3) AL-1713-6958 A SOW.pdf

Advanced Light Source Upgrade Project Lawrence Berkeley National Laboratory

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Printed hard copies of this document are for reference only.

ATS-STA Vacuum Assembly Statement of Work

Release Date: Apr 3 2024 11:58:30 AM PDT

Document Number: AL-1713-6958 Revision: C

Document Status: Released

Document Type: SPECIFICATION

Category Code: AL7426

ALS-U - ACCUMULATOR TO STORAGE RING TRANSFER LINE

VACUUM CHAMBERS

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Table of Contents

1 Revision History

2 Approvals

3 Abbreviations and Acronyms

4 Introduction

4.1 Project Overview

4.1 Scope Overview

4.2 Description of Items

4.2.1 Component Design Summary

4.2.1.1 Vacuum CHambers

4.2.1.1.1 Multipole/Drift Chambers

4.2.1.1.2 Dipole Chambers

4.2.1.1.3 Bellows

4.2.1.1.4 Special Diagnostics Chamber

4.2.1.1.5 Generic or modified off-the-shelf chambers

4.2.1.2 Vacuum Supports

4.2.1.3 Fasteners and hardware

4.2.2 Components included and delivery state

4.3 Roles and Responsibilities

5 Deliverables

5.1 Deliverables

5.1.1 Documentation Deliverables

5.1.2 Drawings and CAD Models Deliverables

5.1.2.1 LBNL provided models and drawings

5.1.3 Hardware Deliverable

5.1.3.1 First article

5.1.3.2 Production

5.2 Execution Requirements

5.2.1 Management and Quality plan

5.2.2 Final Design Review Requirements

5.2.3 First article

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5.2.4 First article delivery

5.2.5 Complete Production

5.2.6 Delivery

5.3 Final documentation package(s)

6 Management, Reporting, Documentation and reviews

6.1 Schedule

6.2 Reporting requirements

6.3 Proposal documentation requirements

6.4 Reviews

6.5 Hold points

7 Packaging and shipping specifications

7.1 Container

7.2 Marking

7.3 Packaging

7.4 Handling and storage

8 Quality Assurance

8.1 Control plan

8.2 Type of control points

8.3 Deviation requests

8.4 Nonconformance reports

8.5 Numbering and/or Serialization

8.6 Completed ACL

9 Applicable Documents

Appendix A: Control Plan

Appendix B: CAD Model and drawing requirements ci al ly R el ea se d to th e

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1 REVISION HISTORY

Rev. CM Number Description of Change A Baseline

2 APPROVALS

The following individual(s) must approve this document:

Approver Project Role Ken Chow Chief Engineer/ Accelerator Mechanical

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

3 ABBREVIATIONS AND ACRONYMS

ALS Advanced Light Source ACL Acceptance Criteria List

ALS-U

ATS

Advanced Light Source Upgrade Accumulator to Storage Ring Transfer line

AR Accumulator Ring ARO After Receipt of Order BPM Beam Position Monitor CAD Computer Aid Design CMM Coordinate Measuring Machine CP Control Plan FAT Factory Acceptance Test FDR Final Design Review HHL High Heat Load HP Hold Point

IR

KOM

InfraRed Kick Off Meeting

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

SR

STA

Storage Ring Storage Ring to Accumulator Ring Transfer Line

UHV Ultra High Vacuum VC Vacuum Chamber W Witness ci al ly R el ea se d to th e

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4 INTRODUCTION

4.1 Project Overview

ALS-U is an upgrade project to the LBNL Advanced Light Source (ALS). The ALS is a 1.9

GeV storage ring operating at 500 mA of beam current. It is optimized to produce intense beams of soft x-rays, which offer spectroscopic contrast, nanometer-scale resolution, and broad temporal sensitivity. The ALS facility includes an accelerator complex and photon delivery system that is capable of providing the foundations for an upgrade that will achieve world-leading soft x-ray coherent flux. The existing ALS provides a ready-made foundation, including conventional facilities and also includes extensive beamlines (up to

40 simultaneously operating beamlines) and instrumentation, an experimental hall, computing resources, ancillary laboratories, offices, and related infrastructure that will be heavily utilized in an upgrade scenario.

The ALS will be upgraded with a multibend achromat (MBA) lattice design that will provide a soft x-ray source that is orders of magnitudes brighter — an up to 100-1000 times increase in brightness and will provide a significantly higher fraction of coherent light in the soft x-ray region than is currently available at ALS.

