3) AL-1685-4598B HBEND SOW.pdf

Statement of Work for the ALS-U Storage Ring HBEND

Magnets

D. Munson, P. Wehle

Release Date: Sep 12 2024 1:03:02 PM PDT

Document Number: AL-1685-4598 Revision: B

Document Status: Released

Document Type: NOTE

Category Code: AL7510

ALS-U - STORAGE RING

MAGNETS - GENERAL

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Advanced Light Source Upgrade Project Lawrence Berkeley National Laboratory

All officially released LBNL documents are watermarked and contain LBNL Document

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

Printed hard copies of this document are for reference only.

Table of Contents

Revision History

Approvals

Abbreviations and Acronyms

1 Introduction

1.1 Project overview

1.2 Description of items

2 Scope of Work

2.1 Work Packages

2.2 Schedule

2.3 LBNL-provided tooling (Work Package 1 only)

3 Deliverables

3.1 List of items

3.2 Magnet core design verification (Work Packages 1 and 2)

3.3 Work Package 1: HBEND production assemblies

3.4 Work Package 2: Magnet core assemblies only

3.5 Closeout Checklist

4 Project Administration

4.1 Roles and responsibilities

4.2 Reporting / communication requirements

4.3 Documentation requirements

4.4 Reviews

4.5 Hold points and what is required

5 Shipping, Handling, and Storage

5.1 Containers

5.2 Packaging

5.3 Storage

5.4 Shipping

6 Quality Assurance

6.1 Subcontractor quality program

6.2 Standard QA forms

6.2.1 Deviation requests

6.2.2 Nonconformance reports

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6.3 Required QA Data

6.3.1 Calibration data

6.3.2 Certifications

6.3.3 Mechanical inspection reports

6.4 Required inspections and testing

6.5 Magnet blocks and poles QA data

6.5.1 Magnet blocks QA data package

6.5.2 Poles QA data package

6.5.3 Magnetic measurement requirements

6.6 Acceptance criteria

7 Applicable Documents

Appendix A: Closeout Checklist

Appendix B: Storage Ring Multibend Achromat Sectors

Appendix C: Subcontractor Data Requirements List

REVISION HISTORY

Rev. CM Number Description of Change A Initial Release

APPROVALS

Approver Project Role

Ken Chow ALS-U Chief Engineer

Sol Omolayo ALS-U Magnets Control Account Manager

Charles Swenson ALS-U Magnet Design Technical Lead

Dawn Munson ALS-U Lead Technical Representative

Windchill Approved / Concurred By

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ABBREVIATIONS AND ACRONYMS

ACL Acceptance Criteria List

ALS Advanced Light Source

ALS-U Advanced Light Source Upgrade

ARO After Receipt of Order

ARR Assembly Readiness Review

CoFe Cobalt iron

FAT Factory Acceptance Test

HBEND “Hard Bend” Permanent Magnet Dipole Bending Magnet

LBNL* Lawrence Berkeley National Laboratory

MRR Manufacturing Readiness Review

NCR Nonconformance Report

NdFeB Neodymium Iron Boron

PM Permanent Magnet

QA Quality Assurance

QC Quality Control

SOW Statement of Work

University* The Regents of the University of California

*For the purposes of this SOW, the terms University and LBNL are used interchangeably.

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1 INTRODUCTION

1.1 Project overview

Lawrence Berkeley National Laboratory’s (LBNL’s) Advanced Light Source (ALS) is an electron storage ring-based synchrotron radiation facility that generates extremely bright beams of light – ranging from infrared through x-rays – that are used to conduct basic, applied, and industrial research. The ALS has been in operation since the early 1990s, and its present-day capability is the result of a series of modernization projects. In its current configuration, the ALS complex can support an array of up to 40 simultaneously operating beamlines and associated instrumentation, and includes an experimental hall, computing resources, and ancillary laboratories.

The objective of the current ALS Upgrade Project (ALS-U) is to achieve an increase in the brightness and coherent flux of soft x-rays by at least two orders of magnitude by replacing the storage ring and installing new arrays of much more powerful magnets. The resulting more sharply focused light will enable entirely new ways of conducting research in such areas as materials science, biology, chemistry, physics, and environmental sciences. Once completed, the upgrade will position the ALS at the forefront of this type of particle accelerator capability.

1.2 Description of items

The purpose of this statement of work (SOW) is to define the multiphase process for the manufacturing, assembly, inspection, and testing work to produce the “Hard Bend”

(HBEND) permanent magnet (PM) dipole bending magnets, which will be manufactured as build-to-print components.

