XGH-SW-30-0001-R00

HFIR Neutron Velocity Selector System(s)

Statement of Work

Author(s):

Bill McHargue

Date Published:

April 2026

Prepared by

OAK RIDGE NATIONAL LABORATORY

Oak Ridge, TN 37831-6283 managed by

UT-BATTELLE, LLC

for the

US DEPARTMENT OF ENERGY

under contract DE-AC05-00OR22725

This report was prepared as an account of work sponsored by an agency of the United States Government. Neither the United States Government nor any agency thereof, nor any of their employees, makes any warranty, express or implied, or assumes any legal liability or responsibility for the accuracy, completeness, or usefulness of any information, apparatus, product, or process disclosed, or represents that its use would not infringe privately owned rights. Reference herein to any specific commercial product, process, or service by trade name, trademark, manufacturer, or otherwise, does not necessarily constitute or imply its endorsement, recommendation, or favoring by the United States Government or any agency thereof. The views and opinions of authors expressed herein do not necessarily state or reflect those of the United States Government or any agency thereof.

ii

CONTENTS

1. APPROVALS

2. INTRODUCTION

3. SCOPE OF WORK

4. TECHNICAL REQUIREMENTS

4.1 General Requirements

4.1.1 External Environment

4.1.2 Internal Environment

4.1.3 Velocity selector Orientation

4.1.4 Operating Speeds

4.1.5 Resonances and Vibrations

4.1.6 Reliability

4.1.7 Serviceability

4.2 Drive System

4.2.1 Motor System

4.2.2 Control System

4.3 Rotor Components

4.3.1 General Requirements

4.3.2 Rotor Design

4.3.3 Rotor Information

4.3.4 Lamellae and Neutron Absorber

4.4 Housing and Support Structure

4.4.1 Velocity selector Housing

4.4.2 Structural and Mechanical Lifting Devices

4.4.3 Service Connections

4.4.4 Structural Analysis

4.4.5 Thermal Analysis

4.5 Installation

4.6 Maintenance

4.6.1 Recommended Maintenance Schedule

4.6.2 Spare Parts Listing

4.6.3 Drawings, Schematics, and Procedures

4.6.4 Special Tooling

4.6.5 Training

4.7 Coatings and Marking

4.7.1 Painting

4.7.2 Stainless Steel

4.7.3 Aluminum

4.7.4 Marking

5. PRELIMINARY DESIGN REVIEW

6. FINAL DESIGN REVIEW

7. FACTORY ACCEPTANCE TESTING

7.1 Factory Acceptance Testing Constraints

7.2 Factory Acceptance Testing – Phase I

7.2.1 Long-Term Testing

7.2.2 Vacuum Pump-Out Time

7.3 Factory Acceptance Testing – Phase II

7.3.1 System Fault Testing

7.3.2 Acceleration and Deceleration Tests

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7.3.3 Speed Accuracy Testing and Vibration Levels

7.3.4 Remote Control Testing

8. DIMENSIONAL INSPECTION

9. COMPANY ACCEPTANCE

10. PACKAGING AND SHIPPING

10.1 Packaging and Shipping Plan

10.1.1 Scope of Plan

10.1.2 Corrosion Protection

10.1.3 Packaging Labels

10.1.4 Shipping Container Design

10.1.5 Crate Handling Design

10.2 Partial Shipment

10.3 Shipping Inspection

10.4 Shipping Notification

10.5 Deviations from Shipping Plan

10.6 Shipping Address and Details

11. QUALITY ASSURANCE

11.1 Quality Assurance Program

11.1.1 QA Plan Application

11.1.2 Testing, Inspections, and Examinations

11.1.3 Company Witness

11.1.4 Access for Source Surveillance Inspections

11.1.5 Calibration Program

11.2 Manufacturing Plan

11.3 Reporting

11.4 Control of Nonconformances

11.4.1 Warranty Provisions

11.4.2 Acceptance Limitations

11.5 Deviations

11.5.1 Deviation Request Document

11.6 Examination, Testing, and Inspection

11.6.1 Examination, Testing, and Inspection Report Content

11.7 Documentation

11.7.1 Document Language

11.7.2 Document Format

11.7.3 Drawings

11.7.4 Certificate of Compliance

11.7.5 Contract Submittals and Deliverables

11.7.6 Operation Manual

11.8 Submittals

12. REFERENCES

12.1 American National Standards Institute (ANSI)

12.2 American Society of Mechanical Engineers (ASME)

12.3 American Society for Testing and Materials (ASTM)

12.4 American Welding Society (AWS)

12.5 International Electromechanical Commission (IEC)

12.6 Institute of Electrical and Electronics Engineers (IEEE)

12.7 International Organization for Standardization (ISO)

12.8 Military Specifications

12.9 National Fire Protection Association (NFPA)

12.10 Occupational Safety and Health Standards (OSHA)

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APPENDIX A : RADIATION HARDNESS

A.1 Issues Concerning Equipment in Radiation Areas A.2 Motors in Radiation Environments A.3 Sensors and Control Systems A.4 Activation Specification

1. APPROVALS

Rev 00 Rev 01 Rev 02 Rev 03

Approvals Neutron Scattering Division

LV3 Scientist LV3 Scientist

Neutron Technologies Division Neutronics Scientist Instrument Development and Neutronics Group Lead

Neutron Instrument Technologies Section Head

Instrument Engineering Group Lead

Neutron Technologies Engineering Section Head

HBRR Project Controls

HBRR Project Manager HBRR Science Lead

Technical Concurrence

LV3 Engineer LV2 Engineer QA Representative Vacuum Group Lead Electrical Group Lead Instr. Data Acq. & Cont.

