Statement of Work Cryostats Side Penetrations 1_2 Feb5 final.docx

Statement of Work References

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

LBNF/DUNE-US

Cryostats 1 and 2 Side Penetration Inline Safety Valves Statement of Work

Document Number: EDMS 2914218 v.1

Statement of Work

Long-Baseline Neutrino Facility (LBNF) / Deep Underground Neutrino Experiment (DUNE) - US Page 1 Document Approvals

Originator:

Zachery West, Cryogenic Engineer 12.15.2023

Checker:

Roza Doubnik, Cryogenics Systems Engineer 01.16.2024

Approver:

Mark Adamowski, Lead Cryogenics Systems Engineer

Approver:

David Montanari, LBNF FDC Deputy Project Manager for Cryogenics

Approver:

Approver:

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 at https://edms.cern.ch/document/2914218.

List of Figures

List of Tables

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

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

Cryostats 1 and 2 Side Penetration Inline Safety Valves - Statement of Work - Rev. 1

Long-Baseline Neutrino Facility (LBNF) / Deep Underground Neutrino Experiment (DUNE) - US Page iii Scope of Document This document outlines the specifications for the safety valves on the inline side penetrations of Cryostats 1 and 2 within the Long-Baseline Neutrino Facility (LBNF). The supply scope encompasses the design and production of eight (8) valves, inclusive of testing and certification, as well as packing and shipping.

Exceptions to these specifications shall not be permitted, except by written approval from Fermilab Research Alliance (FRA).

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

ACI 318 Building Code Requirements for Structural Concrete and Commentary ALPEMA standards ANSI ASC A14.3 Safety Requirements for Fixed Ladders ANSI/ASSE A1264.1 Safety Requirements for Workplace Surfaces ANSI/ISA-5.1 Instrumentation Symbols and Identification ANSI/ISA-75.01.01 Flow Equations for Sizing Control Valves ANSI/NEMA IM 60000-2021 Industrial Laminated Thermosetting Products API 520 Sizing, Selection, and Installation of Pressure-reliving Devices API 521 Pressure-relieving and Depressurizing Systems API 526 Flanged Steel Pressure-relief Valves API RP 615 Valve Selection Guide ASCE/SEI 7 Minimum Design Loads for Buildings & Other Structures ASME B30.20 Below-the-Hook Lifting Devices ASME B30.26 Rigging Hardware ASME B30.9 Slings ASME B31.3 Process Piping ASME B31E Standard for the Seismic Design and Retrofit of Above-Ground Piping Systems ASME BPVC Boiler and Pressure Vessel Code ASME BTH-1 Design of Below-the-Hook Lifting Devices ASME Y14.100 Engineering Drawing Practices ASME Y14.5M Dimensioning Tolerance Code ASTM E2734/E2734M Standard Specification for Dimensions of Knife-Edge Flanges ASTM A380 Standard Practice for Cleaning, Descaling, and Passivation of Stainless-Steel Parts, Equipment, and Systems ASTM E493 Standard Test Methods for Leaks Using the Mass Spectrometer Leak Detector in the Inside-Out Testing Mode ASTM E498 Standard Test Methods for Leaks Using the Mass Spectrometer Leak Detector or Residual Gas Analyzer in the Tracer Probe Mode ASTM E499 Standard Test Methods for Leaks Using the Mass Spectrometer Leak Detector in the Detector Probe Mode CGA S-1.3 Pressure Relief Standards CGA G-4.1 Cleaning Equipment for Oxygen Service, Seventh Edition EN 764-7 Pressure Equipment Safety Systems for Unfired Pressure Vessels EN 10220 Seamless and Welded Tubes EN 12300 Cryogenic vessels -Cleanliness for cryogenic service EN 13445 Unfired Pressure Vessels EN 13480 Metallic Industrial Piping EN 13648 Cryogenic Vessels – Safety Devices EN 60534-2 Industrial Process Control Valves EN 61508 Functional safety of electrical/electronic/ programmable electronic safety-related systems EJMA standards IEC 61511 Functional safety - Safety instrumented systems for the process industry sector IEEE 315 Graphics Symbols for Electrical and Electronics Diagrams (Including Reference Designation Letters) ISA-75.01.01 Industrial-Process Control Valves ISA 84.00.01 Functional Safety: Safety Instrumented Systems for the Process Industry Sector ISA-S20 Specification Forms for Process Measurement and Control Instruments, Primary Elements, and Control Valves ISA-S5.4 Instrument Loop Diagrams ISO 262 General Purpose Metric Screw Threads ISO 1127 Stainless Steel Tubes ISO 5817 Welding - Fusion-Welded Joints In Steel, Nickel, Titanium And Their Alloys (Beam Welding Excluded) - Quality Levels For Imperfections ISO 9712 Non-Destructive Testing – Qualification and Certification of Personnel ISO 10675 Non-destructive testing of welds — Acceptance levels for radiographic testing ISO 13920 Class C and G Welding – General Tolerances for Welded Constructions – Dimensions for Lengths and Angles – Shape and Position ISO 14731 Welding Coordination: Tasks and Responsibilities ISO 14732 Welding Personnel – Approval Testing of Welding Operators for Fusion Welding and of Resistance Weld Setters for Fully Mechanized and Automatic Welding of Metallic Materials ISO 15607 Specification and Qualification of Welding Procedures for Metallic Materials – General Rules ISO 17636 Non-Destructive Testing of Welds -- Radiographic Testing Of Fusion-Welded Joints ISO 4126 Safety Valves – Part 1: General Requirements ISO 23208 Cryogenic vessels - Cleanliness for cryogenic service ISO 28921-1 Industrial valves. Isolating valves for low-temperature applications - Design, manufacturing, and production testing ISO 3669 Vacuum technology. Dimensions of knife-edge flanges NFPA 70E National Electric Code (NEC) NIST (National Institute of Standards and Technology) Reference Fluid Thermodynamic and Transport Properties Database, Version 9.1 OSHA Standard 1910 General Industry Regulation OSHA Standard 1926 Safety and Health Regulations for Construction Pressure Equipment Directive (PED) Essential Safety Requirements UL 471 Commercial Refrigerators and Freezers UL 61010-2-011 Safety Requirements for Electrical Equipment for Measurement, Control, and Laboratory Use - Part 2-011: Particular Requirements for Refrigerating Equipment UL 508A Industrial Control Panels The Subcontractor may propose other recognized standards. Their application is subject to prior written approval by Fermi Research Alliance (FRA). In such cases, the Subcontractor shall submit all the necessary documentation for approval to FRA. FRA, at its discretion, reserves the right to veto the use of certain codes or standards, in part or whole. In no event will FRA be responsible for schedule delays or cost increases associated with the review and evaluation of alternative codes or standards proposed by the Subcontractor.

