Specification_GPS-200.210-001_HFIR Cold Source Refrigeration System.pdf

Approval for Revision 1

Reviewer Title

GJ Laughon Writer 05/06/2024 Online

DD Haskell Design Reviewer 05/10/2024 Online

RL Hapney Jr CSOL 05/06/2024 Online

YS Kwon PLEX Mgr. 05/08/2024 Online

AL Chandler Safety 05/16/2024 Online

MA Grooms CCM 05/16/2024 Online

Approved: MA Grooms Sponsor 05/16/2024 Online

GPS-200.210-001, HFIR Cold Source Refrigeration System Approvals

1 5/16/2024

HFIR COLD SOURCE REFRIGERATION SYSTEM REV. 1 GPS-200.210-001

HFIR COLD SOURCE REFRIGERATION SYSTEM

GENERAL PROCUREMENT SPECIFICATION

Table of Contents

1. Purpose And Scope

2. Definitions

3. Descriptions Of Existing System Components To Be Replaced

4. Operating Modes

5. Existing System Performance Parameters

6. General System Requirements For The New Helium Refrigeration System

7. Interface Requirements

8. Specific Reliability, Redundancy, And Operational Flexibility Requirements

9. Technical Requirements

10. General Document Requirements

11. Testing and Training

12. Quality Assurance

13. Acceptance

14. Deliverables (See Section 10.2)

15. Installation

16. Manufacturing

17. Project Schedule

Appendix A. P-11530-CS-744

List of Tables

Table 1. Process Pressures and Temperatures Table 2. Process Mass Flows

List of Figures

Figure 1. Helium Compressors Figure 2. Oil Removal System Figure 3. Helium Refrigerator Figure 4. Existing System Layout Figure 5. Facility Layout Available Space Figure 6. Electrical Power Distribution Figure 7. Helium Transfer Lines (In Cable Trays) Figure 8. Helium Transfer Lines Range of Motion Figure 9. Liquid Nitrogen Interface (Insulated) Figure 10. Helium Conditioning and Flow Measurement System

1. PURPOSE AND SCOPE

1.1 Summary

The High Flux Isotope Reactor (HFIR) cold neutron source (Cold Source) is designed to circulate supercritical hydrogen pressurized to 14 bar at temperatures between 14-24 K at a rate of approximately one liter per second through a moderator vessel inside the Horizontal Beam Tube 4 (HB-4) located adjacent to the HFIR core. The HFIR and HFIR Cold Source are part of the Research Reactors Division (RRD) at the Oak Ridge National Laboratory.

The hydrogen fluid is cooled via a heat exchanger with a stream of cryogenically cooled helium gas. The helium gas is supplied by a helium refrigeration system that is comprised of a 3.5 kW helium refrigerator with liquid nitrogen precooling, five (5) helium compressors with inventory control, an oil removal system, a helium storage vessel, a helium transfer module that contains heaters and appropriate valving for conditioning the helium gas as it exits and re-enters the refrigerator, gas piping, and a Distributed Control System (DCS).

It is the intention of RRD to acquire replacements for the helium refrigerator, the helium compressors, the inventory control system, the oil removal system, the helium transfer module, and the portion of the control system associated with these components. The helium storage vessel, liquid nitrogen supply, and main components of the DCS are to remain as currently installed. The replacement components noted above must interface with these components. Installation of gas piping will be under the responsibility of RRD.

The completed new helium refrigeration system shall have a refrigeration capacity of 4 kW to 4.5 kW. This increase over the existing capacity is for additional margin to support 30+ more years of HFIR operation. The current heat load from the hydrogen fluid is not expected to change.

This procurement is to include all systems requisite for the proper fabrication, installation, testing, operation, and maintenance of the proposed components. The proposed system shall be able to fit within the existing HFIR Cold Source building and include but not be limited to the following:

1. Helium Compressors

2. Inventory Control System

3. Oil Removal System

4. Helium Refrigerator (Cold Box)

5. Cold Box Vacuum System

6. Instrumentation and Controls

7. Ancillary Systems/Components

Sections 3, 4, and 5 in this document provide specific descriptions, operational details, and performance parameters of this existing system. This is intended to provide an understanding of the cryogenic system to which replacement equipment must interface. Requirements for the new system components begin in Section 6.

The equipment described within this document are classified as Quality Significant

(QS).

1.2 Applicable Documents

The current issues of the following documents, or Company approved equivalents, form portions of this specification. The contents of this specification take precedence in the event of a conflict.

ANSI B16.5 – Pipe Flanges and Flanged Fittings

ANSI B40.1 – Gauges – Pressure Indicating Dial Type-Elastic Element

ANSI S2.19.1999 - Balance Quality Grade G6.3

ASME B31.3 – Process Piping

ASME B16.34 – Valves – Flanged, Threaded, and Welding End

ASME Boiler and Pressure Vessel Code, Sections II, V, VIII, and IX

ISA-520-1901 – Specification Forms for Process Measurement and Control Instruments, Primary Elements, and Control Valves

MSS SP25 – Valve Marking

MSS SPG1 – Pressure Testing

NEMA MG-1 – Motors and Generators

NEMA MG-10 – Energy Guide for Selection and Use of Polyphase Motors

NFPA-70 – National Electric Code

TEMA – Standards of the Tubular Exchange Manufacturers Association

2. DEFINITIONS

Cold Source CS, System that supplies supercritical hydrogen to the moderator in the reactor.

Company UT-BATTELLE.LLC

Company Agent Person identified by the Company as the point of contact for the Company.