Group Lead

Instrument Operations Neutron Chopper/VS SME

Revision Description of Changes

00 Initial Release per NB3-DCN-00-0001 and NB5-DCN-00-0001

10:31 am 21-Apr-2026

FRANZ GALLMEIER | GALLMEIERFZ@ORNL.GOV

10:36 am 21-Apr-2026

LISA DEBEER-SCHMITT | DEBEERSCHMITTLM@ORNL.GOV

10:20 am 21-Apr-2026

IAN TURNBULL | TURNBULLIS@ORNL.GOV

9:46 am 29-Apr-2026

MARK CHAMPION | CHAMPIONMS@ORNL.GOV

3:03 pm 24-Apr-2026

KYLE GRAMMER | GRAMMERKB@ORNL.GOV

5:06 pm 27-Apr-2026

R. AARON HANKS | HANKSRA@ORNL.GOV

5:48 pm 28-Apr-2026

AMY JONES | BLACKA@ORNL.GOV

3:46 pm 27-Apr-2026

MATTHIA D. FRONTZEK | FRONTZEKMD@ORNL.GOV

1:36 pm 23-Apr-2026

WILLIAM MCHARGUE | MCHARGUEWM@ORNL.GOV

8:49 am 30-Sep-2021

JAMES A. KOHL | KOHLJA@ORNL.GOV

8:03 am 28-Apr-2026

DOUG KYLE | KYLEDJ@ORNL.GOV

3:39 pm 28-Apr-2026

JEREMY P. PRICE | PRICEJP@ORNL.GOV

1:20 pm 27-Apr-2026

MARK S. LYTTLE | LYTTLEMS@ORNL.GOV

3:55 pm 29-Apr-2026

JOHN CARRUTH | CARRUTHJW@ORNL.GOV

1:00 pm 30-Apr-2026

SAI VENKATESH PINGALI | PINGALIS@ORNL.GOV

2:24 pm 30-Apr-2026

KLEMEN VODOPIVEC | VODOPIVECK@ORNL.GOV

2. INTRODUCTION

The velocity selector shall be manufactured for use at small-angle neutron scattering instruments at the High Flux Isotope Reactor (HFIR) at the Department of Energy’s Oak Ridge National Laboratory (ORNL) in Oak Ridge, Tennessee, USA.

The General-Purpose Small-Angle Neutron Scattering instrument (GP-SANS) is uniquely suited to provide information into structure in a wide-range of materials across multiple scales of length and time.

The Biological Small-Angle Neutron Scattering (Bio-SANS) instrument provides unique insights into the structure of biological systems across multiple scales of length. This includes the nano- to mesoscale structure and dynamics of functional complexes and hierarchical assemblies within a cell. The scientific challenges span from fundamental mechanistic studies of biomolecular function to complex hierarchical materials and in-cellulo systems.

3. SCOPE OF WORK

This statement of work establishes the requirements for analysis, design, materials of construction, fabrication, assembly, inspection, testing, and delivery of the neutron velocity selector system(s), hereafter referred to as “velocity selector” to the Company. The Company is defined as the purchasing entity, UT-Battelle, LLC in care of Oak Ridge National Laboratory, who is contracting the services of the Seller. The Seller refers to the parties responsible for providing the neutron velocity selector that meets the requirements that are defined herein and other documents that are referred to. It will be the Seller’s responsibility to repair or remake any components which are found to not meet requirements.

The velocity selector includes mechanical components that interact with the neutron beam, as well as the electrical control system required for operation. The Seller shall manufacture, inspect, assemble, balance, helium leak test, package, and ship the velocity selector in accordance with all requirements in this statement of work.

The Company’s quality assurance requirements include but are not limited to: Contract Submittals and Deliverables (CSD’s), vendor oversight, hold points, approved plans, and reporting. These requirements are explained further in sections below.

Any minor part not specifically defined in this statement of work but required for a complete velocity selector, shall be considered included herein, unless specifically excluded. Where the statement of work appears to conflict with the requirements of a reference document, such conflicts shall be brought to the attention of the Seller for resolution before proceeding.

Any exceptions to this statement of work shall be clearly noted as such in the Seller’s proposal documentation. Where exceptions are taken the Seller shall propose alternatives.

4. TECHNICAL REQUIREMENTS

4.1 General Requirements

All material and equipment shall be new. Material or equipment specified by manufacturer model or catalog number on Company supplied drawings, is intended to clearly indicate the minimum standard or quality acceptable.

The Seller shall assure that suspect or counterfeit items are not provided as part of the end item for delivery. Items containing suspect/counterfeit parts will not be accepted. Items shall be new and not reconditioned, refurbished, or repaired. Seller’s procurement, receipt, and/or material control procedures shall incorporate such safeguards as necessary to prevent suspect or counterfeit items use on this project.

4.1.1 External Environment

The velocity selector control electronics shall operate in an industrial environment characterized by the following:

− AC-power available: 120V, 1-phase, 60 Hz or 208V, 1-Phase and 3-phase, 60 Hz or 480V, 3-phase, 60 Hz. Typical utility power fluctuations, line surges, and power transients are expected.

