2. AL-1704-8931C_SR - VC01 & VC16 - SOW.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 - VC01 & VC16 - SOW

Thomas GAUCHER

Release Date: Apr 16 2024 8:21:41 AM PDT

Document Number: AL-1704-8931 Revision: C

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 Project Overview

4.2 Scope Overview

4.3 Description of Items

4.3.1 Chamber Design Summary

4.3.1.1 VC01 – Variant A

4.3.1.2 VC01 – Variant B

4.3.1.3 VC01 – Variant C

4.3.1.4 VC16 – Variant A

4.3.1.5 VC16 – Variant B

4.4 Roles and Responsibilities

5 Deliverables

5.1 Deliverables

5.1.1 Documentation Deliverable

5.1.2 Drawings and CAD Models Deliverable

5.1.2.1 LBNL provided models and drawings

5.1.3 Hardware Deliverable

5.1.3.1 Components included

5.1.3.2 First article

5.1.3.3 Production

5.2 Scope of work

5.2.1 Management and Quality Assurance

5.2.2 Final Design Review Requirements

5.2.3 First article

5.2.4 First article delivery

5.2.5 Complete Production

5.2.6 Delivery

5.2.6.1 VC01 – Variant A

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5.2.6.2 VC01 – Variant B

5.2.6.3 VC01 – Variant C

5.2.6.4 VC16 – Variant A

5.2.6.5 VC16 – Variant B

5.3 Final documentation package(s)

6 Management, Reporting, Documentation and reviews

6.1 Schedule

6.2 Reporting requirements

6.3 Proposal documentation requirements

6.4 Reviews

6.5 Hold points

7 Fabrication

8 NEG Coating

9 Packaging and shipping specifications

9.1 Container

9.2 Marking

9.3 Packaging

9.4 Handling and storage

10 Quality Assurance

10.1 Quality plan

10.2 Control plan

10.3 Type of control points

10.4 Deviation requests

10.5 Nonconformance reports

10.6 Numbering and/or Serialization

10.6.1 VC01 – Variant A

10.6.2 VC01 – Variant B

10.6.3 VC01 – Variant C

10.6.4 VC16 – Variant A

10.6.5 VC16 – Variant B

10.7 Completed ACL

11 Applicable Documents ci al ly R el ea se d to th e

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Appendix A: Control Plan

Appendix B: 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 Baseline B Section 4.4 Update of term in Roles and Responsibilities section

C Section 5.1.3.1 Modification of the term in column “Quantity” of the Id 9 in Table 5-8. From “lump sum” to “vendor specified”.

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 oomolayo

3 ABBREVIATIONS AND ACRONYMS

ALS Advanced Light Source ACL Acceptance Criteria List ALS-U Advanced Light Source Upgrade ARO After Receipt of Order CAD Computer Aid Design CMM Coordinate Measuring Machine CP Control Plan FAT Factory Acceptance Test FDR Final Design Review HP Hold Point

ID

KOM

Insertion Device Kick Off Meeting

LBNL Lawrence Berkeley National Laboratory LCW Liquid Cooled Water NCR Nonconformance Report NP Notification Point NTP Notification to Proceed SR Storage Ring UHV Ultra High Vacuum VC Vacuum Chamber W Witness 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 Overview

This scope of work is for the manufacturing design fabrication, dimensional inspection, fiducialization, vacuum testing and delivery of vacuum chambers for the ALS-U project.

The chambers are VC01 and VC16, each has three and two sub variants respectively. There are therefore five vacuum chambers variants in this scope. All chambers in this scope must be NEG coated.

4.3 Description of Items

The VC01 and VC16 vacuum chambers are located within the 12 sectors of the Storage

Ring (SR). Each sector of the SR is divided into units comprising one straight section and one arc section, further divided into four raft units as depicted inFigure 4-7. Each raft includes magnets, vacuum chamber assemblies, and support structures, as illustrated in

Figure 4-6. The VC01 and VC16 (as exemplified in Figure 4-1 to Figure 4-5) typically ci al ly R el ea se d to th e

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features an electron beam only. VC01 has a BPM block in the middle of the chamber whereas VC16 does not. The scope of work is to provide LBNL with a total of 26 chambers.

