J-8_PMR-QAP-LAr_Circulation-July_25_2025_Final.pdf

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

LBNF/DUNE-US

LAr Circulation Packages J-8 Project Management Requirements, Quality Assurance and Quality Control Plan

Document Number: EDMS 3327678

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Document Approvals

Signatures Required Signature Date

Originator:

Zachery West Cryogenic Systems Engineer

07.25.25

Co-Author:

Kevin Fahey LBNF QA Manager

Approver:

David Montanari LBNF FDC Cryogenics Project Manager

Approver:

Jolie Macier LBNF FDC Project Manager

Zachery West, UID:zwest

Digitally signed by Zachery West, UID:zwest Date: 2025.07.25 12:21:11 -05'00'

Kevin Fahey, UID:kfahey

Digitally signed by Kevin Fahey, UID:kfahey Date: 2025.07.25 12:58:14 -05'00'

Digitally signed by David Montanari, UID:dmontana Date: 2025.07.26 06:41:13 -07'00'

Jolie Macier, UID:jrmacier

Digitally signed by Jolie Macier, UID:jrmacier Date: 2025.07.28 09:12:58 -05'00'

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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 Engineering & Equipment Data Management Service (EDMS) where internal Project document approvals are managed. 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 currently approved version is always available in https://edms.cern.ch/document/3327678/1

Author Revision Date Location (EDMS) Description of Changes

Zachery West 07/25/2025 3327678/1 Initial Release

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Table of Contents

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

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

Acronyms, Abbreviations and Definitions .....................................................................................................vi

1 Purpose and Scope ............................................................................................................................. 1-1

2 Project Introduction ........................................................................................................................... 2-3

3 Responsibilities for Project Management .......................................................................................... 3-4

4 Manufacturing, Installation, and Assembly Requirements................................................................. 4-6

4.1 Manufacturing ............................................................................................................................ 4-6

4.2 Welding ...................................................................................................................................... 4-6

4.3 Installation .................................................................................................................................. 4-6

5 Shipping Requirements....................................................................................................................... 5-8

6 Project Management .......................................................................................................................... 6-9

7 Quality Assurance Program .............................................................................................................. 6-11

7.1 Quality Assurance Plan (QAP) ................................................................................................... 6-11

7.2 Personnel Training and Qualification ....................................................................................... 6-13

7.3 Documents and Records ........................................................................................................... 6-13

7.4 Submittals ................................................................................................................................. 6-15

7.5 Design Process .......................................................................................................................... 6-16

7.5.1 Design Verification and Validation ................................................................................... 6-17

7.5.2 Preliminary Design Review (PDR) ..................................................................................... 6-17

7.5.3 Final Design Review (FDR) ................................................................................................ 6-18

7.5.4 Production Readiness Review (PRR) ................................................................................. 6-18

7.6 Fabrication Work Processes ..................................................................................................... 6-19

7.7 Change Control / Modifications Management ......................................................................... 6-20

7.8 Calibration of Equipment ......................................................................................................... 6-20

7.9 Examinations, Inspections, and Tests ....................................................................................... 6-20

7.10 Receipt and Installation Inspection and Test ............................................................................ 6-22

8 Procurement ..................................................................................................................................... 8-23

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8.1 Subcontractor ........................................................................................................................... 8-23

9 Control of Nonconforming Material ................................................................................................. 9-24

10 Assessments ............................................................................................................................... 10-26

References

11 Appendix A – Ross Shaft Load Envelopes

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Acronyms, Abbreviations and Definitions

Acronym Definition

EFS External Floor Supports

FDR Final Design Review

FermiForward Fermi Forward Discovery Group, LLC

GAr/LAr Gaseous Argon / Liquid Argon

HP Hold Point: A milestone requiring the subcontractor to notify FermiForward of task completion and suspend processes until written authorization is issued

MAWP Maximum Allowable Working Pressure

NIST National Institute of Standards and Technology

NP Notification Point: A milestone requiring the subcontractor to inform FermiForward of task completion before proceeding

NWD Autodesk Navisworks

OEM Original Equipment Manufacturer

PDR Preliminary Design Review

PM Project Management or Project Manager, depending on context

PMP Project Management Plan

PRR Production Readiness Review

QAM Quality Assurance Manager

QAP Quality Assurance Plan

QAR Quality Assurance Representative

SME Subject Matter Expert

Subcontractor Company subcontracted to perform work and/or Project Partner providing in-kind contributions

SOW Statement of Work

SPM Subproject Manager

STEP Standard for the Exchange of Product Data; a common ISO standard format for 3D modeling and printing

WBS Work Breakdown Structure

WPS Weld Procedure Specification

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Acronym Definition

WPQ Weld Procedure Qualification

WQR Welder Qualification Record

Quality Assurance and Quality Control Plan Purpose and Scope

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1 Purpose and Scope

The Subcontractor is responsible for managing, controlling, and documenting all activities related to the procurement, fabrication, and, if applicable, installation of the LAr Circulation Packages. This work shall comply with the Subcontract documents, Statements of Work, and internationally recognized quality standards such as ISO 9001 and ASME.

