Exhibit A - PIP-II SSRs and LB650 Cryomodules - ED0031626 - Rev - Specification.pdf

PIP-II

Procurement and Fabrication Specification

Document Title:

PIP-II SSRs and LB650 Cryomodules - Procurement and Fabrication Specification – JT Heat Exchangers

Document Number: ED0031626 Rev -

Fermi National Accelerator Laboratory 1

PIP-II SSRs and LB650 Cryomodules

- Procurement and Fabrication Specification -

JT Heat Exchangers

Author: J. Bernardini

Document Title:

PIP-II SSRs and LB650 Cryomodules - Procurement and Fabrication Specification – JT Heat

Fermi National Accelerator Laboratory 2

Document Approval Date Approved

Originator Jacopo Bernardini, Sub-project manager for SSR Cryomodules As in TC

Checker

Benjamin Hansen, Cryogenic Technology Division Director

Michael J White, Cryogenic Operations Department Head

Mattia Parise, L3 Manager for SSR Cryomodules

Joe Ozelis, L3 Manager for 650 Cryomodules

As in TC

Approver Donato Passarelli, SRFCRYO System Manager As in TC

Author Revision Date Description of Change

Jacopo Bernardini May 2024 Initial Release

Document Title:

PIP-II SSRs and LB650 Cryomodules - Procurement and Fabrication Specification – JT Heat

Fermi National Accelerator Laboratory 3

Table of Contents

1 Scope 4

2 Procurement Specification 4

2.1 Bidding Phase 4

2.2 Technical and Cost Evaluation Phase 5

2.3 Execution Phase and Hold Points 5

2.3.1 Hold Points 6

3 Fabrication Specification 6

3.1 List of Standards and Procedures 6

3.2 Performance 7

3.3 Mechanical Design 8

3.4 Interfaces 8

3.5 Fabrication Requirements 10

3.6 Factory Tests 10

3.7 Documentation to be provided at the time of the MRR 11

3.8 Documentation to be provided at the time of the Shipping Readiness Review 11

3.9 Shipping Plan 11

Document Title:

PIP-II SSRs and LB650 Cryomodules - Procurement and Fabrication Specification – JT Heat

Fermi National Accelerator Laboratory 4

1 Scope

The Single Spoke Resonator Type 1 Cryomodule (SSR1 CM), Single Spoke Resonator Type 2 Cryomodule

(SSR2 CM), and Low Beta 650 Cryomodules are three of the five different types of cryomodules (total of

25 units) that will constitute the PIP-II linear accelerator complex. The PIP-II linac will house a total of 18

SSR1, SSR2, and LB650 CMs, each one of those will house a JT Heat Exchanger. The present specification is intended to inform the procurement and fabrication of 20 Heat Exchangers.

The Manufacturer shall provide all materials necessary to fabricate complete deliverables. The

Manufacturer shall provide manufacturing engineering services required to generate internal shop drawings and all documentation needed to manage and support their suppliers. The Manufacturer shall fabricate jigs and fixtures to ensure ports, brackets, and other important components are maintained to specified tolerances. Any information of a proprietary nature must be identified in the bid response.

FRA is requesting that offerors provide firm-fixed pricing for DDP shipping (HTS code 8543.90.88.45) as part of their firm-fixed-price proposal to the RFP.

2 Procurement Specification

Purchase Order will be owned and managed by Fermilab Research Alliance (FRA).

2.1 Bidding Phase

Bidder shall provide Quotation including all costs to deliver 20 Heat Exchangers to Fermilab:

- 7 x SSR2 type.

- 2 x SSR1 type.

- 11 x LB650 type.

In addition to quotation, the following documentation shall be provided:

a) Schedule that meets a lead time of 4 months for the first and second units (1 x LB650, 1 x SSR1), starting from the date that the FRA Purchase Order is awarded to the bidder running through fabrication, including hold points reported in Table 1. After acceptance of the first unit from FRA, the lead time for the subsequent 3 units (1 x LB650, 1 x SSR1, 1 x SSR2) shall be 6 months, and less than 12 months for the remaining units. Supporting documentation, to demonstrate that the bidder will deliver within the specified timeframe, is recommended.

