TABLE OF CONTENTS. 1.0 INTRODUCTION Page SCOPE Page REFERENCES Page REQUIREMENTS Page QUALITY ASSURANCE Page 8

Size: px
Start display at page:

Download "TABLE OF CONTENTS. 1.0 INTRODUCTION Page SCOPE Page REFERENCES Page REQUIREMENTS Page QUALITY ASSURANCE Page 8"

Transcription

1

2 TABLE OF CONTENTS 1.0 INTRODUCTION Page SCOPE Page REFERENCES Page REQUIREMENTS Page QUALITY ASSURANCE Page SUBMITTALS Page PREPARATION FOR SHIPMENT Page 10 Page 2 of 10

3 1.0 INTRODUCTION SPECIFICATION CRM S-1006 The Helium Vessels in this specification will house the seven-cell cavity, used to accelerate the electron beam, in a liquid helium bath at a temperature of two degrees Kelvin. This operating temperature makes the cavity superconducting which facilitates the acceleration of a continuous wave electron beam. 2.0 SCOPE 2.1 PURPOSE This Statement of Work (SOW) describes the requirements necessary to specify, manufacture, and procure sets of components for C100 Cryomodule Helium Vessel Assembly in compliance with the ASME BOILER AND PRESSURE VESSEL CODE SECTION VIII for use in the Jefferson Lab 12GeV cryomodule upgrade. An ASME certificate of authorization is not required. The contractor shall provide all materials necessary to fabricate complete deliverables as stated below with the exception of stated government supplied materials. The contractor shall provide all consumable materials, personnel (labor), engineering and management associated with the fabrication and procurement of the stated deliverables. Even though the design reflects a built-to-print product, additional requirements are imposed on the manufacturer. Additional (aside from fabrication) responsibilities will include: Any in-process manufacturing details such as cut sheets and travelers Sequencing and Parts Control Quality Assurance Any special crating or preparation for shipment 2.2 In this text, and in applicable specifications, references such as vendor, seller, manufacturer, subcontractor, fabricator and the like, mean the same thing. We understand this to be the commercial contractor responsible for making and delivering the Helium Vessel Assembly. Furthermore, CEBAF and JLAB are different names for the same entity. Herein references to older documents that denote CEBAF are still valid and are applicable. 2.3 DELIVERABLES TO JLAB Manufacturer shall offer for acceptance fabricated sets of Helium Vessel Assembly components according to this statement of work, associated drawings, and quality control specifications in this document Completely fabricated and tested sets of components for Helium Vessel Assembly per the list below. One set of required components for assembling a Helium Vessel Assembly consists of all items in the list, with specified quantities. Vendor may also reference the latest revision of Page 3 of 10

4 CRM The JLAB procurement documents describe how many sets of Helium Vessel Assembly components to be fabricated. Item# Drawing # Qty Description 2 CRM Helium Vessel Bellows 4 CRM Helium Vessel Shell Assy 6 CRM Tuner Tab 7 CRM Helium Vessel Head Assy Cold shock procedure required in Section Leak check evidence required in Section All documentation required in Section Quality assurance provisions as stated in Section MANUFACTURER FURNISHED MATERIALS, EQUIPMENT, AND SERVICES Manufacturer shall provide manufacturing engineering services required to generate internal shop drawings and all documentation needed to manage and support their suppliers. This will include all technical and commercial supervision required in order for JLAB to receive an assembly that meets all requirements and specifications Manufacturer shall provide all labor to assemble, test, and supervise the manufacture of all components regarding where these are made: within the manufacturer s plant or in a second facility or sub-contractor There will be no Government Furnished Material (GFM) provided by JLAB. Suggested vendors are supplied on drawings where applicable Manufacturer will provide all facilities, tools, and fixtures necessary to fabricate and test the Helium Vessel Assembly. 3.0 REFERENCES The following baseline drawings, design specifications, and procedures are required technical documents and shall be used by vendor to manufacture and test Helium Vessel Assembly components. No substitutions or deviations from these drawings and specifications may be made without written authorization from the TJNAF procurement representative. 3.1 The latest revision of JLAB Drawing CRM , C100 Cryomodule, Helium Vessel, Helium Vessel Assembly. 3.2 The latest revision of JLAB Drawing CRM , C100 Cryomodule, Helium Vessel, Helium Vessel Head Assy. Page 4 of 10

