Technical Specification of a Helium Refrigerator … CTF Equipment...Technical Specification of a . Helium Refrigerator Coldbox ... for the . Cryogenic Testing Facility (CTF) ... ASME

8 Oct 2014

Technical Specification of a

Helium Refrigerator Coldbox (CB-3) for the

Cryogenic Testing Facility (CTF)

THOMAS JEFFERSON NATIONAL ACCELERATOR FACILITY

Specification Number: 72200-S001

Date: 08 October, 2014

Mat Wright Pete Knudsen Lead Operations Engineer Process Engineer

Kelly Dixon Rao Ganni Mech. & Pr. Systems Engineer Principal Staff Engineer

Jonathan Creel Mike Smith Cryogenic Department Head Quality

REV. ECO# DESCRIPTION BY CHK. APP. APP. DATE

SUMMARY OF CHANGES FROM PREVIOUS REVISION:

TABLE OF CONTENTS1. SCOPE ............................................................................................................................................................ 3

1.1 INTRODUCTION ............................................................................................................................... 3 1.2 ACRONYMS ..................................................................................................................................... 3 1.3 HARDWARE & ENGINEERING DELIVERABLES ................................................................................ 3

1.3.1 Proposal stage ....................................................................................................................................... 3 1.3.2 Final Design Review ................................................................................................................................ 4 1.3.3 Hardware and Engineering Deliverables and Schedule After FDR ......................................................... 5

1.4 DOCUMENTATION ........................................................................................................................... 5 1.4.1 Drawing Formats ................................................................................................................................... 6 1.4.2 Drawings, Diagrams, Lists and Procedures ............................................................................................ 6 1.4.3 Electronic Sumittal Exchange Protocool ................................................................................................ 7

1.5 QUALITY ASSURANCE PROGRAM ................................................................................................... 8 1.6 FINAL DESIGN REVIEW ................................................................................................................... 8 1.7 FINAL DOCUMENTATION PACKAGE ............................................................................................... 8 1.8 JLAB FURNISHED ITEMS ................................................................................................................. 9 1.9 ENVIRONMENTAL CONDITIONS ...................................................................................................... 9 1.10 EXCEPTIONS .................................................................................................................................. 10

2. APPLICABLE DOCUMENTS AND CODES ......................................................................................................... 10

3. PERFORMANCE ............................................................................................................................................ 12

3.1 COLD BOX .................................................................................................................................... 12 3.1.1 General ................................................................................................................................................ 13 3.1.2 Cold Box Operation Modes .................................................................................................................. 13 3.1.3 Cold Box Interface ................................................................................................................................ 15 3.1.4 Control and Instrumentation ............................................................................................................... 16 3.1.5 Vacuum Requirements ......................................................................................................................... 16 3.1.6 Requirements for Key Components ...................................................................................................... 17

3.2 SYSTEM MECHANICAL REQUIREMENTS ....................................................................................... 22 3.3 VALVES ......................................................................................................................................... 23 3.4 PROCESS CONTROL AND INSTRUMENTATION ............................................................................... 25

3.4.1 Control Diagram .................................................................................................................................. 25 3.4.2 Instrumentation ................................................................................................................................... 25 3.4.3 Electrical Installation............................................................................................................................ 27 3.4.4 Plant Protection and Alarms ................................................................................................................ 28

4. INSPECTION AND TESTING ........................................................................................................................... 28

4.1 INSPECTION ................................................................................................................................... 28 4.1.1 General ................................................................................................................................................ 28 4.1.2 Shop Tests ............................................................................................................................................ 29

4.2 CLEANING ..................................................................................................................................... 29 4.3 PAINTING ...................................................................................................................................... 30

5. DELIVERY AND ACCEPTANCE TESTS .............................................................................................................. 30

5.1 SHIPMENT ..................................................................................................................................... 30 5.1.1 Packing ................................................................................................................................................. 30 5.1.2 Shipment .............................................................................................................................................. 30

5.2 INSTALLATION .............................................................................................................................. 30 5.3 ACCEPTANCE TESTS ..................................................................................................................... 31 5.4 SPARE PARTS ................................................................................................................................ 31

CTF Refrigeration System Specification

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5.5 WARRANTY .................................................................................................................................. 32

APPENDIX A. DEVICE NUMBERING AND COMPUTER NAMING CODE .............................................................. 33

APPENDIX B. SUSPECT/COUNTERFEIT PARTS.................................................................................................. 36


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1. SCOPE 1.1 Introduction

This specification details the technical requirements for the design, fabrication, delivery, installation and acceptance test of a helium refrigeration cold box system for the Cryogenic Testing Facility (CTF) at Thomas Jefferson National Accelerator Facility (also known as Jefferson Lab or JLab) in Newport News, Virginia. This contract is to provide a 4.5-K helium refrigerator cold box to work with the existing helium compressors and with the JLab controls interface to vendor supplied PLC control system for the cold box. The cold box will be installed indoors in a non-air conditioned room. Subcontractor shall submit a technical proposal of the system based on this technical specification as part of the bid documents.

1.2 Acronyms

Table 1.1. List of Acronyms AAT After Acceptance Test ARO After Receipt of Order AD After Delivery

BAT Before Acceptance Test CR Cold (Gas) Return

CTF Cryogenic Test Facility FDR Final Design Review GN Gaseous Nitrogen HP High Pressure (Helium)

JLab Jefferson Lab LN Liquid Nitrogen LP Low Pressure (Helium)

MAWP Maximum Allowable Working Pressure PLC Programmable Logic Controller POC Point of Contact PS Prior to Shipment

SOTR Sub-Contracting Officer Technical Representative TS Temperature-Entropy

1.3 Hardware & Engineering Deliverables 1.3.1 Proposal stage

Proposal shall include items listed in Table 1.2 and have at least two references using a refrigerator of comparable capacity and similar design with back-up technical information and POC’s to demonstrate proposed refrigeration system and proposed turbines, are commercially available standard products with a proven service record.


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Table 1.2. List of technical documents required for proposal Item Reference

Preliminary Outline Drawings - All Hardware 1.4.2, 3.1.3 Preliminary Flow Diagrams 1.4.2, 3.1.2 References & POC For Proposed Refrigerator/Liquefier 1.3.1, 3.1.6 General Quality Assurance Program 1.5 Preliminary Process Design (all Modes); including Utility Process Paths 3.1.2 Preliminary Process and Utility Requirements, Interface Dimensions, Type and Size 3.1.3, 3.4.2 Preliminary Required Envelope Dimensions, Footprint and Floor Loading 3.1.3 Control System and Interfaces – Preliminary Details 3.1.4 Vacuum System – Preliminary Details 3.1.5 Cold Box 80 K Adsorption Bed Design, Regeneration Process, Controls and Calculations 3.1.6 References & POC For Similar Turbines Proposed 3.1.6 Preliminary Instrument List (Manufacturers and Part Numbers) 3.4.2 Manufacturing, Inspection and Testing Plan 4.1.1 Cleaning-Cleanliness Procedures 4.2 Preliminary Spare Parts List & Pricing 5.4

1.3.2 Final Design Review

Table 1.3. List of technical documents required for FDR Item Reference

Final Outline Drawings - All Hardware 1.4.2, 3.1.3 Final Process & Instrumentation Diagrams 1.4.2, 3.1.2 Final Process Design (all Modes); including Utility Process Paths 3.1.2 Cool-Down & Warm-Up Process and Calculations 3.1.2 Final Process and Utility Requirements, Interface Dimensions, Type and Size 3.1.3, 3.4.2 Complete Annotated PLC Programming and Ladder Logic 3.1.4 Vacuum System – Equipment Details, Controls, Calculations 3.1.5 80K Bed Design, Regeneration Process, Controls and Calculations 3.1.6 Heat Exchanger Design 3.1.6 Turbine Brake Cooler Design 3.1.6 Cold Box Insulation System 3.1.6 Final Mechanical Parts/Component List (Including Transition Joints) 1.4.2, 3.2 ASME Mechanical Design Code Calculations (Piping, Vessels/Beds, Relief Valves, etc.) 3.2 Lifting Load & Stress Calculations; Including Lift Plan 3.2 Piping Layout – Thermal Stability and Stress 3.2 Valve Sizing, Selection, Leakage Rate and Failure Mode 3.3 Final Control Schematics and Wiring Diagrams 3.4.2 Temperature Measurement Selection, Wiring and Thermal Anchoring Details 3.4.2 Final Instrument List 3.4.2 Overall Accuracy of Each Measurement 3.4.2 Heater and Sensor Wiring Details 3.4.3 Electrical Enclosures and Connectors 3.4.3 Alarms & Shut-Down Set-Points 3.4.4 Manufacturing, Inspection and Testing Plan 4.1.1 Cleaning-Cleanliness Procedures 4.2 Painting Procedure 4.3 Final Spare Parts List and Pricing 5.4


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1.3.3 Hardware and Engineering Deliverables and Schedule After FDR

Table 1.4. List of required hardware deliverables and other technical documents

Item Due Date Reference

Material Certifications 2 weeks PS 1.4.2 ASME Weld Inspection Report As Completed 4.1.2 ASME Code Leak Test As Completed 4.1.2 Helium Mass-Spectrometer (Sensitive) Leak Test Reports As Completed 3.1.6, 4.1.2 Insulating (Shell) Vacuum Test As Completed 4.1.2 Turbine Test Reports As Completed 4.1.2 Wiring End-to-End Checks As Completed 4.1.2

