08 AL-1730-9428A Specification.pdf

Advanced Light Source Upgrade Project Lawrence Berkeley National Laboratory

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Printed hard copies of this document are for reference only.

SR - RF Bellows - ESD

Thomas GAUCHER

Release Date: May 16 2024 4:17:09 PM PDT

Document Number: AL-1730-9428 Revision: A

Document Status: Released

Document Type: SPECIFICATION

Category Code: AL7531

ALS-U - STORAGE RING

VACUUM CHAMBERS

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TABLE OF CONTENTS

1 Revision History

2 Approvals

3 Abbreviations and Acronyms

4 Introduction

4.1 Introduction to ALS-U

4.2 Subject of this Engineering Specification

5 Specification Definition

6 Description of the RF Bellows

6.1 Presentation of the RF Bellows

6.2 Dimensional properties of the RF Bellows

7 Environmental Requirements

7.1 Cleanliness environment

7.2 Cleaning fluids

7.3 Cutting fluids

7.4 Fasteners

8 Technical requirement

8.1 General Mechanical Dimensions

8.2 Vacuum properties

8.3 Manufacturing process

8.3.1 Material

8.3.2 Fabrication

8.3.2.1 Part fabrication

8.3.2.2 Cleaning after manufacturing

8.3.2.3 Part joining

8.4 Final Cleaning

8.5 Final Assembly

8.6 Final Component Inspection

8.6.1 Bellows Weldment

8.6.2 Spring Finger

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8.6.3 Contact Finger

8.7 Final Assembly Inspection and Test

8.7.1 Visual inspection

8.7.2 Measurement points

8.7.3 Bellows movement inspection

8.7.4 Final He Leak Test

8.8 Packing and shipping

9 Applicable Documents 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 Baseline

2 APPROVALS

The following individual(s) must 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

KPChow,oomolayo,jianiniu

3 ABBREVIATIONS AND ACRONYMS

ALS Advanced Light Source ALS-U Advanced Light Source Upgrade ASTM American Society for Testing and Materials CAD Computer Aid Design EN-ISO European International Organization for Standardization He Helium LBNL Lawrence Berkeley National Laboratory SR Storage Ring UHV Ultra High Vacuum WPS Welding Procedure Specification ci al ly R el ea se d to th e

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4 INTRODUCTION

4.1 Introduction to ALS-U

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

4.2 Subject of this Engineering Specification

The purpose of this Engineering Specification is to outline all technical requirements for the fabrication and testing of the storage ring RF bellows. The detailed design of the RF bellows has been carried out by the project following prototyping and testing development. The designs are now considered final. There are five types of RF bellows designs covered in this document.

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5 SPECIFICATION DEFINITION

Must, will, may, and should are used to define every specification listed in this document.

The definitions of these terms are as follows

May – is used to indicate a desire or goal of a specification. This can also be interpreted

‘as nice to have’ and are not contractually binding.

Must –is a specification that is contractually binding and must be implemented.

Should – is used to indicate a desire or goal of a specification. This can also be interpreted ‘as nice to have’ and are not contractually binding.

Will – is used to inform intent or declaration of purpose. This is not a specification.

Example, the author will use the word ‘must’ to indicate that a specification is contractually binding and must be implemented.

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6 DESCRIPTION OF THE RF BELLOWS

6.1 Presentation of the RF Bellows

The RF Bellows is an essential component of the ALS-U Storage Ring vacuum system. The primary functions of the RF bellows include:

1. Providing a flexible interface between chains of vacuum chambers and components to mitigate fabrication, assembly and installation misalignments.

2. Installation aid for creating air gaps during the modular installation of the SR raft units

3. Thermal expansion joints for in-situ bakeout and beam induced heating of vacuum chambers.

This fabrication is a “build to print”. The Figure 6-1 shows an image of the five RF bellows design

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

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

Figure 6-1: SR RF Bellows

The RF bellows consist of sub components assembled between each other as illustrated in Figure 6-2 (example of SR RF Bellows 18mm Keyhole - QF100-F).

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Figure 6-2: SR RF Bellows: 18mm Keyhole - QF100-F

All RF bellows include a Beryllium Copper contact finger, bellow weldment, Inconel spring finger, stainless steel sleeve, and an internal retainer. The assembly of these components must be carried out to ensure the correct contact of the components.