5 3.3 The latest revision of JLAB Drawing CRM , C100 Cryomodule, Helium Vessel, Helium Vessel Bellows. 3.4 The latest revision of JLAB Drawing CRM , C100 Cryomodule, Helium Vessel, Helium Vessel Shell Assy. 3.5 The latest revision of JLAB Drawing CRM , C100 Cryomodule, Helium Vessel, Tuner Tab. 3.6 CEBAF Specification 11141S0034, Stainless Steel Cleaning and Handling 3.7 CEBAF Specification 11141S0030, GTAW Specification for Stainless Steel 3.8 CEBAF Specification 11141S0029, Vacuum Leak Test Internal Evacuation Small Items 3.9 CEBAF Specification S-001 Rev. B, Fabrication of UHV Equipment 3.10 CEBAF QA Specification Rev A American Society of Mechanical Engineers (ASME) Boiler & Pressure Vessel Code, Section VIII, Division I, Rules for Construction of Pressure Vessels ASTM Standards for materials as called out on the applicable drawings. 4.0 REQUIREMENTS 4.1 MATERIALS The material used in the fabrication of the Helium Vessel Assembly shall conform to the specifications in associated drawings. It is the responsibility of the manufacturer to ensure that ALL material used is traced to the stated specification. 4.2 MANUFACTURING ENGINEERING Manufacturer shall fabricate jigs and simple fixtures to ensure run pipes, pipe fittings, brackets and other important components are maintained to specified tolerances JLAB component parts are detailed to the nominal and assembled material conditions. It is the responsibility of manufacturer to allow for fitting and welding tolerances by adjusting said drawings to their manufacturing style Manufacturer is required to generate shop travelers and sequencing documentation to assemble the Helium Vessel Assembly. 4.3 WELDING The Helium Vessel Assembly welding shall be performed using the Gas- Tungsten-Arc Welding (GTAW) method. Manufacturer shall ensure that no entrapped gases, fluxes, pits, cracks, or like imperfections are left in the Page 5 of 10

6 heat affected zones. All edges shall be rounded and burrs removed from all seams, joints and welded areas All welders shall be qualified to the ASME B & PV Code, Section IX. In addition to the standard ASME procedure qualifications, a qualification sample weld shall be cold shocked at the weld with liquid nitrogen (LN 2 ) and helium leak checked prior to the required ASME tests as stated in BPV code, Section IX, QW-141 Mechanical Tests Post cleaning of welds is required to leave the surface in a bright finish condition with no trace of solvents residue. The manufacturer shall identify the cleaning process used to remove the residue as part of the bid package. Manufacturer's cleaning procedure shall clearly demonstrate that the requirements of Section 4.10 will be met or exceeded. 4.4 DIMENSIONAL CONFORMANCE The JLAB assembly drawings, CRM and CRM , and all drawings referenced shall be used by the manufacturer for configuration control and dimensional conformance. Dimensional variances and overall envelope configuration shall be maintained within specified tolerances. 4.5 COLD SHOCK The completed helium vessel shall be cold shocked with liquid nitrogen after final welding is complete. The testing procedure must be certified by JLAB SOTR in writing prior to being performed in order for results to be accepted as being in compliance with this specification. 4.6 LEAK CHECKING All welded seams shall be vacuum leak checked, after the cold shock test, with a calibrated Mass Spectrometer Leak Detector (MSLD) as described in Section 3.8 above. Manufacturer shall provide recorded evidence in the form of independent reports or line items in the manufacturing travelers that clearly state the date, time, and conditions of these tests. Strip chart recording may be waived by JLAB s Subcontracting Office Technical Representative (SOTR). 4.7 INSPECTION Visual inspection shall show that the Helium Vessel is structurally sound and free of scale, cracks, splits, gaps, inclusion porosity or any defect which could be considered a source of structural failure. Page 6 of 10

7 4.8 DOCUMENTATION A project specific Quality Assurance Plan (QAP), as stated in Section 5.1, must be provided within 4 weeks after contract award. In addition, said plan shall be maintained during the term of the contract Certified mill test reports (CMTR) of all raw materials used to fabricate deliverables shall be provided to JLAB with each delivery. These material certifications shall include all processes and tests with grade and composition being clearly identifiable Copies of all travelers shall be provided to JLAB with each delivery Copies of all inspection and test reports shall be provided to JLAB with each delivery Certifications of all welding personnel and procedures that will perform any welding task on the deliverables shall be in accordance with ASME Boiler & Pressure Vessel Code, Section IX, Welding and Brazing Qualifications. All certificates shall be current and up to date with all applicable standards and codes. Copies of Weld Procedure Specification (WPS), the Procedure Qualification Records (PQR) being used, and the Welder Performance Qualification for the WPS s being used shall be provided to JLAB as part of the bid package Copies of certified qualifications in accordance with ASNT SNT-TC-1A or equivalent for personnel performing visual examination and leak checking NDE of welds shall be provided to JLAB as part of the bid package A production timeline that meets our delivery schedule for fabrication, starting from time of award running through F.O.B. JLAB shall be provided as part of the bid package. Following JLAB s approval of timeline and contract award, it is the responsibility of the contractor to comply with and meet dates specified in approved timeline. 4.9 MARKING AND TRACEABILITY REQUIREMENTS Manufacturer shall inscribe all parts with clear markings (0.25" high characters) such that a visual inspection will provide traceability and fast identification. Assemblies need to be serialized. Serial Numbers and Purchase Order Number shall be marked on shipping box. Identification applies to the smallest mechanically disassembled component. At a minimum, markings shall include identification of the component s source (i.e. contractor/subcontractor), material specification, part number and any other information that will allow for immediate recognition of said components and their source. Page 7 of 10