Complete and Final Documentation Package with Updates from FDR 15 days PS 1.7, 3.2, 4.1.2

Cold Box and Spare Turbine(s) (Hardware) 450 days ARO 5.4 Vacuum Pumping System (Hardware) 450 days ARO Shipping (Supports, Packaging, Route) and On-Site Reassembly Details & Plans 30 days PS 5.1 System Commissioning (Service) 30-90 days AD 5.3 Acceptance Test Plan 30 days PS 5.3 Operating Procedures 30 days BAT 5.3, 1.4.2 Acceptance Test Report 30 days AAT 5.3 Final Operating and Maintenance Manuals 30 days AAT 5.3, 1.4.2

Monthly Reports Progress Reports 5th day of each month ARO 1.4

1.4 Documentation

All documents shall be submitted in an unsecured (modifiable, not password protected) electronic format as follows: (a) 2D drawings: DXF and PDF (b) 3D drawings: STP and PDF (c) Lists and Calculations: XLSX (or XLSM) or DOCX, and PDF (d) All other documents: DOCX (or Native Format) and PDF It is the sub-contractor’s responsibility to provide a drawing (2D and 3D) file format that can be properly viewed by JLab. Presentations (such as the FDR) and operation and maintenance manuals shall also be submitted as (3) full size hardcopies in a professionally bound format. Subcontractor shall provide monthly progress reports describing in detail the (month’s) accomplished and (next month’s) planned design, ordering, fabrication, testing and inspection activities (as applicable). Report shall be in electronic format, either DOCX or PDF, and sent (copied) to the SOTR. Updates occuring between FDR and equipment shipment shall be incorporated (in to the documentation) and sent prior to shipment. Updates occuring as a result of acceptance testing shall be incorporated into operating and maintenance procedures/manuals. Documentation submitted for the proposal, FDR and final document package (prior to


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shipment) and final operating and maintenance manaual shall not contain mark-ups or red-lines.

1.4.1 Drawing Formats (a) All drawings delivered to JLAB shall be CAD drawings. Drawings shall be

created so they are fully legible (minimum lettering height of 1/8 inch). (b) Submitted drawings shall be black (lines) ink on white (background) paper

and be full size (or the orginal size). (c) Electronic copies shall be delivered in AutoCAD file format based on

ISO/IEC 29500-2:2012 open packaging convention. (d) All revisions of a drawing(s) shall be indicated on the drawing(s) by clouding

and shall specifically be noted in the revision block of that drawing. (e) Parts lists/bills of materials shall be prepared integrally with any drawings

where it is required and shall begin on the first sheet of those drawings.

1.4.2 Drawings, Diagrams, Lists and Procedures (a) Documents submitted as part of Final Document Package (prior to shipment)

shall include all as-built changes, updated into drawings, not red-lined or marked-up.

(b) Outline drawings shall be non-cartoon, scaled dimensional drawings showing equipment and interface locations (both process and utility).

(c) Simplified flow diagrams may be provided with the proposal. However, detailed process and instrumentation diagrams (P&ID’s) shall be provided at FDR. P&ID’s shall be in accordance with ISA standards and are diagrammatic/symbolic drawings showing flow paths, line sizes, process components, instrumentation and interfaces. The P&ID shall follow the naming rules provided in Appendix A. If there is a confilict between ISA and the appendix, Appendix A shall be used.

(d) Final parts lists (or bill of materials) shall be provided at FDR and provide the identification number (as specified herein) on the flow diagrams, manufacturer, complete part number and specifications. The actual manufacturer name and complete part number shall be used; NOT the cold box suppliers name and a part number. Mechanical parts lists shall contain all process components (e.g., valves, filters, vessels, heaters, heat exchangers, rotating machinery, etc.). Instrument parts lists shall contain all instruments (e.g., pressure, differential, temperature, flow, speed, I/P’s, PLC’s, power supplies, etc.). Piping parts lists shall contain all piping components (e.g., piping, tubing, flex-hoses, fluid fittings/flanges/joints, structural elements, hardware, etc.). Piping parts lists shall provide both material and design specifications (e.g., for flanges, ASTM A182-F304 and ASME B16.5) where applicable and as required by ASME codes listed in section 2 in this specification.

(e) Operating manual and procedures shall be in DOCX and PDF format. The procedures shall be complete and in a step-by-step format for all the normal operating and utility modes. Procedures shall include flow diagrams with


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depicted flow path(s) and valve/component configuration. Operating manual and procedures shall be provided prior to acceptance testing with updates incorporated after completion of acceptnce testing.

(f) The maintance manual shall contain a detail list of all parts, manufacturer name, model numbers, catalog cut sheets for all componets that require any type of maintainance or repair. Maintance manual with updates incorporated shall be provided after completion of acceptance testing.

(g) Subcontractor shall supply the material certifications for all piping components of the system prior to shipment.

1.4.3 Electronic Submittal Exchange Protocool

(a) Deliverables shall be transmitted to JLab in electronic (PDF) format using Submittal Exchange, a website service designed specifically for transmitting information between project team members. The intent of electronic submittals is to expedite the construction process by reducing paperwork, improving information flow, and decreasing turnaround time. The electronic submittal process is not intended for Word or CAD drawings.

(b) Files shall be named with a unique identifier including revision identifier. (c) Electronic Submittal Procedures

(1) Vendor shall post electronic submittals as PDF electronic files directly to the CTF Equipment website specifically established for Project. Contractor may use any or all of the following options.

(2) Subcontractor shall review and apply electronic stamp certifying that the submittal complies with the requirements of the Contract Documents including verification of manufacturer / product, dimensions and coordination of information with other parts of the work.

(3) Subcontractor shall transmit each submittal to SOTR using the Submittal Exchange website, www.submittalexchange.com.

(d) SOTR review comments will be made available on the Submittal Exchange website for downloading. Contractor will receive email notice of completed review.

(e) Distribution of reviewed submittals to lower tier subcontractors and suppliers is the responsibility of the Subcontractor

(f) The cost of Submittal Exchange services has been paid in full by JLab. (1) At Subcontractor’s option, training is available from Submittal Exchange

regarding use of website and PDF submittals. Contact Submittal Exchange at 1-800-714-0024.

(2) Internet Service and Equipment Requirements. • Email address and Internet access at Subcontractor’s main office. • Adobe Acrobat (www.adobe.com), Bluebeam PDF Revu

(www.bluebeam.com), or other similar PDF review software for applying electronic stamps and comments.

(g) JSA review period will normally be 14 days.

http://www.submittalexchange.com/

http://www.adobe.com/

http://www.bluebeam.com/


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1.5 Quality Assurance Program

The general quality assurance program required in the proposal shall be in sufficient detail and scope that JLAB can evaluate the adequacy of quality controls to be expected from the Subcontractor. The QA program shall conform to the Quality Assurance Criteria, Paragraph 3, Attachment 2 of DOE Order 414.1C for the following elements,

(a) Personnel Training and Qualification (b) Quality Improvement (c) Documents and Records (d) Work Process (e) Procurement (f) Inspection and Acceptance Testing (g) Management Assessment

1.6 Final Design Review

The final design review is a formal technical review of the design to occur at 30 to 90 days ARO. The main goals of the FDR are the understanding of how the design satisfies the requirements, verifying the adequacy of the design, and authorizing approval to proceed with manufacture. As such, Subcontractor shall provide the complete and final detailed design for the refrigeration system during this review. The review shall be coordinated with JLab Technical Coordinator and shall be held at at the subcontractor’s site. Subcontractor shall deliver the review document package described in Table 1.3 at least 14 days prior to the review. A FDR presentation agenda shall include: (a) Project overview of objectives (b) Requirements list defining the design and options (c) Final process design and P&ID’s (d) Final equipment layout and the compressor and utility interface requirements and

cold box design. (e) Final electrical schematics, wiring diagrams, controls/instrumentation (f) Detailed control system software and logic requirements, function description of

the system and the interface requirements to the JLab control system. (g) Final acceptance test plans (h) Summary of work plans (i) Summary of procedures (j) Schedule (Gantt chart) (k) Open Items

1.7 Final Documentation Package

Prior to shipment of refrigeration system, Subcontractor shall compile the final documentation package containing all required final documents and reports and all FDR documentation, with all updates incorporated after FDR. Package shall be completed, professionally presented and well organized.


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1.8 JLab Furnished Items

(a) Hardware

(1) JLab style bayonet connections (2) Hardware required for acceptance testing; except for items required for

interface or connection that are only available through the Subcontractor.

(b) Utilities (1) Electrical power will be supplied as

• For instrumentation and control 120/208VAC /60 Hz • For motors < 450 kW, 480 V/60 Hz

(2) Cooling water ASME B16.5, 150# Class • Supply pressure < 7 barg • Allowable pressure drop 1 bar • Supply temperature 12.8 to 30.6 oC • Allowable temperature rise 20 oC

(3) Instrument air ANSI 150# Class • Supply pressure 4 to 6 barg • Dew point -28.9 oC, max.

(4) Helium • Helium Grade 5.0

Purity > 99.999% O2 < 1 ppm N2 < 4 ppm H2O < 1 ppm Hydrocarbons < 0.5 ppm

(5) Liquid nitrogen

(c) Material Handling JLab shall provide material handling equipment and labor to unload the vehicle transporting 4.5-K helium refrigerator on-site at Jefferson Lab.

