2. AL-1720-3469 SR Photon Absorbers Statement of Work.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 Photon Absorbers Statement of Work

Release Date: May 22 2024 8:21:14 PM PDT

Document Number: AL-1720-3469 Revision: A

Document Status: Released

Document Type: SPECIFICATION

Category Code: AL7530

ALS-U - STORAGE RING

VACUUM - GENERAL

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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 Crotch Absorbers

4.3.2 Mask Absorber

4.4 Roles and Responsibilities

5 Deliverables

5.1 Deliverables

5.1.1 Documentation Deliverable

5.1.2 Drawings and CAD Models

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 plan

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

5.3 Final documentation package(s)

6 Management, Reporting, Documentation and reviews

6.1 Schedule

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6.2 Reporting requirements

6.3 Proposal documentation requirements

6.4 Reviews

6.5 Hold points

7 Packaging and shipping specifications

7.1 Container

7.2 Marking

7.3 Packaging

7.4 Handling and storage

8 Quality Assurance

8.1 Quality Plan

8.2 Control plan

8.3 Type of control points

8.4 Deviation requests

8.5 Nonconformance reports

8.6 Numbering and/or Serialization

8.7 Completed ACL

9 Applicable Documents

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

2 APPROVALS

The following individual(s) must approve this document:

Approver Project Role Ken Chow Chief Engineer/ Accelerator Mechanical

Systems lead Jiani Niu Project QA manager Olusola Omolayo Vacuum CAM and Technical Lead Windchill Approved / Concurred By

KPChow,oomolayo,jianiniu

3 ABBREVIATIONS AND ACRONYMS

ALS Advanced Light Source ACL Acceptance Criteria List ALS-U Advanced Light Source Upgrade AR Accumulator Ring ARO After Receipt of Order BPM Beam Position Monitor CAD Computer Aid Design CP Control Plan FAT Factory Acceptance Test FDR Final Design Review HHL High Heat Load HP Hold Point

IR

KOM

InfraRed Kick Off Meeting

LBNL Lawrence Berkeley National Laboratory LCW Liquid Cooled Water NEG Non Evaporable Getter NCR Nonconformance Report NP Notification Point NTP Notification To Proceed PTL Photon Transfer Line 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.

4.2 Scope Overview

This scope of work is for the fabrication, dimensional inspection, fiducialization, vacuum testing, and delivery of photon absorbers for the ALS-U project. The scope includes 7 absorber variants: 6 crotch absorbers and 1 mask absorber. In total, there are 39 absorber units to be delivered.

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4.3 Description of Items

The photon absorbers are located in the 12 sectors of the ALS-U Storage Ring (SR). Each sector of the SR is sectioned into units consisting of 1 x straight section and 1 x arc section that further divide into 4 raft units as shown in Figure 4-1. The photon absorbers are installed on the storage ring vacuum chambers and are design to intercept unwanted synchrotron radiation as well as protect uncooled vacuum chambers.

Figure 4-1: Sector #5 (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 ci al ly R el ea se d to th e

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There are 7 photon absorbers designs within this scope. The 7 designs can be further divided into two groups: Crotch Absorbers (6 designs) and Mask Absorbers (1 design), as shown in Figure 4-4.

Figure 4-1: Photon Absorber variants ci al ly R el ea se d to th e

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4.3.1 Crotch Absorbers

There are 6 variants of crotch absorbers in 2 sub-group: 2 x ID absorbers, 2 x standard absorbers, and 2 x HBEND absorbers. The absorber sub-groups relates to the source of the synchrotron radiation the absorber intercepts. The crotch absorbers also vary in terms of their overall size, the position, number and size of the photon window, the shape and orientation of the teeth features.

The crotch absorber cooling is a “squirt tube” design. This features a stainless steel center cooling tube for water ingress. The flow direction turn 180 degrees at the base of the tube to egress on following the outer diameter of the center cooling tube. An example of the crotch absorber is shown in Figure 4-4

Each absorber features fiducial posts to allow for accurate positioning of the absorber relative to the photon beam.

4.3.2 Mask Absorber

The mask absorber is designed to protect uncooled vacuum chambers from direct synchrotron radiation. The basic design concept is similar to the crotch absorber except that there are no photon windows. An image of the mask absorber design is shown in figure 4-5. Figure 4-6 shows the crotch and mask absorbers inside the host chambers.

