3) AL-1416-9212A ALS-U - IDBL White Beam Slit and Pink Beam SOW.pdf

SOW: ALS-U, IDBL White Beam Slit and Pink Beam

Slits & Screens

Release Date: Jul 17 2024 10:57:55 AM PDT

Document Number: AL-1416-9212 Revision: A

Document Status: Released

Document Type: ACCEPTANCE CRITERIA LIST (ACL)

Category Code: AL7820

ALS-U - INSERTION DEVICE BEAMLINES

BEAMLINES

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Advanced Light Source Upgrade Project Lawrence Berkeley National Laboratory

All officially released LBNL documents are watermarked and contain LBNL Document

Control Center release information in the lower-left corner of the document's pages.

Printed hard copies of this document are for reference only.

Table of Contents

1 Revision History

2 Approvals

3 Abbreviations and Acronyms

4 Applicable Documents

5 Introduction

5.1 Project Overview

5.2 Scope of Work

5.3 Roles and Responsibilities

6 Deliverables and Schedule

7 Management

7.1 Kick-off meeting

7.2 Reporting/Communication requirements

7.3 Documentation requirements

7.4 Reviews

7.5 Control points

8 Engineering

8.1 General Requirements

8.2 Preliminary Design File

8.3 Analysis

8.3.1 Thermo-mechanical

8.3.2 Modal

8.3.3 Radiation Line of Sight Analysis

8.3.4 Seismic safety

8.4 Final Design File

9 Fabrication

9.1 Documentation packages

10 Shipping

11 OSAT

12 Quality Assurance

12.1 Quality reporting requirements

12.1.1 Subcontractor quality program

12.1.2 FEA

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12.1.3 Deviation requests

12.1.4 NCR

12.2 FATP

12.3 ACL

13 Standards and Codes

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 Elaine DiMasi ALS-U BOSS System Manager Shrenik Shah ALS-U BOSS IDBL Control Account Manager Maxime Bergeret ALS-U BOSS IDBL Technical Lead

3 ABBREVIATIONS AND ACRONYMS

ACL Acceptance Criteria List ALS-U Advanced Light Source Upgrade ANSYS Analysis Systems Inc.

ARO After Receipt of Order BOM Bill of Materials CAD Computer-Aided Design COSMIC Coherent Scattering and Microscopy (Beamline) FAT Factory Acceptance Test FATP Factory Acceptance Test Plan FATR Factory Acceptance Test Plan Report FDPR Final Documentation Package Review FDR Final Design Review FEA Final Element Analysis FEM Final Element Model HP Hold Point HPN2 High Purity Nitrogen – dry gas IDBL Insertion Device Beamlines LBNL Lawrence Berkeley National Laboratory MAESTRO Microelectronic And Electronic Structure Observatory (Beamline) NA Not Applicable NCR Non Conformance Report NTP Notice to Proceed ci al ly R el ea se d to th e

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NP Notification Point OSAT Onsite Acceptance Test QAP Quality Assurance Plan SOW Statement of Work TS Technical Specification UHV Ultra-High Vacuum W Witness ci al ly R el ea se d to th e

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4 APPLICABLE DOCUMENTS

This section identifies applicable documents that are considered to be a part of this document. All information contained in an applicable document shall be valid to the full extent, unless specifically noted within this document.

Number Rev. Title

27K813 C HEYS NEST FIDUCIAL POST

29E064 C COMPACT FIDUCIAL POST

M7957A A ALS Beamline Coordinate Systems

AL-1009-9880 B ALS-U Units Definition AL-1208-0209 C ALS-U supplier quality evaluation survey

AL-1265-6612 B

ALS-U Build-to-Specification CAD Model and Drawing Requirements

AL-1502-6480 B FEA EN: FEA Engineering Note Template AL-1220-7841 F UHV Chamber and Component Production Requirements AL-1613-0852 A TS: ALS-U, White Beam Slit and Pink Beam Slits & Screens AL-1595-3412 C Drawing: MAESTRO 7.0.2 Pink Beam Slit/Screen Interface AL-1595-2995 C Drawing: COSMIC 7.0.1 White Beam Slit Interface AL-1595-3099 C Drawing: COSMIC 7.0.1 Pink Beam Slit/Screen Interface AL-1433-3831 B ACL: COSMIC White Beam Slit AL-1395-9008 A ACL: COSMIC Pink Beam Slit & Screen AL-1395-9025 A ACL: MAESTRO Pink Beam Slit & Screen

5 INTRODUCTION

5.1 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.