The Subcontractor shall provide adequate Quality Assurance/Control (QA/QC) services for all on-site and off-site work performed by its organization, suppliers, sub-tier subcontractors, technical laboratories, and consultants. A Quality Assurance Program shall be implemented, with a designated quality-responsible person(s), and the Subcontractor shall submit its Company Quality Assurance Program with its proposal.

Any revisions to the quality program issued during the performance period shall be submitted to FermiForward within 14 business days of issuance.

The Subcontractor’s welding program shall comply with nationally recognized standards, such as ASME and AWS, and include qualified welders, Weld Procedure Specifications (WPS), and Weld Qualification Records (WQR).

The QA/QC requirements outlined in this document, along with referenced procedures, will ensure that the LAr Circulation Packages—including the two (2) packages for cryostats Vertical Drift (VD) and Horizontal Drift (HD)—are manufactured, assembled, installed (if applicable), and commissioned (if applicable) to meet quality standards. All relevant instructions shall be provided to FermiForward.

The inspections and tests detailed in this document and its references will ensure the proper functioning of all components as the cryogenic system is manufactured, assembled, installed (if applicable), and commissioned (if applicable).

This document defines the requirements for:

1. LAr Circulation System VD,

2. LAr Circulation System HD, Quality Assurance and Quality Control Plan Purpose and Scope

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The following information will be provided in the individual Statements of Work for each LAr Circulation Package:

• Statement of Work

• Applicable Codes and Standards

• System Description

• Interface Requirements

• Technical Requirements

• Functional Requirements

• Operational Requirements

• Mechanical Requirements

• Supplied Equipment Specifications

• Manufacturing, Installation, and Assembly Requirements

• Shipping Requirements

• Inspection, Examination, and Testing

• Phase Deliverables

• Kick-Off Meeting

• Engineering Phase

• Manufacturing Phase

• Quality Assurance

• Project Management

• Required Documents Summary

• Project Schedule

Quality Assurance and Quality Control Plan Project Introduction

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2 Project Introduction

The Deep Underground Neutrino Experiment (DUNE) at the Long-Baseline Neutrino Facility (LBNF) was borne out of the 2014 U.S. Particle Physics Project Prioritization Panel (P5) recommendations. The recommendations called for the formation of a truly international collaboration for constructing a US-based long-baseline neutrino oscillation experiment with a powerful neutrino beam (~MW scale), a massive liquid argon TPC (40 kt) sited several hundred kilometers downstream of the neutrino source and deep underground, and a smaller detector just downstream of the beamline. Together these elements will have the capability to unambiguously determine the neutrino mass ordering, search for CP violation in the lepton sector, search for proton decay, and observe neutrinos from core collapse supernovae.

The LBNF/DUNE-US Project is the DOE-funded construction project to create the facility and contribute US scope to the international DUNE Collaboration. The major participants in the overall LBNF/DUNE enterprise are the international DUNE collaboration, the LBNF/DUNE-US construction project, the DOE, international funding agencies, Fermilab (in Batavia, Illinois) as the host laboratory, and the Sanford Underground Research Facility (SURF, in Lead, South Dakota), where the far detector will be located.

Figure 1 illustrates the general underground work area at the SURF (far) site.

Figure 1: DOE Underground Leased Space at SURF

Quality Assurance and Quality Control Plan Responsibilities for Project Management

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3 Responsibilities for Project Management

Overall QA Supervision. The LBNF/DUNE-US Project Manager (PM) is ultimately responsible for QA supervision, providing necessary resources for project success and quality assurance, and ensuring compliance with quality standards and techniques throughout the project.

Key Personnel Responsibilities.

The LBNF/DUNE-US Subproject Manager (SPM). SPM may designate Quality Assurance Representatives (QARs) within their organization to execute portions of the QA/QC Plan.

• Manages subprojects to meet performance goals.

• Provide necessary resources for project success and quality assurance.

• Oversees quality control within the subproject and reports QA issues to the PM and QAM.

• Retains overall responsibility for subproject quality control activities.

• Responsible for determining and documenting acceptance criteria for subproject components and systems

• May request independent quality assessments as needed.

The LBNF/DUNE-US Quality Assurance Manager (QAM).

• Establishes, implements, and maintains the QA system.

