1. SOW AL-1772-1589A.pdf

STATEMENT OF WORK FOR ALS-U SR MAGNET

VERTICAL SUPPORTS

Ryan P. Johnson

Release Date: Nov 6 2025 3:34:29 PM PST

Document Number: AL-1772-1589 Revision: A

Document Status: Released

Document Type: REQUIREMENT

Category Code: AL7525

ALS-U - STORAGE RING

MAGNET SUPPORTS

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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

Revision History

Approvals

Abbreviations and Acronyms

1 Introduction

1.1 Project Overview

1.2 Description of Items

1.3 Roles and Responsibilities

2 Scope of Work

3 Deliverables

3.1 Pre-Kitting Documentation Deliverables Package

3.2 Deliverables

3.3 Hardware Deliverables Package

3.4 Paperwork

3.5 Kitting Height

3.6 Kitting Parts List

3.7 Kitting Vertical Studs

3.8 Kitting Spherical Washers

3.9 Kitting Nuts

3.10 Kitting Thrust Washers

3.11 Kitting Flat Washers

3.12 Kitting Magnets Used On

3.13 Kitting Individual Quantities of Subcomponents

3.14 Production

3.15 Spares

3.16 Verification summary

4 Management

4.1 Reporting/Communication requirements

4.2 Documentation requirements

4.3 Hold points and what’s required

5 Engineering

6 Shipping, Handling, and Storage

6.1 Packaging

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6.2 Shipping

7 Quality Assurance

7.1 Quality reporting requirements

7.1.1 Subcontractor Quality program

7.1.2 Deviation requests

7.1.3 Nonconformance reports

7.2 Factory Inspection and Test Plan

7.3 ACL upon receipt at LBL

7.4 Other QA documents as needed

8 Applicable Documents

Appendix A: Verification Table

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REVISION HISTORY

Rev. CM Number Description of Change A - Initial Release

APPROVALS

The following individual(s) shall approve this document:

Approver Project Role Charles Swenson ALS-U Magnet Design Technical Lead Catalina Espino Devine ALS-U Controls Account Manager Jiani Niu ALS-U QA Lead Windchill Approved / Concurred By espinodevine,jianiniu,CASwenson

ABBREVIATIONS AND ACRONYMS

ALS Advanced Light Source ALS-U Advanced Light Source Upgrade LBNL Lawrence Berkeley National Laboratory QTY Quantity SR Storage Ring University The Regents of the University of California ci al ly R el ea se d

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1 INTRODUCTION

1.1 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.

1.2 Description of Items

The purpose of this statement of work is to define the production work required to provide all kitted hardware for the ALS-U SR Magnet Vertical Support Kits. The magnets in the

Storage Ring are mounted to support rafts using either QTY 4, 5, or 6 vertical studs ranging from M16 to M24 diameter fine threaded studs. The fine threads are required to allow for the sensitive vertical positioning of the SR Magnets to meet the ALS-U beam sensitivity. Torque requirement on these studs require them to be a high strength grade of steel. There are three nuts on the vertical stud assembly: lower, middle, and upper. The lower nut controls the depth of the stud into the raft. This lower nut has a flat washer interface between it and the raft top surface. The middle and upper nut control the height of the magnet with respect to the raft top surface. Spherical washers interface between the nut and the magnet baseplate. A specialized oil impregnated flat bearing washer is used between the lower spherical washer and a hardened 440C steel plate affixed to the bottom of the magnet baseplate. This allows for a smooth translational interface when positioning the magnets.

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Several magnet vertical support kits are nearly identical, with the primary difference between the oil impregnated copper bearing washers.

1.3 Roles and Responsibilities

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

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

2. 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.

2 SCOPE OF WORK

The scope of work is for the procurement, kitting, packaging and delivery of the items listed in Table 3.1. This work is to be completed as specified in this SOW.

3 DELIVERABLES

This section details the required deliverables for the magnet vertical support kit design, build and test process.

All materials and tooling that are purchased or fabricated under this effort, but not appearing on the list of deliverables, shall be considered Government Property and shall be shipped to LBNL at the end of the contract warranty period unless otherwise directed.

3.1 Pre-Kitting Documentation Deliverables Package

Item No. Name Qty Description

0001 Manufacturing Plan 1

The manufacturing plan shall include how & where components will be manufacture or procured and the engineering & manufacturing schedule (EPMS). (The EPMS shall include schedule for procurement, fabrication, inspections and in-ci al ly R el ea se d

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3.2 Deliverables

Deliverables are:

1. QTY 2,022 vertical support positioning kits for the SR Magnets as detailed by

Section 3.3, pre-assembled, packaged, and delivered ready for installation to their respective SR Magnet.