1.9 Environmental Conditions

The table below presents the dry and wet bulb temperatures (Tdb, Twb) for the Newport News, Virginia area. In the summer, the temperature would be at or above the listed temperature. In winter the temperature would be at or above the listed temperature.

Winter Summer

Tdb [1] Tdb [2] Twb [2] 99% 97.5% 1% 2.5% 5% 1% 2.5% 5%

-6.7 °C -5.6 °C 33.9 °C 32.8 °C 31.7 °C 25.0 °C 24.4 °C 24.4 °C Notes: Ref. ASHRAE Handbook – Fundamentals [1] Design dry-bulb temperature and frequency (out of 2160 winter hours in northern hemisphere) which

temperature is above the listed value.


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[2] Design dry-bulb and mean coincident wet-bulb temperatures with frequency (out of 2928 summer hours in northern hemisphere) which temperature is above the listed value.

The following factors shall be used for the structural design per ASCE 7-05. Cold box shall NOT be considered exempt.

Site Class C Importance Factor (I and Ip) 1.0 Mapped MCE, 5% Damped, Spectral Response Acceleration Parameter at Short Periods (SS)

15 (%g)

Mapped MCE, 5% Damped, Spectral Response Acceleration Parameter at a Period of 1 sec. (S1)

5 (%g)

Long Period Transition Period (TL) 8 sec. Response Modification Coefficient (R) 3 System Overstrength Factor (Ω0) 3 Deflection Amplification Factor (Cd) 3 Component Response Modification Factor (Rp) Per Table 13.6-1 Component Amplification Factor (ap) Per Table 13.6-1

1.10 Exceptions

All the exceptions to the specifications shall be identified by referencing the section of the specification with a clear and detailed statement of the exception taken. Exceptions shall be noted on the PD 46 Certification. A sheet titled PD 46 Exceptions may be attached to the PD 46 form if more space is required.

2. APPLICABLE DOCUMENTS AND CODES

The following documents are part of this specification. The issue used shall be one in effect at the date of the invitation for proposal. If any apparent conflict between the requirements of the reference documents and the specification is found, it shall be brought to the attention of JLAB Sub-Contracting Officer and Sub-Contracting Officer Technical Representative (SOTR).

(a) American Society of Mechanical Engineers (ASME)

ASME B31.3, Process Piping ASME Boiler and Pressure Vessel Code (BPVC), Sections II, V, VIII (Divisions I or II), IX

(b) American Society of Civil Engineers (ASCE) ASCE 7, Minimum Design Loads for Buildings and Other Structures

(c) American Petroleum Institute (API) API Std. 520, Sizing, Selection, and Installation of Pressure Relieving Devices in Refineries, Part I – Sizing and Selection

(d) Compressed Gas Association (CGA) CGA S-1.3, Pressure Relief Device Standards – Part 3 – Stationary Storage Containers for Compressed Gases


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(e) National Electrical Manufacturers Association (NEMA)

Std. 250, Enclosures for Electrical Equipment (1000 Volts Maximum)

(f) National Fire Protection Association (NFPA) NFPA-70, National Electric Code 2008 Edition (NEC)

(g) Instrument Society of America (ISA) ISA-S5.1, Instrumentation Symbols and Identification ISA-S5.2, Binary Logic Diagrams for Process Operations ISA-S5.3, Graphic Symbols for Distributed Control/Shared Display Instrumentation, Logic and Computer Systems ISA-S5.4, Instrument Loop Diagrams ISA-S75.01, Flow Equations for Sizing Control Valves

(h) American National Standard/Fluid Controls Institute (ANSI/FCI) ANSI/FCI 70-2, Control Valve Seat Leakage

(i) American Society for Testing and Materials (ASTM) ASTM E493, Testing for Leaks Using the Mass Spectrometer Leak Detector in the Inside-Out Testing Mode ASTM E498, Testing for Leaks Using the Mass Spectrometer Leak Detector in the Tracer Probe Mode ASTM E499, Testing for Leaks Using the Mass Spectrometer Leak Detector Probe Mode

(j) National Institute of Standards and Technology (NIST) NIST Technical Note 1334: Thermo physical Properties of Helium-4 from 0.8 to 1500 K with Pressures to 2000 MPa NBS Technical Note 129: Thermo physical Properties of Nitrogen from 64 to 300 K between 0.1 and 200 Atmospheres

(k) ALPEMA (The Standards of the Brazed Aluminum Plate-Fin Heat Exchangers Manufacturers’ Association) .

(l) Tubular Exchanger Manufacturers Association (TEMA) TEMA sections 1 to 9 and sections 11 and 12

(m) State Codes

In addition to the requirements shown or specified, the Subcontractor shall comply with all applicable national, state, county, city, township, and local codes, rules, regulations, ordinances, and standards. However, the Subcontractor shall comply with the requirements shown or specified in this document when Codes, Rules, Regulations, Standards, and Ordinances are not in excess of these requirements.


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NOTE: JLab is not authorized to accept any suspect counterfeit hardware, some of which are shown in Appendix B. All fittings incorporated in this delivery will be marked "WP". "CR" fittings (SP-43) and -TR- fittings shall not be incorporated in this delivery.

3. PERFORMANCE The refrigeration system specified in this document includes a cold box (designated as CB-3) and a control system to work with the JLab compressor, oil removal system, and gas management system. A simplified system flow diagram is shown in Fig. 3.1. The system will support the cryogenic needs of the CTF loads; i.e., cryo-module testing or dewar testing of cryo-module cavities as shown in the figure. The specified system will share the compressor system, 10,000 liter helium dewar system, helium purifier system, recovery system, gas storage system and liquid nitrogen system with the current CTF at JLab. This new cold box will be connected to a helium compressor station consisting of three Mycom compressors. Each compressor can provide 1.05 bar suction, up to 18 bar discharge with a flow capacity of 55 g/s. Depending on the cryogenic loads at a given time, this new cold box is expected to operate with any combination of one or two fully loaded compressors or one partially loaded compressor (that uses a VFD controlled motor). Note that unless otherwise specified, the units of “bar” shall be assumed to indicate absolute pressure.

3.1 Cold Box


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Interfaces: A – HP Supply from compressor to cold box (HP) B – LP Return to compressor from cold box (LP) C – LP cold gas from cold box to ambient vaporizer (VP) D – LN supply to cold box (LN) E – GN vent from cold box to atmosphere (GN) F – LP cold gas return to cold box (CR) G – Primary supply (nominal) 3.25 bar 4.5 K super-critical He (PS1) H – Primary return (nominal) 1.25 bar 4.5 K He vapor (PR1)

Figure 3.1. Simplified flow diagram of proposed CTF cryogenic system.

3.1.1 General

The cold box system shall be a complete operational subsystem. The cold box system shall contain all components including heat exchangers, turbo-expanders with gas bearings, adsorbers, valves, instrumentation & controls, vacuum pump, required safety devices and other components necessary to produce 4.5 K helium refrigeration and liquefaction. The LP cold gas line enters the cold box at interface “F” (see Figure 3.1) and exits at “C”. This line does not pass through any heat exchanger and is connected to the LP return through four injection valves (at 80-K, 30-40-K, 10-15-K and 5-K, nominally), exiting the cold box through the 300-K cold gas valve and then through the “C” connection (see Figure 3.1). There is also a 5-10-K bypass/cool-down valve between the HP stream and the cold gas line. An integrated freeze-out purifier is not necessary (the existing JLab system already has this capability). Cold box system shall utilize liquid nitrogen (LN or LN2) pre-cooling. For process design, Subcontractor shall use the thermodynamic and transport properties per the NIST documents specified herein and assume that LN is supplied at approximately 4 bar saturated liquid. Only the main cold box system is part of this Contract.

3.1.2 Cold Box Operation Modes The cold box system shall function to accommodate all of the following modes of operation. As the compressor system is existing, the design for the operating modes (“a” to “e” below) shall maximize the cold box efficiency; defined as the exergy load flux divided by the exergy flux supplied to the cold box from the compressor system and LN. The process (“T-S”) design shall be provided for each of the following five operational modes with the proposal and at FDR. All turbines shall be running for each operational mode design and preferably with the inlet valve full open. (a) Maximum 4.5-K liquefaction mode: Minimum of 6.6 g/s of make-up gas is

supplied at approx. 1.05 bar and 300 K to the compressor suction. This mode shall require less than 14 bar supply pressure to the cold box and consume less than 30 g/s of LN supplied as a saturated liquid at 4 bar. This shall be a guaranteed mode.

(b) Minimum 4.5-K liquefaction mode: Make-up gas is supplied at approx. 1.05 bar

and 300 K to the compressor suction. This mode shall require less than half of the


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supply pressure to the cold box required for the maximum 4.5-K liquefaction mode. LN is supplied as a saturated liquid at 4 bar. This shall be an expected mode.

(c) Maximum 4.5-K refrigeration mode: Minimum of 650 W isothermal load at 4.45

K (1.25 bar). Return condition from load shall be saturated vapor at 4.45 K (1.25 bar). This mode shall require less than 90 g/s of supply and return flow, to and from (respectively) the compressor system. This shall be a guaranteed mode.

(d) Minimum 4.5-K refrigeration mode: Isothermal load at 4.45 K (1.25 bar). Return

condition from load shall be saturated vapor at 4.45 K (1.25 bar). This mode shall require less than 55 g/s of supply flow from the compressor system. This shall be an expected mode.