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5.2 Scope of Work

The scope of work outlines the manufacturing tasks necessary to deliver built-to-specification white and pink beam slits & screens for the ALS-U project. Project management, design, fabrication, control, shipping, and quality assurance tasks, as described in Section 7 through 12 below, must all be included in the required work.

The white beam slit and pink beam slits & screens are specified in the LBNL Technical

Specification AL-1613-0852.

The scope of work must include:

- Internals

- Vacuum chamber and components

- Motion stages

- Support structure for pink beam slits and screens

- Radiation shielding

- Patch panel and feedthroughs with wiring diagrams to connect the motors, the encoders, the switches, the temperature monitoring sensors, and drain current cables

- Bake out heaters

- Camera and lens system

Scope of work exclusions are:

- Motion control system and connecting cables

- Floor mounting plate (pink beam slits and screens) or stand mounting plate (white beam slit)

- Support structure for white beam slit

This procurement includes the white beam slit and pink beam slits & screens listed in

Table 2.1. The Subcontractor must provide a technical proposal for all diagnostics.

Table 2.1. List of all diagnostics in the scope of the work.

Beamline Label Type Qty.

COSMIC 7.0.1 AP101 White Beam Slit 1

MAESTRO 7.0.2 AP201/DIAG201 Pink Beam Slit and Screen 1 COSMIC 7.0.1 AP102/DIAG202 Pink Beam Slit Screen 1

5.3 Roles and Responsibilities

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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.

6 DELIVERABLES AND SCHEDULE

The Subcontractor must deliver the items summarized in Table 6.1. The milestones are for planning purposes, with the final negotiated timeline and schedule to be incorporated into the subcontract.

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Table 6.1. List of deliverables and due dates ARO in weeks (unless otherwise noted).

Due date ARO

Item Description MAESTRO COSMIC

001 Kick-off meeting 2 2

002 Initial schedule 2 2

003 Progress reports monthly monthly

CAD model with preliminary shielding

6 6

Shielding drawings, with modified CAD models and a list of design modifications, if applicable (LBNL)

14 14

PDR material – White beam slits and pink beam slits/screens (per section 7.4)

16 16

HP (LBNL action per Section 7.5)

HP date:

20 ARO

Final design file(s) (per section 8.4)

22 22

FDR material – White beam slits and pink beam slits/screens (per section 7.4)

24 24

HP (LBNL action per Section 7.5)

HP date:

28 ARO

Final documentation package (per section 9.1)

52 52

012 FDPR (per section 7.4) 54 54

Delivery to LBNL (shipping per section 10)

61 61

7 MANAGEMENT

The Subcontractor must provide all supervision, labor, materials, tools, testing equipment, and all other services to meet the requirements of this Subcontract.

7.1 Kick-off meeting

Upon award of the Subcontract, the LBNL technical representative will contact the

Subcontractor to set up a project kick-off meeting.

The Subcontractor must:

- Present its organization, the team assigned to this project and the initial schedule ci al ly R el ea se d to th e

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- Discuss a preliminary FATP (identifying measurement equipment for example)

LBNL will:

- Establish the requirements for communication

- Present the LBNL portal that will be used for data information exchange only and train the Subcontractor in its use

- Emphasize important aspects of the final design file(s) and expectations

7.2 Reporting/Communication requirements

The Subcontractor must assign a person responsible for the technical execution of the subcontract and its follow-up, as well as a person responsible for the administrative follow-up, throughout the duration of the subcontract. The Subcontractor must provide

English translations and/or a translator if needed.

LBNL reserves the right to visit the production site(s) to witness activities. In that situation, LBNL will coordinate with the Subcontractor prior to the visit.

The Subcontractor must conduct biweekly phone calls with the LBNL Technical Team responsible for the technical execution of the Subcontract. In addition, the Subcontractor must send a progress report monthly, to be submitted by the 5th of each month. The report must include:

- Actual progress in comparison with the schedule

- Issues encountered, solutions proposed, and responsible party

- Information about any risks in failing to fulfil the requested quality or schedule

- Other reports or data as requested by LBNL

- Action item tracking

7.3 Documentation requirements

Upon Subcontract award, a Windchill Project portal will be established by LBNL and access provided to the Subcontractor. Windchill will be used as the repository for all documentation, QA data, certificates of conformance, test results, models, and drawings.