2. All material data sheets detailing the sourcing of materials and hardware certifying compliance with requested material grades shall be furnished prior to delivery and acceptance of components by LBNL (i.e. Certificate of Conformance and Material Traceability for all nuts and studs).

3. A kitting plan and shipping plan will be shown to LBNL prior to kitting of studs detailing how components will be packaged in individual kits and bulk kits.

4. A shipping schedule will be delivered showing when kitting components will be delivered in accordance with the schedule. Minimum shipping quantities are 1/3 of the total individual kits.

The following sections detail the types of vertical support studs, and is provided as reference for convenience for the vendor to review commonality of parts between various vertical support stud kits and assembly heights. Drawings of vertical support studs take precedence when determining components, materials, and assembly heights.

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3.3 Hardware Deliverables Package

Table 3.1 Hardware Deliverables: Individual Vertical Support Kits

Item No. LBNL Assy # Name Qty Description

AL-1478-4858 MAGNET POST ASSY KIT, M20,

SF/SD

M20x1.5 MM Class 8.8 Steel with QTY 3 M20 nuts, QTY 2 M20 Spherical

Washers, QTY 1 Oil Impregnated Thrust Washer, and QTY 1 M20 Flat Washer

0002 AL-1547-7647

MAGNET POST ASSY KIT, M24,

QDA/QFA/QFRA

M24x1.5 MM Class 8.8 Steel with QTY 3 M24 nuts, QTY 2 M24 Spherical

Washers, QTY 1 Oil Impregnated Thrust Washer, and QTY 1 M24 Flat Washer

0003 AL-1477-3952

MAGNET POST ASSY KIT, M20,

QDB/QFRB

M20x1.5 MM Class 8.8 Steel with QTY 3 M20 nuts, QTY 2 M20 Spherical

Washers, QTY 1 Oil Impregnated Thrust Washer, and QTY 1 M20 Flat Washer

0004 AL-1478-3603 MAGNET POST ASSY KIT, M24 360

M24x1.5 MM Class 8.8 Steel with QTY 3 M24 nuts, QTY 2 M24 Spherical

Washers, QTY 1 Oil Impregnated Thrust Washer, and QTY 1 M24 Flat Washer

0005 AL-1510-4700

MAGNET POST ASSY KIT, M24,

BENDA

M24x1.5 MM Class 8.8 Steel with QTY 3 M24 nuts, QTY 2 M24 Spherical

Washers, QTY 1 Oil Impregnated Thrust Washer, and QTY 1 M24 Flat Washer

0006 AL-1480-0777

MAGNET POST ASSY KIT, M24,

BENDB/BENDC

M24x1.5 MM Class 8.8 Steel with QTY 3 M24 nuts, QTY 2 M24 Spherical

Washers, QTY 1 Oil Impregnated Thrust Washer, and QTY 1 M24 Flat Washer

0007 AL-1474-3266

MAGNET POST ASSY KIT, M24,

HBEND

M24x1.5 MM Class 8.8 Steel with QTY 3 M24 nuts, QTY 2 M24 Spherical

Washers, QTY 1 Oil Impregnated Thrust Washer, and QTY 1 M24 Flat Washer

0008 AL-1779-1451

MAGNET POST ASSY KIT, M16,

SHA/SHB

M16x1.5 MM Class 8.8 Steel with QTY 3 M16 nuts, QTY 2 M16 Spherical

Washers, QTY 1 Oil Impregnated Thrust Washer, and QTY 1 M16 Flat Washer

3.4 Paperwork

All material sourced for the vertical support studs and nuts shall have:

1. Certificate of Conformance specifying Class 8.8 or equivalent material specs are met.

2. Material Traceability for each lot.

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3.5 Kitting Height

Item No. LBNL # Name Base to Lower Nut Flat

Washer [mm] Lower to Middle Nut Height

[mm] Thrust Washer to Upper

Spherical Washer Height [mm]

