3) AL-1692-2466A - SOW ATS-STA Base Supports Rafts.pdf

Statement of Work for the ALS-U ATS/STA Base

Supports & Rafts

Rifeta Gara Zejnic, Petra Wehle

Release Date: Apr 3 2024 2:29:27 PM PDT

Document Number: AL-1692-2466 Revision: A

Document Status: Released

Document Type: NOTE

Category Code: AL7420

ALS-U - ACCUMULATOR TO STORAGE RING TRANSFER LINE

MAGNET SUPPORTS

O ffi ci al ly R el ea se d to th e

LB

N L

D oc um en t C on tr ol

C en te r

Re le as ed

: A pr il 3r d, D C

C A ut h

K ey

: E Q

2Q X

EV

9N

D

Downloaded by: Rifeta Gara Zejnic at April 03, 2024 16:18:33

AL-1692-2466 Rev. A Doc. Status: Released Page 2 of 26

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

3 Deliverables and Schedule

3.1 List of items

3.2 Material samples

3.3 First articles

3.4 QA documentation deliverables

3.5 Delivery schedule

3.6 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 Packaging, Storage, and Shipping Requirements

5.1 Packaging

5.2 Storage

5.3 Shipping logistics

5.4 LBNL arrival logistics

6 Quality Assurance

6.1 Subcontractor QA program

6.2 Standard QA forms

6.2.1 Deviation requests

6.2.2 Nonconformance reports

ci al ly R el ea se d to th e

LB

N L

D oc um en t C on tr ol

C en te r

Re le as ed

: A pr il 3r d, D C

C A ut h

K ey

: E Q

2Q X

EV

9N

AL-1692-2466 Rev. A Doc. Status: Released Page 3 of 26

All officially released LBNL documents are watermarked and contain LBNL Document

6.3 Inspection plans

6.4 QA inspection requirements

6.5 QA data requirements

6.5.1 Certificates

6.5.2 Material samples

6.5.3 Process documentation

6.5.4 Inspection reports

6.6 Acceptance criteria

7 Applicable Documents

Appendix A: Closeout Checklist

REVISION HISTORY

Rev. CM Number Description of Change A N/A Initial Release

APPROVALS

Approver Project Role

Ken Chow Chief Engineer, ALS-U Project

Sol Omolayo Technical Deputy, ALS-U Mechanical Engineering Systems

Catalina Espino Devine Control Account Manager, ALS-U Supports and Alignment Subsystem

Ryan Miller Technical Lead, ALS-U Supports and Alignment Subsystem

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

LB

N L

D oc um en t C on tr ol

C en te r

Re le as ed

: A pr il 3r d, D C

C A ut h

K ey

: E Q

2Q X

EV

9N

AL-1692-2466 Rev. A Doc. Status: Released Page 4 of 26

All officially released LBNL documents are watermarked and contain LBNL Document

ABBREVIATIONS AND ACRONYMS

ACL Acceptance Criteria List

ALS Advanced Light Source

ALS-U Advanced Light Source Upgrade

ANSI American National Standards Institute

ARO After Receipt of Order

ATS Accumulator Ring To Storage Ring (transfer line)

AWS American Welding Society

CMM Coordinate Measurement Machine

GD&T Geometric Dimensioning and Tolerancing

ISO International Standards Organization

LBNL* Lawrence Berkeley National Laboratory mm Millimeters

NCR Non-Conformance Report

NTP Notice to Proceed

QA Quality Assurance

QTY Quantity

RAL Reichs-Ausschuß für Lieferbedingungen (European Color Management System for powder coating)

RFP Request for Proposal

SOW Statement of Work

STA Storage Ring To Accumulator Ring (transfer line)

University* The Regents of the University of California

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

ci al ly R el ea se d to th e

LB

N L

D oc um en t C on tr ol

C en te r

Re le as ed

: A pr il 3r d, D C

C A ut h

K ey

: E Q

2Q X

EV

9N

AL-1692-2466 Rev. A Doc. Status: Released Page 5 of 26

All officially released LBNL documents are watermarked and contain LBNL Document

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 ALS complex includes conventional facilities, an array of up to 40 simultaneously operating beamlines, instrumentation, an experimental hall, computing resources, ancillary laboratories, and offices.

The current ALS Upgrade Project (ALS-U) will replace the existing ALS storage ring with a new next generation multi-bend achromat-type storage ring to achieve an increase in brightness and coherent flux of soft X-rays by at least two orders of magnitude, while leveraging the existing beamlines and infrastructure of the ALS facility. The improved capabilities of the upgraded ALS will enable transformative science that cannot be performed on any existing or planned light source in the world.

The project scope includes a new full-energy accumulator ring along with transfer regions between the two rings – the accumulator ring to storage ring (ATS) and the storage ring to accumulator (STA) transfer lines for electron beam injection into the new storage ring.

1.2 Description of items

This statement of work (SOW) defines the fabrication requirements for custom support structures of various weights and sizes that will be installed in the ATS and STA transfer line regions, where they will be exposed to radioactivity and potential seismic activity. The primary function and requirement for these structures is to securely hold magnet components in position and orientation, aligned within a few tens of microns accuracy.