An electronic copy of all required documentation noted in this document is required and must be transmitted to LBNL via the designated Windchill portal. LBNL document AL-

1265-6612: ALS-U BUILD TO SPECIFICATION CAD MODEL AND DRAWING

REQUIREMENTS, identifies the acceptable file formats and requirements for the final drawings and CAD models.

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Acceptable document formats include .docx, .xlsx, and other editable Office file formats or as noted in this document.

The Subcontractor must comply with professional and/or LBNL’s standards/codes in matters of document editing, design/drawing process, design reviews and approval, naming conventions and tagging, quality assurance/control, etc. The Subcontractor may propose other design standards, subject to prior written approval by LBNL. LBNL reserves the right to disallow the use of certain codes or norms.

7.4 Reviews

The LBNL Technical Representative will work with the Subcontractor to establish an appropriate timeline and location for all reviews. At the discretion of LBNL, reviews may be conducted at either the Subcontractor’s or the LBNL sites, or via web/video conference tools. External, non-LBNL reviewers may be included with 5 days advance notification to the Subcontractor. Acceptable document formats include .docx, .xlsx, and other editable

Office file formats or as noted in this document.

For all white and pink beam diagnostics, the following reviews are required:

- PDR: Ten weeks after receipt of the preliminary design file(s) by LBNL, the

Subcontractor will organize a technical review. The review must cover all deliverable items included in the preliminary design file(s). A check list of files will be provided by LBNL for the Subcontractor to fulfill and a Powerpoint presentation must be developed by the Subcontractor for the technical review meetings.

- FDR: Two weeks after receipt of the final design file(s) by LBNL, the Subcontractor will organize a technical review. The review must cover all deliverable items included in the final design file(s). A check list of files will be provided by LBNL for the Subcontractor to fulfill and a Powerpoint presentation must be developed by the Subcontractor for the technical review meetings.

- FDPR: Two weeks after receipt of the final documentation package by LBNL, the

Subcontractor will organize a review. The review must cover all deliverable items included in the final documentation package. A check list of files will be provided by LBNL for the Subcontractor to fulfill and a Powerpoint presentation must be developed by the Subcontractor for the technical review meetings.

7.5 Control points

The following definitions apply in this document:

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NP: The Subcontractor must notify LBNL before proceeding to an activity at least 3 weeks in advance. LBNL reserves the right to visit the production site(s) to witness the activity.

NP’s do not affect the schedule.

W: LBNL will visit the production site(s) to witness the activity. The activity must not be performed without a LBNL representative or without a written NTP. The Subcontractor must notify LBNL before proceeding to the activity at least 3 weeks in advance. If LBNL delivers an NTP, the Subcontractor may proceed with the activity.

HP: The Subcontractor must not proceed beyond a HP without a written NTP. After completion of an activity marked with HP:

- When LBNL delivers an NTP, the Subcontractor may proceed with the following activity

- If LBNL rejects the deliverables of the activity marked with HP, the Subcontractor must propose a recovery plan within 2 weeks from the date of the rejection

8 ENGINEERING

The Subcontractor must design slits and screens that meet all performance, interface, and integration requirements as specified in the LBNL Technical Specification AL-1613-0852.

Several analyses must be performed, as listed in Section 8.3.

8.1 General Requirements

It is the responsibility of the Subcontractor to guarantee that the final system will meet all requirements in AL-1613-0852 and other relevant documents.

8.2 Preliminary Design File

Activity (Hold point)

Type of control point

Next activity (Upon HP completion)

Review and Acceptance of the preliminary design files and successful

PDR for all slits and screens HP After NTP, Final Design of all slits and screens may start

Review and Acceptance of the final design files and successful FDR for all slits and screens

HP

After NTP, Fabrication of all slits and screens may start

FAT for all slits and screens W Acceptance of the final documentation package and successful FDPR for all slits and screens

HP Shipping

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In Preliminary design, the subcontractor must provide a preliminary CAD model that aligns to the radiation shielding requirements as closely as possible. LBNL may provide examples of previous successful designs and offer guidance to the subcontractor during this phase. Upon receipt of the preliminary design package from the subcontractor, LBNL will generate radiation shielding drawings per LBNL standards, which may require design modifications. If design modifications are needed, LBNL will update the subcontractor's design in CREO Parametric after consultation to confirm feasibility. All modifications will be justified and reasonable to meet shielding requirements. LBNL aims to complete this work within 8 weeks for all diagnostics, and return to the Subcontractor a CAD models that meets the shielding requirements with a list of design modifications.