0001 AL-1478-4858 MAGNET POST ASSY KIT, M20, SF/SF 35.4 17.6 44

0002 AL-1547-7647 MAGNET POST ASSY KIT, M24 25.1 7.3 48

0003 AL-1477-3952 MAGNET POST ASSY KIT, M20 30.4 13.6 48

0004 AL-1478-3603 MAGNET POST ASSY KIT, M24 19.1 7.3 60

0005 AL-1510-4700 INTERFACE HDW KIT-BENDA 32 11.3 43

0006 AL-1480-0777 BASEPLATE ADJUSTMENT HDW KIT 24.2 7.3 54.8

0007 AL-1474-3266 RAFT POSITIONER HARDWARE KIT 23.3 7.1 50.7

0008 AL-1779-1451 MAGNET POST ASSY KIT, M16 30.3 12.3 60

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3.6 Kitting Parts List

Item No. LBNL # Name Vertical Stud Nut Spherical Washer

Thrust Washer Flat Washer

0001 AL-1478-4858

MAGNET POST ASSY KIT, M20,

SF/SD

Al-1799-5303 Hw-1001-4883 HW-1000-2161 AL-1418-3483 HW-1000-0012

0002 AL-1547-7647

MAGNET POST ASSY KIT, M24,

QDA/QFA/QFRA

AL-1523-4034 HW-1000-3513 HW-1000-2144 AL-1460-8003 HW-1000-0013

0003 AL-1477-3952

MAGNET POST ASSY KIT, M20,

QDB/QFRB

AL-1487-4223 HW-1001-4883 HW-1000-2161 AL-1418-3713 HW-1000-0012

0004 AL-1478-3603 MAGNET POST ASSY KIT, M24 AL-1523-4034 HW-1000-3513 HW-1000-2144 AL-1460-8003 HW-1000-0013

0005 AL-1510-4700

MAGNET POST ASSY KIT, M24,

BENDA

AL-1523-4034 HW-1000-3513 HW-1000-2144 AL-1460-8003 HW-1000-0013

0006 AL-1480-0777

MAGNET POST ASSY KIT, M24,

BENDB/BENDC

AL-1523-4034 HW-1000-3513 HW-1000-2144 AL-1460-8003 HW-1000-0013

0007 AL-1474-3266

MAGNET POST ASSY KIT, M24,

HBEND

AL-1523-4034 HW-1000-3513 HW-1000-2144 AL-1454-6896 HW-1000-0013

0008 AL-1779-1451

MAGNET POST ASSY KIT, M16,

SHA/SHB AL-1572-8095 HW-1001-4884 HW-1000-6803 AL-1474-3642 HW-1000-0010

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3.7 Kitting Vertical Studs

Item No. LBNL # Name Vertical Stud Vertical Stud Description Material Full Length [mm] Threaded

Length [mm]

0001 AL-1799-530

MAGNET POST ASSY

KIT, M20, SF/SD

AL-1799-5303

ROD, THREADED, M20X1.5MMX1M LG, STL,

ISO 898 CLASS 8.8 STEEL, B.O

Steel 180 165

0002 AL-1547-7647

MAGNET POST ASSY

KIT, M24,

QDA/QFA/QFRA

AL-1523-4034

STUD THREADED M24 X 1.5MM X 180MM

LG STL ISO 898 CLASS 8.8, B.O

Steel 180 165

0003 AL-1477-3952

MAGNET POST ASSY

KIT, M20, QDB/QFRB

AL-1487-4223

ROD, THREADED, M20X1.5MMX1M LG,

CLASS 8.8 STEEL, DIN 976

Steel 180 165

0004 AL-1478-3603

MAGNET POST ASSY

KIT, M24

AL-1523-4034

STUD THREADED M24 X 1.5MM X 180MM

LG STL ISO 898 CLASS 8.8, B.O.

Steel 180 165

0005 AL-1510-4700

MAGNET POST ASSY

KIT, M24, BENDA

AL-1523-4034

STUD THREADED M24 X 1.5MM X 180MM

LG STL ISO 898 CLASS 8.8, B.O.

Steel 180 165

0006 AL-1480-0777

MAGNET POST ASSY

KIT, M24,

BENDB/BENDC

AL-1523-4034

STUD THREADED M24 X 1.5MM X 180MM

LG STL ISO 898 CLASS 8.8, B.O.

Steel 180 165

0007 AL-1474-3266

MAGNET POST ASSY

KIT, M24, HBEND

AL-1523-4034

STUD THREADED M24 X 1.5MM X 180MM

LG STL ISO 898 CLASS 8.8, B.O.

Steel 180 165

0008 AL-1779-1451

MAGNET POST ASSY KIT,

M16, SHA/SHB AL-1572-8095

STUD, THREADED, M16X1.5X158 MM LG,

GRADE 8.8 STL, ISO 898, B.O

Steel 168 158 ci al ly R el ea se d

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3.8 Kitting Spherical Washers

