J-4 - Internal Cryogenics - SOW 07-10-2024.pdf

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

LBNF/DUNE-US

Internal Cryogenics

Scope of Work and Performance

Specification

Document Number: EDMS 2211972

Mark Adamowski

Lead Cryogenics System Engineer

Matt Maciazka

Cryogenics System Engineer

David Montanari

LBNF FDC Cryogenics Project Manager

Internal Cryogenics Scope of Work and Performance Specification

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

Document Approvals

Signatures Required Signature & Date Approved

Originator: Matt Maciazka Cryogenics Systems Engineer

Approver: Jeremy Duncan Procurement Responsible Person

Approver: Jolie Macier LBNF FDC Project Manager

Approver: David Montanari LBNF FDC Cryogenics Project Manager

Approver: Mark Adamowski Lead Cryogenics Systems Engineer

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

Revision History and Version Control

This version of the document may not be the current or approved revision. The current revision is maintained in the LBNF/DUNE Document Management System (DocDB) or the Engineering & Equipment Data Management Service (EDMS) where internal Project document approvals are managed. DocDB can be accessed through the web by authorized users (https://docs.dunescience.org/), and EDMS can be accessed through the web at https://edms.cern.ch. This document can be identified by the revision date as indicated in the Version Control Table below.

The current, approved version is always available in DocDB or EDMS.

Author Revision Date

Location (EDMS) Description of Changes

Kevin Haaf 08/10/21 Original

David Montanari 06/22/21 General comments

Kevin Haaf 09/01/22 Updates to major sections

Matt Maciazka 07/27/23 2211972 v.5 Updates, new template

Matt Maciazka 12/27/23 GAr Purge Line descoping

Matt Maciazka 04/11/24 2211972 v.6 Document name change for RFP release.

Minor editorial changes.

Appendix list update.

David Montanari 07/09/24 Comments

Matt Maciazka 07/10/24 2211972 v.7

Exclusive use of HD (FD-1) and VD (FD-2) names for the cryostats instead of “first” and “second”.

Figures update.

Not applicable tests deleted.

Language polished.

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

Table of Contents

Document Approvals .................................................................................................................................... ii

Revision History and Version Control .......................................................................................................... iii

List of Figures .............................................................................................................................................. vii

List of Tables .............................................................................................................................................. viii

Acronyms and Abbreviations ....................................................................................................................... ix

1 Scope of the Document ..................................................................................................................... 1-1

2 Terms Used in the Document ............................................................................................................ 2-1

3 Applicable Codes and Standards ........................................................................................................ 3-1

4 Introduction ....................................................................................................................................... 4-3

5 Scope of the Supply............................................................................................................................ 5-3

5.1 Scope of the Supply Structure ................................................................................................... 5-4

5.2 Additional Requirements for the Scope ..................................................................................... 5-5

6 General Description ........................................................................................................................... 6-6

6.1 Modes of Operation ................................................................................................................... 6-6

7 General Requirements ....................................................................................................................... 7-9

7.1 LAr Distribution Requirements ................................................................................................ 7-10

7.2 External Supports (LAr Distribution) ........................................................................................ 7-11

7.3 External Supports (Cooldown) ................................................................................................. 7-14

8 Interface Requirements ................................................................................................................... 8-15

9 Other Requirements ........................................................................................................................ 9-16

9.1 Mechanical ............................................................................................................................... 9-16

9.2 Flexible Elements in Pipes ........................................................................................................ 9-16

9.3 Thermal Isolation ..................................................................................................................... 9-16

9.4 MLI Use .................................................................................................................................... 9-19

9.5 Leak Tightness .......................................................................................................................... 9-20

9.6 Materials .................................................................................................................................. 9-20

10 Manufacturing and Assembly Requirements ............................................................................ 10-21

10.1 Manufacturing ....................................................................................................................... 10-21

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

10.2 Welding .................................................................................................................................. 10-21

10.3 Tube and Pipe Bending .......................................................................................................... 10-22

10.4 Cleaning .................................................................................................................................. 10-22

11 Shipping ...................................................................................................................................... 11-22

12 Examinations, Inspections, Tests ............................................................................................... 12-23

12.1 General ................................................................................................................................... 12-23

12.2 Non-Destructive Tests of Welds ............................................................................................ 12-25

12.3 Helium Leak Tightness Tests .................................................................................................. 12-26

12.3.1 General ........................................................................................................................... 12-26

12.3.2 From the Atmosphere to Insulation Vacuum ................................................................ 12-26

12.3.3 From Process Pipes to Insulation Vacuum ..................................................................... 12-26

12.3.4 From the Atmosphere to Process Pipes ......................................................................... 12-27

12.4 Cold Test................................................................................................................................. 12-27

12.5 Pressure Test .......................................................................................................................... 12-27

12.6 Cleanliness Control ................................................................................................................ 12-28

12.7 Dimensional Control .............................................................................................................. 12-28

12.8 Factory Acceptance ................................................................................................................ 12-28

12.9 Transport Accelerations ......................................................................................................... 12-28

12.10 Factory Outlet Inspection .................................................................................................. 12-29