− Temperature: 15-35°C − Relative humidity: 10 to 70%

The velocity selector housing, rotor assembly, motor, bearing components, housing-mounted sensors, and cabling shall operate in an enclosed shielding volume with elevated radiation. Environmental conditions inside the shielding volume are characterized by the following:

− High Radiation:

o The calculated average absorbed radiation dose across the lamellae of the velocity selector is

6.9 x 106 rad/hour (6.9 x 104 Gray/hour). The cumulative dosage over the 3-year maintenance interval is 9.5 x 1010 rad (9.5 x 108 Gray).

o The calculated average absorbed radiation dose across the drive motor of the velocity selector is 1.6 x 103 rad/hour (16 Gray/hour). The cumulative dosage over the 3-year maintenance interval is 2.2 x 107 rad (2.2 x 105 Gray). Additional information is provided in Appendix A.

o The calculated average absorbed radiation dose across the bearings and grease of the velocity selector is 910 rad/hour (9 Gray/hour). The cumulative dosage over the 3-year maintenance interval is 1.3 x 107 rad (1.3 x 105 Gray).

o The calculated average absorbed radiation dose across the sensors of the velocity selector is 400 rad/hour (4 Gray/hour). The cumulative dosage over the 3-year maintenance interval is

5.5 x 106 rad (5.5 x 104 Gray).

o With the calculated average absorbed radiation doses listed, no active electronic equipment can be installed at the velocity selector, or within four meters of the velocity selector. All active electronic equipment requires a cable or hose of four meters in length, minimum, between the equipment and the velocity selector due to routing through the radiation shielding and a minimally sized utility passage. Any gauges, valve controls, position sensors, or signal distribution boxes within four meters of the velocity selector shall be passive.

− Temperature: 20-50°C − Relative humidity: 10 to 70%

4.1.2 Internal Environment

The internal environment in the neutron beam region of the velocity selector shall be a vacuum. The rotor assembly and bearings shall be designed to operate at a pressure less than or equal to three mTorr, with no lower pressure limit.

All vacuum connections shall be made via welding, O-ring seal, standard quick release vacuum flange, or vacuum CF flange.

All machined sealing surfaces and O-ring groves shall have a 16 micro-inch or 0.4 micrometer surface finish or better.

With the calculated radiation levels listed in Section 4.1.1, the vacuum pump associated with the velocity selector will be mounted at a location away from the velocity selector that requires four meters of 25 mm inside diameter piping, through shielding, between the vacuum pump and the velocity selector.

Associated piping and vacuum pump are the responsibility of the Company.

This velocity selector shall be designed to operate with an internal vacuum. However, it is expected that the Company will backfill the velocity selector during downtimes and maintenance activities therefore, the system design shall accommodate backfilling per Section 4.1.2.1. The pressure differential requirements do not require it to be Code Symbol stamped or certified per the American Society of Mechanical Engineers (ASME) Boiler and Pressure Vessel Code (BPVC), however federal regulations (10 CFR 851) specifically identify vacuum Vessels as “pressure systems” and require that “pressure systems are designed, fabricated, tested, inspected, maintained, repaired, and operated by trained and qualified personnel in accordance with applicable and sound engineering principles.” In keeping with this requirement, the Company stipulates the manufacturing design, fabrication, and inspection be accomplished in accordance with the requirements of the latest edition and addenda of the ASME BPVC, Section VIII, Division 1 to the greatest extent practical.

4.1.2.1 Housing Venting

Seller shall specify in writing the procedure required for venting the velocity selector housing to atmospheric pressure.

The Company requires the option to backfill the velocity selector housing with dry gas. The Company shall provide pressure relief on the backfill system to ensure the velocity selector will not experience a maximum backfill pressure greater than positive seven psi.

The Seller shall certify that the velocity selector housing is rated for a pressure range from full vacuum to the maximum backfill pressure. The neutron beam windows shall meet this requirement and those listed in Section 4.4.3.5. The Seller shall provide the housing volume in the proposal and final design documentation.

4.1.2.2 Helium Leak Testing

The velocity selector completed assembly shall be leak tested by helium mass spectrometer leak testing techniques in accordance with ASME BPVS, Section V, Article 10, Appendix 9 (or a Company approved alternative method). The completed assembly includes all parts assembled and sensors installed that define the vacuum envelope. The evacuated assembly must achieve and maintain a leak rate equal to or less than 1.0 x 10⁻⁸ std. cc/sec or 7.6 x 10⁻⁹ Torr liters/sec for the duration of the test. The helium leak detector shall be calibrated to a National Institute of Standards and Technology (NIST) traceable leak standard and have a minimum detectable leak rate of 1 x 10⁻⁹ std. cc/sec or better.

The Vessel shall satisfy the requirements for leak tightness as specified in ASME BPVS, Section 5.10.4.

If leaks are found they must be repaired and the tests must be repeated until the requirements of ASME BPVS, Section 5.10.4, are satisfied. The testing shall be successfully completed prior to shipping.

Detectable leaks shall be reworked or repaired by the Seller at their expense. Any components which require rework or repair to pass the leak test shall be brought to the attention of the Company prior to re-machining.

The Seller is required to provide proof of vacuum leak test results prior to shipping the velocity selector to the Company. A printout from the vacuum test equipment in English is acceptable or a certified leak test report shall be generated.

− A vacuum equipment printout shall include the date, a plot of the leak test or highest background reading during testing, velocity selector number, and appropriate signature(s) by the Seller certifying that the enclosure passed the specified leak test, based upon criteria from this statement of work.

− A generated report shall include the completed and approved alternative test procedure if required, leak test date, highest background reading during testing, velocity selector number, and appropriate signature(s) by the Seller certifying that the enclosure passed the specified leak test, based upon criteria from this statement of work.