• Reports to the PM and provides oversight and support to SPMs for consistent quality assurance.

• Develops, implements, assesses, and improves the QA program.

• Provide necessary resources for project success and quality assurance.

• Periodically reports on quality system performance to the PM for improvement.

• Coordinates work with designated Testing Laboratory personnel, ensuring schedule and quality standards compliance.

• responsible for observing work and monitoring safe work practices, with authority to address deficiencies.

• Manages submittals, coordinates testing, and ensures compliance with project requirements.

• Focuses on planning work to minimize or prevent rework, with authority to correct deficiencies.

• Maintain all QA-related records, certifications, and documentation.

• Ensure current As-Built/As-Installed Drawings and Records of Materials are available on-site.

• Participate in non-conformances and final inspections.

Quality Control (QC) Specialist (s).

• Assisting the QA Manager in specific areas of responsibility.

• Attending QC meetings, preparing sections of QC reports, and ensuring quality control duties are fulfilled.

Manufacturer or Factory Representative.

• Ensures compliance with installation recommendations and other technical specifications.

Quality Assurance and Quality Control Plan Responsibilities for Project Management

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• May be required on-site during certain periods of the work to ensure quality.

Responsibilities of Team Members.

• All LBNF/DUNE-US team members, collaborators, contractors, and subcontractors are responsible for the quality of their work.

• They have the authority to stop work and report adverse conditions affecting quality to the SPM and the QAM.

Quality Assurance and Quality Control Plan Manufacturing, Installation, and Assembly Requirements

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4 Manufacturing, Installation, and Assembly Requirements

4.1 Manufacturing

The Subcontractor shall provide a manufacturing plan outlining the steps and details, which will be subject to FermiForward approval at the time of the Production Readiness Review (PRR) or earlier.

4.2 Welding

All welding joint preparation and welding techniques shall be performed by the applicable codes. Vacuum jacket welding shall be performed in a manner equivalent to a standard welding procedure specified and qualified under the rules of the applicable codes.

All welding performed on the cryogenic process piping circuits shall be done by the Gas Tungsten Arc Weld (GTAW) process, using welding quality argon gas for the inert shield.

All welds shall be internally purged with welding-quality argon gas during the time of welding and post-welding treatment.

Welds that show evidence of a lack of purge shall not be accepted.

All welding shall be performed in such a manner that the welding surface is smooth and free of irregularities. No visible metal chips or foreign material may be detectable inside any component. 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.

No production welding shall be performed until all WPS, PQR, and WPQ documents have been qualified by the applicable codes. Welding will be performed by qualified welders.

If possible, longitudinal welds shall be avoided in tubes and pipes.

4.3 Installation

The subcontractor shall provide installation manuals and procedures and all documentation for the installation process.

Subcontractor Documentation.

The Subcontractor’s reports in conjunction with the LBNF Project’s reports provide a written record of job progress, control inspections, and tests. Therefore, the Subcontractor’s reports shall be accurate, complete, and submitted promptly. These reports provide the official documentation of work performance and compliance with the project’s drawings and specifications. The QA Representative is responsible for obtaining and reviewing the Subcontractor’s reports daily to ensure accuracy and completeness. Any discrepancies or areas of disagreement should be resolved at the field level on the same day, whenever possible. The LBNF Cryogenics Infrastructure Project Manager shall review these reports to verify that the QA/QC process is functioning effectively.

Quality Assurance and Quality Control Plan Manufacturing, Installation, and Assembly Requirements

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Documentation Maintenance. All documentation generated by the QA System shall be stored and maintained within the document management system.

Report Types.

• Subcontractor Production Report, prepared by the Subcontractor’s Project Manager, this report documents daily efforts and progress, including on-site labor details for each Sub-subcontractor. It is not strictly a Quality Control (QC) document but shall align with scheduled activities.

• The Subcontractor Quality Control Report, prepared by the QC Manager, this report focuses on the Quality Control Program’s progress, issues, and corrective actions. It must detail all work, including rework, with entries tied to scheduled activities. Follow-up inspections shall be also documented. Each report shall include a certification from the QA Manager confirming compliance with contract requirements, except as noted.

• Submittal Status Log shows the status of all shop drawings, certifications, and other submittals. For each submittal, the log shall show the contract and/or specification paragraphs requiring the submittal, a description of the submittal, whether it is Subcontractor-approved or LBNF-approved, and actual submission and approval dates on all actions. This allows the QA Manager to track the status as well as pending or planned actions required by the Subcontractor or the LBNF Project.

• Subcontractors are required to prepare and maintain a Testing Plan and Log to document the specification requirements, test plan, test location, tester, and frequency of all required tests.

