Group Code : - Nikhef · Web viewdetailed principle schematics (PID diagrams) with all components...

Group Code.: TS-CVEDMS No.: xxxxxxLHC Project document No.: xxxxxx

The LHCb detector Project IT-3307/TS/LHCb

Invitation to tender

Supply and Installation of cooling equipment for LHCb detector

Technical Specification

AbstractThis Technical Specification concerns the supply and installation of a demineralised water cooling plant and general cooling infrastructure for LHCb experiment; electrical cabling, control systems, test and commissioning are included in the supply. All steps required from design to final acceptance are described.

Installation and commissioning should be completed by October 2005.

November 2004

IT-3307/TS/LHCbLHC Project document No.: xxxxx

Table of Contents

1. GENERAL....................................................................................................................................................11.1 INTRODUCTION..........................................................................................................................................1

1.1.1 Introduction to CERN................................................................................................................................11.1.2 Introduction to the LHC project................................................................................................................11.1.3 Introduction to LHCb experiment.............................................................................................................11.1.4 Subject of this technical specification.......................................................................................................1

1.2 SCOPE OF THE TENDER............................................................................................................................21.2.1 Scope of the supply....................................................................................................................................21.2.2 Items supplied by CERN............................................................................................................................3

1.3 GENERAL CONDITIONS FOR TENDERING AND CONTRACTING....................................................51.3.1 Bidders’ Conference..................................................................................................................................51.3.2 Pre-tender Discussions.............................................................................................................................51.3.3 Alternative Solutions.................................................................................................................................51.3.4 Preliminary Programme...........................................................................................................................51.3.5 Subcontractors..........................................................................................................................................61.3.6 Documents to be submitted with the tender..............................................................................................61.3.7 Presentation of Tender..............................................................................................................................61.3.8 Country of Origin......................................................................................................................................6

1.4 CONTRACT EXECUTION...........................................................................................................................61.4.1 Responsibility for Design, Components and Performance.......................................................................61.4.2 Contract Follow-up...................................................................................................................................6

1.4.2.1 Contract Engineer............................................................................................................................................61.4.2.2 Progress Report...............................................................................................................................................71.4.2.3 Design Approval and Production....................................................................................................................7

1.4.3 Deviations from this Technical Specification............................................................................................71.4.4 Factory Access..........................................................................................................................................71.4.5 Packaging, transport and handling of the equipment...............................................................................71.4.6 Site organization.......................................................................................................................................7

Refer to document: Organization of the installation work of the LHC and its experiments LHC-PM-IP-0001 rev 1.0.. 71.4.6.1 Site installation................................................................................................................................................71.4.6.2 Contractor’s liability for equipment, installations and constructions..............................................................8

1.4.7 Working sequence.....................................................................................................................................81.4.8 Work surveillance......................................................................................................................................81.4.9 Work coordination.....................................................................................................................................81.4.10 Manpower and tooling..............................................................................................................................91.4.11 Assembly....................................................................................................................................................91.4.12 Waste disposal...........................................................................................................................................91.4.13 Cleaning....................................................................................................................................................91.4.14 Insurance.................................................................................................................................................101.4.15 Internet....................................................................................................................................................10

1.5 DOCUMENTS TO BE PROVIDED............................................................................................................101.5.1 Document for Approval Prior to Work Starting......................................................................................101.5.2 On Completion of Work...........................................................................................................................111.5.3 Document Format...................................................................................................................................121.5.4 Archiving of Drawing and Internal Approval on CDD...........................................................................13

1.6 APPLICABLE DOCUMENTS....................................................................................................................131.6.1 Standards.................................................................................................................................................13

1.6.1.1 CERN Standards............................................................................................................................................131.6.1.2 International Standards..................................................................................................................................141.6.1.3 National Standards........................................................................................................................................15

1.6.2 Other References.....................................................................................................................................151.6.2.1 On-site Work Regulations.............................................................................................................................15

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IT-3307/TS/LHCBLHC Project document No.: xxxxx

1.6.2.2 Other Documents...........................................................................................................................................151.7 SAFETY.......................................................................................................................................................15

1.7.1 Introduction.............................................................................................................................................151.7.2 Co-ordination in matters of safety and health protection.......................................................................151.7.3 Additional Stipulations............................................................................................................................161.7.4 Specific recommendations.......................................................................................................................16

1.8 QUALITY ASSURANCE PROVISIONS...................................................................................................171.9 DELIVERY AND COMMISSIONING.......................................................................................................18

1.9.1 Provisional Delivery Schedule................................................................................................................181.9.2 Packing and Transport to CERN............................................................................................................181.9.3 Handling at CERN..................................................................................................................................181.9.4 Commissioning........................................................................................................................................181.9.5 Acceptance and Guarantee.....................................................................................................................18

1.9.5.1 Partial Acceptance.........................................................................................................................................181.9.5.2 Provisional Acceptance.................................................................................................................................181.9.5.3 Final Acceptance...........................................................................................................................................19

1.9.6 Training...................................................................................................................................................191.10 CERN CONTACT PERSONS.....................................................................................................................192. BASIC DATA.............................................................................................................................................202.1 PRESENTATION OF THE STRUCTURES...............................................................................................202.2 SUMMARY OF THE STRUCTURES........................................................................................................232.3 ENVIRONMENTAL CONDITIONS..........................................................................................................232.4 NOISE LEVEL LIMITS...............................................................................................................................232.5 GENERAL MECHANICAL REQUIREMENTS........................................................................................23

2.5.1 Materials.................................................................................................................................................232.5.2 Reliability, Risk and Breakdown Analysis...............................................................................................23

2.6 REFERENCE DRAWINGS AND SCHEMATICS.....................................................................................242.6.1 Schematic List.........................................................................................................................................242.6.2 Drawing List............................................................................................................................................24

3. TESTS.........................................................................................................................................................253.1 Tests to be carried out at the Contractor's Premises.....................................................................................253.2 Tests to be carried out at CERN...................................................................................................................25

3.2.1 Hydraulic.................................................................................................................................................253.2.2 Control....................................................................................................................................................263.2.3 Noise........................................................................................................................................................27

4. DESCRIPTION OF THE WORKS..........................................................................................................284.1 WORK LOT 1: HYDRAULIC AND MECHANICAL WORKS FOR OUTER TRACKER COOLING SYSTEM..................................................................................................................................................................28

4.1.1 General description.................................................................................................................................284.1.2 Requirements for the design of the cooling station.................................................................................284.1.3 Technical Requirements for components................................................................................................29

4.1.3.1 Pumps............................................................................................................................................................294.1.3.2 Heat Exchangers............................................................................................................................................304.1.3.3 Piping Work..................................................................................................................................................304.1.3.4 Two-way manual balancing valves...............................................................................................................354.1.3.5 Two-way motorized regulating valve............................................................................................................354.1.3.6 Pressure controller.........................................................................................................................................354.1.3.7 Filters.............................................................................................................................................................354.1.3.8 Non-return valves..........................................................................................................................................364.1.3.9 Shutoff valves................................................................................................................................................364.1.3.10 Solenoid valves.........................................................................................................................................364.1.3.11 Expansion Vessel......................................................................................................................................364.1.3.12 Demineraliser (CERN Supply).................................................................................................................374.1.3.13 Welding.....................................................................................................................................................37

4.2 WORK LOT2: CONTROL WORKS FOR OT COOLING SYSTEM.......................................................384.2.1 Instrumentation.......................................................................................................................................38

4.2.1.1 On/off detector switches................................................................................................................................384.2.1.2 Analog sensor and transmitter sets................................................................................................................394.2.1.3 Analog sensor and local gauge sets...............................................................................................................404.2.1.4 Actuators.......................................................................................................................................................40

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4.2.2 Process control and local supervision....................................................................................................404.2.2.1 Communication.............................................................................................................................................414.2.2.2 Security..........................................................................................................................................................42

4.2.3 Safety.......................................................................................................................................................424.2.4 Other work...............................................................................................................................................42

4.3 WORK LOT 3: ELECTRICITY WORKS FOR OT COOLING SYSTEM................................................424.3.1 Scope of the supply..................................................................................................................................424.3.2 Power requirements................................................................................................................................43

4.4 WORK LOT 4: HYDRAULIC AND MECHANICAL WORKS FOR PRIMARY COOLING SYSTEM.43

4.4.1 Description..............................................................................................................................................434.4.2 Operating conditions...............................................................................................................................444.4.3 Technical Requirements for components................................................................................................45

4.4.3.1 Piping Work..................................................................................................................................................454.4.3.2 Technical requirements for lagging...............................................................................................................494.4.3.3 Two-way manual balancing valves...............................................................................................................504.4.3.4 Shutoff valves................................................................................................................................................504.4.3.5 Motorized valves...........................................................................................................................................504.4.3.6 Welding.........................................................................................................................................................51

4.5 WORK LOT 5: CONTROL WORKS FOR PRIMARY COOLING SYSTEM..........................................514.5.1 Instrumentation.......................................................................................................................................51

4.5.1.1 On/off detector switches................................................................................................................................524.5.1.2 Analog sensor and transmitter sets................................................................................................................524.5.1.3 Analog sensor and local gauge sets...............................................................................................................524.5.1.4 Actuators.......................................................................................................................................................53

4.5.2 Process control........................................................................................................................................534.5.2.1 Communication.............................................................................................................................................534.5.2.2 Security..........................................................................................................................................................53

4.5.3 Safety.......................................................................................................................................................544.5.4 Other work...............................................................................................................................................54

4.6 WORK LOT 6: ELECTRICAL WORKS FOR PRIMARY COOLING SYSTEM.....................................544.6.1 Scope of the supply..................................................................................................................................544.6.2 Power requirements.................................................................................................................................55

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IT-3307/TS/LHCBLHC Project document No.: xxxxx

Documents appended to this technical specification

Annex A: Unit Price List Annex B: Technical questionnaire Annex C: Provisional delivery schedule Annex D: Software requirements Annex E: Electrical works

List of FiguresFigure 1 : underground structures at point 8............................................................................................................20Figure 2 : Experimental cavern configuration..........................................................................................................22

List of TablesTable 1 : LHC QAP topics and documents..............................................................................................................18Table 2: operating conditions of the cooling station................................................................................................29Table 3 : pressure rating and nominal diameter for the piping................................................................................31Table 4 : Distance between supports........................................................................................................................34Table 5: electrical power requirements in nominal conditions................................................................................43Table 6 : primary circuits parameters.......................................................................................................................45Table 7 : Distance between supports........................................................................................................................49Table 8: electrical power requirements in nominal conditions................................................................................55

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Terms and Definitions

Term DefinitionCDD CERN Drawing DirectoryCPU Central Processor UnitCV Cooling and Ventilation

DNS Domain Name ServerDCS Detector Control SystemJEC Equipment controller software moduleECR Experiment Control Room

EDMS Engineering Data Management SystemLEP Large Electron Positron ColliderLHC Large Hadron ColliderMTF Manufacturing and Test FolderPLC Programmable Logic ControllerQAP Quality Assurance PlanTS Technical Support

TCP/IP Transmission Control Protocol/Internet ProtocolCCC CERN Control CenterTIM Technical Infrastructure Monitoring system

PGCSPS Overall Safety and Health Protection PlanPPSPS Special Safety and Health Protection Plan

CISSCT Inter-Firm Health, Safety and Working Conditions Committee

SCADA Supervisory, Control and Data Acquisition systemUIAO Electric control cubicle “normal power”

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IT-3307/TS/LHCbLHC Project document No.: xxxxxx

1. GENERAL

1.1 INTRODUCTION

1.1.1 Introduction to CERNThe European Organization for Nuclear Research (CERN) is an intergovernmental

organization with 20 Member States*. It has its seat in Geneva but straddles the Swiss-French border. Its objective is to provide for collaboration among European States in the field of high energy particle physics research and to this end it designs, constructs and runs the necessary particle accelerators and the associated experimental areas.

At present more than 5000 physicists from research institutes world-wide use the CERN installations for their experiments

1.1.2 Introduction to the LHC projectThe Large Hadron Collider (LHC) is the next accelerator being constructed on the

CERN site. The LHC machine will mainly accelerate and collide 7 TeV proton beams but also heavier ions up to lead. It will be installed in the existing 27 km circumference tunnel, about 100 m underground, that previously housed the Large Electron Positron Collider (LEP). The LHC design is based on superconducting twin-aperture magnets which operate in a superfluid helium bath at 1.9 K.

1.1.3 Introduction to LHCb experimentThe LHCb experiment is one of the four detectors that will be installed at the LHC. It

is being constructed by a worldwide collaboration involving 45 institutions from 14 countries. The LHCb experiment will be installed some 100 m below ground level in the

Experimental Area at Point 8 of LHC (close to Ferney-Voltaire in France), hereinafter referred to as “Point 8”. The underground cavern that will house LHCb experiment is referred to as UX85.

The Outer Tracker (OT) is a sub-system of the LHCb experiment. It consists of three vertical rectangular stations (about 5 m high and 6 meters wide) arranged along the beam line.

1.1.4 Subject of this technical specificationThis Technical Specification concerns to main supplies.

Work lots 1, 2 and 3: supply, installation and commissioning of an independent demineralised water cooling station that shall remove the heat released by the Outer Tracker readout electronic. The cooling station shall be able to provide demineralised water at a constant temperature around 20oC; its cooling capacity shall be 23 kW. The transfer lines bringing the demineralised water from the cooling station to the detector periphery are included in the supply.

Work lots 4, 5 and 6: supply and installation of the primary cooling pipes and compressed air distribution for the LHCb detector and its infrastructure inside

* CERN Member States are: Austria, Belgium, Bulgaria, Czech Republic, Denmark, Finland, France, Germany, Greece, Hungary, Italy, The Netherlands, Norway, Poland, Portugal, Slovak Republic, Spain, Sweden, Switzerland and the United Kingdom.

