07 AL-1730-9427A SOW.pdf

SR - RF Bellows - SOW

Thomas GAUCHER

Release Date: May 20 2024 1:17:40 PM PDT

Document Number: AL-1730-9427 Revision: A

Document Status: Released

Document Type: SPECIFICATION

Category Code: AL7530

ALS-U - STORAGE RING

VACUUM - GENERAL

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Advanced Light Source Upgrade Project Lawrence Berkeley National Laboratory

All officially released LBNL documents are watermarked and contain LBNL Document

Control Center release information in the lower-left corner of the document's pages.

Printed hard copies of this document are for reference only.

Table of Contents

1 Revision History

2 Approvals

3 Abbreviations and Acronyms

4 Introduction

4.1 Project Overview

4.2 Scope of Work Summary

4.3 Description of Items

4.4 Roles and Responsibilities

5 Deliverables / Scope of Work

5.1 Documentation Deliverables

5.2 Hardware Deliverables

5.2.1 First Article

5.2.2 Production Articles

5.3 Scope of Work Execution Requirements

5.3.1 Management and Quality Assurance

5.3.2 Final Design Review Requirements

5.3.3 First article

5.3.4 First article delivery

5.3.5 Complete Production

5.3.6 Delivery

5.4 Final documentation package

6 Management, Reporting, Documentation and reviews

6.1 Schedule

6.2 Reporting requirements

6.3 Technical documentation requirements

6.4 Reviews

6.5 Hold points

7 Fabrication

8 Packaging and shipping specifications

8.1 Container

8.2 Marking

8.3 Packaging

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8.4 Handling and storage

9 Quality Assurance

9.1 Subcontractor Quality program

9.2 Type of control points

9.3 Deviation requests

9.4 Nonconformance reports

9.5 Numbering and/or Serialization

9.6 ACL upon receipt at LBL

10 Applicable Documents

Appendix A: CAD Model and drawing requirements ci al ly R el ea se d to th e

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1 REVISION HISTORY

Rev. CM Number Description of Change A Initial Release

2 APPROVALS

The following individual(s) shall approve this document:

Approver Project Role Ken Chow Chief Engineer/ Accelerator Mechanical Systems lead Jiani Niu Project QA manager Olusola Omolayo Vacuum CAM and Technical Lead Windchill Approved / Concurred By jianiniu,oomolayo,KPChow

3 ABBREVIATIONS AND ACRONYMS

ACL Acceptance Criteria List ALS Advanced Light Source ALS-U Advanced Light Source Upgrade ARO After Receipt of Order CAD Computer Aid Design FDR Final Design Review HP Hold Point LBNL Lawrence Berkeley National Laboratory NTP Notice to Proceed QA Quality Assurance RF Radio Frequency RFP Request For Proposal SR Storage Ring University The Regents of the University of California ci al ly R el ea se d to th e

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4 INTRODUCTION

4.1 Project Overview

ALS-U is an upgrade project to the LBNL Advanced Light Source (ALS). The ALS is a 1.9

GeV storage ring operating at 500 mA of beam current. It is optimized to produce intense beams of soft x-rays, which offer spectroscopic contrast, nanometer-scale resolution, and broad temporal sensitivity. The ALS facility includes an accelerator complex and photon delivery system that is capable of providing the foundations for an upgrade that will achieve world-leading soft x-ray coherent flux. The existing ALS provides a ready-made foundation, including conventional facilities and also includes extensive beamlines (up to

40 simultaneously operating beamlines) and instrumentation, an experimental hall, computing resources, ancillary laboratories, offices, and related infrastructure that will be heavily utilized in an upgrade scenario.

The ALS will be upgraded with a multibend achromat (MBA) lattice design that will provide a soft x-ray source that is orders of magnitudes brighter — an up to 100-1000 times increase in brightness and will provide a significantly higher fraction of coherent light in the soft x-ray region than is currently available at ALS.

