Statement of Work for Re-design of CRPS Motor and Controller

Transcription

1 SG-PLN Page: 1 of 21 Motor and Controller

2 SG-PLN Page: 2 of 21 Table of Contents 1. Purpose and Scope Purpose Scope Background Overview of the functionality of CRPS Re-engineering of CRPS Statement of Work Project Deliverables Conceptual design and project management documents Complete design CRPS Prototype with operating and training documentation Final product Business requirements Implementation of the project Output quality control system Roll-out phase of the project Cost of the re-designed CRPS Acceptance Testing Location of acceptance testing Contractor s participation Period of performance Intellectual Property ownership Warranty References and abbreviation Documents applicable to the SoW Abbreviations applicable for the SOW... 9 A. Annexes A.1 CRPS Specifications A.1.1 Scope A.1.2 Functional Requirements A.1.3 Design requirements A.1.4 Software requirements A.1.5 Environmental requirements A.1.6 Mechanical requirements A.1.7 Electromagnetic compatibility and immunity A.1.8 Power supply requirements A.1.9 Conformity with EU directives - CE Marking A.1.10 Reliability A.1.11 Operating Documentation A.2 Operating Manual of the existing CRPS (for information only) A.3 Design description of the existing CRPS (for information only)... 20

3 SG-PLN Page: 3 of Purpose and Scope 1.1 Purpose This document is meant to provide the necessary for the project to re-design the Cask Radiation Profiling System (CRPS). The document defines business and performance requirements, as well as the requested work activities, deliverables, and timeline. 1.2 Scope This document shall be used by the IAEA and the Contractor to form the basis of the Contractor s preparation of the technical and financial proposals, and to establish a set of criteria for acceptance of the product, to be delivered under this Statement of Work (SoW). 2. Background 2.1 Overview of the functionality of CRPS CPRS is a complete hardware and data acquisition system for acquiring gamma radiation profiles from CANDU spent fuel dry storage facilities. The electronics are provided in a compact carrying case that also protects the electronics during transportation. A motor (hoist) system is provided to maintain consistent probe motion, and the speed of the probe movement is recorded in the data acquisition file. The integration of hardware and software into one system is intended to simplify cask profiling.

4 Department of Safeguards SG-PLN Page: 4 of Re-engineering of CRPS Under the project entitled Re-Design of CRPS Motor and Control Unit, SGTS/NDAI intends to re-design and implement a new mechanical and electrical part for the CRPS by replacing the existing motor unit and electronics unit 1 with a new design, due to the obsolescence of components. The functional part of the CRPS, i.e. the CdZnTe detector with preamplifier, Tungsten Collimator, MCA-527 and data acquisition laptop, will remain unchanged under this project. Compliance between new and existing components shall be assured by the Contractor and will be verified by the IAEA technical representative(s). 3. Statement of Work The Contractor shall carry out the activities listed here below and provide the deliverables specified. 3.1 Project Deliverables The Contractor shall, in accordance with the agreed implementation plan, deliver to the IAEA the following items: Conceptual design and project management documents Within two weeks after start-up meeting: a. Conceptual design with definition of the principal components and interfaces; b. Implementation plan in the form of the MS Project-compatible Gantt chart; c. Name and contact information for the Contractor s Project Manager and Technical Officer, responsible for coordination and implementation Complete design Within six weeks after approval of conceptual design: a. Mechanical parts of CRPS, such as detailed drawings in hardcopy and electronic format (CAD), component specifications, assemblies, chassis, etc.; b. Electronic part of CRPS: multilayer drawings of printed circuit boards with specification of electronic components (EDA); c. Connection diagrams; d. User interface similar to that of WinScan (authorized for Safeguards) e. Software requirements documentation and software architecture description to assure functionality of WinSCAN; f. MSDS for all batteries, whether they are primary cells or rechargeable batteries, except for the MCA-527 and IAEA supplied data acquisition laptop. 1 MCA-527 multichannel analyser will be integrated as a component into the Electronics Unit or case.

