3) AL-1745-9712_SOW.pdf

AL-1745-9712 Rev. B Doc. Status: Released Page 1 of 30

SR Welded and Dual BPM Button Statement of Work

Release Date: Aug 2 2024 8:44:45 AM PDT

Document Number: AL-1745-9712 Revision: B

Document Status: Released

Document Type: SPECIFICATION

Category Code: AL7530

ALS-U - STORAGE RING

VACUUM - GENERAL

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Downloaded by: Olusola Omolayo at August 02, 2024 15:38:01

AL-1745-9712 Rev. B Doc. Status: Released Page 2 of 30

Advanced Light Source Upgrade Project Lawrence Berkeley National Laboratory

All officially released LBNL documents are watermarked and contain LBNL Document

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

Printed hard copies of this document are for reference only.

Table of Contents

1 Revision History

2 Approvals

3 Abbreviations and Acronyms

4 Introduction

4.1 Project Overview

4.2 Scope Overview

4.3 Description of Items

4.4 Work Packages

4.5 Roles and Responsibilities

5 Deliverables

5.1 Deliverables

5.1.1 Documentation Deliverables

5.1.2 Drawings and CAD Models

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

5.1.4 Verification summary

5.2 Scope of Work

5.2.1 Management and Quality Plan

5.2.2 Final Design Review Requirements

5.2.3 First article

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

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7 Packaging and shipping specifications

7.1 Container

7.2 Marking

7.3 Packaging

7.4 Handling and storage

8 Quality Assurance

8.1 Quality Plan

8.2 Control plan

8.3 Type of control points

8.4 Deviation requests

8.5 Nonconformance reports

8.6 Numbering and/or Serialization

8.7 Completed ACL

9 Applicable Documents

Appendix A: Verification Table

Appendix B: Control Plan

Appendix C: 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 Initial Release B Revision for work packages

2 APPROVALS

The following individual(s) must approve this document:

Approver Project Role Ken Chow Chief Engineer/ Accelerator Mechanical Systems lead /

Interim QA Manager Olusola Omolayo Vacuum CAM Changchun Sun Diagnostics CAM Windchill Approved / Concurred By oomolayo

3 ABBREVIATIONS AND ACRONYMS

ALS Advanced Light Source ACL Acceptance Criteria List ALS-U Advanced Light Source Upgrade 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

FE

Final Design Review Beamline Front End

HHL High Heat Load HP Hold Point

IR

KOM

InfraRed Kick Off Meeting

LBNL Lawrence Berkeley National Laboratory LCW Liquid Cooled Water NCR Nonconformance Report NP Notification Point NTP Notification To Proceed PTL Photon Transfer Line SR Storage Ring 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.

4.2 Scope Overview

This scope of work is for the manufacturing design, fabrication, dimensional inspection, electrical inspection and delivery of Welded and Dual Beam Position Monitor (BPM) buttons for the ALS-U project. The scope includes 5 button design variants. In total, there are 478 BPM button units to be delivered. The delivery of the BPM buttons will be split into two work packages as described in section §4.4.

4.3 Description of Items

The welded and dual BPM buttons in this scope feature dual BPM feedthrough assembly welded to a stainless-steel vacuum flange as shown in Figure 4-1, as well as standalone welded BPM. For the dual type BPMs, the feedthrough assembly features two button stems that varies in length between the three designs (as shown in Figure 4-2), connected to a flange that utilizes a helicoflex vacuum seal. Conversely for the welded BPMs there are two design types that does not feature any flanges, as shown in Figure 4-3. Both welded and dual buttons has button heads that are either 4mm or 6mm in diameter, and both features SMA type connector on the atmosphere side of the feedthrough.

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Figure 4-1: SR Dual BPM Construction

Figure 4-2: SR Dual BPM button Variants

Figure 4-3: SR Welded BPM button Variants ci al ly R el ea se d to th e

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The welded and dual buttons will be installed on BPM blocks on various vacuum chamber sections, as shown in Figure 4-4 and Figure 4-5 examples. The buttons will be installed in groups of 4 and in either an I pattern or an X pattern around the BPM block.