With this information, the QA Manager and the QA Representative can monitor the plans and status of all required testing.

The QA Manager shall establish a list of items requiring rework, and an agenda item for the QC meetings to review the progress of corrective actions on these items. The list shall indicate the date identified, describe each deficiency, contract requirement, action taken, and resolution, and indicate the date corrected. Deficiencies corrected on the same day they are discovered are exempt from the rework list.

The QA Manager should not allow the adding to, building upon, or enclosing of nonconforming work.

Quality Assurance and Quality Control Plan Shipping Requirements

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5 Shipping Requirements

The Supply sub-components shall be carefully packed for transport and their value shall be covered by transport insurance. The Subcontractor shall take all appropriate precautions necessary to avoid damage to equipment or interference from any kind of other FermiForward contractors or users.

For shipments coming from outside the US, packaging materials shall meet the US Customs standards for entry into the US Ports.

Accelerometers with logging capabilities shall be mounted before shipment and inspected after each transport and handling up to the final positioning of each item in the detector caverns. The peak value shall not exceed 4 g.

All openings shall be sealed against moisture, dirt, or air penetration with appropriate plastic caps or blind flanges.

All items shall be crated or boxed to be readily handled with a forklift truck and shall have suitable lifting attachments for the use of an overhead crane.

The design of the crate and lifting fixtures (if used) shall respect the weight and size limitations listed in Appendix A.

Each crate shall be marked indicating contents, contract number, and gross weight. In addition, the following features shall be incorporated into the design of each crate:

i. The full enclosure on all sides.

ii. Sufficient interior restraint to prevent the components from shifting within each crate.

iii. Vacuum-insulated components shall be supported only on the exterior surfaces of the vacuum vessels.

iv. Appropriate and marked exterior features to allow tie-down during transport and lifting using both a crane and a forklift.

v. Protection from prolonged exposure to the weather without corrosion or other damage to their contents.

vi. Clear labels in the English language and point of origin indicating the presence of fragile contents.

vii. Extra interior space and restraints for miscellaneous hardware (mounting jacks, etc.). The list of hardware shall be identified on the bill of lading for easy identification.

viii. Any welds used in the construction of the shipping crate shall conform to welding codes.

The following inspections shall be performed upon arrival:

i. Verification of the Transport accelerometers.

ii. FermiForward incoming inspection (at SURF) including visual inspection for shipping damage and verification of Bill Of Lading.

Quality Assurance and Quality Control Plan Project Management

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6 Project Management

The Subcontractor shall coordinate and control all project-specific activities and corresponding resources and shall ensure the realization of the standards of the SOWs and the successful fulfillment of the subcontract.

The Subcontractor shall assign a person responsible for the technical execution of the contract and its follow-up, as well as a person responsible for the commercial follow-up, throughout the contract. They shall be able to communicate in English.

The Subcontractor shall appoint a safety correspondent who shall act as its representative with FermiForward in matters of safety.

The LBNF Project uses cost and scheduling tools (Primavera P6 and Cobra) by FermiForward standards. In addition, FermiForward utilizes the Earned Value Management System (EVMS) for cost, schedule, and scope change control. This system will be used by FermiForward to monitor and evaluate project progress and performance against the deliverables for the duration of the subcontract.

The performance of the Subcontractor will be monitored through a project schedule that is prepared by the Subcontractor and accepted by FermiForward. The Subcontractor shall provide submittals, as defined in the schedule specification, and shall be inclusive of but not limited to:

A comparison of the resources planned versus actual work completed with an explanation of any variances from the plan.

Review and approval of the schedule and monthly updates including the following:

Actual Start Dates for activities begun during the status period.

Actual Finish Dates for the activities completed during the status period.

Physical Percent Complete for those activities started but not completed.

Forecast completion dates for activities started but not yet completed.

Narrative description of actual project progress versus planned progress, highlighting risk areas and work that is behind the plan.

End-of-month status of any issues tracking including but not limited to Requests for Information, Change Orders, Submittals, etc.

Schedule of Values based on resource loaded schedule.

In special cases, especially in the case of technical problems and delays, FermiForward may also request more frequent reporting intervals.

In case of events affecting the schedule, the Subcontractor shall take suitable measures to ensure that the schedule is maintained. This expressly includes the assignment of additional personnel (overtime and shift work) and additional equipment at the Subcontractor’s expense.

Quality Assurance and Quality Control Plan Project Management

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Independent of the scheduled reports, all events that may influence the schedule shall be reported to FermiForward. In case of serious problems that endanger the achievement of contractually agreed milestones, the FermiForward shall be informed immediately in writing. The subcontractor shall present to FermiForward a recovery plan to minimize or offset the adverse impact on the schedule.