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LHC Project document No.: xxxxx

the UX85 cavern. These pipes will transport water at various temperatures. These pipes are in charge of cooling the various “secondary” cooling systems that are not part of this technical specification (except the cooling system for Outer Tracker).

The Technical Specification includes the piping work, the electrical and control work, the installation and integration of the various components, the testing, commissioning and validation of the systems.

All the installation shall take place in the LHCb experimental cavern.

1.2 SCOPE OF THE TENDER

1.2.1 Scope of the supply Construction of the OT cooling station on a self-contained metallic frame at the

contractor’s premises. Transportation of the cooling station at point 8 surface. The station will be brought

underground at its exact location by the CERN transport service. Fixation of the cooling station at its final position, installation of the transfer line,

connection to the CERN existing hydraulic network. Supply and installation of all primary cooling pipes, including support, fixing, valves and

fittings. Supply and installation of compressed air lines. Control and electricity work:

Supply, installation, verification and validation of the power and control cubicles, including the PLC racks and modules and the supervision PC.

The electrical design, the specification of power supply components and protections.

Power, control and communication cables and cable trays (sized on the basis of the equipment proposed) from the power and control cubicles to the various components, including the electrical connection and all the tests.

Control cabling between the PLCs and the DCS (Detector Control System) of the various interlock signals. The Contractor shall also provide the connections and all the tests at the PLC’s end.

Equipotential links and the earthing of all metallic equipment in conformity with CERN standards.

The supply of all the instrumentation required to operate the process and their mechanical and electrical installation, their connections and connection tests, tuning and verification of the measurements.

Detailed studies for the regulation, control and supervision of the installation, in compliance with the functional requirements.

The supply of the hardware components and instrumentation technical data sheets, in electronic and paper format.

Software development and documentation for the process control PLCs. Software development and documentation for the SCADA supervision application. The connection and configuration of the PLCs in the CERN Ethernet network. The connection and configuration of the SCADA supervision platform in the

CERN Ethernet network.

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The dialogue between the PLCs and the PLC that controls the mixed water supply to the cooling station.

The dialogue between the PLCs and the SCADA supervision platform. The dialogue between the PLCs and the DCS. The dialogue between the PLCs and the CCC remote monitoring system.

The supply of design memoranda and execution drawings for approval by CERN technical services before the execution of the work.

The factory and preliminary tests. The supply in electronic and paper format of the documents, drawings, schematics and

diagrams of the complete installation (hydraulic, control, electricity, pneumatic). The supply in electronic and paper format of the technical description sheets of all the

components (hydraulic, control, electricity). The supply in electronic and paper format of all the control, regulation and supervision

software sources, along with the necessary documentation, libraries and licenses associated with the development of the control system.

The supply in electronic and paper format of the calculation notes showing clearly the selection of the electrical equipments (circuit-breakers, cables, fuses, …)

The supply of the technical files about the organisation and management of the processes operation and the training for the CERN staff in charge of the operation and the maintenance of the equipment.

The labelling and panel signs of the systems and equipment (identification of all hydraulic, electrical, etc…, components by means of engraved plastic labels) in compliance with CERN standards,

The regular cleaning, and cleaning upon completion of the work, of the premises and all the components.

The general commissioning including all the partners involved in the installation of the equipment concerned.

The on-site acceptance tests. All the test records.

The power and control cubicle for the OT cooling station shall be prepared and integrated on the metallic frame at the contractor’s premises.

The Contractor shall be solely responsible for carrying out the work and for the commissioning of the various installations. CERN’s responsibility will be limited to defining the scope of the required supplies and checking the factory and acceptance tests.

1.2.2 Items supplied by CERN The sockets and network parameters (address, gateway, subnet mask, DNS and domain)

for connection of the PLCs and SCADA supervision platform to the CERN Ethernet network.

The software module (JEC) for communication between the PLCs and the CCC remote monitoring system, as well as its associated user manual and installation procedure documentation.

Transport of the cooling station from point 8 surface, to its exact underground location. The supply, installation and electrical connection of the cable from the main power supply

to the power and control cubicles (400 V, 3P+N+E).

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LHC Project document No.: xxxxx4


1.3 GENERAL CONDITIONS FOR TENDERING AND CONTRACTINGPlease refer to the commercial documents for more complete information.Tenders will only be considered from firms having been selected as qualified bidders

by CERN, as a result of the Market Survey MS-3307. CERN reserves the right to disqualify any bidder whose reply to this Market Survey is found to have been incorrect.

1.3.1 Bidders’ ConferenceBefore Tenders are submitted, CERN will give bidders notice to attend one

compulsory one-day joint information meeting at CERN, at which they will be given additional information on technical matters and specific work-related details. In the case of consortia, at least one person from each consortium partner but not more than five persons per consortium must attend the bidders’ conference. Each bidder must be represented by at least one technical manager and one commercial manager.

The following subjects will be covered in the course of this meeting:- information from the CERN Purchasing Service- relations with the Host States- safety criteria- specific requirements to this Invitation to Tenders- visit to the CERN site- questions and answers

Bidders will be invited, wherever possible, to send in their questions by letter or fax in advance so as to reach CERN before the compulsory bidders’ conference. A summary of questions raised and answers given during the conference will be forwarded to all participants without mentioning names. Tenders submitted by bidders failing to attend this conference will not be taken into consideration.

1.3.2 Pre-tender Discussions The Bidder is strongly encouraged to contact CERN and discuss details of this

Technical Specification before submitting a tender. In particular, CERN wishes to ensure that no doubt exists as to the interpretation of this Technical Specification.

1.3.3 Alternative SolutionsIf the Bidder finds that any part of this Technical Specification is difficult, or costly

to meet, he is free to propose an alternative solution, provided that the deviations from this Technical Specification, together with the reasons and advantages, are clearly indicated in the tender. Such alternative solutions shall always be made in addition to a conforming bid, which must comply fully with this Technical Specification.

CERN reserves the right to accept or reject the proposed alternative solutions without justification.

1.3.4 Preliminary ProgrammeThe Bidder shall propose a preliminary design and manufacturing schedule with the

tender, based on the specified CERN provisional delivery schedule.

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1.3.5 SubcontractorsThe Bidder shall declare in his Tender any subcontractors whose services he intends

to use in the event of a Contract. Refer to the commercial documents for more details. If awarded the Contract, the Bidder shall restrict himself both to the subcontractors and the amount mentioned in the Tender. If, for some reason, he wants to change any subcontractor, or the scope of subcontracted work, or the amount subcontracted, he must obtain CERN’s prior agreement in writing.

1.3.6 Documents to be submitted with the tenderThe Bidder’s Tender shall contain the following documents: The Technical Questionnaire (TQ – Annex B), fully completed and in duplicate, The originals of the technical descriptions and documentation issued from the

manufacturers for all the proposed equipment, clearly showing the results of the selection as per the list of technical documentation requested in the TQ,

A detailed schedule for the various phases of the work (following provisional schedule given in Annex C)

The Unit Price List (UPL- Annex A), fully completed and in duplicate,The Bidder shall submit with his Tender any observations or suggestions he may

consider useful concerning the requirements and the prices given in the UPL.The costs associated with drawing up the Tender shall be met entirely by the Bidder.

CERN will not contribute in any way to the expenses incurred by bidders in connection with the tendering procedure.

1.3.7 Presentation of TenderThe Bidder may be required to make a formal presentation of his Tender at CERN at

his own expense. He shall be ready to do so within a week of notification.

1.3.8 Country of OriginPlease refer to the commercial documents for specific conditions concerning the

country of origin of the equipment or services to be supplied.

1.4 CONTRACT EXECUTION

1.4.1 Responsibility for Design, Components and PerformanceThe Contractor shall be responsible for the correct performance of all items supplied,

irrespective of whether they have been chosen by the Contractor or suggested by CERN. CERN's approval of the design and component choice does not release the Contractor from his responsibilities in this respect.

CERN assumes responsibility for the performance of items and sub-systems supplied by CERN.

1.4.2 Contract Follow-up

1.4.2.1 Contract EngineerThe Contractor shall assign an engineer to be responsible for the technical execution

of the Contract and its follow-up throughout the duration of the Contract.

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1.4.2.2 Progress ReportThe Contractor shall supply, within one month of notification of the Contract, a

written programme detailing the manufacturing and testing schedules. The programme shall include preliminary dates for inspections and tests.

1.4.2.3 Design Approval and ProductionThe detailed design shall be submitted to CERN for approval within one month

after notification of the contract. CERN will give its approval or refusal, in writing, within two weeks. Component ordering and equipment manufacture shall not start without CERN’s written prior agreement. CERN reserves the right to refuse any equipment not complying with this technical specification.

1.4.3 Deviations from this Technical SpecificationIf, after the Contract is placed, the Contractor discovers that he has misinterpreted this

Technical Specification, this will not be accepted as an excuse for deviation from it and the Contractor shall deliver equipment in conformity with this Technical Specification at no extra cost.

During execution of the Contract, all deviations proposed by the Contractor from this Technical Specification, the Tender, or any other subsequent contractual agreement, shall be submitted to CERN in writing. CERN reserves the right to reject or accept such proposals without justification.

CERN reserves the right to modify this Technical Specification during execution of the Contract. The consequences of such modifications shall be mutually agreed between CERN and the Contractor, being understood that any additional costs shall be calculated on the basis of the unit prices quoted in the UPL.

All amendments to the Contract shall be in writing.

1.4.4 Factory AccessCERN and its representatives shall have free access during normal working hours to

the manufacturing or assembly sites, including any subcontractor’s premises, during the Contract period. The place of manufacture, as stated in the Tender, may only be changed after written approval by CERN.

1.4.5 Packaging, transport and handling of the equipmentThe Contractor shall be responsible for and shall include in his Tender all the

transport, off-loading and installation of the supply, with its own equipment.

1.4.6 Site organization

Refer to document: Organization of the installation work of the LHC and its experiments LHC-PM-IP-0001 rev 1.0.

1.4.6.1 Site installationAny space which may be required by the Contractor or its Subcontractors shall be

made available by the Contractor from the space allocated to him by CERN.

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The Contractor shall in particular ensure that he complies with CERN’s instructions relating to materials depots, time limits for the use of roadways, lighting, special conditions relating to scaffolding, fencing, etc.

No site huts will be provided by CERN.No fabrication shall be allowed on the CERN site. All material delivered to the work

site shall be ready for assembly.

1.4.6.2 Contractor’s liability for equipment, installations and constructionsWhether on the CERN site or not, the Contractor shall be responsible and liable for

any supplies and any equipment or materials owned by him in accordance with the Contract. He shall take all necessary action to protect them against damage or loss.

1.4.7 Working sequenceIn the following cases, CERN shall issue a work order: approval of Contractor’s

documents, deviations from the specification, action to perform follow-up meetings, schedule modifications, etc.

The work orders shall state: The completion period and the date of work starting (if this date is not specifically

given, it shall be deemed to be the day after the issue of the work order). The definition of the work or construction to be made (descriptions of any

working drawings or sketches).The Contractor shall not carry out any work, which is not covered by a work order. In case the Contractor considers that the instructions in a work order go beyond his

obligations under the Contract he shall state his case in writing within eight calendar days dating from the day after the notification of the work order. This claim shall in no way suspend the execution of the work order, unless otherwise decided by CERN.

1.4.8 Work surveillanceDuring the Contract, the Contractor shall provide access to the work site to all CERN

representatives appointed to supervise the work. He shall appoint a representative on the worksite who supervises the personnel, equipment and the execution of the work. This representative shall be in a position to provide CERN with all the information it needs to monitor the work. He shall be able to communicate in either English or French.

1.4.9 Work coordinationA work coordination team is in place at point 8. The Contractor shall comply with the

recommendations of this team regarding the installation works. The Contractor will not be the only trade present on the work site, and following coordination needs, schedule adjustments may be necessary. These adjustments shall not entitle the Contractor to claim compensations from CERN.

Any interruption during the works shall be acknowledged immediately by both parties (CERN and the Contractor). In case of work interruption (for any reasons independent from the Contractor), the Contractor shall therefore report it immediately to CERN. No claims regarding work interruption that would not have been acknowledged by CERN, will be accepted.

The dimensions of the scaffolding and metallic structures necessary for the installation of the pipelines shall be communicated and submitted to the approval of the work

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coordination team. The successive working positions inside the cavern as well as the provided duration of the installation work shall be submitted to the same authority.

The design and calculation of these structures shall be signed by an agreed person. Their construction shall be done by qualified personnel following the rule of the French authority. (“Décret 2004-924, 01 Septembre 2004, Décret relatif à l'utilisation des équipements de travail mis à disposition pour des travaux temporaires en hauteur et modifiant le code du travail et le décret n° 65-48 du 8 janvier 1965 “).

1.4.10 Manpower and toolingContractor’s personnel: Prior to the start of the work the Contractor shall provide a

list of all his personnel working on the CERN site and their qualifications, which he shall update as necessary.

He shall be responsible for any specific training required for the work at CERN and shall submit the corresponding certificates if so required by CERN.

He shall be solely responsible and liable for obtaining, from the competent national or local authorities, all authorisations required to enable him to fulfil his obligations under the Contract. (Ex. Work permits).

Working period: The Contractor’s personnel shall respect CERN’s working hours. They shall not work on weekends, except if expressly requested by CERN. Please refer to the CERN official holiday calendar for the non working day period.

Replacement of personnel: CERN reserves the right to request at any time the immediate replacement of any of the Contractor’s personnel whose actions or administrative situation are likely to be prejudicial to CERN or any third party working on the CERN site.

Special tooling and equipment: the Contractor shall equip his personnel with all the necessary individual tooling and any special equipment such as: scaffolding, ladders and special hoisting gear as the fulfilment by such personnel of his obligations under the Contract may require. All such tooling or equipment shall comply with applicable laws.

1.4.11 AssemblyThe assembly work shall be done in accordance with the suppliers’ instructions and

with good trade practice.