4.1 Scope Overview

This scope of work is for the final design, fabrication, dimensional inspection, fiducialization, vacuum testing, preassembly and delivery of vacuum chambers for the

ALS-U project ATS and STA transfer lines. The scope also includes vacuum supports associated with the chambers in this scope. The scope excludes some custom diagnostics elements that are part of the vacuum system.

4.2 Description of Items

The scope of the ALS-U project includes the construction of two new transfers line that connects the new Accumulator Ring (AR) to the new Storage Ring. The two new transfer lines are the Accumulator-To-Storage Ring (ATS) and Storage Ring-To-Accumulator Ring

(STA) transfer lines. The transfer lines are located in sector 12 and sector 1 of the ALS tunnel as shown in Figure 4-1. The transfer lines are near mirror images of each other with both lines emanating or terminating in straight 1 of the SR and straights 12 and 1 of the AR.

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The ATS is in close proximity to the Booster-To-Accumulator (BTA) transfer line in addition to the AR and SR arcs in sector 12. This makes the sector 12 region very congested.

Figure 4-1: ATS/STA Region of ALS Tunnel

The ATS and STA vacuum beamline is divided into 9 and 10 modules respectively. The modules are illustrated in Figure 4-4. Figure 4-2 shows two example modules ATS

Module #8 and ATS Module #11. The aspects of ATS Module #8 included in this scope would be chambers #1 and #2 along the beamline, the 4 x vacuum support assemblies and the 3 x magnets spacers. The ion pump and R/A valve will be provided by LNBL. All other items shown in ATS Module #8 of Figure 4-2 is not included in this scope.

Similarly, on ATS Module #11 shown in Figure 4-3, the elements included in this scope includes: 2x Non-RF bellow, Spool chamber, TV monitor chamber (excluding TV scintillator assembly and camera lens assembly), vacuum chamber #1 (including welded

BPM block & fiducial – no buttons) and the 6 x vacuum support assemblies.

Table 4-1 & 4-2 shows each module and lists aspects of each module included in this scope.

ATS

STA

BTA

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Figure 4-2: ATS Module #8 ci al ly R el ea se d to th e

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Figure 4-3: ATS Module #11 ci al ly R el ea se d to th e

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Figure 4-4: ATS/STA Modules including magnets, vacuum chamber and support

ATS Transfer Line

STA Transfer Line ci al ly R el ea se d to th e

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4.2.1 Component Design Summary

The design of the ATS and STA vacuum system has been carried out to meet the following summary requirements and objectives:

Provide appropriate vacuum apertures for high efficiency injection through the transfer lines.

Provide vacuum pressures that meets requirement of 1e-7 Torr average and lower pressures at the interfaces to the AR and SR.

Provide low magnetic permeability vacuum chamber materials to minimize chamber impact on magnetic field quality

Provided modular vacuum design for ease of integration to magnets, support rafts and the congested sector 12 region

A summary count of all vacuum components of the ATS/STA transfer line and included in this scope is shown in Table 4-5.

4.2.1.1 VACUUM CHAMBERS

The beamline vacuum chambers are made from 316L or LN stainless steel tubes. The beam tubes are readily available stock item. There are 4 general types of vacuum chambers found on the ATS and STA transfer lines: Multipole/Drift chambers, Dipole chambers, Non-RF bellows, Special Diagnostics Chambers and Generic off-the-shelf chambers

4.2.1.1.1 Multipole/Drift Chambers

The multipole/drift chambers range in complexity from simple tubular chambers with a simple featureless piece of stainless tube with welded flanges at both ends to more complex chambers with several intermediate weld joints to BPM blocks and pumping appendages. An example of a complex multipole chamber is shown in Figure 4-5.

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Figure 4-4: Example Multipole/Drift Chamber – ATS Module #1 Multipole chamber

4.2.1.1.2 Dipole Chambers

The dipole chambers are located within each of the Dipole bending magnets in the ATS and STA transfer lines. They are tubular chambers with a slight constant bend radius to follow the path of the injected electron beam. Potions of the beam tube towards the entry and exit of the dipole chambers are straight while the curved potion is in the middle.

Figure 4-5: Example Dipole Chamber

4.2.1.1.3 Bellows

The bellows on the ATS/STA transfer lines are simple edge welded bellows with no RF shielding features on the inside.