Any resulting Subcontract will be between the University and the party identified as the

Subcontractor and will be issued under Prime Contract No. DE-AC02-05CH11231 between the University and the United States Government (hereinafter “U.S.

Government”), represented by the Department of Energy (hereinafter “DOE”) for the management and operation of LBNL and the performance of research and related work.

4.2 Scope of Work Summary

This scope of work is for the fabrication, dimensional inspection, assembly, vacuum testing and delivery of RF bellows assemblies for the ALS-U project. There are five types of RF bellows assembly types in this scope. The total quantity of RF bellows units to be delivered is 63.

4.3 Description of Items

The detailed design of the RF bellows has been completed by LBNL. Some of the RF bellows designs has been prototyped and tested by LBL. This fabrication is a “build to print” however the subcontractor is able to propose minor changes for ease of fabrication.

The Figure 4-1 shows an image of the five RF bellows designs.

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18mm Round - QF50-F 18mm Keyhole - QF100-F 13mm Round - QF50-F

13mm Round - QF40-F 13mm Keyhole - QF63-F

Figure 4-1: RF Bellows Designs

The RF bellow assembly consist of sub components assembled together as illustrated in

Figure 4-2.

Figure 4-2: SR RF Bellows: 18mm Keyhole - QF100-F

Clamping plate

Contact finger

Adapter contact

Spring finger

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4.4 Roles and Responsibilities

The subcontract will name two University specialists to oversee the contractual aspects and another to oversee the technical aspects of the procurement:

The University Procurement Specialist is responsible for contract administration from solicitation to subcontract award, and any contractual issues that arise thereafter.

The University Technical Representative is responsible for the technical aspects, beginning with the subcontract award through receipt and acceptance of deliverables.

The Subcontractor must identify a project manager who will act as the single point of contact for the University representatives. The project manager must be available for the duration of the subcontract to resolve issues and provide technical, programmatic, and schedule updates as specified in this SOW and in the subcontract.

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5 DELIVERABLES / SCOPE OF WORK

This section details the required deliverables for each phase of the Bellows build process.

5.1 Documentation Deliverables

The Table 5-1 provides the list of documentations to be submitted by the selected subcontractor to LBNL.

Table 5-1: list of documentation to be provided to LBNL.

Id Documentation Due Date*

Project Documentation 1 Initial schedule 7 days ARO

Bimonthly status / progress meeting until the delivery of the first batch and then monthly status / progress meeting

For the duration of the contract

3 Monthly Updated Schedule 5th of each month 4 Monthly Progress report 5th of each month

Quality Documentation 5 Acceptance Criteria List duly completed and signed 10 days prior shipment

Manufacturing Documentation 6 Final 2D drawing – if applicable 10 days before FDR 7 Final 3D CAD model – if applicable 10 days before FDR 8 Final Bill of material 10 days before FDR 9 Manufacturing plan for each type RF Bellow 10 days before FDR 10 Assembly / Disassembly plan for each type RF Bellow 10 days before FDR 11 Test report (dimension, He leak, …) 10 days prior shipment

12 Nonconformance Report or / and deviation request Within 3 business days of occurrence

13 Material Certification 10 days before manufacturing

Delivery documentation 14 List of packing crate(s) and contents 10 days prior shipment

Other 15 Certificate(s) of conformity 10 days prior shipment 16 Final document package 10 days prior shipment

Fabrication cannot start prior to the review, approval, and closure of all related FDR action items.

*Days noted herein are based on a 5 business day work week ci al ly R el ea se d to th e

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5.2 Hardware Deliverables

5.2.1 First Article

The selected subcontractor is required to produce the following quantities and designs of

RF Bellows as a first Article.

Table 5-2: List of hardware to be provided to LBNL Id Designation Windchill number Qty Due Date 17 18mm Round - QF50-F AL-1657-8305 5 14 weeks ARO 18 18mm Keyhole - QF100-F AL-1519-4314 5 14 weeks ARO

5.2.2 Production Articles

The selected subcontractor is required to produce the following quantities and designs of production units.