The Subcontractor shall plan and prepare a series of project meetings (in addition to the scheduled reviews), whereby the agenda, the participants, the location, and means are to be determined in coordination with FermiForward. There shall be provision for weekly teleconferences throughout the whole duration of the Subcontract using a mutually agreed teleconferencing system. FermiForward and the Subcontractor have the right to request special meetings as needed.

Unless otherwise arranged, the Subcontractor shall prepare all minutes of the meetings and share them with FermiForward within five (5) workdays.

Quality Assurance and Quality Control Plan Quality Assurance Program

Long-Baseline Neutrino Facility (LBNF) / Deep Underground Neutrino Experiment (DUNE) - US 6-11

7 Quality Assurance Program

7.1 Quality Assurance Plan (QAP)

Design and Manufacturing Standards. The Supply shall be designed and manufactured in accordance with generally applied quality standards and techniques.

Quality Assurance Program (QAP). The subcontractor shall prepare and implement a QAP to cover the design, procurement, fabrication, testing, inspection, and delivery of the Supply and its subassemblies.

The QAP shall address the criteria outlined in this document. If the subcontractor’s QAP system is currently certified to ISO 9001 requirements, specific elements may be satisfied by reference to the appropriate ISO document.

Procurement Activities. The QAP shall provide for the planning and execution of procurement activities following documented instructions and/or procedures.

Verification of Purchased Items. The QAP shall provide for verification of conformance of purchased items to the Subcontractor’s design specifications and procurement document requirements.

Periodic Audits. The QAP shall provide for planned, periodic audits of the various aspects of the program by individuals not directly responsible for implementation shall be conducted.

Fabrication Planning and Control. The QAP shall provide for fabrication planning, material and process control, cleanliness control, inspection, testing, non-conformance control, and documentation of the inspection function.

Calibration Procedures. Calibration procedures, status indication on test equipment, serialization, traceability to NIST or other standards, and calibration records shall be maintained.

Material and Equipment Identification. The QAP shall provide for the material and equipment identification maintained throughout the manufacturing process, either on the material or equipment or on records traceable to the material or equipment. The status of acceptability of materials and equipment with respect to inspections and tests shall be readily discernible through the subcontractor’s use of tags, stamps, routing cards, or other means.

Subcontractor’s QA Program Plan. The Subcontractor’s QA Program Plan shall include:

• A QA/QC Organization detailing the qualifications, duties, responsibilities, and authorities of each person assigned a Quality function, including the Project Quality Assurance Manager.

• In-process inspection and testing.

• Completion inspections.

• QC certifications and documentation necessary to verify that all subcontracted work complies with the requirements of the Subcontract, including materials, equipment, workmanship, manufacturing, installation, and commissioning.

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Inspection System. The Subcontractor shall maintain an adequate inspection system to ensure that the work conforms to contract requirements, along with complete inspection records available for review by the FDC Sub-Project.

1. The Subcontractor shall provide a tailored Quality Assurance (QA) Plan to the FermiForward Procurement Representative, meeting project-specific quality control requirements. This document should outline the procedures, instructions, and reports the Subcontractor will utilize throughout the project. The QA Plan should include the following elements:

• Table of Contents

• QA Organization Chart

• Personnel Training and Qualifications

• Duties and Responsibilities

• Procurement Quality Assurance

• Design Process

• Work Process

• Submittal Procedures

• Inspection and Acceptance Testing

• Control of Nonconforming Material and Equipment

• Quality Improvement

• Documents and Records

• Independent Assessment

• Completion Inspection Procedures

• Suspect and Counterfeit Items

2. Approval from the FDC Sub-Project is necessary before the Subcontractor commences work. This plan delineates the process the Subcontractor will follow, and the roles personnel will undertake to meet QA Program requirements. Typically, work initiation awaits the approval of the QA Plan. Any exceptions shall be explicitly authorized by the LBNF/DUNE-US QA Manager in writing.

3. Acknowledging the impracticality of delaying work initiation until a complete QA Plan is submitted and approved, exceptions may be granted for mobilization work. The sole other possible exception is work sanctioned under an "Approved as Noted" submittal of the QA Plan, permissible under the following two circumstances:

• First 90 Days: If the QA Plan serves as a preliminary submittal for the initial ninety (90) days of work, the LBNF/DUNE-US QA Manager may grant approval as "Approved as Noted" solely for these initial activities. Upon completion of the authorized work, unless an acceptable follow-up QA plan is submitted and approved, the Argon Cryogenics Project Manager shall stop the work.

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• Minor Changes: Approval of the QA Plan with minor changes or additions is permissible. The Argon Cryogenics Project Manager may use an "Approved as Noted" approach to authorize work initiation if the Subcontractor agrees in writing to rectify the plan by a specified date.

