3) AL-1687-0894 ALS-U Storage Ring Struts SOW.pdf

Statement of Work for the ALS-U Storage Ring Struts

D. Munson, P. Wehle

Release Date: Mar 19 2025 9:24:55 AM PDT

Document Number: AL-1687-0894 Revision: B

Document Status: Released

Document Type: NOTE

Category Code: AL7525

ALS-U - STORAGE RING

MAGNET SUPPORTS

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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 Government furnished materials

3 Deliverables

3.1 List of items

3.2 Material samples

3.3 First articles

3.4 Production series

3.5 Closeout checklist

4 Project Administration

4.1 Roles and responsibilities

4.2 Reporting / communication requirements

4.3 Document management

4.4 Reviews

4.5 Hold points

5 Shipping, Handling, and Storage

5.1 Packaging

5.1.1 Crates and containers

5.1.2 Packing materials

5.1.3 Markings

5.2 Handling and storage

5.3 Shipping logistics

6 Quality Assurance

6.1 Subcontractor QA program

6.2 Standard QA forms

6.2.1 Deviation requests

6.2.2 Nonconformance reports

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6.3 Required inspections

6.3.1 Plans and reports

6.3.2 Material samples

6.4 Required QA data

6.5 Acceptance criteria

7 Applicable Documents

Appendix A: Subcontractor Data Requirements List

Appendix B: Closeout Checklist

Appendix C: 6-strut Assembly Example

REVISION HISTORY

Rev. CM Number Description of Change

A Initial Release

APPROVALS

Approver Project Role

Ken Chow ALS-U Accelerator Mechanical Systems Lead

Catalina Espino Devine ALS-U Supports Control Account Manager

Ryan Miller ALS-U Supports Technical Lead

Dawn Munson ALS-U Lead Technical Representative

Windchill Approved / Concurred By espinodevine,ryanmiller ci al ly R el ea se d to th e

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ABBREVIATIONS AND ACRONYMS

ACL Acceptance Criteria List

ALS Advanced Light Source

ALS-U Advanced Light Source Upgrade

AWS American Welding Society

COTS Commercial off the shelf

LBNL* Lawrence Berkeley National Laboratory

GD&T Geometry dimensioning and tolerancing mm Millimeter

NCR Nonconformance Report

NTP Notice to Proceed

QA Quality Assurance

RFP Request for Proposal

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.

The current ALS Upgrade (ALS-U) project entails installation of components for which a high degree of alignment precision, stability, and support is required. This is achieved by integrating strut groupings into various support structures to handle gravity, vacuum, and seismic loads.

1.2 Description of items

This statement of work (SOW) provides the requirements and specifications for the manufacture, assembly, inspection, and shipment for 20 millimeter (mm) strut assemblies as shown in Figure 1-1.

The strut assemblies will be installed into kinematic 6-strut systems that provide stable support and precise positioning. An example of a 6-strut system is shown in Appendix C.

Figure 1-1. The 20 mm turnbuckle strut assembly has a right-hand thread on one end and left-hand thread on the other.

20 mm turnbuckle strut assembly

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2 SCOPE OF WORK

The scope of work is for the manufacture, procurement of parts, assembly, painting, packaging, and delivery of the items listed in Table 3-1 in Section 3. The work is to be completed as specified in this SOW and the applicable documents in Table 7-1 in

Section 7. Documentation requirements are summarized in Appendix A.

2.1 Government furnished materials

LBNL will supply the custom designed rod ends to the Subcontractor. Drawings are provided for reference only.

Table 2-1 Items to be supplied by LBNL

Item No. Name Qty1 Description

A-1 Rod ends for 20 mm struts (right hand) 262 AL-1067-5618

A-2 Rod ends for 20 mm struts (left hand) 262 AL-1067-5622

3 DELIVERABLES

3.1 List of items

The required deliverables consist of the one work package noted in Table 3-1. The required documentation types are listed in Sections 3.2 – 3.5.

Table 3-1 List of deliverables.

Work Package

Item No.

Name Qty2 Description Delivery

Weeks ARO

20 MM TURNBUCKLE STRUT (first article)

1 AL-1072-3380 12

20 MM TURNBUCKLE STRUT

(production)

261 AL-1072-3380 16

1 005 Closeout Checklist 1 Per Appendix B 16

3.2 Material samples

To ensure that weld and paint procedures meet the required standards and specifications, weld test coupons and a painted material sample must be submitted to LBNL for review and approval before any fabrication is initiated. The paint samples must be marked per the method specified in the drawings.

