VF-3 Cold wall SoW.pdf

PART 1: GENERAL

1.01 DESCRIPTION

The Space Simulation test facilities at NASA Glenn simulate space pressures and temperatures for space exploration related hardware testing. To accomplish this, a cryogenically cooled shroud, Ln2 control valve, manual isolation valve, and associated Vacuum Jacketed (VJ) supply and mechanically insulated vent piping are required.

1.02 SCOPE

NASA is purchasing a liquid nitrogen (LN2) thermal shroud, LN2 control valve and vacuum insulated supply and mechanically insulated vent piping for Vacuum Facility 3 (VF-3). Previous relevant experience is required.

1.03 GOVERNMENT FURNISHED INFORMATION (GFI)

1. The following relevant drawings

a. VF-3 Facilities drawings

b. 0016-W1451488-M-801 Redline (LN2 system)

c. Facility/LN2 system photographs

d. VF-3 Facility Model (reference only, subject to change)

Provided drawings are for quotation purposes only.

NASA requires that vendors take field measurements of the test facility prior to fabrication of the thermal shroud.

1.04 TRAVEL AND INSPECTION

NASA reserves the right to inspect the fabrication and witness testing of the thermal shroud and associated equipment at the vendor location.

Visitation by the awarded company to take field measurements prior to fabrication is required.

Proper mating of thermal shroud passthroughs shall be the vendor’s responsibility.

PART 2: QUOTATION

2.01 COST AND SCHEDULE

The contractor shall provide a cost and schedule estimate in response to this solicitation for the products described in Part 3. The quotation shall include fabrication of the thermal shroud, supply and vent LN2 VJ piping, control valves, cold wall to facility interface connections, and the cost of shipping.

PART 3: PRODUCTS

3.01 DRAWINGS

Contractor shall provide drawings of the thermal shroud, supply and vent piping, and all mechanical and electrical interfaces.

3.02 DESIGN REPORT

Contractor shall provide a design report that, at a minimum, contains the following items. The final design shall be reviewed and approved by NASA prior to fabrication.

• Design Calculations o Thermal analysis o Conductance estimates o Baffle design and design basis o Maximum Allowable Working Pressure (MAWP) at design temperatures o Weight o Structural o Relief valve sizing calculations, which include backpressure due to vent lines o Thermal shroud vent line sizing calculations

• Manuals

• Cut/Spec sheets

• Results of pneumatic leak test o Pneumatic leak test to be conducted with inert gas and in accordance with ASME B31.3 Normal Fluid Service

• Results of helium leak test

• Material list, mill test reports, and material certifications/specifications

• Welder's Qualification Documentation (WPS, PQR, and WPQ)

• Non-Destructive Examination Reports (Visual, Radiography)

• Lift plan for moving cold wall into and around facility.

3.03 THERMAL SHROUD

The contractor shall provide one (1) thermal shroud assembly

Thermal Shroud Design Requirements

Design the thermal shroud for installation within the existing vacuum chamber required features of this element are as follows.

i. The VF-3 chamber is nominally 5’ diameter and 15’ long. The nominal outer dimensions of the thermal shroud shall be 50” x 146”. The thermal shroud and all associated hardware and insulation shall fit inside this facility. Multi-layer insulation to be provided and installed by NASA.

ii. The thermal shroud shall be actively cooled by ½” minimum “D”-tube in a parallel flow configuration and spaced such that there shall be no more than a 10K gradient across the shroud during flooded operation in high vacuum.

iii. The thermal shroud shall consist of an open end with a passive, removable cover and a closed end with active cooling via LN2 piping. The open end shall be located at the main chamber opening (hinged end) and the closed end shall be positioned in the non-hinged, rear end of the chamber. The main chamber opening will be referred to as the “Open End” of the chamber for the remainder of this document.

iv. The removable end cover shall have 2 handles for easy removal. It shall have a 3” hemispherical “notch” in the bottom dead center to allow cables to pass through. The cover shall also be thermally synched to the cold wall with a thermally conductive gasket, and tightened down with ¼”-20 bolts, spaced evenly around the circumference of the cover and thermal shroud, spaced approximately every 6 inches.

v. The thermal shroud shall be removable and shall be installed and removed via the Open End of VF-3.

vi. The thermal shroud shall employ optically dense chevrons or baffles in the location of the turbomolecular pump. The thermal shroud shall also employ (3) 4” pass through holes, with detachable covers. Contractor shall verify placement with NASA PoC prior to construction.

vii. The thermal shroud design shall include inlet, outlet, and fin temperature instrumentation. Instrumentation shall consist of roughly 14 Type T thermocouples, 10 spaced evenly across the shroud and 2 on the inlet and 2 on the outlet. Thermocouple locations shall be approved by NASA engineers.