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

Project Introduction LBNF (http://lbnf-dune.fnal.gov/) will provide the infrastructure necessary to support the massive neutrino detectors located deep underground at the Sanford Underground Research Facility (SURF) in Lead, South Dakota (SD). The Deep Underground Neutrino Experiment (DUNE) will employ four (4) such detectors, housed in cryostats requiring almost 70,000 tons of liquid argon (LAr), about 17,400 tons for each cryostat. DUNE (http://www.dunescience.org/) is expected to achieve transformative discoveries, making definitive determinations of neutrino properties, examining the dynamics of supernovae that produced the heavy elements necessary for life, and probing the possibility of proton decay. Figure 3-1 shows an overview of LBNF/DUNE.

Figure 31: LBNF/DUNE at Fermilab and SURF.

The cryogenics infrastructure for LBNF is split between two locations:

aboveground at the Receiving Facility belowground within the Detector Caverns and the Central Utility Cavern (CUC), shown in Figure 3-2.

The two locations are separated vertically by nearly one mile.

Figure 32: Underground Facility.

They are joined by the Ross Shaft, through which all underground equipment must pass, shown in Figure 3-3. The Ross Shaft Cage Dimensions are shown in Appendix B.

Figure 33: Ross and Yates Shafts.

The Cryostats 1 and 2 Inline Side Penetration Safety Valves shall be housed entirely underground, within the North Detector Cavern 4850 feet (1478 meters) below the surface, at the West side of the Cryostats 1 and 2. Figure 3-4 shows the Process Flow Diagram (PFD) for the cryogenic systems at LBNF.

Figure 34: The LBNF/DUNE process flow diagram. The side penetration inline safety valves for cryostats are outlined in red.

Figure 3-5 shows the simplified overall system PFD and illustrates the flow interaction between subsystems and components.

