4) AL-1758-9513_SR Scraper ES.pdf

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Advanced Light Source Upgrade Project Lawrence Berkeley National Laboratory

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SR Scraper Engineering Specification

Release Date: Nov 12 2024 5:11:52 PM PST

Document Number: AL-1758-9513 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 Introduction to ALS-U

4.2 Subject of this Engineering Specification

5 Document Definitions

6 Description of SR ScraperS

6.1 Horizontal Single-Sided Scraper

6.2 Vertical Double-Sided Scraper

6.3 Fabrication process

6.3.1 Main chamber body

6.3.2 Allowable Design Modifications

7 Mechanical Design Requirements

7.1 General Requirements

7.2 Actuator Mechanism

8 Environmental requirements

8.1 Codes and Standards

8.2 Cleanliness environment

8.3 Cleaning fluids

8.4 Cutting fluids

8.5 Fasteners

8.6 Flange and Gaskets

9 Technical requirement

9.1 Vacuum pressure

9.2 Manufacturing process

9.2.1 Material

9.2.2 Fabrication

9.2.2.1 Part fabrication

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9.2.2.2 Cleaning after manufacturing

9.2.2.3 Part joining

9.3 Final Cleaning

9.4 Final Assembly

9.5 Final test

9.5.1 Visual inspection

9.5.2 CMM Measurement

9.5.3 Water pressure test

9.5.4 Mechanical test

9.5.4.1 Hard stop setup

9.5.4.2 Motion test and Setup

9.5.5 Bakeout

9.5.6 Residual Gas Analysis

9.5.7 Final He Leak Test

9.5.8 Final Pressure measurement

9.5.9 HPN2 Backfill

9.5.10 CMM Measurement after Bakeout

9.6 Packing and shipping

10 Applicable Documents 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 and System Engineer Olusola Omolayo Vacuum CAM Windchill Approved / Concurred By

KPChow,oomolayo

3 ABBREVIATIONS AND ACRONYMS

ALS Advanced Light Source ALS-U Advanced Light Source Upgrade ASTM American Society for Testing and Materials AR Accumulator Ring CC Cooling Chanel CF Conflat Flange CMM Coordinate Measuring Machine COTS Commercial Off the Shelves DCC Document Control Center He Helium HPN2 High-Pressure Nitrogen EN-ISO European International Organization for Standardization LBNL Lawrence Berkeley National Laboratory

US

UHV

Ultrasound Ultra-High Vacuum

VC Vacuum Chamber VCR Vacuum Coupling Radiation WPS Welding Procedure Specification ci al ly R el ea se d to th e

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4 INTRODUCTION

4.1 Introduction to ALS-U

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 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 Subject of this Engineering Specification

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. This document defines the technical specification of the scrapers. Further introductory details of the scrapers can be found in the SR Scraper Statement of Work AL-1758-9512, §4.2.

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5 DOCUMENT DEFINITIONS

Must, will, may, and should are used to define every specification listed in this document.

The definitions of these terms are as follows

May – is used to indicate a desire or goal of a specification. This can also be interpreted

‘as nice to have’ and are not contractually binding.

Must –is a specification that is contractually binding and must be implemented.

Should – is used to indicate a desire or goal of a specification. This can also be interpreted ‘as nice to have’ and are not contractually binding.

Will – is used to inform intent or declaration of purpose. This is not a specification.

Example, the author will use the word ‘must’ to indicate that a specification is contractually binding and must be implemented.

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6 DESCRIPTION OF SR SCRAPERS

The pictures below illustrate the main components of the vertical and horizontal scrapers.

Figure 6-1: Vertical and horizontal Scraper

Exit flange

Actuator

Main Chamber

Entry flange

Horizontal

Scraper

Main Chamber

Actuator

Vertical

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6.1 Horizontal Single-Sided Scraper

There are two sub-variants of the horizontal single-sided scrapers. Both sub-variants share similar overall constructions. The differences between the sub-variants are:

• External geometry of the cooling channels

• NEG pump appendage

• Entry and exit flange.

