Fabricate and Inspect I-Loop Zircalloy Testing Facility

INL-23-003Fabricate and Inspect I-Loop Zircalloy Testing Facility for INLI. INTRODUCTIONBattelle Energy Alliance, LLC (BEA), Management & Operating Contractor of the U.S. Department of Energy (DOE) owned Idaho National Laboratory (INL), is seeking an Expression of Interest (EOI) from prospective vendors to provide labor, material, equipment, and services to fabricate, inspect, test, and the deliver  an I-Loop tube prototype to an INL testing facility. This EOI shall serve as a method of identifying qualified firms interested in providing the I-Loop tube prototype  to INL. Participation in the activities described herein neither prequalifies nor disqualifies the prospective vendor for later material supply to the INL. Requests for Proposals (RFPs) may be issued as a result of responses from this EOI.II. BACKGROUNDThe I-Loop project is creating experiment tubes. The experiment tubes will facilitate Light Water Reactor (LWR) testing. The experiment tubes are named I-Loop Tubes (ILT). The

I-Loop system will complete the experimental suite offered by the Idaho National Laboratory (INL) and would support the high-value objectives of the United States (U.S.) nuclear energy industry. Testing of the I-Loop Tube Prototype will be performed at an Idaho Falls laboratory facility. This ILT Prototype is intended to identify unforeseen machining, inspection, or testing challenges with the current design. This allows for alterations to the ILT design before finalizing. To achieve this, the ILT Prototype will comply to Nuclear Grade Boiler and Pressure Vessel Code (BPVC) section III Class 1 Component and procured as a Commercial Grade item. After delivery of the ILT Prototype to INL, it will be used as a testing facility. The ILT Prototype will be connected to the Flowing Autoclave system. This allows INL to complete operational testing of the ILT by subjecting it to design operating temperatures, pressures, and flows prior to procuring the actual ILTs.III. SCOPE OF WORKThe scope of work associated with this Expression of Interest shall provide all labor, material, equipment, and services necessary to fabricate, inspect, test, and deliver to INL the Flowing Autoclave I-Loop Tube L Weldment within the specified code and subject to the terms and conditions of the contract or purchase order.The I-Loop Tube Prototype will consist of three Zircaloy tubes that will fit inside one-another and be welded together. All three of these tubes consist of a Zirc-4 (ASME B351 R60804) section and a section of Zr-2.5Nb (ASME B351 R60901). The final assembly will be approximately 9 feet tall with a diameter of 6 inches.The assembly requires extensive electron beam welding and Tungsten Arc Welding. These welds are required to be inspected by Liquid Penetrant, Ultra-sonic, and Radiography inspection methods.After fabrication is completed, the assembly must be pressure tested using an inert gas. A hydrostatic test using de-ionized water is also required.Any exceptions to this Expression of Interest shall be clearly defined in the Supplier's initial proposal submittal and specifically identified as exceptions. SPC-2971, “Specification, Flowing Autoclave I-Loop Tube Prototype,” Rev. 1 will be provided upon request.IV. APPLICABLE CODES AND STANDARDSThis ILT Prototype is intended to identify unforeseen machining, inspection, or testing challenges with the current design. This allows for alterations to the ILT design before final procurement.  To achieve this, the ILT Prototype will comply to Nuclear Grade Boiler and Pressure Vessel Code (BPVC) section III Class 1 Component and procured as a Commercial Grade item.  A list of standards selected by the Supplier for, fabrication, examination and testing shall be submitted to the Buyer for approval. Conflicts in any Code or Standard requirements shall be documented by the Supplier and provided to the BEA Purchasing Agent for resolution concurrence.ASME Boiler and Pressure Vessel Code Section III, Division 1 – Subsection NB, Class 1 Components, 2021 editionASME Boiler and Pressure Vessel Code Section VIII, Division 1, 2021 editionASME Boiler and Pressure Vessel Code Section V, Nondestructive Examination, 2021 editionNQA-1-2018/2019, Quality Assurance for Nuclear Facility ApplicationsASME-Y14.5 – 2018, Dimensioning and Tolerancing Engineering Product Definition and Related Documentation Practices, 2018 editionSNT-TC-lA, Non-Destructive Testing Recommended PracticeASTM B353-12 Standard Specification for Wrought Zirconium and Zirconium Alloy Seamless and Welded Tubes for Nuclear Service (Except Nuclear Fuel Cladding), 2017 editionB351/B351M-13 (Reapproved 2018) Standard Specification for Hot-Rolled and Cold-Finished Zirconium and Zirconium Alloy Bars, Rod, and Wire for Nuclear Application, 2018 editionAdditionally, supply Zirc-4/Zircaloy-4. Refers to the ASTM standard alloy B353-12 (2017) UNS R60804 (Seamless tube where applicable) or B351-13 (2018) UNS R60804.Zr-2.5Nb. Refers to the ASTM standard alloy B353-12 (2017) UNS R60901 or B351-13 (2018) UNS R60901 annealed.V. CODE CLASSIFICATION AND SAFETY CLASSIFICATION Code Requirements – The I-Loop Tube Prototype will not be installed in a nuclear facility; however, it is intended to be a proof of concept for the design and fabrication. As such, it will be fabricated and inspected to ASME BPVC Section III, Division 1, Class 1 Components, 2021 edition. This is to ensure code compatibility of the design and fabrication process that will be used for the actual I-Loop Tube. Section III provides the equivalent level of rigor of section VIII, which is required for use in the Flowing Autoclave where the prototype will eventually be used.IV. SUBMITTAL REQUIREMENTS To qualify for consideration, prospective subcontractors shall provide brief statements of how they meet the mandatory requirements listed below:Overview of the candidate Company.  Applicants must show experience in fabrication of Zircaloy components, ability to produce tubes with tight tolerances, and an expertise in electron beam welding, preferably with zirconium alloys.The Supplier shall have a documented quality program and must demonstrate effective implementation of their quality process and controls during an in-person evaluation by Idaho National Laboratory (INL). Must also demonstrate the ability to perform proper weld inspection techniques involving Liquid Penetrant, Ultra-sonic, and Radiographic inspections.Due to programmatic requirements, delivery of the ILT Prototype will be required 1 year after APO.Name, telephone number, and e-mail address of a representative of your firm who can answer questions regarding this request for expression of interest.BEA plans to issue a Request for Proposal that will allow award of a subcontract to fabricate the ILT Prototype. Subsequent subcontract awards may include fabrication of additional experiment ILT tubes Please provide your expression of interest by email Blake Weekes at Blake.Weekes@inl.gov by Close-of-Business, December 9, 2022. Included must be sufficient written information confirming the responder’s qualifications as a potential offeror under a prospective RFP(s). Note that qualification packages must be no more than 10 pages in length.  Questions can be submitted via email to Blake Weekes (Blake.Weekes@inl.gov).