Figure 35: Simplified flow schematic (block diagram).

General Description of Inline Safety Valves for Side Penetrations in Cryostats 1 and 2 Each of the eight (8) withdrawal lines from the cryostat there shall be equipped with a single (1) On/Off safety valve. Installing inline safety valves for the side penetration of the membrane cryostats is crucial to guarantee the safe and effective functioning of the cryogenic system. Each safety valve shall be fitted with a DN100 CF flange at the interface point connecting to the LAr circulation pump's inlet pipe to ensure proper integration.

The successful bidder hereafter referred to as the “Subcontractor” shall engineer, manufacture, test, pack, deliver, and provide documentation for the installation, certification, and testing procedures of the valve units.

The Cryostats 1 and 2 Side Penetration Inline Safety Valves hereafter referred to as the “Supply” comprises eight (8) safety on/off valve units.

The Supply will be installed through the insulation and the steel support structure of the cryostat. The actuator will be normally closed and SIL 2 rated. A typical interface between the Cryostat and the Supply can be seen in Figure 4-1 below:

Figure 41: Cryostat and Supply Interface.

The figure above provides an overview of the interface between warm and cold vessels, and additional elaboration can be provided post-award.

The following technical specification requirements:

Leak Tightness: The leak tightness requirement of 1E-09 mbar*liter/sec is mandatory to maintain the high purity of liquid argon within the cryostat. The Supply shall be verified to meet the leak tightness criterion, ensure minimal contamination, and preserve the integrity of the sensitive detectors installed inside the cryostat. A valve seat tightness test will also need to be performed by the manufacturer. Detailed methods and requirements are covered further in Section 6.4 of this SOW.

Thermal Insulation: For cryogenic services, valves must incorporate vacuum insulation along with aluminized mylar, Multi-layer Insulation (MLI), to minimize heat leakage without the use of active mechanical pumping. The precise specifications for each component will be subject to approval by FRA during the design reviews.

High Purity: In order to maintain the desired purity of the liquid argon, the cryostat safety valves must be constructed from materials compatible with cryogenic applications. The valves shall be made from stainless steel and copper to ensure high purity and minimize the risk of impurities introduced into the cryogenic system.

High Reliability: Reliability is paramount for cryogenic systems, particularly when they are involved in scientific measurements. The inline valves shall have a proven track record of reliability with experience in designing and manufacturing safety valves.

SIL Rating: Safety Integrity Level (SIL) shall be considered when integrating cryogenic systems into regulated environments. The valves shall meet SIL 2 or greater rating to ensure compliance with safety regulations and provide the necessary interface with process control systems.

Temperature and Pressure Rating: The valves shall be designed to withstand the cryogenic operating conditions of 87 K minimum, a 2.5 bara minimum, and a flow rate of 10 kg/s.

Compact Design and Interface: The layout of the valves, with the body situated outside the cryostat and only the valve seat located inside the tank, is strategically chosen to optimize space utilization within the cryostats. This compact design minimizes the dimensions of the cryostats, reduces interference with detectors, and maximizes the usable volume for scientific measurements. The interface of the valves aligns perfectly with the membrane cryostat system, ensuring seamless integration and compatibility.

Vendor Qualification: The selected vendor shall possess extensive expertise and a solid reputation in the design and manufacturing of inline safety valves for side penetration of cryogenic vessels. Their valves shall have been successfully implemented in a wide range of demanding applications worldwide. The company's long-standing experience and track record shall further validate their qualification for this critical cryogenic application.

Given the urgency and importance of this procurement in terms of both schedule and product quality, opting for the inline valve’s provider ensures a dependable solution that satisfies all the required technical specifications.

Additional requirements for the Supply are outlined below:

4.1 All documents shall be issued in English language only.

4.2 Certificates of Conformity shall be provided by Subcontractor.

4.3 Testing reports and procedures shall be provided by the Subcontractor.

4.4 Guarantee shall be 12 months after commissioning or 24 months after the announcement of “ready for shipment” (whichever occurs first). The Subcontractor shall perform stress and thermal analyses for the Supply to verify the performance requirements.

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

4.6 Installation is not included in the Supply. It will be performed by FRA or its designee.

Interface Requirements

5.1 The Supply shall be located inside eight (8) spaces allocated in the North and South Detector Caverns at West Side of the Cryostats 1 and 2.

