Statement_of_Work.pdf

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Statement of Work for the 1293B Vacuum Chamber Upgrades

Item 1:

The vendor shall provide cryogenic vacuum pumps (cryopumps) to provide the maximum pumping speed performance for each of the following gases: nitrogen, hydrogen, argon, xenon and water vapor; while meeting the requirements listed below.

1.a. General Requirements

The Government vacuum chamber access is restricted to eleven (11) ASME B16.47, 42” diameter ports. These ports are the only connection/equipment location points allowed for proposed cryopump installation. Existing chamber drawings and documentation are minimal, and will be made available at award.

Volume of the chamber is 144,000 cubic feet.

Existing chamber roughing pumps will provide vacuum to vendor’s specified crossover pressure.

Equipment proposed shall be catalog offerings and standard products. Custom, prototype, beta, or one-of-a kind systems are not acceptable for this system.

Individual cryopump cooldown time shall be less than 5 hours to 20 degrees Kelvin.

External coolant shall be liquid nitrogen.

Noise level shall be less than 65dB at 10 feet.

All materials and equipment shall be new.

All mounting hardware shall be included.

(1) Set of cryopump recommended spare parts shall be included.

Manufacturer’s Warranty shall be minimum 24 month after delivery.

Within two weeks after award, a one day meeting shall be held at the vendor’s shop to review requirements and inspect manufacturing facilities and a one day meeting shall be held at the

Government site for the vendor to take onsite verification measurements.

Cryopump and compressor service must be located in the United States, and be available to

Hampton, Virginia within 24 hours.

On-site start-up services shall be provided for installation oversight and initial cryopump operation. The Government will provide the labor and materials for installation of the cryopumps through the onsite service contractor. The vendor shall be onsite during the installation and start up of the compressors. The vendor shall be responsible for parts, gases, and installation consumables needed during the installation and start-up period.

1.b. Cryopump Compressor Requirements

The Cryopump Compressor shall be:

Rated for continuous operation in an ambient environment temperature range of: 50-105 degrees F.

Water cooled, scroll-type design, rated for helium service. (available inlet water temperature

(maximum): 75 degrees F).

Equipped with minimum front panel displays for: compressor suction and discharge pressures, hourmeter, On, Off, Interlock Status.

Fitted with removable panels for access and maintenance.

Connected to available electrical power: 480VAC, 3 phase, 60 Hz, maximum 100 amp service

(total for all units proposed).

Compatible with low voltage control signal interface: 24 VDC, failsafe de-energized.

Shipped with coldhead interconnecting helium lines, minimum 20’ in length, field installable. The interconnecting lines shall be stainless braided, with a minimum bend radius of at least 6 inches.

The lines shall be factory leak checked using mass spectrometry at operating pressure.

Equipped with the following interlocks: Compressor over temperature, helium under pressure.

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Performance checked at the factory in the presence of a Government witness prior to shipment, date to be coordinated with the Government’s technical point of contact.

1.c. Cryopump Cold Head Requirements

The Cryopump Cold Head shall be:

Of stainless steel and aluminum construction.

Equipped with instrumentation: (2) Silicon diode array temperature sensors and (1) thermocouple for coolant.

Provided with all mounting and supporting hardware.

1.d. Quality Assurance Requirements

Factory checks shall be Government witnessed. A ten day advance notification of each test is required.

Factory Test Reports

1.e. Documentation Requirements

Equipment drawings, including outline dimensions, interconnecting details, and physical details.

Drawings shall be .pdf format.

Installation instructions

Operating and Maintenance instructions

Parts List

1.f Delivery Schedule (to NASA Langley Research Center, Bldg. 1206, Hampton, VA. 23666)

Cryopump coldheads and compressors: No later than 7 months after award

Cryopump spare parts set: No later than 7 months after award

Factory Test Report Plan for Review: No later than 4 weeks prior to factory test

Completed Factory Test Report: No later than 2 weeks after factory test

Documentation, 4 copies required, (Ref 1.e): No later than 7 months after award

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Optional Item 2:

The vendor shall provide a control system to integrate the operation, sequencing, and interlocks of the cryopump components provided in Item 1. The control system shall meet the following requirements:

2.a. Control System General Requirements

The Control System shall be a vendor’s standard product.

The control unit shall be a Programmable Logic Controller (PLC).

The input power shall be 120 VAC, 60Hz, with vendor specified ampacity required.