BPM Block &

Fiducial posts

Pump & Gauge Ports

Conical transition

Curved section

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4.2.1.1.4 Special Diagnostics Chamber

There are three special diagnostics chambers found on each of the ATS/STA transfer lines that are part of this scope. Diagnostics M1 chamber, TV monitor chamber and Special dipole chamber. CAD images of these chambers are pictured below in Figure 4-6, Figure

4-8, and Figure 4-9.

Each chamber is design for hosting or facilitating electron beam diagnostics components.

This scope includes that fabrication of these chambers. The specific diagnostics elements are excluded.

The special dipole diagnostics chamber is main made from Aluminum while the M1 and

TV monitor chambers are stainless steel. The special diagnostics chamber’s main body is made from two halves of machined Aluminum plates that are tig welded together. The chamber also features bi-metallic flanges on the entry and exit ports.

Figure 4-6: ATS Module # M1 Chamber Figure 4-7: ATS Module # TV Monitor Chamber

Figure 4-8: ATS Module # Special Dipole

Main body made from welded two halves of Al

Bi-metal flanges

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4.2.1.1.5 Generic or modified off-the-shelf chambers

There are several generic or modified off-the-shelf chambers such as tees and crosses.

Figure 4-9: Example of generic or modified COTs

4.2.1.2 VACUUM SUPPORTS

In addition to the vacuum chambers, the scope of this work includes fabrication of vacuum chamber supports. They are various support designs found on the ATS/STA vacuum system. They are generally made from custom machines pieces of Aluminum blocks, threaded rods and generic fasteners.

Figure 4-10: Example vacuum supports

Machined

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4.2.1.3 FASTENERS AND HARDWARE

The scope of work includes delivery of all fasteners, blank flanges and gaskets necessary to assemble the vacuum chambers and supports for the ATS/STA vacuum system.

4.2.2 Components included and delivery state

The scope of work includes pre-assembly of complete or sections of each modules as shown in Table 4-3. Each shipped section must be assembled (excluding turbo pumps), bakeout and vented to nitrogen for shipment.

The component provided by LBNL and listed in Table 4-4 must be integrated to the shipped assemblies.

Table 4-1: Summary of ATS vacuum modules

Modules Features Illustration LBNL Assy Num

2 x vacuum chambers

6 x support assemblies

2 x Non-RF bellows

1 x Tee chamber

AL-1471-6731

Excluded

ICT Setup

1 x vacuum chambers

3 x support assemblies

1 x Non-RF bellows

AL-1471-6733

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1 x vacuum chambers

2 support assemblies

AL-1472-3609

4 x vacuum chambers

5 x support assemblies

3 x Non-RF bellows

1 x Tee chamber

1 x Mirror

AL-1420-7841

SRM Camera Setup

TV Camera Setup

Scintillator Setup

Mirror Holder

2 x Viewport Flange

2 x vacuum chambers

4 x support assemblies

3 x PEAK spacers

AL-1420-7866

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2 x vacuum chambers

4 x support assemblies

1 x Non-RF bellows

3 x PEAK spacers

AL-1425-9304

2 x vacuum chambers

3 x support assemblies

AL-1425-8616

4 x vacuum chambers

6 x support assemblies

2 x Non-RF bellows

AL-1425-7898

SRM Camera Setup

Scintillator Setup

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2 x vacuum chambers

4 x support assemblies

2 x Non-RF bellows

AL-1408-8418

Magnetic Shield

Table 4-2: Summary of STA vacuum modules

2 x vacuum chambers

7 x support assemblies

2 x Non-RF bellows

1 x Tee chamber

AL-1424-4976

2 x vacuum chambers

5 x support assemblies

AL-1424-4995

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4 x vacuum chambers

5 x support assemblies

3 x Non-RF bellows

1 x Tee chamber

1 x Mirror

AL-1424-4993

SRM Camera Setup

TV Camera Setup

Scintillator Setup

Mirror Holder

2 x Viewport Flange

2 x vacuum chambers

4 x support assemblies spacer

AL-1424-4994

2 x vacuum chambers

3 x support assemblies

1 x Non-RF bellows spacer

AL-1426-6077

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2 x vacuum chambers

3 x support assemblies

1 x Non-RF bellows

AL-1426-6056

4 x vacuum chambers

6 x support assemblies

2 x Non-RF bellows

AL-1426-3525

SRM Camera Setup

Scintillator Setup

1 x Viewport Flange

2 x vacuum chambers

4 x support assemblies

2 x Non-RF bellows

AL-1424-4985

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Table 4-3: Shipped Subassemblies