The BPM block and helicoflex seals are not part of the deliverables in this scope of work.

Figure 4-4: Dual BPM installation in its example vacuum chamber block

Figure 4-5: Welded BPM installation in its example vacuum chamber block ci al ly R el ea se d to th e

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4.4 Work Packages

LBNL anticipates that the hardware deliverables will be split into two work packages to be completed by two unique suppliers. The work packages are designated WP#1 and WP#2 in the remainder of this document. Table 4-1 summarizes the hardware deliverables for each work package. All documentation deliverables and work management requirements stipulated in this document apply to both work packages.

Table 4-1: Summary of Work Packages Hardware Deliverables

Work Package First Article Hardware Production Hardware

Work Package 1 (WP#1) Table 5-3 Table 5-5

Work Package 2 (WP#2) Table 5-4 Table 5-6

4.5 Roles and Responsibilities

The subcontract will name two University specialists to oversee the contractual and technical aspects of the procurement:

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

The University Technical Representative is responsible for the technical aspects, beginning with the subcontract award through receipt and acceptance of deliverables.

The vendor 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.

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5 DELIVERABLES

This section details the required deliverables for each phase of the SR Welded and Dual

BPM Buttons build process.

5.1 Deliverables

5.1.1 Documentation Deliverables

Table 5-1 provides the list of documentation to be provided by the vendor to LBNL.

Fabrication cannot start prior to the review, approval, and closure of all related FDR action items.

Table 5-1: list of required documentation

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 Quality Plan 7 days ARO 5 Control plan (see Table 5-7 and §8.2) 10 days before FDR 6 Control plan duly completed and signed 10 days prior shipment

Acceptance Criteria List (AL-1746-5339) duly completed and signed 10 days prior shipment

Manufacturing Documentation 8 Manufacturing Drawing 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 5-7) 10 days before FDR 12 Test Plan and Associated procedures (see Table 5-7) 10 days before FDR

Test report (dimension, capacitance, He leak, etc..) AL-

1745-9711, section §8 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

*Days noted herein are based on a 5 business day work week ci al ly R el ea se d to th e

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5.1.2 Drawings and CAD Models

LBNL will provide the vendor with reference drawings and CAD models. The vendor is responsible for the detailed design of the BPM buttons. The fabrication must take into consideration all requirements of the SR Welded and Dual BPM Buttons Engineering

Specification Document AL-1745-9711. The vendor is able to propose changes to the design for ease of manufacture or improved performance. Such changes will be reviewed and approved/declined by the LBNL technical representative. The tolerances and dimensions stipulated in the LBNL drawings must be respected except in cases where a waiver in writing, has been explicitly provided by the LBNL technical representative.

5.1.2.1 LBNL PROVIDED MODELS AND DRAWINGS

LBNL is providing the vendor with the design information packages. See Table 5-2.

Table 5-2: LBNL Design Information

Id Drawing Description LBNL Design

Information Type

1 AL-1455-1567 WELDED, BPM, 6MM, 28.4 L

Reference Design1

2 AL-1455-2849 WELDED, BPM, 4 MM, 35.5 L

3 AL-1645-6489

BUTTON, BPM, DUAL, 4 MM DIA,

35.5 LG

4 AL-1460-3111 BUTTON, BPM, DUAL, 6 MM, 28.4 L

5 AL-1430-7412

BUTTON, BPM, DUAL, 4 MM DIA,

35.47 LG

5.1.3 Hardware Deliverables

The schedule and phasing of hardware delivery are defined in this section.

5.1.3.1 FIRST ARTICLE

The vendor must produce a batch of first article buttons, of all 4 variants designs for WP

#1 (Table 5-3), and of all 3 variant designs for WP #2 (Table 5-4).

1 Design can be modified by Sub-contractor with approval by LBNL ci al ly R el ea se d to th e

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Table 5-3: List of First Article Units WP#1

Table 5-4: List of First Article Units WP#2

5.1.3.2 PRODUCTION

Table 5-5 and 5-6 list the production articles and the respective quantities. The quantities include spares as determined for each variant by LBNL. The delivery order and batches can be proposed by the vendor, otherwise full delivery in a single shipment applies.