Id Designation Windchill number Qty Due Date 19 18mm Round - QF50-F AL-1657-8305 12 36 weeks ARO 20 18mm Keyhole - QF100-F AL-1519-4314 8 36 weeks ARO 21 13mm Round - QF50-F AL-1657-8249 12 36 weeks ARO 22 13mm Round - QF40-F AL-1511-2875 14 36 weeks ARO 23 13mm Keyhole - QF63-F AL-1670-2483 7 36 weeks ARO

In addition to the fully assembled first article and production units, the selected subcontractor is required to produce the following quantities of spare subcomponents.

Id Designation Windchill number

Qty Due Date

24 Contact finger 18 mm Round Aperture AL-1518-7308 5 36 weeks ARO 25 Spring Finger 18mm Round Aperture AL-1642-6630 5 36 weeks ARO 26 Contact Finger 18mm KH Aperture AL-1662-0696 5 36 weeks ARO 27 Contact Finger Side 18mm KH Aperture AL-1683-6995 5 36 weeks ARO 28 Spring Fingers 18mm KH Aperture AL-1662-2259 5 36 weeks ARO 29 Contact finger 13 mm Round QF50 AL-1698-1349 5 36 weeks ARO 30 Spring Finger 13mm Round Aperture AL-1576-2243 10 36 weeks ARO 31 Contact finger 13 mm Round DN40 AL-1445-6672 5 36 weeks ARO 32 Contact Finger 13mm KH Aperture AL-1673-5807 5 36 weeks ARO 33 Contact Finger Side 13mm KH Aperture AL-1700-0995 5 36 weeks ARO 34 Spring Fingers 13mm KH Aperture AL-1673-5806 5 36 weeks ARO ci al ly R el ea se d to th e

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5.3 Scope of Work Execution Requirements

5.3.1 Management and Quality Assurance

The selected subcontractor will be responsible for supplying an initial schedule 7 days

ARO.

5.3.2 Final Design Review Requirements

A final design review is required once the subcontractor has completed the detail manufacturing design for all RF bellows and relevant tooling. The selected subcontractor must be responsible for supplying all documentation related to the FDR prior to fabrication of the RF bellows. Documentations shall take into account the RF bellows engineering specification (AL-1730-9428) and drawings (see applicable document in section 10). CAD model and drawing requirements are detailed in Appendix A:

The FDR is required to include of the following documentation:

1. Final 2D drawing (if modified by subcontractor)

2. Final 3D CAD model (if modified by subcontractor)

3. Bill of material

4. Manufacturing plan (see table below for detail)

5. Assembly / Disassembly procedure

Table 5-3: Documentation description

Documents Description

Manufacturing plan

The manufacturing plan documents step-by-step all the manufacturing process from the procurement of raw material to the delivery. The manufacturing plan has to contain at least the following details:

Standards required for the procurement of raw material

Description of each step of the fabrication

Internal procedures applicable to this effort

Procedures and/or standards used for fabrication must be referenced in the manufacturing plan.

Close out of the FDR includes review, written approval, and resolution of all related FDR action items prior to fabrication. This is also required to satisfy the Notice to Proceed, reference §9.2 ci al ly R el ea se d to th e

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5.3.3 First article

Following approval of the FDR, the first articles must be produced. The first article must be subjected to the same testing and quality assurance processes as the production units.

After assessments of the first article, LBNL will give the selected subcontractor approval for the rest of the production. Reference §5.2.1 First Article, and §9.2 Notice to Proceed for additional information.

5.3.4 First article delivery

The selected subcontractor will be responsible for delivering the first article production to LBNL in accordance with the parameters outlined in this document. Refer to section §5.3.6 for the delivery conditions.

5.3.5 Complete Production

In accordance with section 5.3.3 LBNL will give final approval for the commencement of fabrication of the production units once the first article unit has been received and satisfactorily tested.