5 Department of Safeguards SG-PLN Page: 5 of CRPS Prototype with operating and training documentation Within eight weeks after review and approval of design documentation by the IAEA: a. A fully functional prototype of CRPS with software application (APP) to control pushpull drive of CRPS and to collect and analyse spectrometric data; b. Operating and configuration manuals; c. Training materials Final product and Blanket Purchase Agreement Proposal (BPA) a. If required, within 6 weeks after acceptance testing of the CRPS, modified deliverables of pos. 3.1 for re-testing; b. A final report, summarizing the work done and containing transfer of all Intellectual rights for modification and production of the CRPS to the IAEA. c. Proposal for BPA within the ceiling price as per Business requirements Implementation of the project The Contractor shall: a. Attend a one-day technical meeting at the IAEA to participate in the technical demonstration of the existing CRPS and to clarify any business and technical questions with the relevant IAEA staff. The meeting shall take place at the time agreed upon between the IAEA and the Contractor, but not later than within 2 weeks after awarding a Purchase Order; b. Develop a conceptual design of the CRPS with the performance, compliant with Annexes A.1 to this SOW. Both the reference in Annex A.2 and Annex A.3 are for information on the existing CRPS only; c. Develop detailed design of the CRPS and transportation box(es) with the performance, compliant with Annex A.1 to this SOW. Both the reference in Annex A.2 and Annex A.3 are for information of the existing CRPS only; d. Present the complete design package at the IAEA to relevant technical staff; e. Manufacture all required hardware (mechanical, electronic and auxiliary components), transportation boxes, and develop necessary software for the CRPS prototype, meeting the requirements of Annex A.1 to this SOW. The prototype shall be manufactured in strict accordance with the developed and approved design documentation package, so that completeness and correctness of the design documentation will be verified;

6 SG-PLN Page: 6 of 21 f. Develop operating and configuration manuals; g. Develop training material on operation and configuration of the CRPS; h. Deliver, install and configure the CRPS at the IAEA at the time agreed upon with relevant IAEA staff; i. Participate in the final acceptance testing(s) 2 of the CRPS prototype; j. Improve performance of the CRPS, review the corresponding design documentation and user manual to reflect the final CRPS design as built ; k. Assure hand-over of all project deliverables to the relevant IAEA staff; l. Deliver a two-day training course at IAEA HQ on the design, operation, configuration and the software of the CRPS for the technical staff nominated by the IAEA at the time agreed upon between the Contractor and the IAEA Output quality control system The Contractor shall specify the output quality control system used for the acceptance testing of the CRPS. Results obtained by the Contractor shall be delivered to the IAEA. 2 If the initial acceptance testing of the CRPS fails, a follow up test will be required to assure the product compliance with the SOW requirements

7 Department of Safeguards SG-PLN Page: 7 of Roll-out phase of the project Following successful completion of the re-design project and upon the IAEA s request, the IAEA intends to conclude with a contractor a Blanket Purchase Agreement (BPA) for manufacturing of up to 20 CRPS within three years at the fixed price Cost of the re-designed CRPS Design of the CRPS (motor drive, controller unit, collimator, transportation boxes and auxiliary components), and the work required for assembling the fully functional CRPS, MCA-527 and a data acquisition laptop shall be in compliance with the upper cost limit defined below. However, some of the components to be integrated in the CRPS, viz. the data acquisition laptop, CdZnTe detector and MCA-527, will be provided from the IAEA without costs for the production. The Contractor shall provide detailed proposal for the manufacturing up to 20 units for the Blanket Purchase Agreement (BPA) as part of the deliverables. The cost of the new CRPS shall be minimized. Provided that the IAEA requests a Contractor to conclude a Blanket Purchase Agreement (BPA) for manufacturing and testing of up to 20 CRPS within three years, the cost of each CRPS (including the labour cost, but excluding the cost of IAEA-provided components as defined above) shall not exceed EUR. 3.3 Acceptance Testing Location of acceptance testing Acceptance testing of the CRPS shall take place at the test platform located at IAEA HQ. Acceptance testing will consist of verification that technical, functional, design and other requirements as specified in Annex 1 of the SOW are met Contractor s participation The Contractor shall nominate a technical representative(s) for a period of at least three (3) working days to participate in the acceptance testing to be performed by the IAEA with participation of the end user (Operations Divisions) and the Contractor.