Modules Illustration LBNL Assy

Num

ATS

Module 4A & B

AL-1471-6731

AL-1471-6733

AL-1472-3609

7A & B

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LBNL Assy

Num

ATS

8A & B

AL-1420-7866

9A & B

AL-1425-9304

AL-1425-8616

11A & B

AL-1425-7898

12 A & B

AL-1408-8418

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Num

STA

4A & B & C

AL-1424-4976

AL-1424-4995

6 A & B

AL-1424-4993

7A & B

AL-1424-4994

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Num

STA

8A & B

AL-1426-6077

AL-1426-6056

10 A & B

AL-1426-3525

11A & B

AL-1424-4985

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Table 4-4: Materials provided by LBNL to be integrated in the shipped Assemblies

Id Features Illustration LBNL ID Quantity

1 R/A Valves

HW-1317-6108 16

2 Pirani Gauge

HW-1319-9330 4

Cold Cathode

Gauge

HW-1319-9259 4

4 Gate Valve

HW-1000-6541 4

5 Ion Pumps

Hw-1000-8337 16

SEAL, DELTA,

HF, HNV-200,

0.102in

HW-1000-9657 65

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Table 4-5: Summary counts of all components included in this scope

Id Vacuum components ATS Quantity STA Quantity

1 Vacuum chambers 18 18

2 Vacuum Tee 4 4

3 Vacuum support assemblies 34 30

4 TV monitor chambers 2 2

5 M1 Chambers 1 1

6 Non-RF bellows 12 12

4.3 Roles and Responsibilities

Two individuals will be identified in the awarded contract: a University Procurement Specialist and a University Technical Representative. The University Procurement Specialist is responsible for the contract administration from the Solicitation to the award of any subcontract. The University Technical Representative is responsible after award for the technical aspects of any subcontract through the receipt and acceptance of the purchased item.

University Procurement Representative – See subcontract for details.

University Technical Representative – See subcontract for details.

The selected subcontractor is required to identify a project manager to act as the single point of contact at the subcontractor. The project manager interfaces directly with the University Technical Representative for all technical issues.

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5 DELIVERABLES

This section details the required hardware and documentation deliverables for each phase of the ATS/STA Chambers subcontract execution process. It also details the technical management and oversight requirements during the execution process.

5.1 Deliverables

5.1.1 Documentation Deliverables

Table 5-1 provides the list of documentations to be provided by the selected Subcontractor to LBNL. Fabrication cannot start prior to the review, approval, and closure of all related FDR action items.

Table 5-1: list of documentation to be provided to LBNL.

Id Documentation Due Date

Project Documentation 1 Initial schedule 7 days ARO

2 Weekly status / progress meeting For the duration of the contract 3 Monthly Status Summary & Updated Schedule 5th of each month

Quality Documentation 4 Management and Quality Plan (§5.2.1) 7 days ARO 5 Control plan (see Table 5-5 and §9) 10 days before FDR 6 Control plan duly completed and signed 10 days prior shipment

Acceptance Criteria List (AL-1685-4169) duly completed and signed 10 days prior shipment

Manufacturing Documentation

Manufacturing Drawing

Assembly drawings 10 days before FDR

9 Final 3D model 10 days before FDR 10 Bill of Material 10 days before FDR 11 Manufacturing plan (see Table 5-5) 10 days before FDR 12 Test Plan and Associated procedures (see Table 5-5) 10 days before FDR 13 Test report (dimension, He leak, etc…) 10 days prior shipment

14 Nonconformance Report or / and deviation request Within 3 business days of occurrence

15 Material Certification 10 days before manufacturing

Delivery documentation 16 List of packing crates and contents 10 days prior shipment 17 Shipping plan (see §7) 10 days prior shipment

Other 18 Certificate of Conformance 10 days prior shipment 19 Final document package (see §5.3) 10 days prior shipment

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5.1.2 Drawings and CAD Models Deliverables

LBNL will provide the vendor with reference drawings and CAD models. The fabrication must take into consideration all requirement of the Engineering Specification Document

AL-1713-6959 (also see Appendix B). The vendor is responsible for carrying out the detailed and final design for each chamber and component of the ATS/STA vacuum system. The tolerances and dimensions stipulated in the LBNL provided reference drawings must be respected except in cases where a waiver in writing, has been explicitly provided by LBNL technical representative. Tolerances and dimensions of the vendor produced detail drawings must be appropriate for overall fit and function of the ATS/STA vacuum system.