Prior to shipment of the production units, the subcontractor must provide the following:

1. Fully completed and signed ACL for each RF bellow.

2. A complete mechanical inspection report for each RF bellow.

3. A complete vacuum inspection report for each RF bellow.

4. Quality assurance receipts and certifications

5. Nonconformance or deviation documentation pertaining to each individual assembly

6. Written authorization from LBNL to proceed with shipping

LBNL personnel reserve the right to perform an evaluation of hardware, documentation, and shipping scheme at the subcontractor’s production site prior to authorizing shipment.

5.3.6 Delivery

The selected subcontractor will be responsible for delivering the complete production to LBNL in accordance with the parameters outlined in this document. All RF bellows, contacts fingers and spring fingers shall be packed and sealed individually in compatible UHV plastic bags under clean conditions.

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5.4 Final documentation package

LBNL shall be provided with a full and complete documentation package for the whole production. The documentation package shall contain the items listed below.

1. A complete, as-built bill of materials identifying both fabricated and commercially available components,

2. A complete, as built CAD model in an editable format (if available),

3. Complete, as built drawings in English, in an editable format (if available),

4. Other documentation as requested.

6 MANAGEMENT, REPORTING, DOCUMENTATION AND REVIEWS

6.1 Schedule

The following table provides the main schedule point and hold point.

Table 6-1 : Summary timetable of the project

Section # Designation Schedule Responsibility

§5.3.1 Initial Schedule 7 days ARO subcontractor

§5.3.2 Final Design Review 3 weeks ARO subcontractor

HP#1 Completion of FDR 1 week after submission of the final drawings

LBNL

§0 Completion of Manufacturing of the first batch 8 weeks after approval of final drawing subcontractor

§5.3.4 Delivery 2 weeks after completion of the first batch subcontractor

HP#2 Approval of the first batch 2 weeks after receiving of the first batch

LBNL

§5.3.5 Completion of the rest of the production and spare 16 weeks after approval of first batch subcontractor

HP#3 Approval of the production 2 weeks after completion of production

LBNL

§5.3.6 Delivery 2 weeks after approval of complete production subcontractor ci al ly R el ea se d to th e

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6.2 Reporting requirements

Upon award of the subcontract, the LBNL technical representative will contact the selected subcontractor to set up a Project Kick-off meeting. This meeting will establish the requirements for communication and introduce the portal that will be used for data exchange.

Written progress updates are required on before the fifth of each month. This may include information on drawings, manufacturing plans, test plans, QA plans, schedule updated or other documents upon request in any state.

Visits by LBNL personnel, including access to the factory where the units are being built, as the discretion of LBNL, may be required.

Subcontractor must be responsible for maintaining an action item list for documenting the actions resulting from each meeting, identifying the responsible party and providing an anticipated completion date for each action.

Other reports or data as requested in writing.

6.3 Technical documentation requirements

Upon subcontract award, a Windchill Project portal will be established by LBNL and access provided to the subcontractor. Windchill will be used as the repository for all information, QA data, and drawing transference related to the magnet development and production. A brief overview of Windchill will be provided at the kickoff meeting.

Additional training may be available upon request.

An electronic copy of all required documentation noted in the Deliverables section of this document is required. Appendix A: specifies acceptable file formats for the final drawings and CAD models.

Other document formats include .docx, .xlsx, and other editable file formats may be used with advance written approval from the LBNL technical representative.

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6.4 Reviews

A final design review is required for this project. The LBNL technical representative will work with the subcontractor to establish an appropriate timeline and location for all reviews. Reviews may be conducted at either the subcontractor’s or the LBNL site or via web/video conference tools. External, non-LBNL reviewers may be included at LBNL’s discretion.

Review drawings, documentation, and presentations are required to be delivered to the

LBNL technical representative a minimum of 10 business days prior to the scheduled review.

6.5 Hold points

The Table 6-2 provides the list of control points.