Table 5-5: List of Production Units WP#1

Id Drawing ID Description Qty Due Date

1 AL-1455-1567 WELDED, BPM, 6MM, 28.4 L 130

30 weeks After First

Article Approval

2 AL-1455-2849 WELDED, BPM, 4 MM, 35.5 L 60

3 AL-1645-6489

BUTTON, BPM, DUAL, 4 MM DIA,

35.5 LG

4 AL-1460-3111 BUTTON, BPM, DUAL, 6 MM, 28.4 L 20

1 AL-1455-1567 WELDED, BPM, 6MM, 28.4 L 13

18 weeks After FDR’s

Approval

2 AL-1455-2849 WELDED, BPM, 4 MM, 35.5 L 6

3 AL-1645-6489

BUTTON, BPM, DUAL, 4 MM DIA,

35.5 LG

4 AL-1460-3111 BUTTON, BPM, DUAL, 6 MM, 28.4 L 4

Id Drawing ID Description Qty Due Date

1 AL-1455-1567 WELDED, BPM, 6MM, 28.4 L 13

18 weeks After FDR’s

Approval

2 AL-1455-2849 WELDED, BPM, 4 MM, 35.5 L 6

3 AL-1430-7412

BUTTON, BPM, DUAL, 4 MM DIA,

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Table 5-6: List of Production Units WP#2

1 AL-1455-1567 WELDED, BPM, 6MM, 28.4 L 130

30 weeks After First

Article Approval

2 AL-1455-2849 WELDED, BPM, 4 MM, 35.5 L 60

3 AL-1430-7412

BUTTON, BPM, DUAL, 4 MM DIA,

5.1.4 Verification summary

At the time of delivery, the vendor must follow the instructions in Appendix A; print and complete the table with the correct information. Attachments may be added if needed for further explanation.

5.2 Scope of Work

5.2.1 Management and Quality Plan

The vendor must be responsible for supplying an initial Schedule and a Quality Plan 7 days ARO. This must include an organizational policy on quality, controlled documents for Non-conformance, material inspection, and vendor qualification. (see §8.1)

5.2.2 Final Design Review Requirements

A final design review is required once the vendor has completed the detail manufacturing design for all buttons and tooling. The vendor must be responsible for supplying all documentations related to the FDR prior to fabrication of the SR Welded and Dual BPM

Buttons. Documentations must take into account AL-1745-9711 SR Welded and Dual BPM

Buttons Engineering Specification. CAD model and drawing requirements are dictated by

LBNL document AL-1265-6612 (also see Appendix C).

The FDR is required to include the following documentation:

1. Control Plan and Manufacturing plan for the BPM buttons

2. Final manufacturing drawings

3. Final CAD model

4. Test plan and associated procedures ci al ly R el ea se d to th e

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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 §8.3.

Table 5-7: 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 documents step-by–step activities of all tests prior to the FAT to validate the vacuum hardware such as:

Dimensional tolerance (essential)

Isolation to ground (essential)

Capacitance (desirable)

TDR (desirable)

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 vendor. LBNL will provide a template to the selected vendor ci al ly R el ea se d to th e

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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 vendor approval for the rest of the production. Reference §5.1.3.1 First Article, and §8.3 Notice to Proceed for additional information.

5.2.4 First article delivery

The vendor will be responsible for the delivery of the first articles to LBNL in accordance with the parameters provided within this document.

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 vendor must provide the following:

1. Complete SR Welded and Dual BPM Buttons packed in appropriate crates

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 vendor’s production site prior to authorizing shipment.

