Technical Specification EIC TSD SPC 001 dated 8.9.2024.pdf

Electron-Ion Collider, Brookhaven National Laboratory

Doc No. EIC-TSD-SPC-001 Author: D. Landwehrle Effective Date: 8/9/2024 Review Frequency: N/A

Specification Title: Technical Specification for the Robotic Welding System Revision: 00

TECHNICAL SPECIFICATION

for the Robotic Welding System Quality Classification: A-3

Prepared By:

_________________________________ Date: __________________ D. Landwehrle, Mechanical Engineer

Reviewed By:

W. Halbig, Deputy Technical Systems Division Director

R. Muscolino, Deputy Technical Systems Division Director

C. Schaefer, ESH Manager

P. Hamblen, ESH Engineer

J. Zipper, Quality Assurance Representative

C. Galdamez, Procurement Liaison Engineer

Docusign Envelope ID: 5156A456-30BD-42F1-994F-9EB8BE75FD76

8/9/2024

8/9/2024

8/9/2024

8/9/2024

8/9/2024

8/9/2024

8/12/2024

Approved By:

J. Tuozzolo, Technical Systems Division Director

8/13/2024

REVISION HISTORY

Revision # Effective Date Summary of Change

00 8/9/2024 Initial Release

Table of Contents

LIST OF ACRONYMS

1 SCOPE

1.1 Background

2 APPLICABLE DOCUMENTS

3 REQUIREMENTS

3.1 Technical/Performance Characteristics

3.1.1 MIG Welding

3.1.2 Welding Speed

3.1.3 Welding Geometry

3.1.4 Fume Extraction

3.1.5 Seam Finding

3.1.6 Seam Tracking

3.1.7 Mobility

3.1.8 Execution

3.1.9 Detailed Reach Analysis Requirements

3.2 Materials

3.3 Construction/Layout/Location Requirements

3.3.1 Cobot Reach

3.4 Environment, Safety and Health

4 VERIFICATION

4.1 Classification of Inspections

4.1.1 Commissioning

5 OPTIONAL

5.1 TIG Welding

LIST OF ACRONYMS

AC Alternating Current ANSI American National Standards Institute ASTM American Society for Testing and Materials ATP Acceptance Test Procedure BNL Brookhaven National Laboratory

BSA

COBOT

Brookhaven Science Associates Collaborative Robot

DC Direct Current EIC Electron-Ion Collider ESH Environment, Safety and Health

MIG

MMA

Metal Inert Gas Manual Metal Arc

OSHA Occupational Safety and Health Association RHIC Relativistic Heavy Ion Collider

SOW

TIG

Statement of Work Tungsten Inert Gas

Robotic Welding System

1 SCOPE

This specification defines the technical requirements for the Robotic Welding System to be used at the Electron-Ion Collider (EIC) at Brookhaven National Laboratory (BNL) managed by Brookhaven Science Associates (BSA). This document outlines the Contractor’s responsibilities and obligations necessary for completing the requirements as set forth herein. BSA will procure two identical systems for redundancy. Both systems will be deployed and may be used in-tandem or independently. BSA is also inviting bids for an optional TIG welding system (Section 5) to be included in the proposal.

1.1 Background

The EIC Project will design, build, and install the accelerator hardware for a new electron storage ring, an electron injector, and modifications to the hadron ring required to produce an electron ion collider and infrastructure. It will include one interaction region, with an allowance for a second, and one detector. The facility is designed to meet requirements to ensure high reliability and availability for the user program.

The equipment specified herein shall create a mechanical sealing interface on the Cryostat Interconnect assemblies. The assemblies will be subjected to a vacuum environment that serves the purpose of an insulating jacket around the inner cold mass components. There are 576 Cryostat Interconnects requiring disassembly and re-welding. The welding effort will require over 2.5 miles of bead to be laid down.

2 APPLICABLE DOCUMENTS

The following specifications, standards and drawings form a part of this specification to the extent specified herein. Unless otherwise specified, the issues of these documents shall be that in effect on the date of the solicitation or contract. Exceptions must be approved in writing by BSA.

In the event of a conflict between the applicable documents and this specification, the Contractor shall immediately notify the BSA Contractual Representative who shall in each instance determine which document takes precedence and advise the Contractor accordingly. Failure to notify BSA of a document conflict shall not relieve the Contractor’s responsibility to ensure full compliance to all requirements.