Table 6-2: List of hold points

Section Activity Control point Type

5.3.2 Closeout of FDR NTP

5.3.3 Approval of first article NTP

5.3.5 Approval of complete production NTP

Control point types are defined in section 9.2

7 FABRICATION

The selected subcontractor shall follow the RF bellows Engineering Specification referenced as AL-1730-9428 for the fabrication of all Bellows.

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8 PACKAGING AND SHIPPING SPECIFICATIONS

8.1 Container

Containers for the RF bellows may be used for both shipping and storage. Construction of the containers must be sufficient to adequately support and protect the RF bellows throughout shipping. Containers shall be shrink wrapped and palletized.

8.2 Marking

Mark the exterior of the containers with clear and obvious labels indicating the presence of fragile contents. Shipments originating outside of the United States must have pictorial labels or labels written in both the originating native language and English.

The exterior of the containers shall have up arrows indicating the appropriate boxes orientation.

Boxes shall be marked with the serial numbers of each Bellows contained therein.

All shipping containers must be labeled with all subcontract information including subcontract number, contact, and delivery information.

8.3 Packaging

All Bellows must be free of any liquid prior to shipping. The use of desiccant is strictly forbidden.

The RF bellows shall be blocked/cribbed/supported to prevent movement or overstressing the component during transport. The following has to be included:

Bellows shall each be boxed in its own shipping carton

Place foam between the Bellows and the sides of the carton to assist in minimizing movement during transportation.

Bellows shall be cleanroom double bagged.

The exterior of each shipping SR RF bellow carton shall be equipped with a self-adhesive shock indicator.

8.4 Handling and storage

The subcontractor must pay particular attention during phases of lifting operation to avoid damage on the chambers

Should the chambers require storage, the storage location must be a temperature and moisture controlled, secured storage facility. Ambient air temperature during storage is between 10 C and 40 C.

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9 QUALITY ASSURANCE

9.1 Subcontractor Quality program

The subcontractor shall complete the ALS-U Supplier Quality Evaluation Survey (AL- 1208-0209) during RFP. The subcontractor shall maintain and apply an effective QA program for the manufacture, and testing of all hardware provided. Post-award surveys may be required and shall be supported.

9.2 Type of control points

Notice to Proceed (NTP): the current process cannot continue (next tasks) without the relevant NTP being cleared. The NTP notification point for this contract must be the following:

Successful completion and acceptance of the FDR. LBNL will provide a written approval to the selected subcontractor indicating the NTP that has been satisfied.

Successful completion and acceptance of the First article. LBNL will provide a written approval to the selected subcontractor indicating the NTP that has been satisfied

Successful completion and acceptance of production articles test report prior to shipment. LBNL will provide a written approval to the selected subcontractor indicating the NTP that has been satisfied

9.3 Deviation requests

Any deviations from the LBNL documents must be requested by the subcontractor and approved by LBNL prior to implementation. LBNL will provide a standard deviation request form however; a subcontractor’s existing or internal document may be utilized with LBNL approval. Deviation requests apply to requests to modify processes or documented drawings. Deviation requests DO NOT apply to hardware that is built and does not conform to the specification.

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9.4 Nonconformance reports

A nonconformance report provides a summary for products or procedures, which do not conform to the defined requirements. Nonconformance may be determined and reported by either the subcontractor or LBNL staff. LBNL will provide a standard nonconformance report form however; a subcontractor’s existing or internal document may be utilized with LBNL approval. Nonconformance reports are to be submitted to LBNL within 2 business days of the nonconformance identification.

Nonconformance reports apply to hardware that is built and does not conform to the specification(s). LBNL will provide a written disposition establishing a path forward for each nonconformance. No operations may be performed on the nonconforming item without LBNL’s written disposition or approval to proceed.