Either test shall be signed off by the Company’s representative witnessing the test, if present. If a Company’s representative is not present, this shall be indicated.

4.1.3 Velocity selector Orientation

The velocity selector shall be mounted and operated with its axis of rotation oriented within ±10° of a horizontal plane.

4.1.4 Operating Speeds

The rotor assembly, motor, and bearings of the velocity selector shall be designed to operate continuously at any speed from 1,600 RPM to the maximum operating speed in one RPM increments. If there are any resonances of the velocity selector within this operating range, these resonance speeds shall be clearly defined.

4.1.5 Resonances and Vibrations

Refer to Section 4.1.4 for defining resonances within the operating speed range.

There shall be no resonances in the velocity selector within the required operating wavelength range(s).

Refer to equipment specifications NB3-EQ-30-0001 and NB5-EQ-30-0001 for the neutronic requirements of the velocity selector rotor(s).

The velocity selector design shall minimize vibration and its subsequent transmission to nearby equipment.

4.1.6 Reliability

The reliability of the entire velocity selector including the rotor assembly, bearings, drive motor, and drive motor control system shall be such that it can operate continuously at the maximum operating speed, for at least three years between maintenance periods, based on a usage of 4,600 hours per year.

The Seller shall provide a listing of components subject to performance degradation due to wear, radiation, or other factors along with mean times between failures for the components.

The velocity selector shall be designed for a minimum operating lifetime of twenty (20) years.

4.1.7 Serviceability

Ease of servicing the velocity selector shall be a design objective.

4.2 Drive System

4.2.1 Motor System

The motor system consists of the drive motor, power supply, and controller; any associated diagnostics and/or instrumentation; and all interconnecting cables.

4.2.1.1 Speed and Acceleration

The motor system of the velocity selector shall be designed to operate continuously at any speed from 1,600 RPM to the maximum operating speed in one RPM increments.

The motor system shall control speed variations of the velocity selector to 0.2% or less at all speeds within this range.

The maximum time allowable to accelerate from zero RPM to the maximum operating speed shall be 15 minutes.

The maximum time allowable to decelerate from the maximum operating speed to zero RPM shall be 15 minutes.

The motor controller shall provide a local digital read-out of the operating speed.

4.2.2 Control System

4.2.2.1 General Requirements

To maintain interchangeability and the potential for future spares, the velocity selector control system shall be compatible with the NVS076 velocity selector control systems that the Seller produced.

The system shall be controllable by a speed request. The controller shall then calculate and display the corresponding wavelength request. The system shall also be controllable by a wavelength request. The controller shall then calculate and display the corresponding speed request.

The velocity selector shall be controllable in two modes selectable by a local hardware switch:

− Local control via a human-machine interface (HMI) and/or local computer via a Graphical User

Interface (GUI) − Remote control via serial communication (RS232 or RS485) or TCP/IP Ethernet with an ASCII-based protocol

4.2.2.2 Local Control

The following shall be included as part of the local control system baseline design and delivered with the velocity selector.

While in local mode, the control system shall respond to remote status requests but shall not respond to any remote request that changes the system configuration, except for any emergency stop requests.

Local controller functions and display shall include:

− Start / Stop control − Speed requested and actual speed display − At requested speed indication

− Neutron wavelength requested and actual wavelength display − Vacuum level in mTorr − Status indication and set-point value of vacuum interlock − Water temperature in °F before returning to water chiller − Status indication and set-point value of water temperature interlock − Water flow rate in liters/minute − Status indication and set-point value of water flow rate interlock − Rotor temperature in °F − Status indication and set-point value of rotor temperature interlock − Bearing vibration level in mm/second − Status indication and set-point value of bearing vibration interlock − Setting all interlock set-points − Setting all alarm limits − Fault identification and reset − Emergency stop control

There shall be a front panel mounted, red, emergency stop push-button control that is latched. The emergency stop push-button shall always be operable and never disabled. The emergency stop push-button shall stop the rotor assembly from spinning as quickly and safely as possible, without creating additional hazards. The emergency stop push-button shall require manual unlatching prior to allowing any restart. The emergency stop push-button shall also conform to the following standards:

− International Electromechanical Commission (IEC) 60947-5-5 − International Organization for Standardization (ISO) 13850 − Occupational Safety and Health Standards (OSHA) 29 CFR 1910.144

If motor parameters are changed dynamically for different speeds, local control and readout of all motor parameters needed to configure and run the velocity selector at all speeds shall be available.

To assist with maintenance schedules, the drive system shall indicate and record hours of operation while spinning.

The Seller shall provide the fully documented local interface protocols, with examples, to the Drive Control Unit via CAN-Bus and to the Monitoring System via Ethernet.

The Seller shall provide copies of the local control program with source-code.

4.2.2.3 Remote-Control

While in remote mode, the control system shall display the velocity selector status on the local controller display but shall not respond to any local request that changes the system configuration, except for any emergency stop requests.

Remote control shall provide the remote computer with the following:

− Start / Stop control − Speed requested and actual speed display − At requested speed indication − Neutron wavelength requested and actual wavelength display − Vacuum level in mTorr − Status indication and set-point value of vacuum interlock − Water temperature in °F before returning to water chiller − Status indication and set-point value of water temperature interlock

− Water flow rate in liters/minute − Status indication and set-point value of water flow rate interlock − Rotor temperature in °F − Status indication and set-point value of rotor temperature interlock − Bearing vibration level in mm/second − Status indication and set-point value of bearing vibration interlock − System health status − Setting all interlock set-points − Setting all alarm limits − Fault identification and reset − Emergency stop control

The remote emergency stop command shall always be followed, and never ignored or disabled. The emergency stop command shall take precedence over any other actions the controller is completing and shall be acted upon immediately. The remote emergency stop command shall stop the rotor assembly from spinning as quickly and safely as possible, without creating additional hazards. Once received, the emergency stop command shall remain active until an emergency stop all-clear command is received.