The HBEND magnet type is designed to provide a nominal 3.76-degree bend angle to the electron beam at energies between 1.9 and 2.0 giga electron volts (GeV) in the new ALS-U storage ring configuration. The HBEND design allows the magnetic field strength to be adjusted by varying the amount of magnetic flux entering the magnet poles. This is accomplished mechanically by moving axial PMs made of neodymium iron boron

(NdFeB) with respect to the stationary upper and lower magnet core assemblies by means of a drive system. The stationary magnet core assemblies are composed of a tapered cobalt iron (CoFe) magnet pole piece around which an array of NdFeB core PM blocks is epoxy bonded.

Figure 1-1 shows the fully assembled HBEND magnet in the 2.0 GeV position, in which the axial magnets are in close proximity to the upper and lower magnet core assemblies.

(The axial magnets are located behind field clamps that shield surrounding magnets from magnetic fields.) Figure 1-2 illustrates the location of the upper and lower core assemblies.

The figures in Appendix B show where the HBEND magnets will be located in Sectors 4, 8, and 12 of the new ALS-U storage ring configuration.

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Figure 1-1 HBEND magnet with field clamps in place.

The drive system moves the axial magnets (not shown) to adjust the magnetic flux.

Figure 1-2 Vertical mid-line cross-section of the upper and lower magnet core assemblies (circled in red). Each core assembly is composed of a central CoFe pole piece and three different shapes of NdFeB PM blocks.

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2 SCOPE OF WORK

2.1 Work Packages

The scope of work is defined by Work Package 1 and Work Package 2.

The scope of work for each work package is as follows:

1. Work Package 1 includes magnet core assembly design verification, production of

8 of these assemblies, and production of 8 HBEND full assemblies into which the magnet core assemblies will be integrated. Deliverables for Work Package 1 are summarized in Table 3-1.

2. Work Package 2 focuses on magnet core assemblies only. Like Work Package 1, this scope of work includes magnet core assembly design verification, but the production work is limited to producing only the magnet core assemblies.

Deliverables for Work Package 2 are summarized in Table 3-2.

The work is to be completed as specified in this SOW and the technical specification document listed in Section 7. Data and documentation requirements are summarized in

Appendix C.

2.2 Schedule

Deliverables for each work package are due as follows after receipt of order (ARO):

Table 2-1 Projected delivery requirements.

Deliverable Delivery due ARO (months)

Work Package 1 20

Work Package 2 14

2.3 LBNL-provided tooling (Work Package 1 only)

Specialized tooling is required to manage magnetic forces in the assembly and magnetic testing of the fully assembled HBEND unit. LBNL will provide items LBNL.A through

LBNL.D in Table 2-2 for this purpose. This tooling cannot be modified without written approval from LBNL and must be returned to LBNL for the successful closeout of the subcontract. Item LBNL.E is provided to test the drives in the HBEND assembly (the complete drive system will be installed at LBNL).

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Table 2-2 LBNL-owned hardware required to be used in producing HBEND magnet assemblies

Label Work Package 1 Tooling and Test Equipment Description Applicability

LBNL.A HBEND splitting tooling AL-1473-5582

Work Package 1

LBNL.B Field harmonic adjustment tooling TBD

LBNL.C Field shunt tooling TBD

LBNL.D Tuning magnet installation tooling TBD

LBNL.E Complete motor controls chassis, cables, and software TBD

3 DELIVERABLES

3.1 List of items

The required deliverables for Work Package 1 are listed in Table 3-1 and the required deliverables for Work Package 2 are listed in Table 3-2.

Associated documentation requirements are described in Sections 3.2 through 3.5, Appendix C, and Section 7, Applicable Documents.

Table 3-1 List of deliverables for Work Package 1

Item No.

Work Package 1: HBEND magnet

(magnet core design verification and HBEND magnet production)

Qty Description

001 Document: Magnetic verification plan 1 TBD

002 UPPER MAGNET CORE ASSEMBLY- (verification) 1 AL-1208-2802

003 LOWER MAGNET CORE ASSEMBLY- (verification) 1 AL-1195-4932

004 Document: Detailed assembly process (core assemblies only) 1 TBD

005 HBEND FULL ASSEMBLY – FIRST ARTICLE 1 AL-1615-8572

006 HBEND FULL ASSEMBLY – PRODUCTION 7 AL-1615-8572

007 Work Package 1 Closeout Checklist 1 per Appendix A ci al ly R el ea se d to th e

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Table 3-2 List of Deliverables for Work Package 2

Item No.