Figure 4-1: VC01 – Variant A Figure 4-2: VC01 – Variant B

Figure 4-3: VC01 – Variant C Figure 4-4: VC16 – Variant A

Figure 4-5: VC16 – Variant B

Figure 4-6: Sector 4 Raft #1 VC01 and support / Magnet, VC01 and support ci al ly R el ea se d to th e

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Figure 4-7: Sector #4 (Magnet, Vacuum chamber and support)

Straight Section Bend Section

Raft # 01

Bend Section

Raft # 02

Bend Section

Raft # 03

Bend Section

Raft # 04 Electron Beam Direction

PTL 4.3

PTL 4.2

PTL 4.0

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4.3.1 Chamber Design Summary

4.3.1.1 VC01 – VARIANT A

The VC01 – Variant A is made of 316L and 316LN stainless. The chamber has the following feature:

One BPM housing or block (1)

Brazed-on copper and welded-on stainless cooling channel (2)

Round Stainless steel tube beam aperture (3)

Flanges (4)

Figure 4-8: VC01 – Variant A

The VC01 – Variant A passes through four magnets - a sextupole, quadrupole, quadruple and sextupole magnets

Figure 4-9: Sextupole Figure 4-10: Quadrupole

(1)

(3)

(2)

Upstream

Downstream

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Figure 4-11: View of VC01 – Variant A through the magnets

Sextupole

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4.3.1.2 VC01 – VARIANT B

The VC01 – Variant A is made of 316L and 316LN stainless. The chamber has the following feature:

One BPM housing (1)

Integrated cooling channel with welded-on entry and exit tubes (2)

Elliptical Stainless steel tube beam aperture (3)

Flanges (4)

Figure 4-12: VC01 – Variant B

The VC01 – Variant B passes through a sextupole, quadrupole, quadruple and sextupole magnets

Figure 4-13: Sextupole Figure 4-14: Quadrupole

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Figure 4-15: View of VC01 – Variant A through the magnet

4.3.1.3 VC01 – VARIANT C

The VC01 – Variant C is the same chamber as the VC01 – Variant B. The VC01 – Variant C passes through the same magnet and possesses identical features. The only distinction is the upstream flange geometry (see Figure 4-16 and Figure 4-17).

Figure 4-16: VC01 – Variant B

Upstream flange (female) Figure 4-17: VC01 – Variant C

Upstream flange (male)

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4.3.1.4 VC16 – VARIANT A

The VC16 – Variant A is made of 316L and 316LN stainless steel. The chamber has the following feature:

Integrated cooling channel (1)

Round aperture EDM beam channel with shadowing feature (2)

Flanges (3)

Figure 4-18: VC16 – Variant A

The VC16 – Variant A passes through a quadrupole and a sextupole magnet

Figure 4-19: Sextupole Figure 4-20: Quadrupole

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Figure 4-21: View of VC16 – Variant A through the magnets

4.3.1.5 VC16 – VARIANT B

The VC16 – Variant B is the same chamber as the VC16 – Variant A. The VC16 – Variant B passes through the same magnet and possesses identical features. There are two distinctions, one is in the geometry of the upstream flange

Figure 4-22: VC16 – Variant B

Upstream flange (femal) Figure 4-23: VC16 – Variant A

Upstream flange (male)

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The other distinction is the welded-on support under the VC16-B chamber.

Figure 4-24: VC16 – Variant B

With Support Figure 4-25: VC16 – Variant A

Without support

4.4 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 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

This section details the required hardware and documentation deliverables for each phase of the subcontract execution process. It also details the technical management and oversight requirements during the execution process.

5.1 Deliverables

5.1.1 Documentation Deliverable

Table 5-1 provides the list of documentations to be provided by the selected Subcontractor to LBNL. Fabrication cannot start prior to the review, approval, and closure of all related FDR action items.