HFIR High Flux Isotope Reactor

Hold Point Stages of work that require Company witness or examination before proceeding further. The Seller is required to notify the Company of an upcoming witness point at least 15 working days in advance.

Notification Point Stages during fabrication and/or inspection activities at which the Company wishes to witness progress. The Seller is required to notify the Company of an upcoming notification point at least 15 working days in advance. The Company reserves the option to pass on any notification point. This action will not hold up the Seller’s progress.

RRD Research Reactors Division

Seller Company contracted to perform the Design/Fabrication.

3. DESCRIPTIONS OF EXISTING SYSTEM COMPONENTS TO BE REPLACED

The function of the existing cryogenic helium system is to remove up to 3.5 kW of heat from the hydrogen loop during reactor operation. Additionally, it can be used to circulate liquid nitrogen-cooled helium into the hydrogen/helium heat exchange following a power outage. The cryogenic helium system interfaces with several ancillary systems including compressor cooling, instrument air, liquid nitrogen, and the equipment temperature conditioning system (ETCS).

The refrigerator coldbox, helium compressors (with oil removal system), expansion engines, and helium transfer module form the main components of the cryogenic helium system. The cryogenic helium system also provides helium inventory and pressure control.

3.1 Helium Compressors (Figure 1)

The helium compressor system consists of five (5) screw-type, PSI (now Linde) RSX compressors. The compressors each have a 150 hp, 480 VAC, 3-phase motor, are water cooled, and are connected to common manifolds for suction and discharge.

The existing system requires five (5) compressors for full (3.5 kW) capacity. Normal operation, however, requires a minimum of three (3) compressors. Four (4) compressors are normally operated with bypass flow for additional redundancy.

Operating in this manner, the fifth compressor is for backup in case of failure.

Figure 1. Helium Compressors

3.2 Oil Removal System (Figure 2)

Each helium compressor has an on-board oil removal system. However, these have proven to be inadequate. A separate, skid-mounted oil removal system is used to take the full flow of all the compressors. Target oil removal is <10 ppb by weight.

Figure 2. Oil Removal System

3.3 Helium Refrigerator (Figure 3)

The helium refrigerator is a PSI (now Linde) model 2820 utilizing piston expansion engines, plate-fin heat exchangers, and liquid nitrogen precooling. It is capable of

3.5 kW of cooling at 14-17K with a return temperature of 20K. The helium flow is sent through the Helium Transfer Module and then the Helium to Hydrogen Heat Exchanger where it cools the hydrogen fluid to 14-24K.

Figure 3. Helium Refrigerator

3.4 Controls/Instrumentation

The control system for the helium refrigeration system is governed by the Distributed Control System (DCS). This is an integrated system that monitors and controls essentially all aspects of the HFIR Cold Source. It is the primary control interface for the Cold Source operators and directly controls the helium refrigerator.

3.5 Helium Transfer Module

The Helium Transfer Module contains the valves, heaters, and flow meter necessary to control the flow of helium to the helium to hydrogen heat exchanger.

For the new helium refrigerator, the Helium Transfer Module is to be replaced with the Helium Conditioning and Flow Measurement System which is to be located within the new cold box. For specific details on this system, see section 9.4.x.

4. OPERATING MODES

The current helium refrigerator has four modes of operation. The replacement helium system must be capable of functioning within these Operating Modes.

The Operating Modes are identified as the Refrigeration Mode, Standby Compressor Mode, Warm-up Mode, and Off Mode. Refrigeration Mode, Warm Up Mode, and Off Mode are operating modes which are normally initiated by the CS operators concurrent with phases of normal HFIR fuel cycles. Warm-up Mode is used to perform a rapid warm-up from cryogenic temperatures to near-ambient temperatures. Standby Compressor Mode will be activated either automatically by the DCS in response to normal AC power loss or manually by CS operators in response to system upsets, breakdowns, etc. Each mode is listed below with a description of how it operates and an explanation of when operation in the mode is required.

4.1 Refrigeration Mode

Refrigeration Mode is the primary operating sequence where the helium refrigerator is initially cooled down from ambient and then configured to support CS Production Mode and its subsequent Submodes (i.e. Cooldown Submode, Cold Neutron Submode). CS Production Mode requires cooling the helium refrigerator and the hydrogen circulation loop to Cold Neutron Submode temperatures of ~20 K to support the mission of producing cold neutrons.

4.2 Standby Compressor Mode

Standby Compressor Mode of operation is intended primarily for instances where normal AC power has been disrupted or is unavailable or the refrigerator expander is inoperable. This represents a failed condition where the Cold Source Operators need to place the Cold Source in a SAFE condition and possibly may have to evacuate the cold box room. Operators may manually select Standby Compressor Mode.

In this mode, the helium flow is cooled with liquid nitrogen. A single helium compressor, operating on normal or emergency power, will maintain flow through the cold box. The helium gas will be cooled by the Liquid Nitrogen system in the cold box. This nominal 80K flow will be used to cool the hydrogen loop.

The expansion turbine will be bypassed as well as the return sides of the cold box heat exchangers. The cold box design must include sufficient piping and valving to support this mode.

4.3 Warm-Up Mode

Warm-up Mode is provided to raise the temperature of the refrigerator cold box components AND the hydrogen system loads simultaneously from cryogenic temperatures to near ambient temperature. If warm-up Mode is not utilized, components will warm due to ambient heating in approximately three to four days.

Use of Warm-up Mode will raise the temperature in approximately seven to eight hours.

