3) AL-1779-0022_SR Scraper 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.

SR Scraper SoW

Release Date: Nov 12 2024 5:12:00 PM PST

Document Number: AL-1779-0022 Revision: A

Document Status: Released

Document Type: SPECIFICATION

Category Code: AL7531

ALS-U - STORAGE RING

VACUUM CHAMBERS

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Table of Contents

1 Revision History

2 Approvals

3 Abbreviations and Acronyms

4 Introduction

4.1 Project Overview

4.2 Scope Overview

4.3 Description of Items

4.4 Scraper Design Summary

4.4.1.1 Horizontal Scraper

4.4.1.2 Vertical Scraper

4.5 Roles and Responsibilities

5 Deliverables

5.1 Deliverables

5.1.1 Documentation Deliverable

5.1.2 Drawings and CAD Models Deliverable

5.1.2.1 LBNL provided models and drawings

5.1.3 Hardware Deliverable

5.1.3.1 Components included

5.1.3.2 First article

5.1.3.3 Production

5.2 Scope of work

5.2.1 Management and Quality Assurance

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

5.2.6.1 Horizontal Scraper

5.2.6.2 Vertical Scraper

5.3 Final documentation package(s)

6 Management, Reporting, Documentation and reviews ci al ly R el ea se d to th e

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6.1 Schedule

6.2 Reporting requirements

6.3 Proposal documentation requirements

6.4 Reviews

6.5 Hold points

7 Fabrication

8 Packaging and shipping specifications

8.1 Container

8.2 Marking

8.3 Packaging

8.4 Handling and storage

9 Quality Assurance

9.1 Quality plan

9.2 Type of control points

9.3 Deviation requests

9.4 Nonconformance reports

9.5 Numbering and/or Serialization

9.5.1 Horizontal Scraper

9.5.2 Vertical Scraper

9.6 Completed ACL

10 Applicable Documents

Appendix A: 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 Olusola Omolayo Vacuum CAM and Technical Lead Windchill Approved / Concurred By

KPChow,oomolayo

3 ABBREVIATIONS AND ACRONYMS

ALS Advanced Light Source ACL Acceptance Criteria List ALS-U Advanced Light Source Upgrade ARO After Receipt of Order CAD Computer Aid Design CMM Coordinate Measuring Machine FAT Factory Acceptance Test FDR Final Design Review HP Hold Point KOM Kick Off Meeting LBNL Lawrence Berkeley National Laboratory LCW Liquid Cooled Water NCR Nonconformance Report NTP Notification to Proceed SR Storage Ring UHV Ultra High Vacuum 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 encompasses the design, fabrication, dimensional inspection, fiducialization, vacuum testing, and delivery of scrapers for the ALS-U project. There are three distinct scraper designs in total. Among these, the vertical scraper design requires the manufacture of two units, resulting in a total of four scrapers: two horizontal and two vertical

4.3 Description of Items

There are 4 scrapers on the new storage ring (SR). Two of them are single sided horizontal scraper, the other two are double sided vertical scraper. The Storage

Ring (SR) is divided into units comprising one straight section and one arc section, each further divided into four raft units. The scrapers are located as follows: two double sided vertical scrapers in straight section #1, one single sided horizontal scraper on raft #4 of sector #11, and another single sided horizontal scraper on raft #4 of sector #12.

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Figure 4-1: SR - S11 - raft #4 Single sided horizontal scraper assy

Figure 4-2: Double sided vertical scraper Figure 4-3: SR - S12 - raft #4 Single sided horizontal scraper assy ci al ly R el ea se d to th e

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4.4 Scraper Design Summary

4.4.1.1 HORIZONTAL SCRAPER

The main body of the horizontal scraper is made of copper alloy C18150 and includes the following external features:

• NEG Cartridge port (NEG Cartridge not included in this Scope of Work - SOW) (1)

• Integrated cooling channel with welded-on entry and exit tubes (2)

• Actuator (3)

• Entry and exit flanges (4)

Internal features are shown in Figure 4-6

Figure 4-4: Horizontal scraper

(1)

(3)

(2)

(4)

(4)

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4.4.1.2 VERTICAL SCRAPER

The main body of the vertical scraper is also made of copper alloy C18150 and includes the following external features:

• NEG Cartridge port (NEG Cartridge not included in this SOW) (1)

• Integrated cooling channel with welded-on entry and exit tubes (2)

• Actuator (3)

• Entry and exit flanges (4)

Figure 4-5: Vertical scraper

(1) (2)

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Figure 4-6: Vertical scraper ci al ly R el ea se d to th e

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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 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.