5.1.2.1 LBNL PROVIDED MODELS AND DRAWINGS

LBNL is providing the vendor the design information packages, see Table 5-2.

Table 5-2: LBNL design package type

Id Drawing Description LBNL Design Information

Type

1 AL-1714-1003 ATS Vacuum Only Assembly

2 AL-1714-2063 STA Vacuum Only Assembly

3 AL-1714-1000 ATS Master Assembly

4 AL-1714-2062 STA Master Assembly

5 AL-1471-6731 ATS Module #4

6 AL-1471-6733 ATS Module #5

7 AL-1472-3609 ATS Module #6

8 AL-1420-7841 ATS Module #7

9 AL-1420-7866 ATS Module #8

10 AL-1425-9304 ATS Module #9

11 AL-1425-8616 ATS Module #10

12 AL-1425-7898 ATS Module #11

13 AL-1408-8418 ATS Module #12

14 AL-1424-4976 STA Module #4

15 AL-1424-4995 STA Module #5

16 AL-1424-4993 STA Module #6 ci al ly R el ea se d to th e

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Id Drawing Description LBNL Design Information

Type

17 AL-1424-4994 STA Module #7

Reference Assemblies

18 AL-1426-6077 STA Module #8

19 AL-1426-6056 STA Module #9

20 AL-1426-3525 STA Module #10

21 AL-1424-4985 STA Module #11

22 AL-1593-3796 ATS - 16MM OD STRAIGHT CHAMBER

Reference Design

23 AL-1430-4347 CHAMBER, TUBE, 16 OD, ICT INTERFACE

24 AL-1430-6136

ATS - CHAMBER, DN25,TUBE 16 OD,

CURVED

25 AL-1430-6203

CHAMBER, DN16, TUBE Ø16, PUMP &

BPM

26 AL-1502-0034 CHAMBER, TV BOX - L

27 AL-1334-3444 ATS, B1 CROTCH CHAMBER

5.1.3 Hardware Deliverable

The schedule and phasing of hardware delivery is defined in this section

5.1.3.1 FIRST ARTICLE

The selected subcontractor is required to produce two vacuum modules listed in Table 5-

3. The shipping configuration for each module is listed in Table 4-3.

Table 5-3: List of first articles

Id Model Description Qty Due Date

1 AL-1420-7841 ATS Module #7A & B 1 20 weeks After FDR Approval

2 AL-1425-9304 ATS Module #9A & B 1 ci al ly R el ea se d to th e

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5.1.3.2 PRODUCTION

Table 5-4 list the production articles and the respective quantities. The delivery order and batches can be proposed by the subcontractor otherwise full delivery in a single shipment applies. The shipping configuration for each module is listed in Table 4-3.

Table 5-4: List of production articles

Id Drawing ID Description Qty Due Date

1 AL-1471-6731 ATS Module 4 A & B 1

20 weeks After First

Article Approval

2 AL-1471-6733 ATS Module #5 1

3 AL-1472-3609 ATS Module #6 1

4 AL-1420-7866 ATS Module #8 A & B 1

5 AL-1425-8616 ATS Module #10 1

6 AL-1425-7898 ATS Module #11 A & B 1

7 AL-1408-8418 ATS Module #12 A & B 1

8 AL-1424-4976 STA Module #4 A & B & C 1

9 AL-1424-4995 STA Module #5 1

10 AL-1424-4993 STA Module #6 A & B 1

11 AL-1424-4994 STA Module #7 A & B 1

12 AL-1426-6077 STA Module #8 A & B 1

13 AL-1426-6056 STA Module #9 1

14 AL-1426-3525 STA Module #10 A & B 1

15 AL-1424-4985 STA Module #11 A & B 1 ci al ly R el ea se d to th e

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5.2 Execution Requirements

5.2.1 Management and Quality plan

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

Quality Plan within 7 days ARO. This must include organizational policy on quality, controlled documents for Non-conformance, material inspection, and subcontractor qualification (see §8.1)

5.2.2 Final Design Review Requirements

A final design review is required once the subcontractor has completed the detail manufacturing design for all chambers and tooling. The selected subcontractor is responsible for supplying all documentations related to the FDR prior to fabrication of the ATS/STA Chambers and components.