Warm-Up Mode is a normal operation of the HFIR Cold Source that is performed after every cycle.

4.4 Off Mode

Off Mode is provided as a means for stopping all automatic refrigerator functions from any of the other Modes. This is accomplished by sequentially stopping running compressors and expander(s). After the stopping of the last expander and prior to the stopping of the last compressor, the control system lowers system pressures, as necessary, to prevent actuation of relief devises due to warming gases in the system.

The control system is also configured such that compressors and inventory control can be operated independently with the cold box remaining in Off Mode.

5. EXISTING SYSTEM PERFORMANCE PARAMETERS

This section provides an illustration of the various performance parameters of the existing helium refrigeration system.

5.1 The existing system functional layout is illustrated in Figure 4. Drawing P-11530- CS-744 is also included in Appendix A.

Figure 4. Existing System Layout

5.2 The nominal pressure and temperature values for key process points during normal operation (Cold Neutron Submode) are listed in Table 1. (Ref. Figure 4)

Table 1 Process Pressures and Temperatures

Location Pressure Instrument

Temperature Instrument

Pressure (psig)

Temperature (K)

Compressor Discharge PT-302 (TE-106) 235 (305)

Compressor Suction PT-303 (TE-108) 2.5 (297)

Cold Box Inlet PT-101 TE-106 235 305

Cold Box Outlet (PT-303) TE-108 (2.5) 297

Upstream Expanders PT-111 TT-200 235 28

Downstream Expanders PT-120 TE-104 20.4 16

Transfer Module Inlet PT-120 (TE-104) 20.4 (16)

Transfer Module Outlet (PT-303) TE-105 (2.5) 25.6

Notes: Values in parentheses are inferred from accompanying sources Table 1. Process Pressures and Temperatures

5.3 The nominal flow values for the existing system for the various CS Production sub-modes are listed in Table 2.

Table 2 Process Mass Flows

Submode Mass Flow (g/s) Compressors

Cold Neutron 66.5 4

Cooldown Varies 2

Warmup (Standby) Varies 1

Table 2. Process Mass Flows

Section 6

NOTE

The following sections pertain to the new equipment for the helium refrigeration system.

6. GENERAL SYSTEM REQUIREMENTS FOR THE NEW HELIUM REFRIGERATION

SYSTEM

6.1 The helium refrigeration system shall provide 4 to 4.5 kW of cooling at 14 to 17K with a return temperature of 20K.

a. This increase in refrigeration capacity over the existing refrigerator is to ensure sufficient cooling power for continuing operation of the HFIR.

b. The hydrogen fluid temperature range of 14-24K is unchanged regardless of future heat load changes.

6.2 The helium refrigeration system shall be capable of supporting the Cold Source Operational Modes.

6.3 The helium refrigeration system shall be capable of performing a minimum of eight

(8) complete cooldown and warmup cycles per year to support HFIR operations.

6.4 The helium refrigeration system shall be designed to support HFIR operations for a lifespan of 30+ years.

6.5 The new helium refrigeration system shall interface with existing Cold Source equipment. (See section 7)

a. CS Facility

b. Electrical Power

c. Helium Transfer Lines

d. Liquid Nitrogen System

6.6 The helium refrigeration system shall be capable of satisfying the reliability, redundancy, and operational flexibility requirements. (See Section 8)

6.7 Interface connections between major components and Company supplied piping (helium gas, nitrogen exhaust, cooling water) shall be of Imperial dimensions.

6.8 Major maintenance items to be handled by the Company (flanges, O-rings, fasteners) shall be of Imperial dimensions.

7. INTERFACE REQUIREMENTS

7.1 Facility Layout (Figure 5)

The replacement helium refrigerator, helium compressors, inventory management, oil removal system, and controls shall all fit within the confines of the existing Building 7977 facility. The equipment shall be able to pass through the existing facility roll up doors.

a. The floor plan of Building 7977 with existing equipment and optional additional space is shown on Figure 5.

b. Facility equipment access rollup door dimensions are as follows:

• Cold Box room door dimensions: width - 10 ft, height – 13 ft.

• Compressor room door dimensions: width - 8 ft, height – 10 ft.

Figure 5. Facility Layout Available Space

7.2 Electrical Power (Figure 6)

The helium compressors’ power requirements shall be within the constraints of the existing electrical power and distribution as shown on Figure 6.

a. Panel P-59 (800 amps at 480V, 3-phase) provides sufficient power for two 150 hp compressors.

b. Motor Control Center “P” (1000 amps at 480V, 3-phase) provides sufficient power for three 150 hp compressors.

c. The three compressors on MCC-P are connected to the emergency 400 kW backup diesel generator, however, only a single compressor can be started by this generator.

Figure 6. Electrical Power Distribution

7.3 Helium Transfer Lines (Figure 7)

The replacement helium refrigerator shall interface with the existing Helium Transfer Lines.

a. The interface point is a NEXANS cryogenic bayonet connection.

b. The specific bayonet design and connecting transfer lines between the helium refrigerator and the existing transfer lines shall be determined by the Company and Seller later. The Company will provide range of motion of the existing helium transfer lines. (See Figure 8)

Figure 7. Helium Transfer Lines (In Cable Trays)

Figure 8. Helium Transfer Lines Range of Motion

7.4 Liquid Nitrogen System (Figure 9)

The replacement helium refrigerator shall interface with the existing liquid nitrogen system.

a. Liquid nitrogen is transferred from the liquid nitrogen storage tank to the helium refrigerator via a vacuum jacketed, flexible line.

b. The existing liquid nitrogen storage tank operates normally at 20 psig with a maximum of 40 psig. Seller shall confirm sufficiency of this pressure for optimum cold box operation. Any deviation shall be submitted to the Company for approval.

c. The interface with the existing liquid nitrogen transfer line shall be a Nexans, ½”, screw type male coupling.

d. Liquid level measurement and control valving for the proper delivery of liquid nitrogen to the helium refrigerator shall be provided by the Seller.

e. Waste nitrogen gas shall be vented to outside the cold box room. Seller shall specify vent connection size and type.