9.5 Numbering and/or Serialization

Each Bellows shall be serialized. The following indicate the methodology of serialization for the Bellows (18mm Round / QF50-F). The same methodology shall be applied on all Bellows

Windchill Number Serialization

AL-1657-8305 AL-1657-8305-0001

AL-1657-8305-0002

AL-1657-8305-0003

AL-1657-8305-0017

The serialization shall be laser etched

Figure 9-1: Bellows (18mm Round / QF50-F)

Serialization ci al ly R el ea se d to th e

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9.6 ACL upon receipt at LBL

The subcontractor shall provide a completed ACL to the LBNL technical representative for each Bellows. The ACL shows that the following requirements are validated:

1. Visual inspection

2. Magnetic permeability inspection

3. Verification of functional dimension

4. RF bellows movement inspection

5. He Leak Test of the RF bellows

6. Test report

See doc AL-1730-9426, Acceptance Criteria List for Bellows.

10 APPLICABLE DOCUMENTS

See document references AL-1731-1719_SR - Bellows - Applicable Documents List ci al ly R el ea se d to th e

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APPENDIX A: CAD MODEL AND DRAWING REQUIREMENTS

The following requirements are applicable to 2-d drawings and 3D CAD models supplied in support of the MRR

1. All dimensions are to be in millimeters.

2. Dimensioning scheme to adhere to ASME Y14.5 (2009 or later), “Dimensioning and Tolerancing”.

3. Unless otherwise specified, all features to be modeled at the mean.

4. Threads, both internal and external to be modeled as cosmetic, for external threads the solid geometry to be at the maximum minor diameter, for internal threads the solid geometry to be at the maximum minor diameter. Threads represented as helical features is forbidden.

5. A material must be specified and the properties of the material must be applied to the object, such that the weight/mass of the object is a property of the file/object.

The material file must include these properties, density, modulus of elasticity, Poisson’s ratio, Coefficient of Thermal Expansion and Thermal Conductivity. The units of these properties to be consistent with the units of the model, and in SI

Units (International System of Quantities).

6. All solid models must be “water tight”, meaning there cannot be “holes” or “gaps” in the solid surface such that the feature does not close upon itself.

7. Drawings and Models must use English as the language used to describe the dimensions, notes, descriptions, text and features.

8. A minimum note based tolerance scheme to use is, X ± 1, X.X ± 0.5, X.XX ± 0.15, Angles ± 0.5°. Alternate: Individual tolerance of each dimension, not making use of a note based scheme. The vendor may use a scheme which has tolerances that are smaller than the minimum.

9. ALS-U will supply the batch of serial numbers to be applied/consumed for items requiring serial numbers. ALS-U Serial Numbers must be used, vendor generated serial numbers are not allowed.

10. If an item is to be serialized ALS-U must approve of the marking method to be used for attaching the ALS-U supplied serial number to the object, and the process must be included in the drawing describing the object, possibly included in the notes of the drawing.

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11. The 3-D CAD Model digital file must one that is consumable by PTC’s Creo

Parametric software. The preferred format is Creo Parametric (check with LBNL for current version). Consumable in this context means when imported into Creo

Parametric (check with LBNL for current version), the file is interpreted by Creo properly, there are no failures, and the integrated model can be regenerated successfully. If the vendor does not use Creo Parametric, then they must supply the software name and version, along with the file format they would supply to be used by LBNL.

12. The CAD Drawing digital file must one that is consumable by PTC’s Creo

Parametric software. The preferred format is Creo Parametric (check with LBNL for current version). Consumable in this context means when imported into Creo

Parametric (check with LBNL for current version), the file is interpreted by Creo properly, there are no failures, and the integrated model and drawing can be regenerated successfully.

13. The 3-D CAD Model and the Drawing files must be parametric. Parametric meaning that if any feature, dimension, attribute, data set is modified in one object, the other object automatically inherits the change upon regeneration.

14. Drawings should use driven dimensions inherited from the model. Creating dimensions which only exist in the drawing is not recommended and may be a cause for rejection of the drawing.

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