Document Number Document Title

12130086 INDEPENDENT INTERCONNECTIONS CRYOSTAT INTERCONNECT

ASSEMBLY, LOWER INTERCONNECT SHELL

12130052 INDEPENDENT INTERCONNECTIONS CRYOSTAT INTERCONNECT

SHELL, LOWER INTERCONNECT SHELL

Interconnect_Repair_S patial_asm

3D Model of Typical Interconnect Assembly with Spatial Constraints and Weld Prep Geometries

2606M0001 HADRON STORAGE RING, ROBOTIC WELDING ICD

3 REQUIREMENTS

3.1 Technical/Performance Characteristics

The contractor shall provide a system that can weld the defined circumferential and linear welds on the Cryostat Interconnect Assembly as per the referenced drawings. The welding system shall be mobile and capable of performing the welding task by moving the system into no more than (2) locations at each Interconnect Assembly. The mobile system shall fit and operate within the existing Relativistic Heavy Ion Collider (RHIC) tunnel and obstructions shown in figure 6. The system shall utilize Seam Finding and Seam Tracking technology to improve autonomy and weld quality.

3.1.1 MIG Welding

The MIG Welding system shall use a Fronius TPS 400i power supply and have at a minimum the following capabilities:

• MIG Welding with splatter control processes

• Second welding torch integrated into the same power supply for manual welding

• Utilize 480V, 3 phase power

• Input frequency of 50-60 Hz

• Minimum range current: 3A

• Maximum range current: 400A

• Continuous duty cycle: 320A

• Self-contained

• Water-cooled system

• Protection level of IP23 or greater

3.1.2 Welding Speed

The system shall have an estimated target welding speed of 20 inches per minute or greater on linear welds. The system shall have an estimated target welding speed of 12 inches per minute or greater on circumferential welds.

3.1.3 Welding Geometry

The system shall be able to adapt to a wide range of welding geometries. At a minimum the system shall be able to weld the geometry detailed in Figure 1 and described below.

Figure 1: Assembly and Clearance Overview

Two edge welds, approximately 0.25” thick total, from two 0.125” individual pieces, and 60” in length. Each 180 degrees to the other on a 12.75” radius cylinder as shown in Figures 2 and 3.

Figure 2: Linear Flange

Figure 3: Linear and Circumferential Weld Prep

Two circumferential slot welds on a 12.75” radius cylinder, one at each end of the interconnect assembly as shown in Figures 4 and 5. The slot is 0.063” wide by 0.125” deep.

The slot width may vary from 0.031” to 0.094”.

Figure 4: Circumferential Overview

Figure 5: Circumferential Weld Prep

3.1.4 Fume Extraction

The system shall have fume extraction integrated into the welding torch. The fumes may include residual paint near the weld bead. This extraction shall be a traditional welding fume extraction system where the fumes are passed through a series of filters, the extracted air is then released back into the space, safe for all those who come into contact, meeting OSHA Standards.

3.1.5 Seam Finding

The contractor shall provide a system capable of finding a welding seam. The system shall perform as follows:

• The system shall be able to locate a seam of an edge weld with a cross section of 0.25” and approximately 60 inches long. It shall center the weld within a half-width of the weld wire.

• The system shall be able to locate a seam in a square groove weld with a spacing that is 0.031-0.094” on the circumference of a 25.5” diameter pipe. It shall center the weld within a half-width of the weld wire.

• The system shall be capable of being jogged in a manual teach mode to a start and end location for each welding operation.

3.1.6 Seam Tracking

The contractor shall provide a seam tracking system that complements section 3.1.5 (seam finding). The system shall perform active seam tracking to reduce welding discrepancies to industry standards. The system shall perform as follows:

• The system shall be able to track a seam of an edge weld with a cross section of 0.25” and approximately 60 inches long. It shall center the weld within a half-width of the weld wire.

• The system shall be able to locate a seam in a square groove weld with a spacing that is 0.031-0.094” on the circumference of a 25.5” diameter pipe. It shall center the weld within a half-width of the weld wire.

3.1.7 Mobility

The equipment shall meet the following mobility requirements:

• One mobile platform with no more than (4) casters.

• Any pressurized tanks shall be incorporated into the mobile platform.

• Lock in place mechanism(s).

• Mobility in confined space as shown in Figure 6.

• The equipment shall be mobile and moved into position by no more than (1) persons.

Separate electric tug systems are acceptable.