Figure 9. Liquid Nitrogen Interface (Insulated)

8. SPECIFIC RELIABILITY, REDUNDANCY, AND OPERATIONAL FLEXIBILITY

REQUIREMENTS

System reliability is of paramount importance at HFIR. Any event or situation that would cause a shutdown of the cryogenic system would result in subsequent shutdown of the HFIR. Redundancy and Operational Flexibility of key process components is required.

This is presently achieved by redundant components, flexibility in flow bypass capabilities, and direct operator control over automated sequences.

8.1 Helium Compressors

Helium compressor design must be tied to flexibility of the system and be capable of supporting the various operational modes.

a. The number and sizing of compressors shall be selected to fulfill the reliability, redundancy, and operational flexibility requirements.

b. The number and sizing of compressors shall be selected to support the helium refrigerator capacity and operating modes.

c. Compressors may be of varying size/capacity provided that features (e.g.

variable frequency drives VFD, etc.) fulfill the reliability, redundancy, and operational flexibility requirements.

d. The number and sizing of compressors must conform to the available electrical power and distribution (See section 7.2).

8.2 Helium Refrigerator

a. The helium refrigerator shall be capable of performing a minimum of eight (8) complete cooldown and warmup cycles per year to support HFIR operations.

b. The helium refrigerator shall be designed to support HFIR operations for a lifespan of 30+ years.

c. The Seller shall provide recommendations for redundancy of helium refrigerator critical process components. This may include, but is not limited to: expanders, filters, bypass valves, on-board heaters, etc.

d. The Seller shall provide detailed descriptions of their expander design and function particularly associated with reliable operation.

e. The Seller shall provide evidence and/or examples of reliability/redundancy in the operational history of their expander design.

8.3 Controls/Instrumentation

a. The controls system must have redundancy in critical components. This may include, but is not limited to: processors, power supplies, network switches, etc.

b. Pressure transducers shall be externally accessible and provided with isolation valves, calibration ports, and pumpout/backfill capability.

c. Temperature instrumentation shall be redundant and replaceable.

9. TECHNICAL REQUIREMENTS

9.1 Helium Compressors

a. The compressors shall meet the requirements of ANSI S2.19.1999 Balance Quality Grade G6.3

b. The design and fabrication of all pressure vessels shall meet the requirements of ASME Boiler and Pressure Vessel Code (B&PVC), Section VIII and shall be stamped accordingly.

c. The compressors shall be provided in a non-grouted skid configuration; skids shall be anchored.

d. Each compressor skid shall contain isolation valves with integrated locking devices on the suction and discharge ports.

e. The compressors and associated components shall be designed for indoor installation.

f. The compressors shall be rotary screw, oil injected, with flow control capability.

g. The compressors shall be controllable to allow a linear turndown capability from fully loaded down to 50% capacity.

h. The compressors shall be equipped with Soft Start controls and be individually capable of starting and operating on a 400 kW generator.

i. Each compressor shall be provided with equipment protection and annunciation circuitry to:

• Provide indication of an approaching potential fault condition.

• Shutdown the compressor and positively identify the fault condition.

j. The compressors shall be provided with all ancillary equipment required for proper operation such as cooling water temperature control valves, oil pumps, sump heaters, etc.

k. The compressors and associated controls and equipment shall continue to operate without damage during and after a minimum 30-cycle power interruption.

l. The compressors shall be water cooled. The Seller shall submit all cooling system requirements necessary for proper operation of the helium compressors to the Company for approval. These shall include pressure, inlet and outlet temperatures (and/or temperature differential), flow rate, and water quality (e.g. purity, pH value, hardness, conductivity, chemistry, etc.).

m. The Company will design and build the cooling system.

n. Shell and Tube heat exchangers shall be designed and fabricated in accordance with TEMA C standards.

o. The compressor cooling components minimum design pressure shall be 150 psig at operating temperature.

p. All cooling water connections shall be submitted for review and approval by the Company. All piping/tubing to be inch dimensioned (Imperial).

q. All proposed refrigerant piping/tubing connections shall be submitted for review and approval by the Company. All piping/tubing to be inch dimensioned (Imperial).

r. All instrument/tubing connections shall be standard Swagelok tube fittings or Company approved equal.

s. Compressor oil reservoirs shall be provided with sight glasses.

t. The compressor oil filtration systems shall be specified by the Seller and approved by the Company.

u. Pneumatically operated components shall be designed to operate at a nominal instrument air supply pressure of 90 psig, pressure dewpoint of -10°F.

v. The Seller shall develop a complete process and instrumentation drawing of the Helium Compressors for review and approval by the Company.

9.2 Inventory Control System

a. An inventory control system shall be provided to maintain refrigerant system pressure within ±2% (or less if required) of design during all modes of operation.

b. The inventory control system shall control refrigerant flow between the refrigeration loop and the existing HFIR Cold Source helium storage vessel.

c. The inventory control system shall have ports on the helium supply and return lines to support a hydrogen detection system. These ports shall be Swagelok VCR fittings with isolation valves. The precise location of these ports will be determined later. The Company will provide the hydrogen detector.

d. The Seller shall develop a complete process and instrumentation drawing of the Inventory Control System for review and approval by the Company.