1.4.12 Waste disposalCERN will install a series of rubbish containers on the work site, the number of

which shall vary according to the different types of waste to be removed. The Contractor shall carefully sort and place all the waste arising from the dismantling of existing installations or new construction work in the appropriate containers. In case he does not comply with his obligations hereunder CERN may sort and/or remove the waste on the Contractor's behalf and charge him with the related costs.

1.4.13 CleaningThe Contractor shall be responsible for cleaning his installations and work site on a

daily basis. Prior to the provisional acceptance, all the structures and all the equipment installed shall be carefully cleaned ready for use.

Furthermore, the Contractor may not store any material, such as combustible packaging, inside CERN buildings. As the work progresses, the Contractor shall remove, at his own expense, all waste and unused materials.

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1.4.14 InsuranceThe Contractor shall be covered by an insurance throughout the duration of his work

at CERN. Any damage caused to other equipment or trade (not related to this Invitation to Tender) shall be covered as well.

1.4.15 InternetWith a view to optimising the exchange of information, the Contractor shall have

Internet access. He shall in particular use Internet for: Exchanging e-mails and files. For security reasons, the CERN mail gateways no

longer accept emails coming from hosts without a valid reverse DNS name for their IP address (reverse DNS is used to get the server name from the IP address). The Contractor shall contact the mail system administrator of his Internet Service Provider, who must configure properly the reverse DNS.

Archiving documents on CERN’s Intranet system, Consulting CERN’s databases to monitor progress with the work.

1.5 DOCUMENTS TO BE PROVIDED

1.5.1 Document for Approval Prior to Work StartingThe following documents shall be submitted to CERN for approval within one

month after notification of the contract: the detailed project timetable with start up and completion dates of the various

tasks to be done, as a function of the provisional delivery schedule appended to this specification,

the technical files of all the proposed equipment (hydraulic components, control and electricity equipment),

a detailed description of safety and health measures (PPSPS see 1.7.2 associated with the proposed installation methods.

OT cooling station (Work lots 1, 2 and 3):o Detailed execution drawings (with the exact location of

instrumentation, drains, air vents…),o detailed principle schematics (PID diagrams) with all components and

instrumentation,o detailed electrical drawings ,

Primary cooling systems (Work lots 4, 5 and 6):o Detailed execution drawings (with the exact location of

instrumentation, drains, air vents…),o detailed principle schematics (PID diagrams) with all components and

instrumentation,o detailed electrical drawings

documents related to the control system:o a full list of the hardware and software,o the line diagram showing the functional links between the various

components used in the installation, including the operation start-up

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and stop sequences, regulation flow charts, instrumentation loop-diagrams, and alarms and security handling,

o the control software development and verification documents, including the functional and dysfunctional analysis. These documents shall contain detailed lists of inputs and outputs, data allocation in the PLC memory (data blocks, flags, temporisations, etc.), data allocation in the SCADA database, with all the related parameters,

o the structure of the PLC and SCADA application programs,o the overall diagram and wiring diagram for the control structure

including all the components,o the electric wiring diagram of the digital and analog inputs-outputs.

electrical calculation notes, a reliability, risk and breakdown analysis (see 2.5.2)

Among all these documents, some need to be supplied before other; the contractor shall refer to the provisional delivery schedule to organise his work.

Unless specified otherwise, the Contractor shall submit to CERN two paper copies and one electronic copy. CERN will inform the Contractor within five weeks of any changes that may be required.

The Contractor shall not start manufacturing, coding or installing on site before approval by CERN of the documents concerned. The Contractor will use only those documents stamped ‘’bon pour execution’’ or “approved” [work authorisation] and signed by the CERN engineer responsible for work on the site.

Approval of these documents in no way discharges the Contractor from his responsibilities as to his installations' compliance with this technical specification.

1.5.2 On Completion of WorkProvisional acceptance can only be pronounced after the hand-over of the relevant as-

built documents by the Contractor.The Contractor shall submit, three weeks prior to acceptance, three paper copies and

one electronic copy of the following amended as-built documents: Reviewed versions of the documents submitted before construction (see

1.5.1), all the software programs (standard IEC 1131.3), source and object files, fully

documented and detailed in accordance with the state of the programming when in service (comments in the programs either in English or French or both),

a folder containing the documents related to all the power and control cubicle components, the functional and operation diagrams and the cabling schematics, the lists of I/O, PLC memory allocation, cross-references, SCADA database and user manual, etc. shall be placed in an adapted documentation pocket inside of one of the cubicle doors,

full sets of drawings based on the completed work, stating in particular the makes and types of all equipment and materials used,

11


technical documentation relating to the appliances installed, giving the manufacturer's name, the types and references of the equipment, and maintenance and operating instructions,

operating instructions giving the different settings, the handling operations, the regularity and types of maintenance work, and providing all the information needed for problem-free care,

the manufacturers' technical documents, the Contractor shall enter the technical parameters of the components on

Excel-type templates supplied by CERN for CERN’s Computer Aided Maintenance Management (CAMM) software in accordance with the coding system of CERN’s quality assurance plan,

the control tests reports, including the regulation, control and communication parameters in accordance with the state of the programming when in service,

the hydraulic tests reports, the noise tests reports.

The Contractor shall submit five paper copies and two electronic copies of the following final documents, updated with any modifications that may have been requested during the acceptance procedure:

reviewed versions of the above mentioned documents, record of any additional tests, originals of the manufacturer’s guarantee certificates.

1.5.3 Document FormatAll the text, instructions and notes appearing on the drawings and in the documents

shall be in English or French or both. All the abbreviations and codes used shall comply with CERN’s coding systems. All the documents drawn up by the Contractor shall be sent to CERN in both paper and electronic format. The Contractor shall draw up his design memoranda using preferably Microsoft Word or Microsoft Excel and his schedules using Microsoft Project. He shall provide CERN with a source version (DOC, XLS, MPP, etc.).

The Contractor shall supply a paper copy, a DWG drawing source file and an HPGL plotter type file for each drawing. The drawings shall comply with the QAP document, ref. LHC-PM-QA-306.00, Drawing Process External Drawings. The electrical wiring diagrams shall be made with software imposed by CERN (TRACE ELEC release 2.2.4 or later); the sheets shall be supplied as source and PDF files (or DWG, associated files, and HPGL if necessary). The other documents (qualifications, technical documentation, etc.) not available on the above-mentioned software shall be scanned by the Contractor and supplied in PDF format. As a general rule, the various documents, drawings and diagrams shall be sent to CERN in both paper copy and electronic format.

The support medium for the electronic versions shall be CD-ROM. Each CD-ROM supplied shall be accompanied by a delivery slip and shall also comprise a Word-type file indicating the contents of the files and directories of the information contained in them.

1.5.4 Archiving of Drawing and Internal Approval on CDDThe Bidder shall refer to the documents mentioned in section 1.8 under the QAP

reference LHC-PM-QA-609.00 rev1.1.

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In addition to the paper copies, the drawings shall be submitted to CERN for archiving in duplicate, in the form of printer files (HPGL) and source files (DWG and DXF) on CD-ROM. Following an initial check by CERN, the Contractor shall archive his drawings in CERN’s CDD via Internet. To this end, the Contractor shall be put in contact with CERN’s CDD technical support team in order to obtain rights of access to the CDD Web server (registration of the Contractor, obtaining of a user name and password, etc.). For each drawing, the Contractor shall enter all the information relating to his drawing in the relevant fields on the site’s Web pages from his own Internet browser. He shall then upload the files (source files and HPGL) of the drawing in question onto a directory of the CDD server via Internet. An automatic procedure generated by the CERN server will check the drawing entries and will send all the correctly formatted drawings for approval to the various CERN services concerned. Every person receiving a drawing will be able to accept or reject it and will make comments in textual format. The Contractor may consult the CDD via Internet on his own initiative in order to check the approval or rejection status of his documents. He shall take account of any comments made, amend his drawings accordingly, index them and put them back in the system until all his drawings have been fully approved. This procedure shall apply to all the drawings submitted for approval prior to the start of the work and to the as-built drawings submitted prior to provisional acceptance for final archiving.

1.6 APPLICABLE DOCUMENTSThe contents of all the documents referred to below shall be applicable throughout the

execution of the Project. This list is non exhaustive and serves only as a reminder of the main documents that are applicable.

The supplies and assembly work shall comply with international (ISO, IEC) or European (EN) standards or, where these do not exist, the most recent standards in force in the country where the installation is to be located.

1.6.1 StandardsThe following additional standards are applicable for the execution of the Project.

1.6.1.1 CERN StandardsCERN expects the Contractor to attach great importance to compliance with the

safety regulations, by which he is bound, and to implementing, without restriction, all the appropriate safety measures to prevent personnel suffering accidents and professional illnesses, to avoid damage to equipment and to protect the environment. He shall take account of these considerations in his Tender. If new regulations come into force during the work, the Contractor shall be required to refer them to CERN in writing.

Attention is drawn to the fact that CERN has specific rules concerning safety regulations applicable to works of Contractors at CERN, access to and activities on the CERN site, occupational health and safety on the Organization's site and special health and safety matters.

The following CERN regulations, which are also applicable to the performance of the contract can be found on the attached CD-ROM.

The safety regulations, ref. CERN/TIS/GS/98-10, dated May 1998, Safety code A3 relating to safety colours and safety signs, 1992 edition Organisation of the installation work of the LHC and its experiments, LHC-

PM-IP-0001, rev. 1.0,

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Safety code A8 relating to noise protection, 1993 edition Electrical Safety Code C1 Rev., 1990 edition, Safety Code D1 Rev., 1997 edition, relating to lifting equipment, Safety Code D2 (Rev. 1998) pressure equipment code, which refers to the

European Directive 97/23/EC, Safety Code E Rev. - Fire Protection, 1995, Safety instruction IS5 relating to emergency stops, 1985 Safety instruction IS23 Rev. 2 relating to criteria and standard test methods

for the selection of electric cables and equipment from the point of view of fire safety and radiation resistance (1993),

Safety instruction IS24 Rev. covering regulations applicable to electrical installations (1993),

Safety instruction IS37 Rev. 2 covering regulations applicable to alarms and alarm systems (1998),

Safety instruction IS41 relating to the use of plastics and other non-metallic materials at CERN from the point of view of fire safety and radiation resistance,

PG: General requirements (ST/IE, December 1994), PGI: CERN standards (ST/IE, December 1994).

Further information on the safety regulations applicable at CERN may be obtained from the SC-GS, SC-TE and TS-CV groups.

1.6.1.2 International Standards IEE 802.3 concerning Ethernet, IEC 60204 concerning electrical machinery, IEC 1131-3 concerning programming representation, EN 50136, "Alarm systems and alarm transmission systems and equipment", ISO 10628 "flow diagram for process plants – general rules". EN 22858 on centrifugal process pumps, EN 25817 on weldings, ISO 1127 on stainless steel tubes, ISO 4200 concerning stainless steel piping, ISO 9906 on pump performance, ISO 3744 on noise power measurements, ISO 5251 on stainless steel butt welding ISO 5252 on steel tubes tolerances, ISO 2604-5 on steel products for pressure purposes, Eurocode 3 concerning the design of steel structures. ISO 2084 ISO 5817 (x-ray) ISO 9002 ISO Manual 19

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1.6.1.3 National Standards NF C 15-100 (or its international equivalent IEC 364), on low voltage

electrical installations –standard used by the Office of Controls and Inspections prior to acceptance.

1.6.2 Other References

1.6.2.1 On-site Work RegulationsIf work is to be carried out on the CERN site, attention is drawn to the fact that

CERN has specific rules concerning e.g. safety regulations applicable to works of Contractors at CERN, access to and activities on the CERN site, occupational health and safety on the Organization's site and special health and safety matters.

1.6.2.2 Other Documents The assembly and maintenance instructions provided by the manufacturers.

1.7 SAFETY

1.7.1 IntroductionThe term "safety" covers safety, health protection and working conditions. The

work covered by this call for tenders is subject to compliance with the applicable safety rules set out in the document:

Safety Regulations Applicable to the Work of Contractors at CERN, ref CERN/TIS-GS/98-10 dated May 1998 and attached to this tender (hereinafter referred to as "Safety regulations").

1.7.2 Co-ordination in matters of safety and health protection The LHC project is the subject of a safety coordination operation established from the

design stage.For the LHC installation work and its experiments, CERN has designated GTD-

APAVE responsible for Coordination in matters of Safety and Health Protection.The Safety Coordinators appointed by GTD-APAVE with CERN's approval are

responsible for ensuring the proper conduct of the Coordination in matters of Safety and Health Protection procedure. They are, in particular, required to ensure the application at all the stages in the project (design to completion) of all the measures needed for the performance of the work in accordance with the safety regulations in force at CERN. Furthermore they are required to integrate all necessary safety measures to ensure safe final use and maintenance of the structures and equipment.

One of the tasks of the safety coordinator is to draw up the Overall Safety and Health Protection Plan (P.G.C.S.P.S.). This document, which was drawn up during the design phase of the project, is appended to the tendering documents sent to firms. Bidders when submitting their tenders shall observe the preventive, organizational and coordination measures recommended therein.

Take note that the PGCSPS is an integral part of the contract.

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Before any work is started, the contractor (main contractor and/or sub-contractor) must draw up a Special Safety and Health Protection Plan (P.P.S.P.S.) and submit it to the Safety Coordinator and Project Manager for their opinion and comments.

The PPSPS must take account of the provisions of the PGCSPS and be drawn up after the Joint Inspection of the premises organised by the Safety coordinator and in the presence of the Project Manager

In addition, it is pointed out that an Inter-Firm Health, Safety and Working Conditions Committee (C.I.S.S.C.T.) is established for the LHC work. The board will meet, at least once every three months and, in accordance with its rules, the contractors concerned must be represented on it.