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5.2.6 Delivery

The vendor must be responsible for the delivery of the production batches to LBNL. The vendor must determine the batch delivery schedule. Complete delivery is due as stated in

Tables 5-5 for WP#1, and 5-6 for WP#2. Button from each production batch must also be part of the same delivery batch

The following documentation will be required from the vendor prior to each shipment:

1. Fully completed and signed ACL

2. Test reports:

a. A complete mechanical inspection report for all button units

b. A complete electrical inspection report for all button units

c. A complete vacuum inspection report of all button units

3. Quality assurance receipts and certifications

4. Nonconformance or deviation documentation pertaining to each individual button

5. 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 vendor’s production site prior to authorizing shipment.

5.3 Final documentation package(s)

LBNL must be provided with a full and complete documentation package for the whole production, of both work packages. Reference LBNL document AL-1265-6612 ALS-U

Build to Specification CAD Model and Drawing Requirements 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, in an editable format

4. Other documentation as requested.

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6 MANAGEMENT, REPORTING, DOCUMENTATION AND REVIEWS

6.1 Schedule

The following table provides the main schedule point and hold point.

Table 6-1 : Timetable of the project

Section # Designation Schedule Responsibility

§5.2.1

Management and Quality plan

7 days ARO vendor

§6.2 Kick-off Meeting 1 week ARO vendor

§5.2.2

Final BPM button design review (FDR)

6 weeks ARO vendor

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

FDR

LBNL

§5.2.3 Completion of Manufacturing (First article)

18 weeks after the approval of

FDR

vendor

§5.2.4 Delivery

(First article) 2 weeks after completion of manufacturing vendor

HP#2

Approval of the first article 2 weeks after delivery

LBNL

§5.2.5 Completion of Manufacturing (Production)

30 weeks after approval of the first articles vendor

HP#3

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

LBNL

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

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6.2 Reporting requirements

Upon award of the subcontracts, the LBNL technical representative will contact the vendors 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 or LBNL delegate, including access to the factory where the units are being built, as the discretion of LBNL, may be required.

Vendor 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 vendor. 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 vendors to establish an appropriate timeline and location for all reviews.

Reviews may be conducted at either the vendor’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 the review of the Acceptance Criteria List reference §10.

Table 6-2 : List of hold points

Section Activity Control point Type

Work Contingent upon NTP

§5.2.2 Closeout of FDR NTP First article fabrication

§5.2.3 Approval of first articles NTP Production fabrication

§5.2.5 Approval of complete production NTP Production Delivery to LBNL ci al ly R el ea se d to th e

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7 PACKAGING AND SHIPPING SPECIFICATIONS

The vendor 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 SR Welded and Dual BPM Buttons may be used for both shipping and storage. Construction of the containers must be sufficient to adequately support and protect the buttons throughout 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 buttons. 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 SR Welded and Dual BPM Buttons 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 buttons must be free of any liquid prior to shipping. The use of desiccant is strictly forbidden.

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

Placement of eco-friendly packing foam between the buttons

Placement of eco-friendly packing foam between the buttons and the sides of the container to assist in minimizing movement during transportation.

Button shipping containers should incorporate a moisture barrier to prevent condensation during air shipment.

The packaging must be compliant with the Toxics in Packaging Prevention Act, AB-4552.

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

7.4 Handling and storage

The vendor must pay particular attention to the handling of the buttons to avoid damage.

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

2 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 SR Welded and Dual BPM Buttons must follow the quality plan during the first article and production fabrication

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

8.1 Quality Plan

As part of our project requirements, we are requesting that the vendor provide a comprehensive quality plan to ensure the successful execution and delivery of the project.

The quality plan should encompass various essential components to guarantee adherence to high standards throughout the project lifecycle. Below are the specific elements that should be included:

Quality Manual: The vendor must provide a detailed quality manual outlining the company's quality management system (QMS). This manual should encompass all relevant quality procedures, standards, and methodologies adopted by the company to ensure consistency and effectiveness in delivering quality products or services.

Organizational Chart: An organizational chart specific to the project should be included, illustrating the hierarchical structure of the team involved. This chart will help delineate roles, responsibilities, and reporting lines within the project team, ensuring clarity and accountability.

Key Personnel: A list of key personnel involved in the project, along with their respective roles and responsibilities should be provided. This includes project managers, quality assurance personnel, technical experts, and any other relevant stakeholders critical to the project's success.