Work Package 2: Magnet core assemblies ONLY

(magnet core design verification and production) Qty Description

001 Document: Magnetic verification plan 1 TBD

002 UPPER MAGNET CORE ASSEMBLY – (verification) 1 AL-1208-2802

003 LOWER MAGNET CORE ASSEMBLY – (verification) 1 AL-1195-4932

004 Document: Detailed assembly process (core assemblies only) 1 TBD

005 UPPER MAGNET CORE ASSEMBLY – PRODUCTION 8 AL-1208-2802

006 LOWER MAGNET CORE ASSEMBLY – PRODUCTION 8 AL-1195-4932

007 Work Package 2 Closeout Checklist 1 per Appendix A

3.2 Magnet core design verification (Work Packages 1 and 2)

The scope of work for both work packages includes verification of the upper and lower magnet core assembly design to ensure that magnetic properties meet technical specifications. This work effort will require close coordination with LBNL – from design analysis and adjustment (if needed) through intermediate and final testing and proof of concept. Exceptions to the technical specification or requirements must be detailed in

The Subcontractor’s proposal.

The Subcontractor must be able to propose design refinement(s) based on prior technical experience and analysis of magnetic fields and material properties. Any proposed modifications will be subject to LBNL review and approval.

A magnetic verification plan will be developed by the Subcontractor in coordination with

LBNL, subject to LBNL review and approval. Once LBNL approves design modifications

(if any), the Subcontractor will produce a complete magnet core assembly (upper and lower) and a document detailing the assembly process.

Once fully tested and verified, the core assembly will be integrated into the HBEND mechanical system at LBNL. LBNL will perform full magnetic testing and provide the results to the Subcontractor.

3.3 Work Package 1: HBEND production assemblies

The magnet core verification described in Section 3.2 must be completed before any

HBEND production work can begin. The LBNL-supplied tooling and equipment listed in

Section 2.3 must be used to produce the HBEND assemblies. The following five items are required for each delivery (deliveries may be split into batches per prior LBNL approval):

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1. Completely assembled and tested HBEND magnet(s) (full integration and testing of all mechanical and magnet core components)

2. The complete FAT report package for each unit

3. All applicable certificates and product data

4. All applicable nonconformance or deviation documentation, if any

5. Written approval from LBNL to proceed with shipping

3.4 Work Package 2: Magnet core assemblies only

The magnet core verification described in Section 3.2 must be completed before magnet core production work can begin. Deliveries may be split into batches per LBNL approval but must be shipped in matched sets. Each delivery of magnet core assemblies requires the following:

1. Completely assembled and tested magnet core assemblies (matched sets of upper and lower assemblies produced from the same material lot)

2. The complete FAT report package for each unit

3. All applicable certificates and product data

4. All applicable nonconformance or deviation documentation, if any

5. Written approval from LBNL to proceed with shipping

3.5 Closeout Checklist

At the time of the final delivery, the Subcontractor must submit the Closeout Checklist for the applicable work package in Appendix A to verify that all required deliverables have been provided and that any hardware supplied by LBNL has been successfully returned.

4 PROJECT ADMINISTRATION

4.1 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.

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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.

4.2 Reporting / communication requirements

1. Upon award of the subcontract, the University Technical Representative will contact the Subcontractor to set up a project kick-off meeting to establish communication requirements, including the use of the project portal that will be used for data exchange.

2. Project meetings are required to be held twice per month once production has begun, but the frequency of required meetings may be higher during the period leading up to production.

3. Written monthly schedule updates are required. The schedule must include lead times for components and materials, high-level production sequences of key components (e.g. actuators, magnetic core parts) and planned dates for shipment to LBNL.

4. Written monthly status reports are required and must include an explanation for schedule changes as well as a list of completed quantities of key components throughout the production sequence.

5. Site visits by LBNL personnel or a selected designee will be at the discretion of

LBNL and must include access to the site where the manufacturing and assembly work is performed.

6. Action item tracking is required. The Subcontractor must document action items in written form for all project meetings.

7. Other reports or data may be required by LBNL, as requested in writing.

4.3 Documentation requirements

Upon award of the subcontract, LBNL will establish a Windchill project portal to be used by the Subcontractor to both gain access to applicable documents and submit – in electronic format – all documentation required in this SOW, including Quality Assurance

(QA) data, certificates of conformance, test results, models, and drawings, as applicable.

Subcontractors performing work in a non-English speaking country: all documents must include an English translation and provide data that is represented in U.S. customary formats for dates (month/day/year) and numbers.

Acceptable document formats include .docx, .xlsx, and other editable Microsoft Office file formats, pdf format, image formats, and .txt or .csv for measurement data, as applicable.

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4.4 Reviews

The University Technical Representative will work with the Subcontractor to establish a timeline and location for reviews. Reviews may be conducted onsite (LBNL or

Subcontractor facilities) or via web/video conferencing. External (non-LBNL) reviewers may be included at LBNL’s discretion.

Work Package 1 requires the following full set of reviews. Work Package 2 requires only the applicable subset of each review type.