A summary of the main features and requirements of the horizontal single sided scrapers are:

External Features:

1. Main chamber machined from CuCrZr

2. Beam entry and exit flange and beam tube

3. Cooling line connections

4. Helicolflex seal obround flange connection to actuator assembly

5. Thermocouple Type K feedthrough on a CF16 flange

6. NEG pump mounting port

7. Base support mounting

8. Stepper motor for driving actuator mechanism

Internal Features:

1. Actuator mechanism for the beam intercepting plates

2. Actuator travel range beam intercepting plates from the parallel position to greater than half of the beam aperture

3. UHV compatible motion mechanism

4. Low beam impedance along beam aperture

Figure 6-2 to Figure 6-4 below shows a cross-sectional image of the horizontal single sided scraper, the actuator mechanism and the beam intercept plate assembly ci al ly R el ea se d to th e

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Figure 6-2: Horizontal scraper cross sections ci al ly R el ea se d to th e

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Figure 6-3: Beam intercept plate assembly ci al ly R el ea se d to th e

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Figure 6-4: Linear actuator assembly (not exploded) ci al ly R el ea se d to th e

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6.2 Vertical Double-Sided Scraper

The vertical double-sided scraper is similar to the afore described horizontal scraper. The two units are identical. The primary difference between the vertical and the horizontal scrapers is that the vertical scraper has two opposing actuation and beam intercept assemblies. Figure 6-5 below shows a cross-sectional image of the vertical double-sided scraper.

Figure 6-5: Vertical Absorber ci al ly R el ea se d to th e

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6.3 Fabrication process

6.3.1 Main chamber body

The main chamber body are primarily constructed from stainless steel 316L and copper

(C18150). The fabrication process for the parts involves CNC and EDM machining. The parts are joined by TIG welding and EB welding. The fabrication processes are similar for all chamber bodies.

Parts joining along the beam channel is by E-beam welding while appendage (fiducial, pump ports, cooling tubes) joining is done by TIG welding.

Figure 6-6: Vertical Scraper (left) and Horizontal Scraper (right)

The beam entry port and the electron beam exit port flanges utilize Helicoflex vacuum seals, while other ports use standard CF copper gaskets.

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6.3.2 Allowable Design Modifications

To facilitate the fabrication process, certain design modifications may be permitted, provided they do not compromise the core functionality of the system. For instance, adjustments to weld preparation can be made, to improve the welding process, enhancing both quality and efficiency. Additionally, repositioning fiducial nests or modifying the layout of cooling channels can be considered to improve accessibility during fabrication, making the assembly process more straightforward without affecting the system's performance.

LBNL has also developed an alternative design, manufactured from a monolithic block.

This design simplifies fabrication by eliminating the need for welding, resulting in a more streamlined and efficient manufacturing process. The alternative designs are included with this Request for Proposal.

Welded Design Monolithic Design

Horizontal Scraper / Initial design Horizontal Scraper / alternate design

Vertical Scraper / Initial design Vertical Scraper / alternate design

In any case, LBNL must be notified for approval prior to implementing any changes.

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7 MECHANICAL DESIGN REQUIREMENTS

7.1 General Requirements

ID NUM

(SYY-XX-)

Specification

S09-94-000587 All components along the beam path shall be made from copper or copper alloys

S09-94-000588 The mount of the actuator shall be aluminum 6061-T6

S09-94-000589 The flange actuator shall be SS 316L

S09-94-000590 All the bolts shall be Silver Plated

S09-94-000591 The material of the bolt shall be A4-70

S09-94-000592 The cooling pipe shall be mounted with fitting

S09-94-000593 The material of the fitting shall be SS316

7.2 Actuator Mechanism

ID NUM

(SYY-XX-)

Specification

S09-94-000594 The stroke on the horizontal single-sided scraper shall be greater than 5.7mm

S09-94-000595 The stroke on the vertical double-sided scraper shall be greater than 8.2mm

S09-94-000596 Maximum beam aperture opening at the center of the beam intercepting chamber is 9mm square for horizontal single-sided scraper and 14mm square for vertical double-sided scraper ci al ly R el ea se d to th e

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8 ENVIRONMENTAL REQUIREMENTS

8.1 Codes and Standards

ID NUM

(SYY-XX-) Specification

S09-94-000151

The following standards must apply for the fabrication and test of the Scrapers:

• EN ISO 13919 or EN ISO 5817

• EN ISO 17637

• ASTM E498.

• ASTM E2734/E2734 M − 10.