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5 DELIVERABLES

This section outlines the required hardware and documentation deliverables for each phase of the execution process. It also specifies the technical management and oversight requirements throughout the execution process.

5.1 Deliverables

5.1.1 Documentation Deliverable

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 Quality Plan 7 days ARO 7 Acceptance Criteria List 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 Assembly plan for each type of scraper see (Table 5-8) 10 days before FDR 12 Manufacturing plan (see Table 5-8) 10 days before FDR 13 Test Plan and Associated procedures (see Table 5-8) 10 days before FDR 14 Test report (dimension, He leak, etc…) 10 days prior shipment

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

16 Material Certification 10 days before manufacturing

Delivery documentation 17 List of packing crates and contents 10 days prior shipment 18 Shipping plan (see §8) 10 days prior shipment

Other 19 Certificate of Conformance 10 days prior shipment 20 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 Deliverable

LBNL will provide the Subcontractor with drawings and CAD models. Fabrication must adhere to all requirements outlined in the Engineering Specification Document AL-1758-

9513. The Subcontractor may propose design modifications to facilitate manufacturing or enhance performance, however, these changes will require review and approval by the

LBNL technical representative. All specified tolerances and dimensions in the LBNL drawings must be strictly followed, unless a written waiver is explicitly provided by the

LBNL technical representative

5.1.2.1 LBNL PROVIDED MODELS AND DRAWINGS

LBNL will provide the Subcontractor with the design information packages listed in Table

5-2. This list is not exhaustive. For further details, please refer to the document AL-1778-

9925, “SR Scraper Applicable Documents”

Table 5-2: LBNL design package

Id Drawing Revision Description

1 AL-1455-1500 A Horizontal Scraper S11

2 AL-1779-0417 A Horizontal Scraper S12

3 AL—1779-0422 A Vertical Scraper 4 AL-1779-0422 A Shipping assembly of Vertical Scraper 5 AL -1779-0417 A Shipping assembly of Horizontal Scraper S12 6 AL-1779-0392 A Shipping assembly of Horizontal Scraper S11 ci al ly R el ea se d to th e

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5.1.3 Hardware Deliverable

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

5.1.3.1 COMPONENTS INCLUDED

In addition to the scrapers, each delivery must include blank flanges, fittings, support brackets, and scraper supports as detailed in Table 5-3 and Table 5-4. The quantities of these ancillary parts and their assembly status at the time of shipment are specified in the shipping assembly models listed in the applicable documents.

Table 5-3: Components that subcontractor will source or manufacture for Vertical and horizontal Scraper

ID Features Illustration LBNL ID

Vertical Scraper

AL-1580-6341-

rev A

Horizontal

Scraper

AL-1455-1500

AL-1553-3161

Blank Flange

QF-40-F

AL-1698-2417

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Table 5-4: Components that subcontractor will source or manufacture for Vertical and horizontal Scraper

ID Features Illustration LBNL ID

Cover flange

BPM

AL-1698-2423

6 Swagelok

HW-1000-7000

Note: See shipping assembly drawing associated to each Scraper for the total quantity of all features needed.

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LBNL will provide vacuum seals and chain clamps, as illustrated in Table 5-5.