1 These quantities correspond to the total number needed plus overage.

2 These quantities include an overage of 20% for spares.

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3.3 First articles

There is one first article the work package, item 001 in the table of deliverables. The requirements for the first article delivery are:

1. The complete strut assembly

2. All applicable material certifications, certificates of conformance, and inspection reports

3. All applicable nonconformance or deviation documentation, if any

4. LBNL’s written notice to proceed (NTP) with shipping

3.4 Production series

The production series may be split into multiple deliveries, provided each batch contains sets of six and follows the provisions of the subcontract. The requirements for the production series for each work package delivery are:

1. Complete strut assemblies (in sets of no less than 6 pieces)

2. All applicable material certifications, certificates of conformance, and inspection reports

3. All applicable nonconformance or deviation documentation, if any

4. LBNL’s written NTP for shipping

3.5 Closeout checklist

At the time of final delivery, the Subcontractor must submit the Closeout Checklist in

Appendix B to verify that all required deliverables have been provided.

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:

1. The University Procurement Specialist is responsible for contract administration from solicitation to subcontract award, and any contractual issues that arise thereafter.

2. 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 portal for project data exchange.

2. Project meetings are required to be held twice per month, but the frequency 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, and planned dates for shipments 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 designee) are at LBNL’s discretion upon providing advance notice. If a visit is scheduled, access to the factory where the manufacturing and assembly work for the listed items is performed is required.

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 as requested in writing.

4.3 Document management

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, inspection results, and drawings, as applicable.

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, which may be conducted onsite (LBNL or

Subcontractor facilities) or via web/video conferencing.

The review types required for this scope of work are:

1. Preliminary manufacturing readiness review: Prior to the start of fabricating any items, the Subcontractor must submit to LBNL, for review and approval, a pre-manufacturing deliverables package that includes:

a. Manufacturing schedule. The schedule should include 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 plan. This plan must include a report template that conforms to the requirements in Section 6.4.

d. Paint sample with markings. The material sample should be the type as specified for a strut body that is painted in accordance with LBNL paint specification 10068 (per Section 6.3.2) and includes the type of markings specified in the strut drawings.

e. Welding test coupons. The Subcontractor must prepare and weld an equivalent test coupon (per Section 6.3.2) for each type of weld that will be used for first articles and the production series. Coupons must be provided to LBNL for inspection and approval before beginning any welding on this project.

2. Shipping plan review. The Subcontractor must present, for LBNL review and approval, a shipping plan that meets the requirements in Section 5.

4.5 Hold points

Each hold point requires LBNL’s written NTP before any action can be taken beyond the listed approval item.3

Hold Point Approval item Subcontractor action items / submittals

Anticipated LBNL response

1 First article shipment

a. Successful completion of the preliminary manufacturing readiness review

b. Successful completion of the shipping plan review

c. Complete QA documentation package submitted:

-first article inspection report, -material certifications, -welder and weld inspector certificates, Within 10 business days of receipt of required items / submittals

3 The Subcontractor may propose long lead purchases and/or fabrication ahead of hold points, subject to LBNL approval.

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Hold Point Approval item Subcontractor action items / submittals

Anticipated LBNL response

-weld inspection report, -photographs of the first article welds

2 Series production Successful verification of first article performance and conformance with any other acceptance criteria

3 Production shipment Submittal of complete QA documentation package(s)

4 Subcontract closeout Submittal of Closeout Checklist (Appendix B) –

5 SHIPPING, HANDLING, AND STORAGE

Before any items are shipped, LBNL requires that a shipping plan be submitted for review and approval (per Section 4.4, item 2). The plan must include packaging design (i.e.

containers, crates, and packaging) and the shipping logistics as described below. Once the shipping plan is approved, no shipment can be initiated without LBNL’s written NTP.

Once items are shipped, additional communication requirements apply per Section 5.3.

5.1 Packaging

No crates or containers are to be constructed or items packaged without an approved shipping plan. Packaging must be able to support and protect items before they are shipped, during storage (if applicable), and throughout shipment.

5.1.1 Crates and containers

If a crate or container that requires a forklift or pallet jack is used:

1. The container must be constructed of materials that meet or exceed the quality standards for the type of material used. For containers made of wood, the requirement for international shipments is: Wood Groups II, III, or IV per ASTM D6199 – Standard

Practice for Quality of Wood Members of Containers and Pallets.

2. Large containers must consist of a base structure capable of being transported with a standard forklift or pallet jack on at least two sides.

3. The design and construction must allow for air shipment. If shipped by air, the container should incorporate a moisture barrier to prevent condensation.

