Brookhaven Science Associates is seeking exchanges with industry to determine the feasibility of a planned procurement for radiant tolerant power supplies in support of the U.S. ATLAS program. This exchange of information will improve the understanding of the requirement and industry capabailities, enhance Brookhaven's ability to obtain these supplies and services at a reasonable price as well as increase the efficiency in the proposal preparation, proposal evaluation and the contract award. The Statement of Work contained herein is an abridged version and all interested parties are encouraged to request a complete copy of the Statement of Work that will be provided electronically. All exchanges, comments, concerns, questions, and requests are to be submitted via email to the attention of JoAnna Black, Procurement Supervisor, at
[email protected] no later than 4:00 pm (local time) on December 19, 2006. Telephonic requests will not be considered. Exchanges with industry are requested for the following Statement of Work, inclusive of providing estimated pricing, delivery, market information, capabilities, and additional information concerning the feasibility of the requirement: 1 Scope 1.1 This specification defines the performance, design and construction requirements, quality assurance aspects, and the inspection and testing protocol, of radiation tolerant DC to DC converters, hence forth called power supplies, to be used at the ATLAS Liquid Argon Calorimeter Detector. The power supplies will be installed at CERN, the European Organization for Nuclear Research, located near Geneva, Switzerland. The equipment will be procured be Brookhaven National Laboratory under a contract to the United States Department of Energy. The detailed design parameters for these power supplies appear in the Specification Data Sheets section 11. 1.2 The power supplies shall convert an input voltage of + 280 Volts DC into seven (7) low voltage DC outputs of various current levels, to provide power for the Detectors front end electronics (FEC) crates.(see specification data sheet) 1.3 The power supplies will be mounted in the detector and as such their physical dimensions must be compatible with the detector geometry. The power supplies shall have the exact form factor and physical dimensions as describe in this specification (See the Specification Data Sheet section 11 and figure 1). 1.4 The power supplies will operate in a radiation environment and must comply with the radiation tolerance requirements of this specification in sections 4.13.8 and 4.13.9. 1.5 The power supplies shall operate in a continuous magnetic field, as specified in the Specification Data Sheets section 4.13.10. They shall meet all requirements of this specification while operating in this field. No component of the power supply shall be adversely affected by this level of magnetic field. 1.6 Each voltage section of the power supplies shall be modular in design. Each section shall be made up of N+1 modules. They shall be able to supply the rated currents of each of the seven (7) output sections with one module of each output section faulted that is with N modules. This will be known as N+1 redundancy. 1.7 The power supplies shall be designed for extreme reliability. They will be inaccessible for long periods of time and must perform continuously for two year periods without servicing or maintenance. They will operate continuously seven days a week, twenty-four hours per day, 365 days per year. 1.8 The design of these power supplies shall be conservative, using standard commercially available component parts and techniques that insure high reliability and minimum maintenance. It shall have an expected service life of greater than fifteen years. 1.9 The Vendor shall give a very high priority to equipment availability concerns such as mean time between failures (MTBF) and mean time to repair. The design shall stress and be judged on such issues as modularity, layout of critical components and ease of serviceability. 1.10 The Vendor will be held responsible for the design, construction, and factory testing of the power supply. Due to the critical nature of these supplies, they shall undergo complete, full power testing before shipment to BNL. The Vendor shall be responsible for conducting this testing either at the Vendor?s facility or a subcontract?s facility chosen by the Vendor. 1.11 Two prototype power supplies shall be designed, built, and fully tested by the Vendor. Further testing of the prototype units shall be performed at BNL and upon written acceptance of the prototype units by BNL , work shall begin on the production units. 1.12 No changes shall be made to the production units with respect to the prototype units without express written consent from the BNL Division of Contracts and Procurement (DCP). 1.13 The Vendor shall provide all the labor and resources required to produce detailed, as built, documentation of the power supply. 