6.2 Dimensional properties of the RF Bellows

The following tables give the dimensional requirement of the RF bellows

Table 6-1: Bellows design displacement

Designation Windchill number

Bellow length (mm)

Axial displacement

(mm)

Radial displacement

(mm) 18mm Round -

QF50-F

AL-1657-

31 -2.2 0.6

18mm Keyhole -

QF100-F

AL-1519-

24.95 -4.6 0.1

13mm Round -

QF50-F

AL-1657-

21 -3.48 0.467

13mm Round -

QF40-F

AL-1511-2875 13 -2.4 0.1

13mm Keyhole -

QF63-F

AL-1670-

24.6 -6.26 0.9

Clamping plate

Contact finger

Adapter contact

Spring finger

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Table 6-2: Bellows hard stop limits

Designation Windchill number

Axial hard stop (mm)

Radial hard stop (mm)

18mm Round / QF50-F AL-1657-8305 -5.5 / +2.5 1 18mm Keyhole / QF100-F AL-1519-4314 -6 / +1.5 1

13mm Round / QF50-F AL-1657-8249 -5 / +2.5 1 13mm Round / QF40-F AL-1511-2875 -4.5 / +2.5 1

13mm Keyhole / QF63-F AL-1670-2483 -8.0 / +1 1

7 ENVIRONMENTAL REQUIREMENTS

7.1 Cleanliness environment

ID NUM

(SYY-XX-) Specification

S09-05-000152 The cleaning environment shall comply with UHV Chamber and Component Production Requirements AL-1220-7841_Rev F, §7.2.

7.2 Cleaning fluids

ID NUM

(SYY-XX-) Specification

S09-05-000153 The cleaning fluids must comply with UHV Chamber and Component Production Requirements AL-1220-7841_Rev F, §7.3.

7.3 Cutting fluids

ID NUM

(SYY-XX-) Specification

S09-05-000154 The cutting fluids must comply with UHV Chamber and Component Production Requirements AL-1220-7841_Rev F, §7.4

7.4 Fasteners.

ID NUM

(SYY-XX-)

Specification

S09-05-000213 All internal fasteners must be vented and must comply with UHV Chamber and Component Production Requirements AL-1220- 7841_Rev F, §7.6.

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8 TECHNICAL REQUIREMENT

8.1 General Mechanical Dimensions

ID NUM

(SYY-XX-)

Specification

S09-05-000301 The mechanical dimension of the RF bellow must be in accordance with associated drawing

8.2 Vacuum properties

ID NUM

(SYY-XX-)

Specification

S09-05-000308 The maximum thermal outgassing rate must be better than 1.00e-11 Torr.l.s-1.cm-2

S09-05- 000309 Achievable final pressure must be 1e-10 Torr

S09-05-000367 The Bellows must sustain a bakeout temperature of 200C

8.3 Manufacturing process

8.3.1 Material

The procurement of the raw material by the Sub-contractor must comply with the following requirements

ID NUM

(SYY-XX-)

Specification

S09-05-000163 All materials must be new.

S09-05-000164 All material must be free from surface cracks and fissures, forge and other tool marks, burns, delamination and other defects that would make it incompatible with a high vacuum environment.

S09-05-000165 Certification must be in accordance with EN ISO 10204 3.1.

S09-05-000303 The flanges of the RF Bellow must be stainless steel 316L.

S09-05-000304 The RF Bellow convolutions and end pieces must be stainless steel 316L.

S09-05-000366 The RF finger must be BeCu.

S09-05-000307 The ring spring must be Inconel 718.

S09-05-000211 Magnetic permeability for base material must be 1.01 and for welds 1.04.

S09-05- 000322 The material must be compatible with synchrotron radiation ci al ly R el ea se d to th e

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8.3.2 Fabrication

8.3.2.1 PART FABRICATION

The fabrication of the RF Bellow must comply with the following requirements

Cutting fluids

ID NUM

(SYY-XX-)

Specification

S09-05-000170 Eater-soluble and non-halogenated cutting fluids must be used for fabrication.

S09-05-000171 All others requirements relative to the vacuum components fabrication must comply with UHV Chamber and Component Production Requirements AL-1220-7841_Rev F, §8.1, §8.2, §8.3.

8.3.2.2 CLEANING AFTER MANUFACTURING

An intermediate cleaning must be done after manufacturing and must comply with the following requirements

ID NUM

(SYY-XX-) Specification

S09-05-000172 UHV surfaces must be protected as per best practices during handling operations.

S09-05-000173 Parts must be stored in a clean area from the workshop (See §7.1).

S09-05-000174 Parts must be suspended in tanks by wire, hooks or in baskets.

S09-05-000175 All others requirements relative to the vacuum components cleaning must comply with UHV Chamber and Component Production Requirements AL-1220-7841_Rev F, §9.

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8.3.2.3 PART JOINING

The joining process of the components must comply with the following requirements

General requirement

ID NUM

(SYY-XX-)

Specification

S09-05-000177 All parts must be cleaned prior to welding.

S09-05-000178 A WPS is not required, S09-05-000180 All requirements relative to welding stainless steel must comply with UHV Chamber and Component Production Requirements AL-1220- 7841_Rev F §10.2.