Failure to approve a corrected plan by the specified date mandates cessation of work.

4. Should the Subcontractor opt to make any alterations to its QA Plan, including personnel changes, the revised QA Plan shall be submitted to LBNF for approval. The FDC Sub-Project retains the prerogative to modify the QA Plan, including conducting interviews with QA/QC Personnel to verify submitted qualifications, and if necessary, to request personnel replacement.

7.2 Personnel Training and Qualification

All subcontractor personnel are required to have the necessary experience, knowledge, and skills to perform their jobs. Personnel are qualified to perform their job based on previous experience, education, and training; on-the-job training; and completion of training courses or qualification programs.

Subcontractor management is required to evaluate and ensure that the people performing work are appropriately qualified, and having the appropriate skills, background, education, and training necessary to carry out their assigned tasks.

The QAP shall delineate the required qualifications for personnel assigned to perform the special processes as required by the applicable codes and standards. These processes include but are not limited to, welding, heat treatment, non-destructive examination, helium mass spectrometer leak check, and others as may be required by the specifications.

7.3 Documents and Records

The subcontractor shall provide copies of mill certification reports for all materials and/or code listed components supplied by the subcontractor.

For “Commercial Off the Shelf Items” such as weld rods, electrodes, and fasteners, the subcontractor shall supply certificates of compliance in lieu of mill certification reports. Conflat flanges are not excluded from having to provide material certifications.

The subcontractor shall furnish copies of the WPS utilized in welding operations on the Supply.

The subcontractor shall furnish all weld maps and nondestructive weld inspection results.

The subcontractor shall furnish copies of the WPQ and WQR for each welder utilized in the welding operation on the Supply.

The subcontractor shall furnish all engineering and design information for the lifting lugs on the Supply if used.

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The subcontractor shall furnish a code-compliance certificate for all process piping circuits as well as design calculations for all code process piping components to verify that all component pressure ratings are at or below the circuit design pressures.

The subcontractor shall furnish a code compliance certificate for all pressure vessels as well as design calculations for all code components to verify that all component pressure ratings are at or below the design pressures.

The subcontractor shall furnish a code compliance certificate for all vacuum vessels as well as design calculations for all code components to verify that all component pressure ratings are at or below the design pressures.

The subcontractor shall furnish specifications and manuals for purchased components used in the Supply.

The subcontractor shall furnish quality control reports, including but not limited to leak-check test reports with the name and qualification of the person(s) performing tests.

The following applies to all documents, drawings, notes, calculations, results of inspections, analysis, testing reports, etc. prepared by the Subcontractor and submitted to FermiForward related to the design, manufacturing, and testing of the Supply:

• All documents shall be written in English.

• All documents shall use dual units: Imperial first followed by SI in parenthesis.

• 3D models shall be submitted in native CAD format, STEP format, and, whenever possible, NWD format.

• All drawings shall be submitted in Drawing Exchange Format (DXF) and Portable Document Format (PDF).

• All electronically generated documents shall be supplied in MS Office format and PDF.

Documents with handwritten entries shall be submitted in PDF.

• Schedule information shall be submitted in PDF.

• All documents shall include the name and qualification of the originator, checker, approver, release date, version number, and, if applicable, validity. Each version (excluding the first one) shall include a clean copy and a red markup highlighting the changes from the previous version.

• The final documentation with all updated documents shall be submitted within 30 days of the conclusion of each phase.

Quality Control Certifications

1. Each QC Report signed by the Subcontractor QA Manager shall contain the following statement:

"On behalf of the Subcontractor, I certify that this report is complete and correct, and the equipment and material used, and work performed during this reporting period is in compliance with the Subcontract drawings and specifications to the best of my knowledge, except as noted in this report."

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2. Upon completion of the work or a specific portion thereof, the QA Manager shall furnish a completion certificate to the FDC Sub-Project attesting that "the work has been completed, inspected, tested and is in compliance with the Subcontract."

7.4 Submittals

The following items are subject to submittal to FermiForward for written approval following the time frame and requirements defined in the Scope of Work:

• Complete assembly fabrication drawings of the Supply, including, but not limited to, piping layouts, piping supports, pressure, and vacuum vessels, and thermal intercept details.

• Any polymer and composite materials to be used for the Supply fabrication.

• Engineering analysis of the Supply cryogenic process piping (piping) as required by the code, see Statements of Work (SOW) for each package.

• Engineering analysis of the Supply:

− piping flexibility according to the code.

− pressure drops.

− internal support structure.

− vacuum vessel as required by the code.

− lifting lugs or comparable components.