After receiving an emergency stop all-clear command, the system shall remain in its current state, until another remote request is received.

4.2.2.4 Communication Requirements

− Fundamental access to the Remote Interface Protocol shall be provided via a vendor-supplied computer system, as included and embedded within the velocity selector control system.

o Any vendor-supplied computer system shall run an appropriately supported operating system, e.g. the latest version of Microsoft® Windows®.

o Administrative login access will be provided to the Company for this vendor-supplied computer system, to enable the Company to fully patch the software on the computer to ensure continued system compatibility and maintainability over time.

− remote interface protocol shall be provided and fully documented, with examples.

− The Seller shall not use closed, undocumented, or proprietary protocols. The Seller shall fully document how third-party software can gain access to all the parameters that exist in the control software, with examples.

− ASCII based command/response with single character line terminator (\r or \n) shall be used.

− Should not use binary protocol; if binary protocol is used, Linux-compatible source code or example code shall be provided.

− If a checksum is required, CRC8, XOR each byte, or other standard checksum shall be available.

− Device shall not send out unsolicited information.

− Device shall not use non-standard line terminators.

− Encoding multiple parameters into single commands shall be minimized. Maximum number of parameters encoded into a single command shall be four.

− Command echo may be used, but if used, it shall echo back the entire command, not each character.

− Shall not use GPIB communications.

− Shall not use USB for communications.

− Shall not use PCI cards for communications.

− Shall not require Microsoft® Windows®-only drivers or libraries.

− ModBUS over serial or TCP/IP may be used but is not preferred.

− For Serial Communication:

o RS232/485 shall be used in a star topology. Daisy chain topology shall not be used.

o Baud rate shall be at least 9600.

o Shall not use software or hardware flow control.

o Shall use standard 9-pin D-sub connector.

o Default operation shall be configured for two stop bits, eight data bits, and no parity bit.

o Data shall be sent in the “Little Endian” format.

− For Ethernet Communication:

o Shall use TCP/IP with ASCII based protocol (e.g., LXI) o Shall be able to reset to the default IP address.

o Shall allow a net mask and gateway address setting.

o Shall allow setting static IP address manually and allow setting by DHCP o Shall respond to ICMP ping.

o Shall be tolerant of broadcast traffic on subnet.

o Shall use standard RJ45 connector.

o Shall not use ethernet interfaces listening on multiple port numbers.

− If system uses UDP protocol for server discovery, then:

o System shall provide the ability to modify or disable the UDP capabilities of the device to maintain stable operation.

o System software shall continue to function without the UDP protocol enabled.

If motor parameters are changed dynamically for different speeds, remote computer control and readout of all motor parameters needed to configure and run the velocity selector at all speeds shall be available.

Specific communications hardware for development and verification testing is to be coordinated with the Company.

To resolve high latency, polling-based designs, asynchronously returned data, and 3-5 Hz monitoring rate issues without requiring a redesign of Microsoft® Windows®-based control software, a parallel monitoring approach using Beckhoff PLC's native ADS (Automation Device Specification) interface shall be utilized.

− Implementation: The vendor's Microsoft® Windows® software continues to handle high-level control (Accelerate, Brake, etc.) via the existing interface.

− Performance: Beckhoff PLC's native ADS interface allows for deterministic monitoring with cycle times typically under 10 ms.

− Reliability: This approach provides full data visibility and sustainable control integration that aligns with ORNL standards.

− No XML Parsing: Beckhoff PLC's native ADS interface allows EPICS to map directly to PLC variables, removing the need for slow XML processing and TCP polling.

At a minimum, the following parameters shall be exposed as PLC readable variables for direct ADS mapping:

− Primary Metrics:

o Actual Wavelength o Actual Speed o Operating at Synchronous Speed o Motor Current

− System parameters:

o Vacuum level o Water flow rate o Vibration level o Rotor temperature o Water temperature (both in/out) o Goniometer actual position and stage parameters o In-speed o At target speed

4.2.2.5 Start-Up Procedure

On initiating the start command, the motor controller shall spin up the rotor assembly automatically to the preset operating speed in accordance with Sections 4.2.1.1, 4.2.2.2, and 4.2.2.3.

4.2.2.6 Shut-Down Procedure

Once given the command to stop, the motor controller shall spin down the rotor assembly automatically to full-stop condition in accordance with Sections 4.2.1.1, 4.2.2.2, and 4.2.2.3.

4.2.2.7 Safety Interlocks

Interlocks shall be provided, subject to Company approval, that cause the control system to stop the rotor assembly as quickly as possible while remaining in accordance with Sections 4.2.1.1, 4.2.2.2, and 4.2.2.3.. At a minimum, the following fault conditions shall be included:

− Rotor temperature − Vibration level − Vacuum level − Coolant flow − Coolant temperature − External stop signal (Company-supplied signal)

Sufficient interlock inputs shall be incorporated into the system to prevent start-up under conditions such as insufficient vacuum, no cooling, etc.

A simple interlock override feature shall be provided for diagnostic/troubleshooting purposes.

All interlocks shall be user adjustable.