Item No. LBNL # Name Spherical Washer Spherical Washer Description Material

0001 AL-1478-4858

MAGNET POST ASSY

KIT, M20, SF/SD

HW-1000-2161 WASHER, SPHERICAL, M20, SS 18-8 Stainless Steel

0002 AL-1547-7647

MAGNET POST ASSY

KIT, M24,

QDA/QFA/QFRA

HW-1000-2144 WASHER, SPHERICAL, M24, 18-8 SST Stainless Steel

0003 AL-1477-3952

MAGNET POST ASSY

KIT, M20, QDB/QFRB

HW-1000-2161 WASHER, SPHERICAL, M20, SS 18-8 Stainless Steel

0004 AL-1478-3603

MAGNET POST ASSY

KIT, M24

HW-1000-2144 WASHER, SPHERICAL, M24, 18-8 SST Stainless Steel

0005 AL-1510-4700

MAGNET POST ASSY

KIT, M24, BENDA

HW-1000-2144 WASHER, SPHERICAL, M24, 18-8 SST Stainless Steel

0006 AL-1480-0777

MAGNET POST ASSY

KIT, M24,

BENDB/BENDC

HW-1000-2144 WASHER, SPHERICAL, M24, 18-8 SST Stainless Steel

0007 AL-1474-3266

MAGNET POST ASSY

KIT, M24, HBEND

HW-1000-2144 WASHER, SPHERICAL, M24, 18-8 SST Stainless Steel

0008 AL-1779-1451

MAGNET POST ASSY KIT,

M16, SHA/SHB HW-1000-6803 WASHER, SPHERICAL, M16, 18-8 SST Stainless Steel ci al ly R el ea se d

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3.9 Kitting Nuts

Item No. LBNL # Name Nut Nut Description

0001 AL-1478-4858

MAGNET POST ASSY

KIT, M20, SF/SD

HW-1001-4883

NUT, HEX, M20x1.5x10MM, LOW PROFILE, STEEL, GRADE 8, ZP, DIN 934/ISO4032

Steel

0002 AL-1547-7647

MAGNET POST ASSY

KIT, M24,

QDA/QFA/QFRA

HW-1000-3513

NUT, HEX, M24X1.5X10MM LOW PROFILE, STEEL,

GRAD 8, ZP, DIN 934/ISO4032

Steel

0003 AL-1477-3952

MAGNET POST ASSY

KIT, M20, QDB/QFRB

HW-1001-4883

NUT, HEX, M20x1.5x10MM, LOW PROFILE, STEEL, GRADE 8, ZP, DIN 934/ISO4032

Steel

0004 AL-1478-3603

MAGNET POST ASSY

KIT, M24

HW-1000-3513

NUT, HEX, M24X1.5X10MM LOW PROFILE, STEEL,

GRADE 8, ZP, DIN934/ISO 4032

Steel

0005 AL-1510-4700

MAGNET POST ASSY

KIT, M24, BENDA

HW-1000-3513

NUT, HEX, M24X1.5X10MM, LOW PROFILE, STEEL,

GRADE 8, ZP, DIN 934/ISO 4032

Steel

0006 AL-1480-0777

MAGNET POST ASSY

KIT, M24,

BENDB/BENDC

HW-1000-3513

NUT, HEX, M24X1.5X10MM, LOW PROFILE, STEEL,

GRADE 8, ZP, DIN 934/ISO 4032

Steel

0007 AL-1474-3266

MAGNET POST ASSY

KIT, M24, HBEND

HW-1000-3513

NUT, HEX, M24X1.5X10MM, LOW PROFILE, STEEL,

GRADE 8, ZP, DIN 934/ISO 4032

Steel

0008 AL-1779-1451

MAGNET POST ASSY KIT,

M16, SHA/SHB HW-1001-4884

NUT, HEX, M16X1.5X10MM, LOW PROFILE, STEEL,

GRADE 8, ZP, DIN 934/ISO 4032

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3.10 Kitting Thrust Washers

Item No. LBNL # Name Thrust Washer Thrust Washer Description Material

0001 AL-1478-4858

MAGNET POST ASSY

KIT, M20, SF/SD

AL-1418-3483

THRUST WASHER, OIL IMPREGNATED

Bronze

0002 AL-1547-7647

MAGNET POST ASSY

KIT, M24,

QDA/QFA/QFRA

AL-1460-8003 Thrust Washer, Oil Impregnated, 34MM ID Bronze

0003 AL-1477-3952

MAGNET POST ASSY

KIT, M20, QDB/QFRB

AL-1418-3713 Thrust Washer, Oil Impregnated, 34MM ID Bronze

0004 AL-1478-3603

MAGNET POST ASSY

KIT, M24

AL-1460-8003 Thrust Washer, Oil Impregnated, 34MM ID Bronze

0005 AL-1510-4700

MAGNET POST ASSY

KIT, M24, BENDA

AL-1460-8003 Thrust Washer, Oil Impregnated, 34MM ID Bronze

0006 AL-1480-0777

MAGNET POST ASSY

KIT, M24,

BENDB/BENDC

AL-1460-8003 Thrust Washer, Oil Impregnated, 34MM ID Bronze

0007 AL-1474-3266

MAGNET POST ASSY

KIT, M24, HBEND

AL-1454-6896 Thrust Washer, Oil Impregnated, 34MM ID Bronze

0008 AL-1779-1451

M16, SHA/SHB AL-1474-3642 Thrust Washer, Oil Impregnated, 21MM ID Bronze ci al ly R el ea se d