9.3 Oil Removal System

a. The oil removal system shall be capable of reducing the oil carryover to less than 10 ppb by weight in the helium gas during all operating conditions.

b. The oil removal system shall consist of coalescing units and a charcoal adsorber sized to accept the flow of all helium compressors operating at full capacity plus 25% overcapacity.

c. The oil removal system shall be capable of returning captured oil to the helium compressor skids. This operation shall be manually controlled.

d. The oil removal system vessels, piping, valves, tubing, and associated fittings shall be 300 series stainless steel. Piping and tubing shall be of seamless construction.

e. The oil removal system shall be designed for ease of maintenance.

f. The oil removal system shall be fitted with all equipment necessary for complete dehydration of the charcoal media including inert gas connections and electrical heating blankets or elements.

g. The oil removal system shall have sufficient instrumentation to properly monitor normal system operation.

h. The Seller shall recommend an appropriate helium analysis and oil detection instrument for the helium flow.

i. The Seller shall develop a complete process and instrumentation drawing of the Oil removal System for review and approval by the Company.

9.4 Helium Refrigerator (Cold Box) Assembly

a. The cold box shall be designed to provide 4 kW to 4.5 kW refrigeration with an outlet temperature between 14 K to 17K, and a return temperature of 20K.

This will hitherto be referred to as the LOAD.

b. The cold box shall be a vacuum insulated enclosure containing all interstage heat exchangers, expander(s), and associated valving and controls.

c. The cold box shall be designed and fabricated to operate at <1X10-6 Torr at 90°F, and at the maximum positive pressure developed by the cold box safety relief valves at maximum compressor flowrate, at 110°F in accordance with ASME B&PVC, Section VIII and shall be stamped accordingly.

• In lieu of fabrication of the vessel in accordance with Section VIII, the following requirements shall each be met:

(1) The vessel shall be provided with pressure relief devices capable of limiting vessel internal pressure to less than 15 psig at 110% of rated compressor capacity including relief device uncertainty.

(2) The maximum stored energy during the condition stated above shall be demonstrated by analysis to be less than 1.5 x 105 ft. lbs.

d. The cold box shall be provided with redundant, isolatable, safety relief valve/rupture disk combinations to provide full compressor capacity relief in the event of system failure in accordance with ASME B&PVC, Section VIII.

e. The safety relief devices shall be constructed in accordance with ASME B&PVC, Section VIII and stamped accordingly.

f. Each safety relief valve to be provided with a tee and a lockable isolation valve to permit in situ testing.

g. The cold box design shall provide access for maintenance and/or removal of all internal components.

h. The heat exchangers shall be fabricated in accordance with ASME B&PVC, Section VIII, Division 1.

i. The refrigerator shall be liquid nitrogen precooled.

j. The refrigerator shall employ turbine expander(s).

k. Provided the turbine expander(s) are water cooled, the Seller shall submit all cooling system requirements necessary for proper operation of the turbine expander(s) to the Company for approval. These shall include pressure, inlet and outlet temperatures (and/or temperature differential), flow rate, and water quality (e.g. purity, pH value, hardness, conductivity, chemistry, etc.).

l. The Company will design and build the cooling system.

m. Expander replacement shall be permitted without breaking cold box vacuum.

n. The expander(s) shall be interlocked to key parameters such as: bearing gas pressure and temperature, brake gas pressure and temperature, turbine inlet pressure, turbine outlet temperature, and turbine speed and acceleration as well as other parameters specified by the Seller. The expander(s) shall be provided with equipment protection and annunciation circuitry to:

• Provide indication of an approaching potential fault condition.

• Shutdown the turbine expander(s) and positively identify the fault condition.

o. The expander(s) shall be designed to accept variations in flow, temperature, and pressure without damage.

p. The Cold Box control system shall provide automatic system start-up from ambient to operating temperature without operator action. The control system shall be microprocessor-based providing complete system status, setpoints, and setpoint adjustment. System to be menu driven with selection of all system operating modes available to the operators.

q. The Cold Box control system shall be pre-programmed to allow the refrigerator to run unattended from start-up through steady state operation and shut down. The system shall have sufficient capacity to control additional field equipment.

r. The Cold Box control system shall permit an automatic warm-up of the system from steady state operation to ambient within eight hours. Warm-up rate shall not exceed 1K/min.

s. The Cold Box and associated support equipment shall function without damage during and after a minimum 30-cycle power interruption.

t. The Cold Box control system shall maintain the selected system temperature to less than +/- 0.1K of setpoint during normal operation.

u. Automatic controls shall be provided to allow operation of the refrigerator at reduced capacity. The Seller shall provide specifications for the turndown capability of the refrigerator.

v. The Cold Box shall operate at rated capacity with a pressure drop of 8 psid from the Company’s transfer lines and heat exchanger.

w. The Cold Box shall be equipped with sufficient valves, piping, instrumentation, and controls to provide bypass flow circuits around the turbine expander and return (low pressure) of the heat exchangers. This is to facilitate operation under the Standby Compressor Mode. This operating mode is defined in section 4.2.

x. Helium Conditioning and Flow Measurement System (Figure 10)

• The Cold Box shall contain a Helium Conditioning and Flow Measurement system to control the helium flow at the proper temperature and accurately measure the helium flow rate. This system shall be located in the Cold Box at the interface with the helium transfer lines and the LOAD.