Document Title:

PIP-II SSRs and LB650 Cryomodules - Procurement and Fabrication Specification – JT Heat

Fermi National Accelerator Laboratory 5

b) Technical Proposal to demonstrate the ability of the bidder to deliver the assembly with performance that meets or exceeds Fabrication Specification reported in section 3 of this document. The Bidder shall document their ability to perform factory tests as specified in section

3 and within the timeframe identified. Examples of past projects (within the last five years) that closely match the scope in complexity and value, and that best illustrate the bidder’s capability, experience, and performance will be considered for the technical evaluation. The Bidder shall provide the organizations’ name, the date of completion, and the total value of the project. The

Bidder shall disclose what part of the work, if any, will be sub-contracted.

c) Management Control Plan to demonstrate the ability to ensure the required quality standard (see section 3) throughout the entire execution of the project. To be considered for an award, the

Bidder shall provide examples of documentation developed for past projects (within the last five years), which demonstrate the ability of performing inspection and testing.

All required documentation shall be organized with a table of contents and corresponding sections.

2.2 Technical and Cost Evaluation Phase

An FRA Purchase Order will be awarded to one bidder after that the proposals will have been evaluated by technical and cost evaluation teams.

2.3 Execution Phase and Hold Points

Upon FRA purchase order award, the Manufacturer shall assign a person responsible for the technical execution and Quality Control (QC) of the project, and a person responsible for the commercial follow-up, throughout the duration of the contract. They shall be able to communicate in English.

Within two weeks from FRA purchase order award, a kick-off meeting shall be carried out to initiate technical and commercial discussion between the technical and commercial representatives from FRA and the Manufacturer. Action items from the meeting shall be addressed within one week.

Within eight weeks from FRA purchase order award and before starting any fabrication / procurement activity, the Manufacturing Readiness Review (MRR) shall be organized to allow FRA reviewers to assess the Manufacturer’s level of preparation to proceed to the manufacturing and procurement phase. The review’s recommendations (if any) based on the presented material (see MRR deliverables in Table 1), shall be addressed within two weeks from the conclusion of the MRR.

Upon conclusion of the MRR, the Manufacturer will be allowed by FRA to proceed with the fabrication / procurement phase. Quality Controls (see section Error! Reference source not found.) and technical reports, as detailed in Table 1, shall be provided by the Manufacturer to FRA.

Document Title:

PIP-II SSRs and LB650 Cryomodules - Procurement and Fabrication Specification – JT Heat

Fermi National Accelerator Laboratory 6

The readiness to ship the units shall be assessed through an appropriate review.

2.3.1 Hold Points

A Hold Point is defined as the moment in time wherein the process needs to be stopped in order to allow a FRA representative to perform reviews and QCs deemed necessary.

Table 1 lists the main hold points and associated documentation deliverables for this project.

Hold Point

Description Deliverables When required

A Kick-off Meeting

Address action items from the meeting Within 2 weeks of contract award

B

1st and 2nd units Manufacturing Readiness

Review (MRR) Documentation listed in section 3.7

Within 8 weeks from FRA purchase order award and before starting any Fabrication / Procurement activities for the 1st and 2nd units.

C 1st and 2nd units Shipping

Readiness Review Documentation listed in section 3.8

Shipping Plan Prior to shipping the 1st and 2nd units.

D

Remaining units Manufacturing Readiness

Review (MRR) Documentation listed in section 3.7

After acceptance of the 1st and 2nd units from

FRA and before starting any Fabrication /

Procurement activities for the subsequent units

E Discrepancies /

Nonconformities Discrepancy report(s) As soon as identified

F Remaining Units Shipping

Readiness Review Documentation listed in section 3.8

Shipping Plan Prior to shipping

Table 1: Hold Points and Documentation Deliverables for Fabrication Phase

3 Fabrication Specification

This section provides a technical introduction of the scope, assembly to be manufactured, quality controls, and shipping plan.

3.1 List of Standards and Procedures

The following list of codes or their latest edition, drawings and standards or equivalent

European/DIN/ISO/US standards, shall be applied to the engineering, design, fabrication, assembly, and tests.

• 3.1. ASME Boiler and Pressure Vessel Code (BPVC).