12.11 FRA Incoming Inspection (at SURF) .................................................................................... 12-29

13 Deliverables for the Kick-Off Meeting........................................................................................ 13-30

14 Deliverables for Engineering Phase ........................................................................................... 14-30

15 Deliverables for Option #1 Manufacturing ................................................................................ 15-31

16 Deliverables for Option #2 Manufacturing ................................................................................ 16-31

Appendix A – Weight and Dimensions Limit for Transport ..................................................................... 16-1

Appendix B – Internal Cryogenics 3D Model and Drawings .................................................................... 16-1

Appendix C – Internal Cryogenics Interfaces ........................................................................................... 16-1

Appendix D – LBNF Cryostat Penetrations ............................................................................................... 16-1

Appendix E – LBNF P&ID .......................................................................................................................... 16-1

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

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

List of Figures

Figure 6-1: 3D view of the LAr Recirculation distribution networks .......................................................... 6-7 Figure 6-2: 3D view of the Cooldown manifolds (blue lines) within the first cryostat .............................. 6-8 Figure 6-3: Zoom in of the P&ID of the GAr Purge and LAr Distribution for the LBNF cryostats (shown on the VD) ....................................................................................................................................................... 6-8 Figure 6-4: Zoom in of the P&ID of the Cooldown Manifolds for the LBNF HD Cryostat .......................... 6-8 Figure 7-1: LAr recirculation pipe penetrations on the HD cryostat (with red arrows pointing to them) .. 7- Figure 7-2: Cryostat walls and floor membrane visualization ................................................................. 7-13 Figure 7-3: Cooldown penetrations into the second cryostat (circled in light blue) ............................... 7-14 Figure 7-4: Pipe routing for Cooldown Manifolds (shown in blue).......................................................... 7-15 Figure 7-5: Example of cross-beam element to be used to support the Cooldown manifold................. 7-15

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

List of Tables

Table 6-1: Modes of operation .................................................................................................................. 6-6 Table 9-1: Maximum allowable heat leaks for cryogenic vacuum insulated pipes ................................. 9-16 Table 9-2: Vacuum levels in an insulation vacuum jacket (vacuum jacket) ............................................. 9-17 Table 9-3: Vacuum vessel pressure range ............................................................................................... 9-18 Table 9-4: Maximum acceptable helium leak rates ................................................................................. 9-20 Table 12-1: Minimum control point for manufacturing and installation of the supply ........................ 12-24

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

Acronyms and Abbreviations

Acronym Definition

AACEI AACE International (Formerly the Association for the Advancement of Cost Engineering)

ACI American Concrete Institute

ANSI American National Standards Institute

APA Anode Plane Assembly

API American Petroleum Institute

ASCE American Society of Civil Engineers

ASME American Society of Mechanical Engineers

ASTM American Society for Testing and Materials

AUP Authorization for Use and Possession

BPVC Boiler and Pressure Vessel Code (ASME)

CAD Computer-Aided Design

CGA Compressed Gas Association

CFR Code of Federal Regulation

CUC Central Utility Cavern

DOE Department of Energy

DUNE Deep Underground Neutrino Experiment

DXF Data Exchange Format

EJMA Expansion Joint Manufacturers Association

EN European Norm

ES&H Environment Safety & Health

ESH Environment Safety and Health

EVMS Earn Value Management System

FAT Factory Acceptance Tests

FD-1 Far Detector 1

FD-2 Far Detector 2

FDC Far Detectors & Cryogenics

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

Acronym Definition

FDR Final Design Review

FEA Finite Element Analysis

FEED Front-End Engineering Design

FMEA Failure Mode and Effect Analysis

FRA Fermi Research Alliance LLC

FSCF Far Site Conventional Facilities

FSF Far Site Facilities

GAr Gaseous Argon

GAN Gaseous Nitrogen

GC General Contractor

GN2 Gaseous Nitrogen

HAZOP Hazard and Operability Analysis

HP Hold Point

IC Installation Coordinator

IEC International Electric Code

IEEE Institute of Electrical and Electronics Engineers

IKC In-Kind Contribution

IRR Installation Readiness Review

ISA International Society of Automation

ISO International Standards Organization

LAr Liquid Argon

LBNF Long-Baseline Neutrino Facility

LBNF/DUNE-US Long-Baseline Neutrino Facility/Deep Underground Neutrino Experiment-United States – Refers to the US DOE line-item project