1.14 After award of contract, no deviation from this specification is permitted unless written approval is obtained from the BNL DCP. 1.15 Due to the importance of these power supplies, BNL may wish to purchase spare components, boards, modules, or other critical components necessary for their quick repair. The Vendor shall agree to furnish these required spare parts for a period of five years after final acceptance of the units. 2 Applicable Documents 2.1 The following documents form a part of this specification and are to be used as standards in the design and manufacture of this equipment. Any exceptions to these standards must be approved in writing by BNL. Number Title BNL - QA -101 Supplier Quality Assurance Requirements Code of Federal Regulations OSHA General Industry Safety and Health Title 29, Section 1910 Regulation and Standards NFPA 70 National Electric Code IEEE 383 Vertical Flame Test EN 55011 Class A Emission of noise EN 61000-3-2 Harmonic Current Emissions EN 61000-4-4 Fast Transient Immunity EN 61000-4-5 Surge Immunity 2.2 All equipment supplied under this specification shall be in strict accordance with the latest standards, publications and definitions of the IEEE, ANSI, NEMA and NEC. Corresponding European standard may be acceptable if approved in writing by the BNL DCP. Applicable European standard shall be listed in the Vendors quotation. The power supplies shall be manufactured in accordance with the best of existing techniques and recognized engineering practices. In all cases reference shall be made to the applicable procedures and standards of the above organizations. Where this specification calls for a more conservative requirement than the above standards and procedures, this specification shall apply, (see 3.1.3). 3 General Requirements This section of the specification describes the performance and physical characteristics of the power supply. Alternate solutions, offered by the Vendor, that provide equal or better performance and reliability will be considered. Acceptance of any alternate solutions will be at the discretion of the BNL Cognizant Engineer and must be given in writing from the DCP. 3.1 Parts, Materials and Processes 3.1.1 Materials that may be defined as hazardous in accordance with Title 29, Code of Federal Regulations, Section 1910.1200 shall not be used. Asbestos or asbestos-type insulation, and components containing PCB's, etc., shall not be used. Where a choice of materials is available, e.g. Cables, insulating materials, etc., preference shall be given to materials exhibiting a higher level of fire retardancy. 3.1.2 This specification requires various equipment, materials, processes, and products of manufacture that will be required unless BNL?s DCP specifically approves equal construction in writing. Should the Vendor propose to furnish other "equal" materials, processes, or products either in substitution for, or as an alternate to the specifications, Brookhaven can approve such substitution only if described in full detail. The Cognizant Engineer's decision as to the equality of any materials, processes and products to those specified shall be final, but the approval of BNL shall not relieve the Vendor from his responsibility concerning such work or affect the guarantee covering all parts of the work. 3.1.3 The BNL Cognizant Engineer shall have final approval as to the determination of design parameters, operational margins, specification interpretation, control, protection and testing. Differences between the Vendor's proposal and the standards or Brookhaven's requirements shall be resolved by the Cognizant Engineer's determination. Vendors shall obtain written approval from BNL?s DCP before proceeding with the final design and fabrication of this equipment. 3.2 Submittals by Vendor Before Award of Contract 3.2.1 The Vendor shall submit a proposal that gives a PARAGRAPH-by-PARAGRAPH response as to how he intends to comply with this specification. Any exceptions that the Vendor may take to the specification shall be clearly noted in the proposal, in a section labeled ?Exceptions to the Specification.? The Vendor shall be in full compliance with all aspects of these specifications that are not noted in the ?Exceptions to the Specification? section. 3.2.2 The Vendor shall state in the proposal what steps in the design, component selection, and construction, are being taken to ensure radiation tolerant equipment 3.2.3 The Vendor shall state in the proposal what steps in the design, component selection, and construction, is being taken to ensure reliability of the power supplies and what are the expected MTBF of the power supplies. 3.2.4 The Vendor?s proposal shall include a list of power supplies with similar ratings and construction that the Vendor has produced and shipped. Special emphasis will be placed on units that operate in radiation environments. The list shall include the performance data for these power supplies, the purchaser's name and shipping date, and the radiation environment in which the equipment operates. 3.2.5 The Vendor shall list in his proposal the materials which will be used in and have contact with the ATLAS water system. 