The small structures are mainly support frames for cameras.

The welded structures are fabricated primarily from plate and bar steel that is welded together, machined on critical surfaces, and painted. A series of tapped and through holes are required for mounting and alignment purposes. “Paint” implies powder coating as noted in the drawings and these two terms are used interchangeably throughout this

SOW. The maximum envelope size for the base support frames is 2665 x 1070 x 560 millimeters (mm).

The components for the ATS and STA transfer lines are similar in structure, but the design of the components for each transfer line is unique. The following series of figures provides a view of the entire STA configuration (Figure 1-1), the largest base support structure in ci al ly R el ea se d to th e

LB

N L

D oc um en t C on tr ol

C en te r

Re le as ed

: A pr il 3r d, D C

C A ut h

K ey

: E Q

2Q X

EV

9N

AL-1692-2466 Rev. A Doc. Status: Released Page 6 of 26

All officially released LBNL documents are watermarked and contain LBNL Document the ATS transfer line (Figure 1-2), and a single raft weldment for the ATS transfer line

(Figure 1-3).

Figure 1-1 Base support and raft structures in the STA region (magnets and associated equipment is shown positioned on the support structures).

Figure 1-2 The largest ATS base support structure shown with an assemblage of equipment that relies on stability to achieve a high degree of accuracy.

ci al ly R el ea se d to th e

LB

N L

D oc um en t C on tr ol

C en te r

Re le as ed

: A pr il 3r d, D C

C A ut h

K ey

: E Q

2Q X

EV

9N

AL-1692-2466 Rev. A Doc. Status: Released Page 7 of 26

All officially released LBNL documents are watermarked and contain LBNL Document

Figure 1-3 Raft support weldment (bottom view showing detail).

2 SCOPE OF WORK

The scope of work is the manufacture, inspection, and delivery of the ATS and STA support structures as defined in Section 3.1. The work is to be completed as specified in this SOW and the documents listed in Table 7-1 in Section 7, Applicable Documents.

The scope of work includes the manufacturing, quality assurance (QA), packaging, and delivery of the specified items.

The Subcontractor is responsible for ensuring the structural integrity and functionality of all specified parts, including conducting all required quality control inspections. The technical requirements and specifications are incorporated primarily in the technical notes section of each drawing. The list of drawings is provided in the document reference list (AL-1713-6747 in Table 7-1).

3 DELIVERABLES AND SCHEDULE

This section describes the deliverables required for this scope of work, which include fabricated items, material samples, and QA documentation types. The desired delivery schedule for the fabricated items is also provided.

3.1 List of items

The required items to be fabricated per this scope of work are listed in Table 3-1, and the associated required documentation is listed in Table 3-3 (Section 3.4). First Articles are addressed in Section 3.3.

ci al ly R el ea se d to th e

LB

N L

D oc um en t C on tr ol

C en te r

Re le as ed

: A pr il 3r d, D C

C A ut h

K ey

: E Q

2Q X

EV

9N

AL-1692-2466 Rev. A Doc. Status: Released Page 8 of 26

All officially released LBNL documents are watermarked and contain LBNL Document

Table 3-1 Fabricated deliverables

Item # LBNL ID* Title Quantity

Base Supports

001 AL-1354-0931 Support, Module #4, BPM 1, ATS 1

002 AL-1334-4020 Support, Module #5, Q1, ATS 1

003 AL-1504-7148 Adapter Plate, Module #5, Q1, ATS 1

004 AL-1511-3285 Weldment, Base Support, Q2-B1, ATS 1

005 AL-1512-1171 Weldment, Bridge, Q4, ATS 1

006 AL-1507-8995 Support, Raft1 Base, Sector12 1

007 AL-1507-7378

Mini-raft Base Plate Weldment, ATS 11 Q7-Q9 (ATS Q7-Q9 Strut Baseplate)

008 AL-1505-6811 Vacuum Drift Support, ATS 1

009 AL-1613-2941 Diving Board, ATS Shield (TV camera shield diving board) 1

010 AL-1545-4931 Weldment, Base Support, M9-M10, Q5-B3, Q6-B4, STA 1

011 AL-1595-5383 Weldment, Base Support, M8, Q4-B2, STA 1

012 AL-1596-0512 Weldment, Pedestal, M6-M8, STA 1

013 AL-1595-5168 Weldment, Base Support, M6, Q2-Q1, STA 1

014 AL-1550-0852 Weldment, Pedestal Support, Vacuum, STA 1

015 AL-1546-2606 Weldment, Pedestal Support, BPM, STA 1

016 AL-1595-3755

Mini-raft Base Plate Weldment, STA 12 Q7-Q9 (STA Q7-Q9 Strut Baseplate)