All these provisions are described in detail in the P.G.C.S.P.S. and the specific addendum for the work covered by this call for tenders.

1.7.3 Additional StipulationsTaking part in the LHC project stipulates de facto involvement in the safety co-

ordination procedure. In addition, CERN expects the contractors to attach great importance to the observance of the safety regulations and implement all the necessary measures without restriction in order to prevent accidents and occupational illnesses.

Contractors shall also ensure the presence of a safety officer on the work site, and shall take account of all these provisions in their tenders.

Any further information on the safety regulations applicable at CERN may be obtained from the Safety Coordinator and the CERN group in charge of the work.

Contractors will nevertheless be deemed to be familiar with the provisions of the regulations applicable to them and may in no circumstances plead a lack of information from CERN to justify a failure to apply safety measures.

1.7.4 Specific recommendationsAll safety precautions and measures shall be taken, considering:

Organisational measures described in the present technical specification. The environmental conditions of the existing structures and their particular hazards The work to be done by the Contractor in order to protect people from injuries or

illnesses, installations and equipment from damages and environment from pollution and to avoid interference’s with possible other work in the vicinity.

The existing travelling crane may be used under the approval from CERN TS/IC and SC/GS groups. The Contractor’s staff shall follow the due certification training at the Contractor’s expense before work commences.

All handling methods from the Contractor shall have the CE label and obtain CERN’s approval. The Contractor’s staff shall be trained and certificated.

The Contractor shall install all the necessary site signs and fences (fixed, height 1.5 m),

The Contractor shall install premises for the staff and the work site switchboards with 30 mA differential protection,

The Contractor shall clearly define the hoisting and handling means and methods; if the Contractor will use his own crane, he shall take all precautions to stop the existing crane during this handling,

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The Contractor shall install all the necessary safety devices for work performed at a height, in particular for the installation of ducts in the shafts and underground halls, etc.

Concerning the personnel, the Contractor will guarantee the presence of at least one rescuer-first-aid worker for every 10 workers on the work site.

Concerning the performance of work on roofs, bidders are informed that access to the roofs of buildings will be restricted and that it shall be subject in every instance to CERN’s prior approval. The Contractor shall be responsible for making roofs safe in the case of access of this nature.

Bidders are further informed that the work will be carried out on sites that are operational and in the vicinity of the major LHC work sites, and that the associated activities shall under no circumstances be disturbed. All the necessary measures shall therefore be taken, in agreement with CERN’s safety co-ordinator, to limit the interference and risks inherent in the simultaneous performance of several kinds of work.

1.8 QUALITY ASSURANCE PROVISIONSThe Contractor must plan, establish, implement and adhere to a documented quality

assurance program that fulfils all the requirements described in this Technical Specification and drawn up according to the Quality Assurance Plan for the LHC Project.

Please note that the quality assurance documents, CERN standards and Purchasing documents referred to in this Technical Specification are on the enclosed CD-Rom entitled "CERN Official Documents".

The list of relevant topics covered by the LHC Quality Assurance Plan, together with the corresponding documents, is given in Table 1 below.

Topic Document Title Doc. Number

Policy and Organisation Quality Assurance Policy and Organisation LHC-PM-QA-100.00

Glossary, Acronyms, Abbreviations LHC-PM-QA-203.00

Planning Planning and Scheduling Requirements for Institutes, Contractors and Suppliers

LHC-PM-QA-301.01

Design Quality Assurance Categories LHC-PM-QA-201.00

Design Process and Control LHC-PM-QA-307.00

Drawing Management and Control LHC-PM-QA-305.00

Drawing Process-External Drawings LHC-PM-QA-306.00

Change Control Configuration Management - Change Process And Control LHC-PM-QA-304.00

Drawings Storing of contractor drawings in EDMS/CDD LHC-PM-QA-609.00 rev 1.1

EDMS number 306327

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Manufacturing and Inspection Manufacturing and Inspection of Equipment LHC-PM-QA-309.00

Handling of Non-conforming Equipment LHC-PM-QA-310.00

LHC Part Identification LHC-PM-QA-206.00

Table 1 : LHC QAP topics and documents

1.9 DELIVERY AND COMMISSIONING

1.9.1 Provisional Delivery ScheduleSee Annex C.

1.9.2 Packing and Transport to CERNThe Contractor is responsible for the packing and, where included, the transport to

CERN. He shall ensure that the equipment is delivered to CERN without damage and any possible deterioration in performance due to transport conditions.

1.9.3 Handling at CERNAll handling of material shall be done with equipment conforming to TIS Safety

Code D1 Rev. - Lifting equipment. The handling of the materials and machines to the underground areas will be done by CERN’s services, however once it is transported to the underground work site the contractor takes at his charge further handling actions.

1.9.4 CommissioningOnce all the tests have been achieved, the contractor may inform CERN that the

installation is ready for commissioning. CERN shall send him confirmation of the date of commissioning. The necessary resources for all the tests and commissioning (material plus the staff) shall be supplied by the Contractor.

1.9.5 Acceptance and GuaranteeAt acceptance, test checks shall be made on the basis of the test and commissioning

reports (listing the measured and rated characteristics) supplied by the Contractor. Comments and reservations made by one of the parties shall be entered in the acceptance reports.

1.9.5.1 Partial AcceptanceCERN may freely make pre-acceptance tests to formalise the progress of certain

phases of the work.

1.9.5.2 Provisional AcceptanceOnce the installation has been fully completed, commissioned and adjusted in

accordance with CERN’s specifications, CERN and the Contractor will agree on a date for provisional acceptance.

The Contractor shall first send CERN all the “as-built” documents.Provisional acceptance cannot be granted until all the equipment supplied fully

complies with the specification and the approved documents and until all the requested documents have been submitted in full.

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1.9.5.3 Final AcceptanceOnce the Contractor has made any necessary alterations and/or provided any further

information requested, CERN’s reservations will be lifted, following an additional partial acceptance procedure.

Final acceptance will take effect upon expiry of the guarantee period, provided that the Contractor has met all his obligations.

The guarantee period is defined in the commercial documents.

1.9.6 TrainingAs soon as CERN has taken possession of the installations, the contractor shall

appoint one of his qualified representatives to train, on site, CERN operation staff (about 5 persons) on the operation and maintenance of the plant, at a date agreed upon between CERN and the contractor.

1.10 CERN CONTACT PERSONS

Persons to be contacted for technical matters:

Name/Department/Group Tel-Fax Email

Daniel GASSER (TS/CV)

In case of absence:

Paolo Guglielmini (TS/CV)

Tel: +41 22 767 82 06

Fax: +41 22 767 87 67

Tel: +41 22 767 06 78

Fax: +41 22 767 87 67

[email protected]

[email protected]

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2. BASIC DATA

2.1 PRESENTATION OF THE STRUCTURESThe UX85 experimental cavern is part of point 8 experimental area (see Figure 1). A lift, installed in PZ85 shaft, allows a direct access to the cavern. The PX84 shaft is linked to the cavern via TX84 gallery, this shaft is used to bring down big materials into the cavern. Another lift, installed in PM85 shaft, allows an access to the US85 cavern, which is adjacent to UX85 cavern.

Figure 1 : underground structures at point 8

UX85 cavern is split transversally into two parts by a concrete shielding wall, the two areas located on either side of this wall are called “detector area” (where LHCb detector will be installed) and “protected area” (this area will be accessible all year long). The protected area is located on the PZ85 side and will be therefore accessible through this shaft (see Figure2).

The Outer Tracker cooling station is located on the protected area next to the shielding wall.

The various “secondary” cooling systems that shall be fed by the primary cooling pipes are (see Figure 2):

Electronic racks located in the counting houses. The electronic racks are distributed in 4 separate rooms and 3 storeys: room D1 (1st storey), room D2 (2nd

storey), rooms D3/A and D3/B (3rd storey).

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Cooling stations that are located on a metallic platform in the protected area and close to the shielding wall. There are five cooling stations for the following LHCb sub-detectors: Outer Tracker, Inner Tracker, Trigger Tracker, VErtex LOcator and RICHes.

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Figure 2 : Experimental cavern configuration

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2.2 SUMMARY OF THE STRUCTURES

NAMEOF

BUILDING

CODEN°

FUNCTION Length Width Height

UX85 2828 Experimental cavern 70 m 20 m 18 m

2.3 ENVIRONMENTAL CONDITIONSThe environmental conditions provided inside the cavern (for both areas) by the ventilation system are:

Dry temperature: 17oC at the bottom, 27oC at the top Dew point: <12oC

2.4 NOISE LEVEL LIMITSThe levels of noise pressure at a distance of 1m from the cooling station shall not

exceed 55dBA. The Contractor shall take all necessary precautions to meet these values when

selecting the equipment. Should the maximum values indicated by CERN be exceeded, the Contractor shall propose alternatives measures to CERN for approval (palliative measures of the sort of sound-proof casings around noisy equipment, like pumps, shall not be accepted). If these measures are found unsatisfactory by CERN, the Contractor shall, at his own expense, replace any items necessary to meet CERN specifications.

The same limitations apply to the transmission of noise or vibrations through the pipework. The Contractor shall install the necessary vibration and shock absorbers as to insure that none is transmitted outside the cooling station to the rest of the hydraulic network.

2.5 GENERAL MECHANICAL REQUIREMENTS

2.5.1 MaterialsAll materials and components used in the construction shall be new and suitable for

the use for which they are intended. The specifications for the materials will be subject to approval by CERN.

The choice of any non-metallic material shall be in accordance with the CERN Safety Instruction IS41.

2.5.2 Reliability, Risk and Breakdown AnalysisThe Contractor shall provide before work starting, as stated in 1.5.1, a reliability, risk

and breakdown analysis for the whole of the supply based on the following criteria: Reliability MUT1>10,000 h Repairability MTTR2<2h Availability > 99.98 %The analysis shall identify risks and safety features to implement. The breakdown

analysis shall be performed in accordance with the AMDEC method or an equivalent one.1 Mean Up Time2 Mean Time To Repair

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2.6 REFERENCE DRAWINGS AND SCHEMATICS All the supply shall be in compliance with the following documents.

2.6.1 Schematic List

Reference TitleEDMS No xxxx Cooling station - Manifolds

2.6.2 Drawing List

Reference TitleLHCF-2828-xxxx OT cooling station – Transfer lines manifoldsLHCF-2828-xxxx Primary cooling pipes

Paper format Demineraliser

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3. TESTS

3.1 Tests to be carried out at the Contractor's PremisesCERN reserves the right to be present, or to be represented by an organization of its

choice, to witness any tests carried out at the Contractor's or his subcontractors' premises. The Contractor shall give at least a 10 working days notice of the proposed date of any such tests.

Leak tests on the Outer Tracker (OT) cooling station shall be carried out at the contractor premises. The test pressure shall be 1.5 times the pressure rating.

The Outer Tracker cooling station shall be hydraulically tested with a fake load (simulating the OT and transfer lines pressure drop). These tests shall include all the functioning modes of the cooling station.

The power and control cubicles shall be tested at the contractor premises as well, including:

A check of the mechanical assembly (type of equipment, installation method, compliance with specifications),

a check of the continuity of the control system inputs and outputs, and of the measurements accuracy,

a check of the automatic control sequences and manual commands of the equipment,

a check of the supervision and operation means, a check of the documentation.The PLC and SCADA software applications shall be verified and validated together

with the power and control cubicle, in the presence of a CERN representative. Each functionality shall be checked, and each control loop tested independently. The performance of the control loops shall be tested by means of simulated inputs to the PLC, verification of the correct processing and its outputs. The significant measured parameters shall be recorded (values of controlled variables, set-points, overshoot and steady-state errors, rise delays, dead times).

These tests and inspections shall take place at least four weeks before the date on which the equipment is shipped to CERN. All costs entailed by these tests (supply, manpower, apparatus, instrumentation, etc.) shall be borne by the Contractor and shall form an integral part of his Tender. The Contractor shall set out the results of all the tests in a document, which shall be approved by CERN before installation on the site. The Contractor shall propose a date for delivery to the site.

3.2 Tests to be carried out at CERN

3.2.1 HydraulicThe following shall be tested:

Correct make up of the secondary loop for the Outer Tracker cooling station. Leak tests at 1.5 times the pressure rating for 6 hours for all supplied

hydraulic network

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Swapping correctly from one pump to another Measurement of the following parameters for the OT cooling station:

o Flow rate on the primary and secondary loopo Flow rate on the by-passo Pressure given by the expansion vesselo Leak detection systemo Temperature o Water conductivityo Pressure head given by the pumps

Leak detection on the expansion vessel

3.2.2 ControlThe Software Validation and Verification Plan (SVVP) defines the test cases and

procedures that shall be applied during the factory and on-site testing validation phase. The SVVP shall provide a step-by-step description of how to carry out each test case. The integration, system and acceptance tests in the SVVP shall specify the inputs, predicted results and execution conditions.

A table of the contents that should be included in a SVVP is presented in Annex DMandatory practices which apply to the software verification and validation are listed

in Annex D

Some of the integration and system test cases in the SVVP are static tests, this means, they can be executed with the electrical power of the cooling station equipment turned off. The SVVP shall include static test cases allowing the verification and validation of at least:

Check on the continuity of the PLC inputs and outputs, full testing of the process control measurements (sensor, transmitter and signal

transmission), check on the automatic sequences, check on process alarms and safety actuations (faults, alarms, interlocks), check on the operation interfaces and operating mode, test on the Ethernet communication.

The dynamic test cases are all those for which electrical power of the cooling station equipment is required. Some of them can demand dynamic periods in order to verify and validate some functional and performance requirements related to steady-state conditions and stability of the process. The duration of these periods shall be defined in the SVVP.

Once all the operating defects discovered with the application of the static test cases have been corrected, the Contractor shall submit for CERN’s approval, in accordance with the project global schedule, the expected date of the dynamic integration and system test cases and final acceptance testing. Representatives of CERN operation teams will participate in the final acceptance tests.