− external floor supports (EFS).

− heat leak.

− pressure relief devices.

• Temperature sensor surface mounting method and procedure.

• Pipe material selection.

• Cryogenic and high-temperature Insulation selection.

• Pressure relief valves and placement within the Supply.

• Type and make of heaters to be used in the Supply.

• Type and make of instrumentation feedthroughs and connectors to be used in the Supply.

• Project Management (PM) Plan.

• Quality Assurance Plan (QAP).

• Cleanliness Quality Assurance Plan.

• Fabrication Plan.

• Rigging and Handling Plan.

• Installation Plan.

• Format and material of labels.

• WPS, WPQ, and PQR for all welding performed on the Supply and subassemblies.

• Inspection, examination, pressure test, and leak test procedures.

• Detailed project schedule listing tasks in one-month or shorter time increments.

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• Shipment plan including the design of any shipping fixtures and packaging of the Supply for shipment to the SURF site.

7.5 Design Process

The subcontractor’s design process shall provide appropriate control of planning, design inputs, outputs, verification and validation, configuration and design changes, and technical and administrative interfaces.

Design work shall be based on sound engineering judgment, scientific principles, and applicable codes and standards.

Required Meetings.

1. The Project Kickoff Meeting is an important meeting required on all major subcontracts for discussion of the administrative procedures for the Subcontract. During the Kickoff Meeting, which takes place before starting work, ground rules are established, and understandings are reached that will establish positive relationships at the start of the Subcontract.

This will be done before the start of Phase 2 - engineering, manufacturing, and installation.

This is also an opportunity to emphasize the importance of the QA organization to the Subcontractor.

Discussion of the QA System requirements and their due dates should be included. An extensive discussion of the Quality Program, however, is best reserved for the QA Plan meeting. Where practical, the Project Kickoff Meeting and a QA Plan Meeting (if required) may be scheduled for the same day, provided the two agendas are properly separated.

2. The first meeting specifically relating to the Quality Program is the QA Plan Meeting. This meeting is an excellent communication forum to ensure the QA Plan and Program are quickly and efficiently instituted. The purpose of the meeting is to develop a mutual understanding of the QA Plan requirements. All QA/QC requirements from the contract and the specifications should be discussed.

3. QA Meetings shall be held on a regular basis, e.g., weekly. The QA Manager develops the agenda, conducts the meeting, and prepares the minutes. All problems or questions should be directed to him or her.

These meetings should be used to reinforce the philosophy of the Quality Program. Submittal status should be the lead-off agenda item of each QA Meeting.

Sub-Subcontractor QA/QC personnel should attend the meetings to discuss approaches to upcoming phases of work and correction of any deficiencies. Agendas for these meetings include items such as:

• Status of submittals.

• Review of test reports for deficiencies and results.

• Review Schedules to see which tests or inspections are scheduled for upcoming work.

• Review of outstanding problems from previous meetings.

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The QA Manager shall be required to address how the Subcontractor intends to correct any problems. As part of the project documentation, the QA Manager shall keep the minutes of the meeting and distribute them to attendees. These minutes become part of the official contract file.

7.5.1 Design Verification and Validation

Design shall be verified and validated to an extent commensurate with its importance to safety, complexity of design, degree of standardization, state of the art, and similarity to proven design approaches. Acceptable verification methods include but are not limited to any one or combination of (1) design reviews, (2) alternative calculations, and (3) prototyping, plus qualification testing and/or comparison of the new design with a similar proven design if available. Verification work shall be completed before approval and implementation of the design.

Wherever the design method involves the use of computer software to make engineering calculations or static dynamic models of the structure, system, or component's functionality, the software shall have been demonstrated to produce valid results. The demonstration needs to be documented in a formal Report of Validation that is maintained in records that are accessible for inspection. However, exemptions may be made for commercially available software that is widely used and for codes with an extensive history of refinement and use by multiple institutions. Exemptions affecting systems or components shall be identified to the LBNF/DUNE Systems Engineering team.

Critical software and firmware computer codes shall also be subjected to reviews for verification and validation. Some items to be considered during computer code review are as follows:

• Adequacy of code testing scheme.

• Code release control and configuration management.

• Output data verification against code configuration.

• Verification that code meets applicable standards.

• Verification of code compatibility with other systems that use the data.

• Verification that code meets applicable hardware requirements.

• Adequacy of code maintenance plans.

• Adequacy of code and data backup systems.

7.5.2 Preliminary Design Review (PDR)

A PDR is held when the design is advanced and understood sufficiently to begin design modeling and engineering analysis of the subcomponents. Detailed designs are not required at this time, but preliminary design analyses shall be provided to demonstrate compliance with specification requirements. The subcontractor shall present the design and interfaces by means of configuration and layout sketches, analyses, 3-D models, and any early results. Preliminary mechanical and thermal supporting data and analyses shall be included in the PDR.