(e) 2-K refrigeration recovery mode: This is a non-isothermal load but is equivalent

to an isothermal load into a dewar at 1.25 bar (4.45 K) with heat input (maintaining a constant liquid level), and 10 g/s of the exiting vapor superheated and re-injected into the cold box at 30 K. This shall be an expected mode.

(f) Utility modes

• Evacuation, purge and warm gas circulation (clean-up and commissioning) • Turbine cartridge change during normal operation • Cold box system cool down from 300 K • Cold box system warm-up to 300 K • Those necessary for the safe behavior and recovery of the cold box system in

case of utilities failure (power, instrument air, water, controls/PLC, etc.)

Subcontractor shall furnish a cold box system that can be consistently brought to steady state operating conditions (i.e., to any of the operating modes listed herein) from a warm condition within 8 hours and brought to warm conditions from any of the operational modes within 8 hours. Warm conditions are defined as those existing at the completion of purification at 300 K. Subcontractor shall provide process path description (procedure and annotated flow diagrams) and supporting calculations. The flow diagrams with the appropriate controls and instrumentation for these utility modes and any other deemed necessary for the proper operation and maintenance are to be provided for the FDR.

(g) Shut down modes

As a minimum, the cold box system shall be designed and instrumented so that it can be shut down and secured under the following three circumstances:

(1) Normal shutdown: The cold box system shall be shut down in a controlled

fashion with minimal loss of helium and secured within one hour by no more than two operators.


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(2) Emergency shutdown: It shall be possible to shut down any or all

components without damage to the system or any of its components. (3) Shutdown due to utility failure: The cold box system shall shut down any

or all components without damage to the system or any of its components due to a loss of any utility (e.g., electrical power, control power, cooling water, instrument/control air, etc.).

Final process design shall be presented at FDR. Subcontractor shall provide the process design and flow diagrams with the necessary controls and instrumentation for all these operating modes with the proposal. At a minimum, the process design information provided by the Subcontractor shall contain the mass flow, pressure, temperature and enthalpy at the inlet and outlet of each component, as well as specified loads and all heat in-leaks; there shall be at least five significant figures for all values given.

3.1.3 Cold Box Interface The connections/interfaces shown in Table 3 shall be provided by the Subcontractor for the cold box system. Flange connections at the room temperature interface with flow coming out of the cold box shall have a 304L or 316L stainless steel vacuum extension sleeve to prevent cold box shell from excessive cold return temperatures (especially in transient and upset conditions). Bayonet connections shall the JLab type (and will be furnished by JLab). Subcontractor shall provide a thermal relief (Circle Seal p/n M5132N-4M, or JLab approved equal) on the (JLab) lower bayonet flange and a bellows-seal purge valve (Swagelok p/n B-4HK2, or JLab approved equal) on the (JLab) upper bayonet flange using 3M Scotch-Weld epoxy adhesive 1838 B/A (Green) (or JLab approved equal).

Table 3. CBX Interfaces CBX Interface ID Type Size

HP Supply from Compressor HP Flange 3 IPS LP Return to Compressor LP Flange 5 IPS

LP Cold Gas Return to Ambient Vaporizer VP [2] 4 IPS GN Vent from CBX to Atmosphere GN Flange 1-1/2 IPS

LN Supply to CBX LN Bayonet JLab 1” [3] Primary 4.5K Supply from CBX PS1 Bayonet JLab 1” [3]

Alternate 4.5 K Supply from CBX PS2 Bayonet JLab 1” [3] Primary 4.5K Return to CBX PR1 Bayonet JLab 2” [3]

LP Cold Gas Return to CBX [1] CR Bayonet JLab 2” [3] [1] The LP cold gas return line is connected to the LP return through several cold gas

return valves, but does not pass through any heat exchangers; entering the cold box through the “CR” connection and leaving through the “VP” connection.

[2] This connection must be capable of operating at temperatures below 80 K for an extended period of time. It is the exit from cold gas header through the 300-K cold gas return valve to the ambient vaporizer, which returns to compressor suction.

[3] JLab bayonet size designation is based on the tube outside diameter of the female.

Subcontractor shall provide scaled drawing of cold box system showing, at a minimum, the following information with the proposal (as preliminary) and (the final) at FDR.


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• All process and utility connection type and size. • All process and utility interface dimensions and requirements. • Envelope; height, width, diameter, clearances, etc. • Footprint (installation). • Floor loading, center of gravity, lifting connections, etc.

3.1.4 Control and Instrumentation

(a) Subcontractor shall supply an Allen-Bradley ControlLogix or CompactLogix PLC

for the refrigerator system. The PLC shall be wired by the subcontractor to all of the refrigerator instrumentation and control devices.

(b) Subcontractor shall write and supply the software to operate the cold box system. (c) PLC logic and source code supplied by the subcontractor shall be capable of

being modified, clearly documented and not password protected. The following information shall be provided at FDR: • Detailed control flow charts covering programming to handle all modes of

operation (normal and utility). • Ladder logic for turbine control (start, shutdown, operation).

(d) Subcontractor shall provide hardwire safeties. (e) The Subcontractor shall provide the instrumentation transmitters and other

devices wired to terminal strips for interface with the control system. The terminal strips shall be mounted in a suitable enclosure that provides adequate space for wiring connections.

(f) Preliminary control system hardware and interface information shall be provided with the proposal.

3.1.5 Vacuum Requirements Under steady state operating conditions, the vacuum vessel of the cold box shall be able to maintain a pressure level less than 10-4 Pa (10-6 Torr). Cold box vacuum shall have an adequately sized flanged connection to connect a vacuum pumping system. This vacuum port shall be properly screened to prevent inlet blockages from multi-layer insulation. The maximum leak rates allowed for different components are listed in Table 3.2. Subcontractor shall provide an active, dedicated vacuum system for the cold box system. It shall be adequately sized to evacuate the cold box vacuum within 12 hours to a pressure level of 10-3 Pa (10-5 Torr) or better with all internal components at ambient temperature (i.e., no benefit from cold surface cryo-pumping). Subcontractor shall provide vacuum list and details of vacuum system components, assembly drawings and supporting calculations at FDR. Vacuum system size, capacity and control concept, including component manufacturer and part numbers information shall be provided with the proposal. The vacuum pump port shall be a minimum size of ISO-KF100. A vacuum gate valve (not a swing butterfly type) of at least the size of the vacuum pump port shall be installed between cold box and its vacuum system. It shall provide a mechanical position


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indication of its status (open or closed) and shall close upon any power outage or loss of instrument air (if used). The valve shall reliably seal allowing the replacement of vacuum system components without spoiling or degrading the cold box vacuum. The vacuum vessel, the gate valve and the pump system shall be closely coupled to ensure maximum pumping speed. A bypass from the cold box vacuum to the roughing pump shall be provided using a manual isolation valve (at least ISO-KF40). Vacuum system shall be supplied with the local controls to automatically protect the cold box from vacuum oil back streaming upon power loss or vacuum equipment failure or shutdown. The minimum instrumentation shall include both local and remote vacuum indications at/of the high vacuum pump and the roughing pump. Both a local and a remote vacuum indication of cold box shall be provided at a separate location that is at least 18 inches from the vacuum pump port and oriented vertically up. All instruments shall be equipped with a dedicated vacuum isolation valve, so that the instrument can be removed without affecting the cold box or vacuum system. The cold box system shall be permanently equipped with all components required to evacuate process lines and components, re-pressurize and circulate with warm helium gas to remove any contaminants. Helium gas circulation shall be possible through all sections of piping; stagnate dead-end pipe sections are not allowed.

Table 3.2. Maximum leak rates for cold box system

Item Maximum Leakage Rate (mbar-l/s) Single components 10-9 Demountable seals 10-7 Plate fin heat exchanger - leak to vacuum 10-6 Plate fin heat exchanger cross stream leakage 10-5 New relief valves 10-6 Relief valves after repeated use (20 times) 10-4

Connections in the vacuum system shall be 304 or 316 stainless steel rigid tube or flexible bellows. Rubber and plastic hoses or fittings are not permitted in the vacuum system. Subcontractor shall design and construct the equipment supplied in such a way that it can operate with total helium losses which do not exceed 0.25 standard-m3 per day and with no air-in leakage. The allowable helium loss includes adsorber regeneration losses.

3.1.6 Requirements for Key Components (a) Adsorption Bed

(1) A 20-K bed is not required since the risk of having one supersedes the concern of contaminates below 80-K (which are very low). An 80-K bed with normally closed inlet and outlet valves is required. Also, a normally closed bypass valve (around the bed) is required.

(2) Upstream and downstream screens shall be furnished in both beds to prevent migration of the adsorption bed particles. The adsorption beds shall be sized to prevent any fluidization of the bed during any operating


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condition encountered including the lifting of relief valves. Also, the process piping shall include a permanently installed 30 micron filter with adequate surface area, on the inlet and outlet of each bed to prevent migration of carbon dust in normal operation and in the event of bed screen failure. The filter element shall be a non-collapsible, reinforced particulate filter rated for a minimum differential pressure of 5 bar.

(3) Both beds shall have remote upstream pressure and differential pressure indications. Contamination taps shall be located on the piping between the bed outlet and the outlet isolation valve; not in the bed-vessel.