8 SG-PLN Page: 8 of Period of performance All work required under this SOW shall be completed within six months after receipt of the purchase order. 3.5 Intellectual Property ownership All rights to modify and/or manufacture the CRPS shall be transferred to the IAEA as part of the hand-over process. 3.6 Warranty Warranty on the deliverables under this SOW shall be no less than two years from the signature date of the acceptance protocol. The warranty shall include labour, travel if applicable, and parts. 4. References and abbreviation 4.1 Documents applicable to the SoW [1] IEC Electromagnetic compatibility (EMC) Part 6-3: Generic standards Emission standard for residential, commercial and light-industrial environments; [2] IEC Electromagnetic compatibility (EMC) Part 6-2: Generic standards Immunity for industrial environments; [3] IEC Functional Safety of Electrical/Electronic/Programmable Electronic Safety-related Systems; [4] IEC 60529: Degrees of protection provided by enclosures (IP Code).

9 SG-PLN Page: 9 of Abbreviations applicable for the SOW AC APP CAD CANDU CRPS CdZnTe DSC EDA HQ IEC IP MSDS MCA PRNDA ROI SOW USB Alternating Current CRPS Software Application Computer-aided Design Canada Deuterium Uranium Cask Radiation Profiling System Cadmium Zinc Telluride Dry Storage Cask Electronic Design Automation IAEA Headquarters Electrotechnical Commission Ingress Protection Material Safety Data Sheet Multichannel Analyzer Portable and Resident Non-Destructive Assay Region of Interest Statement of Work Universal Serial Bus

10 SG-PLN Page: 10 of 21 A. Annexes A.1 CRPS Specifications A.1.1 Scope A.1.2 Functional Requirements A.1.3 Design requirements A.1.4 Software requirements A.1.5 Environmental requirements A.1.6 Mechanical requirements A.1.7 Electromagnetic compatibility and immunity A.1.8 Power supply requirements A.1.9 Conformity with EU directives - CE Marking A.1.10 Reliability A.1.11 Operating Documentation A.2 Operating Manual of the existing CRPS (for information only) A.3 Design description of the existing CRPS (for information only)... 20

11 SG-PLN Page: 11 of 21 A.1 CRPS Specifications A.1.1 Scope The CRPS Cask Radiation Profiling System uses a shielded CdZnTe detector powered by a motor unit to measure gamma ray intensity along the height of a dry storage baskets with fuel bundles. The measurement is conducted by moving a shielded detector vertically at a preselected constant speed inside a verification tube along the face of the dry storage baskets while a scanning sequence is executed on the computer. The system records a sequence of gamma spectra and displays gamma ray intensity either with gross counts or within the selected ROI as a function of the vertical position. In the primary application, the detector is manually positioned to the lower start position of the verification tube and the detector cable is installed into the transportation wheel of the motor unit. There is no collimation on the detector shielding, and therefore no alignment is required. The motor unit is mounted on a tripod on top of the dry storage silo above the opening of the verification tube. In a special application for DSC the detector is manually entered without any collimator into a narrow verification tube through combined horizontal and vertical pathways to the start position. The motor unit is mounted to a scaffold with a special adapter instead of the tripod. The detector cable is installed into the transportation wheel. Once the detector is pulled towards the exit of the verification tube by the motor unit, the actual speed is measured by an encoder and recorded within the measurement data file. There are sensors to detect the upper (lower) limit of the detector, which can be marked on the detector cable, causing an automatic stop of the detector movement.