• Equipment associated with the Helium Conditioning and Flow Measurement system shall be configured as shown in Figure 10.

• The Helium Conditioning and Flow Measurement system shall consist of the following:

(1) A fully controllable (automatic and CS Operator controllable) flow control valve on the supply line to the LOAD (Valve V3). This valve must have very fine flow controllability. A Parabolic valve plug is desired.

(2) An Isolation valve on the return line from the LOAD (Valve V1).

(3) A fully controllable (automatic and CS Operator controllable) bypass valve on the Cold Box side of the isolation valves across the helium lines (Valve V2). This valve must have very fine flow controllability.

A Parabolic valve plug is desired.

(4) A Trim Heater with 6 kW heating capacity in the Supply Line to condition the helium flow at the proper temperature prior to entering the LOAD.

(5) A Compensating Heater with 6kW capacity in the Return Line to add sufficient heat load to the returning helium flow for proper balance of the cold box. This heater may also be used as the load bank for refrigerator-only operation.

(6) The Trim and Compensating Heaters shall be removable for repair or replacement without violating the insulation vacuum space of the cold box.

(7) The Helium Flow Meter shall be capable of accurately measuring the helium flow rate from 300K down to 14K at all system pressures.

(8) Pressure and Temperature instrumentation shall be as shown in Figure 12 as a minimum.

Figure 10. Helium Conditioning and Flow Measurement System

y. Cold Box Helium Purifier

• The Seller shall recommend a helium purifier sized appropriately for the gas purity requirements of the refrigerator design.

• The purifier may either be internal or external to the refrigerator cold box.

The Seller shall recommend the appropriate configuration.

• The purifier shall not contain consumables requiring disposal but shall provide for in-place regeneration.

z. Pneumatically operated components shall be designed to operate at a nominal instrument air pressure of 90 psig, pressure dewpoint of -10°F.

aa. The Seller shall develop a complete process and instrumentation drawing of the Cold Box for review and approval by the Company.

9.5 Cold Box Vacuum System

a. The cold box pressure vessel shall be maintained under vacuum by a dedicated vacuum system.

b. The vacuum system shall consist of redundant turbo molecular pumps backed by oilless roughing pumps.

c. The vacuum system shall have the capacity to maintain the cold box at <1x10-6 Torr minimum in warm condition.

d. The vacuum system isolation valves shall automatically isolate from the cold box upon failure and/or a poor vacuum condition and start the standby units.

Annunciation upon startup of redundant vacuum pump shall be provided.

e. Redundant pressure sensing elements shall be provided for monitoring of low vacuum, and high vacuum on the cold box with external signal connections.

f. Vacuum system piping connections shall be Conflat flanges.

g. Vacuum system piping, valves, and fittings shall be 300 series stainless steel.

h. The refrigerator cold box pressure vessel shall have a vacuum port on its external shell for use as a service connection or leak check port.

• This connection port shall be a (minimum) 2.75” Conflat flange.

• Specific size and location of this port shall be determined by the Seller and Company later.

9.6 Piping

a. All piping (refrigerant, cooling water, air, etc.) and fittings shall be designed and fabricated in accordance with ASME B31.3 “Process Piping” latest edition.

b. Piping, valves, tubing, and associated fittings shall be 300 series stainless steel and of seamless construction.

c. Refrigerant system piping shall be of butt-welded construction.

d. Helium system piping and pressure retaining sub-components shall be leak tight for a combined system leakage of <1E-4 std cc/sec.

e. Installation of helium piping interconnecting the compressors, oil removal system, inventory control, and the cold box shall be the responsibility of the Company.

f. The Seller shall recommend sizing of interconnecting piping to ensure proper system operation.

9.7 Welding

a. All welding and fabrication shall be in accordance with ASME B31.3 and ASME B&PV Code, Section VIII, Division 1, as applicable.

b. Welders and weld procedures shall be qualified by testing in accordance with the ASME Boiler and Pressure Vessel Code, Section IX.

c. All welds for piping system shall be in accordance with ASME B31.3.

d. All welds for system pressure vessels (including Cold Box vessel) shall be in accordance with ASME B&PV Code, Section VIII

e. Weld inspectors shall be certified for the appropriate NDE in accordance with the ASNT TC-1A or ASNT CP-189 per the applicable paragraphs of ASME Section VIII.

9.8 Motors – Compressors and Auxiliary Equipment

a. The motors shall be energy efficient per NEMA MG10-1983 “Energy Guide for Selection and Use of Polyphase Motors.”

b. The motor horsepower, speed, and type shall be determined by the Seller based on operating requirements per NEMA MG1-2016, “Motors and Generators.”

c. The compressor motor shall be rated for a minimum of 120% of maximum compressor power.

d. The motor shall be drip proof, guarded and air cooled per NEMA MG1-2016, Section 1.25. The motors shall be continuous duty. With the exception of the continuous duty requirement, this specification does not apply to hermetic motors.

e. The motors shall operate in ambient air of 0 to 40°C, 0-95% relative humidity, non-condensing, altitude less than 3300 ft. mean sea level. Specification does not apply to hermetic motors.

f. Compressor motor shall have reference marks scribed on the rotor shaft indicating magnetic center and limits of end play. Specification does not apply to hermetic motors.

g. Motors shall have Class F or better insulation per NEMA MG1-2016, operating within the NEMA Class B temperature rise limit at its service rating.

h. Motors service factor shall be 1.0.

i. Motors shall be capable of full voltage across the line start.

j. Motors shall be capable of 2 starts in succession per NEMA MG1-2016, Section 12.54, or be provided with protective features to prevent motor damage from successive starts.

k. Motor vibration shall meet the acceptance criteria per NEMA MG1-2016.