(4) For 80-K bed regeneration, a purge line on the bed outlet piping (upstream of the outlet isolation) and a line on the bed inlet (downstream of the inlet isolation) that branches to an ambient vaporizer (supplied by others) and an evacuation port shall be provided. Purge line shall be designed to prevent bed fluidization. Line from the bed inlet shall have a stainless steel vacuum sleeve extension to prevent local shell from becoming less than 10 K below ambient temperature.

(5) The warm-up of the 80-K bed shall be accomplished by means of electric heaters. There shall be an equal number of spare heaters and spare temperature sensors (for control and protection) as required for the (regeneration process) design. Spare heaters and sensors shall be located in an alternating and/or symmetric pattern, such that they are located in an equally optimal manner as the primary ones. Heaters shall be secured mechanically (e.g., hold-down bars) and by temperature-compensating tension. Copper sheet between heaters and vessel-shell shall be used to ensure good thermal contact. Aluminum-backed fiberglass insulation, appropriate for a vacuum, shall be used for the bed to prevent multi-layer (super) insulation from being damaged from the heat or local hot spots. All wiring for heaters and sensors shall extend to terminal block enclosures mounted outside the cold box.

(6) The controls specifically required for the regeneration process shall be local only. Subcontractor shall provide all instrumentation and controls necessary for the expedient regeneration: (i) Platinum resistor temperature (RTD) sensors on the beds,

including spares. (ii) Bed pressure gauge. (iii) Bed vacuum (thermocouple) gauge. (iv) Warm-up temperature controller. (v) Control system shall have over-temperature protection, including

consideration of a sensor failure (i.e., whether it fails with a ‘high’ or ‘low’ indication) and shall prevent the heater from being powered if there is not a positive pressure in the bed (i.e., > 1 bara).

(vi) Prevention of bed fluidization and bed screen damage during pressurization and blow-down.

(7) Regeneration process for the 80-K bed at maximum adsorption capacity shall require less than 24 hours (warm-up, repeated evacuation/back-


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fill/heating and cool-down) to bring total contamination content below 0.1 parts-per-million (ppm).

(8) Subcontractor shall provide the preliminary design and calculations for 80-K adsorber bed, as well as, the regeneration process and heater control system with the proposal. Final bed design, calculations (demonstrating compliance with all the specified requirements), regeneration process and heater control system shall be presented at FDR for review and approval by JLab.

(b) Heat Exchangers (1) The heat exchangers shall be designed and fabricated in accordance with

ASME BPVC Sec. VIII and have a U-stamp. The MAWP and minimum service temperature shall be set to cover all operation and utility modes.

(2) Subcontractor shall demonstrate for every heat exchanger that the surface area, cross-sectional flow area, layering, pressure drop distribution and nozzle sizes are adequate for all modes of operation.

(3) All plate fin heat exchangers shall be mounted in the cold box in the vertical orientation with the warm end up. JLab approval is required for any other orientation.

(4) All heat exchangers, other than the plate-fin, shall be in accordance with TEMA or as approved by JLab.

(5) All plate-fin heat exchangers shall be in accordance with ALPEMA, vacuum furnace brazed and cleaned of foreign material prior to cold box installation.

(6) The 300-80K heat exchanger shall have pressure taps for differential pressure monitoring.

(7) Prior to installing into the cold box vacuum shell, each heat exchanger core shall be independently leak checked in accordance with ALPEMA using a helium mass-spectrometer leak test equivalent to ASTM E493. Subcontractor shall submit leak test reports at completion of testing and in the final documentation package.

(8) Subcontractor shall provide the following for each heat exchanger section at FDR, or before ordering the heat exchangers, whichever comes first: (i) Process data for each stream at different modes (as minimum at

maximum capacity refrigeration and liquefaction). (ii) Effective section dimensions; length, width and height (iii) Inlet and outlet nozzle sizes and orientations (with respect to the

core-section) (iv) Total UA provided. (v) UA required for heat transfer (vi) UA required for longitudinal conduction (vii) UA margin. (viii) NTU’s. (ix) Thermal effectiveness. (x) Total heat transfer area for each stream. (xi) Free flow area for each stream. (xii) Hydraulic radius for each stream.


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(xiii) Ratio of total heat transfer area per stream to volume between plates of that stream (if there were no secondary heat transfer surface).

(xiv) Number of layers for each stream. (xv) Stream layer stacking sequence. (xvi) Section pressure drop. (xvii) Ratio of core-section to distributor pressure drop (suggest a

minimum ratio of 3). (xviii) Ratio of (core-section + distributor) to (header + nozzle) pressure

drop (suggest a minimum ratio of 3). (9) UA margin shall be at least 10% i.e., Total UA provided / (UA required

for heat transfer + UA required for longitudinal conduction) > 1.1. (10) Unless otherwise approved by JLab, each cold box heat exchanger shall be

equipped with temperature sensors at the inlet and outlet of each process stream for remote monitoring.

(c) Turbo-Expanders (1) The turbo-expanders used in the cold box system shall be of the gas

bearing type with a proven performance history of 20,000 hours or more in helium service. The performance of the proposed turbo-expanders shall have been documented by previous cold box installations and have been of the same type and approximate size or larger. Subcontractor shall provide JLab with at least two references of installations and the POC at each installation with the proposal.

(2) Each expander, including the brake system, shall have provisions for automatic continuous and efficient capacity modulation from 30 to 100% of the maximum expander output. This shall be clearly demonstrated with the references to be submitted with the proposal. The maximum allowable rate of inlet pressure change (dP/dt) for each expander shall be stated and the control system shall be designed to prevent exceeding these values.

(3) The expanders shall be capable of continuous operation and safely shutting themselves off (by the built-in protection or hard wired safeties) when the process conditions warrant (e.g., cold box is operating in an unbalanced mode). An unbalanced mode is defined as excess cold gas returning to the cold box from the load and some part of it is recovered as warm gas in the gas storage. Turbines shall not be damaged in the case of the loss of utilities like electricity, coolant, or instrument air.

(4) Unless otherwise approved, each turbine-string shall have a manual outlet isolation valve. The control system shall be configured so that the turbine-string cannot be started until the outlet valve is fully opened.

(5) The bearing gas supply shall have an appropriately sized particulate filter to prevent particles 10 microns or larger from the entering the gas brake circuit. The particulate filter shall have a collapse pressure difference greater than 5 bar.

(6) Both a local indication and a remote signal of turbine speed shall be provided.


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(7) A flow control valve shall be installed at the inlet of each turbine expander string. The control of this valve shall be continuous from full closed to full open at the operating pressure and temperature. Over this range, the expander shall operate properly and without damage or shutdown.

(8) Inlet temperature sensors shall be placed between inlet valve and turbine inlet and outlet temperature sensors shall be placed between turbine outlet and outlet valve. Spare (back-up) inlet and outlet temperature sensors shall be provided which do not require spoiling insulating vacuum or component removal. All alarm and trip initiation signals must be provided for monitoring. Running time meters shall be furnished which show total operating time.

(9) The brake and bearing cooler heat exchangers shall be designed per TEMA (or another code specifically approved by JLab) and for use with open-tower cooling water. It shall be cleanable and made of corrosion-resistant materials for all surfaces in contact with water. It shall be designed with surface area margin acceptable to JLab at the maximum braking capacity with a 0.001 fouling factor on the water side and with a water side pressure drop in the heat exchanger less than 1 bar.

(10) A closed water cooling system for the brakes shall be quoted as a separated option item if required.

(d) Cryogenic Process Valves (1) Cryogenic valves selected shall have a proven industrial cryogenic service

history greater than 10 years. All cryogenic valves shall be approved by JLab.

(2) All cryogenic valves mounted in/on the cold box shall not include any threaded or flanged connections, including bonnets or stuffing boxes within the vacuum space. Packed valves shall not be incorporated in this cold box design.

(3) All cryogenic valves shall be mounted with the warm end up and with piping loops on both sides of the valve to allow the valve seat to reach within 5 K of the thermal equilibrium temperature (from the fluid temperature on both sides of the seat) in the fully closed position. This can usually be accomplished with a vertical pipe loop height of 12 inches (300 mm) to 24 inches (600 mm) for pipe sizes up to 6 IPS (150 mm).

(4) All valves supplied, as a part of the cold box or external systems shall be stamped with the manufacturer flow arrows on the body; and if relevant, on the vacuum jacket.

(5) Extended stem valves shall be of suitable length and positioned so that the O-ring seal at the bonnet of the valve remains at or within 2 K of the ambient temperature during normal operation.

(e) Thermal Insulation System - Subcontractor shall provide details for the proposed

thermal insulation system, also known as, multi-layer and super insulation. Test data and calculations of its performance shall be submitted for review by JLab.


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3.2 System Mechanical Requirements

(a) Cold box HP helium stream shall be rated for 20 bar. MP helium, LP helium and nitrogen (LN and GN) shall be rated for 10 bar. Instrument air and cooling water shall be rated for 10 bar.

(b) All mechanical design calculations required herein and by the applicable ASME, ASCE and industry codes shall be submitted to JLab for review and approval at FDR.

(c) Adsorber beds and other vessels shall be designed in accordance with ASME BPVC Sec. VIII and be U-stamped.

(d) Cold box vacuum vessel shall be designed in accordance with ASME BPVC Sec. VIII, but a U-stamp is not required. The vacuum vessel shall be designed to withstand an external pressure of at least 1 bar (differential).

