1c. Statement of Work, AL-1918-8544A, Group D.pdf

STATEMENT OF WORK: BPM CHASSIS - GROUP D

RELEASE DATE :

AUTHOR:

DOCUMENT NUMBER: AL-1918-8544 REVISION: A

DOCUMENT STATUS: WORKING

DOCUMENT TYPE: REQUIREMENT

CATEGORY CODE: LS151400

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1 REVISION HISTORY 3

2 APPROVALS 3

3 Abbreviations and Acronyms 3 4 Introduction 4

4.1 Project Overview 4

4.2 Description of Items 4

4.3 Roles and Responsibilities 5

5 Scope of Work 5 6 Deliverables and Schedule 6

6.1 First Article Deliverables 6

6.2 Production Batch 1 & 2 Deliverables 7

6.3 Schedule 7

6.3.1 First Article Schedule 8

6.3.2 Production Schedule 9

7 Management 9

7.1 Reporting/Communication requirements 9

7.1.1 Kick-Off Meeting 9

7.1.2 Weekly Status Reporting and Coordination 10

7.1.3 Issue Notification and Escalation 10

7.2 Documentation requirements 10

8 Shipping, Handling, and Storage 10 9 Quality Assurance 11

9.1 Quality reporting requirements 11

9.1.1 Subcontractor Quality program 11

9.1.2 Deviation requests 11

9.1.3 Nonconformance reports 11

9.2 Factory Inspection and Test Plan 12

9.3 ACL upon receipt at LBL 12

9.4 TIP upon receipt at LBL 12

10 Applicable Documents 12 11 Reference Documents 12

Advanced Light Source

Lawrence Berkeley National Laboratory

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https://docs.google.com/document/d/1z-COCENNh6E_PVjiNGqzIhy0m3ca6JRrYzhNiXfELjo/edit?tab=t.0#heading=h.31idmo12afxy https://docs.google.com/document/d/1z-COCENNh6E_PVjiNGqzIhy0m3ca6JRrYzhNiXfELjo/edit?tab=t.0#heading=h.9obydzej3lfp https://docs.google.com/document/d/1z-COCENNh6E_PVjiNGqzIhy0m3ca6JRrYzhNiXfELjo/edit?tab=t.0#heading=h.zhal3t6plr5d

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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 Jonah Weber ALS-U Instrumentation Technical Lead Alessandro Ratti ALS-U Electrical System Manager Changchun Sun ALS-U Instrumentation CAM Jiani Niu ALS-U QA Manager

The following individual(s) approved this document:

Approved by:

3 ABBREVIATIONS AND ACRONYMS

ALS Advanced Light Source ALS-U Advanced Light Source Upgrade AFE Analog Front End BOM Bill of Materials BPM Beam Position Monitor ESD Electrostatic Discharge LBNL Lawrence Berkeley National Laboratory MBA Multibend Achromat PCB Printed Circuit Board PTM Pilot Tone Module RF Radio Frequency SOW Statement of Work TIP Test & Inspection Procedures University The Regents of the University of California

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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 Description of Items

Beam Position Monitor (BPM) electronics assemblies provide signal conditioning, timing distribution, and processing necessary to measure the transverse position of the particle beam.

The assemblies consist of multiple printed circuit board (PCB) sub-assemblies grouped into major functional assemblies, including the Timing + Balun assembly, Analog Front End (AFE) assemblies, and Chassis-level electronics.

The required assemblies for this work package are summarized in the table below, which identifies the BPM major assembly, sub-assembly description, total required quantity, and the associated drawing number that defines fabrication and build requirements.

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Table 1

BPM Sub-Assembly Qty Part #

CLK104A Board 130 AL-1871-8740

Balun Board 130 AL-1877-2686 Each assembly shall be fabricated in accordance with the latest released revision of the referenced drawings, schematics, bills of materials (BOMs), and applicable specifications.

4.3 Roles and Responsibilities

The subcontract will name two University specialists to oversee the contractual and 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

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

The selected 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..

5 SCOPE OF WORK

The contractor shall fabricate, assemble, inspect, and test the CLK104 Board and Balun Board assemblies identified above in accordance with released engineering documentation and applicable quality standards.