017 AL-1595-5256 STA Vacuum Drift Support 1

018 AL-1605-0942 Diving Board Shield, STA (TV camera shield diving board) 1

Rafts

019 AL-1506-9923 ATS Raft 1, Weldment 1

020 AL-1507-8666 ATS Raft 2, Weldment 1

021 AL-1507-8867 ATS Raft 3, Weldment 1

022 AL-1509-4380 ATS Raft 4, Weldment 1

023 AL-1507-6856 ATS Mini-Raft Weldment 1

024 AL-1595-4641 STA Q1-Q2 Raft, Weldment 1

025 AL-1595-2510 STA Raft 1, Weldment 1

026 AL-1595-2395 STA Raft 2, Weldment 1

027 AL-1593-7670 STA Raft 3, Weldment 1

028 AL-1593-7618 STA Raft 4, Weldment 1

029 AL-1595-3075 STA Mini-Raft Weldment 1 ci al ly R el ea se d to th e

LB

N L

D oc um en t C on tr ol

C en te r

Re le as ed

: A pr il 3r d, D C

C A ut h

K ey

: E Q

2Q X

EV

9N

AL-1692-2466 Rev. A Doc. Status: Released Page 9 of 26

All officially released LBNL documents are watermarked and contain LBNL Document

Item # LBNL ID* Title Quantity

Camera Supports and Shields

030 AL-1635-5911 Base Plate, SRM Camera Support 1

031 AL-1590-0850 Bracket, Camera Mount, ATS 1

032 AL-1590-0963 Bracket, Camera Mount, ATS 1

033 AL-1617-3590 Plate, Mounting, Camera Shield 1

034 AL-1697-9998 Shield Camera-3, Plate 12.7mm (1/2"), STA 1

035 AL-1697-9999 Shield Camera-3, Round Bar 44.5mm (1-3/4"), STA 1

036 AL-1697-5829 Shield CameraA-2, Plate 12.7mm (1/2"), STA 1

037 AL-1697-9676 Shield Camera-2, Round Bar 44.5mm (1-3/4"), STA 1

038 AL-1698-0338 Shield Camera-1, Plate 12.7MM(1/2"), STA 1

039 AL-1698-0435 Shield Camera-1, Round Bar 44.5MM(1-3/4"), STA 1

040 AL-1633-9142 Shield, Bottom Cover 1

041 AL-1633-7060 Plate, Bracket Shim 2

042 AL-1633-6312 Weldment, SMR Bracket, STA 2

043 AL-1633-7070 Support, Vert. Mounting Post-2 1

044 AL-1635-5613 Support, Vert. Mounting Post-1 1

045 AL-1635-5621 Support, Camera Mounting 1

046 AL-1697-9690 Support, Camera Shield Mounting, STA 1

*Note: the part numbers are identical to the drawing numbers, provided with applicable revisions in a separate document per Table 7-1

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.

3.3 First articles

A rigorous QA process for First Article items is needed to verify that all technical data and specification requirements are correctly understood, accounted for, verified, and recorded. This process includes an inspection of fabricated parts both prior to painting and after.

Table 3-2 lists the two items for the First Article evaluation. LBNL will confirm the items at the project kick-off meeting.

ci al ly R el ea se d to th e

LB

N L

D oc um en t C on tr ol

C en te r

Re le as ed

: A pr il 3r d, D C

C A ut h

K ey

: E Q

2Q X

EV

9N

AL-1692-2466 Rev. A Doc. Status: Released Page 10 of 26

All officially released LBNL documents are watermarked and contain LBNL Document

Table 3-2 First article items

Item # LBNL ID Description

004 AL-1511-3285 Weldment, Base Support, Q2-B1, ATS

022 AL-1509-4380 ATS Raft 4, Weldment

3.4 QA documentation deliverables

The required QA documentation deliverables (QA data) are itemized in Table 3-3. In this table, parts A through E are organized to follow the process from planning through closeout. The referenced review items are described in Section 4.4, the hold points are described in Section 4.5, and detailed information for each QA data item is described in

Sections 6.3 through 6.5.

Table 3-3 QA data deliverables packages

Item # QA Data Item Deliverable Description / Requirement Basis Sections

Part A: Deliverables required by reviews prior to start of First Article fabrication

046 Manufacturing schedule Manufacturing schedule requirements are in review item 1.a.

4.4 6.5.3

047 Inspection plan Inspection plan requirements are in review item 1.b.

4.4, 6.3

6.4, 6.5.4

048 Weld test coupons Weld test coupons and inspection report requirements are in review item 1.c.

Welder and weld inspection certification requirements are in review item 2.a.

4.4 6.4

6.5.1

049 Paint samples Paint sample and marking requirements are in review item 1.d.

4.4, 6.4 6.5.2

050 Anti-corrosion protection The anti-corrosion product must be identified in advance so that LBNL can verify compatibility, as required by review item 1.e.

4.4 6.4

051 Shipping plan Shipping plan and shipping checklist requirements are in review item 1.e, hold point 3, and Section 5.

4.4, 4.5

Part B: QA data required prior to painting First Article items

052 Certificates / certifications (First Articles)

Material certificates, weld inspector certificates, and heat treatment certificates are required per review item 2.a and hold point 2.