CAD model and drawing requirements are dictated by LBNL document AL-1265-6612.

The FDR is required to include of the following documentation:

1. Control Plan and Manufacturing plan for the ATS/STA Chambers and components

2. Final manufacturing drawings

3. Final CAD model (Required if Reference Design was modified)

4. Test plan and associated procedures

5. Bill of material

Close out of the FDR includes review, written approval, and resolution of all related FDR action items prior to fabrication. This is also required to satisfy the Notice to Proceed, reference §8.2.

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Table 5-5: Documentation description Documents Description

Manufacturing plan

The manufacturing plan documents step-by-step all the manufacturing process from the procurement of raw material to the delivery (except tests for FAT, which are covered in the test plan). The manufacturing plan has to contain at least the following details:

Standards required for the procurement of raw material

Description of each step of the fabrication

Internal procedures applicable to this effort

Procedures and/or standards used for fabrication must be referenced in the manufacturing plan.

Test Plan

The test plan at a minimum document step-by–step activities of all tests prior to the FAT to validate the vacuum hardware such as:

He leak test

Bakeout

RGA

Outgassing rate

Beam center measurement in reference to fiducials

All criteria relative to tests performed have to be mentioned in the test plan. Procedures and/or standards used for tests must be referenced in the test plan.

Control plan

The control plan must describe all steps of the fabrication, including, verification of materials, manufacturing/execution operations, inspection, tests and delivery and any work to be performed by subcontractor.

LBNL will provide a template to the selected subcontractor

5.2.3 First article

Following approval of the FDR, a first article will be produced. The first article will be subjected to the same testing and quality assurance processes as the production units.

After assessments of the first article, LBNL will give the selected subcontractor approval for the rest of the production. Reference §5.1.3.1 First Article, and §8.2 Notice to Proceed for additional information.

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5.2.4 First article delivery

The selected subcontractor will be responsible for the delivery of the first article to LBNL in accordance with the parameters provided within this document. Refer to section §5.2.6 for the delivery conditions.

5.2.5 Complete Production

In accordance with section §5.2.3 LBNL will give final approval for the commencement of fabrication of the production units once the first article unit has been received and satisfactorily tested.

Prior to shipment of the production units, the subcontractor must provide the following:

1. Photos of completed ATS/STA vacuum assemblies packed in an appropriate crate.

2. Completed FAT and associated reports

3. Final and completed CP

4. Final and completed ACL

5. Quality assurance receipts and certifications

6. Nonconformance or deviation documentation pertaining to each individual assembly

7. Final, approved shipping plan

8. Written authorization from LBNL to proceed with shipping

LBNL personnel reserve the right to perform an evaluation of hardware, documentation, and shipping scheme at the subcontractor’s production site prior to authorizing shipment.

5.2.6 Delivery

The selected subcontractor will be responsible for the packing, shipping and delivery of the production units to LBNL in accordance with the requirements provided herein. The shipped modules must be delivered in the assembled state shown in Table 4-3.

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5.3 Final documentation package(s)

LBNL will be provided a full and complete documentation package at the end of the production. Reference LBNL document AL-1265-6612 for specific file requirements. The documentation package must contain the items listed below.

1. A complete, as-built bill of materials identifying both fabricated and commercially available components

2. A complete, as built CAD model in an editable format

3. Complete, as built drawings in English, and in an editable format.

4. Other documentation as requested ci al ly R el ea se d to th e

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6 MANAGEMENT, REPORTING, DOCUMENTATION AND REVIEWS

6.1 Schedule

The following table provides the main schedule items and hold points.

Table 6-1 : Summary of timetable of the project

Section # Designation Schedule Responsibility

§6.2 Kick-off Meeting 7 days ARO subcontractor

§5.2.1

Management and Quality plan

7 days ARO subcontractor

§5.2.2

Final ATS/STA vacuum design review (FDR)

6 weeks ARO subcontractor

HP#1 Approval of the FDR 2 weeks after completion of

FDR

LBNL

§5.2.3 Completion of Manufacturing (First article)

20 weeks after approval of

FDR

subcontractor

§5.2.4 Delivery

(First article) 2 weeks after completion of manufacturing subcontractor

HP#2

Approval of the first article 2 weeks after delivery

LBNL

§5.2.5 Completion of Manufacturing (Production)

20 weeks after approval of first article subcontractor

HP#3

Approval of the production 2 weeks after completion of each manufacturing batch

LBNL.