After successful results for all the test cases in the SVVP, the software will be declared ready for provisional acceptance. The Software Transfer Document (STD) shall be submitted at the provisional acceptance, together with the totality of the updated software

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project documentation resulting from the previous phases. A table of the contents that should be included in a STD is presented in Annex D

Mandatory practices which apply to the software transfer are listed in Annex D

3.2.3 Noise CERN attaches particular importance to reducing the noise pollution from its

equipment in the outside environment to the minimum. Checks on noise damping shall therefore include various kinds of noise measurement.

The noise measuring instruments and specialised manpower shall be provided by the Contractor. The measurements taken shall be appended to the test reports.

The noise level measurements shall be taken by the Contractor in the presence of CERN’s Acoustics Service and in accordance with its instructions.

The measurement campaigns shall comprise the following stages: Measurement of the background noise spectra (before work, equipment switched off),

which shall be used as reference values, measurement of the noise limits of the cooling stations alone (pumps operating at their

design points, valves open, etc.),

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4. DESCRIPTION OF THE WORKS

4.1 WORK LOT 1: HYDRAULIC AND MECHANICAL WORKS FOR OUTER TRACKER COOLING SYSTEM

4.1.1 General description.The cooling station shall be installed in the protected area on an existing metallic

platform; the transfer line bringing the cooling demineralised water to the detector shall pass through the shielding wall via a chicane. The transfer lines shall be installed up to manifolds (that are included in the supply) installed in the vicinity of the detector. These manifolds shall be installed on either side of the detector. The connection between the manifolds and detectors will be made by other trades.

The cooling station consists of one demineralised water independent loop connected to the Outer Tracker cooling circuit (via the transfer line); this loop is cooled down, through a heat exchanger, by the existing CERN mixed water network (13-19oC) ; the connection to the mixed water network shall be made with flexible hoses.

The demineralised water loop is filled via a make-up line coming from the CERN demineralised water network; this line starts close to the UX85/US85 separation wall and is routed up to the cooling station via the chicane (Work Lot 4). The contractor shall connect this line to the cooling station.

The expansion vessel shall be pressurized via the compressed air network that will be available close to the cooling station.

4.1.2 Requirements for the design of the cooling stationThe cooling station shall be built at the contractor’s premises on a self contained

metallic rack. The dimensions of the cooling station shall not exceed 1.8 m x 1.2 m x 2 m (length x width x height), including power and control cubicle.

The metallic rack shall be equipped with hoisting points allowing it to be hanged to a crane via one hook. The mass distribution shall therefore be adequately foreseen.

A dripping pan shall be installed under the metallic frame; it shall be able to contain the entire capacity of the secondary loop. A drain valve shall be installed on the dripping pan.

The hydraulic components shall be fitted so that all maintenance can be carried out easily.

All the drawings show the layout only in order to help the bidders make an offer. During the study phase, the contractor shall make all the necessary execution drawings.

The cooling installation shall be able to work during the whole LHCb detector lifetime (about 20 years); it shall operate round the clock about 9 months per year, the 3 other months being used for maintenance.

The pressure difference available on the mixed water network is 2 bars. The flow rate inside the detector shall be 10 m3/h. About 1m3/h shall be bypassed through an ion-exchange cartridge in order to keep the required water conductivity. Two pumps are installed in parallel, one as a backup.

28


The inlet water temperature shall be controlled, using a standard closed-loop regulation, via a motorized two-way valve fitted on the mixed-water side.

The flow rate shall be equally divided in all the manifolds. The overall manifolds dimensions shall not exceed 1 m high, 0.3m long (for return manifolds), 0.7 m long (for inlet manifolds) and 20 mm thick.

The by pass between inlet and return line shall be equipped with a self regulated back pressure controller to allow the inlet pressure to be constant in the transfer line.

The operating conditions for the cooling station are given in the table below

Pressure drop inside the detector* 1.5 barsDemineralised water flow rate 10 m3/h (detector) + 1 m3/h (bypass)Inlet/outlet temperature 19oC/21oCDemineralised water conductivity 0.1 to 1 S/cmCooling capacity 23 kWMixed water

Flow rate max ΔP available Inlet/outlet temperature Pressure

4 m3/h2 bars13oC/18oC10 bars

Ambient condition inside the cavern Dry temperature Dew point

17 to 27oC≤12oC

Table 2: operating conditions of the cooling station

* This figure includes actually all the piping located after the manifolds.

4.1.3 Technical Requirements for components

4.1.3.1 Pumps Two pumps are installed in parallel (one as a backup) on the secondary loop to allow

the demineralised water circulation inside the Outer Tracker. The flow rate given by each pump covers the flow in the detector (10 m3/h) and in the by-pass (1 m3/h ).

The pressure drop in the detector is 1.5 bars at 10 m3/h. In order to choose the appropriate pump, the contractor shall calculate the pressure drop in the transfer line to be added to the pressure drop inside the detector. The operation range shall be in the part of the flow/pressure curve which has a negative slope; the difference between the pressure head at zero flow (H0) and the pressure head at the nominal flow (Hnom) shall be within 0.3 H0. The suction side required head (NPSH) shall be calculated by the contractor on the assumption that the expansion/pressurization vessel is at atmospheric pressure and allowing a safety coefficient (NPSH available/NPSH required) of at least 2.

The technical features required for the motor-pump sets shall be the following: water tight (immerged rotor), pressure rating: PN16

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horizontal volute-type centrifugal and mono-stage, flange connection to the piping, all parts in contact with demineralised water shall be made of stainless steel

(AISI 316), thermal protection through a PTC probes, asynchronous three-phases motor with 400 V, squirrel cage type, electrical frequency : 50 Hz, starting: direct ( 7.5 In), rated power : 5.5 kW, index protection : IP55, insulation class: H

4.1.3.2 Heat Exchangers The thermal and hydraulic parameters for the dimensioning are:

Maximum power: 23 kW Primary side:

o Inlet/Outlet temperature: 13oC/19oCo Pressure drop: below 50 kPa

Secondary side:o Flow rate: 11 m3/ho Pressure drop: below 50 kPao Inlet/Outlet temperature: 19oC/21oC

The technical features required for the heat exchanger are the following: welded plates and counter-current, frame material : carbon steel (painted, colour blue RAL 5012) plate material : stainless steel (AISI 316), flange connection to the piping, design pressure shall be calculated by the contractor, taking into account the

pump pressure head and the pressurization of the expansion tank, which shall be between 1 and 2 bars over atmospheric pressure. The design pressure shall not exceed the operating conditions given in Table 2.

4.1.3.3 Piping WorkAll material and components used in the construction shall be new and suitable for

the use for which they are intended in the given operating conditions. The specifications for the materials will be subject to approval by CERN.

In addition to the requirements of the codes of practice the Contractor shall conform to the following special requirements:

The pipes should end in flanges, the flanges and blank flanges on the ends of a pipe shall be of the same material

as the pipe itself,

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all pipework shall be made from straight pipe segments or prefabricated T-pieces and bends. In no case CERN will accept that short pieces are welded together in order to replace standard pipes of 6 m of length,

the inside of the pipework has to be clean, degreased and free from contamination, dirt, welding scale and oil,

metric dimensions shall be used for bolting, at a change of direction, the bends shall be used. Only if there is a small change

in direction and the distance between the two welds is less than 13 mm, measured on the inner part of the bend, then the bend may be replaced by a bevelled cut on the pipes,

when two pipes are joined by a weld, care should be taken that the two longitudinal welds do not fall in line. They should be at least 13 mm apart, measured along the circumference.

The imposed pressure rating and nominal diameter are given in the table below.

Primary loop (mixed water) DN32, PN16Secondary loop (demineralized water), including transfer lines

DN50, PN16

Make-up line DN50, PN16By pass DN25, PN16Compressed Air DN25, PN16Manifolds DN15, PN16

Table 3 : pressure rating and nominal diameter for the piping

4.1.3.3.1Material to be Used (except for mixed water loop and compressed air pipe)

Raw materialThe material for the pipes and the connections is austenitic stainless steel with a low

carbon content. The composition of the steel shall correspond to the DIN EN 10088-1/2.Pipe manufactureThe pipes shall be longitudinally welded.They shall be made from hot or cold rolled sheet. After welding, they shall undergo

descaling followed by passivation. This treatment corresponds to procedure dl or kl of the DIN Norm 17440. The guaranteed welding coefficient must be at least 0.8. In order to keep the pipes clean during transport and storage, they must have their ends adequately protected.

Pipe dimensionsAll pipes shall follow the ISO 4200 for outside diameters and wall thickness.ElbowsThe elbows shall follow the ISO R 285-1962. They shall have the same outer

diameter as the pipe to which they are joined. Their wall thickness shall be as close as possible

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but in no case less than that of the pipe to which they are joined. The elbows shall undergo the same surface treatment as the pipes. The guaranteed welding coefficient shall be 0.8.

ReducersThe reducers may be either eccentric or concentric according to their use. Their

largest outer diameters shall be the same as the outer diameters of the pipes to which they are to be joined.

The wall thickness of the reducer shall be that of the pipe having the largest diameter. The length of the cone shall never be less than 3 times the difference of the end diameters.

The reducers shall undergo the same surface treatment as the pipes. The guaranteed welding coefficient shall be at least 0.8.

Flanges and collarsThe flanges mounted on the pipework shall be of the welded collar type. The rotable

flange shall be hot galvanised. The material of the collar is that defined below.Blank flangesThey shall be of form B as defined by DIN 2527. They shall be covered on the fluid

side by an austenitic stainless steel 18/8 washer of 2 mm thickness. This washer shall have the same outer diameter as the gasket. The blank flange shall be galvanised.

Bolts, washers and nutsThe nuts and bolts must be calculated to withstand the specified pipework test

pressures. The bolt lengths must be adapted to the connections for which they are to be used. A washer must be placed under each nut. The bolts, nuts and washers must be cadmium plated and graphite coated for assembly.

GasketsThese shall be of the Klingerit1 type or equivalent. Whatever their diameter, they

shall be 2 mm thick. The outer diameter must be such that during assembly the gasket is centred by the bolts of the flanges.4.1.3.3.2Material to be used for the mixed water loop and compressed air pipe.

PipesAll pipes shall be made of carbon steel. Common parts such as drain top-up and bleed

valves etc… shall be made of carbon steel.All pipes shall be seamless. In order to keep the pipes clean during transport and

storage, they must have their ends adequately protected.All the pipes shall be of ST37-2 carbon steel and comply with standards ISO 559.ElbowsThese shall comply with standard DIN 2605. Their outside diameter and wall

thickness shall be the same as those of the pipes to which they are welded.FlangesThe flanges mounted on the pipework shall be of the welded collar type and comply

with DIN norm 2633. They shall be neck flanges with raised seal beds. The material of the flanges shall be that of the pipe they belong to. They shall be fitted with blank flanges.

Blank flangesThey shall be of form B as defined by DIN norm 2527. They shall be covered on the

fluid side by a washer of 2 mm thickness of the same material as the pipe they belong to. This 1 Klingerit is a registered Trade Mark of Klinger

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washer shall have the same outer diameter as the gasket. Any part of the blank flange which is not made of stainless steel shall be galvanised.

GasketsThe gaskets shall be of the Klingerit® 3 type or equivalent. Whatever their diameter,

they shall be 2 mm thick. The outer diameter must be such that during assembly the gasket is centred by the bolts of the flanges.


pressures. The bolt lengths must be adapted to the connections for which they are to be used. A washer must be placed under each nut. The bolts, nuts and washers must be zinc coated and passivated for assembly.

Reducers and dished endsThese may be forged or standard commercial items. Whatever their source, their

outside diameters shall be the same as those of the pipes to which they are to be welded. The wall-thickness of the reducer shall be that of the larger-diameter pipe.4.1.3.3.3Method of Assembly and Laying of the Piping Work

The assembly shall be made by welded or flanged connections.Drawn or longitudinally welded pipes may be proposed. All the welding shall be

submitted to a CERN inspection (X-rays control). The bolts shall perfectly fit the union for which they are used. A washer shall be fitted

beneath each bolt. Nuts, washers and bolts shall be designed to resist the specified test pressure for the piping work.

The outside diameter shall be such that, during the assembly, the gaskets are centred by the flange bolts.

The outside diameter and the wall thickness of the bends shall be at least the same as those of the piping work to which they are welded. The radius of curvature shall be R = 3D for all DN. Bends consisting of welded sections are forbidden.

The wall thickness of the tapers shall be that of the larger-diameter pipe and the cone angle shall not exceed 40°. The reference standard is ISO 5251.4.1.3.3.4Requirements for support and fixings

The supports and fixed points shall be arranged so that the pipework imposes no stresses on the seals, fittings and accessories.

The supports shall be made from commercially available steel sections.The pipes shall be secured to the fixed points by flat collars or another locking

system. Fixings shall not be welded directly to the pipe. Sliding supports shall be positioned to allow the pipework to expand, absorb lateral forces to maintain the alignment of the pipework, and allow the pipes to move longitudinally without noticeable wear and without damage to the lagging.

The supports shall be carefully protected and spaced so that the deformation of the pipework during operation or testing results in neither any undue stresses in the pipes, nor reverse gradients which could hamper the flow of fluids, condensates or the escape of air from liquids.

3 Klingerit® is a registered Trade Mark of Klinger

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The steel components shall be generously designed to allow for accidental overloads. In all cases the pipes shall be assumed to be full of water.

The supports shall be thoroughly examined before fitting. Cut steel components shall be deburred and any sharp edges rounded off. Holes shall be drilled or punched (a cutting torch may in no circumstances be used for this operation).

The concealed parts of the supports shall be coated with rustproof paint, or hot galvanised, before the various components are assembled together or secured to the building framework.

The supports and fixed points shall be arranged so that the pipework imposes no stress on the unions, fittings and accessories.