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3.11 Kitting Flat Washers

Item No. LBNL # Name Flat Washer Flat Washer Description

0001 AL-1478-4858

MAGNET POST ASSY

KIT, M20, SF/SD

HW-1000-0012 FW M20X3 MS DIN125 ZP Steel

0002 AL-1547-7647

MAGNET POST ASSY

KIT, M24,

QDA/QFA/QFRA

HW-1000-0013 FW M24X4 MS DIN125 ZP Steel

0003 AL-1477-3952

MAGNET POST ASSY

KIT, M20, QDB/QFRB

HW-1000-0012 FW M20X3 MS DIN125 ZP Steel

0004 AL-1478-3603

MAGNET POST ASSY

KIT, M24

HW-1000-0013 FW M24X4 MS DIN125 ZP Steel

0005 AL-1510-4700

MAGNET POST ASSY

KIT, M24, BENDA

HW-1000-0013 FW M24X4 MS DIN125 ZP Steel

0006 AL-1480-0777

MAGNET POST ASSY

KIT, M24,

BENDB/BENDC

HW-1000-0013 FW M24X4 MS DIN125 ZP Steel

0007 AL-1474-3266

MAGNET POST ASSY

KIT, M24, HBEND

HW-1000-0013 FW M24X4 MS DIN125 ZP Steel

0008 AL-1779-1451

M16, SHA/SHB HW-1000-0010 FW M16X3 MS DIN125 ZP Steel ci al ly R el ea se d

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3.12 Kitting Magnets Used On

Item No. LBNL # Name Magnet Family

Magnets Used On QTY Per Magnet QTY Bulk Kit

Required

0001 AL-1478-4858

MAGNET POST ASSY KIT,

M20, SF/SD

SF

SD

SF-A, SF-B, SF-D, SD-A, SD-B 5 48

0002 AL-1547-7647

MAGNET POST ASSY KIT,

M24, QDA/QFA/QFRA

MAGNET POST ASSY KIT,

M20, QDB/QFRB

QDA

QFA

QDA-A, QDA-B, QDA-C, QDA-D, QFA-A,

QFA-B, QFA-C, QFA-D,

6 48

QFRA QFRA-A, QFRA-B, QFRA-C, QFRA-D 5 24

0003 AL-1477-3952 MAGNET POST ASSY KIT, M24

QDB

QFRB

QDB-A, QDB-B, QDB-C, QFRB-A, QFRB-B,

QFRB-C, QFRB-D, QFRB-E

5 24

0004 AL-1478-3603

MAGNET POST ASSY KIT,

M24, BENDA

QFRC

QFRD

QFRC-A, QFRC-B, QFRC-C, QFRC-D,

QFRC-E, QFRD-A, QFRD-B, QFRD-C,

QFRD-D

5 36

0005 AL-1510-4700

MAGNET POST ASSY KIT,

M24, BENDB/BENDC

BENDA BENDA-A, BENDA-B 6 24

0006 AL-1480-0777

MAGNET POST ASSY KIT,

M24, HBEND

BENDB

BENDC

BENDB, BENDC 6 83

0007 AL-1474-3266

MAGNET POST ASSY KIT, M16,

SHA/SHB

HBEND HBEND 5 6

0008 AL-1779-1451

MAGNET POST ASSY KIT,

M20, SF/SD

SHA

SHB

SHA-A, SHA-B, SHB-A, SHB-B 4 48

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3.13 Kitting Individual Quantities of Subcomponents

LBNL # Name QTY Total

AL-1799-5303

ROD, THREADED, M20X1.5MMX1M LG, STL, ISO

898 CLASS 8.8 STEEL, B.O.

AL-1523-4034

STUD THREADED M24 X 1.5MM X 180MM LG STL

ISO 898 CLASS 8.8, B.O

AL-1572-8095

STUD, THREADED, M16X1.5X158 MM LG, GRADE

8.8 STL, ISO 898, B.O

HW-1000-2161 WASHER, SPHERICAL, M20, SS 18-8 840

HW-1000-2144 WASHER, SPHERICAL, M24, 18-8 SST 2898

HW-1000-6803 WASHER, SPHERICAL, M16, 18-8 SST 384

HW-1001-4883

NUT, HEX, M20x1.5x10MM, LOW PROFILE, STEEL, GRADE 8, ZP, DIN 934/ISO4032

HW-1000-3513

NUT, HEX, M24X1.5X10MM LOW PROFILE, STEEL,

GRAD 8, ZP, DIN 934/ISO4032

HW-1001-4884

NUT, HEX, M16X1.5X10MM, LOW PROFILE, STEEL,

GRADE 8, ZP, DIN 934/ISO 4032

AL-1418-3483 THRUST WASHER, OIL IMPREGNATED 240

AL-1460-8003 Thrust Washer, Oil Impregnated, 34MM ID 1410 AL-1418-3713 Thrust Washer, Oil Impregnated, 34MM ID 180 AL-1454-6896 Thrust Washer, Oil Impregnated, 34MM ID 36 AL-1474-3642 Thrust Washer, Oil Impregnated, 21MM ID 192