12 SG-PLN Page: 12 of 21 A.1.2 Functional Requirements REQ 1. The motor unit shall be controlled via a linking cable from the electronics unit with the data acquisition laptop. This is referred to as the Remote Mode. REQ 2. The motor unit shall be functional without any linking cable to the data acquisition laptop and therefore comprise controls and indicators required for the setup. This is referred to as the Local Mode. REQ 3. The motor unit shall provide for a bi-directional vertical movement of up to 5 kg load, the CdZnTe detector with tungsten shielding (see below), at a constant speed in the range of 5 to 20 mm/s with an accuracy of ±1%. REQ 4. The motor unit shall allow for the manual adjustment of the movement speed in steps for 5; 7.5; 10; 15; 20 mm/s, in the selected range and the movement direction (up or down). REQ 5. The motor unit shall allow for the manual stop of the movement at any position. The time from the submission of STOP (or Emergency Stop) command to the complete stop of the lifting detector cable, i.e. response time, shall not exceed 1 s. REQ 6. The motor unit shall monitor the actual movement of the detector cable and transmit it to the electronics unit where it will be recorded in the data file. If the movement deviates from the setup, e.g. due to a low grip on the cable, CRPS Software Application (APP) shall stop the running measurement cycle. REQ 7. Driving up or down, the motor unit shall automatically stop when: a. The upper/lower limit marked on the detector cable is reached; b. There is excessive tension exceeding maximum nominal load. A.1.3 Design requirements REQ 8. The Contractor shall re-design the motor unit and electronics unit to meet specific requirements for each of these components. The Contractor shall assure full compatibility with the existing CRPS, the MCA-527, the data acquisition laptop and the CdZnTe detector; these components will always be provided free of cost by the IAEA. The types of power and data connector on the electronics case shall match the corresponding cable connectors with MCA-527 (USB 2.0 Type A), CdZnTe detector (Lemo connector PHG.2B.704.CLLD72), and data acquisition laptop (USB 2.0 Type A). One MCA-527, data acquisition laptop, CdZnTe detector will be lent by the IAEA to the Contractor for the whole period of project performance. REQ 9. Design of the motor unit and electronics unit shall be safe for the intended use and comply with safety requirements of IEC , IEC and IEC standards. REQ 10. The outer surfaces of the components shall allow for easy de-contamination.

13 SG-PLN Page: 13 of 21 REQ 11. Design of the motor unit, electronics unit (except for the MCA527 and the data acquisition laptop) shall assume no need for preventive maintenance (such as replacement of batteries) over the whole lifecycle of the CRPS device. Replacement of fuse(s) shall not require opening of the enclosure. REQ 12. The electronics unit shall: a. Include all power supply unit(s) or cross boards to provide operating power to the MCA 527, data acquisition laptop and required control boards; b. Serve as an enclosure for Controller board(s), MCA-527 ( mm without connectors see elektronik.de/en/leistungen/nuklearmesstechnik/vielkanalanalysatoren/mca- 527/ for details), and a cross board to link internal and chassis connectors; c. Interface with the data acquisition laptop; d. The control board shall include a TTL input for optional neutron counting. REQ 13. The motor unit shall: a. Provide bidirectional movement to the CdZnTe detector with direct transportation of the detector cable of the type EPD 82342B (Tyco); b. Control and monitor with the required accuracy the speed and direction of the movement both in local mode and remote mode (controlled from the electronics case with APP); c. Have all control elements clearly marked. The colouring of the markings shall be durable and resistant against wear-off through frequent touching in the course of operating the control elements; d. Enable emergency stop of the motor; e. Have provisions for installation on a tripod to be included by the Contractor.