Scope includes:

● Procurement of components per the latest approved revision of the bills of materials:

○ CLK104A Board BOM, AL-1871-8740-C

○ Balun PCB BOM, AL-1877-2686-C

● PCB fabrication and population per the latest approved revision of the manufacturing packages:

○ CLK104A Board Manufacturing Package AL-1871-8740-L

○ Balun Board Manufacturing Package AL-1877-2686-L

● Soldering in accordance with applicable workmanship standards (e.g., IPC Class as specified)

● Cleaning, conformal coating (if required), and labeling per drawings

● In-process and final inspection

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● Documentation of inspection and test results per IPC-9252 and manufacturing drawings included in the manufacturing packages

● Packaging and delivery in ESD-safe materials

All work shall comply with specified tolerances, configuration control requirements, and applicable laboratory or project quality assurance standards.

6 DELIVERABLES AND SCHEDULE

The Contractor shall provide the following deliverables for the AMI PCB, AFE RF A PCB and AFE RF B PCB assemblies as identified in this SOW.

Table 2: Deliverables

Item No. Name Qty Part Number Schedule

0001 CLK104A Board and Test Data - First Article 4 AL-1871-8740 3 weeks ARO

0002 CLK104A Board and Test Data - Production Batch 1 40 AL-1871-8740 4 weeks after Hold

Point approval

0003 CLK104A Board and Test Data - Production Batch 2 86 AL-1871-8740

10 weeks after Hold Point approval

0004 Balun Board and Test Data - First Article 4 AL-1877-2686 3 weeks ARO

0005 Balun Board and Test Data - Production Batch 1 40 AL-1877-2686 4 weeks after Hold

Point approval

0006 Balun Board and Test Data - Production Batch 2 86 AL-1877-2686

10 weeks after Hold Point approval

6.1 First Article Deliverables and Schedule

For each PCB assembly type, the Contractor shall fabricate and deliver a First Article of fully assembled boards within three (3) weeks after ARO

● First Article units shall be delivered in a single batch per assembly type

● These units shall be clearly identified as First Article material.

● Delivery shall include:

○ Certificate of Conformance (CoC)

○ Inspection and test reports

■ Balun (AL-1877-2686)

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● Inspection and test results per IPC-9252 and manufacturing drawings

● Completed additional “Verification Signoff Sheets” per Balun

Board TIP (AL-1880-6070)

■ CLK104A (AL-1871-8740)

● Inspection and test results per IPC-9252 and manufacturing drawings

○ As-built configuration documentation

○ Traceability documentation for components (as required)

○ Any deviations or waivers identified during fabrication

Any anticipated schedule deviation shall be communicated in writing immediately upon identification, along with a recovery plan.

The First Article assemblies will be subject to inspection, testing, and formal approval by the Technical Representative (Hold Point). Written approval from the Technical Representative is required prior to commencement of full production quantities.

No production fabrication beyond the First Article quantities shall proceed without formal written authorization.

6.2 Production Batch 1 & 2 Deliverables and Schedule

A hold period of one (1) week is anticipated, in accordance with Section 7.3, to allow LBNL to perform inspection and testing. Following written approval of the First Article assemblies, the Contractor shall proceed with Production.

Production quantities for each PCB assembly type shall be delivered in two (2) batches within the schedule outlined below.

● Batch 1 delivery within four (4) weeks of the Hold Point approval

● Batch 2 delivery within ten (10) weeks of the Hold Point approval

Each production batch shall include:

● Completed PCB assemblies per drawing

● Certificate of Conformance

● Inspection and electrical test data

○ Balun (AL-1877-2686)

■ Inspection and test results per IPC-9252 and manufacturing drawings

■ Completed additional “Verification Signoff Sheets” per Balun Board TIP

(AL-1880-6070)

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○ CLK104A (AL-1871-8740)

■ Inspection and test results per IPC-9252 and manufacturing drawings

● Lot traceability documentation

● Serialized identification (if required by drawing)

All assemblies shall be packaged in ESD-safe materials and shipped in accordance with specified handling requirements.

All production units shall undergo 100% testing in accordance with Section 9.2.

Any anticipated schedule deviation shall be communicated in writing immediately upon identification, along with a recovery plan.

7 MANAGEMENT

7.1 Reporting/Communication requirements

Timely, transparent, and proactive communication between the Contractor and Technical and Procurement Representatives is essential to ensuring successful execution of this work. The Contractor shall maintain open lines of communication throughout the period of performance and promptly elevate any issues that could affect cost, schedule, or technical performance.

7.1.1Kick-Off Meeting

A formal Contract Kick-Off Meeting shall be conducted within one (1) week of contract award.

The meeting will be held virtually.

The purpose of the Kick-Off Meeting is to establish a clear and common understanding of:

● Technical scope and applicable engineering documentation

● First Article requirements and approval process

● Production quantities and batch cadence

● Quality standards, inspection requirements, and documentation expectations

● Delivery schedule and milestone expectations

● Points of contact, communication channels, and escalation procedures

The Contractor shall present the agreed upon production schedule per the contract award and associated execution plan at or prior to the Kick-Off Meeting.