HW-1000-0012 FW M20X3 MS DIN125 ZP 420

HW-1000-0013 FW M24X4 MS DIN125 ZP 1446

HW-1000-0010 FW M16X3 MS DIN125 ZP 192

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3.14 Production

Drawings for each of the SR Magnet vertical support kits govern the type, quantity, and positioning of the vertical studs, spherical washers, thrust washers, flat washers, and nuts that make up the kitted assembly.

All SR Magnet Vertical Support Studs are comprised of vertical support studs, low profile washers, spherical washers, thrust washers, and flat washers. The size of the components range from M16 to M24. The studs within each diameter size can vary by length. The thrust washers within each metric size can vary by inner and outer diameter.

All studs are of grade Class 8.8 steel. All nuts are of Class 8.8 steel or equivalent strength.

All spherical washers are stainless steel. Any spherical washers sourced from alternative suppliers beyond McMaster-Carr, need to meet or exceed performance of the catalog part.

All thrust washers are oil impregnated bronze. An alternate can be made with steel

PTFE impregnated washer with the same dimensions as the oil impregnated bronze washer.

All nuts are low profile variants.

All nuts and studs are 1.5mm pitch.

Individual components have been broken out into sub-tables for the vendor to see commonality between different vertical support stud kits.

All vertical support stud kits for Items 0001 through 0008 shall first be packaged individually as a pre-assembled unit per their drawing.

Items 0001 through 0008 shall be packed in bulk (QTY of 4, 5, or 6) to completely furnish an individual magnet per Section 3.12.

Packaging at the individual and bulk level shall ensure no threads are damaged during shipping and handling of the kits.

Bulk kits shall be kept separate from other magnet types. If shipped in the same crate as other magnets, divisions shall be added to the container to ensure separation between bulk kits.

Total quantities of subcomponents are listed as reference in Section 3.13.

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3.15 Spares

After initial delivery of the components, vendor shall supply the following number of individual spare vertical support kits. These spares shall be delivered within 1 year of final delivery initial delivery of kits.

Item No. LBNL Assy # Name Qty Description

AL-1478-4858 MAGNET POST ASSY KIT, M20,

SF/SD

M20x1.5 MM Class 8.8 Steel with QTY 3 M20 nuts, QTY 2 M20 Spherical

Washers, QTY 1 Oil Impregnated Thrust Washer, and QTY 1 M20 Flat Washer

0002 AL-1547-7647

MAGNET POST ASSY KIT, M24,

QDA/QFA/QFRA

M24x1.5 MM Class 8.8 Steel with QTY 3 M24 nuts, QTY 2 M24 Spherical

Washers, QTY 1 Oil Impregnated Thrust Washer, and QTY 1 M24 Flat Washer

0003 AL-1477-3952

MAGNET POST ASSY KIT, M20,

QDB/QFRB

M20x1.5 MM Class 8.8 Steel with QTY 3 M20 nuts, QTY 2 M20 Spherical

Washers, QTY 1 Oil Impregnated Thrust Washer, and QTY 1 M20 Flat Washer

0004 AL-1478-3603 MAGNET POST ASSY KIT, M24 36

M24x1.5 MM Class 8.8 Steel with QTY 3 M24 nuts, QTY 2 M24 Spherical

Washers, QTY 1 Oil Impregnated Thrust Washer, and QTY 1 M24 Flat Washer

0005 AL-1510-4700

MAGNET POST ASSY KIT, M24,

BENDA

M24x1.5 MM Class 8.8 Steel with QTY 3 M24 nuts, QTY 2 M24 Spherical

Washers, QTY 1 Oil Impregnated Thrust Washer, and QTY 1 M24 Flat Washer

0006 AL-1480-0777

MAGNET POST ASSY KIT, M24,

BENDB/BENDC

M24x1.5 MM Class 8.8 Steel with QTY 3 M24 nuts, QTY 2 M24 Spherical

Washers, QTY 1 Oil Impregnated Thrust Washer, and QTY 1 M24 Flat Washer

0007 AL-1474-3266

MAGNET POST ASSY KIT, M24,

HBEND

M24x1.5 MM Class 8.8 Steel with QTY 3 M24 nuts, QTY 2 M24 Spherical

Washers, QTY 1 Oil Impregnated Thrust Washer, and QTY 1 M24 Flat Washer

0008 AL-1779-1451

MAGNET POST ASSY KIT, M16,

SHA/SHB

M16x1.5 MM Class 8.8 Steel with QTY 3 M16 nuts, QTY 2 M16 Spherical

Washers, QTY 1 Oil Impregnated Thrust Washer, and QTY 1 M16 Flat Washer

3.16 Verification summary

At the time of delivery, the vendor Shall follow the instructions in Appendix A; print and complete the table with the correct information. Attachments may be added if needed for further explanations.