Thermocouple leads shall extend one foot beyond the leading edge of the shroud while bundled. The thermocouples shall be terminated with Mini style plugs with flat conductors.

viii. The thermal shroud design shall allow for instrumentation maintenance and replacement. Bolt on thermocouples shall be used where appropriate.

Rationale: Easy maintenance and replacement (e.g. without requiring shroud removal or significant disassembly) are requested where feasible to minimize potential facility downtime due to instrumentation failure.

ix. The thermal shroud shall have ease of maintenance, easily replaceable piece parts and designed for ease of inspection.

Rationale: Inspection and repair of the shroud without removal or significant disassembly minimizes potential facility downtime. For cases where removal is required, accessible hard points make maintenance easier to perform. The thermal shroud assembly should be removable as a unit utilizing the existing chamber rail system.

x. The thermal shroud shall be supported by thermally isolated casters/rollers that fit the existing chamber mounting rails, one of which is flat and one of which is round. Caster/rollers shall be thermally isolated from cold wall via insulating blocks or mounts. Caster/roller selection shall be discussed and approved by NASA engineer/POC.

xi. The thermal shroud connections shall be easily accessible from the Open End.

The contractor shall provide flex lines of sufficient length to connect the LN2 feed throughs to the thermal shroud supply and vent connections. These flex lines shall utilize DN40CF (2.75” OD) 304L SS Rotatable Conflat fittings to connect to the facility feed throughs (feed throughs provided by NASA). Proper mating of thermal shroud passthroughs shall be the vendor’s responsibility.

Rationale: The locations of the thermal shroud supply and vent feedthroughs are a couple feet into the chamber and will not be accessible with the cold wall in place. For this reason, flex lines must be provided to bring the connection points into reach from the chamber opening.

xii. The thermal shroud shall have 2 internal mounting rails, located 12” vertically from the bottom-dead-center of the shroud, spanning the length of the shroud.

These rails shall be designed to support 1000lbs over their length. Rail placement and design to be approved by NASA prior to fabrication.

Rationale: Thermal Shroud needs to adequately support various test articles.

xiii. Surface finishes, coatings, and augmentations shall be consistent with the use of the thermal shrouds in high vacuum facilities. The interior shall be coated with a high emissivity coating suitable for high vacuum use, such as Cat-A-Lac Black (or equivalent), as delivered (applied and cured).

xiv. The thermal shroud shall be designed, fabricated, tested, and inspected in accordance with ASME B31.3 Normal Fluid Service at a design pressure of 35 psig from -320 F to 120 F.

xv. The thermal shroud shall be designed to operate properly with a nominal liquid nitrogen supply pressure of 35 psig. After fabrication of the thermal shroud, the contractor shall perform a pneumatic leak test in accordance with ASME B31.3 Normal Fluid Service at 40 psig. Pneumatic leak test shall be performed with inert gas. The thermal shroud shall also be vacuum leak tested using a helium mass spectrometer, calibrated to a sensitivity of 5x10^-9 std cc/sec helium. Any leaks shall be fixed prior to delivery. No detectable leaks shall be permitted. A certificate of compliance shall be provided to NASA as part of the documentation package.

xvi. Upon completion of fabrication, the thermal shroud shall be examined in accordance with ASME B31.3 for Normal Fluid Service. Per Section 341.4.1 (b) (1), “Not less than 5% of circumferential butt and miter groove welds shall be examined fully by random radiography. The welds to be examined in each designation lot shall be include the work product of each welder or welding operator whose welds are part of the lot.”. 100% of all completed welds shall be visually examined. Welds shall be accepted in accordance with ASME B31.3 and acceptance documentation shall be submitted to NASA.

xvii. Contractor shall be qualified to design the thermal shroud in accordance with ASME B31.3 Section 301.1.

xviii. Non-Destructive Examination (NDE) technicians shall be qualified in accordance with ASNT SNT-TC-1A.