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

Id Documentation Due Date

Project Documentation 1 Initial schedule 7 days ARO

2 Weekly status / progress meeting For the duration of the contract 3 Monthly Status Summary & Updated schedule 5th of each month

Quality Documentation 4 Quality Plan 7 days ARO 5 Control plan (see Table 5-11 and §10.1) 10 days before FDR 6 Control plan duly completed and signed 10 days prior shipment 7 Acceptance Criteria List duly completed and signed 10 days prior shipment

Manufacturing Documentation 8 Manufacturing Drawing 10 days before FDR 9 Final 3D model 10 days before FDR 10 Bill of Material 10 days before FDR 11 Manufacturing plan (see Table 5-11) 10 days before FDR 12 Test Plan and Associated procedures (see Table 5-11) 10 days before FDR 13 Test report (dimension, He leak, etc…) 10 days prior shipment

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

15 Material Certification 10 days before manufacturing

Delivery documentation 16 List of packing crates and contents 10 days prior shipment 17 Shipping plan (see §9) 10 days prior shipment

Other 18 Certificate of Conformance 10 days prior shipment 19 Final document package (see §5.3) 10 days prior shipment

*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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5.1.2 Drawings and CAD Models Deliverable

LBNL will provide the vendor with final drawings and CAD models. The fabrication must take into consideration all requirement of the Engineering Specification Document AL-

1704-8932. The vendor is able to propose changes to the design for ease of manufacture or improved performance. Such changes will be reviewed and approved/declined by

LBNL technical representative. The tolerances and dimensions stipulated in the LBNL drawings must be respected except in cases where a waiver in writing, has been explicitly provided by LBNL technical representative.

5.1.2.1 LBNL PROVIDED MODELS AND DRAWINGS

LBNL is providing the vendor the design information packages listed Table 5-2

Table 5-2: LBNL design package

Id Drawing Revision Description

1 AL-1709-0867 A COVER FLANGE, DUAL BUTTON, QF 2.6 IN.

2 AL-1708-4480 A COVER FLANGE, BPM VC01

3 AL-1633-7355 A FLANGE, RF GEN II, QF40-F, BLANK (SST)

4 AL-1633-8516 A FLANGE, RF GEN II, QF50-F, BLANK (SST)

5 AL-1633-7073 A FLANGE, RF GEN II, QF50-M, BLANK (SST)

6 AL-1633-7068 A FLANGE, RF GEN II, QF40-M, BLANK (SST)

9 AL-1222-6788 A Vc01 – variant a 10 AL-1418-2267 C Vc01 – variant b 11 AL-1582-3025 C Vc01 – variant c 12 AL-1418-7454 B Vc16 – variant a 13 AL-1582-2681 B Vc16 – variant b 14 AL-1709-1469 A Shipping assembly of AL-1418-2267 15 AL-1709-0862 A Shipping assembly of AL -1582-3025 16 AL-1709-7000 A Shipping assembly of AL -1418-7454 17 AL-1708-9140 A Shipping assembly of AL -1582-2681 18 AL-1708-4465 B Shipping assembly of AL -1222-6788 ci al ly R el ea se d to th e

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5.1.3 Hardware Deliverable

The schedule and phasing of hardware delivery is defined in this section

5.1.3.1 COMPONENTS INCLUDED

In addition to the vacuum chambers, each chamber delivery must include blank flanges, fittings, support brackets and chambers supports as listed in Table 5-3 to 5-7. The quantities of the ancillary parts and assembly state during shipment is shown in the shipping assemblies models listed in the Applicable Documents. LBNL will supply vacuum seals, chain clamps and fiducialization hardware as illustrated in Table 5-8.