5.2 Details of the interface with the cryostat (warm and cold vessels) will be discussed after award (See Figure 4-2 for broad detail of that interface). They shall include a welded connection to the warm vessel (made of carbon steel), riveted connections to the insulation space and welded connections to the inner cold vessel (made of 304L stainless steel).

5.3 Each valve shall have limit switches for open ZSO and closed ZSC position.

5.4 Each valve shall have one solenoid valve for instrument air and one safety valve for the safety PLC.

Technical Requirements Internal Safety Valve Unit

6.1.1 Design Pressure PS: 2.1 bar (30.5 psi).

6.1.2 Design Temperature is -186.15°C (87K).

6.1.3 Design Flow per valve is 10 kg/s (22 lb/s).

6.1.4 Diameter DN: 150 mm (6 in).

6.1.5 Test Pressure: 4 bar (58 psi).

6.1.6 Special design for tanks with triple shell.

6.1.7 Flange Connection: Conflat Flange DN 100 (4 in).

6.1.8 Housing Module: 3 main parts housing (head, middle, end piece). This device will need to be dismountable for installation purposes.

6.1.9 There shall be a slide bearing provided for the valve spindle guide. The end of the head piece shall serve as the valve seat. The valve pallet shall rest on a valve seat. There shall be a shaft exit at the end piece. The shaft exit shall be equipped with slide bearing and PTFE sleeve sealing joint. The pneumatic actuator shall be connected to specially designed supports of the end piece.

6.1.10 Valve Seat Seal shall be PTFE O-ring.

6.1.11 Within the system shall be CF-flanges.

6.1.12 The valve pallet shall be connected to the spindle via a screwed cover, the gasket shall be exchangeable and made of PTFE.

6.1.13 Valve spindle shall be with 3 parts with double cardan joint. The sealing of the valve spindle shall be an axial compensator which is welded to the internal cover.

6.1.14 The valve shall be driven by a pneumatic actuator with handwheel.

6.1.15 Vacuum Insulation (one on the main body at the point of connection to the warm vessel; other to far side of valve, after the body of the valve to reduce the heat going to the main fluid).

Functional Test with Liquid Nitrogen. Cold Test.

6.2.1 The functional test with liquid nitrogen shall be conducted per DIN / EN 10204/3.1. Supplier to provide inspection certificate that demonstrates:

a. Function control and adjusted settings with LN2 (for valves only)

b. Tightness test with LN2 for over 30 min.

6.2.2 Materials used for testing shall be provided.

Standard Documentation

6.3.1 Welding documentation (welding plan, welding procedure qualification, and welder qualification) according to DIN EN ISO shall be provided.

6.3.2 Material certifications for welding consumables (3.1 chemical composition and 2.2 mechanical properties) shall be provided per DIN EN 10204.

6.3.3 Material certifications for pressure containing parts shall be provided per DIN EN 10204.

Helium Leak Check

6.4.1 Scope of testing shall be as follow: main chamber, compensator chamber with CF flange and vacuum chamber with CF flange.

6.4.2 Helium leakage test on assembled valve without vacuum chamber from outside to inside

6.4.3 Helium leakage test on the valve with vacuum chamber from outside to inside

6.4.4 Helium leakage test on valve with vacuum chamber from inside to outside.

Inspection and Test Plan

6.5.1 Inspection and Test Plan shall be accomplished with FRA approval.

Pressure Test

6.6.1 Pressure test of housing with air shall be performed with FRA approval.

Penetrant Test

6.7.1 Liquid penetrant examination for all weld seams (DIN EN ISO) with FRA approval.

Testing of Valve Seat Leak

6.8.1 Testing of valve seat leak rate with FRA approval.

Marking

6.9.1 Marking on an additional stainless steel tag plate fixed at the device shall be provided.

Drawings with Parts List

6.10.1 Drawings and parts list shall be provided for FRA approval.

Cleaning for Oxygen Service

6.11.1 Cleaning for Oxygen Service shall be with FRA approval.

Special Packing

6.13.1 Special packing for transport by sea freight if necessary.

6.13.2 Shipping may be one 1 box per device.

Inspection

6.14.1 Depending on the scope of the test, several working days may be required for the inspection.

6.14.2 Inspection intervention steps shall be considered as per approved Inspection and Test Plan (ITP).

6.14.3 Notification for inspection shall be provided for Witness and Hold points according to notification period.

6.14.4 Unless otherwise agreed, notification for inspection is issued 14 days in advance.

Functional Requirements

7.1. The Supply shall be designed for an operational lifetime of 30 years.

7.2. The Subcontractor shall inform FRA of consumable and utility needs (pneumatic, concrete floor loading, etc.) based on the engineering analysis.