• The system shall be capable of being positioned and ready for welding within 10 minutes of total labor time. The timer would commence once the equipment is within 5 feet of the Cryostat Assembly. The contractor shall demonstrate the capability to meet this requirement through simulation and real-time during commissioning. The contractor may use their own personnel for this demonstration. It shall be assumed that the floor is flat, level, and unobstructed.

• The contractor shall include any tooling used to repeatable locate, position and orientate the system to the Cryostat Assembly.

3.1.8 Execution

The equipment shall be operated from a safe distance once all the teaching points have been completed. It shall execute the welding process without any human intervention. The system shall have a remotely operated E-Stop that disables power to the equipment. An emergency E-Stop event shall not damage the equipment. The welding process, including any teaching functions and repositioning, shall be targeted to be less than 30 minutes per Cryostat Interconnect Assembly.

The contractor shall demonstrate the capability to meet this target through simulation and real-time during commissioning. The contractor may use their own personnel for this demonstration.

3.1.9 Detailed Reach Analysis Requirements

The contractor shall perform the following analysis to ensure the equipment meets the requirements. Models and results shall be provided electronically in their native CAD, or equivalent, format.

• The equipment shall be capable of reaching welded areas as detailed in Figure 6.

• The maximum allowable position procedures per Cryostat Interconnect Assemblies is (2).

A position procedure is defined by moving the equipment into a fixed location to perform the welding operation.

• The maximum allowable welding operations is (6).

• Direction of weld with regards to gravity shall be considered.

• Proper angle of welding torch shall be considered.

3.2 Materials

• All Cryostat Interconnect Assemblies are made from A36 Steel per ASTM A366.

• All welding techniques, filler material, and shielding gases shall be compatible with the stated material.

• The welding wire material shall be Carbon Steel, ER70S-2.

3.3 Construction/Layout/Location Requirements

3.3.1 Cobot Reach

The equipment shall have a reach of at least 1,900 mm (75”) and be capable of performing the required tasks with the obstructions outlined in drawing 2606M0001, avoiding the working section.

3.4 Environment, Safety and Health

Identification of hazards, and their mitigation, during all stages of the life of the Equipment including; installation, commissioning, operation, maintenance, and repair. Identification of means to eliminate or manage each hazard shall be provided based on the following hierarchy:

• Eliminate the hazard, or manage the hazards in the following hierarchy;

• Substitute with something less hazardous, or

• Engineer – mitigate the severity of the hazard, or

• Administrative Control, or

• User Personal Protective Equipment (least desirable).

3.4.1 Robotic Safety

• The robot shall be designed for collaborative operation and be in compliance with

ANSI/RIA R15.06-2012 Part 1 or ISO 10218-1:2011.

• The safety-related parts of the robot control system shall comply with PL=d with structure category 3 as described in ANSI/RIA R15.06-2012 Part 1 or ISO 13849-1:2006.

Alternatively, compliance with SIL 2 with a hardware fault tolerance of 1 with a proof test interval of not less than 20 years as described in IEC 62061:2005 is also acceptable.

• The robot system shall have an integrated anti-restart device or function to prevent unplanned movement or operation of the robot system upon restoration of power after an unplanned power loss.

4 VERIFICATION

4.1 Classification of Inspections

Appropriate inspection/tests shall be performed to ensure Equipment conforms to all requirements in section 3 of this specification.

4.1.1 Commissioning

The commissioning effort shall be broken out as a separate line item and treated as the final milestone. The contractor shall provide onsite commissioning of the equipment at BNL. The equipment shall demonstrate competency in meeting all design requirements. The commissioning shall ensure that all test requirements as defined in the ATP are achieved. BSA will provide a simulated physical environment to reproduce the EIC tunnel conditions. The contractor shall prove out runtimes for the system and may choose to use their own personnel for this effort.

5 OPTIONAL

5.1 TIG Welding

TIG welding capabilities shall be considered as a potential add-on to the system. This shall be broken out as a separate line item and will be considered at the discretion of BSA. The TIG system will integrate and reuse much of the existing equipment for robotic welding applications. The TIG system does not need to be secured on the mobile cart at the same time as the MIG welding equipment. The TIG Welding system shall use a Fronius power supply and have at a minimum the following capabilities:

• AC/DC TIG Welding

• Pulse Welding Functionality

• AC/DC Waveform setting.

• Second welding torch integrated into the same power supply for manual welding.

• Utilize 480V, 3 phase power.

• Input frequency of 50-60 Hz.

• Low range of operating current: 3A or less

• High range of operating current: 400A or more.

• Continuous duty cycle @ 320A or more.

• Protection level of IP23 or greater.