(e) Heat exchangers shall be designed, fabricated and tested in accordance with ASME BPVC Section VIII and be U-stamped. Subcontractor shall furnish two U-stamp name plates for each heat exchanger internal to the cold box; one affixed to the heat exchanger and the other affixed to the exterior vacuum shell.

(f) Piping materials, design, examination, fabrication and testing shall be in accordance with ASME B31.3 and all supporting documents shall be provided to JLab 15 days PS. Unless otherwise approved by JLab, all piping shall be fabricated from 304L or 316L series stainless steel.

(g) The cold box system shall be designed for 7000 full thermal and pressure cycles; i.e., 300 to 4.5-K and (maximum) design pressure to vacuum, respectively.

(h) The design shall insure that cold box piping layout prevents the occurrence of thermal oscillations that could interfere with stable cold box operation and supporting the loads. It is the subcontractor’s responsibility to demonstrate this by experience in operating a similar or same design (under comparable load conditions) and/or by calculation(s).

(i) A complete and detailed mechanical component and parts list, including transition joints shall be provided at the FDR.

(j) Subcontractor shall provide properly design and rated lifting lugs/attachments to the cold box for shipping and installation at JLab. Weights, load rating(s) and design calculations shall be provided to JLab.

(k) Safety devices (i) Process relief devices shall be selected, sized and rated (by a qualified

manufacturer) in accordance with ASME BPVC Sec. VIII and ASME B31.3. Process relief valves shall be sized according to API Standard 520. Thermal reliefs shall be sized per CGA S-1.3 using criteria not less conservative than the two references below. Set point for relief devices shall not be less than the (maximum) process design pressure unless specifically allowed by JLab. • R.H. Kropschot (ed.), et al, “Technology of Liquid Helium”, NBS

Monograph 111, (formerly) National Bureau of Standards, 1968, p. 270.

• W. Lehmann, G. Zahn, “Safety Aspects for LHe Cryostats and LHe Transport Containers,” Proc. ICEC-7, London, July 4-7, 1978, p. 569-579.


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(ii) All volumes throughout the system which can be isolated (intentionally or unintentionally) with cryogenic fluids and/or have a potential for overpressure shall be equipped with (thermal) relief valves. These valves, provided that they are not set low enough to become the main reliefs, can be locally vented.

(iii) Cold box vacuum vessel shall be equipped with a relief device sized to handle 125% of the flow from the cold box high pressure supply at the maximum design capacity, should there be a failure of any component in the cold box, or 110 g/s (two existing Mycom compressors), whichever is more conservative. The pressure relief device shall insure the vacuum vessel does not exceed 1 barg. Otherwise, vessel shall be fully constructed to ASME Section VIII (U-stamped).

(iv) The thermal insulation system shall be sufficiently secured so that during such a component failure (resulting in the cold box vacuum vessel relief lifting), the insulation does not come loose and block the relief inlet. Relief valve ports of vessels and chambers with multi-layer insulation shall be properly screened to prevent inlet blockages.

(v) All relief devices shall be easily demountable for repeated inspection, calibration and resetting.

(vi) Unless specifically approved by JLab, only direct spring-operated or pilot operated relief valves that are certified in accordance with ASME BPVC Sec. VIII UG-126 shall be used. Although coded relief devices are not required for the vacuum vessel, any non-coded relief device shall be qualified through operability tests demonstrating function and flow capacity or calculations showing adequate flow capacity. Parallel plate relief valves, designed to prevent binding of plate on guide rods and using a dove-tail O-ring groove, are acceptable for vacuum vessel relief provided a discharge coefficient not greater than 0.6 is assumed for sizing.

(vii) All pressure relief devices shall be located so that there is unobstructed access to them with a hot-air blower.

(viii) The vent on relief devices shall be directed away from impinging on personnel and equipment. The effect of the discharge momentum reaction force shall be considered in the design.

(ix) Subcontractor shall provide all relief device sizing calculations (including reaction forces) at the FDR and in the final documentation package.

(l) Noise levels shall be less than 85 dBA - slow, when measured with a Type 1 meter, at 1 meter from any area of the Cold Box. Vendor shall provide noise survey data with unit. (x)

3.3 Valves

(a) The following valves shall be provided at a minimum: (1) Isolation/control (whichever is appropriate) of all warm gas supply and

return from the cold box; both utility and main process lines. This includes HP supply, LP return, and LN supply (which is a cryogenic


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control valve). However, GN vent to atmosphere does not require an isolation valve, but a cryogenic (80-K) check valve is required.

(2) Turbine-string inlet and outlet. These are cryogenic valves with the inlet a control valve.

(3) Cold gas return valves at the following temperature levels: 300K, 80K, 30-40-K, 10-15K, 5K. These are all cryogenic control valves, including the 300K valve. Each of these valves shall connect from the cold gas return to the LP stream, except for the 300K valve which is planned to be connected to an ambient vaporizer (by others).

(4) HP stream to cold gas return bypass at the 5-10K temperature level. This is a cryogenic control valve.

(5) Primary 4.5-K supply (PS-1 and PS-2) and primary 4.5-K return (PR-1). These are all cryogenic control valves.

(6) 80-K bed inlet and outlet. 80-K bed bypass. These are cryogenic control valves.

(7) Additional valves are required for utility functions; e.g., process line purge and evacuation, bed regeneration, turbine warm-up/cool-down, insulating vacuum, instrument air, cooling water, etc. Any valve subject to process temperatures, including due to an upset condition, less than 245 K shall be a cryogenic valve. Any valve requiring any flow control variation (other than full open and full close) for any required process mode (or transition between modes) or utility mode shall be a control valve.

(b) All control valves shall be sized in accordance with ISA-S75.01 for all operation and utility modes (including cool-down and warm-up). Sizing calculation shall be provided at FDR. Unless otherwise approved, valves shall be sized so that at the maximum flow condition the valve is approximately at 85% of the total travel. In general, control valves shall have an equal percent flow characteristic and a range of (approx.) 100 to 1.

(c) Valve through leakage shall conform to ANSI/FCI 70-2 Class VI, unless otherwise specifically approved by JLab.

(d) Unless approved by JLab or otherwise specified herein all control valves shall be failed close. Subcontractor shall provide the fail mode information of all control and solenoid valves to JLab during FDR.

(e) Valve selection (i.e., construction, rating, design information), sizing calculations, through leakage rate and fail-position shall be reviewed and approved by JLab.

(f) If the flow through a valve is sonic, the plug and seat material shall be stellite or have a comparable hardness.

(g) All valves shall be stamped with the manufacturer flow arrows on the body; and if applicable, on the vacuum jacket.

(h) All manual service valves shall be collected in (no more than) a few well organized, convenient and easily accessible locations

(i) All main process valves that are on/off (digital) shall be provided with “dry” electrical contact position limit switches (minimum and maximum), which indicate the position of these valves, and shall be wired by the Subcontractor to a local terminal enclosure. The contacts shall close when the valve is in the maximum or minimum stroke position.


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3.4 Process Control and Instrumentation

Subcontractor shall provide a PLC system and all instrumentation required to allow the cold box to operate independently of the JLab CTF control system (which is not in scope). ALL equipment signals for monitor and control of the cold box system shall be available and accessible to the JLab CTF control system. This includes process control parameters and digital (on/off, open/close, etc.) signals. The Subcontractor shall provide the necessary required hard wired safety shutdown and protections to protect both equipment and operator(s) in the event of a failure of JLab’s control system and/or to protect from utility failure or interruptions and from sudden process upsets (e.g., excess cold gas from load, compressor tripping, etc.), especially those necessary for all the rotating equipment. The control system of the cold box system shall be designed to allow continuous and stable operation with minimal operator intervention.

3.4.1 Control Diagram (a) The Subcontractor shall use instrumentation and control symbols on process and

instrumentation diagrams per ISA S5.1 to S5.4. (b) The loop numbering system shall comply with JLab requirements as listed in

Appendix A.

3.4.2 Instrumentation (a) Subcontractor shall provide the anticipated instrument air usage and supply

pressure requirements of the refrigeration system to JLab. (b) Subcontractor shall provide a common instrument air manifold for each usage

pressure level utilized on the cold box. The manifolds shall derive their source of instrument air from the common instrument air manifold by way of pressure reducing regulators as required. Each manifold shall be provided with a pressure gauge. Subcontractor shall provide tubing and instrument air isolation valves between the each control device and the instrument air manifold.

(c) Where the temperature sensor location is to be used for control purposes, dual temperature sensors shall be installed. Pressure and differential pressure sensors shall be replaceable without contaminating the process or requiring cutting, welding, etc.

(d) Pressure transducers shall be of the absolute type (not gauge), 24 VDC excitation, 4-20 mA, 2-wire design. Pressure transducers shall have a minimum 0.1% of span overall accuracy. The transducer wiring shall be shield and terminated to the terminal enclosure.

(e) The minimum stem size for process pipe mounted pressure gauges shall be 1/4 IPS. All pressure gauges shall be silicon oil filled for vibration protection. Dial pressure gauges shall have a minimum dial size of 4-1/2 inches, and a minimum accuracy of 1-1/2% of span. System operating pressure shall not exceed 75% of the pressure gauge span. Pressure gauges which normally operate near atmosphere pressure shall be the compound type capable of measuring down to 760 mm of mercury (vacuum). All pressure gauges shall be capable of being evacuated without being damaged or affecting their calibration.