7.3. Lifting eyes and/or other means of lifting shall be included in the design of the equipment and packaging.

7.4. The Supply shall be designed for indoor use inside the Detector Cavern, for the portion of valve outside of the cryostat. Temperature, humidity, and other environmental factors are shown in Table 7-1.

Table 71: The Environmental conditions for Detector Cavern

Operational Requirements

8.1 Connectors

I. Electrical connectors shall be of the type D-subminiature or MIL-DTL-26482 (circular quick-disconnect).

II. The connector body shall be corrosion-resistant, electrically conducting, and made of aluminum.

III. The connector pins shall be corrosion-resistant and electrically conducting. Gold-plated pins are preferred. The connector shall be able to handle voltages up to 50 V and currents up to 2 A from pin to pin and from pin to ground.

IV. The connector insulator shall be made of glass, ceramic, or a combination of these materials. The insulator and its junction to neighboring parts shall be corrosion resistant. The electrical resistance from pin to pin and from any pin to ground shall be higher than 300 MΩ.

V. The Subcontractor shall provide the mating connector for all connectors in the envelope.

8.2 Wireless control communication is not allowed.

8.3 All wire/cable shall be of type low smoke zero halogens (LSZH).

Mechanical Requirements General Mechanical Requirements

9.1.1 Design and placement of all valves and instrumentation or other external components shall allow for ease of operation, inspection, maintenance, and troubleshooting. Features shall be included for the control of hazardous energies (i.e., electrical, mechanical, hydraulic, pneumatic, chemical, and thermal) under Lockout/Tagout (LOTO) for safety inspections, maintenance, and troubleshooting.

9.1.2 All recommended LOTO schemes shall be included in maintenance manuals to be provided upon delivery of the Supply. All LOTO schemes shall be proposed to the FRA and are subject to FRA written approval.

Specification of Supplied Equipment Valves

10.1.1 All valves within the LAr process path to the cryostat shall be Ultra-High Purity (UHP) series.

10.1.2 The valve icon shows the conceptual piping and instrumental diagrams (P&ID) symbol for the side penetration valve depicted in Figure 10-1. The valve type designated to the Flow Safety Valve, with an actuator (shall be actuated by instrument air). These valves shall be equipped with two limit switches for readback of the closed and open positions. SV – actuated by main process controls, and EV – actuated by Safety Instrumented System.

10.1.3 All actuators shall be of the pneumatic spring-loaded type, fail-closed unless otherwise stated, operating at an air pressure from 4.5 – 6 barg.

Figure 101: P&ID Valve Icon Materials

10.2.1 Materials known to become brittle at cryogenic temperatures shall not be used for components that may become cold under any circumstances whether normal operations or accidental.

10.2.2 All materials used in the system shall be new and designed for the operating parameters.

10.2.3 Any materials or components used in the pressure boundary shall meet all requirements of the Codes listed in Section 2.

10.2.4 Any materials used in pressure-containing piping shall conform to the piping code for the appropriate fluid service category.

10.2.5 All fittings, bends, miters, laps, and branch connections shall conform to the piping code requirements for the appropriate fluid service category.

10.2.6 Any flanges and blanks shall conform to the piping code requirements for the appropriate fluid service category.

10.2.7 The Subcontractor shall identify any plastic or polymer-based components and any low thermal conductivity materials planned to use. They are subject to FRA approval.

10.2.8 The materials for other components of the Supply are shown in Table 22-4 in Appendix A.

Manufacturing, Installation, and Assembly Requirements Manufacturing

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

Welding

11.2.1 All welding joint preparation and welding techniques shall be performed by the applicable codes.

11.2.2 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.

11.2.3 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.

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

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

11.2.6 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.

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

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

Installation

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

Shipping

12.1 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 FRA contractors or users.

12.2 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.

