemical and physical properties of the items meet the material specification requirements.

• Copies of manufacture’s certification for the welding consumables

• Manufacturer’s product data sheets or catalog data for welding filler metals and fluxes

• Welding procedure specifications (WPS)

• Procedure qualification records (PQR) for WPS that are not prequalified.

• Welding personnel performance qualification records

Long-Baseline Neutrino Facility (LBNF) / Deep Underground Neutrino Experiment (DUNE) - US 11

• NDT personnel qualifications

• Dimensional Inspection Reports

• NDE Reports

• Flatness Inspection Reports

• Fit-up Test Report

• Load Bearing Beam Load Test Report

• Nonconformance Reports that have been dispositioned as Use As Is and/or Repair with approval from the Project Design Authority.

8.4.5 SDWF Receipt Inspection

8.4.5.1 Description

The following inspections will be performed on the Coldboxes upon receipt at the SDWF:

• Comparison of the Bill of Lading against the items received

• Visual inspection of packaging to verify there is damage

8.4.5.2 Location(s)

South Dakota Warehouse Facility (SWDF)

8.4.5.3 Justification

Ensure there has been no damage to the coldbox material during shipping and that all items shipped have been received.