4.4 6.5.1

053 Inspection reports (First Articles, pre-paint)

First Article pre-paint inspection report, weld inspection report, and photographic evidence are required per review item 2.a and hold point 2.

4.5 6.5.4 ci al ly R el ea se d to th e

LB

N L

D oc um en t C on tr ol

C en te r

Re le as ed

: A pr il 3r d, D C

C A ut h

K ey

: E Q

2Q X

EV

9N

AL-1692-2466 Rev. A Doc. Status: Released Page 11 of 26

All officially released LBNL documents are watermarked and contain LBNL Document

Item # QA Data Item Deliverable Description / Requirement Basis Sections

054 Production tracking document template

A production process tracking documentation template, such as traveler, is required per review item 2.a and hold point 3.

4.4 4.5

6.5.3

Part C: Deliverables prior to shipping First Article items

055 First Article inspection reports (post-paint)

First Article post-paint inspection report, weld inspection report, and photographic evidence is required per review item 2.b and hold point 3.

4.4 4.5

6.5.4

056 Shipping plan The shipping plan must meet the requirements in review item 2.b, hold point 3, and Section 5.

Part D: Required prior to shipment of production units

057 Certificates (production) Certificates for welders and weld inspector(s) and heat treatment certificates are required per review item 3 and hold point 5.

4.4 4.5

6.5.1

058 Weld process certification Certification of the weld process is required per review item 3 and hold point 5.

4.4, 4.5 6.5.1

059 Production inspection reports

Inspection reports for the production parts, including visual inspection reports, are required per review item 3 and hold point 5.

4.4 4.5

6.5.4

060 Fabrication tracking documentation

Travelers or similar tracking documentation are required per review item 3 and hold point 5.

4.4, 4.5 6.5.3

061 Shipping checklist A shipping checklist is required for each shipment per review item 3, hold point 5, and Section 5 to verify conformance to shipping process requirements.

4.4 4.5

062 Additional applicable documentation, if any

Deviation requests, nonconformance reports, and other documentation as applicable, or as requested by LBNL.

6.2

Section E: Closeout

061 Closeout Checklist The Closeout Checklist is a Subcontractor statement that verifies that all required deliverables have been delivered, as required per hold point 5.

3.6, 4.5, Appendix A

3.5 Delivery schedule

The preferred delivery schedule is provided in Table 3-4. A phased delivery is anticipated, as determined by the Subcontractor and subject to LBNL approval. The final negotiated timeline and schedule will be incorporated into the procurement subcontract and will dictate the required delivery rates for shipping batches, with progress updates required at predetermined intervals. All First Articles must be provided to LBNL within 20 ci al ly R el ea se d to th e

LB

N L

D oc um en t C on tr ol

C en te r

Re le as ed

: A pr il 3r d, D C

C A ut h

K ey

: E Q

2Q X

EV

9N

AL-1692-2466 Rev. A Doc. Status: Released Page 12 of 26

All officially released LBNL documents are watermarked and contain LBNL Document calendar weeks After Receipt of Order (ARO), and all deliverables to be provided to LBNL within 61 calendar weeks ARO.

Table 3-4 Desired delivery schedule

Shipment

Calendar weeks ARO

QA Package Delivered Shipment Authorized LBNL Receipt

Pre-manufacturing deliverables package

– – 6

First Articles 17 19 20

Final deliverable 58 60 61

3.6 Closeout checklist

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

Appendix A 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 administration, 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.

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 a brief overview of the portal that will be used for data exchange.

ci al ly R el ea se d to th e

LB

N L

D oc um en t C on tr ol

C en te r

Re le as ed

: A pr il 3r d, D C

C A ut h

K ey

: E Q

2Q X

EV

9N

AL-1692-2466 Rev. A Doc. Status: Released Page 13 of 26

All officially released LBNL documents are watermarked and contain LBNL Document

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 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 designee) may be scheduled with advance notice at LBNL’s discretion. Access to any locations where the manufacturing, assembly, inspection or work for the listed items is performed, including lower-tier subcontractors, must be permitted.

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

To ensure efficient and secure project-related documentation, all exchanges will be conducted electronically. Following the award of the subcontract, LBNL will establish and provide access to a dedicated web-based project portal (Windchill) for document management throughout the duration of this project. This portal will facilitate the streamlined access, submission, and storage of all necessary documentation as outlined in this SOW; including QA data, inspection results, CAD models, and drawings, as applicable.

Supported document formats include editable Microsoft Office file formats (.docx, .xlx, etc.), PDF format, image formats (JPEG, PNG, etc.), and plain text or comma-separated values files (.txt or .csv), as applicable.

4.4 Reviews

The University Technical Representative will collaborate with the Subcontractor to schedule reviews, which may occur onsite at either LBNL or Subcontractor facilities, or through web/video conferencing. External reviewers may be included at LBNL’s discretion.