4.2.2.8 Controller Interchange and Mounting

The controller components shall be designed for interchangeability with repaired or replacement hardware in the event of a component failure. Replacement of the controller components shall not require re-tuning of the control system. One example of an acceptable solution is by employing downloadable configurations to the control system.

All control, diagnostic, and power supply component hardware shall be installed in chassis suitable for installation in a standard 19" panel-width electronic equipment rack.

All chassis shall be supplied with a ¼-20 UNC grounding stud installed externally on the back of the chassis. This grounding stud will be used for grounding the chassis to the building safety ground via the rack ground.

All power cords and power strips shall be supplied with NEMA (National Electrical Manufacturers Association) North American standard type connectors without the use of adaptors.

4.2.2.9 Interconnecting Cabling

Power and signal cables between the velocity selector and its control system shall be up to 20 meters long. The actual lengths will be specified at the time of Final Design Review. Any cable length limitations that prevent the 20-meter total length shall be identified in the quotation.

All cables shall be terminated with internationally available commercial connectors incorporating industrial quality strain relief.

All electrical wiring associated with the velocity selector (or the goniometer) shall have an electrical connector mounted on or within 10 cm of the velocity selector vacuum housing. Long cables mounted to the velocity selector or a requirement of breaking the vacuum environment before moving the velocity selector to a maintenance area is not acceptable.

ALL cables shall go through the Seller velocity selector junction box or have a set of in-line connectors at this distance so that all cables entering the high radiation environment are the same length.

For reasons of interchangeability and the potential for future spares, consistency of cable connectors between multiple systems is required. All connections shall be interchangeable with connectors delivered on the NVS076 system.

All cables shall be suitably shielded to avoid interference from external sources or causing interference in other systems.

All cables shall be labeled at both ends with descriptors that correspond to those labeled on the components to be connected. Cable labeling to provide information as follows:

− Identification as neutron velocity selector cabling, i.e., NVS − Function, i.e., control, drive, signal, etc.

− Connected to, i.e., neutron velocity selector, motor power, sensors, etc.

− Schematic ID number.

4.2.2.10 Electrical Code Compliance

The drive system shall be designed and manufactured to conform to applicable national electrical standards and codes for industry. Equipment shall be reviewed at the Company, prior to final acceptance, in accordance with the requirements of the following standards:

− IEC 60204-1

− National Fire Protection Association (NFPA) 70E

− NFPA 79

− National Recognized Testing Laboratories (NRTL) standards of manufacturing

The grounding and wiring methods along with the panel layout of equipment and wiring shall be evaluated for minimizing the impact of noise according to chapter 10 of Institute of Electrical and Electronics Engineers (IEEE) 1100.

All external connections shall be “finger safe”. “Finger safe” is defined in IEC 529 IP20 as any solid foreign object 12.5 mm or larger must not be able to access or contact any hazardous energized part.

Hazardous parts are considered any voltage >50 volts. All electrical leads and exposed connections shall be covered during normal operations to eliminate risk of shock or spark.

The Seller shall submit a list of electrical standards followed during design and manufacturing of the velocity selector.

4.3 Rotor Components

4.3.1 General Requirements

The rotor assemblies delivered in accordance with this statement of work will likely be unique assemblies and shall be specific to the neutronic requirements listed in the NB3-EQ-30-0001 and NB5-EQ-30-0001 equipment specifications.

4.3.2 Rotor Design

The rotor assembly shall be designed to minimize mechanical stress during operation. The maximum stress in the rotor assembly at the maximum operating speed shall be less than the fatigue strength of the material. See Section 4.4.4 for structural analysis requirements.

4.3.3 Rotor Information

The rotor assembly consists of neutron absorbing material, lamellae, their connection to the high-strength aluminum rotor, bearings, and motor.

4.3.4 Lamellae and Neutron Absorber

The rotor lamellae, which carry a neutron absorbing material, shall be fabricated from a carbon fiber composite. The neutron absorbing material shall have an absorption cross section that increases linearly with neutron wavelength (1/v absorber) over the range of λ=0.1-20 Ǻ. The effective thickness of the neutron absorbing material shall be a minimum of 15 µm on each side of the lamella.

A lamella coupon coated with the neutron absorbing material shall be submitted to the Company prior to acceptance testing. The coupon material shall be identical in material and thickness to the lamellae and neutron absorber installed in the velocity selector. The coupon shall be no smaller than 60 x 75 mm. The Company may verify the coupon performance with neutron radiography prior to final acceptance.

4.3.4.1 Rotor Neutronic Requirements

Refer to equipment specifications NB3-EQ-30-0001 and NB5-EQ-30-0001 for the neutronic requirements of the velocity selector rotor(s).

4.3.4.2 Dynamic Balancing

To control vibration and unbalance, the rotating assembly (rotor assembly and all rotating masses) shall be dynamically balanced to a balance grade of G0.4, prior to factory acceptance testing in Section 7, per the following standards:

− ISO 1940-1, Mechanical Vibration – Balance Quality Requirements for Rotors in a Constant (Rigid) State.

− American National Standards Institute (ANSI) S2.19, Mechanical Vibration - Balance Quality Requirements of Rigid Rotors - Part 1, Determination of Permissible Residual Unbalance.

Once the rotating assembly has undergone final balancing, no modifications shall be made to this assembly (removing/installing parts, adjusting set screws, tampering with balance weights, etc.).

All equipment and any necessary test fixtures required to meet this requirement are the responsibility of the Seller to provide and shall be included in the cost proposal. Any test fixtures which are paid for by the Company become the property of the Company at the end of the contract and shall be delivered with the velocity selector assembly.