3. Manufacturing readiness review (MRR). The Subcontractor must provide an MRR package for LBNL review and approval before any fabrication or manufacture of magnet components can begin. At minimum, the MRR package must include:

a. Manufacturing schedule. The schedule should include all reviews and hold points identified in this SOW and any other milestone events.

b. Manufacturing plan. This plan must cover each phase of the work process.

c. Inspection and testing plan(s). Plans must include provisions for inspecting

HBEND components as described in Section 6.4.

d. Draft magnetic measurement plan. This plan must provide a description of the equipment that will be used for magnetic measurements and an outline of the measurements that will be taken for magnets:

i. At the component level (core PM blocks, axial PM blocks, pole pieces, and tuning magnets);

ii. At specific hold points during the production process; and

iii. At the subassembly and final assembly level.

e. Epoxy glue line sample. A glue line sample representative of the final result must be presented, along with a description of the QA process in place to ensure that glue lines are within the specified tolerance.

f. Paint sample with markings. The sample must consist of powder coat that conforms to LBNL paint specification 100681 and it must be applied to the material to be used for the production item. The paint sample must also include the type of markings required in the drawings.

4. Assembly readiness review (ARR). This review occurs prior to integration of the first magnet core assembly into a yoke assembly and must include the following:

a. Updated project schedule

1 LBNL paint specification 10068 is listed in the technical specification document.

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b. Proposed changes or modifications to LBNL-supplied work instructions, if any

c. Proposed changes or modifications to assembly tooling, if any

d. Proposed lubricants and locking agents

e. Shimming plan

5. Factory acceptance test (FAT) procedures review. This review will be conducted at the Subcontractor’s site for the 1st article. The Subcontractor must demonstrate their test and inspection procedures and present, for LBNL review and approval, the report formats corresponding to the FAT report package.2

6. Shipping plan review. The Subcontractor must present, for LBNL review and approval, how their proposed container design, packaging, and shipping procedures meet the requirements in Section 5.

4.5 Hold points and what is required

This section includes all the hold points applicable to the production of the HBEND full assemblies, and all are required for Work Package 1. A subset of these hold points applies to Work Package 2, as summarized in Table 4-1.

Each applicable hold point requires LBNL’s written approval and notice to proceed.

Multiple hold points may be combined into one approval at LBNL’s discretion.

Requirements and specifications are defined in the Technical Specifications document

AL-1685-4599, QA requirements are listed in Section 6, and document deliverables are summarized in Appendix C.

Table 4-1 List of hold points applicable to each work package.

Options (choose only 1) Applicable Hold Points

Work Package 1 1 – 14 (ALL)

Work Package 2 1 – 5, 13, 14

1. Hold for raw material acceptance. Before ingots are made into magnets (pole pieces, core PM blocks, axial PM blocks, and tuning magnets), the Subcontractor must provide the following to LBNL for review and approval:

a. CoFe – for each ingot – a material test report, ring sample performance data, and traceability / assurance that the upper and lower pole pieces for each individual HBEND magnet will be made from the same ingot to ensure uniform magnetic characteristics.

2 Test and inspection demonstrations may be conducted over multiple site visits to accommodate different timelines for components.

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b. NdFeB – for each lot – a material test report and representative data in the form of graphs showing remanence (Br) and coercivity (HC) to demonstrate the material characteristics conform to the specifications in AL-1685-4599.

2. Hold for pole piece acceptance. Prior to beginning fabrication of a magnet core assembly (upper or lower), the Subcontractor must provide, for LBNL review and approval, a data package for each pole piece that includes:

a. Magnetic data, including a B-H curve

b. Verification of fiducialization points location

c. Mechanical inspection data per drawings

d. Verification that the upper and lower pole pieces are from same ingot

e. Heat cycle / annealing information

3. Hold for core PM block selection. Prior to beginning fabrication of a magnet core assembly (upper or lower), the Subcontractor must provide to LBNL mechanical inspection data per drawings for all core PM blocks (vertical, transfer, and trans pole) and magnetic measurements for each. Based on this data:

a. LBNL will specify which core PM blocks are to be used and may also specify the position of each core PM block within the magnet core assembly configuration.

b. LBNL will provide height specifications for the spacer block and vertical core PM blocks.

4. Hold for epoxy glue line thickness verification. The Subcontractor must provide photo evidence of all glue lines after the epoxy fully cures to demonstrate that the thickness of the epoxy glue lines falls within the specified tolerance for the first production of an article. LBNL will provide further requirements as needed thereafter.

5. Hold for LBNL approval of magnet core design verification. LBNL approval of the verification process and resulting core assembly and testing must be provided in a written notice before production work can begin on any additional assemblies.