§5.2.6 Delivery 2 weeks after each approval of manufacturing batch subcontractor ci al ly R el ea se d to th e

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6.2 Reporting requirements

Upon award of the subcontract, the LBNL technical representative will contact the selected subcontractor to set up a Project Kick-off meeting. This meeting will establish the requirements for communication and introduce the portal that will be used for data exchange.

Written progress updates are required on before the fifth of each month. This may include drawings, manufacturing plans, test plans, QA plans, schedule updated or other documents upon request in any state.

Visits by LBNL personnel, including access to the factory where the units are being built, as the discretion of LBNL, may be required.

Subcontractor must be responsible for maintaining an action item list for documenting the actions resulting from each meeting, identifying the responsible party and providing an anticipated completion date for each action.

Other reports or data as requested in writing.

6.3 Proposal documentation requirements

Upon subcontract award, a Windchill Project portal will be established by LBNL and access provided to the subcontractor. Windchill will be used as the repository for all information, QA data, and drawing transference related to the magnet development and production. A brief overview of Windchill will be provided at the kickoff meeting.

Additional training may be available upon request.

An electronic copy of all required documentation noted in the Deliverables section of this document is required.

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

DRAWING REQUIREMENTS, specifies acceptable file formats for the final drawings and

CAD models.

Other document formats include .docx, .xlsx, and other editable file formats may be used with advance written approval from the LBNL technical representative.

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6.4 Reviews

A final design review is required for this project. The LBNL technical representative will work with the subcontractor to establish an appropriate timeline and location for all reviews. Reviews may be conducted at either the subcontractor’s or the LBNL site or via web/video conference tools. External, non-LBNL reviewers may be included at LBNL’s discretion.

Review drawings, documentation, and presentations are required to be delivered to the

LBNL technical representative a minimum of 10 business days prior to the scheduled review.

6.5 Hold points

The Table 6-2 provides the list of control points. Additional control points may be identified following review of the Acceptance Criteria List reference §9.

Table 6-2 : List of hold points

Section Activity Control point Type §5.2.2 Closeout of FDR NTP §5.2.3 Approval of first article NTP §5.2.5 Approval of complete production NTP

Control point types are defined in §8.2.

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7 PACKAGING AND SHIPPING SPECIFICATIONS

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

7.1 Container

Containers or crates for the ATS/STA vacuum assemblies may be used for both shipping and storage. Construction of the containers must be sufficient to adequately support and protect the assemblies during shipping.

Crates must be reusable with sides that attach using clips or other standard attachments that allow for ease of disassembly and/or reuse. LBNL must evaluate and approve shipping crate designs prior to fabrication of the crates or utilizing them for shipping.

Crates can contain multiple assemblies. The crates must be strapped on all sides prior to and during shipment.

7.2 Marking

The exterior of the crates must have markings that clearly identify tie-downs, lifting points, and the crate center of gravity.

Mark the exterior of the crate with clear and obvious labels indicating the presence of fragile contents. Shipments originating outside of the United States must have pictorial labels or labels written in both the originating native language and English.

The exterior of the crate must have up arrows indicating the appropriate crate orientation.

Crates must be marked with the serial numbers of each chamber or component contained therein.

All shipping containers must be labeled with all subcontract information including subcontract number, LBNL point of contact individual, and delivery information.

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7.3 Packaging

All assemblies must be free of any liquid prior to shipping. The use of desiccant is strictly forbidden.

The assemblies must be blocked/cribbed/supported to prevent movement or overstressing the component during transport. The following must be included:

Each assembly must be complete as stipulated in Table 4-3.

Placement of eco-friendly packing foam between the assemblies (if crate contains multiple assemblies)

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

The shipping containers should incorporate a moisture barrier on the assembled units to prevent condensation during air shipment.

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

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

7.4 Handling and storage

The subcontractor must pay particular attention during phases of lifting operation to avoid damage to the chambers and components

Should the ATS/STA assemblies require storage, the storage location must be a temperature and moisture controlled, secured storage facility. Ambient air temperature during storage is between 10 C and 40 C.