7.1.2Weekly Status Reporting and Coordination

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Beginning two (2) weeks after contract award and continuing through final delivery, the Contractor shall provide written weekly status reports. Reports shall be concise but sufficiently detailed to provide clear visibility into performance and risk.

At a minimum, weekly reports shall include:

● Production status by assembly type

● Progress against the approved delivery schedule

● First Article fabrication and testing status (if applicable)

● Completed and upcoming production batches

● Material availability and supply chain status

● Summary of quality issues or nonconformances

● Identification of any technical, manufacturing, or supply risks

● Assessment of any condition that could potentially hinder scheduled delivery dates

● Mitigation or recovery actions being implemented

The Contractor shall participate in recurring coordination meetings (weekly or as otherwise agreed) to review status, address risks, and ensure alignment on upcoming milestones.

7.1.3Issue Notification and Escalation

The Contractor shall notify the Technical and Procurement Representatives in writing within two

(2) business days of identifying any issue that may materially impact schedule, quality, or performance. Early notification is required upon identification of potential risk, regardless of whether full root cause analysis has been completed.

The objective of this communication structure is to enable early visibility, collaborative problem-solving, and uninterrupted production flow to meet the required delivery cadence.

7.2 Documentation requirements

All required documentation shall be submitted to LBNL prior to or upon delivery. The preferred method is electronic format (pdf preferred) sent via email or shared on a secure website. Hard copies included with the deliverable shipment are also acceptable.

7.3 Hold points and what’s required

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

Hold Point: Production Batch Release

● Location: After the first article delivery completion, prior to the production Batch.

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● Period: LBNL is expected to require up to one (1) week to inspect the first article

● Requirement: Written approval from the LBNL Technical Representative

8 SHIPPING, HANDLING, AND STORAGE

Packaging and delivery to be in ESD-safe materials.

9 QUALITY ASSURANCE

9.1 Quality reporting requirements

9.1.1Subcontractor 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.

9.1.2Deviation 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.

9.1.3Nonconformance reports

A nonconformance report provides a summary for products or procedures which do not conform to the defined requirements. Nonconformances 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.

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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.

9.2 Factory Inspection and Test Plan

Factory inspection and test to be performed per fabrication and assembly instructions, as noted in the manufacturing packages as listed in Scope of Work (Section 5). Fabrication shall include electrical testing per IPC-9252.

As part of the factory inspection and test of the Balun Board (AL-1877-2686), subcontractor shall execute the Balun Board TIP (AL-1880-6070), and populate the associated Verification Signoff Sheet for each unit. Completed Verification Signoff Sheets shall be provided to LBL as described in Section 6: Deliverables and Schedule.

No additional factory inspection and test is required for the CLK104A Board (AL-1871-8740).

9.3 ACL upon receipt at LBL

The acceptance criteria list, “Instrumentation PCB ACL” (AL-1567-1040), will be used by LBNL to evaluate and accept all deliverables.

The ACL must be released and placed under change control ahead of procurement award.

9.4 TIP upon receipt at LBL

For the CLK104A board, the Test & Inspection Procedure (TIP) AL-1880-6073 shall be used by LBNL as part of the acceptance process.

For the Balun board, no additional LBNL testing is required, as test and inspection (AL-1880-6070) have been completed and documented by the subcontractor.

10 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

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AL-1918-8544 REV.A Doc.Status:WORKING Page 12 of 12 specifically noted within this document. Applicable documents shall be obtained from the LBNL Document Control Center (DCC).

Table 3: Applicable Documents

Document Number Title AL-1871-8740-C CLK104A Board BOM AL-1871-8740-L CLK104A Board Manufacturing Package AL-1877-2686-C Balun Board BOM AL-1877-2686-L Balun Board Manufacturing Package

11 REFERENCE DOCUMENTS

Documents listed in this section are considered reference documents that can be used to better describe, clarify intent, or provide information where the information was obtained from.

Table 4: Reference Documents

Document Number Title AL-1567-1040 Instrumentation PCB ACL AL-1880-6073 CLK104 Board TIP AL-1880-6070 Balun Board TIP AL-1925-6259 Balun Board Test Procedure - Appendix

AL-1265-6612 ALS-U BUILD TO SPECIFICATION CAD MODEL AND

DRAWING REQUIREMENTS

AL-1208-0209 ALS-U Supplier Quality Evaluation Survey

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