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

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

12.5 Design of the crate and lifting fixtures (if used) shall respect the weight and size limitations listed in Appendix B.

12.6 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.). List of hardware shall be identified in bill of lading for easy identification.

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

12.7 The following inspections shall be performed upon arrival:

i. Transport acceleration according to section 14.10.

ii. FRA incoming inspection (at SURF) according to section 14.12.

Examination, Inspection, and Test General

13.1.1 The supply shall undergo shop testing in the presence of the FRA or its representatives to verify compliance with operational performance, Code, and other safety requirements. The subcontractor is required to furnish a shop test report for the supply to the FRA. Acceptance tests for the supply will be carried out on-site.

13.1.2 In addition to those required by the chosen applicable codes and standards, FRA specific control points shall also be included during manufacturing and installation. They shall be included in the corresponding Manufacturing and Inspection Plans (MIP). Every specific inspection or control shall be covered by a dedicated procedure (to be submitted to FRA for acceptance at the occasion of the review meetings).

13.1.3 In the case of a non-conformity during manufacturing or installation, the non-conformity shall be documented with the condition, the requirement not being met, and the disposition. For dispositions of “Use-As-Is” and “Repair”, the non-conformity report shall be submitted to FRA for approval before implementation. Items that have been dispositioned “Rework” and “Repair” shall be re-inspected after the disposition is complete and the documentation of this inspection shall be recorded on the non-conformity report. The completed non-conformity reports shall be submitted to FRA as deliverables.

13.1.4 The Subcontractor shall ensure a close oversight of the manufacturing process. This monitoring shall include Notification Points and Hold Points.

13.1.5 A Notification Point (NP) is a milestone where the Subcontractor is required to notify FRA that it has completed a specific task or a specific deliverable and is proceeding to the next task or the next action on the specific deliverable. An NP is meant to enable FRA personnel to follow the progress of the contract and possibly to witness a critical manufacturing step at the Subcontractor’s premises. The Notification shall be sent by the Subcontractor to FRA at least fourteen (14) working days before the scheduled manufacturing step. FRA shall then decide on further action for the notification. An NP shall not affect the production flow of the Subcontractor that may continue the work even without a reply from FRA.

Table 131: The Minimum Control Point for Manufacturing and Installation of the Supply

13.1.6 A Hold Point (HP) is a milestone where the Subcontractor is required to notify FRA of the impending completion of a specific task or a specific deliverable and shall stop the associated processes until a written authorization is issued. Such authorization shall be issued based on clearly identified Quality Control, data, and acceptance criteria with associated testing witnessed by FRA if deemed necessary. FRA shall have a maximum of ten (10) working days thereafter to review the Subcontractor’s data. In case of clearance, the Subcontractor shall resume its activity. In case of rejection, the Subcontractor shall develop a recovery plan that shall be submitted and reviewed by FRA within ten (10) working days of submission. In the case of objection, FRA shall detail its reasons in writing and the Subcontractor shall have ten (10) working days to answer FRA objection and, whenever suitable, develop a recovery plan. The Subcontractor shall notify FRA at least ten (10) working days before the execution of any testing associated with a Hold Point.

13.1.7 The list of NP and HP to be implemented during the various phases of the execution of the system described in this Scope of Work will be mutually agreed upon between FRA and the Subcontractor at the occasion of the kick-off meeting. The minimum inspection and controls that shall be performed during manufacturing and installation are specified in Table 14-1. Some of them are to be carried out both at the Subcontractor’s premises during manufacturing and at SURF upon receipt. Otherwise, FRA or its designee will perform them.

13.1.8 FRA reserves the right to be present, or to be represented by an organization of its choice, to witness any tests carried out at the Subcontractor's or his subcontractors' premises. The Subcontractor shall give at least fourteen (14) working days’ notice of the proposed date of any such tests. In general, FRA will be required to witness the test associated with Hold Points. Additionally, FRA reserves the right to visit the Subcontractors or sub-subcontractor facilities during manufacturing with one (1) day’s prior notice. The sum of the tests associated with Hold Points constitutes the Factory Acceptance Test (FAT).

Dimensional control Dimensional controls shall be performed during pre-assembly and in all fabricated elements. The allowable dimensional and geometrical tolerances shall agree with the chosen applicable standards for the assemblies and subassemblies and shall be included in the manufacturing drawings and the welding specification drawings. Final dimensional controls shall be performed on:

Footprint and height of fabricated elements, assemblies, and subassemblies.