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

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8 QUALITY ASSURANCE

The subcontractor must follow the quality plan during first article and production fabrication

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

8.1 Control plan

The Control Plan (see Table 5-5) must cover the entire scope of the phase/task, including any work to be performed by subcontractors like verification of materials, manufacturing/execution operations, inspection and test and delivery. LBNL will provide the selected subcontractor the template of Control Plan (see Appendix A: Control plan and applicable document in §9).

Each activity once finished must be dated and signed by the subcontractor and the LBNL technical representative. The identification of the records released during activity execution (test report, dimensional report, NCR) must be registered with the Control Plan. The Control Plan must be delivered to and approved by the University prior to the FDR. Notification points (NP, W, HP) will be added by LBNL before returning to the selected subcontractor.

8.2 Type of control points

Notification point (NP): means that a notification must be sent to the entity before a task is performed. The notified can decide to visit or not. NP does not affect the production flow of the selected subcontractor. Notification sent to LBNL 10 working days before scheduled operation, LBNL will respond to the subcontractor within 5 working days of the scheduled operation of its intention.

Witness (W): means a visit/presence at the action to witness/monitor. Action cannot occur without the presence or without a written waiver. The production flow is interrupted (before the action) in order to allow the mandatory inspection/surveillance.

Notification sent to LBNL 10 working days before scheduled operation, LBNL will respond to subcontractor within 5 working days of schedule operation of its intention.

In case of “no-show” of a technical representative or delegate: the subcontractor must formally notify the technical representative and may proceed with production after 2 working days.

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Hold point (HP): the process and all related activities cannot continue (work cannot proceed beyond this point) without the relevant HP being cleared. This can be a record of acceptance, an event or a written waiver. Production flow for the associated process is interrupted (after the action) until clearance is given.

Notification sent to LBNL 10 working days before scheduled operation, LBNL notifies the selected subcontractor within 10 working days of the result on the HP activity:

o On rejection: The selected subcontractor has 5 working days to propose a recovery plan, o On objection (duly justified): The selected subcontractor has 10 working days to answer (and if applicable propose a recovery plan).

For HP requiring witness by LBNL, in case of “no-show” of a technical representative or delegate: the subcontractor must formally notify the technical representative and may proceed with production after 2 working day.

Notice to Proceed (NTP): the current process cannot continue (next tasks) without the relevant NTP being cleared. The NTP notification point for this contract must be the following:

Successful completion and acceptance of the FDR. LBNL will provide a written approval to the selected subcontractor indicating the NTP that has been satisfied.

Successful completion and acceptance of the First article. LBNL will provide a written approval to the selected subcontractor indicating the NTP that has been satisfied

Successful completion and acceptance of production articles test report prior to shipment. LBNL will provide a written approval to the selected subcontractor indicating the NTP that has been satisfied

8.3 Deviation requests

Any deviations from the LBNL documents must be requested by the subcontractor and approved by LBNL prior to implementation. LBNL will provide a standard deviation request form however; a subcontractor’s existing or internal document may be utilized with LBNL approval. Deviation requests apply to requests to modify processes or documented drawings. Deviation requests DO NOT apply to hardware that is built and does not conform to the specification.

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8.4 Nonconformance reports

A nonconformance report provides a summary for products or procedures, which do not conform to the defined requirements. Nonconformance may be determined and reported by either the subcontractor or LBNL staff. LBNL will provide a standard nonconformance report form however; a subcontractor’s existing or internal document may be utilized with LBNL approval. Nonconformance reports are to be submitted to LBNL within 2 business days of the nonconformance identification.

Nonconformance reports apply to hardware that is built and does not conform to the specification(s). LBNL will provide a written disposition establishing a path forward for each nonconformance. No operations may be performed on the nonconforming item without LBNL’s written disposition or approval to proceed.

8.5 Numbering and/or Serialization

Each ATS/STA chamber must be serialized. The following indicate the methodology of serialization

Designation Serialization

AL-1308-9874

AL-1308-9874-0001

AL-1308-9874-0002

AL-1308-9874-0003

AL-1304-7560-0006

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

Figure 8-1: Location of the serialization ci al ly R el ea se d to th e

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8.6 Completed ACL

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

1. Visual Inspection

2. CMM measurement after…