14 SG-PLN Page: 14 of 21 REQ 14. One detector shielding to be provided by the Contractor shall be delivered, corresponding to the figure below: REQ 15. One corrugated PTFE tube with a nominal diameter of 1.25 inches and a length of 1.5m shall be provided by the Contractor to reduce the friction of the detector cable in the bent verification tube (inner diameter of 50mm). On one end of the tube, an end piece with an opening to feed the detector shielding into the tube shall be mounted. REQ 16. REQ 17. REQ 18. A.1.4 The mass of the electronics unit, with data acquisition laptop, MCA527 and its dimensions shall not exceed 10.0 kg and mm (W L H) respectively. The mass of the motor unit and its dimensions shall not exceed 15.0 kg and 200x300x350mm (WxLxH) respectively. Transport boxes shall be provided by the Contractor for each delivered CRPS system. Software requirements REQ 19. REQ 20. The motor unit in remote mode shall be controlled via, and the data shall be recorded with the APP installed on the data acquisition laptop. The motor unit application software shall communicate to the electronics unit via a standard communication port (e.g. USB).

15 SG-PLN Page: 15 of 21 A.1.5 Environmental requirements REQ 21. In its transport box(es) the CRPS shall be rugged to the ambient temperature according to IEC in the range from -25 to +70 o C. REQ 22. The CRPS in operation shall be tolerant of ambient temperatures from 0 to +40 o C. REQ 23. The instruments shall be resistant and tolerant to rapid temperature changes within that range. REQ 24. The motor unit and electronics unit shall be designed to meet IP 54 requirements. A.1.6 Mechanical requirements REQ 25. In its transportation box(es) the CRPS shall be rugged to the mechanical vibration as described below in Table 1: Table 1: Mechanical ruggedness requirements Recommended Test # Test Type Applicable Standard Conditions Low Frequency, Frequency Hz 1 transport, secured IEC Table Motion Random cargo 2 Low Frequency, transport, loose cargo IEC Low Frequency IEC Frequency Hz Table Motion Random Frequency Hz Table Motion Sinusoidal Acceleration constant 2g Duration 30 min 10 min 10 min 4 Mechanical Shock IEC Acceleration 15 g 11 msec Mechanical Shock, drop 5 IEC Height 0.25 m n/a test REQ 26. During operation the CRPS shall be tolerant to acceleration of 2 g in the frequency range from 10 Hz up to 33 Hz.

16 SG-PLN Page: 16 of 21 A.1.7 REQ 27. Electromagnetic compatibility and immunity The CRPS shall meet or exceed EMC requirements for Residential, Commercial and Light-Industrial Environments according to the International Generic Standard IEC (Table 2). # Test Type Table 2: EMC requirements Applicable Generic Standard Frequency Range 1 Radiated Emission IEC MHz 1 GHz 2 Conducted Emission IEC khz 30 MHz 3 4 Harmonic Current Emission Voltage changes, voltage fluctuations and flicker IEC Harmonics of Mains Frequency Basic Standards CISPR 16-2 CISPR 16-1 CISPR 16-2, CISPR 16-1 IEC IEC n/a IEC REQ 28. The CRPS shall meet or exceed the Electromagnetic Susceptibility requirements for Industrial Environment according to International Generic Standard IEC (Table 3-Table 6).