Specification does not apply to hermetic motors.

l. Motor power level shall meet the acceptance criteria per NEMA MG1-2016.

Specification does not apply to hermetic motors.

m. Motor nameplate data shall be in accordance with NEMA MG1-2016, Section 20.25.

n. Motors shall be 480V, 3 phase, 60Hz, delta connected, or Company approved alternate.

o. Motors shall operate under running conditions at rated load with variations in voltage and frequency per NEMA MG1-2016, Sections 12.44 and 12.45, or shall provide certification that operation of the motors under the variation prescribed will not result in damage to the motors.

p. System motors and control systems shall be capable of withstanding a minimum 30-cycle voltage loss without affecting steady state operation.

q. Motors shall be given the following tests in accordance with NEMA MG1-2016:

• No load running current (Seller published data in lieu of test data is acceptable for hermetic motors only)

• Locked rotor current (Seller published data in lieu of test data is acceptable for hermetic motors only)

• High potential test

• Winding resistance

• No load vibration check

9.9 Instrumentation and Control

a. The Seller shall provide a complete and integrated control system to properly operate the helium compressors and helium refrigerator in all operating modes stated in this specification.

b. The Seller shall develop a comprehensive Functional Description document that explains in detail the operation of the control logic, descriptive logic diagrams, and includes the complete software code. This Functional Description shall be approved by the Company.

c. The control system shall operate on 110/120 VAC 60 Hz power.

d. The control system shall be an Allen-Bradley ControlLogix Control System PLC (or a Company approved alternate) with redundant processors and components critical to reliable operation.

e. The PLC shall contain the following hardware;

• 1756 ControlLogix Modules

• Ethernet/IP Communications Module

• Secondary Ethernet/IP Communications Module dedicated to Cold

Source DCS communications.

f. Control and monitoring of equipment and process parameters shall be provided via a Human-Machine Interface (HMI).

g. The control system shall be capable of communicating with GE iFix SCADA software via industrial ethernet communications.

h. All discrete input and output cards shall be 24 VDC. The PLC shall provide discrete input points (24 VDC) for start/stop operation and outputs (24 VDC) for operational status to include but not limited to On (Running), Off, Alarm, etc.

i. The Seller shall provide a comprehensive list of recommended process points for control and monitoring. This list shall be approved by the Company.

j. The following accuracy information shall be supplied by the Seller for each instrument provided.

• Drift

• Hysteresis

• Linearity

• Repeatability

• Temperature effects

• Pressure effects

• Other parameters which may contribute significantly to instrument inaccuracy.

• Response time

k. “Wetted” parts shall be 300 series stainless steel.

l. Instrument displays shall be in the following engineering units for process parameters.

• Temperature: Fahrenheit (°F), Kelvin (K)

• Pressure: PSIG, PSID, Torr, millitorr

• Flowrate: GPM, cc/min, cc/sec, gram/sec.

m. Seller shall provide, as an option, 20% spare inventory of I/O, communication, any specialty cards, etc..

9.10 Software and Software QA requirements

a. Company will provide the Seller with IP Addresses

b. The Seller shall remove all software components that are not required for the operation and/or maintenance of the procured product. If removal is not technically feasible, then the Seller shall disable software not required for the operation and/or maintenance of the procured product. This removal shall not impede the primary function of the procured product. If software that is not required cannot be removed or disabled, the Seller shall document a specific explanation and provide risk mitigating recommendations and/or specific technical justification. The Seller shall provide documentation on what is removed and/or disabled. The software to be removed and/or disabled shall include, but not be limited to:

• Games

• Device drivers for product components not procured/delivered.

• Messaging services (e.g., email, instant messenger, peer-to-peer file sharing)

• Software compilers for programming languages that are not used in the delivered system.

• Unused networking and communications protocols

• Unused administrative utilities, diagnostics, network management, and system management functions

• Backups of files, databases, and programs used only during system development.

• All unused data and configuration files

c. The Seller shall provide documentation of software/firmware that supports the procured product, including scripts and/or macros, run time configuration files and interpreters, databases and tables, and all other included software

(identifying versions, revisions, and/or patch levels, as delivered). The listing shall include all ports and authorized services required for normal operation, emergency operation, or troubleshooting.

d. The Seller shall configure each component of the procured product to operate using the principle of least privilege. This includes operating system permissions, file access, user accounts, application-to-application communications, and system services.

e. For Human-Machine Interfaces (HMI’s) the Seller shall provide a configurable account password management system that allows for, but is not limited to, the following:

• Changes to passwords (including default passwords)

• Selection of password length

• Frequency of change

• Setting of required password complexity

• Inactive session logout

• Screen lock by application

f. The Seller shall provide heartbeat signals for all PLC’s.

g. The Seller shall NOT use wireless devices/technology.

h. The Seller shall use a security implementation that complies with the current applicable interoperability and security standards, as specified by NIST (National Institute of Standards and Technology) Special Publication 800- Series.

i. The Seller shall provide summary documentation of its product development life cycle including the standards, practices (including continuous improvement), procedures, and development environment (including coding practices) used to create or modify Seller-provided system hardware, software, and firmware.

j. The Seller shall identify the country (or countries) of origin of the procured product and its components (including hardware, software, and firmware). The Seller shall identify the countries where the development, manufacturing, maintenance, and service for the product are provided. The Seller shall notify the Company of changes in the list of countries where product maintenance or other services are provided in support of the procured product.

k. The Seller shall provide evidence of a Software Quality Assurance program and validate that the software and firmware of the procured product have undergone Quality Control testing to verify and validate (V&V) the software.