6. Hold for axial PM block selection and configuration. Prior to bonding any axial PM block into an axial adjuster plate, the Subcontractor must provide the following QA/QC parameters for each axial PM block for LBNL review and approval:

a. Identification numbers

b. Mechanical inspection data per drawings ci al ly R el ea se d to th e

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c. Remanence and magnetization vector

Based on this data, LBNL will provide the axial PM block configuration for the axial adjustment plates.

7. Hold for tooling modification approval (if needed). No modifications can be made to any LBNL-provided tooling without prior LBNL review and approval of proposed changes. If alternative tooling is proposed, the design must first be reviewed and approved by LBNL.

8. Hold for final mid-plane block height approval – 1st article. Prior to the final grinding of the mid-plane block thickness (yoke midblock-1 and -2), the

Subcontractor must provide, for LBNL review and approval, mechanical inspection data for the 1st article core-yoke assembly, along with a proposal for the final mid-plane block height thickness. Based on these measurements and the proposal, LBNL will provide direction and/or approval for the 1st article. Approvals for subsequent units will be at LBNL’s discretion.

9. Hold for verification of magnet core assembly alignment within the yoke. Prior to test integrating the upper and lower HBEND assemblies, the

Subcontractor must provide, for LBNL for review and approval, fiducialization / alignment data to validate the mechanical position of each magnet core assembly with respect to its assigned yoke assembly.

10. Hold for magnetic field performance verification (after magnet core assembly-yoke integration). Prior to installing any tuning blocks into a carrier assembly, the Subcontractor must provide field harmonic measurements to allow final adjustment of the B1 dipole harmonic and the A2 skew quadrupole harmonic.

Once the values are provided, required adjustments will be made via the tuning block or ferromagnetic shimming.

11. Hold for on-site magnetic measurement verification – 1st article. Once the 1st article HBEND magnet is fully assembled, the Subcontractor must provide an on-site verification and demonstration of the magnetic field harmonics measurement. Subsequent on-site magnetic measurement verification will be at

LBNL’s discretion.

12. Hold for 1st article shipment approval. Shipment of the 1st article can only commence after LBNL has reviewed and approved the shipping plan and the FAT report and documentation package for the 1st article.

13. Hold for production batch shipment approval. Shipment of any items may only occur after the Subcontractor has submitted the FAT report and documentation packages for all batch deliverables and LBNL has reviewed them and approved shipment.

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14. Hold for subcontract closeout. Closeout requires that the Subcontractor complete and submit the applicable Closeout Checklist in Appendix A.

5 SHIPPING, HANDLING, AND STORAGE

LBNL requires that the design of all packaging materials, containers, crates, as well as the shipping plan for each shipment be submitted to LBNL for review and approval. No item may be shipped before written authorization is issued by LBNL as specified. Once items are shipped, additional communication requirements apply as described in Section 5.4

5.1 Containers

The design for any container that will be used to package or ship items must be submitted to LBNL for review and approval before fabrication of the container may begin. The level of design detail provided must be sufficient to recreate or repurchase additional containers of the same type, if needed.

Container requirements are:

1. The container must be constructed of materials that meet or exceed the quality standards for Wood Groups II, III, or IV per ASTM D6199 – Standard Practice for

Quality of Wood Members of Containers and Pallets.

2. The design and construction must allow for air shipment.

3. All containers must consist of a base structure that is capable of being transported with a standard forklift on at least two sides of the container.

4. Containers are to be reusable with sides that attach using clips or other standard attachments that allow for ease of disassembly and/or reuse.

5. Each container must be constructed so that it fully supports and protects each item throughout storage and shipping, and the container must fully enclose the item.

6. The item must be secured to the base pallet or skid in a manner that will prevent shifting during transport.

7. An appropriate shock detection device – such as Shockwatch® – must be affixed to each container.

The design for the exterior of all containers must include the following markings and information:

a. A label with all required identifying information, including the subcontract number, University Technical Representative contact information, and delivery address;

b. Arrows indicating the appropriate container orientation;

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c. Markings that clearly identify tie-down points, lifting points, and the container’s center of gravity;

d. Clear and obvious labels that indicate the contents are fragile and, if the container includes monitoring equipment, that must be noted;

e. Serial or identification numbers of the components contained therein.

f. Shipments that originate from a country with an official language other than

English: include pictorial instructions or labels written in both English and the language from the point of the shipment’s origin.

5.2 Packaging

All packaging design must be submitted to LBNL for review and approval before items are packaged. Each assembly must be blocked/cribbed/supported to prevent movement or overstressing components during transport.

Packaging requirements include:

• The use of desiccant in magnet packaging is strictly forbidden.