LIN Liquid Nitrogen

LN2 Liquid Nitrogen

MIP Manufacturing and Inspection Plan

MLI Multi-Layer Insulation

MS Microsoft

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

Acronym Definition

MTBF Mean Time Between Failures

MTTF Mean Time to Failure

MTTR Mean Time to Repair

NB National Board of Boiler and Pressure Vessels Inspectors

NEC National Electric Code

NEMA National Electrical Manufacturers Association

NET No-Earlier-Than

NFPA National Fire Protection Association

NIST National Institute for Standards and Technology

NLT No-Later-Than

NP Notification Point

NTP Notice To Proceed

NWD Navisworks Document

OEM Original Equipment Manufacturer

OSHA Occupational Safety and Health Administration

PDF Portable Data Format

PDR Preliminary Design Review

PED Pressure Equipment Directive

PFD Process Flow Diagram

PLC Programmable Logic Controller

PRR Production Readiness Review

P&ID Piping and Instrumentation Diagram

QA Quality Assurance

QC Quality Control

QM Quality Manual

RFP Request for Proposals

SCADA Supervisory Control and Data Acquisition

SDSTA South Dakota Science and Technology Authority

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

Acronym Definition

SLD Single Line Diagram

SLIN Subcontract Line Item Number

SOW Statement of Work

SPVD Simple Pressure Vessel Directive

STEP Standard for the Exchange of Product Data

SURF Sanford Underground Research Facility

T&C Terms and Conditions

UL Underwriters Laboratories

V&I Valves and Instruments

VIP Vacuum Insulated Pipe

VJ Vacuum-Jacketed

Scope of Work and Performance Specification Scope of the Document

Long-Baseline Neutrino Facility (LBNF) / Deep Underground Neutrino Experiment (DUNE) - US 3-1

1 Scope of the Document

This document defines the Scope of Work for the Internal Piping for the first two cryostats as part of the Long-Baseline Neutrino Facility (LBNF). Exceptions to these specifications shall not be permitted, except by written approval from FRA.

2 Terms Used in the Document

The following terms define provisions within this document. “May” indicates a condition is neither required nor prohibited. “Should” indicates a recommended provision as good practice but is not a requirement. “Shall” indicates a requirement.

Engineering and Construction Codes will be referred to as Codes to refer collectively to various safety standards the scope shall comply with. This will be reflective of both American and International Codes, depending on the applicable Code used by the Subcontractor’s governing body.

3 Applicable Codes and Standards

Below are codes, standards, and directives to which the Subcontractor shall adhere, and which shall be applied to the engineering, manufacturing, assembly, and testing of the system subject to this Statement of Work (SOW). All the codes, standards, and directives are intended to be used in their latest published edition at the time of engineering, and include, but are not limited to:

ACI 318 Building Code Requirements for Structural Concrete and Commentary

ALPEMA standards

ANSI ASC A14.3 Safety Requirements for Fixed Ladders

ANSI/ASSE A1264.1 Safety Requirements for Workplace Surfaces

ANSI/ISA-5.1 Instrumentation Symbols and Identification

ANSI/ISA-75.01.01 Flow Equations for Sizing Control Valves

API 520 Sizing, Selection, and Installation of Pressure-reliving Devices

API 521 Pressure-relieving and Depressuring Systems

API 526 Flanged Steel Pressure-relief Valves

API RP 615 Valve Selection Guide

ASCE/SEI 7 Minimum Design Loads for Buildings & Other Structures

ASME B30.20 Below-the-Hook Lifting Devices

ASME B30.26 Rigging Hardware

ASME B30.9 Slings

ASME B31.3 Process Piping

ASME B31E Standard for the Seismic Design and Retrofit of Above-Ground Piping Systems

ASME BPVC Boiler and Pressure Vessel Code

ASME BTH-1 Design of Below-the-Hook Lifting Devices

Scope of Work and Performance Specification Applicable Codes and Standards

Long-Baseline Neutrino Facility (LBNF) / Deep Underground Neutrino Experiment (DUNE) - US 3-2

ASME Y14.100 Engineering Drawing Practices

ASME Y14.5M Dimensioning Tolerance Code

ASTM E2734/E2734M Standard Specification for Dimensions of Knife-Edge Flanges

ASTM A380 Standard Practice for Cleaning, Descaling, and Passivation of Stainless Steel Parts, Equipment, and Systems

ASTM E493 Standard Test Methods for Leaks Using the Mass Spectrometer Leak Detector in the Inside-Out Testing Mode

ASTM E498 Standard Test Methods for Leaks Using the Mass Spectrometer Leak Detector or Residual Gas Analyzer in the Tracer Probe Mode

ASTM E499 Standard Test Methods for Leaks Using the Mass Spectrometer Leak Detector in the Detector Probe Mode

CGA S-1.3 Pressure Relief Standards

CGA G-4.1 Cleaning Equipment for Oxygen Service, Seventh Edition

EN 12300 Cryogenic vessels. Cleanliness for cryogenic service

EN 60534-2 Industrial Process Control Valves

EN 61508 Functional safety of electrical/electronic/ programmable electronic safety-related systems

EJMA standards

IEC 61511 Functional safety - Safety instrumented systems for the process industry sector

IEEE 315 Graphics Symbols for Electrical and Electronics Diagrams (Including Reference Designation Letters)

ISA-75.01.01 Industrial-Process Control Valves

ISA 84.00.01 Functional Safety: Safety Instrumented Systems for the Process Industry Sector

ISA-S20 Specification Forms for Process Measurement and Control Instruments, Primary Elements, and Control Valves

ISA-S5.4 Instrument Loop Diagrams

ISO 23208 Cryogenic vessels - Cleanliness for cryogenic service

ISO 28921-1 Industrial valves. Isolating valves for low-temperature applications - Design, manufacturing, and production testing