4 MANAGEMENT

4.1 Reporting/Communication requirements

There are two required meetings that will occur remotely:

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2) A manufacturing plan presentation meeting

The two meetings can be combined in one at the vendor’s discretion.

The manufacturing plan meeting shall take place within the first 10 business days after the contract has been awarded to the vendor.

There will be weekly emails from the vendor to LBNL giving a summary of:

a) QTY of completed kitted vertical support studs broken down by type.

b) QTY of outstanding vertical support studs left to be kitted.

c) Estimated dates for shipment dates of completed vertical support kits

4.2 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 documentation, QA data, certificates of conformance, test results, models, and drawings.

An electronic copy of all required documentation as noted in this document is required and shall be transmitted to LBNL via the designated Windchill portal. Reviews

The LBNL technical representative will work with the sub-contractor 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.

1. Manufacturing plan review] which includes discussion of kitting (bags, P/N, tagging, documentation, etc etc)

4.3 Hold points and what’s required

Written approval from LBNL is required to proceed beyond any identified hold points.

1. Manufacturing plan review.

5 ENGINEERING

The SR Magnet Vertical Support Studs serve a critical role in positioning and stability of the storage ring magnetic field. To prevent out-of-alignment of the magnetic lattice, a high torque for each stud has been determined to prevent slippage during a 4G lateral shock.

The vertical support studs have also been qualified through extensive vibration analysis to ensure the SR Magnets meet vibrational stability of <35nm rms >10Hz. These two requirements necessitate the use of Class 8.8 grade steel. Any lower strength steel will yield under the applied torque or cause detrimental vibrational performance to the process. The quality of these studs are integral to the success of the project.

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6 SHIPPING, HANDLING, AND STORAGE

All vertical support stud kits for Items 0001 through 0008 shall first be packaged individually as a pre-assembled unit with all spherical washers, thrust washers on the vertical stud with the nuts in position. The flat washer can be left free floating in the package. Then they shall be packed in bulk (QTY of 4, 5, or 6) to completely furnish an individual magnet. Refer to Section 3.12 for bulk kitting quantities per magnet type. Packaging at the individual and bulk level shall ensure no threads can be damaged during shipping and handling of the kits.

Bulk kits shall be kept separate from other magnet types. If shipped in the same crate as other magnets, container will be made to ensure separation between bulk kits.

Shipping containers shall have desiccant appropriate for the shipping volume to control for humidity.

6.1 Packaging

All vertical support stud kits for Items 0001 through 0008 shall first be packaged individually as a pre-assembled unit. Then they shall be packed in bulk (QTY of 4 ,5, or 6) to completely furnish an individual magnet. Packaging at the individual and bulk level shall ensure no threads can be damaged during shipping and handling of the kits.

Packaging of individual kits shall have the:

LBNL AL Assembly number clearly displayed.

Packaging of the bulk kits shall have:

LBNL AL Assembly number clearly displayed.

Magnet Family they can be used on per Section 3.12.

QTY in the bulk kit (QTY 4, 5,6).

Shipping containers/crates for containing bulk quantities can be wooden or cardboard or palletized.

If using cardboard boxes, total shipping of the box and its components shall not exceed 25lbs.

If using wooden crates containers shall be moveable with a pallet jack.

6.2 Shipping

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Shipments of the vertical support studs shall be made in minimums of 1/3 the total of the required deliverable for the individual kits. Quantity and name of the kits included in the package must be noted on the packing slip.

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7 QUALITY ASSURANCE

7.1 Quality reporting requirements

7.1.1 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 design, manufacture, testing of all systems and equipment provided

Post-award surveys may be required and shall be supported.

7.1.2 Deviation requests

Any deviations from the dictating 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.

7.1.3 Nonconformance reports

A nonconformance report provides a summary for products or procedures which do not conform to the defined requirements. Non-conformances 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 3 business days of the 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.

7.2 Factory Inspection and Test Plan

The subcontractor shall provide an Inspection and Test Plan which shall be submitted to the LBNL technical representative for written approval by ALS-U Quality Assurance prior to its required use.

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This Inspection and Test Plan shall consist of a plan in the subcontractor’s format listing components, subassemblies, and assemblies; identifying inspections and tests planned for the verification of quality; and identifying documentation/planning for recording the results.