Length of fabricated elements (when applicable).

Angle of fabricated elements (when applicable).

Perpendicularity of fabricated elements (when applicable).

The tolerances specified shall be submitted to FRA for acceptance at the occasion of the review meetings.

Factory Acceptance A factory acceptance shall be performed before the items are cleared for transportation. It shall comprise a verification by FRA or its representative that all the agreed-upon tests (including, but not limited to the applicable minimum control points listed in Table 13-1 have beey completed and passed.

Deliverables for the Kick-Off Meeting The Subcontractor shall:

Provide the final list of codes applicable to the execution of the work.

Final Quality Assurance Plan (QAP) for the execution of the work.

List of NP and HP and proposed dates.

Proposal for design review dates for design reviews List of tentative manufacturing milestones.

Any information and/or documentation that was not fully submitted at the time of the proposal.

Deliverables for the Engineering Phase During this phase, the Subcontractor shall:

Design the Supply to meet FRA requirements and timeframe.

Develop testing plans for the equipment.

Develop the schedule for the testing efforts.

Develop a Quality Control (QC) plan that meets LBNF requirements.

Develop handling and transport plans for the equipment.

Provide design package submittals and schedule submittals at designated intervals.

Participate in design, constructability, and schedule reviews for the Supply manufacturing scope with LBNF and external stakeholders at designated intervals.

Identify and plan any long-lead-item procurements.

Assist with stakeholder coordination to support collaboration between LBNF, external stakeholders, as needed, and the Subcontractor.

Attend meetings with stakeholders, governmental representatives, and regulators as requested by FRA to assist in the resolution of project-related issues.

For the Supply engineering phase, the Subcontractor shall:

Provide stress and thermal analysis reports to verify performance requirements.

Provide all engineering analyses, design models, and manufacturing drawings. This would include a finalized drawing with a parts list attached.

Provide Inspection and Test Plan (ITP) Provide quality cleanliness protocol.

Provide dimensional control protocol.

Provide welding procedure specifications and welding procedure qualifications being planned for use in the manufacturing process.

Provide a preliminary list of recommended spare parts for the system.

Provide progress reporting as required in the subcontract.

Manufacturing and Inspection Plans. This may be submitted later but shall be at least ten (10 days before the Production Readiness Review (PRR). The plan shall also describe any long-lead procurement that may exist, potentially including, but not limited to, commodities such as steel and/or mechanical equipment.

A report describing planning for handling and transport including a quasi-final packing list with weights and dimensions for planning purposes.

The Subcontractor shall provide training material and maintenance manuals to FRA personnel on all aspects of the proper operation of the Supply, including, but not limited to, maintenance and troubleshooting of instrumentation, control valves, and heaters. A table of scheduled maintenance deemed necessary to maintain the system in a high state of reliability shall be included.

Provide progress reporting as required in the subcontract.

Deliverables for the Manufacturing Phase The manufacturing scope of work occurs after the approval of the engineering. The Subcontractor shall:

Procure the materials to manufacture the Supply per the approved design.

Develop handling and transport plans for the equipment and deliver material components to Lead, SD.

After the conclusion of the Production Readiness Review, and when authorized by FRA, manufacture the equipment per the approved design.

Test the equipment in conformance with the specifications and procurement documents and following all applicable codes, according to the mutually agreed-upon schedule.

Identify and provide all special tools, equipment, and process material required to perform inspection and repairs on all components of the Supply.

Provide all the required documents supporting the manufacturing and testing in conformance with the specifications and procurement documents and following all applicable codes.

Provide copies of mill certification reports for all materials and/or code-listed components. For commercial items, such as welding rods, electrodes, and fasteners, certificates of compliance may be supplied instead of mill certificates.

Whenever applicable provide code compliance certificates for the Supply.

Provide a non-conformity report.

Assist with any FRA-provided Quality Control testing of materials.

Deliver all materials and equipment to SURF.

Provide as-built documentation.

Supply specifications and manuals for purchased components.

Assist with stakeholder coordination.

Quality Assurance The Supply equipment is to be designed and manufactured by generally applied quality standards and techniques.

The Subcontractor shall submit its own QA plan for the execution of this SOW with the proposal that meets the requirements of FRA Quality Requirements [1].