5.1.2 Packing materials

Packing requirements include:

1. All items must be clean, dry, and free of cutting chips, cutting fluids, excessive lubricating oils, and sand/bead blasting media.

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2. Each item must be blocked/cribbed/supported as needed to prevent damage (e.g.

scratches, paint damage).

3. LBNL may require the use of soft-adhesive shock indicators (e.g. Shockwatch®) installed on both the inside and outside of containers.

4. The packaging must be compliant with the Toxics in Packaging Prevention Act, AB-4554.

5.1.3 Markings

Required markings on the exterior of all container types are:

1. Identifying information:

o Delivery address o University Technical Representative contact information o Subcontract number o Serial or identification numbers of the components contained therein

2. Arrows indicating the appropriate container orientation; and

3. Markings that clearly identify tie-down and lifting points, if any.

5.2 Handling and storage

The Subcontractor carries responsibility for ensuring that items are handled and stored in a manner that ensures that they arrive at LBNL undamaged. If items or packaging are to be stored, they must be fully sheltered from natural or human-caused conditions that may cause damage or corrosion.

5.3 Shipping logistics

Once LBNL has provided the NTP for a shipment, the following requirements apply:

1. If the truck length exceeds 40 feet, LBNL must be notified in advance for approval.

2. The Subcontractor must share the LBNL-approved shipping 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 the delivery drivers;

4 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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b. 24 hours prior to arrival, the driver must provide an arrival window so that delivery logistics can be coordinated (with the driver and at LBNL);

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

6 QUALITY ASSURANCE

6.1 Subcontractor QA program

The Subcontractor must maintain the QA program that was deemed effective based on the information submitted. Additional QA program information may be requested at any time, and reasonable additions or modifications to QA processes may be deemed necessary. In addition, 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 uses a standard NCR form that the Subcontractor can request. Or, with prior LBNL approval, the Subcontractor can use their own customary NCR documentation.

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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

LBNL’s discretion.

6.3 Required inspections

6.3.1 Plans and reports

The Subcontractor must develop manufacturing and inspection plans that include all procedures needed to produce the strut assemblies according to the specifications in the drawings. All plans and report templates must be submitted for LBNL review and approval before the start of first article production.

Inspection plans must identify:

1. The method(s) and equipment to be used for inspections;

2. The items to be inspected and an annotated drawing identifying all features to be inspected for both the assembled first article components and the production units.

3. How the results will be documented, analyzed, and presented (e.g. report template) to address each inspection item identified in Section 6.4 and

Appendix A.

4. Submittal requirements for in-process inspection reports, which must be submitted to LBNL for review and approval in accordance with the hold points in

Section 4.5

6.3.2 Material samples

Material samples must be provided to LBNL for inspection and approval prior to proceeding with first article production, as noted in Section 4.4.

• Weld coupons. The Subcontractor must prepare and weld an equivalent test coupon for each type of weld using the same material, filler, and weld technique that will be used for production. Weld coupons are required for all welding

Subcontractors, and a new set of coupons is required if there is a change in welding

Subcontractor.

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• Paint sample. The Subcontractor must prepare a paint sample for each type of paint using the same technique and material that will be used for production. If the application of paint is subcontracted to a third party, an additional paint sample is required to ensure paint matching and quality.

6.4 Required QA data

The following QA documentation is required:

1. Material certifications. Certificates are required for all stock materials.

2. Certificate of conformance. Prior to shipping, certificates must be provided for all commercial off the shelf (COTS) items.

3. Welding QA (per American Welding Society (AWS) D1.1).

a. Welder qualifications. All weld inspections must be completed per AWS

D1.1 by a certified weld inspector, and weld certificates for welders and weld inspectors – including for any change of personnel or lower tier

Subcontractors – must be kept on record and current.

b. Weld inspection reports. Weld inspection reports must be provided to

LBNL prior to painting.

c. Weld certification. The Subcontractor must provide a certificate of conformance verifying that the same weld procedures used on the weld coupons were followed for the fabrication of strut components. The certificate must be provided to LBNL prior to shipping assemblies.

4. First article inspection reports. The Subcontractor must document the inspection of each first article and must include verification that:

a. The pin is properly installed;

b. Lubrication has been applied;

c. The welds are certified;

d. The painted surfaces meet quality requirements; and

e. All geometry dimensioning and tolerancing (GD&T) represented on drawings are inspected and conform to the drawings, and all mechanical properties meet specifications.

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5. Production inspection reports. The Subcontractor must document the inspection of:

a. Production weldment of unpainted surfaces;

b. Surfaces – after paint/powder coat is applied – to verify conformance with specifications in the drawings at the article sampling rate specified in

Appendix A prior to shipping; and

c. Full GD&T (for 15% of production strut assemblies).