The control system shall be housed in a free-standing, appropriately sized, NEMA 12 enclosure with a separate Human Machine Interface (HMI) display panel to be integrated into the

Government’s existing control system (see integration requirements below). The appropriately sized enclosure shall be large enough to safely troubleshoot and wire components mounted in the enclosure. All components shall be surface mounted to an internal panel in a manner that allows easy and secure replacement.

The control system shall be designed and rated for continuous duty without overheating when continuously operated in an ambient temperature of no more than 95 degrees F.

The control panel shall be provided with a UL Listed stamp.

The control enclosure door shall incorporate a fusible disconnect interlocked for entry.

A watchdog timer circuit shall be incorporated into the failsafe shutdown circuit to monitor processor execution time.

All materials and equipment shall be new.

All mounting hardware shall be included.

(1) Set of recommended spare parts for the control system shall be included.

Manufacturer’s Warranty shall be minimum 24 month after delivery.

On-site start-up services shall be provided to commission the control system.

2.b. Design Requirements

A Preliminary Design Review shall be held at vendor’s location no later than 60 calendar days after award. The review shall represent a 30% design, and include drawings, screen layouts, component specifications and description of operation.

A Final Design Review shall be held at vendor’s location no later than 120 calendar days after award. The review shall represent a 100% design, and include drawings, screen layouts, component specifications and a written description of operation. The review shall include a proposed test and checkout plan for the control system to be reviewed by the Government and executed by the contractor at the Quality Assurance Factory Check as specified below.

The HMI screens shall include as a minimum the following or equal modes: Cooldown, Operation, Warm-up, and System Secure.

The HMI shall incorporate touch screen sequential operation, instrumentation readouts, liquid nitrogen system status, compressor status, alarm/shutdown annunciation, and security levels of access control.

Hardwired controls shall include an Emergency Stop, On/Off, and System Permissive. A connection for a non-voltage Government Emergency Stop shall be included.

The control system shall control the cryopump compressors, liquid nitrogen system, cooling water flow, and provide interface with the existing facility controls.

Facility integration shall consist of a dedicated block on 10 inputs and 10 outputs, 5 analog inputs, and 5 analog outputs, to be specified by the Government at the Preliminary Design Review.

These inputs and outputs shall be programmed into the control system to provide safety and control features as needed for system operation.

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2.c. Control Hardware Requirements

Digital input/outputs shall be 24 vdc.

Analog inputs/outputs shall be either 0-10 vdc, 4-20 ma, TC, RTD, or others as only approved by the Government.

Compressor power circuits shall include a 3 pole contactor, thermal overloads, and individual circuit breakers.

2.d. Instrumentation Display Requirements

The enclosure shall include a multi-channel front panel readout for each cold head silicon diode.

The enclosure shall include a multi-channel front panel readout for each cold head coolant temperature sensor.

The HMI shall include temperature displays for the silicon diodes and coolant sensors.

2.e. Quality Assurance Requirements

Factory checks shall be Government witnessed. A ten day advance notification of each test is required.

Factory Test Reports (4 copies).

2.f. Documentation

Component literature and specifications.

Design drawings with as-built updates, including schematics, wiring diagrams, mechanical layouts, assembly, and parts lists. Drawings shall be in .pdf format.

Ladder logic diagrams.

Installation instructions.

Operating and Maintenance instructions.

Program software.

Recommended Spare Parts List.

2.g. Delivery Schedule (NASA Langley Research Center, Bldg. 1206, Hampton, VA. 23666)

Control System: No later than 6 months after option award.

Factory Test Report Plan for Review: 4 weeks prior to factory test.

Completed Factory Test Report Plan: 2 weeks after factory test.

Documentation, 4 copies required, (Ref 2.f): No later than 6 months after option award.

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Optional Item 3:

The vendor shall design a liquid nitrogen piping system to provide external cooling to the cryopump cold heads provided in Item 1. The liquid nitrogen system design shall meet the following requirements:

3.a. Liquid Nitrogen (LN2) Piping System Design General Requirements

The LN2 piping system shall be designed to the ANSI/ASME B31.3 Chemical Plant and Petroleum

Refinery Piping Code.

The LN2 piping system design shall be based on a facility dewar as the supply point;

approximately located as shown on the attached sketch. The dewar capacity is 6000 gallons, discharge pressure, minimum 40 psig. All vaporizer, fill, regulation, and safety devices are existing for the dewar.

Design connection to the dewar shall be specified by the Government within 10 days after optional item award.