The review types required for this scope of work are:

1. Manufacturing readiness review: Before fabricating any items, the

Subcontractor must submit a pre-manufacturing deliverables package (Table 3-3, Part A) to LBNL for review and approval as follows:

ci al ly R el ea se d to th e

LB

N L

D oc um en t C on tr ol

C en te r

Re le as ed

: A pr il 3r d, D C

C A ut h

K ey

: E Q

2Q X

EV

9N

AL-1692-2466 Rev. A Doc. Status: Released Page 14 of 26

All officially released LBNL documents are watermarked and contain LBNL Document

a. Manufacturing schedule: The schedule must be submitted within six weeks

ARO and include planning and production milestones, reviews, and hold points.

b. Inspection plan: The plan must include inspection procedures, equipment, and report template for the fabricated parts in accordance with the requirements in Sections 6.3 through 6.5 and the drawings.

c. Weld coupons: An equivalent test coupon must be provided for each type of weld representing the welds of the final weldments, along with its associated inspection report.

d. Paint samples with markings: A painted sample of each color of the materials that will be used for the parts must be provided. The color samples must be marked per the requirements in Sections 6.4, 6.5, and the drawings.

e. Anti-corrosion protection: The product data sheet for the product to be applied to masked surfaces per the drawings must be provided to LBNL for review and approval before use.

f. Shipping plan: The Subcontractor must present a draft shipping plan that meets the requirements in Section 5. No First Articles may be shipped before LBNL approval of the shipping plan.

2. First Article inspections:

a. Pre-paint inspection: Prior to painting a First Article, the Subcontractor must submit a pre-painting deliverables package (per Table 3-3, Part B) for

LBNL review and approval, that includes:

i. QA data conforming to requirements in Sections 6.3 through 6.5 and drawings; including certificates for purchased materials, welders and weld inspectors, and heat treatment; welding reports; and inspection reports; and

ii. Template of a production process tracking document that meets the requirements in Section 6.5.3 and the drawings.

b. Post-paint inspection: After First Articles have been painted, the

Subcontractor must submit a post-painting deliverables package (per Table

3-3, Part C) for LBNL review and approval, including:

i. Confirmation of visual inspections, per Sections 6.4 and 6.5;

ii. Anti-corrosion protection application, per Section 6.4; and

iii. A shipping plan, per Section 5.

ci al ly R el ea se d to th e

LB

N L

D oc um en t C on tr ol

C en te r

Re le as ed

: A pr il 3r d, D C

C A ut h

K ey

: E Q

2Q X

EV

9N

AL-1692-2466 Rev. A Doc. Status: Released Page 15 of 26

All officially released LBNL documents are watermarked and contain LBNL Document

LBNL will issue a written notice to proceed (NTP) with production upon successful review.

3. Production shipping readiness review: Prior to shipping any production batch, the Subcontractor must provide a shipping deliverables package (per Table

3-3, Part D) and conforming to requirements in Section 6.5 and the drawings, including:

a. Certificates for welders, weld inspectors, and heat treatment;

b. Certification of welding process conformance;

c. Production inspection reports;

d. Production tracking documentation (such as traveler, or similar); and

e. Completed shipping checklist.

Additional review types may be implemented at LBNL’s discretion at any time after the

Subcontractor enters into the subcontract with LBNL.

4.5 Hold points

Each hold point requires a written NTP issued by LBNL before proceeding beyond that approval item. Table 4-1 lists all hold points required for this scope of work.

Table 4-1 Hold points

Hold Point Approval item Subcontractor action items / submittals

Anticipated LBNL NTP response time

First Article fabrication (pre-paint steps only)

Successful completion of the manufacturing readiness review

Within 10 business days of receipt of all items

First Article fabrication (pre-paint to completion)

Submit QA data showing pre-paint inspection meets all requirements

3 First Article shipment

Submit QA data showing post-paint inspection meets all requirements

Successful completion of shipping plan review

4 Production

Successful verification of First Article performance, conformance with LBNL acceptance criteria through inspection at LBNL

Within 25 business days of receiving First Article shipments

Production batch shipment

Successful completion of the production shipping readiness review

Additional hold points may be implemented at LBNL’s discretion at any time after the

Subcontractor enters into the subcontract with LBNL.

ci al ly R el ea se d to th e

LB

N L

D oc um en t C on tr ol

C en te r

Re le as ed

: A pr il 3r d, D C

C A ut h

K ey

: E Q

2Q X

EV

9N

AL-1692-2466 Rev. A Doc. Status: Released Page 16 of 26

All officially released LBNL documents are watermarked and contain LBNL Document

5 PACKAGING, STORAGE, AND SHIPPING REQUIREMENTS

The Subcontractor carries responsibility for ensuring that items arrive at LBNL undamaged. The Subcontractor must submit a shipping plan for LBNL review and approval before any applicable packaging (e.g. containers, crates, or pallets) is constructed or items are packaged for shipping. The plan must include a shipping checklist to be used as a confirmation that all requirements were met for each shipping batch. No item may be shipped before a written NTP is issued by LBNL as specified in

Section 4.4 and Section 4.5, item 5.

5.1 Packaging

The shipping plan must comply with the following requirements throughout the delivery process, including storage and transportation:

1. The packaging must be able to support and protect the items.

a. The packaging frame design (pallet or container/crate if used) must include a base structure capable of being transported with a standard forklift or pallet jack on at least two sides;

b. The frame’s structural integrity must be sturdy enough to endure multiple forklift applications, including post-delivery handling at LBNL.