6.5 Acceptance criteria

The NTP for shipment of deliverable items is contingent upon receipt – and LBNL review and approval – of the following:

1. All applicable material certifications, certificates of conformance, and inspection reports;

2. All applicable nonconformance or deviation documentation, if any;

Upon delivery of the assemblies, LBNL will conduct receiving inspection, including measurements to verify the functional acceptance criteria list (ACL) for each strut size.

The applicable ACL 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 that remained undetected, the Subcontractor is responsible for correcting the non-conformance.

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7 APPLICABLE DOCUMENTS

The released version of the documents listed in Table 7-1 are integral to this SOW, and all information contained therein is to be taken as valid to the fullest extent unless specifically noted within this SOW. The released version is water marked and includes a stamp in the lower left corner that provides version data.

Table 7-1 Applicable documents list

Document Number Title

General

LBNL Engineering Spec 10068 LBNL Paint Specification

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

20 mm Struts

AL-1072-3380 20 MM TURNBUCKLE STRUT 211 MM NOM

AL-1357-0272 STRUT BODY WELDMENT

AL-1067-5612

LBNL reference number only5

COLLAR CLAMP 25MM' BORE X 45MM OD STAFFORD

Commercial component

AL-1072-3381 TUBE, STEEL 31.75mm OD X 3.175mm WALL

AL-1067-5601 STRUT STUB END – LH THREAD (M20 - 1.5)

AL-1067-5608 STRUT STUB END – RH THREAD (M20 - 1.5)

AL-1098-9941

LBNL reference number only5

PIN, SPRING, 3MM X 24MM LG. 18-8 SST

Commercial Component

Rod end drawings (for reference only)

AL-1067-5618 Rod ends for 20 mm struts (right hand)

AL-1067-5622 Rod ends for 20 mm struts (left hand)

5 No drawing provided.

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APPENDIX A: SUBCONTRACTOR DATA REQUIREMENTS LIST

The types of documents the Subcontractor is required to provide as defined by this SOW and the applicable documents in Section 7 is summarized in the table below.

Document Type For Personnel / Item / Component Qty Work pkg

SOW

ref

Certificate of conformance

AL-1067-5612

COLLAR CLAMP 25MM’ BORE X 445MM

OD STAFFORD

All

§3.3 3.4 6.4

All hardware integrated into the main assembly (e.g. clamping collars, nuts, fasteners, screws)

Weld inspection AL-1357-0272 STRUT BODY WELDMENT

First article and 15% of production units

Weld certifications AL-1357-0272 STRUT BODY WELDMENT

All

Welder certificates All welders and weld inspector certifications per AWS D1.1 1

Material certification

AL-1072-3381

TUBE, STEEL 31.75mm OD X 3.175mm

WALL

AL-1067-5601 Strut stub ends for left hand thread 1

AL-1067-5608 Strut stub end for right hand thread 1

Inspection reports AL-1072-3380 20 MM TURNBUCKLE STRUT

First article and 15% of production units

Project Administration

Document Type Qty Work pkg SOW ref

Meeting minutes 1/meeting

§ 4.2

Status report 1/month

Shipping plan

1/work package § 4.4 Manufacturing plan

Inspection plan

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APPENDIX B: CLOSEOUT CHECKLIST

The Closeout Checklist summarizes Subcontractor deliverables. Submitting this completed checklist is required to close out the contract.

For each item, the Subcontractor must indicate if it was delivered according to all applicable requirements. If the response is “No,” an explanation must be provided in the comments section, 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 Section Item

Requirements Met Comments /

Attachment Title Yes No

Work Package 1

4.4

6.3.1 All plans required by reviews for manufacturing, inspection, and shipping

2 3.1 20 mm Strut Assemblies, Qty. 262

3 6.4 All applicable material certifications, certificates of conformance, and inspection reports

4 6.2 All applicable nonconformance or deviation documentation, if any

Subcontractor statement

Prepared by:

Title / role:

Date:

Number of attachments:

ci al ly R el ea se d to th e

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AL-1687-0894 Rev. B Doc. Status: Released Page 19 of 19

All officially released LBNL documents are watermarked and contain LBNL Document

APPENDIX C: 6-STRUT ASSEMBLY EXAMPLE

Strategic placement of struts is the basis for a mechanical support system that meets seismic requirements, minimizes vibration, and allows easy and precise alignment of hardware in the beamline. The larger struts are rated for heavier hardware.

20 mm struts are used for heavier objects ci al ly R el ea se d to th e

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