ISO 3669 Vacuum technology. Dimensions of knife-edge flanges

NFPA 70E National Electric Code (NEC)

OSHA Standard 1910 General Industry Regulation

OSHA Standard 1926 Safety and Health Regulations for Construction

UL 471 Commercial Refrigerators and Freezers

UL 61010-2-011 Safety Requirements for Electrical Equipment for Measurement, Control, and Laboratory Use - Part 2-011: Particular Requirements for Refrigerating Equipment

UL 508A Industrial Control Panels

Scope of Work and Performance Specification Introduction

Long-Baseline Neutrino Facility (LBNF) / Deep Underground Neutrino Experiment (DUNE) - US 5-3

The Subcontractor may propose other recognized standards. Their application is subject to prior written approval by Fermi Research Alliance (FRA). In such cases, the Subcontractor shall submit all the necessary documentation for approval to FRA. FRA, at its discretion, reserves the right to veto the use of certain codes or standards, in part or whole. In no event will FRA be responsible for schedule delays or cost increases associated with the review and evaluation of alternative codes or standards proposed by the Subcontractor.

The International Electric Code (IEC) may be used if supporting documentation is provided to prove an equivalent or greater level of safety to that afforded by NFPA 70E NEC. The use of IEC shall be approved by FRA.

4 Introduction

LBNF (http:/lbnf-dune.fnal.gov/) will provide the infrastructure necessary to support the massive neutrino detectors located deep underground at the Sanford Underground Research Facility (SURF) in Lead, SD.

The Deep Underground Neutrino Experiment (DUNE) will employ four (4) such detectors, housed in cryostats requiring almost 70,000 tons of liquid argon (LAr), about 17,500 tons for each cryostat. DUNE (http://www.dunescience.org/) is expected to achieve transformative discoveries, making definitive determinations of neutrino properties, examining the dynamics of supernovae that produced the heavy elements necessary for life, and probing the possibility of proton decay.

5 Scope of the Supply

The Internal Cryogenics serves to transfer liquid and gaseous argon (LAr and GAr, respectively) inside the cryostats for the purposes of purging them of their native atmospheres, cooling them down, filling them with LAr, and recirculating that LAr from dedicated purification equipment outside the scope of this supply. In addition, they serve to transfer the boil-off GAr outside the cryostat for normal recondensation inside the argon condensers and vent in case of a pressure rise over the allowable limit.

The successful bidder (hereafter referred to as the “Subcontractor”) shall engineer, manufacture, pack and deliver the Internal cryogenics piping systems for the first two of the LBNF cryostats (hereafter referred to, in whole or in part, as the “supply”) to the project warehouse in the vicinity of the Sanford Underground Research Facility (SURF) in Lead, SD.

The project consists of thirty (30) vacuum insulated and uninsulated cryogenic transfer lines and their supports to the cryostat as defined in this technical specification, and the documents and drawings attached to it.

Scope of Work and Performance Specification Scope of the Supply

Long-Baseline Neutrino Facility (LBNF) / Deep Underground Neutrino Experiment (DUNE) - US 5-4

5.1 Scope of the Supply Structure

The Internal Cryogenics acquisition is broken down into a Base Subcontract with two Options, as follows:

Base Subcontract

The Base Subcontract includes the detailed engineering for the internal cryogenics for each of the first two (2) LBNF cryostats. The VD (FD-2) cryostat’s internal cryogenics consists of:

1. Two (2) LAr distribution manifolds, each with two (2) branches, also running along the bottom of the cryostat.

2. A single (1) LAr pipe from the top of the cryostat.

3. Two (2) GAr boiloff lines.

4. External supports for items above.

The HD (FD-1) cryostat’s internal cryogenics consists of the following:

5. A series of twenty (20) cooldown manifolds distributed along the top of the cryostat. Each manifold terminates with a special spray nozzle to distribute atomized LAr toward the center of the cryostat.

Additionally, some manifolds branch into two paths before terminating with the spray nozzle.

6. Two (2) LAr distribution manifolds, each with two (2) branches, also running along the bottom of the cryostat.

7. A single (1) LAr pipe from the top of the cryostat.

8. Two (2) GAr boiloff lines.

9. External supports for items above.

Option #1

The Option #1 Subcontract SOW is the procurement of materials and manufacturing of the Internal Cryogenics subsystem for the VD (FD-2) cryostat. It also includes the testing of the fabricated items per applicable codes and standards and in accordance with the specifications, and the delivery of equipment to SURF.

The extent of the work is the engineering, procurement of materials, manufacturing, manufacturing drawings, factory inspection and testing, documentation, packing, transport, and delivery to SURF for the VD cryostat’s Internal Cryogenics and its support as described in this SOW.

Upon completion of Final Acceptance tests, a two (2) year warranty against materials and workmanship defects shall commence.

Scope of Work and Performance Specification Scope of the Supply

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

Option #2

The Option #2 Subcontract SOW is the procurement of materials and manufacturing of the Internal Cryogenics subsystem for the HD (FD-1) cryostat. It also includes the testing of the fabricated items per applicable codes and standards and in accordance with the specifications, and the delivery of equipment to SURF.