Thermal shroud fluid interfaces

Nitrogen inlet DN40CF (2.75" OD) 304L SS Rotatable ConFlat Nitrogen outlet DN40CF (2.75" OD) 304L SS Rotatable ConFlat NASA supplied feedthroughs shall be DN40CF (2.75” OD) 304L SS ConFlat

3.04 LN2 SUPPLY AND VENT PIPING

The contractor shall provide Liquid Nitrogen supply line to tie into existing facility systems and

GN2 vent line to vent the cold wall outside of the building and into the overflow bucket on the roof. The contractor shall determine layout and design of piping and support structure, with NASA approval.

Piping Requirements

i. The contractor shall supply static vacuum jacketed LN2 supply piping that shall mate to the existing supply manifold near VF-3, which utilizes a 1” NPT connection. The contractor shall verify proper fitment to the existing fittings. The supply shall be designed in accordance accordance with ASME B31.3 Normal Fluid Service at a MAWP of 150 psig from -320 F to 120 F. All inner line parts shall be designed in accordance with ASME B31.3, current edition.

ii. Expansion joints shall be installed, where necessary, to allow thermal expansion of different materials and/or sections.

iii. The contractor shall provide a pneumatically controlled vacuum jacketed cryogenic control valve to maintain the LN2 level in the thermal shroud. The contractor shall also provide a vacuum jacketed manual supply valve. Valves shall be in accordance with ASME B16.34 and meet the system design conditions of 150 psig from -320 to 120F.

iv. The contractor shall provide mechanically insulated vent line that is adequately sized to prevent backpressure from LN2 supply or vaporization. The vent line shall be vented outside of the building and into the existing overflow bucket installed on the building roof. The insulation shall be compatible with cryogenic fluids and have an R-value of 8 or more. Vent line layout and design shall be verified with NASA POC before construction.

v. Contractor shall install cryogenic thermal relief protection for the LN2 supply line wherever trapped liquid is possible. Relief valves shall be ASME Code Stamped and sized and set in accordance with ASME B31.3, API 520 and API 521. Relief valves shall have a set pressure of 150 psig to protect the piping at the system design pressure. The relief valve(s) shall be vented to the outside of the building in non-vacuum jacketed pipe or tubing and vent lines shall be sized to prevent backpressure on the relief devices that affect their set pressure and flow rate.

vi. All welding shall be done in accordance with Section IX, ASME B31.3 for piping.

All welds and procedures shall be qualified for low temperature service.

vii. The contractor shall mechanically insulate any non-vacuum jacketed joints or areas as necessary, excluding relief valves and relief valve vents.

viii. Upon completion of piping fabrication, the contractor shall perform a pneumatic leak test in accordance with ASME B31.3 Normal Fluid Service at 165 psig.

Also, a leak test, using a helium mass spectrometer, calibrated to a sensitivity of 5x10^-9 std cc/sec helium, shall be performed on the interior pipe and in the annular space between the inner pipe and outer jacket . Any leaks shall be fixed prior to delivery. No detectable leaks shall be permitted. A certificate of compliance shall be provided to NASA as part of the documentation package.

ix. Upon completion of fabrication, the piping shall be examined in accordance with ASME B31.3 for Normal Fluid Service. Per Section 341.4.1 (b) (1), “Not less than 5% of circumferential butt and miter groove welds shall be examined fully by random radiography. The welds to be examined in each designation lot shall be include the work product of each welder or welding operator whose welds are part of the lot.”. 100% of all completed welds shall be visually examined. Welds shall be accepted in accordance with ASME B31.3 and acceptance documentation shall be submitted to NASA.

x. Contractor shall be qualified to design cryogenic systems in accordance with

ASME B31.3 Section 301.1

3.05 INSTALLATION

Installation of the LN2 supply line and vent line shall be completed by the contractor. Employees must be United States citizens. The contractor is responsible for all associated mounting, support, and related hardware. The contractor shall coordinate the installation schedule with

NASA.

The thermal shroud and piping shall be delivered to the following.

NASA Glenn Research Center Building 16 21000 Brookpark Road Cleveland, Ohio 44135