• Foam packing material must be placed between the magnet / pole components to ensure there is no interaction between the cores or other hardware during shipment.

• Cribbing must be placed between the magnet and the sides of the container to minimize movement during transportation.

The shipping container should incorporate a moisture barrier to prevent condensation during air shipment.

Packaging must be compliant with the Toxics in Packaging Prevention Act, AB-4553.

5.3 Storage

Should items require storage, the storage location must be a temperature and moisture controlled, secured storage facility. Acceptable ambient air temperature during storage is between 5◦ and 40◦ C, with the humidity level remaining below 85%. Items must be stored in such a way as to be fully sheltered from any natural or manmade conditions that may cause damage. This shelter requirement also applies for shipping containers should items require storage once they have been packaged.

3 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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5.4 Shipping

Mishandling of a magnet assembly can result in excessive loading that may be catastrophic to the shipping container and/or magnet assembly. The worst hypothetical accident condition (HAC) is anticipated to be a 0.3 meter drop onto an unyielding surface.

• When transported by road, fragile items must be transported on air ride trailers with the air ride feature engaged.

• The shipping container must be secured in the transportation vehicle at a minimum of two mounting locations in such a way that prevents the container’s movement or tilting.

• LBNL arrival logistics requirements:

1. If the truck utilized for the final delivery at LBNL exceeds a length of 40 feet, LBNL must be notified in advance for approval.

2. The Subcontractor must share the LBNL shipping and storage specifications with the contracted transportation company.

3. The following information must be provided to the University Technical

Representative to finalize delivery logistics:

a. Contact information for delivery drivers;

b. 24 hours prior to arrival, the driver must provide an arrival window to ensure coordination logistics with the driver and at LBNL;

c. Upon arrival in Berkeley, CA, the driver must call to allow for coordination of logistics at LBNL.

6 QUALITY ASSURANCE

All requirements described in this section apply to Work Package 1 (which includes production of HBEND full assemblies). A subset of these requirements applies to Work

Package 2 because only the magnet core assemblies will be produced: refer to assembly identifiers and their associated parts and subassemblies.

6.1 Subcontractor quality program

The Subcontractor must apply and maintain the QA program that LBNL has deemed effective for this procurement based on the Subcontractor’s response to the ALS-U

Supplier Quality Evaluation Survey (AL-1208-0209).

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If requested, the Subcontractor must provide additional information regarding aspects of their QA program relevant to this SOW. Upon review, LBNL may deem that reasonable additions or modifications to certain QA processes are necessary, and post-award surveys may be required and must be supported by the Subcontractor.

6.2 Standard QA forms

6.2.1 Deviation requests

A deviation request applies to any request that seeks to modify a process, document, or drawing. A deviation request does NOT apply to components that the Subcontractor manufactured that do not conform to the specifications provided by LBNL; see Section

6.2.2 for nonconformance reporting.

To submit a deviation request, the Subcontractor must provide a written request that can only be implemented after review and approval by LBNL. If needed, LBNL can provide a deviation request form, or – with LBNL approval – the Subcontractor can submit their own customary deviation request documentation.

6.2.2 Nonconformance reports

A nonconformance report (NCR) provides a written summary that describes how a particular product does not conform to defined specifications or how a procedure does not conform to defined requirements. A nonconformance may be determined and reported by either the Subcontractor or LBNL.

Once a nonconformance is identified, an NCR must be submitted to LBNL within three business days. LBNL can provide an approved NCR form or review the Subcontractor’s customary NCR documentation, which can only be used after LBNL approval.

LBNL will provide a written dispensation establishing a path forward for each nonconformance. However, once a nonconformance has been identified, no further operation may be performed on the nonconforming item without LBNL’s written approval to proceed. Additionally, if any process is found to produce nonconforming components, all work utilizing that process must immediately cease upon discovery until the process can be reviewed with input from LBNL. Leave to resume the process is at the discretion of LBNL.

6.3 Required QA Data

6.3.1 Calibration data

All inspections and testing must be performed with calibrated instruments, and the

Subcontractor must provide LBNL with calibration certifications upon request to validate traceability of measurements.

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6.3.2 Certifications

The components for which certification is required are itemized in Appendix C. The type of certifications required are:

• Material certifications.

• Certificates of conformance. In addition to the certificates required in Appendix C, note that certificates of conformance are required for all hardware integrated into the assembly (e.g. pins, nuts, fasteners, screws).

• Heat treatment and weldment certifications, as applicable.

6.3.3 Mechanical inspection reports

Appendix C lists the components for which a mechanical inspection report is required.

6.4 Required inspections and testing

The inspection and test plans described below must be submitted to LBNL for ALS-U QA review and approval and presented at the indicated review. The submittal must include any instructions, test and inspection procedures, or report templates needed to ensure that items are produced according to the provided or LBNL-approved technical specifications and drawings.