The extent of the work is the engineering, procurement of materials, manufacturing, manufacturing drawings, factory inspection and testing, documentation, packing, transport, and delivery to SURF for the HD cryostat’s Internal Cryogenics and its support as described in this SOW.

Upon completion of Final Acceptance tests, a two (2) year warranty against materials and workmanship defects shall commence.

5.2 Additional Requirements for the Scope

Additional requirements for the scope are outlined below:

1. The Subcontractor shall furnish all facilities, equipment, special tooling, consumables, materials, and labor for the work described in this SOW except where explicitly excluded in this and related documentation.

2. The Subcontractor shall provide all materials and labor for engineering, analysis, manufacturing, validation, and delivery of the supply.

3. The Subcontractor shall provide detailed, signed, certified shop drawings that meet the requirements referenced in Section 3.

4. The Subcontractor shall perform stress and thermal analyses for the supply to verify the code and performance requirements.

5. The Subcontractor shall provide the complete technical documentation for the supply, including individual technical items and elements.

6. All engineering analyses, engineering models, and manufacturing drawings shall be subject to approval by FRA.

7. The Subcontractor shall conduct all tests, inspections, examinations, material tests, and non-destructive examinations required by the applicable codes and perform any resulting repairs or replacements.

8. The Subcontractor shall furnish all parts deemed necessary during the installation process, including spare parts for non-reusable items (e.g., gaskets for Conflat Flanges).

9. FRA (or its designated representative agent) reserves the right to witness and inspect any part during the fabrication, assembly, and testing at the Subcontractor or Subcontractor’s suppliers / sub-Subcontractors’ site with as little as one day’s notice.

Scope of Work and Performance Specification General Description

Long-Baseline Neutrino Facility (LBNF) / Deep Underground Neutrino Experiment (DUNE) - US 6-6

6 General Description

The internal cryogenics piping is responsible for circulating GAr and LAr within the cryostat itself, in order to purge the vessel of its initial atmosphere, cool it to cryogenic temperatures, fill it, and circulate purified LAr back into the cryostat throughout the life of the experiment. The supply also accommodates the circulation of boil-off gas out of the cryostat and relieve over and under-pressure conditions as necessary.

This scope includes those transfer pipe networks required for each of the operational modes of the experiment. For the purposes of this Statement of Work, the pipe networks shown in Figure 6-1, Figure 6-2, and referenced in the appendices are the maximum size envelopes that can be used in the final design. These spaces shall not be exceeded by the Subcontractor.

6.1 Modes of Operation

The cryogenic systems at LBNF function in a variety of operational modes at all phases of the experiment lifecycle (note that all but the Cooldown mode are common for both cryostats; the VD cryostat does not require an initial Cooldown phase and is instead filled directly with LAr). These modes are described in Table 6-1.

Table 6-1: Modes of operation

Mode Name Description

GAr Purge and Circulation

Initially, each cryostat will be filled with air, which shall be removed by means of a “piston purge”, a relatively slow flow of warm GAr originating from the bottom of the cryostat, which pushes impurities to the top of the vessel and out to be vented. Following the initial purge, the loop is closed, with GAr sweeping impurities from the bottom to the top of the cryostat and out to a dedicated purification system. The re-purified argon is subsequently reintroduced to the bottom of the cryostat until the contaminant levels are reduced to sub-ppm levels. This GAr circulation within the cryostats is handled entirely by one of the LAr Recirculation lines, shown in in Figure 6-1.

Cryostat Cooldown

The HD cryostat and detector must be cooled in a controlled manner—to this end, purified LAr is introduced at the top of the cryostat to be circulated within the vessel. The Cooldown manifolds for the HD cryostat are shown in Figure 6-2; isometric drawings are included in Appendix B. The VD cryostat does not feature this mode (and consequently lacks the Cooldown manifolds as well).

Long-Baseline Neutrino Facility (LBNF) / Deep Underground Neutrino Experiment (DUNE) - US 6-7

Mode Name Description

Cryostat Filling and Steady State Operations

Once the cryostat and detector are cooled to roughly 90 K, they may be filled with purified LAr. The filling of each cryostat varies in duration, from eight to fourteen months depending on the cooling power available. Once filled, each cryostat proceeds to the primary operational phase of the experiment.

During this time, the cryostats’ LAr must be continually re-circulated through the purification system by means of external pumps (not part of the Supply).

Initially, two pumps per cryostat are used to circulate a large flow through the purification skids; this flow is maintained until the required argon purity level is achieved, at which time the flow (and therefore the number of pumps in operation) is reduced. Boiloff gas is concurrently recondensed in the condensers above the cryostat and combined with the recirculation flow prior to purification, with the total flow reintroduced into the cryostat at the bottom. The circulation of LAr into each cryostat are handled by their two LAr distribution headers, shown in blue in Figure 6-1.