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Figure 4-5: Crotch and Mask Absorbers ci al ly R el ea se d to th e

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Figure 4-6: Crotch and Mask Absorbers inside host chambers ci al ly R el ea se d to th e

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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 deliverables for each phase of the Photon Absorbers build 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 Updated Schedule 5th of each month

Quality Documentation 4 Quality Plan 7 days ARO 5 Control plan (see Appendix A:) 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 10 days before FDR 12 Test Plan and Associated procedures 10 days before FDR

Test report (dimension, He leak, etc…) AL-1720-3468, section §9.5 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 §7) 10 days prior shipment ci al ly R el ea se d to th e

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Other 18 Conformity Certificate 10 days prior shipment 19 Final document package 10 days prior shipment

*Days noted herein are based on a 5-business day workweek

5.1.2 Drawings and CAD Models

LBNL will provide the vendor with final drawings and CAD models. The fabrication must take into consideration all requirements of the SR Photon Absorber Engineering

Specification Document AL-1720-3468. 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 the 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 the LBNL technical representative.

5.1.2.1 LBNL PROVIDED MODELS AND DRAWINGS

LBNL is providing the vendor with the design information packages. See Table 5-2.

Table 5-2: LBNL design package type

Id Drawing Description LBNL Design Information

Type

1 AL-1636-0076 Crotch Absorber, ID, Non-WIGGLER Final Design

2 AL-1637-3574 Crotch Absorber, ID, WIGGLER Final Design

3 AL-1468-1176 Crotch Absorber, Standard, X.1 Final Design

4 AL-1633-8716 Crotch Absorber, HBND, X.2 Final Design

5 AL-1635-5870 Absorber MASK Final Design

6 AL-1633-6274 Crotch Absorber, Standard, X.3.X Final Design

7 AL-1635-5721 Crotch Absorber, HBND, X.3 Final Design

8 AL-1630-2156 Modified DN40 Flange Final Design

9 AL-1618-4579 Modified DN63 Flange Final Design 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 photon absorbers, the selected subcontractor is responsible for delivery the associated LCW fittings as illustrated in Table 5-3.

Table 5-3 Components that subcontractor will source or manufacture for the absorbers ID Features Illustration LBNL ID

Modified

DN40 Flange

AL-1630-2156

Modified

DN63 Flange

AL-1618-4579

Fitting 8mm x 6mmOD

HW-1000-6922

Bored Thread

Fitting

AL-1630-1624

5.1.3.2 FIRST ARTICLE

The selected subcontractor must produce AL-1636-0076 Crotch Absorber, ID, Non-

WIGGLER, quantity 1, as first articles.

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Table 5-4: First articles

5.1.3.3 PRODUCTION

Table 5-5 list the production articles and the respective quantities. The quantities include spares as determined for each variant by LBNL. The delivery order and batches can be proposed by the subcontractor otherwise full delivery in a single shipment applies.

Table 5-5: List of production articles

Id Drawing ID Description Qty Due Date

1 AL-1636-0076 Crotch Absorber, ID, Non-WIGGLER 9

30 weeks After First

Article Approval

2 AL-1637-3574 Crotch Absorber, ID, WIGGLER 2

3 AL-1468-1176 Crotch Absorber, Standard, X.1 7

4 AL-1633-8716 Crotch Absorber, HBND, X.2 4

5 AL-1635-5870 Absorber MASK 7

6 AL-1633-6274 Crotch Absorber, Standard, X.3.X 8

7 AL-1635-5721 Crotch Absorber, HBND, X.3 4

Id 2D drawing Description Qty Due Date

1 AL-1636-0076 Crotch Absorber, ID, Non-WIGGLER 1 12 weeks

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5.2 Scope of work

5.2.1 Management and Quality plan

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

Quality Plan 7 days ARO. This must include an organizational policy on quality, controlled documents for Non-conformance, material inspection, and subcontractor qualification.

(see §8.1)

5.2.2 Final Design Review Requirements

A final design review is required once the subcontractor has completed the detail manufacturing design for all absorbers and tooling. The selected subcontractor must be responsible for supplying all documentations related to the FDR prior to fabrication of the Photon Absorbers. Documentations must take into account the photon absorbers engineering specification AL-1720-3468. CAD model and drawing requirements are dictated by LBNL document AL-1265-6612 (also see Appendix B).

The FDR is required to include of the following documentation:

1. Control Plan and Manufacturing plan for the Photon Absorbers

2. Final manufacturing drawings (if needed)

3. Final CAD model (if needed)

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 §8.3.

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Table 5-5: 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 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 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 must 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 §8.2 Control Plan for additional information.

5.2.4 First article delivery

The selected subcontractor will be responsible for the delivery of the first article to LBNL in accordance with the parameters provided within this document.

5.2.5 Complete Production

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 Photon Absorbers 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 the packing, shipping and delivery of the production units to LBNL in accordance with the parameters outlined in this document.

5.3 Final documentation package(s)

The selected subcontractor must provide a full and complete documentation package at the end of the production. Reference LBNL document AL-1265-6612 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 provide 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

§5.2.1 Kick-off Meeting 1 week ARO subcontractor

§0 Final Photon Absorbers design review (FDR) 6 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)

30 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 or delegate, 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.

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

DRAWING REQUIREMENTS, 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 must be delivered to the LBNL technical representative a minimum of 10 business days prior to the scheduled review.