8.2 Cleanliness environment

ID NUM

(SYY-XX-) Specification

S09-94-000152 The cleaning environment must comply with UHV Chamber and Component Production Requirements AL-1220-7841, §7.2

8.3 Cleaning fluids

ID NUM

(SYY-XX-) Specification

S09-94-000153 The cleaning fluids must comply with UHV Chamber and Component Production Requirements AL-1220-7841, §7.3

8.4 Cutting fluids

ID NUM

(SYY-XX-) Specification

S09-94-000154 The cutting fluids must comply with UHV Chamber and Component Production Requirements AL-1220-7841, §7.4

8.5 Fasteners

ID NUM

(SYY-XX-) Specification

S09-94-000155 The fasteners of the vacuum chambers must comply with AL-1220- 7841, §7.6 ci al ly R el ea se d to th e

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8.6 Flange and Gaskets

ID NUM

(SYY-XX-) Specification

S09-94-000156 The flanges and gaskets of the vacuum chambers must comply with

AL-1220-7841, §7.7

9 TECHNICAL REQUIREMENT

9.1 Vacuum pressure

ID NUM

(SYY-XX-)

Specification

S09-94-000157 The maximum thermal outgassing rate must be better than 1.00e-11 Torr.l.s-1.cm-2

S09-94-000158 Achievable final pressure must be 5.00e-10 Torr

9.2 Manufacturing process

9.2.1 Material

The procurement of the raw material by the Subcontractor must comply with the following requirements

ID NUM

(SYY-XX-) Specification

S09-94-000163 All materials must be new.

S09-94-000164 All material must be free from surface cracks and fissures, forge and other tool marks, burns, delamination and other defects that would make it incompatible with a high vacuum environment.

S09-94-000165 Certification must be in accordance with EN ISO 10204 3.1.

S09-94-000211 Magnetic permeability for vacuum chamber base material must be

1.01 and for welds or braze joints 1.04

S09-94-000168 The tube of the chamber must be seamless

S09-94-000169 The material must be compatible with synchrotron radiation ci al ly R el ea se d to th e

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9.2.2 Fabrication

9.2.2.1 PART FABRICATION

The fabrication of the chambers must comply with the following requirements

Cutting fluids

ID NUM

(SYY-XX-) Specification

S09-94-000170 Water-soluble and non-halogenated cutting fluids must be used for fabrication

S09-94-000171 All other requirements relative to the vacuum components fabrication must comply with AL-1220-7841, §8.1, §8.2, §8.3

9.2.2.2 CLEANING AFTER MANUFACTURING

An intermediate cleaning must be done after manufacturing and must comply with the following requirements

ID NUM

(SYY-XX-) Specification

S09-94-000172 UHV surfaces must be protected as per best practices during handling operations.

S09-94-000173 Parts must be stored in a clean area from the workshop (See §8.2).

S09-94-000174 Parts must be suspended in tanks by wire, hooks or in baskets

S09-94-000175 All others requirements relative to the vacuum components cleaning must comply with AL-1220-7841, §9

9.2.2.3 PART JOINING

The joining process of the components must comply with the following requirements

General requirement

ID NUM

(SYY-XX-) Specification

S09-94-000176 Step change in geometrical profile across weld must be less than 0.2mm

S09-94-000177 All parts must be cleaned prior to welding (See §9.3)

S09-94-000178 A WPS is not required

S09-94-000179 The weld quality must be level D according to EN ISO 13919 or EN

ISO 5817

S09-94-000182 All welds must be free from cracks and fissures or other defects that would make it incompatible with a high vacuum environment.

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Inspection of welded joints

(SYY-XX-) Specification

S09-94-000183 100% of the vacuum boundary welded joints must be visually inspected

S09-94-000184 The visual inspection must comply with EN ISO 17637

Component leak check

ID NUM

(SYY-XX-) Specification

S09-94-000185 100% of the vacuum boundary welded joints must be leak tested.

S09-94-000186 The leak test of the welded joint must comply with ASTM E498.

S09-94-000187 The criteria and parameter expected for the He leak check must comply with AL-1220-7841, §14

9.3 Final Cleaning

The final cleaning of the chambers must comply with the following requirements

General requirement

ID NUM

(SYY-XX-) Specification

S09-94-000188 Once the final cleaning process has started, it must not be stopped before the end.

S09-94-000189 After the final cleaning, all subsequent operations must be performed in a cleanroom.

Cleaning

ID NUM

(SYY-XX-) Specification

S09-94-000190 The cleaning agent used must be identified and approved by LBNL prior to the Factory acceptance test.

S09-94-000191 All other requirements regarding the final cleaning and intermediate inspection must comply with AL-1220-7841, §11 and §12.

9.4 Final Assembly

ID NUM

(SYY-XX-) Specification

S09-94-000192 All requirement with final assembly must comply AL-1220-7841, §13 ci al ly R el ea se d to th e

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9.5 Final test

The final tests to ensure the performance of the scrapers must be performed in the sequence indicated in Figure 9-1.