The PDR shall cover the following items:

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• Documented technical requirements.

• Changes to technical requirements, as needed.

• Closure of action items from the Kick-Off Meeting.

• Interface requirements.

• Preliminary mechanical and structural design and analyses.

• Preliminary thermal design and analyses.

• Preliminary layouts, drawings, and 3-D models.

• Assessment of risk areas and potential delays.

• Updated schedule.

Completion of the PDR and the closure of all action items shall constitute the basis for proceeding with the detailed design and long lead procurements.

7.5.3 Final Design Review (FDR)

The FDR is held to present the final, detailed design using substantially completed drawings, 3-D models, and analyses to show that the design will meet the performance and interface specifications and the required design objectives. The FDR shall present a complete and comprehensive final design and interfaces using detailed drawings, including, but not limited to, layout and assembly drawings, modeling results, engineering analysis results, and all changes to the design presented at the PDR.

The FDR shall include all the items specified for a PDR, updated to the final, present stage of the development process, plus the following additional items:

• Closure of action items from the PDR.

• Any revised technical objectives and requirements.

• Final interface requirements.

• Final results of mechanical and structural design and analysis.

• Final results of thermal design and analysis.

• Final detailed design with 3-D models, layouts, drawings, and analyses.

• Fabrication, assembly, test, and shipment plans.

• Assessment of risk areas and potential delays.

• Updated fabrication and installation schedule, if any.

Completion of FDR and the closure of all action items shall constitute the final design for the Supply. A successful FDR shall allow for the procurement of all required materials.

7.5.4 Production Readiness Review (PRR)

The PRR is held to present a final review of completed fabrication drawings and documents to show that the design is ready for the production phase. The PRR shall also verify that all production documents such as welder qualifications, welding procedures, testing, and shipping plans are in place.

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The PRR shall include the following items:

• Closure of action items from all previous reviews

• Any revised technical objectives and requirements.

• Final detailed design with layouts, drawings, and analyses.

• Updates to fabrication, assembly, test, and shipment plans.

• Assessment of risk areas and potential delays.

• WPS, WPQ, and PQR documents.

• Examination and testing procedures and related documents.

• Updated schedule.

• Design of shipping fixtures.

Completion of the PRR and the closure of all action items shall constitute the final design approval for the Supply to be built. A successful PRR allows for full-scale fabrication and assembly.

7.6 Fabrication Work Processes

Fabrication work on the LBNF/DUNE-US Project shall be performed to established technical standards and administrative controls using approved instructions and procedures. Fabrication work processes with QA inspections and tests shall be documented on travelers that are retained with the hardware item. Items, including consumables, shall be identified, and controlled to ensure their proper use and prevent the use of incorrect, unaccepted, or unidentified items. The Project will define a system of controls to ensure that items are handled, stored, shipped, cleaned, and preserved to prevent them from deteriorating, being damaged, or becoming lost. Equipment used for process monitoring or data collection shall be calibrated and maintained.

The subcontractor shall provide for a system of process sheets, shop travelers, or equivalent means that shall be used to define the sequence of fabrication, inspection, installation, and test activities to be performed.

The process sheets, shop travelers, or manufacturing and inspection plans shall provide for “Hold” and/or “Witness” points. The proposed points shall be submitted by FermiForward at or prior to FDR. The “Hold” and/or “Witness” points shall be designated on the applicable documentation so that there is provision for signoff by the designated inspection personnel (FermiForward and the subcontractor) to assure completion as well as proper sequencing of the required work.

Work shall be performed safely, in a manner that ensures adequate protection for employees, the public, and the environment. Employees and management shall exercise a degree of care commensurate with the work and the associated hazards.

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7.7 Change Control / Modifications Management

Both the FermiForward and the subcontractor have the right to inform the other party of requests for modifications. Each recommended modification shall be clearly identified (by a unique number) to be used in all subsequent correspondence.

All modifications that affect the Supply performance interface requirements or other contractual content shall be documented and approved in writing without delay with respective notice to FermiForward. For each such modification, the following information shall be provided:

• Reason for modification.

• Assessment of technical feasibility, where deemed necessary.

• Assessment of the effect on other elements of the contract.

• Effect on the project schedule.

• Effect on the project's overall cost.

• Other affected factors (reliability, safety, maintenance).

• Any additional documentation.

7.8 Calibration of Equipment

Calibration is a critical step in any process that utilizes measurement or diagnostic tools to ensure success.

Improper calibration can result in injury to workers, damage to…