Vendor Information: If any vendors are engaged in the project, their names, roles, and scope of work should be clearly stated in the quality plan.

Additionally, measures to ensure the quality and performance of subcontracted work should be outlined.

Project-Specific Procedures: The quality plan must outline specific procedures and protocols to be applied within the context of the project. This may include quality control measures, inspection processes, testing methodologies, and any other relevant procedures tailored to the project's requirements.

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QA Documentation Presentation: A presentation of the quality assurance (QA) documentation should be included, highlighting the key documents, records, and forms utilized to manage and track quality throughout the project lifecycle. This must include Control Plans (see §8.2), inspection reports, non-conformance reports (see

§8.5), deviation request (see §8.4) and corrective action plans.

8.2 Control plan

The Control Plan (see Table 5-7) must cover the entire scope of the phase/task, including any work to be performed by vendors like verification of materials, manufacturing/execution operations, inspection, and test and delivery. LBNL will provide the selected vendor with the template of the Control Plan (see Appendix B:

Control plan and §9 applicable document)

Each activity once finished must be dated and signed by the vendor 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 vendor.

8.3 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 vendor. Notification sent to LBNL 10 working days before scheduled operation, LBNL will respond to the vendor 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 the vendor within 5 working days of scheduled operation of its intention.

In case of “no-show” of a technical representative or delegate: the vendor 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 vendor within 10 working days of the result on the HP activity:

o On rejection: The selected vendor has 5 working days to propose a recovery plan, o On objection (duly justified): The selected vendor 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 vendor must formally notify the technical representative and may proceed with production after 2 working days.

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 vendor indicating the NTP that has been satisfied.

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

8.4 Deviation requests

Any deviations from the LBNL documents must be requested by the vendor and approved by LBNL prior to implementation. LBNL will provide a standard deviation request form however; a vendor’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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8.5 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 vendor or LBNL staff. LBNL will provide a standard nonconformance report form however; a vendor’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 within 1 week 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.

8.6 Numbering and/or Serialization

Each SR Welded and Dual BPM Button must be serialized. The following indicate the methodology of serialization

Designation Serialization

AL-1455-1567

AL-1455-1567-0001

AL-1455-1567-0002

AL-1455-1567-0006

The serialization must be laser etched on the flanges of all dual BPM buttons, and printed labels on the packaging for the welded BPM buttons.

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

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8.7 Completed ACL

The vendor must provide a completed ACL to LBNL technical representative before shipping each SR Welded and Dual BPM Buttons. The ACL shows that the following requirements are validated:

1. Visual Inspection

2. CMM measurement

3. Ground Isolation Measurement

4. Capacitance measurement if performed

5. TDR measurement if performed

6. All Required Documentation

The ACL must include the criteria of the requirements and the results of the test related to the requirement. See doc AL-1746-5339.

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9 APPLICABLE DOCUMENTS

This section identifies applicable documents that are considered to be a part of this document. All information contained in an applicable document must be valid to the full extent, unless specifically noted within this document. Applicable documents must be obtained from the LBNL Document Control Center (DCC).

Table 9-9-1: Applicable documents ID Document ID Title

1 AL-1745-9711B SR Welded and Dual BPM Buttons Engineering Specification 2 AL-1746-5339A SR Welded and Dual BPM Buttons ACL 3 AL-1220-7841F UHV Chamber and Component Production Requirements 4 AL-1405-1295A Control plan template 5 AL-1208-0209C ALS-U supplier quality evaluation survey 6 AL-1265-6612B ALS-U Build to Specification CAD Model and Drawing Requirements

7 AL-1455-1567B WELDED, BPM, 6MM, 28.4 L

8 AL-1455-2849B WELDED, BPM, 4 MM, 35.5 L

9 AL-1645-6489B BUTTON, BPM, DUAL, 4 MM DIA, 35.5 LG

10 AL-1460-3111B BUTTON, BPM, DUAL, 6 MM, 28.4 L

11 AL-1430-7412B BUTTON, BPM, DUAL, 4 MM DIA, 35.47 LG

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APPENDIX A: VERIFICATION TABLE

(To be completed with all shipments)

This appendix summarizes the final set of vendor deliverables which are due to LBNL, in addition to the other deliverables listed in section 3 above. It is the lab’s expectation that as a final action, the vendor will print out this page, and complete the “Complete? (Y/N)” column as part of the completed delivery package. For any “N” (no) response, an explanation in the comments section below must be provided as to why that deliverable is not complete. It is then up to LBNL to accept the deliverable as is through a waiver, or work with the vendor for completion of the task before acceptance of the final delivery.