The Seller shall use positive and appropriate negative tests to verify that the procured product operates in accordance with requirements and without extra functionality, as well as monitor for unexpected or undesirable behavior during these tests. This testing may be done by the Seller or an independent entity.

The Seller shall provide summary documentation of the results of the testing that includes unresolved vulnerabilities and recommended mitigation measures.

l. The Seller shall provide summary documentation of its V&V activities including, but not limited to, design reviews, code reviews, simulation testing, functional testing, defect lists, and plans to correct identified vulnerabilities.

m. The Company shall have the right to request documentation of the Seller’s implemented Software Quality Assurance program and associated software development process including recent assessment results or, to conduct an on-site assessment at the Seller’s facilities. This on-site assessment may be conducted by an independent third party, at the discretion of the Company.

n. The Company shall have the right to request documentation of the Seller’s implemented cybersecurity program including recent assessment results or, to conduct an on-site security assessment at the Seller’s facilities. This on-site security assessment may be conducted by an independent third party, at the discretion of the Company.

9.11 Valves

a. Valves shall be designed in accordance with ASME B16.34

b. Valves shall be identified in accordance with MSS SP25

c. Valves shall be pressure tested in accordance with MSS SP61

d. Valves shall be provided with integrated locking devices.

10. GENERAL DOCUMENT REQUIREMENTS

10.1 Documentation

a. All documentation shall be legible, accurate, valid, reproducible, identifiable, and in English.

b. All “company approved equivalent” statements shall be made in writing.

c. All documentation and correspondence shall be delivered to the RRD Procurement Specialist.

d. All documentation shall be identified by facility (HFIR), service (Cold Source Helium Refrigeration System), customer, contract number, and descriptive title.

e. Acceptance shall not occur until after receipt of the component parts and all required documentation by the Company.

10.2 Documents Type and Submittal Requirements (See Section 14)

a. Pre-fabrication Documentation

The following shall be provided for review and approval by the Company prior to shop fabrication.

• Helium Refrigerator cycle design

• Helium Refrigerator Piping and Instrumentation drawing

• Helium Compressor Piping and Instrumentation drawing

• Inventory Control System Piping and Instrumentation drawing.

• Oil Removal System Piping and Instrumentation drawing

• Equipment interface design and component list

• Instrumentation and Control Functional Description document, logic diagrams, and associated drawings (this document shall be provided as early in the design/development process as possible)

• Quality Assurance Program/Manual

• Manufacturing Plan (Company will identify and communicate any Hold Points required during manufacturing process prior to proceeding to next operation)

• Design drawings and calculations

• Welder and weld procedure qualifications

• Inspector qualifications

b. Pre-shipment documentation

The following shall be provided for review and approval prior to shipment:

• Operation and Maintenance Manuals

• Handling, shipping, receiving, and storage instructions.

• Inspection Reports and deviation requests

• Supplier Non-conformance Reports

• Cleaning Reports

• Test and Inspection Reports

• As-Built drawings

• Bills of Materials

• Certified Material Test Reports (CMTR)

c. The Company will acknowledge receipt and return one copy of submitted documentation to the Seller within 15 working days with one of the following status stamps: Approved (A), Approved with Comments as Noted (ACN), Returned for Correction (RC), Accepted for Use (AU), Information Only (IO).

• Fabrication or shipment may proceed in accordance with “Approved” (or stamped “A”) documents and in accordance with “Approved with Comments as Noted” (or stamped “ACN”) documents, provided the Seller documents his acceptance of the comments to the Company.

• “Approved with Comments as Noted” (or stamped “ACN”) documents are to be resubmitted for Company approval after the comments have been incorporated by the Seller.

• Documents “Returned for Correction” (or stamped “RC”) are to be corrected by the Seller and resubmitted for Company approval. They are not to be used with “RC” status.

• Documents returned as “Accepted for Use” (or stamped “AU”) or “Information Only” (or stamped “IO”) indicates they are accepted by the Company and may be used by the Company or the Seller as appropriate. The responsibility for the accuracy and applicability of these documents remains with the Seller but will be demonstrated through use.

10.3 Inspection

a. The Seller shall supply a written notification to the Company 15 working days prior to the start of examination, testing, or inspection activities.

b. All tests, inspection, and/or examination reports prepared by the Seller and subvendors shall contain the following information as a minimum:

• Job Title

• Date of Test

• Identify Equipment/System

• Specific test, inspection, and/or examination performed including the procedure designation, if available

• Identification of equipment and when applicable, the last calibration date

• Test Results

• Signature or initials of the person performing the test and his/her qualifications.

c. The Seller shall submit a Manufacturing Plan to the Company for approval prior to the start of fabrication of the applicable component. At a minimum, the plan shall include the approved procedures for each test, inspection and/or examination, and a sequential listing of all applicable tests, inspection, and/or examinations. The plan shall be approved by the Company prior to the start of fabrication of the applicable component/subcomponent.

d. Acceptance will not occur until after receipt at the destination and any supplemental tests and inspection, as may be deemed necessary by the Company have been performed to assure that all requirements have been satisfied.

e. Surveillance – As part of the Company’s Quality Assurance Program, source surveillance activities may be conducted at the…