Vendor shall perform random sampling of 10% of the total delivered kits per vertical support type performing:

1. Visual inspection of studs to check for damaged threads

2. Visual inspection of spherical washers

3. Range of motion of nuts on studs to ensure no binding occurs and threads are free running.

4. Check one kit per batch to ensure appropriate parts and quantities in each kit are included.

7.3 ACL upon receipt at LBL

LBNL shall perform random sampling of 10% of the each kit type performing:

Visual inspection of studs

Range of motion of nuts on studs to ensure no binding occurs and threads are free running.

7.4 Other QA documents as needed

8 APPLICABLE DOCUMENTS

This section identifies applicable documents that are considered to be a part of this document. All information contained in an applicable document shall be valid to the full extent, unless specifically noted within this document. Applicable documents shall be obtained from the LBNL Document Control Center (DCC).

Document Number Title

AL-1478-4858 MAGNET POST ASSY KIT, M20, SF/SD

AL-1547-7647 MAGNET POST ASSY KIT, M24, QDA/QFA/QFRA

AL-1477-3952 MAGNET POST ASSY KIT, M20, QDB/QFRB

AL-1478-3603 MAGNET POST ASSY KIT, M24

AL-1510-4700 MAGNET POST ASSY KIT, M24, BENDA

AL-1480-0777 MAGNET POST ASSY KIT, M24, BENDB/BENDC

AL-1474-3266 MAGNET POST ASSY KIT, M24, HBEND

AL-1779-1451 MAGNET POST ASSY KIT, M16, SHA/SHB

AL-1799-5303

ROD, THREADED, M20X1.5MMX1M LG, STL, ISO 898 CLASS 8.8 STEEL,

B.O.

AL-1523-4034 STUD THREADED M24 X 1.5MM X 180MM LG STL ISO 898 CLASS 8.8, B.O

AL-1572-8095 STUD, THREADED, M16X1.5X158 MM LG, GRADE 8.8 STL, ISO 898, B.O

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HW-1000-2161 WASHER, SPHERICAL, M20, SS 18-8

HW-1000-2144 WASHER, SPHERICAL, M24, 18-8 SST

HW-1000-6803 WASHER, SPHERICAL, M16, 18-8 SST

HW-1001-4883

NUT, HEX, M20x1.5x10MM, LOW PROFILE, STEEL, GRADE 8, ZP, DIN

934/ISO4032

HW-1000-3513

NUT, HEX, M24X1.5X10MM LOW PROFILE, STEEL, GRAD 8, ZP, DIN

934/ISO4032

HW-1001-4884

NUT, HEX, M16X1.5X10MM, LOW PROFILE, STEEL, GRADE 8, ZP, DIN

934/ISO 4032

AL-1418-3483 THRUST WASHER, OIL IMPREGNATED

AL-1460-8003 Thrust Washer, Oil Impregnated, 34MM ID AL-1418-3713 Thrust Washer, Oil Impregnated, 34MM ID AL-1454-6896 Thrust Washer, Oil Impregnated, 34MM ID AL-1474-3642 Thrust Washer, Oil Impregnated, 21MM ID

HW-1000-0012 FW M20X3 MS DIN125 ZP

HW-1000-0013 FW M24X4 MS DIN125 ZP

HW-1000-0010 FW M16X3 MS DIN125 ZP

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APPENDIX A: VERIFICATION TABLE

(To be completed by delivery date)

This appendix summarizes the final set of subcontractor deliverables which are due to LBNL in addition to the other deliverables listed in section 3 above. It is the lab’s expectation that as a final action, the subcontractor will print out this page, and complete the “Complete? (Y/N)” column as part of the completed delivery package. For any “N” (no) response, an explanation in the comments section below shall be provided as to why that deliverable is not complete. It is then up to LBNL to accept the deliverable as is through a waiver, or work with the subcontractor for completion of the task before acceptance of the final delivery.

Item Section Item Complete?

(Y/N)

1 3.1 Manufacturing Plan

2 3.3 QTY 2,022 vertical support positioning kits for the SR Magnets as detailed by Section 3.3

3 6.1 Packaging of individual kits shall have the:

LBNL AL Assembly number clearly displayed.

4 6.1

Packaging of the bulk kits shall have:

LBNL AL Assembly number clearly displayed.

Magnet Family they can be used on per Section 3.12.

QTY in the bulk kit (QTY 4, 5,6).

5 7.2

Vendor shall perform random sampling of 10% of the total delivered kits per vertical support type performing:

Visual inspection of studs to check for damaged threads

Visual inspection of spherical washers

Range of motion of nuts on studs to ensure no binding occurs and threads are free running.

6 3.2 Certificate of conformance and material traceability delivered for all components.

7 N/A

All Government Furnished Property (GFP) and/or materials purchased by LBNL for this project have been returned to and received by LBNL

Comments:

Attachments:

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DocumentAuthors