2. Each part must be supported as needed to prevent movement, stressing components, or cosmetic damage.

a. All components are to be clean, dry, and free of cutting chips, cutting fluids, excessive lubricating oils, and sand/blasting media;

b. Packaging must protect assemblies from rain or other climatic conditions that may cause damage or corrosion;

c. Heavy items must be stabilized, and fragile items must be cushioned;

d. All weldments must be secured in the transportation vehicle at a minimum of two mounting locations. Tie-down methods and locations must be included in the shipping plan.

3. The packaging must have markings on the exterior for identification and handling.

a. Label with identifying information must include:

i. Delivery address;

ii. University Technical Representative contact information;

iii. Part number of the components contained therein;

iv. Subcontract number.

ci al ly R el ea se d to th e

LB

N L

D oc um en t C on tr ol

C en te r

Re le as ed

: A pr il 3r d, D C

C A ut h

K ey

: E Q

2Q X

EV

9N

AL-1692-2466 Rev. A Doc. Status: Released Page 17 of 26

All officially released LBNL documents are watermarked and contain LBNL Document

b. Arrows indicating the appropriate package orientation;

c. Markings to clearly identify tie-downs, lifting points, and the package’s center of gravity.

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

4551.

5. A packing slip must be provided for each shipment.

6. LBNL requires the use of single-use self-adhesive shock indicators (e.g.

Shockwatch®) installed on both the inside and outside of containers.

5.2 Storage

Should items require storage, they must be stored in such a way as to be fully sheltered from any natural or human-caused conditions that may cause damage or corrosion. This shelter requirement also applies to packaging if packaged items require storage.

5.3 Shipping logistics

The relevant QA data (detailed in Sections 6.3 through 6.5) and the following requirements must be met to release the items for shipping:

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

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

5.4 LBNL arrival logistics

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

2. 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 delivery logistics with the driver and at LBNL;

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

1Reference: 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.

ci al ly R el ea se d to th e

LB

N L

D oc um en t C on tr ol

C en te r

Re le as ed

: A pr il 3r d, D C

C A ut h

K ey

: E Q

2Q X

EV

9N

D https://dtsc.ca.gov/toxics-in-products/toxics-in-packaging-law/

AL-1692-2466 Rev. A Doc. Status: Released Page 18 of 26

All officially released LBNL documents are watermarked and contain LBNL Document

6 QUALITY ASSURANCE

6.1 Subcontractor QA program

As part of the Request for Proposal (RFP) process, Subcontractors must complete the

ALS-U Supplier Quality Evaluation Survey (AL-1208-0209, Table 7-1) to establish the extent of their QA process.

Once the subcontract is awarded, the Subcontractor must maintain the QA program that was deemed effective based on the information submitted. LBNL reserves the right to request additional information on the QA program 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 to LBNL for review and approval before it can be implemented. LBNL can provide their deviation request form or approve the Subcontractor’s customary deviation request documentation prior to it is submitted.

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 the University.

Once a nonconformance is identified, an NCR must be submitted to LBNL within three business days. LBNL can provide their standard NCR form or approve the Subcontractor’s customary NCR documentation prior to it is submitted.

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 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 ci al ly R el ea se d to th e

LB

N L

D oc um en t C on tr ol

C en te r

Re le as ed

: A pr il 3r d, D C

C A ut h

K ey

: E Q

2Q X

EV

9N

AL-1692-2466 Rev. A Doc. Status: Released Page 19 of 26

All officially released LBNL documents are watermarked and contain LBNL Document can be reviewed with input from LBNL. Leave to resume the process is at the discretion of LBNL.

6.3 Inspection plans

Inspection plans must be submitted to the University Technical Representative for written approval. They must include the required inspections and methods detailed in

Sections 6.4 and 6.5, and any additional inspections the Subcontractor deems necessary to ensure the deliverables meet technical, functional, and quality requirements.

All inspection plans must identify:

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

2. The items to be inspected, including their item number. The plan must include an annotated drawing identifying all features to be inspected;

3. How the results will be documented, analyzed, and submitted to LBNL.

6.4 QA inspection requirements

1. All required dimensional inspections must be completed with an appropriate calibrated measurement device, such as a Coordinate Measurement Machine

(CMM).

2. All weld inspections must be completed by a certified weld inspector per AWS D1.1.

This also applies to the weld test coupons.

3. All Geometric Dimensioning and Tolerancing (GD&T) on the drawings are to be inspected and must conform to the drawings.

4. All QA documentation must include the relevant part number.

5. Inspection measurements must be completed in metric units per the LBNL drawings; converted measurements are not acceptable.