Document Title:

PIP-II SSRs and LB650 Cryomodules - Procurement and Fabrication Specification – JT Heat

Fermi National Accelerator Laboratory 7

• 3.2. ASME B31.3 -2014 Process Piping

• 3.3. TEMA: The standards of Tubular Exchanger Manufacturers’ Association.

• 3.4. FNAL Environment, Safety and Health (ES&H) Manual FESHM 5031.1: Piping Systems and

FESHM 5031: Pressure Vessels

3.2 Performance

The Heat Exchanger performance specification and design parameters for each Cryomodule type is presented in Table 2.

Table 2: Heat Exchanger Performance Specification

LB650 SSR2 SSR1

Helium mass flow [g/s] 5.71 4.48 2.10

Minimum effectiveness 0.87 0.87 0.87

High pressure stream (SC)

Inlet temperature [K] 4.73 K 4.73 K 4.73 K

Outlet temperature [K] <2.17 <2.17 <2.17

Nominal Operating Pressure

[kPa]

300 kPa 300 kPa 300 kPa

MAWP (absolute) [kPa] 2000 kPa 2000 kPa 2000 kPa

Pressure drop [kPa] <0.053 kPa <0.053 kPa <0.053 kPa

Low pressure stream (VLP)

Inlet temperature [K] 2.0 K 2.0 K 2.0 K

Pressure [kPa] 3.129 kPa 3.129 kPa 3.129 kPa

Pressure drop [kPa] <0.086 kPa <0.086 kPa <0.086 kPa

Nominal Operating Pressure

[kPa]

3.13 kPa 3.13 kPa 3.13 kPa

MAWP (absolute) [kPa] 410 kPa 410 kPa 410 kPa

During the fast cooldown of cryomodules, helium will return through the VLP passage of JT heat exchanger. The hydraulic performance of heat exchanger corresponding to fast cool down is given in Table

3.

Document Title:

PIP-II SSRs and LB650 Cryomodules - Procurement and Fabrication Specification – JT Heat

Fermi National Accelerator Laboratory 8

Table 3: Hydraulic Performance of Heat Exchanger During Fast Cooldown

Stream Mass flow rate Inlet Temperature Inlet Pressure Pressure Drop

High Pressure ; SC 0 - - -

Low Pressure ; VLP ≥ 80 g/s 45 K 200 kPa ≤ 5 kPa

3.3 Mechanical Design

• The Manufacturer shall ensure that materials to be used for pressure vessel components meet all requirements of ASME BPVC, or EN equivalent.

• All materials used in the construction of the heat exchanger must be certified. CMTRs are to be provided at the time of the shipping readiness review.

• All surfaces in contact with helium must be clean and free of dirt, welding scale or any other contaminant. A cleaning plan is to be provided at the time of the MRR and pictures showing the inner side of the heat exchanger are to be provided at the time of the shipping readiness review.

• Heat exchanger shall be designed to withstand high thermal stress due to cooldown from room temperature to design temperature.

• The heat exchanger shall be a counter flow heat exchanger.

• Any materials used in pressure containing piping components of the device shall conform to ASME

B31.3 material requirements for appropriate fluid service category and operating temperature range. Alternatively, EN equivalent code may be used.

• Any fittings, bends, miters, laps, and branch connections shall conform to ASME B31.3 requirements for appropriate fluid service category. Alternatively, EN equivalent code may be used.

• Any flanges or blanks of the device shall conform to ASME B31.3 requirements for appropriate fluid category. Alternatively, EN code equivalent may be used.

• The heat exchanger shall be made of an appropriate code compliant SS316L.

3.4 Interfaces

The size of the very low-pressure line and the streamline of the heat exchanger are detailed in Figure 1.

Document Title:

PIP-II SSRs and LB650 Cryomodules - Procurement and Fabrication Specification – JT Heat

Fermi National Accelerator Laboratory 9

Very low-pressure line:

• Inner diameter: 56.3 mm

• Outer diameter: 60.3 mm

• Length of the end-tube SSR1 and SSR2: 39 mm

• Length of the end-tube LB650: 170 mm

Stream line:

• Inner diameter: 17.3 mm

• Outer diameter: 21.3 mm

• Length of the end-tube SSR1 and SSR2: 32.6 mm

• Length of the end-tube LB650: 50 mm

Figure 1: Heat Exchanger Connection Sizes.