Submittals must also identify any documents that are provided to or developed by lower-tier subcontractors, and include a sourcing plan that identifies which manufacturing, inspection, and testing activities are performed in-house vs. by lower-tier subcontractors, if applicable.

The required plans are:

• In-process inspection and test plan(s). These documents are presented at the MRR and must describe all in-process inspection and testing that will occur during fabrication. The plans must address all requirements outlined in Sections

6.2, 6.4, and 6.5 of this SOW, and the relevant sections of the HBEND Technical

Specification AL-1685-4599.

• FAT plan. This plan is presented at the ARR and must describe the plan for factory acceptance inspections and testing once the unit is fully assembled. The

FAT plan must address the relevant sections of the HBEND Technical Specification

AL-1685-4599.

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Each inspection and test plan must include the components, subassembly, and assembly to be inspected or tested and a description of each QA/QC activity that will be carried out.

Plans must also include a description of how data will be recorded, analyzed, and summarized. An outline of planned reports must be included in the relevant inspection and test plan.

All in-process inspection and testing and FAT reports must be submitted to LBNL for review and approval.

6.5 Magnet blocks and poles QA data

Specifications for the HBEND magnet blocks and pole pieces are in the Technical

Specification document AL-1685-4599. Requirements for data packages are described in this section and summarized in Appendix C, Table C-2.

6.5.1 Magnet blocks QA data package

The required data package to validate the material quality and production dimensions of each axial and core PM block consists of:

• Documents delineating the representative magnetization of each material;

• The data file for each block measurement must be in the form of an industry standard graph and, as applicable, also in ASCII format (such formats as .csv, .txt, .dat, or .xml may be accepted at LBNL’s discretion);

• Surface voids or chips must be fully documented as specified;

• Mechanical inspection data per drawing dimensions and tolerances.

The magnetic and mechanical properties of all PM blocks are subject to verification by

LBNL or its representatives at any point in the process and upon delivery.

6.5.2 Poles QA data package

The required data package to validate material quality and production dimensions consists of:

• Certification of material chemistry (material test report) and ingot traceability: the two poles in each magnet must be from the same ingot to ensure uniform magnetic properties (i.e. the materials are from a common heat and ingot);

• Documentation of the magnetic anneal used for the pole pieces, e.g. a log of the heat treatment time and temperature curve; and

• Mechanical inspection data per specifications on the drawings.

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6.5.3 Magnetic measurement requirements

The magnetic measurements data package deliverable consists of the following:

• Magnetic measurement raw test data in one of the following editable formats: .asc, .csv, .txt, .dat, or .xml format; and

• Summary report of the magnetic measurement results and documentation of the magnetic measurement process (e.g. magnet test parameters and equipment set-up).

6.6 Acceptance criteria

Items will be accepted upon receipt of:

1. The complete FAT report package;

2. All applicable certificates and product data;

3. All applicable nonconformance or deviation documentation, if any; and

4. Verification of compliance with the technical specifications (items 1 and 2) or with non-conformances and deviations being approved (item 3).

In addition, upon delivery LBNL will conduct receiving inspection and testing, including measurements for each item to verify the functional acceptance criteria list (ACL) for each item type. ACLs will be made available to the Subcontractor upon request. In case an item does not meet functional acceptance criteria and the cause is traced to a non-conformance for which the Subcontractor is responsible but remained undetected, the Subcontractor is responsible for correcting the non-conformance.

7 APPLICABLE DOCUMENTS

The documents listed in this section are considered to be a part of this document. All information contained in an applicable document will be valid to the fullest extent, unless specifically noted within this document. Applicable documents must originate from the

LBNL Document Control Center (DCC) and will be made available by LBNL as needed.

Document Number Title

AL-1685-4599 Technical Specification for the ALS-U Storage Ring HBEND Magnets

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APPENDIX A: CLOSEOUT CHECKLIST

WORK PACKAGE 1 CLOSEOUT CHECKLIST

The Closeout Checklist must be submitted to the University Technical Representative to affirm the status of all Subcontractor deliverables. The signed form is required to close out the contract.

Items 1 – 4 apply to deliverables for the magnet core verification, and items 5 – 10 apply to HBEND magnet assembly production. For each item, the Subcontractor must indicate if the full quantity was delivered according to all applicable requirements. If the response is “No,” an explanation must be provided, along with any applicable attachments. LBNL will determine if the deliverable is acceptable “as is” through a waiver or provide guidance if it is possible for that item to meet acceptance criteria.