6. To ensure conformance with LBNL drawings, the items that are subject to required visual inspections after being painted (powder coated) are:

a. All painted and masked surfaces must be inspected for any unpainted areas, paint peel off, damage, and rust;

b. All tapped and through holes must be inspected for deburr, clearance of chips, or paint buildup;

c. All components must be inspected for the applicable part markings;

d. All masked surfaces must be inspected for full coverage with the LBNL-approved anti-corrosion product because rust adversely affects alignment once these items are installed at LBNL.

ci al ly R el ea se d to th e

LB

N L

D oc um en t C on tr ol

C en te r

Re le as ed

: A pr il 3r d, D C

C A ut h

K ey

: E Q

2Q X

EV

9N

AL-1692-2466 Rev. A Doc. Status: Released Page 20 of 26

All officially released LBNL documents are watermarked and contain LBNL Document

6.5 QA data requirements

This section describes the required QA data referenced in Table 3-3 in Section 3.4.

Requirements for dimensional checks and weld inspections are subject to increase if components do not consistently meet LBNL drawing and quality requirements.

6.5.1 Certificates

1. Material certificates: Material certificates are required for all purchased items including materials, components, and hardware (as applicable and specified in the drawings) and must be provided to LBNL before painting the First Articles.

2. Weld staff and weld inspector certificates: Current weld certificates for welders and weld inspectors are required for both the weld coupons and the fabricated weldments, including any change of personnel and/or subcontracted welders.

3. Certificates of conformance: A welding process certificate is required as verification that the same welding procedures were followed on both the weld test coupons and fabrication of the weldments.

4. Heat treatment certificate: Certificate for post-welding stress relief heat treatment of the weldments is required to verify compliance with welding procedures per drawings.

6.5.2 Material samples

Material samples, and associated reports where applicable, must be provided to LBNL for review and approval as part of the manufacturing readiness review described in Section

4.4, Items 1.c and 1.d. No First Article or production unit may be initiated until LBNL has inspected and approved material samples and any associated inspection reports.

1. Weld test coupons:

a. Prior to commencing welding on components, the Subcontractor must fabricate and weld test coupons, mirroring each type of weld, utilizing identical materials, fillers, and techniques intended for the production units;

b. Weld coupons are mandatory for all welding Subcontractors. A fresh set is required in case of a change in welding Subcontractor;

c. The certified weld inspector must inspect the weld coupons before dispatch to LBNL;

d. All weld joints must undergo machining for clarity where necessary.

ci al ly R el ea se d to th e

LB

N L

D oc um en t C on tr ol

C en te r

Re le as ed

: A pr il 3r d, D C

C A ut h

K ey

: E Q

2Q X

EV

9N

AL-1692-2466 Rev. A Doc. Status: Released Page 21 of 26

All officially released LBNL documents are watermarked and contain LBNL Document

2. Paint and marking material samples:

a. The Subcontractor must provide a paint sample adhering to the RAL colors standard specified on the drawings;

b. Paint samples are mandatory for all paint Subcontractors. A fresh sample is required if a change in paint Subcontractor occurs;

c. The paint samples must bear a marking per the method specified in the drawings;

The samples must be prepared and produced following the same paint and marking procedures intended for the fabricated parts, serving as accurate representations of the final deliverables.

6.5.3 Process documentation

1. Manufacturing schedule: Subcontractor must provide a detailed manufacturing schedule outlining tasks such as planning procurement, fabrication

(including final machining), inspection, coating, and assembly. This schedule requires review and approval by LBNL before implementation.

2. Production tracking documentation: The Subcontractor must utilize job travelers or similar documents to record the fabrication process (steps and methods), materials used, and quality control measures implemented. The job traveler must be provided to LBNL before shipping can be authorized.

6.5.4 Inspection reports

1. Weld inspection verification must:

a. Be submitted for critical welds, confirming weld type, bead size, and skip weld length, as applicable. Photographic evidence is required;

b. Be generated for each weldment and completed before paint is applied;

c. Recorded in Subcontractor’s job traveler (or similar) is acceptable.

2. First article inspection reports

a. Pre-paint inspection must include:

i. Confirmation of visual inspection of welds per item 1 above;

ii. Verification of material and heat treatment as specified in the drawings;

iii. Full dimensional inspection including all critical features:

ci al ly R el ea se d to th e

LB

N L

D oc um en t C on tr ol

C en te r

Re le as ed

: A pr il 3r d, D C

C A ut h

K ey

: E Q

2Q X

EV

9N

AL-1692-2466 Rev. A Doc. Status: Released Page 22 of 26

All officially released LBNL documents are watermarked and contain LBNL Document

1. All features with basic dimensions, and all GD&T, are considered critical (on all sheets and tables with specific notes other than general notes);

2. All critical holes on each top plate must be inspected.

iv. Inspection reports must be completed prior to painting of the parts.

b. Post-paint inspection must include:

i. Confirmation of visual inspection of all welds per item 1 above;

ii. Confirmation of visual inspection of painted and masked surfaces;

iii. Verification that the approved anti-corrosion protection was applied.

3. Production inspection reports must be provided for each item and include:

a. Confirmation of visual inspection of welds per item 1 above;

b. Verification of material and heat treatment;

c. Confirmation of visual inspection of painted and masked surfaces;

d. Dimensional inspection including:

i. All features with basic dimensions, and all GD&T, are considered critical (on all sheets and tables with specific notes other than general notes);

ii. All features with inspection dimensions (inscribed in a rounded box) must be 100% inspected and measured numbers must be reported;

and

iii. Inspection reports must be completed prior to painting of the parts.