The housing end-flange shall incorporate a blank vacuum-flange covering a speed-sensor port used for trim balancing the rotor following bearing maintenance.

The Seller shall specify the proposed method of balancing the rotating assembly in the offer data submitted to the Company with the proposal. Company approval shall be obtained before balancing begins. The Company retains the right to witness the balancing and verify that the balance procedure was completed with satisfactory results. Notification of such balancing shall be made to the Company at least fifty (50) working days in advance to permit Company observation.

A report of the dynamic balancing test results shall be submitted as certified data prior to shipping the velocity selector to the Company.

4.4 Housing and Support Structure

4.4.1 Velocity selector Housing

4.4.1.1 General Requirements

The velocity selector housing delivered in accordance with this statement of work shall conform to the Seller’s standard housing dimensions that accommodate the unique rotor assembly mentioned above.

4.4.1.2 Configuration

The housing shall be designed and fabricated in three sections, a cylindrical housing with a cylindrical bore and two flat end plates.

The maximum radial gap between the rotor assembly outer edge and the housing bore shall be 12 mm.

To fit in the allowable space without compromising the capabilities of the instrument and to minimize losses by divergence of the neutron beam, the overall length of the velocity selector shall be minimized.

The maximum allowable housing length is 310 mm. All mounting features used to mount the velocity selector in place shall also be within the maximum housing length of 310 mm. Both the close proximity of the shielding and the mounting configuration restrict the overall width of the velocity selector to 450 mm (including any equipment or sensors mounted to the side of the housing). Height from the velocity selector mounting surface to the center of the neutron beam windows (vertically) shall be 230 mm or less.

Overall height of the velocity selector assembly shall be less than 500 mm.

In the final installed configuration, the velocity selector will be mounted to a Company designed translation stage. When stopped, the velocity selector shall be capable of being translated out of the neutron beam horizontally 150 mm to facilitate operational modes that do not require use of the velocity selector or in the event of any malfunction of the velocity selector.

4.4.1.3 Physical Compactness

The housing shall be physically compact in nature and uncluttered with features that would complicate installation in the closely shielded chamber.

4.4.2 Structural and Mechanical Lifting Devices

4.4.2.1 Design or Fabrication

Structural and mechanical lifting devices shall be designed and fabricated according to provisions of ASME BTH-1-2017 and the safety requirements addressed in ASME B30.20.

4.4.2.2 Marking

The rated capacity of each lifting device shall be marked on the main structure where it is visible and legible. If the lifting device comprises several items, each detachable from the assembly, each lifting device shall be marked with its rated capacity. At a minimum, a nameplate, name tag, or other permanent marker shall be affixed displaying the following data:

− Manufacturer’s name (contractor’s name if fabricated onsite) − Serial Number (if applicable) − Rated Capacity

Any re-rated lifting device shall be relabeled with the new rated capacity.

Cases may exist where a lifting device cannot be marked with its rated capacity and weight. In these cases, the lifting device shall be marked with an identification number, and its documentation shall describe both its rated capacity and weight.

4.4.2.3 Rated Load Test

All lifting devices shall be tested and inspected before use. The results of the test and inspection shall be documented in the equipment history file and provided to the Company.

The rated capacity shall not be more than 80% of the maximum load sustained during the test. Test loads shall not be more than 125% of the rated capacity unless otherwise recommended by the manufacturer.

The Rated load test shall consist of the following:

− Hoist the test load a sufficient distance to ensure that it is supported by the lifting device or apply the required load if the test is made using a testing machine. Personnel shall remain clear of suspended loads.

− Visually inspect the lifting device for deformation, cracks, or other defects after the load test is completed.

4.4.3 Service Connections

The Seller shall provide connections to services required for the operation of the velocity selector.

Services to the velocity selector include:

− Motor power and control − Interlock sensors − Vacuum − Cooling water

The connections shall be highly reliable and uncomplicated to connect or disconnect. Radiation tolerance shall be an important consideration. All interconnections at the velocity selector shall be made of hard tubing or flexible stainless-steel hoses for radiation tolerance concerns.

Connections shall be vacuum leak tight per Section 4.1.2.2 and be located to minimize radiation exposure in accordance with ISO-2861 parts 1 or 2.

The design and placement of cooling water connections should minimize the likelihood of water leakage onto electrical connections. All water connections shall be made via welding, O-ring seal, or compression fittings.

4.4.3.1 Water Cooling

It is anticipated that the velocity selector will require water cooling to maintain adequate temperature of the bearings, motor, and rotor during operation. The Company will supply water cooling for the velocity selector components while in operation at the Company. The velocity selector shall have a minimum required flow rate of two liters/minute or less. The Seller shall specify velocity selector heat load in watts and water-cooling requirements in the preliminary design review documentation.

4.4.3.2 Pressure Environment

The velocity selector rotor is designed to operate in vacuum. There shall be no hydrocarbon migration into the evacuated space. Dry vacuum pumps shall be employed by the Seller during all testing or any process used to evacuate any part of the velocity selector equipment. The Company will supply a dry vacuum pump for evacuation of the velocity selector while in operation at the Company.

All Seller supplied components of the evacuation path (vacuum connections, piping, valves, etc.) shall have an inside diameter of 25mm minimum, including the vacuum port through the velocity selector housing.

4.4.3.3 Elastomeric Seals

Housing vacuum seals shall have suitable radiation hardness as discussed in Appendix A.