Table 5-5: Materials to be Integrated provided by LBNL

Id Features Illustration LBNL ID Quantity

Flange Chain Clamps

QF 40

HW-1435-4037 4

Flange Chain Clamps

QF 50

AL-1610-0797 4

8 Pressure ring QF40

AL-1613-6265 8+2

8 Pressure ring QF50

AL-1614-6599 4+2

Seal Oval

HW-1000-9647 3+1

Seal Helicoflex 2.290’’

HW-1000-7226 5+1

Seal Helicoflex 1.507’’

HW-1000-6923 2+1

Note: The additional number in the "quantity" column represents the quantity of spares provided by LBNL to the Subcontractor ci al ly R el ea se d to th e

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5.1.3.2 FIRST ARTICLE

The selected subcontractor must produce one Scraper and its ancillaries as the first article.

Table 5-6: List of first articles

5.1.3.3 PRODUCTION

Table 5-7 list the production articles and the respective quantities. The quantities include one spare as determined by LBNL. The subcontractor can propose the delivery order and batches otherwise full delivery in a single shipment applies.

Table 5-7: List of production articles

Id Drawing ID Description Qty Due Date

2 AL-1779-0422 Vertical Scraper (Straight #1) 1 24 weeks After First

Article Approval

3 AL-1779-0392 Horizontal Scraper (S11) 1

4 AL-1779-0417 Horizontal Scraper (S12) 1

Id Drawing ID Description Qty Due Date

1 AL-1779-0422 Vertical Scraper (Straight #1) 1 12 weeks After FDR Approval ci al ly R el ea se d to th e

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5.2 Scope of work

5.2.1 Management and Quality Assurance

The selected subcontractor will 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 §9.1)

5.2.2 Final Design Review Requirements

A final design review is required once the subcontractor has completed the detail manufacturing design for all Scrapers and tooling. The selected subcontractor must be responsible for supplying all documentations related to the FDR prior to fabrication of the Scraper. This documentation must align with the scraper engineering specification

(AL-1758-9513).

CAD model and drawing requirements are detailed in Appendix A:

The FDR is required to include of the following documentation:

1. Manufacturing plan1 for the Scraper

2. Final manufacturing drawings (required if design was modified)

3. Final CAD model (Required if 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 §9.2.

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Table 5-8: Documentation description Documents Description

Manufacturing plan

The manufacturing plan documents the entire manufacturing process step-by-step, from the procurement of raw materials to delivery (excluding tests for Factory Acceptance Testing, which are covered in the test plan). The manufacturing plan must include at least the following details:

• Standards required for the procurement of raw materials

• A description of each step of the fabrication process

• Internal procedures applicable to this effort

All procedures and/or standards utilized for fabrication must be referenced in the manufacturing plan.

Assembly plan

The assembly plan documents the entire assembly process step-by-step of the Scraper. The assembly plan must include at least the following details

• Preparation: Gather all components, tools, and equipment necessary for assembly.

• Sub-Assembly: Assemble the sub-assembly components of each scraper to ensure accuracy and functionality.

• Final Assembly: Combine the sub-assemblies, ensuring all fittings and connections are secure.

• Quality Check: Conduct a thorough inspection of the assembled scrapers for alignment, fit, and functionality.

Test Plan

The test plan must document, at a minimum, the step-by-step activities for all tests conducted prior to the Factory Acceptance Testing (FAT) to validate the vacuum hardware.

This includes:

• Helium leak test

• Bakeout

• Residual Gas Analysis (RGA)

• Outgassing rate measurement

• Beam center measurement in reference to fiducials

All criteria relevant to the tests performed must be included in the test plan. Additionally, procedures and/or standards utilized for the tests must be referenced within the test plan.

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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 grant the selected subcontractor approval to proceed with the remaining production. Reference §5.1.3.2 First Article, and §9.2

Notice to Proceed for additional information.

5.2.4 First article delivery

The selected subcontractor will be responsible for delivering the First Article to LBNL in accordance with the parameters outlined in 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 successfully tested.

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

1. Complete Scraper packed in an appropriate crate.

2. Completed FAT and associated reports

3. Final and completed ACL

4. Quality assurance receipts and certifications

5. Nonconformance or deviation documentation pertaining to each individual assembly

6. Final, approved shipping plan

7. 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.