The Subcontractor shall apply reliability engineering techniques to the engineering, development, and production of each component.

FRA shall perform a Production Readiness Review before the release for manufacturing. The Subcontractor shall perform the specified or required inspections and tests to verify that quality control measures are adequate and conform to the subcontract requirements. Results of all inspections and tests performed shall be documented and the results submitted to FRA. The results may be in the form of either a pass/fail score or the actual quantitative data recorded. Additionally, a Delivery Inspection will also occur during the term of the subcontract, FRA and/or its designee shall conduct this. FRA and/or its designee may perform additional inspections at the Subcontractor’s facility during the manufacturing process.

The Subcontractor shall follow the guidelines for quality control and final acceptance testing.

Project Management The Subcontractor shall coordinate and control all project-specific activities and corresponding resources and shall ensure the realization of the standards of this SOW 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 FRA in matters of safety.

The LBNF Project uses cost and scheduling tools (Primavera P6 and Cobra) by FRA standards. In addition, FRA utilizes the Earned Value Management System (EVMS) for cost, schedule, and scope change control. This system will be used by FRA 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 FRA. The Subcontractor shall provide submittals, as defined in the schedule specification.

In special cases, especially in the case of technical problems and delays, FRA 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.

Independent of the scheduled reports, all events that may influence the schedule shall be reported to FRA. In case of serious problems that endanger the achievement of contractually agreed milestones, the FRA shall be informed immediately in writing. The subcontractor shall present to FRA 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 FRA. There shall be provision for weekly teleconferences throughout the whole duration of the Subcontract using a mutually agreed teleconferencing system. FRA 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 with FRA within five (5) workdays.

Documentation Management The following applies to all documents, drawings, notes, calculations, results of inspections, analysis, testing reports, etc. prepared by the Subcontractor and submitted to FRA 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.

Required Documents Summary The following documents are part of the subcontract:

Engineering analyses

20.1.1 Load stress analysis from all sources of loading; thermal, vacuum, pressure, etc.

20.1.2 Thermal flexibility analysis.

20.1.3 Heat leak analysis.

20.1.4 Lifting lug analysis.

20.1.5 Transportation analysis.

20.1.6 Anchoring analysis.

Drawings

20.2.1 All 3D drawings.

20.2.2 All manufacturing drawings.

20.2.3 Parts lists including, but not limited to pipe/tube sizes, instrumentation with make/model described, MAWP/MAWT of instrumentation, and instrumentation measurement range.

QAP/Project Management

20.3.1 Welder Performance Qualification (WPQ) per welder.

20.3.2 Welding Procedure Specification (WPS).

20.3.3 Procedure Qualification Record (PQR) per welder.

20.3.4 Visual inspection report covering all welds.

20.3.5 Certificates of Compliance for welding materials: welding rods, electrodes, fasteners, etc.

20.3.6 Weld Map with Welder identified at each weld.

20.3.7 Weld Penetrant Testing results/In-process inspection reports.

20.3.8 Shipping plan.

20.3.9 Rigging/Handling plan.

20.3.10 Quality Assurance Plan (QAP) and Quality Control (QC).

20.3.11 Project Management Plan.

20.3.12 Pressure testing method, electrical testing method, etc.

20.3.13 Valve leak rate results.

20.3.14 Leak rate FAT results.

20.3.15 Instrument and wiring testing checks.

20.3.16 Actuator checks.

20.3.17 Cold shock procedure and results.

20.3.18 Pressure test reports.

20.3.19 Cleanliness certifications from procured parts.

20.3.20 Specifications and manuals from procured parts.

20.3.21 Material Mill reports.

20.3.22 Maintainability plan.

20.3.23 Training, Installation, and Maintenance documents/manuals.

20.3.24 Transportation analysis form.

20.3.25 Anchoring analysis form.

20.3.26 Certificate of compliance to various applicable Codes for the Supply.

Statement of Work General Description of Inline Safety Valves for Side Penetrations in Cryostats 1 and 2

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

Appendix A – Design Parameters and Tables Table 211 shows the component of Supply.

Table 211: Materials for Other Components of the Supply

or AISI 316/316L)

or AISI 316/316L)

or AISI 316/316L) galvanized mild-steel or corrosion-proof painted mild-steel