Table 5-3: Components that subcontractor will source or manufacture for VC01 – Variant A

ID Features Illustration LBNL ID

VC01 –

AL-1222-6788-

rev A

Blank Flange

QF-40-M

AL-1633-7068-

3 Dowel Pin

AL-1000-7717-

Cover flange

BPM

AL-1708-4480-

QF-50-F

AL-1633-8516-

6 Swagelok

HW-1000-6992

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Table 5-4: Components that subcontractor will source or manufacture for VC01 – Variant B

ID Features Illustration LBNL ID

AL-1418-2267-

rev C

QF-50-M

AL-1633-7073-

Dual BPM

AL-1709-0867-

Table 5-5: Components that subcontractor will source or manufacture for VC01 –

Variant C ID Features Illustration LBNL ID

Variant C

AL-1582-3025-

rev C

Dual BPM

AL-1709-0867-

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Table 5-6: Components that subcontractor will source or manufacture for VC16 –

ID Features Illustration LBNL ID

VC16 –

AL-1418-7454-

rev B

QF-40-M

AL-1633-7068-

HW-1000-5922

Table 5-7: Components that subcontractor will source or manufacture for VC16 –

ID Features Illustration LBNL ID

VC16 –

AL-1582-2681-

rev B

QF-40-F

AL-1633-7355-

HW-1000-5922

Note: See shipping assembly drawing associated to each chamber for the total quantity of all features needed.

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Table 5-8: Integrated Materials provided by LBNL

Id Features Illustration LBNL ID Quantity

Flange Chain Clamps

QF 50

HW-1610-0797 34

Flange Chain Clamps

QF 40

HW-1435-4037 14

Seal Helicoflex

1.507”ID

HW-1000-6923 14 + 4

4 Seal Helicoflex

AL-1373-1067 8 + 4

Seal Helicoflex

2.290”ID

HW-1000-7226 34 + 4

6 Seal Helicoflex 38.1 ID

HW-1000-9643 20 + 4

7 Pressure ring QF50

AL-1614-6599 136

8 Pressure ring QF40

AL-1613-6265 56

Fiducial ball

½ inch

AL-1551-3974

Vendor specified

Note: The additional number in the "quantity" column represents the quantity of spares provided by LBNL to the vendor ci al ly R el ea se d to th e

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5.1.3.2 FIRST ARTICLE

The selected subcontractor is required to produce one chamber and its ancillaries as the first article.

Table 5-9: List of first articles

5.1.3.3 PRODUCTION

Table 5-10 list the production articles and the respective quantities. The quantities include one spare as determined by LBNL. The subcontractor can propose the delivery order and batches otherwise full delivery in a single shipment applies.

Table 5-10: List of production articles

Id Drawing ID Description Qty Due Date

4 AL-1708-4465 VC01 – Variant A Assembly 1 24 weeks

After First Article

Approval

5 AL-1709-1469 VC01 – Variant B Assembly 5

6 AL-1709-0862 VC01 – Variant C Assembly 5

7 AL-1709-7000 VC16 – Variant A Assembly 12

Id 2D drawing Description Qty Due Date 1 AL-1708-4465 VC01 – Variant A Assembly 1

12 weeks After FDR Approval

2 AL-1709-1469 VC01 – Variant B Assembly 1 3 AL-1708-9140 VC16 – Variant B Assembly 1 ci al ly R el ea se d to th e

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5.2 Scope of work

5.2.1 Management and Quality Assurance

The selected subcontractor will be responsible for supplying an initial Schedule and a

Quality Plan within 7 days ARO. This must include organizational policy on quality, controlled documents for Non-conformance, material inspection, and subcontractor qualification (see §10.1)

5.2.2 Final Design Review Requirements

A final design review is required once the subcontractor has completed the detail manufacturing design for all chambers and tooling. The selected subcontractor must be responsible for supplying all documentations related to the FDR prior to fabrication of the VC01 and VC16 Chambers. Documentations must take into account the VC01 and

VC16 Chambers engineering specification (AL-1704-8932).

CAD model and drawing requirements are detailed in Appendix B:

The FDR is required to include of the following documentation:

1. Control Plan1 and Manufacturing plan1 for the VC01 and VC16 Chambers

2. Final manufacturing drawings (required if design was modified)

3. Final CAD model (Required if Design was modified)

4. Test plan and associated procedures

5. Bill of material

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 §10.3.