The collars shall: Be made of galvanised steel. A protective layer (rubber) shall be fitted between

the pipe and the collar, consist of collars with rubberised strips (MUPRO2) for small diameters < 50

mm.The spacing of the pipework supports shall not be greater than the values below:

Diameter of pipesDN

Largest distance between supports in m

15 to 3240 to 7080 to 150

3.04.55.0

Table 4 : Distance between supports

It should be noted that the pipes may not themselves be regarded as supports and no pipe shall be attached to another by any system whatsoever.

The supports for pipework conveying hot or cold fluids shall be designed so that the pipes may expand freely without excessive stresses.4.1.3.3.5Drains

Ballostar type or similar.Connections according to drawing 15 LHC F 99900001 3.Spherical plug-cock, one-piece brass body, chromium-plated brass ball, PTFE collar

and packing gland.Rated pressure PN 16.Detachable control handle.

4.1.3.3.6Bleed Cocks (Air Vents)

Ronfard type or similarConnections according to drawing 15 LHC F 99900001 3.Cast iron or steel body. Fitted with the same type of spherical plug-cocks as the

drains.Rated pressure PN16.

2 Mupro is a Trade Mark

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4.1.3.4 Two-way manual balancing valvesThe balancing valves shall be manufactured in accordance with ISO 5752, and

mounted in-between flanges of normalised ISO dimensions. They shall have the necessary pressure and temperature ratings (according to the circuit).

They shall be of ROHR® type or similar quality.

4.1.3.5 Two-way motorized regulating valveThe two-way motorized valve shall be manufactured in accordance with ISO 5752,

and provided with flanges of normalised ISO dimensions. It shall have the necessary pressure and temperature ratings (according to the circuit) and be of a modern design for reduced vibration, noise and cavitation. The body of the valve shall be flanged. It shall have the following characteristics:

Equal percentage characteristics, fitted with electrical actuators (the Contractor shall determine the power supply characteristics on the basis of the torque required) controlled by a 4-20 mA input signal.

It shall remain open upon failure of the power supply. The actuator shall be designed to close the valves against the primary circuit design pressure.

Selected with sufficient authority (0.3 through 0.5) without creating unnecessary pressure drops.

Installed downstream stop valves which shall allow the replacement in case of breakdown without requiring the draining of the circuit,

Maximum noise level 80 dB(A) at 1 m. distance for any opening. Maximum leakage admissible 0.001 Kvs.

Materials: body nodular cast iron (external epoxy paint). Seat and plug in stainless steel. All gasket material asbestos and halogen-free.

The Contractor shall provide all necessary fittings (tapers, etc.) for their installation.

It shall be of Baelz® type or similar quality.

4.1.3.6 Pressure controllerThe pressure controllers (pressure reducing valves or excess pressure valves) shall be

self operated, of Samson® type or equivalent.

4.1.3.7 FiltersThe filters shall be installed in-line on the piping and shall be of the single body type

with a removable cartridge. They shall be chosen according to the pressure rating, the flow-rate level to be achieved and the nominal diameter of the pipes they are connected to.

The filters shall be fitted with stainless steel woven wire screen. The mesh size shall be 20 m.

The maximum pressure drop allowable shall be 50 kPa when foul and 20 kPa when clean at nominal flow-rate.

The filters installed in the bypass for demineraliser shall be fitted each with a differential pressure indicator.

The filter installed in the demineralised water loop shall be fitted with a differential pressure switch (delivering an on/off contact) for clogging monitoring.

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4.1.3.8 Non-return valvesSocla type S111 or similarDuo-check spring-loaded, double flap typeStainless steel body, bronze flaps.Manufacture to standard DIN 2501

4.1.3.9 Shutoff valvesShutoff valves shall be manual spherical ball valve

leak proof to standard ISO 5208 overall dimensions to standard DIN 3202 base plate to standard ISO 5211 stainless steel body, stainless steel inner capsule, PTFE seal flanged connections KSB® or similar.

When indicated, shut off valves shall be equipped with an open/close contact switch.

4.1.3.10 Solenoid valves

The solenoid valves shall be:

Normally closed (in case of power cut)

Electrically actuated

Equipped with anti water hammer device

4.1.3.11 Expansion VesselThe expansion vessel shall be a standard one (bought from the shelves) and made of

stainless steel. The expansion vessel shall be vertical, and shall be connected to the circuit in the vicinity of the suction side of the pumps.

The Contractor shall determine the size of the expansion vessel on the basis of the data given in this Technical Specification (volume of circuits and operation temperatures). It shall be pressurised using the CERN compressed air network. A self operated pressure controller (open by lack of pressure) and a non-return valve shall be installed on the pipe connecting the vessel to the compressed air network. Another pressure regulator (opened by overpressure) opened to the air shall be connected to this pipe as well.

The expansion vessel shall be provided with a manhole for inspection and cleaning (in accordance with Safety Code A4 Rev.- Confined spaces), and feature feet and supports, with the following components:

Two pressure relief valves, Level transmitter of the differential pressure type (4-20 mA output signal) for the

control of the water level. It shall provide an alarm signal in case the water level drops down.

Level switch (On/Off signal) to provide a back-up (should the level transmitter not function properly). The switching threshold shall be adjustable.

Kleber is a Trade Mark Ballostar is a Trade Mark

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Pressure transmitter (4-20 mA output signal) for the control of the compressed air pressure. It shall provide two alarm signals for the low (compressed air leak) and high pressure levels.

A pressure indicator mounted on the pipe connecting the vessel to the circuit to be able to control the pressure on site.

A flow switch on the pipe connecting the vessel to the circuit. It shall trigger an alarm in case of flow detection over 1 l/min.

A drain valve

4.1.3.12 Demineraliser (CERN Supply)The demineraliser will be of the cartridge mixed-bed type, contained in vertical

cylinders with dished-heads welded to each end, and shall be supplied by CERN. The demineraliser will have a capacity of 50 litres.

The demineraliser shall be connected to the circuits by the contractor via flexible stainless steel hoses (braided) via quick connectors (according to standard NF E 29 572). Each connection shall have its own stop valve. The cartridges shall sit on concrete plinths.

The water quality is monitored through the conductivity probe CT2.

4.1.3.13 WeldingPipe welders working at CERN will have to pass a test by the CERN Technical

Inspection and Safety Commission (TIS); please refer to TIS document TIS/TE/MI/CM 00-14. The cost of the test shall be borne by the Contractor.

The welds shall be made by the argon arc method (80 to 85% argon and 20 to 15% hydrogen). The protective gas shall be confined in the pipe between two discs located on either side of the weld to reduce gas losses.

The welds shall be made to ISO standard manual 19. The protective gas inside and outside the pipe shall meet standard DIN 32526 or equivalent. The filler metal shall meet standard DIN 8559 or equivalent.

After completion, the welds shall be cleaned with a stainless steel brush to remove any traces of oxidation on the welds, and passivated.

Each weld shall be marked with the welder's identity.Inspection of Welds: the degree of X-ray of welded joints shall be as laid down in the

design code, please refer to TIS document TIS/TE/MI/CM 00-14. Other non-destructive tests may be required by CERN in case of doubt. As a minimum requirement circumferential welds and longitudinal welds in pipework shall be X-rayed at not less than 10%. If faults are discovered, CERN or the inspector may require additional X-rays, up to 100%, if necessary. These X-ray will be evaluated in accordance to ISO standard 5817, requirement B.

All the inspections and tests costs shall be at the contractor’s charge.

4.2 WORK LOT2: CONTROL WORKS FOR OT COOLING SYSTEM

4.2.1 InstrumentationAll the sensors and actuators required to operate the process, their mechanical and

electrical connections, connection tests, tuning and verification of the measurements, shall be included in the tender.

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The pressure ratings, materials and temperature operation range shall be adapted to the particular use of each transmitter or actuator and their environment. The electrical characteristics shall meet industrial standards. They shall be selected to meet the requirements below:

Halogen-free materials (body, connection cubicle, etc.). Industrial-type construction suitable for the environment (relative humidity from 0

to 90%, temperature from 10 to 40°C, vibration resistance, etc). Easy accessibility and interchangeability. Good time and temperature stability (long re-calibration intervals). Accuracy adequate to the requirements of the process. Protection index IP54. All the parts in contact with water shall be made of stainless

steel. Earthing.

CERN reserves the right to require the replacement of certain instruments if they are considered to be of inadequate quality.

4.2.1.1 On/off detector switchesThe control racks shall be dimensioned and fully equipped to integrate the potential-

free contacts. A 30 % of spare capacity shall be foreseen.Differential pressure switches (DPS)

Adjustable switching by means of a screwdriver. The switching range shall be defined by the Contractor to meet the process requirements.

Level switches ( LS) By means of differential pressure switches. Adjustable switching by means of a screwdriver. The switching range shall be

defined by the Contractor to meet the process requirements.Flow-rate switches (FS)

ElettaTM type or equivalent. Adjustable switching by means of a screwdriver. The switching range shall be

defined by the Contractor to meet the process requirements. The device shall have a monitoring face with flow-rate indication. The range shall

be defined by the Contractor.

In addition, the Contractor shall also provide the following switches: The thermal switches of the motors, the fault status switches associated to the motors, the on/off status switches associated to the motors, the open/closed status switches associated to the valves, the hand-operated equipment emergency stop push-buttons, the applicable voltage on indicator lights, the applicable three position switches “Marche”, “Auto”, “Arrêt”, the applicable “Acquittement défaut” buttons,

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4.2.1.2 Analog sensor and transmitter setsVoltage 24 Vdc with electrical isolationOutput signal 4-20 mA. with integrated square root extractor, if applicable.Accuracy > 0.5 % of the set span. At least, all the transmitters shall offer local means (keys) for calibration of the main

parameters as zero point and span. Solutions based on remote intelligent means as HART protocol (via a PC based operating program or via a handheld terminal) will be accepted only if the operating program (version for Windows XP) or the handheld terminal is included in the basic offer.

Pressure transmitter (PT) Fitted on sliding union. The supply includes the manifold aiming at easily

commission the instrument without interrupting the process. Integrated two-wire transmitter with adjustable output range. Integrated square root extractor. The pressure range shall be defined by the Contractor to meet the process

requirements.Level transmitter (LT)

Differential pressure measurement. Fitted on sliding union. The supply includes the manifold aiming at easily

commission the instrument without interrupting the process. Integrated two-wire transmitter with adjustable output range. Integrated square root extractor. The pressure range shall be defined by the Contractor to meet the process

requirements.Flow-rate transmitter (FT)

Differential pressure measurement. Fitted on sliding union. The supply includes the manifold aiming at easily

commission the instrument without interrupting the process. Integrated two-wire transmitter with adjustable output range. Integrated square root extractor. The flow-rate range shall be defined by the Contractor to meet the process

requirements.Temperature transmitter (TT)

Pt 100 temperature probe fitted in protective tube (well). Fitted on sliding union. The Contractor shall supply soldered unions with seals for

fitting the temperature sensors. Integrated two-wire transmitter mounted in the sensor head with adjustable output

range. The temperature range shall be defined by the Contractor to meet the process

requirements.Conductivity transmitter (CT)

Two electrode sensor with concentric stainless steel electrodes and built-in Pt 100 compensation thermometer. The supply includes an electrode holder aiming at easily commission the instrument without interrupting the process.

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Two-wire analyzer. Measuring range 0.01 to 200 S/cm.

4.2.1.3 Analog sensor and local gauge setsPressure indicator (PI)

Bourdon tube. Local display with pressure indication in bar. The range shall be defined by the

Contractor to meet the process requirements.Differential pressure indicator (DPI)


Contractor to meet the process requirements.Flow-rate indicator (FI)

Float-type flow meter with local pressure indication. The flow-rate range shall be defined by the Contractor.

4.2.1.4 ActuatorsOn/off actuators include power contactors for electric motors and solenoid valves.

The control signal shall be 24 Vdc with electrical isolation (or 48 Vdc with electrical isolation; the direct current voltage shall be defined by the Contractor taking in consideration the distance between the power and control cubicle and the position of the two solenoid valves).

The two-way motorized regulating valve, shall be commanded by a 4-20 mA input signal.

4.2.2 Process control and local supervisionThe Contractor shall supply a power and control cubicle housing the PLC, the

SCADA local supervision platform, as well as all the equipment necessary for the regulation, process control and local operation of the cooling station. This power and control cubicle will be powered by CERN. It shall comply with specifications given in Annex E.

Although the control and operation of the cooling station shall be fully automatic, local manual means for maintenance operations shall be installed in the front panel of the power and control cubicle.

For reasons of compatibility with the existing cooling installations, the process control and regulation shall be built on Schneider Premium TSX equipment. A spare I/O capacity of 30% shall be foreseen. For the same reasons, the SCADA local supervision platform shall be Wizcon on a Windows XP PC platform.

In general, all the required PLC development software (packages, libraries and licenses) shall be included in the Tender.

The Wizcon SCADA software package is not included in the Tender. CERN will provide the Wizcon SCADA software package, including the following product references:

Wizcon development 65000 tags (WIZ-DEV-65 000), Wizcon for Internet clients (W4I-5r), Schneider driver for TCP/IP devices.This set of software for developing the local supervision application will be made

available to the Contractor on the acceptance of the Order.

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The Contractor shall develop the process control and regulation application for the PLC and SCADA. These software applications shall conform to the functional, operational and integration requirements.

In particular, the regulation loops shall be designed to ensure the dynamic performances. The PLC software application shall also satisfy the integration requirements to the CCC TIM system and to the ECR DCS system.

The SCADA local supervision application shall offer all the operation means (mimic diagrams, alarms and event lists, selection and display of operation modes, local and remote commands, set points and process variable parameters, trends, archiving, etc.).

The PLC and SCADA software applications shall comply with requirements and specifications given in Annex D.