8 4.10 CLEANLINESS REQUIREMENTS Surfaces shall be cleaned and protected at all stages of fabrication such that dust, oils and other contaminants are removed prior to final assembly and preparation for delivery to JLAB Manufacturer shall follow cleaning and handling procedures prescribed in Section 3.6 above. Manufacturer may propose alternative cleaning methods as part of the bid process The Helium Vessel Assembly shall be cleaned to a bright metal condition by using grit-less abrasive pads, or JLAB approved equivalent. No solvents, waxes, oils, or protective coatings shall be placed (or left) on this surface. This Helium Vessel Assembly will be used in a moderate to high vacuum service. 5.0 QUALITY ASSURANCE 5.1 The Seller shall prepare a project specific Quality Assurance Program for JLAB s approval and shall furnish such documentation as JLAB may require. The Seller shall conduct quality control procedures and tests, which will guarantee that the product to be furnished by the Seller hereunder is in full conformance with these specifications. 5.2 FIRST ARTICLE The first article consists of items/subassemblies for one C100 Cryomodule Helium Vessel Assembly per JLAB drawing CRM Any loose items shall be packaged into a separate kit or box. The FIRST ARTICLE shall be offered to JLAB for inspection at the manufacturer s facility. The FIRST ARTICLE shall be used to demonstrate initial compliance with all stated requirements in particular: form, fit, and dimensional conformance. Advanced notice of two weeks shall be provided to JLAB SOTR for travel arrangements After inspection and acceptance, the FIRST ARTICLE shall be prepared for crating and shipment to JLAB JLAB may choose to perform the FIRST ARTICLE assembly and inspection in Newport News. 5.3 The manufacturer shall maintain records of all inspections and tests. This information shall be made available for inspection to any JLAB technical representative. Page 8 of 10

9 5.4 Acceptance Each shipment of the Helium Vessel Assembly shall be offered to JLAB for inspection at the manufacturer s facility. Advanced notice of two weeks shall be provided to JLAB s technical representative for travel arrangements After inspection, the Helium Vessel Assembly shall be prepared for crating and shipment to JLAB The assemblies will be inspected and tested at JLAB prior to final acceptance JLAB reserves the right to have its technical or procurement representatives witness any or all manufacturing steps, tests, and inspections established under the manufacturers quality assurance program to demonstrate compliance with this specification. Any information of a proprietary nature must be identified in the bid response JLAB representatives shall have unannounced visitation access to the manufacturers plant and personnel during normal operation hours in order to conduct Quality Assurance Audits. 6.0 SUBMITTALS The following table lists all submittals that the Seller shall supply to the Buyer: No. Section(s) Description When required Approval CVI * Cold shock procedure Part of bid package Required Leak checking reports Prior to each delivery Required & 5.1 Project specific QAP Within 4 weeks after contract award Required CMTRs With each delivery - Yes Travelers With each delivery - Yes & 5.3 Inspection/test reports With each delivery Required WPS, PQR, and welder qualification evidences Welds NDE personnel qualification evidences Part of bid package Required - Part of bid package Required Production timeline Part of bid package Required - Page 9 of 10

10 * Certified Vendor Information (CVI). For submittals that require Buyer s approvals, Vendor shall wait for the approval notices to continue fabrication activities. 7.0 PREPARATION FOR SHIPMENT 7.1 The Seller shall ship the specified equipment properly packed, to ensure that damage is not incurred during shipment, in accordance with transportation industry standards. 7.2 Assembly packaging shall be such that no damage is incurred during transit. This shall include weather protection and the closure of all open pipes with test plugs or removable caps. Sizing shall be such that handling is facilitated and weight limitations imposed by the transportation industry can readily be met. 7.3 All deliverables including documentation shall be catalogued and offered for acceptance to JLAB at the time of Helium Vessel Assembly delivery. Documentation must accompany the products such that JLAB receiving personnel clearly understand the contents and can match delivery to a purchase order. Markings shall observe requirements in Any internal component that may be subject to dynamic (road) damage shall be blocked, internally braced or temporarily supported. These shall be easily removed by simple hand tools. 7.5 A packing list of loose items shall be included in any kits required. Page 10 of 10