3.2.6 The Vendor shall describe in his proposal the testing capabilities of his facility. The Vendor will be required to perform a long-term (120 hour on the prototypes) full load test of these power supplies. This test may be performed at an independent test facility if the Vendor so chooses. The location and capabilities of the test facility selected shall be clearly stated in the Vendors proposal. (see section 5) 3.2.7 Five sets of preliminary outline drawings showing the overall dimensions, component placements, block diagrams, preliminary schematics and a preliminary manufacturing schedule shall accompany the proposal. 3.2.8 The Vendor shall fill out the attached form entitled "Vendor Data Sheet" and return it with his proposal. After Award of Contract 3.2.8 The Vendor shall supply adequate documentation for the Final Design Review as specified in 3.4.2. 3.2.9 Four (4) weeks prior to testing the prototype, the Vendor shall submit for BNL's review and approval, a copy of the final test procedure. 3.2.10 Two (2) weeks prior to testing the prototype unit the Vendor shall supply complete schematic diagrams, parts list, and component layouts for the units to be tested. 3.3 Documentation 3.3.1 Paper Drawings - upon delivery of the equipment, the Seller shall supply five (5) sets of final as built, signed prints. These prints shall be made to the highest professional drafting standards. They shall include schematics of all circuits, and all assemblies, down to the card level. Parts lists and component layouts shall also be included. Each component shall be identified by its reference number, as well as its commercial part number. 3.3.2 Electronic Drawings - All drawings supplied in paragraph 3.3.1 shall be supplied in electronic form. AutoCAD format is acceptable. Any other format must be approved by BNL in writing. 3.3.3 Paper Manuals - Five (5) sets of bound design and operations manuals shall be shipped with the equipment. They shall include final parts lists, recommended spare parts lists, technical descriptions of the power supply operation and maintenance recommendations, detailed circuit descriptions, description of critical adjustments and potentiometer settings, and data sheets on fuses, semiconductors, relays, and other pertinent components. All parts shall be identified by their commercial parts number, not solely by the Vendor?s part number. If any component part is built to a specification or otherwise customized that documentation shall be provided to BNL. If customized parts are provided by the Vendor, BNL shall have the right to procure those parts directly from the subcontractor at a later date. 3.3.4 Software Documentation - If software is used to program any device, such as micro-controllers, programmable gate arrays, or PLCs, the source code for that software shall be delivered in electronic form. 3.3.5 Traveler - A traveler shall follow all power supplies through production. This traveler shall contain critical settings for the power supply and shall serve as a history of its production. A copy of this traveler shall be supplied to BNL upon completion of factory tests. The traveler shall contain as a minimum, any rework required, inspection reports, potentiometer settings, torque settings, test results, trip settings, etc. 3.3.5 The Vendor shall supply a list of recommended spare parts 3.4 Design Reviews 3.4.1 Prior to awarding a contract a pre-award meeting shall be held at the either BNL or the Vendor's facility at the discretion of the BNL Cognizant Engineer. At this time a preliminary review of the submitted design will be held and the capability of the Vendor to produce and test this power supply in a timely fashion will be evaluated. 3.4.2 BNL will aid in the radiation testing needed to qualify the power supplies as suitable for a radiation environment. The requirements and responsibilities for these tests will be finalized at the pre-award meeting. 3.4.3 The final design review (FDR) shall be held twelve (12) weeks after receipt of order and prior to the start of fabrication. Three (3) sets of preliminary electrical schematic drawings, mechanical assembly drawings, a manufacturing schedule, a preliminary acceptance test procedure, and a complete parts list shall be submitted to BNL at least two (2) weeks prior to the FDR date. Agreement shall be reached during the FDR not only on the drawings and material submitted, but also on the Vendor's manufacturing plan, preliminary test procedure and schedule. Components and materials used in the power supplies shall also be thoroughly reviewed at this time. The results of the FDR shall be fully documented by the Vendor and submitted to BNL for approval. After written approval of the FDR is given by BNL, the Vendor shall promptly begin the production of the prototype power supplies. The specifications for Performance and Design Characteristics, Power Supply Testing -Factors, Final Acceptance - Testing, Quality Assurance and the Responsibility of the Vendor, and Specification Data Sheets are described in detail in the Statement of Work. The complete Statement of Work is available upon request.