Moreover, lifting lugs need to be mounted on the upper part of the heat exchanger to make the handling and the assembly process of the cryomodule easier.

The envelopes available for the heat exchangers are defined in Figure 2 and Table 4Table 4: Maximum

Envelop Size.

Figure 2: Heat Exchanger maximum envelop size.

Very low-pressure line outlet

Very low-pressure line inlet

Stream line inlet

Stream line outlet

A

B C

D

E

Document Title:

PIP-II SSRs and LB650 Cryomodules - Procurement and Fabrication Specification – JT Heat

Fermi National Accelerator Laboratory 10

Table 4: Maximum Envelop Size

SSR1 & SSR2 Maximum Envelop Size

LB650 Maximum Envelop Size

A: Maximum height (mm) 470 732

B: Maximum width (mm) 188 223

C: Maximum depth (mm) 155 155

3.5 Fabrication Requirements

• Concerning joining techniques, if welding is required, only TIG or MIG techniques are acceptable;

if brazing is required, only vacuum or inert atmosphere brazing techniques are acceptable. Soft soldering is not acceptable.

• The Manufacturer shall furnish copies of the WPS, PQR, and WPQ utilized in welding.

• The standard followed for all welded joints preparation and welding techniques shall be made available.

• The manufacturer shall maintain records in accordance with relevant codes for all welders and the welds made by each so that all the data shall be available.

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

• There shall be no welds that show evidence of a lack of purge.

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

• All external surfaces in the weld area shall be cleaned of heat tint, slag, and other deposits.

3.6 Factory Tests

• The Manufacturer must perform factory tests to ensure that the heat exchanger satisfies the specifications.

• The device shall be cold shocked to saturated liquid nitrogen temperature.

• Pressure test performance concerning maximum working pressures in accordance with applicable code listed in section 3.1 and completed after the cold shock test.

• Leak tightness between streams and vacuum. The leak tests must be done after the pneumatic pressure test. Allowable leak rates are summarized in Figure 3.

Document Title:

PIP-II SSRs and LB650 Cryomodules - Procurement and Fabrication Specification – JT Heat

Fermi National Accelerator Laboratory 11

Figure 3: Allowable leak rates.

3.7 Documentation to be provided at the time of the MRR

• The Manufacturer shall furnish a general assembly drawing of the heat exchanger showing major dimensions and weights.

• Thermal and Hydraulic performance calculations demonstrating chosen design meets the performance specification. The HX’s effectiveness vs flow rate curve shall be provided.

• Code compliance strategy.

• Digital copy of each WPS, PQR, and WPQ.

• Manufacturing and Inspection Plan (MIP) and examples of Travelers.

3.8 Documentation to be provided at the time of the Shipping Readiness Review

• Certificates of all materials used (CMTRs).

• Certificate of code compliance.

• Code required markings, if applicable.

• Reports of all factory tests.

• The Manufacturer shall furnish a as built assembly drawing of the heat exchanger showing major dimensions and weights and configuration.

• Final version of the Manufacturing and Inspection Plan.

• Discrepancy reports, if any.

• Shipping plan: including dimensions and weight of crates or containers used for shipping.

3.9 Shipping Plan

The Manufacturer shall ship each component properly packed to ensure that damage is not incurred during shipment, in accordance with transportation industry standards. This shall include weather protection and shock protection. The vendor shall propose a shipping configuration to FRA, and FRA shall approve prior to any shipments. Recommendations include foam, bubble wrap, and other vibration/shock

Document Title:

PIP-II SSRs and LB650 Cryomodules - Procurement and Fabrication Specification – JT Heat

Fermi National Accelerator Laboratory 12 reducing materials to be used as packing material, and for components to be shipped in hard-side crates to reduce the risk of damage. Sizing shall be such that handling is facilitated and weight limitations imposed by the transportation industry can readily be met. Quantity 9 heat exchangers are to be shipped to Fermilab, quantity 11 heat exchangers are to be shipped to CEA Paris – Saclay.

All deliverables including documentation shall be catalogued and offered for acceptance to FRA by the

Shipping Readiness Review, as detailed in Table 1.