4.2.2.1 CommunicationIn order to conform to system integration requirements, the PLC and the SCADA

local supervision platform need to be connected to the CERN Ethernet network. They shall report the alarms and status, as well as other significant process parameters, and shall handle the remote commands. The Contractor shall configure the communication parameters, which will be provided by CERN, in conformity to the TCP-IP protocol. The Contractor shall also be responsible for the mapping of the process data in the PLC and SCADA platform and for the verification and validation of the data transmission and dialogue with remote partners.

The primary cooling system, which is described in work lots 4 and 5, will be locally supervised and operated from the SCADA local supervision platform. This primary cooling circuit shall be controlled by a PLC, also built on Schneider Premium TSX equipment, which is included in the scope of the supply of this Technical Specification.

The Contractor shall integrate in the SCADA local supervision platform database the process data from the PLC controlling the primary cooling circuit. The Contractor shall develop, test, install and validate on-site the local supervision means (mimic diagrams, alarms and event lists, selection and display of operation modes, local and remote commands, set points and process variable parameters, trends, archiving, etc.) corresponding to this cooling system.

Five additional cooling systems will also be locally supervised and operated from the SCADA local supervision platform. These cooling systems are controlled by 3 PLCs, which are also built on Schneider Premium TSX equipment. These PLCs are not included in the scope of the supply of this Technical Specification.

1 PLC controlling the RICH1 and RICH2 cooling system 1 PLC controlling the IT cooling system and the TT cooling system 1 PLC controlling the VELO cooling systemThe Contractor shall integrate in the SCADA local supervision platform database the

process data from these 3 external PLCs. The Contractor shall develop, test, install and validate on-site the local supervision means (mimic diagrams, alarms and event lists, selection and display of operation modes, local and remote commands, set points and process variable parameters, trends, archiving, etc.) corresponding to these external cooling stations, according to the provisional schedule given in Annex C.

4.2.2.2 SecurityAll the interventions on the CERN Ethernet network have to be authorised by CERN.

CERN requires that all the computing equipment connected to the CERN Ethernet network

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use protocols based on the TCP/IP protocol suite. All computing systems provided shall follow the CERN computer security recommendations; an upgrade of the underlying operating systems shall not have any impact whatsoever on the application programs.

In particular, the PLC shall be configured so that any connection requested over the CERN Ethernet network from a non-authorised partner is rejected, and has not any impact whatsoever on the functional status of the cooling station. Also, the Contractor shall be responsible for the installation in the PC platform of all the Security Patches to the Operating System, as soon as they might be issued by Microsoft. This rule applies from the moment of the computer’s connection to the CERN Ethernet network and until the Acceptance is granted. The installation of the Security Patches shall not have any impact whatsoever on the application programs.

4.2.3 SafetyThe Contractor shall supply, install and validate an Emergency Stop push-button on

the front-door of the power and control cubicle, as well as near each pump. These push-buttons are hardwired to the associated power supply equipment for actuation, and to the PLC terminal blocks for information.

The Contractor shall supply and install the cables for the hardwired interlock signals between the PLC and the ECR detector cooling system. The connection at the PLC end is also included in the supply.

4.2.4 Other workFor functional safety purposes, the PLC also needs to read some general data (status

and/or general alarm) from the PLC at charge of the mixed water production plant in UW85 cavern. This existing PLC, which is also built on Schneider Premium equipment, is reachable through the CERN Ethernet network. The Contractor shall be responsible for configuring, testing and validating this communication.

4.3 WORK LOT 3: ELECTRICITY WORKS FOR OT COOLING SYSTEM

4.3.1 Scope of the supplyThe Contractor shall include in his Tender the following items concerning the

electrical installations for the cooling plant: the electrical study of the entire plant, the specification of power supply components and protections (for CERN to

provide the power supplies of UIAO-00836) and the design memoranda, the supply and installation of the UIAO-00836 power and control cubicle, the supply of the schematics diagrams of the power and control cubicle in

electronic and paper format, the supply and installation of all the cables and cable carriers (sized on the basis of

the equipment proposed) from UIAO-00836 cubicle to the various components, including the electrical connections and all the tests,

the supply and installation of the power, control, bus cables and cable carriers from the instrumentation and actuators to UIAO-00836 cubicle, including connections and their tests,

42


the equipotential links and the earthing of all the components of the plant including the metal structures and piping, all in conformity with CERN earthing standards.

4.3.2 Power requirementsThe contractor shall supply a power and control cubicle (as already indicated in

4.2.2), housing all the necessary equipment to provide the electrical power to the cooling station and its control system. This power and control cubicle shall comply with specifications given in Annex E. This power and control cubicle shall be integrated in the cooling station.

An indicative list of outgoing feeders is given in Table 5 below.

UIAO-00836 OT power and control cubicleItem Power* (kW) Comment

Pump 1 5.5 Direct startingPump 2 5.5 Direct starting (stand by)PLC, sensors and actuators 2

Table 5: UIAO-00836 Load List

* CERN estimated power in kW for the components that has to be sized by the Contractor. The Contractor shall determine the number, type and rating of each individual supply.

4.4 WORK LOT 4: HYDRAULIC AND MECHANICAL WORKS FOR PRIMARY COOLING SYSTEM.

4.4.1 DescriptionThere are existing pipes for chilled and mixed water in the detector area (on RB86

side – see Figure 2). These pipes shall be extended up to the protected area, going through the shielding wall via a chicane. Once in the protected area, these pipes shall be routed along the counting houses and up to the metallic platform supporting the detector cooling station.

The existing chilled water pipes that shall be extended are DN125, these pipes shall be reduced, right after the extension, to DN80 and then, reduced to DN65 once close to the metallic platform.

The existing mixed water pipes that shall be extended are DN250, these pipes shall be reduced, right after the extension, to DN200 and then, reduced to DN80 once close to the metallic platform.

The chilled water pipes shall be insulated.The following straight connection shall be made on the piping at different locations:

1. DN 200 on mixed water for room D1 and D22. DN80 on chilled water for room D1 and D2 (HVAC system)3. DN100 on mixed water for room D3/A4. DN25 on chilled water for room D3/A (HVAC system)5. DN100 on mixed water for room D3/B6. DN25 on chilled water for room D3/B (HVAC system)7. DN32 on mixed water for Outer Tracker cooling station

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8. DN25 on mixed water for Inner Tracker cooling station9. DN20 on mixed water for Trigger Tracker cooling station10. DN20 on chilled water for RICH1 and 2 cooling station11. DN20 on chilled water for VELO cooling station

The straight connections 1, 3 and 5 shall be equipped with: One manual shutoff valve on the return line One manual adjusting valve on the inlet line Two motorized shutoff valves on the inlet and return lines One flow transmitter on the inlet line Two wells (for temperature probes) on the inlet and return lines One fitting for temperature switch (thermostat) on the return line One fitting for pressure indicator (manometer ) on the inlet line

The other straight connections shall be equipped with: One manual shutoff valve on the return line. One manual shutoff valve on the inlet line.

There are two existing air compressed line in the detector area on each side of the cavern. These lines shall be extended on both sides of the cavern up to the protected area, going through the shielding wall, via a chicane. These pipes are DN50. Four straight connections equipped with a shutoff valve shall be made on the pipe located on RB84 side above the metallic platform.

The demineralised water line (DN50), for make-up of OT cooling station, already exists on the RB84 side of the UX85 cavern. This line shall be extended, via the chicane, up to the cooling station and connected to an existing shutoff valve close to the US/UX separation wall.

Specific supports made with galvanized steel profile shall be fixed at different locations on the RB84 side.

4.4.2 Operating conditionsThe main parameters are summarized in the table below.

Item Max flow rate

DN PN Service pressure

Mixed water network Straight connection for D1/D2 142 m3/h DN200

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Straight connection for D3/A Straight connection for D3/B Straight connection for Outer Tracker Straight connection for Inner Tracker Straight connection for Trigger Tracker

20 m3/h30 m3/h4 m3/h2.5 m3/h1.5 m3/h

DN100DN100DN32DN25DN20

PN16 10 bars

Chilled water network Straight connection for D1/D2 Straight connection for D3/A Straight connection for D3/B Straight connection for RICHes Straight connection for VELO

20 m3/h3 m3/h3 m3/h1.5 m3/h1.5 m3/h

DN80DN25DN25DN20DN20

PN16

10 bars

Demineralised water line N.A. DN50 PN16 12 barsCompressed air line N.A. DN50 PN16 7 bars

Table 6 : primary circuits parameters

4.4.3 Technical Requirements for components

4.4.3.1 Piping WorkAll material and components used in the construction shall be new and suitable for

the use for which they are intended in the given operating conditions. The specifications for the materials will be subject to approval by CERN.

In addition to the requirements of the codes of practice the Contractor shall conform to the following special requirements:

The pipes should end in flanges, the flanges and blank flanges on the ends of a pipe shall be of the same material

as the pipe itself, all pipework shall be made from straight pipe segments or prefabricated T-pieces

and bends. In no case CERN will accept that short pieces are welded together in order to replace standard pipes of 6 m of length,

the inside of the pipework has to be clean, degreased and free from contamination, dirt, welding scale and oil,

metric dimensions shall be used for bolting, all pipework shall be welded, at a change of direction, the bends shall be used. Only if there is a small change

in direction and the distance between the two welds is less than 13 mm, measured on the inner part of the bend, then the bend may be replaced by a bevelled cut on the pipes,

when two pipes are joined by a weld, care should be taken that the two longitudinal welds do not fall in line. They should be at least 13 mm apart, measured along the circumference.

4.4.3.1.1Material to be Used for demineralised water line

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Raw materialThe material for the pipes and the connections is austenitic stainless steel with a low

carbon content. The composition of the steel shall correspond to the DIN EN 10088-1/2.Pipe manufactureThe pipes shall be longitudinally welded.They shall be made from hot or cold rolled sheet. After welding, they shall undergo

descaling followed by passivation. This treatment corresponds to procedure dl or kl of the DIN Norm 17440. The guaranteed welding coefficient must be at least 0.8. In order to keep the pipes clean during transport and storage, they must have their ends adequately protected.

Pipe dimensionsAll pipes shall follow the ISO 4200 for outside diameters and wall thickness.ElbowsThe elbows shall follow the ISO R 285-1962. They shall have the same outer

diameter as the pipe to which they are joined. Their wall thickness shall be as close as possible but in no case less than that of the pipe to which they are joined. The elbows shall undergo the same surface treatment as the pipes. The guaranteed welding coefficient shall be 0.8.

ReducersThe reducers may be either eccentric or concentric according to their use. Their

largest outer diameters shall be the same as the outer diameters of the pipes to which they are to be joined.

The wall thickness of the reducer shall be that of the pipe having the largest diameter. The length of the cone shall never be less than 3 times the difference of the end diameters.

The reducers shall undergo the same surface treatment as the pipes. The guaranteed welding coefficient shall be at least 0.8.

Flanges and collarsThe flanges mounted on the pipework shall be of the welded collar type. The rotable

flange shall be hot galvanised. The material of the collar is that defined below.Blank flangesThey shall be of form B as defined by DIN 2527. They shall be covered on the fluid

side by an austenitic stainless steel 18/8 washer of 2 mm thickness. This washer shall have the same outer diameter as the gasket. The blank flange shall be galvanised.


pressures. The bolt lengths must be adapted to the connections for which they are to be used. A washer must be placed under each nut. The bolts, nuts and washers must be cadmium plated and graphite coated for assembly.

GasketsThese shall be of the Klingerit1 type or equivalent. Whatever their diameter, they

shall be 2 mm thick. The outer diameter must be such that during assembly the gasket is centred by the bolts of the flanges.4.4.3.1.2Material to be used for other piping

Pipes

1 Klingerit is a registered Trade Mark of Klinger

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All pipes shall be made of carbon steel. Common parts such as drain top-up and bleed valves etc… shall be made of carbon steel.

All pipes shall be seamless. In order to keep the pipes clean during transport and storage, they must have their ends adequately protected.

All the pipes shall be of ST37-2 carbon steel and comply with standards ISO 559.ElbowsThese shall comply with standard DIN 2605. Their outside diameter and wall

thickness shall be the same as those of the pipes to which they are welded.FlangesThe flanges mounted on the pipework shall be of the welded collar type and comply

with DIN norm 2633. They shall be neck flanges with raised seal beds. The material of the flanges shall be that of the pipe they belong to. They shall be fitted with blank flanges.

Blank flangesThey shall be of form B as defined by DIN norm 2527. They shall be covered on the

fluid side by a washer of 2 mm thickness of the same material as the pipe they belong to. This washer shall have the same outer diameter as the gasket. Any part of the blank flange which is not made of stainless steel shall be galvanised.

GasketsThe gaskets shall be of the Klingerit® 4 type or equivalent. Whatever their diameter,

they shall be 2 mm thick. The outer diameter must be such that during assembly the gasket is centred by the bolts of the flanges.


pressures. The bolt lengths must be adapted to the connections for which they are to be used. A washer must be placed under each nut. The bolts, nuts and washers must be zinc coated and passivated for assembly.

Reducers and dished endsThese may be forged or standard commercial items. Whatever their source, their

outside diameters shall be the same as those of the pipes to which they are to be welded. The wall-thickness of the reducer shall be that of the larger-diameter pipe.4.4.3.1.3Method of Assembly and Laying of the Piping Work

The assembly shall be made by welded or flanged connections.Drawn or longitudinally welded pipes may be proposed. All the welding shall be

submitted to a CERN inspection (X-rays control). The bolts shall perfectly fit the union for which they are used. A washer shall be fitted

beneath each bolt. Nuts, washers and bolts shall be designed to resist the specified test pressure for the piping work.

The outside diameter shall be such that, during the assembly, the gaskets are centred by the flange bolts.

The outside diameter and the wall thickness of the bends shall be at least the same as those of the piping work to which they are welded. The radius of curvature shall be R = 3D for all DN. Bends consisting of welded sections are forbidden.