17 SG-PLN Page: 17 of 21 Table 3: Electromagnetic Susceptibility requirements - Immunity to enclosure ports # Test Type Frequency Range Immunity to Power Frequency Magnetic Fields Immunity to Electromagnetic Radio Frequency Fields, amplitude modulation sinus Immunity to Electromagnetic Radio Frequency Fields, amplitude modulated pulse Electrostatic Air Discharge Electrostatic Contacted Discharge - direct Electrostatic Contacted Discharge - indirect Mains Frequency (50 or 60 Hz) 80 MHz 1 GHz 1.0 GHz 2 GHz 2.0 GHz 2.7 GHz 80 MHz 1 GHz 1.0 GHz 2 GHz 2.0 GHz 2.7 GHz Recommended Test Levels Basic Standards 30 A/m IEC V/m 6 V/m 3 V/m Amplitude Modulated, 80 %,1kHz 10 V/m 6 V/m 3 V/m Square Pulse Modulated, 100 %, 1kHz IEC IEC n/a ± 8 kv IEC n/a ± 4 kv IEC n/a ± 4 kv IEC Table 4: Electromagnetic Susceptibility requirements - Immunity to signal ports Recommended Test # Test Type Frequency Range Basic Standards Levels 10 V Immunity to Radio khz 80 MHz Amplitude Modulated, IEC Frequency Voltage 80 %,1kHz 2 Immunity to Fast Transients (Bursts) 3 Surges, line to earth n/a 5 khz repetition frequency ±1 kv, Pulse shape 5/50 ns ± 1 kv, Pulse shape - 1.2/50 µs IEC IEC Table 5: Electromagnetic Susceptibility requirements - Immunity to DC power ports Recommended Test # Test Type Frequency Range Basic Standards Levels 10 V Immunity to Radio khz 80 MHz Amplitude Modulated, IEC Frequency Voltage 80 %,1kHz 2 Immunity to Fast Transients (Bursts) 3 Surges, line to earth n/a 4 Surges, line to line n/a 5 khz repetition frequency ±2 kv, Pulse shape 5/50 ns ± 1 kv, Pulse shape - 1.2/50 µs ± 0.5 kv, Pulse shape - 1.2/50 µs IEC IEC IEC

18 SG-PLN Page: 18 of 21 Table 6: Electromagnetic Susceptibility requirements - Immunity to AC power ports # Test Type Frequency Range Recommended Test Levels Basic Standards 1 10 V Immunity to Radio 150 khz 80 MHz Amplitude Modulated, Frequency Voltage 80 %,1kHz IEC Immunity to Fast 5 khz repetition ±2 kv, Pulse shape Transients (Bursts) frequency 5/50 ns IEC Surges line to earth n/a ± 2 kv, Pulse shape - 1.2/50 µs IEC Surges line to line n/a ± 1 kv, Pulse shape - 1.2/50 µs IEC Voltage Dips Ref. to IEC IEC Voltage Interruptions Ref. to IEC IEC A.1.8 Power supply requirements The CRPS shall meet the following power supply requirements: REQ 29. The CRPS units shall be designed to operate from single-phase AC supply voltage of nominal VAC, Hz. REQ 30. The maximum power consumption of the CRPS shall not exceed 500 W; the CRPS power supply unit shall be autosensing the nominal main power supply. REQ 31. The power connection point shall be clearly marked. A.1.9 REQ 32. Conformity with EU directives - CE Marking The Contractor declares the conformity of the design with the applicable technical standards of relevant EU directives and affixes the CE mark on the product. A.1.10 Reliability REQ 33. REQ 34. The CRPS shall have an operating lifetime of at least 10 years. The Contractor shall assure availability of spare parts and necessary service for the entire life of all equipment. The mean time between failures of the CRPS shall not be less than two years. A.1.11 Operating Documentation REQ 35. REQ 36. All documentation shall be provided in the English language. The CRPS prototype shall be delivered with technical documentation containing, at a minimum, the following information: a. Detailed contact information for the Contractor, e.g., name, address, telephone, fax, address and a hot-line technical support service;

19 SG-PLN Page: 19 of 21 REQ 37. b. Complete description of the CRPS with general technical data, including intended use, optimum configuration, range of operating constraints, markings, power supply, mechanical, environmental and electrical characteristics, electromagnetic compatibility, reliability, factory test and QA sheet, guarantees and any other relevant information; c. Complete schematic of the CRPS; d. Serial numbers, warranty information, and licenses (where pertinent) for all major components, parts, associated equipment, and software. The CRPS shall be delivered with operating and configuration manuals, a troubleshooting guide and a list of recommended spare parts. A.2 Operating Manual of the existing CRPS (for information only) This can be found in Document Manager under SG-EQ-CRPS-RM-0001 Cask Radiation Profiling System (CRPS Reference Manual). For the purposes of procurement, that document shall be provided along with this SoW.

20 SG-PLN Page: 20 of 21 A.3 Design description of the existing CRPS (for information only)

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