Item Section Item Complete?

(Y/N)

1 §5.3 Providing all final document package(s).

2 §7.2 All marking requirements are compliant.

3 §5.2.6 All ACL have been filed up and provided with each batch.

4 §5.2.6 All tests report have been provided.

Comments:

Attachments:

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APPENDIX B: CONTROL PLAN

Extract of the control plan to be completed by the vendor ci al ly R el ea se d to th e

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APPENDIX C: CAD MODEL AND DRAWING REQUIREMENTS

The following requirements are applicable to 2-d drawings and 3D CAD models supplied in support of the MRR

1. All dimensions are to be in millimeters.

2. Dimensioning scheme to adhere to ASME Y14.5 (2009 or later), “Dimensioning and Tolerancing”.

3. Unless otherwise specified, all features to be modeled at the mean.

4. Threads, both internal and external to be modeled as cosmetic, for external threads the solid geometry to be at the maximum minor diameter, for internal threads the solid geometry to be at the maximum minor diameter. Threads represented as helical features is forbidden.

5. A material must be specified and the properties of the material must be applied to the object, such that the weight/mass of the object is a property of the file/object.

The material file must include these properties, density, modulus of elasticity, Poisson’s ratio, Coefficient of Thermal Expansion and Thermal Conductivity. The units of these properties to be consistent with the units of the model, and in SI

Units (International System of Quantities).

6. All solid models must be “water tight”, meaning there cannot be “holes” or “gaps” in the solid surface such that the feature does not close upon itself.

7. Drawings and Models must use English as the language used to describe the dimensions, notes, descriptions, text and features.

8. A minimum note based tolerance scheme to use is, X ± 1, X.X ± 0.5, X.XX ± 0.15, Angles ± 0.5°. Alternate: Individual tolerance of each dimension, not making use of a note based scheme. The vendor may use a scheme which has tolerances that are smaller than the minimum.

9. ALS-U will supply the batch of serial numbers to be applied/consumed for items requiring serial numbers. ALS-U Serial Numbers must be used, vendor generated serial numbers are not allowed.

10. If an item is to be serialized ALS-U must approve of the marking method to be used for attaching the ALS-U supplied serial number to the object, and the process must be included in the drawing describing the object, possibly included in the notes of the drawing.

11. The 3-D CAD Model digital file must one that is consumable by PTC’s Creo

Parametric software. The preferred format is Creo Parametric (check with LBNL for current version). Consumable in this context means when imported into Creo

Parametric (check with LBNL for current version), the file is interpreted by Creo ci al ly R el ea se d to th e

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All officially released LBNL documents are watermarked and contain LBNL Document properly, there are no failures, and the integrated model can be regenerated successfully. If the vendor does not use Creo Parametric, then they must supply the software name and version, along with the file format they would supply to be used by LBNL.

12. The CAD Drawing digital file must one that is consumable by PTC’s Creo

Parametric software. The preferred format is Creo Parametric (check with LBNL for current version). Consumable in this context means when imported into Creo

Parametric (check with LBNL for current version), the file is interpreted by Creo properly, there are no failures, and the integrated model and drawing can be regenerated successfully.

13. The 3-D CAD Model and the Drawing files must be parametric. Parametric meaning that if any feature, dimension, attribute, data set is modified in one object, the other object automatically inherits the change upon regeneration.

14. Drawings should use driven dimensions inherited from the model. Creating dimensions which only exist in the drawing is not recommended and may be a cause for rejection of the drawing.

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