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Table 5-11: 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 (except tests for FAT, which are covered in the test plan). 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.

Test Plan

The test plan at a minimum documents step-by–step activities of all tests prior to the FAT to validate the vacuum hardware such as:

He leak test

Bakeout

RGA

Outgassing rate

Beam center measurement in reference to fiducials

All criteria relative to tests performed have to be mentioned in the test plan. Procedures and/or standards used for tests must be referenced in the test plan.

Control plan

The control plan must describe all steps of the fabrication, including, verification of materials, manufacturing/execution operations, inspection, tests and delivery and any work to be performed by subcontractor. LBNL will provide a template to the selected subcontractor (see §10.2 for more detail) ci al ly R el ea se d to th e

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5.2.3 First article

Following approval of the FDR, a first article will be produced. The first article will 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 §5.1.3.2 First Article, and §10.3 Notice to Proceed for additional information.

5.2.4 First article delivery

The selected subcontractor will be responsible for delivering the complete production to LBNL in accordance with the parameters outlined in this document. Refer to section §5.2.6 for the delivery conditions.

5.2.5 Complete Production

In accordance with section 5.2.3 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. Complete VC01 and VC16 Chambers packed in an appropriate crate.

2. Completed FAT and associated reports

3. Final and completed CP

4. Final and completed ACL

5. Quality assurance receipts and certifications

6. Nonconformance or deviation documentation pertaining to each individual assembly

7. Final, approved shipping plan

8. 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.

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5.2.6 Delivery

The selected subcontractor will be responsible for delivering the complete production to LBNL in accordance with the parameters outlined in this document. The VC01 and VC16 chamber shall be delivered as depicted in the picture below and under nitrogen.

5.2.6.1 VC01 – VARIANT A

Figure 5-1View of the VC01 – Variant A ready to be delivered

5.2.6.2 VC01 – VARIANT B

Figure 5-2View of the VC01 – Variant B ready to be delivered ci al ly R el ea se d to th e

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5.2.6.3 VC01 – VARIANT C

Figure 5-3View of the VC01 – Variant C ready to be delivered

5.2.6.4 VC16 – VARIANT A

Figure 5-4View of the VC16 – Variant A ready to be delivered

5.2.6.5 VC16 – VARIANT B

Figure 5-5View of the VC16 – Variant B ready to be delivered ci al ly R el ea se d to th e

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5.3 Final documentation package(s)

LBNL will be provided a full and complete documentation package at the end of the production. Refer to Appendix B: for specific file requirements. The documentation package must 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

3. Complete, as built drawings in English, and in an editable format.

4. Other documentation as requested ci al ly R el ea se d to th e

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6 MANAGEMENT, REPORTING, DOCUMENTATION AND REVIEWS

6.1 Schedule

The following table provides the main schedule items and hold points.

Table 6-1: timetable of the project

Section # Designation Schedule Responsibility

§5.2.1 Management and

Quality plan 7 days ARO subcontractor

§5.2.2 Final VC01 and VC16

Chambers design review

(FDR)

4 weeks ARO subcontractor

HP#1 Approval of the FDR 2 weeks after completion of

FDR

LBNL.

§5.2.3 Completion of Manufacturing (First article)

12 weeks after approval of FDR subcontractor

§5.2.4 Delivery

(First article) 2 weeks after completion of manufacturing subcontractor

HP#2

Approval of the first article 2 weeks after delivery

LBNL.

§5.2.5 Completion of Manufacturing (Production)

24 weeks after approval of first article subcontractor

HP#3

Approval of the production 2 weeks after completion of each manufacturing batch

LBNL.

§5.2.6 Delivery 2 weeks after each approval of manufacturing batch 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 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 Proposal 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 B: 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. Additional control points may be identified following review of the Control Plan §10.2.