Item Per SOW Section Quantity

Work Package 1 HBEND magnet assemblies (magnet core design verification and

HBEND magnet production)

Requirements Met

Yes No

1 3.2 1 Magnet core design verification

2 3.1 1 Magnetic verification plan

3 3.1 1 Detailed assembly process documentation (core assembly only)

4 3.1 1 Upper and lower core assembly, fully assembled and tested according to validated design

5 3.3 8 HBEND magnet assemblies, fully assembled and tested

6 3.3 8 HBEND FAT report packages

7 4.4 All Review presentations (MRR, ARR, FAT procedures, Shipping Plan)

8 6.2 All Applicable nonconformance or deviation documentation, if any

Appendix

C All

Applicable material certifications, certificates of conformance, and inspection reports

10 2.3 All All tooling and/or materials provided or purchased by LBNL for this project have been returned to and received by LBNL

Closeout Checklist Subcontractor Statement for Work Package 1

Prepared by:

Title / role:

Date:

Item Explanation for items that do not meet requirements (add rows as needed)

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WORK PACKAGE 2 CLOSEOUT CHECKLIST

The Closeout Checklist must be submitted to the University Technical Representative to affirm the status of all Subcontractor deliverables. The signed form is required to close out the contract.

Items 1 – 4 apply to deliverables for the magnet core verification, and items 5 – 9 apply to magnet core assembly production. For each item, the Subcontractor must indicate if the full quantity was delivered according to all applicable requirements. If the response is “No,” an explanation must be provided, along with any applicable attachments. LBNL will determine if the deliverable is acceptable “as is” through a waiver or provide guidance if it is possible for that item to meet acceptance criteria.

Item Per SOW Section Quantity

Work Package 2: Magnet core assemblies ONLY (magnet core design verification and production)

Requirements Met

Yes No

1 3.2 1 Magnet core design verification

2 3.1 1 Magnetic verification plan

3 3.1 1 Detailed assembly process documentation (core assemblies only)

4 3.1 1 Upper and lower magnet core assembly, fully assembled and tested according to validated design

5 3.1 8 Production Upper and lower core assemblies, fully assembled and tested

6 3.4 8 FAT report packages

7 4.4 All Review presentations (MRR, ARR, FAT procedures, Shipping Plan)

8 6.2 All Applicable nonconformance or deviation documentation, if any

Appendix

C All

Applicable material certifications, certificates of conformance, and inspection reports

Closeout Checklist Subcontractor Statement for Work Package 2

Prepared by:

Title / role:

Date:

Item Explanation for items that do not meet requirements (add rows as needed)

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APPENDIX B: STORAGE RING MULTIBEND ACHROMAT SECTORS

The HBEND magnets will be installed in the new ALS-U storage ring locations as indicated in Figures B-1 and B-2. These arc sectors require additional custom quadrupole magnets to integrate the high-field dipoles into a workable arc sector.

Figure B-1 Sectors 4 and 8 HBEND magnet locations.

Figure B-2 Sector 12 HBEND magnet locations.

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APPENDIX C: SUBCONTRACTOR DATA REQUIREMENTS LIST

The following tables summarize the types of documents the Subcontractor must provide and list where the requirement is described: SOW section, hold point, and the Technical Specification (TS) for the ALS-U Storage Ring HBEND Magnets (AL-1685-4599). Table C-1 summarizes mechanical data requirements; Table C-2 summarizes magnetic data requirements; and Table C-3 summarizes project administration requirements.

Important: All requirements listed apply in full to Work Package 1. A subset of these requirements applies to Work Package 2 based on the

LBNL assembly item number (and all LBNL identifiers under the main assembly item number).

Table C-1 Summary of Subcontractor-provided documentation as required per SOW section or applicable document.

Document Type For Item/Component Qty Standard or

Form Purpose

SOW

Section Hold point

TS

Section

FAT report AL-1615-8572 HBEND Main Production Assy 8 As approved Acceptance § 3.2, 6.4 12, 13 § 6.4

Mechanical inspection data

– components

AL-1207-7003 – Magnet Pole Piece

1/every

Initial and Final Per drawings Acceptance § 4.5

§ 6.3

AL-1185-9693 Lower Trans Pole PM Block 3

AL-1185-9695 Vertical PM Block 3

AL-1185-9698 Axial PM Block 6

AL-1153-6580 Upper Trans Pole PM Block 3

AL-1153-6582 Upper Transfer PM Block 3

AL-1210-1763 Yoke Mid Block-1

1st article

AL-1210-3968 Yoke Mid Block-2 8

Mechanical inspection data

– assemblies

AL-1208-2802 Upper Magnet Core Assembly

1/each Per drawings Acceptance § 6.3 9 § 6.3 AL-1195-4932 Lower Magnet Core Assembly

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