The design shall specify every device and component required to make a fully working system.

The routing shall be generally as shown on the attached sketch from the dewar to the existing chamber access ports. Exact location dimensions shall be provided by the Government within 10 days after optional item award.

The design shall include details of all lines, valves, instrumentation, components, and mounting.

Rigid vacuum jacketed (VJ) supply lines shall be designed from the dewar to the cryopump supply points. VJ line sections shall incorporate bayonet style connections for field assembly.

Flexible jumpers from the supply and return lines shall be designed to make the final connections from the supply/return pipes to the coldheads.

3.b. Design Requirements

The LN2 piping system shall be designed to meet the specific flow, pressure, and temperature requirements of the vendor’s cryopumps.

The piping system shall be analyzed for thermal stress and flexibility. Expansion joints, couplings, supports and stress relief mountings and components shall be incorporated into the design.

The design shall incorporate the most efficient and safe methods to provide high quality cryogenic liquid to the cold heads with minimum heat leak. The design shall properly vent the cold head return side warm gas in a manner consistent with industry codes and practices.

The design shall incorporate valves and safety devices to allow each cryopump to be individually cooled and operated independently of all other cryopumps connected to the LN2 piping system.

Piping supports shall be placed a maximum of 10’ apart, and provided at every direction change.

A Preliminary Design Review shall be held at vendor’s location no later than 60 calendar days after award. The review shall represent a 30% design, and include drawings, routing layouts, component specifications and engineering analysis.

A Final Design Review shall be held at vendor’s location no later than 120 calendar days after award. The review shall represent a 100% design, and include drawings, material lists, component specifications, and description of operation.

The design drawing package shall specifically include an ISA (Instrument Society of America) styled process and instrument drawing (PID) and piping isometric drawing detailing line sizes, spool numbers, materials, devices, pressure and temperature ratings, welds and weld parameters.

For vacuum jacketed piping sections, connection sizes, both inner carrier and jacket sizes, and flex sections shall be indicated.

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3.c. Instrumentation and Control Requirements

The system design shall include electric operated valves for remote automation from a typical control system for example, as specified in Optional Item 2. Instrumentation shall be specified as needed to cooldown and operate the cryopumps as well as vent the warm gas from the cryopumps.

3.d. Documentation

Component literature

Material lists and specifications

Design drawings, drawings shall be in .pdf format.

Description of Operation

3.e. Delivery Schedule

(to NASA Langley Research Center, Bldg. 1206, Hampton, VA. 23666)

LN2 System Design: No later than 3 months after optional item award.

Documentation, 4 copies required, (Ref 3.d): No later than 3 months after optional item award.

Sketch 1 - Approximate routing plan for the LN2 Piping System

Vacuum Sphere

Red Line indicates approximate routing of new LN2 system piping for Supply and Return piping. (Include approximately 20’ of vertical run against building exterior.)

Black Bars indicate approximate location of the existing vacuum ports (8 of 11 shown).

Area where existing

Government LN2

Storage tank will be located.

Area of 20’ vertical piping run.

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Optional Item 4:

The vendor shall fabricate and procure the liquid nitrogen piping system components designed in

Optional Item 3. If possible, the Government will award options 3 and 4 simultaneously. The manufacture of the liquid nitrogen system piping shall meet the following requirements:

4.a. Liquid Nitrogen (LN2) System Piping Fabrication General Requirements

The LN2 piping system shall be fabricated and tested to the ANSI/ASME B31.3 Chemical Plant and Petroleum Refinery Piping Code.

The LN2 piping system shall be fabricated to follow the liquid nitrogen system routing approximately located as shown on the attached sketch.

The vendor shall fabricate or procure every devise and component required to make a fully working system.

The vendor shall use Section VIII certified welders, welding processes, and specifications.

All piping shall be cleaned, sealed, and prepared for shipping at the factory such that no other steps are required on site to prepare the piping system for use once connected.

4.b. Vacuum Jacketed Piping Fabrication Requirements

The VJ piping sections shall be stainless steel, vacuum insulated piping.

The piping shall be fabricated in a minimum number of sections, fitted with bayonet style connections and expansion joints at appropriate locations to accommodate thermal expansion/contraction cycling. Each section shall be factory cleaned, baked, evacuated, and shipped with a static vacuum.