Table 6-2: List of hold points

Section Activity Control point Type §5.2.2 Closeout of FDR NTP §5.2.3 Approval of first article NTP §5.2.5 Approval of complete production NTP

Control point types are defined in §10.3.

7 FABRICATION

The selected subcontractor must follow the SR - VC01 & VC16 – ESD referenced as AL- 1704-8932 for the fabrication of all chambers.

8 NEG COATING

It is required that the selected subcontractor includes NEG Coating of the internal surface on the chamber as part of their proposal. For technical requirement for the NEG Coating see AL-1704-8932 “SR - VC01 & VC16 - ESD” Section 7 and Section 10.2.

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9 PACKAGING AND SHIPPING SPECIFICATIONS

The selected subcontractor must submit to LBNL a shipping plan and be approved in writing by LBNL before the first shipment. The following points must be described in the shipping plan:

9.1 Container

Containers or crates for the VC01 and VC16 Chambers may be used for both shipping and storage. Construction of the containers must be sufficient to adequately support and protect the VC01 and VC16 Chambers throughout shipping.

Crates must be reusable with sides that attach using clips or other standard attachments that allow for ease of disassembly and/or reuse. LBNL must evaluate and approve shipping crate designs prior to fabrication of the crates or utilizing them for shipping.

Crates can contain multiple VC01 and VC16 Chambers. The crates must be strapped on all sides prior to and during shipment.

9.2 Marking

The exterior of the crates must have markings that clearly identify tie-downs, lifting points, and the crate center of gravity.

Mark the exterior of the crate 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 crate must have up arrows indicating the appropriate crate orientation.

Crates must be marked with the serial numbers of each VC01 and VC16 Chambers contained therein.

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

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9.3 Packaging

All VC01 and VC16 Chambers including cooling channels must be free of any liquid prior to shipping. The use of desiccant is strictly forbidden.

The chambers must be blocked/cribbed/supported to prevent movement or overstressing the component during transport. The following must be included:

Each chamber needs to be assembled along with each associated LCW fitting, cooling tube loops, steel support(s), flange blanks and chain clamps

Placement of foam between the chambers (if crate contains multiple chambers)

Placement of foam between the chambers and the sides of the crate to assist in minimizing movement during transportation.

Chambers shipping containers should incorporate a moisture barrier to prevent condensation during air shipment.

The exterior of the crate must have self-adhesive shock indicators affixed.

9.4 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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10 QUALITY ASSURANCE

The VC01 and VC16 Chambers must follow the same quality assurance during the first article and production fabrication. The quality assurance is depicted in the following subsection.

10.1 Quality plan

As part of our project requirements, we are requesting that the vendor provide a comprehensive quality plan to ensure the successful execution and delivery of the project.

The quality plan should encompass various essential components to guarantee adherence to high standards throughout the project lifecycle. Below are the specific elements that should be included:

Quality Manual: The vendor must provide a detailed quality manual outlining the company's quality management system (QMS). This manual should encompass all relevant quality procedures, standards, and methodologies adopted by the company to ensure consistency and effectiveness in delivering quality products or services.

Organizational Chart: An organizational chart specific to the project should be included, illustrating the hierarchical structure of the team involved. This chart will help delineate roles, responsibilities, and reporting lines within the project team, ensuring clarity and accountability.

Key Personnel: A list of key personnel involved in the project, along with their respective roles and responsibilities should be provided. This includes project managers, quality assurance personnel, technical experts, and any other relevant stakeholders critical to the project's success.

Subcontractor Information: If any subcontractors are engaged in the project, their names, roles, and scope of work should be clearly stated in the quality plan.

Additionally, measures to ensure the quality and performance of subcontracted work should be outlined.

Project-Specific Procedures: The quality plan should outline specific procedures and protocols to be applied within the context of the project. This may include quality control measures, inspection processes, testing methodologies, and any other relevant procedures tailored to the project's requirements.

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QA Documentation Presentation: A presentation of the quality assurance (QA) documentation should be included, highlighting the key documents, records, and forms utilized to manage and track quality throughout the project lifecycle. This shall include Control Plans (see §10.2), inspection reports, non-conformance reports (see §10.5), deviation request (see §10.4) and corrective action plans.