Afterward, the Subcontractor shall incorporate the design modifications, and provide the

Preliminary Design Files for review, which must include the CAD models, with the design modifications requested by LBNL. Finally, the Subcontractor shall prepare for a technical review as mentioned in Section 7.4. Only after a successful PDR is achieved, LBNL will provide a written NTP at which point the Subcontractor must initiate the final design activities.

8.3 Analysis

The Subcontractor must generate detailed analysis and FEA during the engineering phase with primary emphasis given to the use of the ANSYS Workbench platform:

All FEM must have the appropriate level of detail, including materials, geometries, boundary conditions, and mesh. The results must meet the requirements listed in AL-

1613-0852, or provide a redesign to satisfy these requirements. The Subcontractor must deliver its analysis according to LBNL FEA QA process in Section 12.1.2. LBNL reserves the right to reject a FEM by providing the technical justification for rejection. In this situation, the Subcontractor shall resubmit the deliverables in 2 weeks.

8.3.1 Thermo-mechanical

The thermo-mechanical analysis must demonstrate that each blade can withstand the full beam power loads as specified by LBL in the technical specification. The power load must be applied at the worst-case location, and LBNL reserves the right to request analysis at another location.

The thermo-mechanical analysis must show that the materials will survive with a margin of 1/3 of the material’s melting temperature. Thermal induced stresses must also not exceed 75% of yield stress limits for each material

8.3.2 Modal

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The Subcontractor shall perform modal analyses to determine the eigenfrequencies and the mode shapes of the internal mechanics, the actuator drives and the support structure up to 400 Hz, and demonstrate that the requirement 0006 in AL-1613-0852 is met.

8.3.3 Radiation Line of Sight Analysis

The Subcontract should perform a ray trace analysis of any line-of-sight between the beam and personnel. It should demonstrate that the chamber protects personnel from scattered synchrotron radiation with a minimum stainless steel equivalent thickness as listed in the Technical Specification.

8.3.4 Seismic safety

Using analytical and/or numerical methods, the Subcontractor must evaluate the seismic loads and perform stress analysis on critical hardware components. These analyses must demonstrate adequate safety margins, which mitigate the risk of damaging the equipment mechanics in the event of an earthquake due to geological activity near California’s

Hayward Fault. The seismic load requirements specified by the building code for the ALS is high, typically around 0.37 g-force vertically and 1.00 g-force laterally, in any direction.

Subcontractor must use these values in the seismic calculations. LBNL will assist the

Subcontractor in defining the seismic load requirements and provide clarifications if needed.

8.4 Final Design File

Following approval of the preliminary design, the Subcontractor shall finalize the design.

Any changes impacting radiation shielding must receive prior approval from LBNL.

The Subcontractor must deliver the final design file, which must include:

- All analyses per Section 8.3

- CAD models and preliminary fabrication drawings

- The welding procedure specification for all welds

- BOM

- UHV system specification, with list of all materials (and surfaces) in UHV

- Bakeout heaters and thermocouples specification

- Motion stage specification

- Full documentation of electrical hardware and wiring

- Seismic safety parameters ci al ly R el ea se d to th e

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- FAT Plan

After submission of the final design files, Subcontractor shall prepare for a technical review as mentioned in Section 7.4.

9 FABRICATION

Only after a successful FDR is achieved, LBNL will provide a written NTP at which point, the Subcontractor must initiate the material procurement and fabrication activities.

During fabrication, the subcontractor must provide the dimensional results reports of all shielding parts, as well as the material certifications. Any proposed changes to the final design must be communicated to LBNL for approval, and once approved, these modifications should be captured in as-built drawings.

9.1 Documentation packages

The Subcontractor must deliver the documentation packages (separate files) for each white and pink beam diagnostic before shipping to LBNL. It must include:

- Documentation related to all control points

- As-built CAD models and drawings

- As-built BOM

- Slit DoF Equation and Calibration

- List of modifications made to final design file

- FATR

- NCR (as applicable)

- Completed and signed QAP per Section 12

- Deviation requests (as applicable)

- Shipping plan per Section 10

10 SHIPPING

The Subcontractor must start shipping activities after receiving the NTP from LBNL allowing shipping. The Subcontractor must be responsible for shipping all diagnostics to

LBNL according to the requirements listed in AL-1220-7841, with special attention to:

- Slit blades and screen optical surfaces must be protected and not come in contact with any materials ci al ly R el ea se d to th e

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- The chamber with internal mechanics must be sealed and backfilled with HPN2

The Subcontractor must submit a shipping plan in the final documentation package. It must include detailed information about the packaging, the crates or other containers and the marking, in accordance with the following requirements:

- The shipping containers must be reusable (e.g. 4-panel hinged crates)

- All shipping container materials must meet or exceed the quality standards for

Wood Groups II, III, or IV per ASTMD6199

- The shipping containers must have markings that clearly indicate tie-downs, mass or weight

- The shipping containers must have markings that clearly indicate the presence of fragile contents

- The contract information must be attached to the exterior of the shipping container

- The white and pink beam diagnostics must each be shipped with a transport data logger to record: shock, tilt, temperature, and humidity. These must be directly mounted onto their respective support structure or vessel. These must have adequate battery life to cover the data logging for the duration of the transport.

- The shipping containers must have soft-adhesive shock indicators (e.g.

Shockwatch®) inside and outside

Shipping must comply with any regulations, in particular with customs. LBNL may approve the shipment of more than one diagnostic in a shipping container after review of the shipping plan.

LBNL reserves the right to perform an evaluation of hardware, documentation, and shipping methods at the Subcontractor’s production site prior to authorizing shipment.

11 OSAT

LBNL will plan, organize, and will execute OSAT within 8 weeks after delivery of the white and pink beam diagnostics, and will then complete and sign the ACL. The Subcontractor must follow up and provide remote assistance if needed.

After OSAT, if LBNL rejects deliverables, the Subcontractor must propose a recovery plan within 2 weeks from the date of the rejection.

12 QUALITY ASSURANCE

12.1 Quality reporting requirements

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12.1.1 Subcontractor quality program

The Subcontractor must complete the ALS-U Supplier Quality Evaluation Survey AL-

1208-0209. The Subcontractor must maintain and apply an effective QAP for the design, manufacture, testing of all systems and equipment provided. Post-award surveys may be required and must be supported.

12.1.2 FEA

The Subcontractor’s analysts must abide by the LBNL FEA QA process. It requires two steps:

- Reporting: The analysis must be reported using the FEA engineering note template AL-1502-6480 provided by LBNL. The report audits the geometries, the materials, the mesh, the parameter loads, and the results and acceptance criteria.

The conclusion must answer the FEA goals listed in Section 8.3. The report must provide all relevant information so that LBNL can fully understand and assess the study. In addition to written reports, the analysts must prepare technical presentations for FDR.

- Archiving: The archives should be self-explanatory and include all files and FEM used by the analysts. The analysts must strive to document all files and FEM, for example “README” files may encompass configuration, installation, operating or troubleshooting instructions if deemed necessary. Finally, the analysts must gather all files in one folder, zip it and import it in Windchill where indicated by LBNL.

12.1.3 Deviation requests

Any deviations from the dictating LBNL documents must be requested by the

Subcontractor and approved by LBNL prior to implementation. LBNL will provide a standard deviation request form however, a Subcontractor’s existing, or internal document may be utilized with prior written 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.

12.1.4 NCR

A NCR provides a summary for products or procedures which do not conform to the defined requirements. NCR may be determined and reported by either the Subcontractor or LBNL staff. LBNL will provide a standard NCR form however, a Subcontractor’s ci al ly R el ea se d to th e

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All officially released LBNL documents are watermarked and contain LBNL Document existing or internal document may be utilized with LBNL approval. NCR are to be submitted to LBNL within 3 business days of the identification.

NCR 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.

12.2 FATP

The Subcontractor must provide a FATP which must be submitted to LBNL for written approval. This FATP must consist of a plan in the Subcontractor’s format listing components, subassemblies, and assemblies; identifying inspections and tests planned for the verification of quality; and identifying documentation/planning for recording the results. The FATP must be derived from the requirements listed in AL-1613-0852.

12.3 ACL

As listed in Section 4, dedicated ACLs have been drafted by LBNL which list the criteria for satisfactory receipt of each diagnostic.

13 STANDARDS AND CODES

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.

Number Title

ASTMD6199

Standard Practice for Quality of Wood Members of Containers and Pallets

ISO 90001:2000 Quality management systems — Requirements Title 24 California Building Code ci al ly R el ea se d to th e

LB

N L

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D C

C A ut h

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: T Q

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