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(f) Isolation and calibration valves shall be installed for each instrument that connects to processing pipes such as pressure transducers. Differential pressure instrumentation shall be provided with an equalization valve in addition to the process isolation valves. Unless otherwise approved, Swagelok VCO fittings (or JLab approved equal) shall be used for external tubing connection if it is not welded. Pressure sensing and contamination monitoring lines shall have an inside diameter of at least 4.6 mm (0.180 inches).

(g) Subcontractor shall provide pressure and temperature measurement for supply and return from loads. If flow meters are provided for supercritical product supply lines, they shall be located upstream before any pressure reduction in the process stream.

(h) Each turbine shall be provided with a local control panel if required. The panel shall provide all local safety shutdowns and interlock control functions to protect the turbine.

(i) Design, selection and installation of all flow measurement, including devices (elements) and transducers, shall be reviewed and approved by JLab. A mass flow measurement with an overall accuracy better than 2% at the guaranteed modes for each turbine-string shall be provided by the subcontractor.

(j) All pneumatic control valves shall be equipped with a pneumatic position controller and an instrument air isolation valve, air regulator, supply and instrument pressure gauges, and shall be capable of being operated from a 4-20 mA signal source.

(k) Local instrumentation shall be affixed to various components or to an instrument panel prior to shipment to the site to minimize field construction requirements.

(l) Subcontractor shall provide color coded wiring with wiring labels to one side of field terminals within the enclosures. The opposite side of the terminals shall be reserved for field wiring by JLab to the JLab control system. Wiring shall be in accordance with NFPA-70 standards and in accordance with Subcontractor supplied wiring schematics. Control schematics, wiring diagrams, termination enclosure locations, and a cold box instrument list shall be provided for review and approval to JLab at FDR.

(m) Temperature measurement devices shall have an accuracy of at least 2.5%. Selection of temperature measurement devices and transducers, wiring used and thermal anchoring details and procedure shall be approved by JLab. Unless otherwise approved by JLab, temperature measurement devices shall be 4-wire devices. Subcontractor shall provide transmitters with a 4-20 mA DC output for the temperature measurement devices.

(n) Subcontractor shall supply instrumentation and valve identification tags with the instrument and valve identification permanently imprinted on the tags. Tags shall be securely affixed to instrumentation and valves.

(o) All instrumentation provided by Subcontractor shall be listed, labeled and recognized or certified by a NRTL (National Recognized Test Laboratories) for its intended use of service.

(p) Subcontractor shall provide at FDR to JLab a complete list of all instrumentation, including manufacturer, part number, component specifications, mechanical and electrical connection type/sizes, and the overall accuracy of each measurement (including the effect of the installation and the range each transmitter is scaled).


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A preliminary instrument list that includes the manufacturer, part number and specification (provided by instrument manufacturer) shall be provided with the proposal.

3.4.3 Electrical Installation

(a) All electrical equipment provided by Subcontractor shall be listed, labeled,

recognized or certified by a NRTL for its intended use of service. (b) All power and signal wire and cable installed both inside and outside the cold box

by the Subcontractor shall be specified in accordance with NFPA-70 requirements.

(c) Wire size for powering electric heaters installed inside the vacuum space shall be at least one size larger than the code requires based solely on the expected maximum electrical load current. This requirement is to compensate for the lack of normal convective cooling in the vacuum environment. Heater wiring length shall be selected to minimize the heat in-leak and shall be thermally anchored to LN to minimize heat in-leak. Heater wiring size, length, insulation, thermal anchoring details and termination details shall be provided for review and approval by JLab at FDR.

(d) Wire insulation selected for inside the cold box shall be a suitable type specifically approved for use inside a high vacuum, considering potentially higher wire temperature, out-gassing and material stability. Teflon insulated wire is normally acceptable for copper (power) wiring. Polyimide insulated wire is normally acceptable for temperature sensor wiring.

(e) All analog sensor and signal wires used inside the cold box shall be (duo, quad, etc.) twisted pairs. Wiring to temperature sensors shall be sized to minimize heat in-leak, be properly thermally anchored and not made of copper (phosphor-bronze or manganin is preferred). Sensor and signal wiring size, material, insulation, length, thermal anchoring details and termination details shall be provided for review and approval by JLab at FDR.

(f) The Subcontractor shall ensure that all electrical power wiring inside the cold box, such as that used for electric heaters, is routed separately from signal cable bundles to minimize electro-magnetic-interference (EMI) noise coupling that would degrade the analog signal quality.

(g) All cold box electrical interfaces between the Subcontractor supplied equipment and JLab shall be inside terminal enclosures reviewed and approved by JLab. Terminal enclosure requirements are as follows: • Enclosure shall have a rating of NEMA type 12. • Subcontractor shall size the enclosure to have adequate space for both the neat

and efficient installation and termination of Subcontractor’s cables and the connection of wireways and conduits associated with the JLab cables.

• All wiring terminals inside the enclosure shall be finger safe. • Wiring for low voltage control signals shall be routed separately from power

wiring. • If active powered components are installed, adequate ventilation shall be

provided. • At least 5% of the terminal blocks shall be spares.


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• Subcontractor shall provide the enclosure details for review and approval by JLab.

• No enclosures are allowed inside the cold box.

(h) The Subcontractor shall specify all fusing required at the cold box in accordance with NFPA-70. The fuses shall be installed inside JLab and code approved electrical enclosures.

(i) Subcontractor shall supply all mating connectors required for connection of JLab installed field wiring. Spares shall be provided for all connector types. Details shall be provided at FDR.

3.4.4 Plant Protection and Alarms (a) Subcontractor shall furnish a list of required alarms and any required externally-

implemented process protection logic. Alarms shall be structured in a logical manner and shall be modifiable by JLab, assessable by the JLab CTF control system and have adjustable set-points and latch times. The cold box system and all its components shall be automatically protected due to any utility or control system failure. All the rotating equipment shall have hard wired safety shut-downs incorporated into the Subcontractors design.

(b) In case of a controls failure or a failure of a utility (vacuum, power, instrument air, water, etc.) required by a turbine-string or a detection of any turbine component failure occurs, the inlet valve to that turbine-string shall close and the turbine-string be shut-down and secured in a safe state without operator intervention.

(c) In case of a vacuum controls failure or a failure of a utility required by the vacuum system, the vacuum gate valve shall close (isolating the cold box vacuum from the high vacuum pump) and the roughing and high vacuum pumps shall be shut down and vented. Additionally, if the vacuum vessel pressure or high vacuum pump fore-line pressure rises above the pressure that high vacuum pump can operate, the vacuum gate valve shall close and the high vacuum pump shall be shut-down (turned-off) and vented without operator intervention.

4. INSPECTION AND TESTING

4.1 Inspection 4.1.1 General

(a) Subcontractor shall provide a manufacturing, inspection and testing plan for

review and approval by JLab with the proposal and at FDR. This plan shall be updated with JLab concurrence as these tasks progress.

(b) JLab reserves the right to observe the testing, dismantling, inspection, and re-assembly of equipment. The inspector representing JLab shall have entry to the plants (including the sub-Subcontractor plants) where the equipment is being fabricated or tested. The Subcontractor shall inform his sub-Subcontractors of JLab’s inspection requirements.


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(c) The Subcontractor shall give JLab at least ten (10) working days advance notice of when tests are scheduled and when equipment is to be inspected prior to shipment.

(d) Where inspection is specified, surfaces or parts shall remain unpainted until the inspection is completed.

(e) The Subcontractor shall maintain records of all inspection and tests. This information shall be made available to any JLab technical representative and shall be included in the final documentation package.

4.1.2 Shop Tests (a) Subcontractor shall submit a Manufacturer’s Data Report, Form U-1 or U-1A, in

accordance with ASME BPVC Section VIII prior to shipment. (b) Examination and testing of all piping within the scope of ASME B31.3 shall be

performed according to Chapter VI of this code. Suitable records of examinations, procedures, and certified qualifications shall be provided to JLab.

(c) Except for the vacuum jacket, all assemblies shall be subjected to a pneumatic test using dry nitrogen. Testing shall be in accordance with ASME BPVC Section VIII UG-101 or paragraph 345.5 of B31.3 as applicable. Subcontractor shall submit a complete report prior to shipment.

(d) The assembly shall be leak tested for tightness. Shop leak test procedures shall be approved by JLab and shall be equivalent to ASTM E493, E498, E499, as applicable. Subcontractor shall submit leak test reports to JLab.

(e) Tests shall not use water (or liquid) unless specifically approved by JLab. (f) Shell vacuum shall be tested to ensure tightness by verifying helium leakage does

not exceed the requirements of the specification due to leakage from process lines (to the vacuum space). Shell vacuum shall be demonstrated to be air-tight by being evacuated below 10-2 Pa with all components at ambient temperature (no cryo-pumping advantage), isolating vacuum pumping system (from pumping on the shell vacuum) and verifying that there is no more than one decade rise in the vacuum over 24 hours. Subcontractor shall submit test results to JLab.

(g) Subcontractor shall provide a test report documenting the successful completion of all end-to-end wire checks.

(h) Manufacture standard turbine testing shall be done at the Subcontractor’s facility to demonstrate that the turbine(s) can operate at the required tip speeds and the brake design is appropriately designed. The results shall be provided to JLab at the completion of the testing and in the final document package.

4.2 Cleaning

(a) Subcontractor shall develop and employ a strict procedure for ensuring a high standard of cleanliness.