The VJ piping annulus shall include the following:

a. Support system to withstand the thermal and pressure load s on the inner pipe at all operating and dynamic shipping conditions while minimizing heat leakage.

b. Laminar radiation shielding

c. Chemical gettering system to include a molecular sieve and hydrogen converter.

d. Combination evacuation and relief port. The relief pressure shall be 15 psig.

4.c. Testing Requirements

A VJ Piping Test Plan shall be developed and submitted to the Government prior to fabricating the pipe.

The VJ piping sections shall be tested with a helium mass spectrometer calibrated to detect a minimum level of 1x10-9 standard cc/sec helium leakage.

A minimum of 10% of welds shall be randomly tested radiographically.

The minimum bake out temperature shall be 200 degrees F.

The piping system shall be proof tested at 120% of design pressure.

4.d. Documentation

Welder certifications, including processes and specifications

Chemical and physical mill material certifications

Instrumentation calibration certification

Component literature

As-built drawings, drawings shall be in .pdf format.

Piping Test Plan and Reports

4.e. Delivery Schedule

LN2 Piping System: No later than 4 months after optional item award.

Documentation, 4 copies required, (Ref 4.d): No later than 4 months after optional item award.

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Optional Item 5:

If required, the vendor shall design an adapter flange to mount the coldheads provided in Item 1 to the existing vacuum chamber ports. The design of the adapter flange shall meet the following

5.a. Adapter Flange Design Requirements

The adapter flanges shall be designed to the ANSI/ASME B16 Standards for Pipes and Fittings.

The adapter flange shall be designed to bolt onto the existing vacuum chamber port as specified in

Item 1 without any degradation of the chamber ratings.

The adapter flange shall be designed to accept the vendor’s mounting flange of the cold head(s) without any degradation of the cryopump performance.

The adapter flange shall incorporate a lifting point lug with 200% capacity.

Progress review drawings shall be submitted at the 50% and 90% design milestones.

5.b. Documentation

Weld specifications

Material specifications

Design drawings, drawings shall be in .pdf format.

5.c. Delivery Schedule

Adapter Flange Design: No later than 2 months after optional item award.

Documentation, 4 copies required, (Ref 5.b): No later than 2 months after optional item award.

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Optional Item 6:

The vendor shall provide the adapter flanges required to mount the coldheads provided in Item 1 to the existing vacuum chamber ports as designed in Optional Item 5. If possible, the Government will award options 5 and 6 simultaneously. The adapter flanges shall meet the following

6.a. Adapter Flange Requirements

The adapter flanges shall meet the ANSI/ASME B16 Standards for Pipes and Fittings.

The adapter flange shall bolt onto the existing vacuum chamber port as specified in Item 1 without any degradation of the chamber ratings.

The adapter flange shall accept the vendor’s mounting flange of the cold head(s) without any degradation of the cryopump performance.

All mounting hardware and bolts shall be provided with the flanges.

At least 5% of the total linear weld length shall be radiographed.

6.b. Documentation

Weld NDE reports

Proof load test report of lifting lug at 200% capacity

Material certifications

As-built drawings, drawings shall be in .pdf format.

6.c. Delivery Schedule

Adapter Flange(s): No later than 3 months after optional item award.

Documentation, 4 copies required, (Ref 6.b): No later than 3 months after optional item award.

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Proposals will be evaluated on a ‘Best Value to the Government’ basis. Pricing data shall be provided separately for each Item 1-6 listed in the Statement of Work. In addition to pricing data, the following evaluation criteria will be used, and each proposal should include the following:

Technical Evaluation Criteria:

1. A system technical description, maximum of (5) 8.5” x 11” pages, shall be submitted. The following data shall be provided:

a. Pumping speed for each gas/vapor specified in the performance criteria. Pumping speeds shall be given by unit and also total capacity in liters/second.

b. Argon throughput at 20 degrees Kelvin in Torr liters/second or millibar liters/sec.

c. A statement of acceptance or exception for each requirement (1.a-1.f), including a brief discussion how each specific requirements will be met.

d. Recommended crossover pressure for cryopump operation.

e. Cryopump cooldown time based on proposed system with all options.

f. Total ampacity of compressors at 480vac, 3 phase power.

g. Cryopump warranty period offered.

h. Location of closest repair center for the cryopump cold head and compressor.

2. Additional information, such as drawings, sketches, pictures, catalog cuts, specification sheets, sequence/description of operation, shipping details, etc. may be submitted for each item (Item 1 and all Optional Items) up to a maximum of 10 pages total.

3. Past Performance references of (3) similar or relevant systems in the last 3 years