4 Klingerit® is a registered Trade Mark of Klinger

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The wall thickness of the tapers shall be that of the larger-diameter pipe and the cone angle shall not exceed 40°. The reference standard is ISO 5251.4.4.3.1.4Requirements for support and fixings

The supports and fixed points shall be arranged so that the pipework imposes no stresses on the seals, fittings and accessories.

The supports shall be made from commercially available steel sections.The pipes shall be secured to the fixed points by flat collars or another locking

system. Fixings shall not be welded directly to the pipe. Sliding supports shall be positioned to allow the pipework to expand, absorb lateral forces to maintain the alignment of the pipework, and allow the pipes to move longitudinally without noticeable wear and without damage to the lagging.

The supports shall be carefully protected and spaced so that the deformation of the pipework during operation or testing results in neither any undue stresses in the pipes, nor reverse gradients which could hamper the flow of fluids, condensates or the escape of air from liquids.

The steel components shall be generously designed to allow for accidental overloads. In all cases the pipes shall be assumed to be full of water.

The supports shall be thoroughly examined before fitting. Cut steel components shall be deburred and any sharp edges rounded off. Holes shall be drilled or punched (a cutting torch may in no circumstances be used for this operation).

The concealed parts of the supports shall be coated with rustproof paint, or hot galvanised, before the various components are assembled together or secured to the building framework.

The supports and fixed points shall be arranged so that the pipework imposes no stress on the unions, fittings and accessories.

The collars shall: Be made of galvanised steel. A protective layer (rubber) shall be fitted between

the pipe and the collar, consist of collars with rubberised strips (MUPRO2) for small diameters < 50

mm.The spacing of the pipework supports shall not be greater than the values below:

Diameter of pipesDN

Largest distance between supports in m

6 to 1015 to 3240 to 7080 to 150200 to 300350 to 400

2.03.04.55.06.07.0

2 Mupro is a Trade Mark

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Table 7 : Distance between supports

It should be noted that the pipes may not themselves be regarded as supports and no pipe shall be attached to another by any system whatsoever.

The supports for pipework conveying hot or cold fluids shall be designed so that the pipes may expand freely without excessive stresses.4.4.3.1.5Drains

Ballostar type or similar.Connections according to drawing 15 LHC F 99900001 3.Spherical plug-cock, one-piece brass body, chromium-plated brass ball, PTFE collar

and packing gland.Rated pressure PN 16.Detachable control handle.

4.4.3.1.6Bleed Cocks (Air Vents)

Ronfard type or similarConnections according to drawing 15 LHC F 99900001 3.Cast iron or steel body. Fitted with the same type of spherical plug-cocks as the

drains.Rated pressure PN16.

4.4.3.2 Technical requirements for laggingThe chilled water pipes shall be surrounded completely by a layer of Foamglas® or

similar, with a minimum thickness of 40 mm. This lagging shall be protected on the outside by a layer of sheet aluminium. The Foamglas® shall be replaced by 40 mm high density polyurethane (RG80 or similar) where the pipe supports are placed, in order to guarantee stability.4.4.3.2.1Application on Pipework

Clean the pipes, supply the lagging, fit the lagging, secure and joint with Intumescent Mastic®, or similar, hold in place with galvanised steel wire, smooth with Intumescent Mastic®, or similar, apply folded riveted or screwed 0.6 mm thick sheet aluminium, any other requirements for a perfect finish.

4.4.3.2.2Application on Accessories

Full lagging of all the accessories in each circuit: Fabrication of removable and re-usable sealed casings of riveted or screwed sheet

aluminium lined with 19 mm thick Armaflex® 5 NH, or similar,

5 Intumescent Mastic is registered Trade Mark of Intumescent Fire Protection Supplies Ltd.

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wiping off the fittings, coating with water-free cold bitumen, fitting the casings, finishing with Armaflex® NH, silicone seal and covers screwed on all the stubs,

wells, bleeds, drains and end of lagging.

4.4.3.3 Two-way manual balancing valvesThe balancing valves shall be manufactured in accordance with ISO 5752, and

provided with flanges of normalised ISO dimensions. They shall have the necessary pressure and temperature ratings (according to the circuit) and be of a modern design for reduced vibration, noise and cavitation. The body of the valves shall be flanged

They shall be of TA® type or similar quality.

4.4.3.4 Shutoff valves Butterfly type Amri3/Isoria F222-3G-6K 3GXA or equivalent for DN > 50

Leak proof to standard ISO 5208 Overall dimensions to standard ISO 5752 Base plate to standard ISO 5211 Cast-iron body with centring lug Epoxy-coated ductile cast-steel butterfly with EPDM sleeve Manual actuation using reduction gear with position indicator, no end of

travel. Spherical ball valve for DN< 50

leak proof to standard ISO 5208 overall dimensions to standard DIN 3202 base plate to standard ISO 5211 cast-iron body, stainless steel inner capsule, PTFE seal flanged connections

4.4.3.5 Motorized valves Butterfly Amri/Isoria F 222-3G-6K 3 GXA or equivalent,

Motor: Bernard 400V 3PH INTEGRAL heating resistor, on-off input and output contacts with IP 55 protection, torque limit switch. For non accessible valves, the control panel shall be installed apart at an

accessible place.

? Armaflex® is a registered Trade Mark of Armstrong World Industries, Inc.3 AMRI is a Trade Mark of KSB Amri is a registered Trade Mark of KSB. Bernard is a Trade Mark

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4.4.3.6 WeldingPipe welders working at CERN will have to pass a test by the CERN Technical

Inspection and Safety Commission (SC); please refer to SC document TIS/TE/MI/CM 00-14. The cost of the test shall be borne by the Contractor.

The welds shall be made by the argon arc method (80 to 85% argon and 20 to 15% hydrogen). The protective gas shall be confined in the pipe between two discs located on either side of the weld to reduce gas losses.

The welds shall be made to ISO standard manual 19. The protective gas inside and outside the pipe shall meet standard DIN 32526 or equivalent. The filler metal shall meet standard DIN 8559 or equivalent.

After completion, the welds shall be cleaned with a stainless steel brush to remove any traces of oxidation on the welds, and passivated.

Each weld shall be marked with the welder's identity.Inspection of Welds: the degree of X-ray of welded joints shall be as laid down in the

design code, please refer to TIS document TIS/TE/MI/CM 00-14. Other non-destructive tests may be required by CERN in case of doubt. As a minimum requirement circumferential welds and longitudinal welds in pipework shall be X-rayed at not less than 10%. If faults are discovered, CERN or the inspector may require additional X-rays, up to 100%, if necessary. These X-ray will be evaluated in accordance to ISO standard 5817, requirement B.

All the inspections and tests costs shall be at the contractor’s charge.

4.5 WORK LOT 5: CONTROL WORKS FOR PRIMARY COOLING SYSTEM

4.5.1 InstrumentationAll the sensors and actuators required to operate the process, their mechanical and

electrical connections, connection tests, tuning and verification of the measurements, shall be included in the tender.

The pressure ratings, materials and temperature operation range shall be adapted to the particular use of each transmitter or actuator and their environment. The electrical characteristics shall meet industrial standards. They shall be selected to meet the requirements below:

Halogen-free materials (body, connection cubicle, etc.). Industrial-type construction suitable for the environment (relative humidity from 0

to 90%, temperature from 10 to 40°C, vibration resistance, etc). Easy accessibility and interchangeability. Good time and temperature stability (long re-calibration intervals). Accuracy adequate to the requirements of the process. Protection index IP54. All the parts in contact with water shall be made of stainless

steel. Earthing.

CERN reserves the right to require the replacement of certain instruments if they are considered to be of inadequate quality.

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4.5.1.1 On/off detector switchesThe control racks shall be dimensioned and fully equipped to integrate the potential-

free contacts. A 30 % of spare capacity shall be foreseen.Temperature switch (TS)

Bi-metal Adjustable switching by means of a screwdriver. The switching range shall be

defined by the Contractor to meet the process requirements.

4.5.1.2 Analog sensor and transmitter setsVoltage 24 Vdc with electrical isolationOutput signal 4-20 mA. with integrated square root extractor, if applicable.Accuracy > 0.5 % of the set span. At least, all the transmitters shall offer local means (keys) for calibration of the main

parameters as zero point and span. Solutions based on remote intelligent means as HART protocol (via a PC based operating program or via a handheld terminal) will be accepted only if the operating program (version for Windows XP) or the handheld terminal is included in the basic offer.

Flow-rate transmitter (FT) Differential pressure measurement. Fitted on sliding union. The supply includes the manifold aiming at easily

commission the instrument without interrupting the process. Integrated two-wire transmitter with adjustable output range. Integrated square root extractor. The flow-rate range shall be defined by the Contractor to meet the process

requirements.Temperature transmitter (TT)

Pt 100 temperature probe fitted in protective tube (well). Fitted on sliding union. The Contractor shall supply soldered unions with seals for

fitting the temperature sensors. Integrated two-wire transmitter mounted in the sensor head with adjustable output

range. The temperature range shall be defined by the Contractor to meet the process

requirements.

4.5.1.3 Analog sensor and local gauge setsPressure indicator (PI)


Contractor to meet the process requirements.

4.5.1.4 ActuatorsOn/off actuators include power contactors for motorized shut-off valves. These valves

shall have an opening or closing time of 30s. The control signal shall be 24 Vdc with electrical isolation (or 48 Vdc with electrical isolation; the direct current voltage shall be defined by the Contractor taking in consideration the distance between the power and control cubicle and the position of the shut-off valves).

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4.5.2 Process controlThe Contractor shall supply a power and control cubicle housing the PLC and all the

equipment necessary for the regulation, process control and local operation. This power and control cubicle will be powered by CERN. It shall comply with specifications given in Annex E.

Although the control and operation of the cooling station shall be fully automatic, local manual means for maintenance operations shall be installed in the front panel of the power and control cubicle.

For reasons of compatibility with the existing cooling installations, the process control and regulation shall be built on Schneider Premium TSX equipment. A spare I/O capacity of 30% shall be foreseen.

In general, all the required PLC development software (packages, libraries and licenses) shall be included in the Tender.

The Contractor shall develop the process control and regulation application for the PLC and SCADA. These software applications shall conform to the functional, integration and operational requirements.

In particular, the regulation loops shall be designed to ensure the dynamic performances. The PLC software application shall also satisfy the integration requirements to the CCC TIM system and to the ECR DCS system.

The PLC software application shall comply with requirements and specifications given in Annex D.

4.5.2.1 CommunicationIn order to conform to system integration requirements, the PLC needs to be

connected to the CERN Ethernet network. It shall report the alarms and status, as well as other significant process parameters, and shall handle the remote commands. The Contractor shall configure the communication parameters, which will be provided by CERN, in conformity to the TCP-IP protocol. The Contractor shall also be responsible for the mapping of the process data in the PLC side and for the verification and validation of the data transmission and dialogue with remote partners.

The Contractor shall integrate the primary cooling circuit in the SCADA local supervision application. The local supervision application shall offer all the operation means (mimic diagrams, alarms and event lists, selection and display of operation modes, local and remote commands, set points and process variable parameters, trends, archiving, etc.).

4.5.2.2 SecurityAll the interventions on the CERN Ethernet network have to be authorised by CERN.

CERN requires that all the computing equipment connected to the CERN Ethernet network use protocols based on the TCP/IP protocol suite. All computing systems provided shall follow the CERN computer security recommendations; an upgrade of the underlying operating systems shall not have any impact whatsoever on the application programs.

In particular, the PLC shall be configured so that any connection requested over the CERN Ethernet network from a non-authorised partner is rejected, and has not any impact whatsoever on the functional status of the cooling station.

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4.5.3 SafetyThe Contractor shall supply, install and validate an Emergency Stop push-button on

the front-door of the power and control cubicle, as well as near each pump. These push-buttons are hardwired to the associated power supply equipment for actuation, and to the PLC terminal blocks for information.

The Contractor shall supply and install the cables for the hardwired interlock signals between the PLC and the ECR detector cooling system. The connection at the PLC end is also included in the supply.

4.5.4 Other workFor functional safety purposes, the PLC also needs to read some general data (status

and/or general alarm) from the PLC at charge of the mixed water production plant in UW85 cavern. This existing PLC, which is also built on Schneider Premium TSX equipment, is reachable through the CERN Ethernet network. The Contractor shall be responsible for configuring, testing and validating this communication.

4.6 WORK LOT 6: ELECTRICAL WORKS FOR PRIMARY COOLING SYSTEM

4.6.1 Scope of the supplyThe Contractor shall include in his Tender the following items concerning the

electrical installations for the cooling plant: the electrical study of the entire plant, the specification of power supply components and protections (for CERN to

provide the power supplies of UIAO-00837) and the design memoranda, the supply and installation of the UIAO-00837 power and control cubicle, the supply of the schematics diagrams of the power and control cubicle in

electronic and paper format, the supply and installation of all the cables and cable carriers (sized on the basis of

the equipment proposed) from UIAO-00837 cubicle to the various components, including the electrical connections and all the tests,

the supply and installation of the power, control, bus cables and cable carriers from the instrumentation and actuators to UIAO-00837 cubicle, including connections and their tests,

the equipotential links and the earthing of all the components of the plant including the metal structures and piping, all in conformity with CERN earthing standards.

4.6.2 Power requirementsThe contractor shall supply a power and control cubicle (as already indicated in

4.5.2), housing all the necessary equipment to provide the electrical power to the cooling station and its control system. This power and control cubicle shall comply with specifications given in Annex E. An indicative list of outgoing feeders is given in Table 8 below.

UIAC-00837 Primary cooling power and control cubicle

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Item Power* (kW) CommentMotorized valves 6x300W Direct startingPLC, sensors and actuators 2

Table 8: UIAC-00837 Load List

* CERN estimated power in kW for the components that has to be sized by the Contractor. The Contractor shall determine the number, type and rating of each individual supply.

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