S09-05-000182 All welds must be free from cracks and fissures or other defects that would make it incompatible with a high vacuum environment.

Inspection of welded joints

ID NUM

(SYY-XX-)

Specification

S09-05-000183 100% of the vacuum boundary welded joints must be visually inspected.

Component leak check

ID NUM

(SYY-XX-) Specification

S09-05-000185 100% of the vacuum boundary welded joints must be leak tested.

S09-05-000186 The leak test of the welded joint must comply with ASTM E498.

S09-05-000187 The criteria and parameter expected for the He leak check must comply with UHV Chamber and Component Production Requirements AL-1220-7841_Rev F, §14.1.

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8.4 Final Cleaning

The final cleaning of the Bellows components must comply with the following requirements:

General requirement

ID NUM

(SYY-XX-) Specification

S09-05-000188 Once the final cleaning process has started, it must not be stopped before the end.

S09-05-000189 After the final cleaning, all subsequent operations must be performed in a cleanroom.

Cleaning

ID NUM

(SYY-XX-) Specification

S09-05-000190 The cleaning agent used must be identified and approved by LBNL prior to the factory acceptance test.

S09-05-000191 All other requirements regarding the final cleaning and intermediate inspection must comply with UHV Chamber and Component Production Requirements AL-1220-7841_Rev F, §11 and §12.

8.5 Final Assembly

ID NUM

(SYY-XX-) Specification

S09-94- 000192 All requirement with final assembly must comply UHV Chamber and Component Production Requirements AL-1220-7841_Rev F, §13.

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8.6 Final Component Inspection

Each critical component of the Bellows must be inspected as follows

8.6.1 Bellows Weldment

ID NUM

(SYY-XX-)

Specification

S09-05-000308 100% of the Bellow weldment must be visually inspected.

S09-05-000309 A written inspection must be documented and approved by LBNL.

8.6.2 Spring Finger

ID NUM

(SYY-XX-)

Specification

S09-05-000310 100% of the spring fingers must be visually inspected.

S09-05-000311 The spring finger must not be deformed by hand to allow it to pass inspection.

S09-05-000312 All fingers must be intact and in the correct position and uniformly spaced.

S09-05-000314 Non-conforming spring finger must be rejected.

8.6.3 Contact Finger

ID NUM

(SYY-XX-)

Specification

S09-05-000315 100% of the contact fingers must be visually inspected.

S09-05-000316 The contact finger must not be deformed by hand to allow it to pass inspection.

S09-05-000317 All fingers must be intact and in the correct position and uniformly spaced.

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8.7 Final Assembly Inspection and Test

(SYY-XX-)

Specification

S09-05-000365

In the round aperture configuration Bellows, the RF finger must be mounted between the Contact sleeve and the Spring finger

S09-05-000364

In the keyhole aperture configuration Bellows, the round RF finger must be mounted between the Contact sleeve and the Spring finger.

The rectangular RF finger must be mounted on the inside of the adapter contact sleeve

Spring finger

RF finger

Contact sleeve

Spring finger

Adapter contact sleeve

Round RF finger

Rectangle

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Each complete Bellows assembly must be inspected and tested as prescribed in Figure 8-1.

Figure 8-1: Final test sequence ci al ly R el ea se d to th e

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General requirement

(SYY-XX-)

Specification

S09-94- 000193 All test must take place in a clean area.

S09-05-000197 LBNL must have right to visit the contractor during these inspection and tests.

8.7.1 Visual inspection

ID NUM

(SYY-XX-)

Specification

S09-05-000319 100 % of Bellows assembly must be visually inspected to be free of scratches and dings.

8.7.2 Measurement points

ID NUM

(SYY-XX-)

Specification

S09-05-000323 A functional dimension verification must be performed on all Bellows assembly. These technical points will be provided in a timely manner.

8.7.3 Bellows movement inspection

ID NUM

(SYY-XX-)

Specification

S09-05-000320 Verify that all copper fingers are pressed by Inconel spring fingers onto the outside of the sleeve cone.

S09-05-000321 Verify that there is axial and radial stroke movement.

S09-05-000322 Verify that the internal retainer prevents the internal fingers from disengaging.

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8.7.4 Final He Leak Test

(SYY-XX-) Specification

S09-05-000207 Final He leak test must comply with UHV Chamber and Component Production Requirements AL-1220-7841_Rev F, §14.5.

8.8 Packing and shipping

ID NUM

(SYY-XX-)

Specification

S09-05-000324 The Bellows must be properly bagged, secured and packaged to maintain cleanliness, and prevent damage and contamination during transit by commercial carriers.

9 APPLICABLE DOCUMENTS

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

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