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5.2.6 Delivery

The selected subcontractor must be responsible for delivering the complete production to LBNL in accordance with the parameters outlined in this document. The scrapers must be delivered as shown in the picture below and under nitrogen atmosphere.

5.2.6.1 HORIZONTAL SCRAPER

Figure 5-1 Horizontal Scraper ready to be delivered

5.2.6.2 VERTICAL SCRAPER

Figure 5-2 Vertical Scraper ready to be delivered ci al ly R el ea se d to th e

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5.3 Final documentation package(s)

The selected subcontractor must provide a full and complete documentation package at the end of the production. Refer to Appendix A: 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. Any 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: timetable of the project

Section # Designation Schedule Responsibility

§5.2.1 Management and

Quality plan 7 days ARO subcontractor

§5.2.2 Final Scraper 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)

12 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)

24 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.

• The 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. Appendix A: 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 collaborate with the subcontractor to establish an appropriate timeline and location for all reviews. Reviews may be conducted either at the subcontractor's site, 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 must 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.

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 §9.2.

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7 FABRICATION

The selected subcontractor must adhere to the SR Scraper Engineering Specification Document (ESD), referenced as AL-1758-9513, for the fabrication of all scrapers.

8 PACKAGING AND SHIPPING SPECIFICATIONS

The selected subcontractor must submit a shipping plan to LBNL and obtain written approval before the first shipment. The shipping plan must include the following points:

8.1 Container

Containers or crates for the Scraper may be used for both shipping and storage.

Construction of the containers must be sufficient to adequately support and protect the Scraper 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 Scraper. The crates must be strapped on all sides prior to and during shipment.

8.2 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 Scraper 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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8.3 Packaging

All Scraper including cooling channels must be free of any liquid prior to shipping.

The use of desiccant is strictly forbidden.

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

• Each Scraper needs to be assembled along with each associated LCW fitting, cooling tube loops, steel support(s), flange blanks and chain clamps

• Placement of foam between the Scrapers (if crate contains multiple Scrapers)

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

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

The packaging must be compliant with the Toxics in Packaging Prevention Act1, AB-

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

8.4 Handling and storage

The subcontractor must pay particular attention during phases of lifting operation to avoid damage on the Scrapers

Should the Scrapers 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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9 QUALITY ASSURANCE

The Scraper must follow the same quality assurance during the first article and production fabrication. The quality assurance is depicted in the following subsection.

9.1 Quality plan

As part of our project requirements, we are requesting that the Subcontractor 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 Subcontractor 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.

• Subcontractor Information: If any subcontractors 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 should 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 shall include, inspection reports, non-conformance reports (see §9.4), deviation request (see §9.3) and corrective action plans.

9.2 Type of control points

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

9.3 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.

9.4 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.

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9.5 Numbering and/or Serialization

Each Scraper must be serialized. The following indicate the methodology of serialization

9.5.1 Horizontal Scraper

Designation Serialization

AL-1553-3161

AL-1418-7454-0001

The serialization must be laser etched on the body of the Scraper. See location of the serialization on the picture below.

Table 9-1: Location of the serialization

Note: The second horizontal scraper must be serialized with AL-1455-1500-0001 on the same location, ci al ly R el ea se d to th e

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9.5.2 Vertical Scraper

Designation Serialization

AL-1580-6341

AL-1580-6341-0001

AL-1580-6341-0002

The serialization must be laser etched on the body of the Scraper. See location of the serialization on the picture below.

Table 9-2: Location of the serialization ci al ly R el ea se d to th e

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9.6 Completed ACL

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

1. Visual Inspection

2. Magnetic permeability measurement

3. CMM measurement

4. Water pressure test

5. Mechanical inspection

6. Vacuum inspection

7. Shipping inspection

8. 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-1778-9923.

10 APPLICABLE DOCUMENTS

All applicable documentation can be found in “AL-1778-9925_SR Applicable documents”.

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APPENDIX A: CAD MODEL AND DRAWING REQUIREMENTS

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

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 Subcontractor 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, Subcontractor 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.

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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 properly, there are no failures, and the integrated model can be regenerated successfully. If the Subcontractor 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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