Figure 6-1: 3D view of the LAr Recirculation distribution networks

Long-Baseline Neutrino Facility (LBNF) / Deep Underground Neutrino Experiment (DUNE) - US 6-8

Figure 6-2: 3D view of the Cooldown manifolds (blue lines) within the HD cryostat

The pertinent sections of the LBNF P&ID are shown in Figure 6-3 and Figure 6-4. The full P&ID is available as Appendix E.

Figure 6-3: Zoom in of the P&ID of the GAr Purge and LAr Distribution for the LBNF cryostats (shown on the VD)

Figure 6-4: Zoom in of the P&ID of the Cooldown Manifolds for the LBNF HD Cryostat

Scope of Work and Performance Specification General Requirements

Long-Baseline Neutrino Facility (LBNF) / Deep Underground Neutrino Experiment (DUNE) - US 7-9

In addition to the piping required for the modes of operation outlined above, this scope also includes an emergency LAr Return line used to drain LAr from the condensers above the cryostat in the event of power failure, the boil-off lines that serve to provide a normal outlet for the GAr to the condensers, and the pipes within the cryostats that serve the pressure relief devices that protect against unacceptable pressure conditions within the vessel. These three networks are small lengths within the cryostat, and their envelopes are shown in Appendix B.

Appendix C lists all of the transfer lines required for this supply, along with their pertinent fluid parameters.

7 General Requirements

Each piping system shall:

Distribute either GAr or LAr from the Infrastructure cryogenics subsystem during the various modes of operation as described above.

− The LAr Distribution manifolds shall have distribution points penetrated along their horizontal runs to evenly distribute LAr and GAr into the cryostats during operations.

− The Cooldown manifolds within the HD cryostat terminate in TPU Unijet Hydraulic Flat Spray, size 70 atomizing spray nozzles from Spraying Systems Co. (Part number 1/4HHSJ- SS6013). There shall be five such nozzles evenly spaced along each manifold near the cryostat center, each pointed horizontally towards the vessel’s centerline.

Each piping system shall have vacuum insulation at heights of 0.55 m relative to the floor of the cryostat. Below that height, the piping manifolds shall be uninsulated.

The thermal contraction of the different materials used at low temperature, whenever giving rise to unacceptable stresses, loads and deformations, shall be compensated by the use of appropriate components and supporting or fixation, systems. These supports shall:

LAr Distribution (horizontal, on the floor): Be supported from the floor of the cryostat by means of pads and/or other supports that are part of this technical specification and supply.

The supports shall include a Teflon layer underneath to avoid scratching the metal that constitutes the floor of the cryostat (SS 304L). They shall also include a Teflon layer where they are in contact with the pipes to avoid scratching them, as well as allowing them to slide to account for their thermal expansion and contraction. Special concerns for these supports are outlined in the External Supports subsection of this scope. No welding is permitted to the floor of the cryostat, only to the top and bottom corners. These are further described in Section 7.2.

LAr Distribution (vertical): Be supported from the side of the cryostat by means of pads and/or other supports that are part of this technical specification and supply. The supports shall include a Teflon layer underneath to avoid scratching the metal that constitutes the wall of the cryostat (SS 304L). They shall also include a Teflon layer where they are in contact with the pipes to

Long-Baseline Neutrino Facility (LBNF) / Deep Underground Neutrino Experiment (DUNE) - US 7-10 avoid scratching them, as well as allowing them to slide to account for their thermal expansion and contraction. Special concerns for these supports are outlined in the External Supports subsection of this scope. No welding is permitted to the side of the cryostat, only to the top and bottom corners. Additional supports for the horizontal parts of the expansion loops (C-shaped portions) may be supported from special M10 threaded connections in the ceiling (close to the top corners).

Cooldown manifolds: The cooldown piping may rest against support beams that carry the detector modules. These beams span the length of the cryostat and shall be made available to simply support the cooldown manifolds. The supports shall include a Teflon layer where they are in contact with the pipes to avoid scratching them, as well as allowing them to slide to account for their thermal expansion and contraction.

No welding is permitted to the side, ceiling, and floor of the cryostat, only to the top and bottom corners.

7.1 LAr Distribution Requirements

The LAr Recirculation piping is divided into two networks. The LAr Recirculation networks main sections span nearly the length of the cryostat on its floor. Both networks, however, enter the cryostat at discrete points on the roof of the cryostat, as shown in Figure 7-1.

Figure 7-1: LAr recirculation pipe penetrations on the HD cryostat (with red arrows pointing to them)

Each of these two piping systems shall be vacuum jacketed within the cryostat at heights exceeding 0.55 m above the vessel floor. Below that height the piping shall be uninsulated. The horizontal runs of the piping systems (at the floor of the cryostats) shall be uninsulated as well. The subcontractor shall employ appropriate means (e.g., flex components or similar) to reduce stresses within the pipe systems and eliminate the potential for the vertical runs to lift any horizontal piping from their supports at the bottom of the cryostat. The subcontractor shall provide stress and deflection analyses to support the design for FRA approval.

Both networks (two LAr Recirculation) shall be directed as shown in Appendix B. The LAr Recirculation networks shall each be split into two sections at the floor, with one leg from each section directed towards

Long-Baseline Neutrino Facility (LBNF) / Deep Underground Neutrino Experiment (DUNE) - US 7-11 the cryostats’ long edges. Both pipe networks then span the length of the cryostat, terminating about 1 m from the short edge opposite their entrance penetrations.