(b) Subcontractor shall submit detailed, preliminary cleaning procedures with the proposal and final versions for JLab review and approval at FDR.

(c) The piping and other systems shall be completely drained and dried of water and solvents following cleaning and any hydrostatic testing.


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(d) Visual inspection under bright light shall indicate no moisture, rust, foreign matter, film, or accumulation of oil, grease, or paint.

(e) Cleanliness shall be maintained at all stages of fabrication, shipping and storage. 4.3 Painting

Subcontract shall specify the paint system and application procedure for JLab review and approval at FDR.

5. DELIVERY AND ACCEPTANCE TESTS 5.1 Shipment

Subcontractor shall be responsible for packing, shipping, unpacking and reassembly from Subcontractor site to JLab installation site. Subcontractor’s quote shall include costs as separate line items. The 4.5-K helium refrigerator delivery shall be FOB destination. Details or shipping, supports, packaging and routing, as well as, re-assembly details and plans shall be submitted for review 30 days prior to shipping.

5.1.1 Packing (a) The Subcontractor shall provide proper protection from shipping loads and any

environmental damage during transportation, hauling and storage. (b) All items heavier than 20 kg shall have lifting lugs. Any special lifting gear such

as spreader bars shall be furnished by the Subcontractor. JLab will retain all special lifting gear, if it is required for maintenance.

(c) The Subcontractor shall design and fabricate protective packaging with adequate performance to ensure protection against natural and induced environments for delivery and storage of the cold box components.

(d) The components shall be shipped in as complete form as possible. Each unit and their internal components shall be blocked, braced and protected from damage during shipment and recording accelerometers for three degrees of motion shall be firmly attached.

(e) Shipping labels and operational warning signs and tags shall be attached as required.

5.1.2 Shipment The Subcontractor shall arrange shipment routes considering weights, clearances, permits statutes and where necessary arrange for escorts and the timing of shipments. If damages were detected after the transport, the repair shall be at expense of Subcontractor.

5.2 Installation

Although reassembly of equipment is the Subcontractor’s responsibility, the installation of the refrigeration system including compressor system, cold box and piping will be performed by JLab. Subcontractor shall provide the supervision for the installation. Subcontractor shall provide all information in sufficient detail for the installation


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including the weight, height, and sizes of each major component. Subcontractor shall provide all special mounting parts. Subcontractor shall provide supervision for the equipment/instrumentation calibration and for the control system validation during the installation.

5.3 Acceptance Tests In order to verify that the helium refrigeration system is performing as designed and has the guaranteed/expected capacity and efficiency stated by the Subcontractor, the system is required to pass the acceptance test described herein. The Subcontractor shall provide the services of competent engineers and technicians to conduct and assume responsibility for initial startup and operations and for the acceptance tests. Subcontractor shall adhere to all JLab site requirements, including training. The Subcontractor shall use, for the purpose of training JLab employees (designated by JLab) to actively participate as required during all phases of acceptance testing. JLab may also assign other personnel to monitor, observe and follow acceptance testing (for training or for evaluation/analysis of Subcontractor testing). JLab will provide the external loads to measure 4.5-K refrigeration and 4.5-K liquefaction loads. The refrigeration load will be measured using electric heaters. The liquefaction load will be measured using an ambient temperature flow meter downstream of an ambient air vaporizer. The overall system will be tested at each operating mode to verify that the cold box system actually performs at or above the Subcontractor’s guaranteed/expected process design capacity and efficiency. Cold box cool-down, cold box warm-up, cold box failure modes (turbine, controls, utility, etc.), 80-K and 20-K bed regeneration, turbine cartridge change-out and cold box system leak tightness shall also be demonstrated by the Subcontractor as part of the acceptance tests. Subcontractor shall be responsible to correct any cold box system performance deficiencies. Acceptance test plan shall be finalized during FDR and submitted for final approval prior to shipment. The Subcontractor shall submit operational test procedures to JLab at least 30 days before start of acceptance test for review and approval by JLab. Final operating procedures, maintenance manuals and acceptance test report are due 30 days after completion of acceptance testing.

5.4 Spare Parts Subcontractor shall provide a complete list of required spare parts required for 12 months of continuous operation including detailed description, drawings, part number and pricing per Option 001 noted in the Bid Schedule, Subcontractor shall supply one spare turbine cartridge for each turbine at the same time as the delivery of the cold box.


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5.5 Warranty

Warranty period of the system shall be no less than 12 months and begin after the successful conclusion of the JLab acceptance test Per JSA Clause 214.


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APPENDIX A. DEVICE NUMBERING AND COMPUTER NAMING CODE All device naming shall have the following format and syntax:

CDDDxxxxx or CDDxxxxx

“C” is not used on the process diagrams. It is used at JLab to designate that the signal belongs to the Cryogenics Group. “DDD” or “DD” represents device type. The device type designations are given in Table A1. “xxxxx” represents device instance (number) and shall follow the requirements in Table A2 and be in sequential order, from the warm-end to cold-end of the cold box.

Table A1. Device Codes Device ID Device Description

CV check valve DP diffusion pump EV electric-actuated control valve FA flow alarm (general) FAH high flow alarm FAL low flow alarm FCV flow control valve or check valve FE flow element (orifice plate, venturi, etc.) FI flow indicator FIC flow indicating controller FS flow switch FSH high flow switch FSL low flow switch FT flow transmitter HIC hand (manual) indicating controller IA amperage alarm (general) II amperage indicator IS amperage switch ISH high amperage switch ISL low amperage switch KAL anti-recycle (inadequate time) KI elapsed time meter LI level indicator LIC level indicating controller LT level transmitter


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LY level signal converter MV manual valve PA power amplifier PAH high pressure alarm PAL low pressure alarm PV pneumatically actuated control valve PDAH high differential pressure alarm PDAL low differential pressure alarm PDI differential pressure indicator PDS differential pressure switch PDSH high differential pressure switch PDSL low differential pressure switch PDT pressure differential transmitter PI pressure indicator PS power supply PSH high pressure switch PSL low pressure switch RV relief valve SA speed alarm (general) SAH high speed alarm SAL low speed alarm SE speed pickup or transducer SIC speed indicating controller SR speed recorder SS substation SSH high speed switch SSL low speed switch ST speed transducer SY speed signal converter TA temperature alarm (general description) TAH high temperature alarm TAL low temperature alarm TC thermocouple temperature sensor TD diode temperature sensor TE temperature element TI temperature indicator TIC temperature indicating controller TJI multi-point temperature indicator TP platinum temperature sensor TR temperature recorder


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TS temperature switch (general description) TSH high temperature switch TSL low temperature switch TT temperature transmitter TY temperature signal converter ZE position sensing element ZI position indicator ZS position limit switch (general) ZSH high position limit switch ZSL low position limit switch

Table A2. Device and control loop number rule Number CTF Cold Box

26100-26199 Helium Low Pressure 26200-26299 Helium Intermediate Pressure 26300-26399 Helium High Pressure 26400-26499 Helium Utility 26500-26599 Nitrogen 26600-26699 Spare 26700-26799 Instrument Air 26800-26899 Cooling Water 26900-26999 Vacuum


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APPENDIX B. SUSPECT/COUNTERFEIT PARTS The list below and all other counterfeit parts shall not be used in any piece of equipment.

A

NF

H

M

MS

E

A Asahi Mfg. (JP)

NF Nippon Fasteners (JP)

H Hinomoto Metal (JP)

M Minamida Sieybo (JP)

MS Minato Kogyo (JP)

Hollow Triangle Infasco (CA TW JP YU)(Greater than 1/2 inch dia)

E Daisi (JP)

KS

RT

FM

KY

J

UNY

KS Kosaka Kogyo (JP)

RT Takai Ltd. (JP)

FM Fastener Co. of Japan (JP)

KY Kyoei Mfg. (JP)

J Jinn Her (TW)

UNY Unytita (JP)

HEADMARK LISTALL GRADE 5 AND GRADE 8 FASTENERS OR FOREIGN ORIGIN WHICH DO NOT BEAR ANY MANUFACTURERS’HEADMARKS:

Grade 5 Grade 8

GRADE 5 FASTENERS WITH THE FOLLOWING MANUFACTURERS’ HEADMARKS:

MARK MANUFACTURER MARK MANUFACTURER

MARK MANUFACTURERMARK MANUFACTURER

J J Jinn Her (TW) KS KS Kosaka Kogyo (JP)

GRADE 8 FASTENERS WITH THE FOLLOWING MANUFACTURERS’ HEADMARKS:

GRADE 3.2 FASTENERS WITH THE FOLLOWING HEADMARKS:

GRADE A325 FASTENERS (BENNETT DENVER TARGET ONLY) WITH THE FOLLOWING HEADMARKS:

MARK MANUFACTURER

MARK MANUFACTURER

KS KS Kosaka Kogyo (JP)

A325KS A325 KS Kosaka Kogyo (JP)

A325KS

A325KS

Type 1

Type 2

Type 3

Key: CA-Canada, JP-Japan, TW-Taiwan, YU-Yugoslavia

ANY BOLT ON THIS LIST SHOULD BE TREATED AS DEFECTIVE WITHOUT FURTHER TESTING.OR, IF YOU SEE ANY INDICATION THAT A CIRCUIT BREAKER MAY BE USED OR REFURBISHED(SEE BULLETIN, NO. DOE/EH-0266)

SUSPECT/COUNTERFEIT PARTS