Figure 9-1: Final test sequence ci al ly R el ea se d to th e

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General requirement

(SYY-XX-) Specification

S09-94-000193 All test must take place in a clean room

S09-94-000194 During pumping down of the part, all connection above the turbo pump must be all-metal

S09-94-000195 The HPN2 port must be all-metal

S09-94-000196 The HPN2 port must be a VCR to CF16 adapter that is replaced with a CF16 blank as the last connection to the chamber prior to shipping.

S09-94-000197 LBNL must have right to visit the contractor during these tests

9.5.1 Visual inspection

ID NUM

(SYY-XX-)

Specification

S09-94-000597

The selected vendor shall conduct a visual inspection of all devices, with particular attention to the following points:

• Verify that the blades show no play when actuated manually.

• Confirm that all retaining rings are installed according to the specifications outlined in the drawing.

• Ensure that all bolts within the device are securely tightened.

• Check that the blade can be actuated manually without any friction in the mechanism.

• Check that the BeCu shield located on the blade maintains contact during both upward and downward actuation.

S09-94-000598 The visual inspection shall be documented in a report, including pictures of the detailed points mentioned above

9.5.2 CMM Measurement

(SYY-XX-) Specification

S09-94-000198 A CMM measurement must be performed

S09-94-000200 The dimensions to be controlled must be specified by the University technical representative.

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9.5.3 Water pressure test

The water pressure for the cooling channel must comply with the following requirements

ID NUM

(SYY-XX-) Specification

S09-94-000201 The cooling channel pressure test must be conducted at 120 psi

S09-94-000202 The cooling channel pressure test must last 10 mins

Criteria

ID NUM

(SYY-XX-) Specification

S09-94-000203 No leak must appear at the completion of the pressure test

9.5.4 Mechanical test

9.5.4.1 HARD STOP SETUP

ID NUM

(SYY-XX-)

Specification

S09-94-000599 The upper hard stop shall be set when the blade is 1 mm above the center of the beam (center of the scraper vacuum chamber).

S09-94-000600 The lower hard stop shall be set to accommodate a blade position that is further down by 1 mm within the Scraper vacuum chamber.

The blade features has slight concave shape

Figure 9-2: View of the hard stop on the Scraper blade mechanisme

Upper hard stop

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9.5.4.2 MOTION TEST AND SETUP

(SYY-XX-)

Specification

S09-94-000601 A motion test shall be performed on the scraper's actuator in open-loop mode (limit switches disabled) in both directions

S09-94-000602 The upper limit switch shall be tested by performing a motion test in closed-loop mode

S09-94-000603 The lower limit switch shall be tested by performing a motion test in closed-loop mode

S09-94-000604 The upper limit switch (blade in scraper mode) shall be configured between 0.5 mm and 1 mm below the center of the beam (center of the scraper vacuum chamber)

Figure 9-3: Blade in Scraper mode

(SYY-XX-) Specification

S09-94-000605 The lower limit switch (Blade Pulled Back) shall be configured to ensure that the blade is flush with the Scraper vacuum chamber

S09-94-000606 All tests / setups requested above shall be documented in a report

Note: these requirements provided in the section 9.5.4 apply on all scrapers.

1mm to 0.5 mm ci al ly R el ea se d to th e

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9.5.5 Bakeout

S09-94-000204 Bakeout must comply with AL-1220-7841, §14.1

9.5.6 Residual Gas Analysis

(SYY-XX-) Specification

S09-94-000205 Residual Gas Analysis must comply with AL-1220-7841, §14.2

9.5.7 Final He Leak Test

ID NUM

(SYY-XX-) Specification

S09-94-000208 Final pressure measurement must comply with AL-1220-7841, §14.5

9.5.8 Final Pressure measurement

ID NUM

(SYY-XX-) Specification

S09-94-000207 Final He leak test must comply with UHV Chamber and Component Production Requirements AL-1220-7841, §14.4

9.5.9 HPN2 Backfill

ID NUM

(SYY-XX-) Specification

S09-94-000209 HPN2 Back fill must comply with AL-1220-7841, §14.6

9.5.10 CMM Measurement after Bakeout

ID NUM

(SYY-XX-) Specification

S09-94-000328 A CMM measurement must be performed on all chamber with the same critical dimension given in §9.5.1 after the bakeout

9.6 Packing and shipping

ID NUM

S09-94-000210 Packing and shipping must comply with AL-1220-7841, §15 ci al ly R el ea se d to th e

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10 APPLICABLE DOCUMENTS

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

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