The sizes of the vertical and horizontal runs for each network are included in Appendix C. The appendix specifies two different pipe envelopes for LAr recirculation networks. The first envelope size refers to the vertical section and manifold (spanning the cryostat short edge) for each network. The second envelope refers to the long horizontal runs that tap from the primary manifold. These envelopes represent the maximum possible pipe size for the respective pipe runs; in all cases, the Supplier is responsible for sizing the pipes based on the flow rates and supply pressures to the pipe networks.

Both pipe networks at the cryostat floor shall have their centerlines at 180 mm above the cryostat floor, irrespective of pipe size. Each secondary pipe (the four total LAr Recirculation pipes that span the length of the cryostat) shall have orifices every 0.25 m along their length penetrated into their underside to distribute their contents evenly throughout the vessel. The subcontractor shall provide flow calculations for each network subject to FRA approval showing the pressure drop through the systems and expected flow through each orifice. Care shall be taken in the sizing of these orifices to ensure the most even flow possible during the appropriate operational modes (i.e., the steady state operations of the cryostat for the LAr Distribution headers).

7.2 External Supports (LAr Distribution)

The long runs of horizontal pipe at the cryostats’ floors require several simple supports distributed along their lengths. These supports shall allow the pipes to contract freely as the internal temperature of the vessel decreases. Care in the support placement shall be taken to avoid allowing the pipes to slide from the supports as they contract.

The Subcontractor shall use structural supports that are designed to withstand all the loads for all modes of operations from the transfer lines to the support brackets to the stainless steel membrane corner pieces, and from the transfer liners to the floor of the cryostats. There shall not be any permanent deformations. The Subcontractor shall submit to FRA all loads for all conditions that the transfer lines may transfer to the supports. The design of the supports (including the support brackets) shall be such to minimize the loads transferred, especially the momenta.

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The Subcontractor shall ensure that all the necessary calculations are performed to verify that:

The overall stresses remain within acceptable values as specified in the chosen applicable standards with all loads applied, including the deformation of the pipes with temperature and pressure.

The displacements of the various manifolds with respect to each other with all loads applied are within acceptable limits (contacts between VJs of different manifolds and VJs and other uninsulated process pipes are not accepted).

The pipes can freely slide in the top supports to avoid adding unnecessary loads to the supports themselves, including the support brackets.

The pipes can freely slide over the side supports to avoid adding unnecessary loads to the supports themselves, including the support brackets.

The pipes can freely slide over the bottom supports to avoid adding unnecessary loads to the supports themselves, including the support brackets. Due to the thermal contraction of the vertical runs, the bottom manifolds will tend to lift and detach from the bottom supports. These items shall be designed in such a way to avoid the detachment of the pipes from the bottom supports.

The floor is made of a 1.2 mm metallic membrane with corrugations on a 0.34 m pitch to allow for thermal expansion and contraction. Each support shall be located inside square corrugations (Figure 7-2) measuring 0.34 m x 0.34 m. If a square shape is selected, each bottom support shall not exceed 200 mm x 200 mm. If a circular shape is selected, each bottom support shall not exceed 200 mm in diameter.

Long-Baseline Neutrino Facility (LBNF) / Deep Underground Neutrino Experiment (DUNE) - US 7-13

Figure 7-2: Cryostat walls and floor membrane visualization

If needed, the vertical runs can also be supported from the side wall. These structural supports, supplied by the Subcontractor, shall be designed to adequately accommodate all loads from the relevant internal cryogenics piping. These loads shall be transferred either to the cryostat floor or side via simple unidirectional supports, or, in the case of momenta, to the cryostat corners. The support design shall be such to minimize these transfer loads, with special care given to the momenta.

Any support scheme shall account for the thermal contraction of the internal piping. As the distribution manifolds for the LAr piping span nearly the length of the cryostat (see Figure 6-1), the thermal contractions will be large, that is, on the order of the corrugation pitch. The bottom support structures are prohibited from contacting the corrugations themselves, either due to the motion of the piping or their own thermal contraction. Therefore, the support structure shall not be free to move with the pipes as they contract. Note that in the given modes of operations the vacuum insulated pipes have two load cases:

Process pipe at cryogenic temperature and vacuum jacket at room temperature during the commissioning and throughout the fill (the part that is in the gas phase).

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Process pipe and vacuum jacket at cryogenic temperature throughout the fill (the part already in the liquid phase) and during steady state operations.

Note that, whatever support structure is chosen, the center of each horizontal pipe run shall be 180 mm above the cryostat floor. Any component of the support structure for the LAr piping at the bottom of the cryostat that passes over a corrugation shall be at least 40 mm above the corrugation’s highest point.

The location of all supports shall be submitted to FRA for approval, along with supporting calculations and all loads transferred to the cryostat. Note that it is preferable that the loads be taken by the ports identified in Figure 7-1 if possible.