4.4.3.4 Housing Construction

The housing shall be made of aluminum with sufficient strength to safely contain the rotor assembly in the event of a failure while operating at the maximum operating speed and provide an adequate vacuum enclosure.

All welding shall be in accordance with the applicable procedures of the American Welding Society Structural Welding Code, American Welding Society (AWS) D1.2 or Company approved international equivalent.

The velocity selector-Company mounting hole location tolerance relative to neutron beam window positions shall not exceed ±0.5 mm in any direction.

4.4.3.5 Neutron Beam Windows

The neutron beam windows shall be thin to maximize neutron transmission while being consistent with standard vacuum practice and operating safety requirements.

The neutron beam windows shall be installed in the housing outer faces with fasteners and elastomeric vacuum seals, having suitable radiation hardness as discussed in Appendix A, that are specific to mounting of the neutron beam windows and no other task. The neutron beam windows shall be removable to allow installation of shipping windows, maintenance windows, and replacement with neutron beam windows of different neutronic design.

The neutron beam windows shall be a non-anodized aluminum alloy. The neutron beam windows shall not be 2000 series aluminum alloys because of the high copper content. The activation of the copper due to the high radiation levels listed in Section 4.1.1, will require several days to decay to negligible levels.

The Company recommends a 6000 series aluminum, where aluminum and the small additive components decay quickly enough to permit access within a few hours.

Neutron beam window design and alloy shall be approved by the Company during the preliminary design review prior to purchasing material.

4.4.4 Structural Analysis

The Seller shall provide a documented report of analysis results. This report shall include at a minimum stress, deflection, containment, and modal results for all critical components including the fasteners, housing, and rotor components. Computer finite element analysis (FEA) is strongly recommended, but not specifically required, in addition to traditionally accepted methods of analysis. These calculations shall be approved by the Company prior to starting fabrication.

These analyses shall be completed at maximum stress or maximum load which is typically encountered when operating at maximum speed. Note:

− Calculations from previously delivered velocity selectors may not be applicable because they may have a lower maximum operating speed than the velocity selectors associated with this statement of work.

− Completed calculations of the highest operating speed velocity selector from this quotation or previous calculations can be copied into the documentation without redoing the calculations from scratch, if they are applicable.

− Calculations for each velocity selector in the quotation shall be listed as separate, unique line items in the quotation.

The following components or assemblies shall be analyzed to determine adequate strength and dimensional stability as applicable:

− Drive system − Rotor assembly − Housing assembly and penetrations − Neutron beam windows − Mounting plate and fasteners

The housing shall also be subjected to a containment analysis. Containment involves the analysis of a minimum of two conditions, piercing and bursting. These analyses shall be conducted on a zero-energy dissipation basis, where all the energy is delivered to the wall of the housing.

4.4.4.1 Piercing Analysis

Piercing involves a localized failure due to compressive and shearing stresses at the point of impact. For piercing, a single element is considered. Assume the largest single component or part from the rotor assembly is launched at the maximum operating speed. The structure shall be sufficient to control piercing by the largest kinetic energy single element of the rotor assembly, at the maximum operating speed.

The neutron beam windows are not expected to contain a piercing event.

4.4.4.2 Bursting Analysis

Bursting is the almost instantaneous destruction of the rotor. The rotor separates into many smaller fragments that travel radially towards the housing with equal velocities. The failure mode in this analysis is due to tensile stress in the housing shell created by the high-speed fragments. The analysis shall assume that the total kinetic energy is applied. The structure shall be sufficient to control bursting by the almost instantaneous destruction of the rotor, at the maximum operating speed.

The neutron beam windows are not expected to contain a bursting event.

4.4.4.3 Neutron Beam Window Analysis

The neutron beam windows shall be analyzed and meet the requirements for ORNL pressure safety for thin neutron beam windows by providing a minimum factor of safety of two on yield strength OR provide a cycle rating for the neutron beam windows, so they may be placed on a replacement schedule.

Replacement schedule may not be less than three years assuming a minimum of 15 vacuum/backfill cycles per year, reference Section 4.1.2.1 for backfill requirements.

All vacuum/backfill analysis of the neutron beam windows shall consist of cycling of neutron beam window pressure from the pressure level equal-to or less-than the velocity selector operating pressure interlock value, directly to the maximum backfill positive pressure referenced in Section 4.1.2.1 for backfill requirements, directly back to the pressure level equal-to or less-than the velocity selector operating pressure interlock value. Partial cycling between pressures is not considered consistent with stresses seen while cycling from normal operation to maintenance operation.

4.4.5 Thermal Analysis

Critical components of the velocity selector assembly shall be subjected to a detailed thermal analysis to ensure adequate heat rejection to the cooling system. Computer finite element analysis (FEA) is strongly recommended but not specifically required in addition to traditionally accepted methods of analysis. The Seller shall provide a documented report of the thermal analysis results.

4.5 Installation

The velocity selector will be installed at the instrument mounted to a carriage mounting plate directly above a horizontal translation stage. The translation stage is needed for operational modes that do not require use of the velocity selector, or in the event of any malfunction that prevents operation of the velocity selector. The Company designed translation stage will move the fully stopped velocity selector horizontally, completely out of the path of the neutron beam.

All mounting features of the velocity selector shall be directly underneath the housing and within the housing dimension constraints listed in Section 4.4.1.2.

To reduce vibrations to surrounding equipment the velocity selector shall be delivered with vibration isolation components. The vibration isolation components shall be directly underneath the housing and within the housing dimensions listed in Section 4.4.1.2.