6.5 Hold points

Table 6-2 Provides the list of control points. Additional control points may be identified following review of the Acceptance Criteria List.

Table 6-2 : List of hold points

Section Activity Control point Type

Work Contingent upon

NTP

§0 Closeout of FDR NTP First article fabrication §5.2.3 Approval of first article NTP Production fabrication §5.2.5 Approval of complete production NTP Production Delivery to

LBNL

Control point types are defined in §8.3.

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7 PACKAGING AND SHIPPING SPECIFICATIONS

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

7.1 Container

Containers or crates for the photon absorbers may be used for both shipping and storage.

Construction of the containers must be sufficient to adequately support and protect the

Photon Absorbers 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 Photon Absorbers. The crates must be strapped all around during shipment.

7.2 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 Photon Absorbers 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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7.3 Packaging

All photon absorbers including cooling channels must be free of any liquid prior to shipping. The use of desiccant is strictly forbidden.

The Photon Absorbers must be blocked/cribbed/supported to prevent movement or overstressing the component during transport. The following has to be include:

Each absorber needs to be assembled along with each associated LCW fitting, copper cooling tube loops, and stainless steel subcomponents, in accordance with their associated, FDR approved ASM drawings.

Placement of foam between the Photon Absorbers (if crate contain multiple Photon

Absorbers)

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

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

The packaging must be compliant with the Toxics in Packaging Prevention Act, AB-4551.

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

7.4 Handling and storage

The subcontractor must pay particular attention during phases of lifting operation to avoid damage on Photon Absorbers

Should the Photon Absorbers 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.

1 Reference: https://dtsc.ca.gov/toxics-in-products/toxics-in-packaging-law/ This AB 455 act prohibits intentional introduction of cadmium, lead, mercury, or hexavalent chromium, and/or incidental presence of those metals above 100 parts per million (ppm) by the combined weight of all of the above metals.

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8 QUALITY ASSURANCE

The Photon Absorbers must have a quality assurance plan to be followed from the first unit built through production

The selected subcontractor must provide a single point of contact for Quality Items. This may be the project manager or another individual.

8.1 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.

Project-Specific Procedures: The quality plan must 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 must include Control Plans (see §8.2), inspection reports, non-conformance reports (see

§8.5), deviation request (see §8.4) and corrective action plans.

8.2 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 B: Control plan and applicable document in §9).

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.

8.3 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.

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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.

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 ci al ly R el ea se d to th e

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8.4 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.

8.5 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 within 1 week. No operations may be performed on the nonconforming item without LBNL’s written disposition or approval to proceed.

8.6 Numbering and/or Serialization

Each SR Photon Absorbers must be serialized. The following indicate the methodology of serialization

Designation Serialization

AL-1636-0076

AL-1636-0076-0001

AL-1636-0076-0002

AL-1636-0076-0003

AL-1304-7560-0006

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

Figure 8-1: Location of the serialization

8.7 Completed ACL

The subcontractor must provide a completed ACL to LBNL technical representative before shipping each SR Photon Absorbers. The ACL shows that the following requirements are validated:

1. Visual Inspection

2. CMM measurement after bakeout

3. Water Pressure Test

4. RGA scan

5. He leak test

6. 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-1720-3470.

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9 APPLICABLE DOCUMENTS

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

Table 9-1: Applicable documents ID Document ID Title

1 AL-1720-3468A SR Photon Absorbers Engineering Specification 2 AL-1720-3470A SR Photon Absorbers ACL 3 AL-1220-7841F UHV Chamber and Component Production Requirements 4 AL-1405-1295A Control plan template 5 AL-1265-6612B ALS-U Build to Specification CAD Model and Drawing Requirements 6 AL-1636-0076B Crotch Absorber - ID, Non-WIGGLER 7 AL-1637-3574B Crotch Absorber - ID, WIGGLER 8 AL-1468-1176C Crotch Absorber - Standard, VC06, X.1

9 AL-1633-8716B Crotch Absorber - HBND, VC08, X.2

10 AL-1635-5870B Mask Absorber

11 AL-1633-6274B Crotch Absorber - Standard, VC09, X.3.X

12 AL-1635-5721C Crotch Absorber - HBEND, VC10, X.3

13 AL-1686-4651A SCREW, ULTRA LOW PROF, M4X0.7X6 LG, 316 SS

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APPENDIX A: CONTROL PLAN

Extract of the control plan to be completed by the subcontractor ci al ly R el ea se d to th e

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APPENDIX B: CAD MODEL AND DRAWING REQUIREMENTS

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

1. All dimensions are to be in millimeters.

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

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

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

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

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

Units (International System of Quantities).

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

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

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

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

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

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

Parametric software. The preferred format is Creo Parametric (check with LBNL for current version). Consumable in this context means when imported into Creo ci al ly R el ea se d to th e

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

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

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

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

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

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

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