The Subcontractor shall also take into account that the position of the external supports has an influence on the natural frequencies of the system and therefore an impact on the system response to transport accelerations, seismic and flow induced vibrations.

7.3 External Supports (Cooldown)

The cooldown piping for the HD cryostat enters the vessel by means of twenty penetrations along its long edges, as shown in Figure 7-3 and detailed in Appendix D.

Figure 7-3: Cooldown penetrations into the HD cryostat (circled in light blue)

From these penetrations, the Cooldown manifolds are routed towards the cryostat’s center. An example of this routing is shown in Figure 7-4, however, final routing shall be designed by the Subcontractor and approved by the FRA. Each pipe is routed such that it may be supported on one of the cross-beams that hold the detector aloft (see Figure 7-5 for an example). The load on the support beam should be no more than 165 lbf (75 kg) per pipe.

Scope of Work and Performance Specification Interface Requirements

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Figure 7-4: Possible pipe routing for Cooldown Manifolds (shown in blue)

Figure 7-5: Example of cross-beam element to be used to support the Cooldown manifold

8 Interface Requirements

The supply primarily interfaces with the LBNF cryostat, though it shall also accept LAr and GAr as appropriate from piping systems outside the cryostat that are themselves beyond the scope of this document. With respect to the cryostat interfaces, the supply shall be subject to the requirements outlined below:

The connections to the cryostat shall be of the flanged type (standard CF flange type). For each transfer line, there shall be a CF on the outside of the outer vacuum jacket (or the process pipe if uninsulated) to connect to a mating flange on the cryostat port. The Internal Cryogenics pipes all have connections to the Infrastructure Cryogenics piping outside of the vessels, with a vacuum break outside the cryostat.

Most connections within the cryostat (i.e., process pipe connections to a manifold or a straight pipe segment) shall be welded. Exempt from welding are the horizontal runs of the LAr Recirculation systems (located near the cryostat floor), which shall be interconnected using Conflat Flanges (CF).

Scope of Work and Performance Specification Other Requirements

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9 Other Requirements

9.1 Mechanical

1. All piping shall have adequate flexibility for all design conditions.

2. Welded connections shall be used wherever possible, including all piping inside the cryostat, except for the horizontal runs of the LAr Recirculation systems.

3. Sections of the horizontal runs of the LAr Recirculation systems (located near the cryostat floor) shall be interconnected using Conflat Flanges (CF).

4. When gaskets are required, metal gaskets shall be used whenever possible.

1. Conflat Flanges (CF) shall be used on process pipes (vacuum insulated and uninsulated).

9.2 Flexible Elements in Pipes

1. Flexible hoses and bellows may be used within vacuum jacket insulation only. However:

2. Bellows should pass a receiving leak test to ensure they are leak-tight before welding.

3. The Subcontractor shall provide a plan to protect the bare convolutions of the bellows during welding, testing, and transport.

4. Unbraided bellows are not allowed; all bellows must have at least a single braid for protection.

2. Whenever possible, all hoses and bellow shall be welded. When not possible, hydroformed bellows are allowed subject to FRA approval.

3. Multiple layered bellows shall be engineered to have a vent hole between each layer to prevent trapped volume gas from over pressurization.

4. The Subcontractor should limit the usage of bellows and flexible hoses, promoting the use of flexibility analysis where possible.

9.3 Thermal Isolation

Cryogenic pipes shall be vacuum insulated, in combination with aluminized mylar, Multi-Layer Insulation (MLI), with no active mechanical pumping. The maximum allowable heat load on the process pipe surface of every vacuum-insulated cryogenic pipe, due to radiation and conduction through the supports, shall be less than maximum allowable heat leak given in the Table 9-1. No ice shall be visible on the outside of the vacuum insulation while in normal operation (with the process pipe carrying cryogenic fluid).

Table 9-1: Maximum allowable heat leaks for cryogenic vacuum insulated pipes

Pipe size, inch Heat leak

Process pipe Vacuum Jacket Btu/hr/ft W/m

0.5 2 1.71 0.50

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Pipe size, inch Heat leak

Process pipe Vacuum Jacket Btu/hr/ft W/m

1 3 2.22 0.65

1.5 3.5 2.90 0.85

2 4 3.92 1.15

3 5 5.97 1.75

4 6 7.68 2.25

6 8 10.24 3.00

The required vacuum levels in the insulation vacuum, also called vacuum jacket, are listed in Table 9-2.

The pumping ports shall be engineered to avoid the intake of any loose MLI. The installation of grids at the inlet of each pumping port is acceptable provided they do not compromise the pumping process by excessive pressure drop and that they are engineered to prevent blocking by MLI. Each vacuum space shall be equipped with an InstuTech Stinger convection vacuum gauge, part number CVM211GGL. Other devices are subject to written FRA approval.

The design of the internal assemblies shall allow for proper conductance during pumping operations.

Conductance holes in the internal supports shall be foreseen whenever deemed necessary to allow evacuation of the complete internal volume to reach the specified insulation vacuum pressures.

The maximum pumping speed shall be determined for transfer lines to avoid deterioration of MLI, taking into account the internal conductance and…