10.2 Control plan

The Control Plan must cover the entire scope of the phase/task, including any work to be performed by subcontractors like verification of materials, manufacturing/execution operations, inspection and test and delivery. LBNL will provide the selected subcontractor the template of Control Plan (see Appendix A:) and applicable document in §11.

Each activity once finished must be dated and signed by the subcontractor and the LBNL technical representative. The identification of the records released during activity execution (test report, dimensional report, NCR) must be registered with the Control Plan. The Control Plan must be delivered to and approved by the University prior to the FDR. Notification points (NP, W, HP) will be added by LBNL before returning to the selected subcontractor.

10.3 Type of control points

Notification point (NP): means that a notification must be sent to the entity before a task is performed. The notified can decide to visit or not. NP does not affect the production flow of the selected subcontractor. Notification sent to LBNL 10 working days before scheduled operation, LBNL will respond to the subcontractor within 5 working days of the scheduled operation of its intention.

Witness (W): means a visit/presence at the action to witness/monitor. Action cannot occur without the presence or without a written waiver. The production flow is interrupted (before the action) in order to allow the mandatory inspection/surveillance.

Notification sent to LBNL 10 working days before scheduled operation, LBNL will respond to subcontractor within 5 working days of schedule operation of its intention.

In case of “no-show” of a technical representative or delegate: the subcontractor must formally notify the technical representative and may proceed with production after 2 working days.

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Hold point (HP): the process and all related activities cannot continue (work cannot proceed beyond this point) without the relevant HP being cleared. This can be a record of acceptance, an event or a written waiver. Production flow for the associated process is interrupted (after the action) until clearance is given.

Notification sent to LBNL 10 working days before scheduled operation, LBNL notifies the selected subcontractor within 10 working days of the result on the HP activity:

o On rejection: The selected subcontractor has 5 working days to propose a recovery plan, o On objection (duly justified): The selected subcontractor has 10 working days to answer (and if applicable propose a recovery plan).

For HP requiring witness by LBNL, in case of “no-show” of a technical representative or delegate: the subcontractor must formally notify the technical representative and may proceed with production after 2 working day.

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

10.4 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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10.5 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.

10.6 Numbering and/or Serialization

Each VC01 and VC16 Chamber must be serialized. The following indicate the methodology of serialization

10.6.1 VC01 – Variant A

Designation Serialization

AL-1222-6788A

AL-1222-6788-0001

AL-1222-6788-0002

AL-1222-6788-0003

The serialization must be laser etched on the fixed flanged of all chamber. See location of the serialization on the picture below.

Table 10-1: Location of the serialization ci al ly R el ea se d to th e

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10.6.2 VC01 – Variant B

Designation Serialization

AL-1418-2267C

AL-1418-2267-0001

AL-1418-2267-0007

Table 10-2: Location of the serialization

10.6.3 VC01 – Variant C

AL-1582-3025C

AL-1582-3025-0001

AL-1582-3025-0005

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Table 10-3: Location of the serialization

10.6.4 VC16 – Variant A

AL-1418-7454B

AL-1418-7454-0001

AL-1418-7454-0012

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10.6.5 VC16 – Variant B

AL-1582-2681B

AL-1582-2681-0001

AL-1582-2681-0002

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10.7 Completed ACL

The subcontractor must provide a completed ACL to LBNL technical representative before shipping each VC01 and VC16 Chamber. The ACL shows that the following requirements are validated:

1. Visual Inspection

2. CMM measurement

3. Magnetic permeability

4. Bakeout / RGA scan

5. He leak test

6. NEG Coating inspection

7. HPN2 backfill

8. CMM after bakeout

9. Water Pressure Test

10. All Required Documentation

The ACL must include the criteria of the requirements and the results of the test related to the requirement. See doc AL-1683-2451A.

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11 APPLICABLE DOCUMENTS

This section identifies applicable…