6.6 Acceptance criteria

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

1. All applicable certificates and QA data;

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

Upon delivery, LBNL will conduct receiving inspection and measurements to verify the functional acceptance criteria list (ACL) for each specified part. The applicable ACL will be made available to the Subcontractor as requested. 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.

ci al ly R el ea se d to th e

LB

N L

D oc um en t C on tr ol

C en te r

Re le as ed

: A pr il 3r d, D C

C A ut h

K ey

: E Q

2Q X

EV

9N

AL-1692-2466 Rev. A Doc. Status: Released Page 23 of 26

All officially released LBNL documents are watermarked and contain LBNL Document

7 APPLICABLE DOCUMENTS

The released version of the documents listed in Table 7-1 are integral to this scope of work.

All information contained therein is valid to the fullest extent unless specifically noted within this SOW. Applicable documents must originate from the LBNL Document Control

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

Table 7-1 Applicable documents list

Document Number Title

General

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

10068 LBNL Engineering Paint Specification

EG-1002-1955 LBNL Marking Methods

Applicable Drawings

AL-1713-6747 Document Reference List for ALS-U ATS/STA Base Supports and Rafts*

*Note: the drawing numbers are identical to the fabrication part numbers listed in Table 3-1 ci al ly R el ea se d to th e

LB

N L

D oc um en t C on tr ol

C en te r

Re le as ed

: A pr il 3r d, D C

C A ut h

K ey

: E Q

2Q X

EV

9N

APPENDIX A: CLOSEOUT CHECKLIST

The closeout checklist summarizes all Subcontractor deliverables as outlined in Sections 3, 5, and 6 of the Statement of

Work (SOW), document number AL-1692-2466. Submitting this completed checklist is required to close out the contract.

For each item, the Subcontractor must indicate “Yes” or “No” that the item was delivered according to requirements. For any “No” response, 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 to the Subcontractor for completion of the deliverable before closeout.

Item

SOW

Section Item

Subcontractor completed

Comments / Attachment title

LBNL

validated

A1 3.4, 6.4 Manufacturing and inspection plans.

☐ Yes

☐ No

Initials:

☐ Yes

Initials:

A2 3.4, 6.4 Paint samples with markings provided to LBNL.

☐ Yes

Initials:

A3 3.4, 6.4 Weld coupons and associated inspection reports delivered.

☐ Yes

Initials:

A4 3.1, 3.3, 3.4, 6.5

First Article items together with complete QA documentation package; anti-corrosion coating applied as approved by LBNL.

☐ Yes ci al ly R el ea se d to th e

LB

N L

D oc um en t C on tr ol

C en te r

Re le as ed

: A pr il 3r d, D C

C A ut h

K ey

: E Q

2Q X

EV

9N

AL-1692-2466 Rev. A Doc. Status: Released Page 25 of 26

All officially released LBNL documents are watermarked and contain LBNL Document

Item

SOW

Section Item

Subcontractor completed

Comments / Attachment title

LBNL

validated

A5 3.4 Complete QA documentation packages for the fabricated parts.

☐ Yes

Initials:

A6 3.4, 5 Completed shipping plan and shipping checklist confirming that packaging and shipping requirements -and, if needed, storage conditions - have been met.

☐ Yes

Initials:

A7 3.1 Fully fabricated, painted, and inspected support structures delivered per the Subcontract, this Statement of Work, and the applicable drawings.

☐ Yes

Initials:

A7 5.1 Shipment packing list for each shipment provided to

LBNL.

☐ Yes

Initials:

A8 5.3 Confirmation that Subcontractor provided the contracted transportation company with LBNL-approved shipping plan and checklist requirements.

☐ Yes

Initials:

A9 5.3

The transportation company met all shipping logistics and advance communication requirements were met (ensuring truck size adheres to limitations and providing contact information timely status notifications).

☐ Yes

Initials:

A10 4.5 Receipt of written NTP from LBNL for shipment confirmed.

☐ Yes ci al ly R el ea se d to th e

LB

N L

D oc um en t C on tr ol

C en te r

Re le as ed

: A pr il 3r d, D C

C A ut h

K ey

: E Q

2Q X

EV

9N

AL-1692-2466 Rev. A Doc. Status: Released Page 26 of 26

All officially released LBNL documents are watermarked and contain LBNL Document

Item

SOW

Section Item

Subcontractor completed

Comments / Attachment title

LBNL

validated

A12 6.2, 6.6 All applicable nonconformance or deviation documentation, if any, submitted.

☐ Yes

Subcontractor closeout statement

Prepared by:

Title / role:

Date:

Number of attachments:

ci al ly R el ea se d to th e

LB

N L

D oc um en t C on tr ol

C en te r

Re le as ed

: A pr il 3r d, D C

C A ut h

K ey

: E Q

2Q X

EV

9N