A.2 Statement of Work.pdf

NATIONAL SYNCHROTRON LIGHT SOURCE II

BROOKHAVEN NATIONAL LABORATORY

BROOKHAVEN SCIENCE ASSOCIATES

UPTON, N.Y. 11973

PROJECT:

Cryogenic Permanent Magnet Undulator for the HRD Beamline

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Statement of Work Number Date

Cryogenic Permanent Magnet Undulator for the HRD Beamline

Statement of Work (SOW)

ESH&Q RISK LEVEL: A-2

Reviewed and Approved By:

Prepared By: Dean Hidas NSLS-II Research Staff 6 Physics, Approved By: Jayce Blood Manager, Subcontracts, PPM Procurement

Approved By: Stephen Sherwood NSLS-II Liaison Engineer

Approved By: Robert Lee NSLS-II ESH&Q Manager

Approved By: Nicole Magliulo NSLS-II Quality Assurance Engineer

Approved By: Daniel Olds NSLS-II HRD Lead Beamline Scientist

Approved By: Timur Shaftan NSLS-II Accelerator Division Director

List of Reviewers (not approving through SharePoint)

Reviewed By: Alexander Chu NSLS-II Mechanical / Project Engineer, Beamline Engineering

Reviewed By: Toshi Tanabe NSLS-II Insertion Devices Group Leader

Reviewed By: Lacy Jones NSLS-II Operations Engineer, NSLS-II Management

Reviewed By: Eli Stavitski NSLS-II NEXT-III Project Management

This information is controlled by the U.S. Department of Commerce Export Administration Regulations 15 CFR Parts 730-774 as EAR99 Technology.

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VERSION HISTORY LOG

VERSION DESCRIPTION DATE WRITTEN BY APPROVED BY

1 First release 15JUL2026 Dean A. Hidas See cover page

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TABLE OF CONTENTS

1 INTRODUCTION

1.1 BACKGROUND

1.2 ACRONYMS

2 APPLICABLE DOCUMENTS

3 REQUIREMENTS

3.1 CONTRACTOR RESPONSIBILITIES

3.1.1 Technical Performance

3.1.2 Materials, Tools, Fixtures, and Test Equipment

3.1.3 Spare Parts

3.2 DESIGN AND MANUFACTURING REQUIREMENTS

3.2.1 Conceptual Design Review Report

3.2.2 Preliminary Design Review Report

3.2.3 Final Design Review Report

3.2.4 Approval to Proceed (FDR Approval)

3.2.5 Test Requirements

3.2.6 Magnet Blocks and Poles

3.3 MANAGEMENT

3.3.1 Program Plan

3.3.2 Progress Teleconference

3.3.3 Manufacturing, Inspection, and Test Plan

3.3.4 Performance Reporting

3.4 DOCUMENTATION AND DATA MANAGEMENT

3.4.1 General Documentation Requirements

3.4.2 Drawing Format Requirements

3.4.3 Installation Drawings

3.4.4 End Item Documentation

3.5 CONFIGURATION MANAGEMENT

3.6 SOFTWARE REQUIREMENTS

3.7 ENVIRONMENT, SAFETY, AND HEALTH (ESH)

3.7.1 Electrical Safety

3.7.2 Pressure Safety

3.7.3 Lifting Fixtures

3.7.4 Cryogenic Safety

3.8 DESIGN REVIEWS

3.8.1 Conceptual Design Review Meeting

3.8.2 Preliminary Design Review Meeting

3.8.3 Final Design Review

3.9 SERIALIZATION

3.10 PACKAGING

3.11 RIGGING

4 ACCEPTANCE TEST REQUIREMENTS

4.1 MAGNET ACCEPTANCE TEST

4.2 MECHANICAL ACCEPTANCE TEST

5 SITE ACEPTANCE

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6 WARRANTY

7 QUALITY ASSURANCE

7.1 QUALITY ASSURANCE REQUIREMENTS

7.2 INSPECTION AND TEST REQUIREMENTS

7.2.1 Test Plan

7.2.2 Testing

7.3 MATERIAL REVIEW BOARD (MRB) AUTHORITY

7.4 QA FLOW-DOWN

8 DELIVERABLES

9 SCHEDULE

10 VALUE ENGINEERING

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1 INTRODUCTION

This statement of work (SOW) is the basis for the procurement of Cryogenic Permanent Magnet Undulator (CPMU) for the High Resolution Powder Diffraction (HRD) beamline. This document outlines the Contractor’s responsibilities and obligations necessary for completing the requirements as set forth herein.

1.1 Background

National Synchrotron Light Source II (NSLS-II) is a state-of-the-art scientific research facility at Brookhaven

National Laboratory (BNL) that operates continuously 24 hours per day, 7 days per week. NSLS-II includes a full-energy booster/injector that injects electrons at 3 GeV into a highly optimized electron synchrotron storage ring that is 792 meters in circumference at the electron beam centerline. The NSLS-II storage ring can accommodate a minimum of 58 experimental beamlines.

1.2 Acronyms

ABL As-Built Listing

ANSI American National Standards Institute

ASME American Society of Mechanical Engineering

ATP Acceptance Test Procedure

BNL Brookhaven National Laboratory

BOB Best OPI (operator interface) Better

BOY Best OPI (operator interface) Yet

BSA Brookhaven Science Associates

CDR Conceptual Design Review

CGA Compressed Gas Association

COTS Commercial Off-The-Shelf

CPMU Cryogenic Permanent Magnet Undulator

CSS Control System Studio

DC Direct Current

DI De-Ionized

EPICS Experimental Physics and Industrial Control System

ESH Environment, Safety, and Health

FDR Final Design Review

GUI Graphical User Interface

HRD High Resolution Powder Diffraction

IAM Inventor Assembly Model

IAW In Accordance With

ID Insertion Device

IEC International Electrotechnical Commission

IEEE Institute of Electrical and Electronics Engineers

IGS Initial Graphics Exchange Specification

IOC Input / Output Controller

IPT Inventor Part

MRB Material Review Board

MRP Material Requirements Planning

NEG Non-Evaporable Getter

NFPA National Fire Protection Association

NRTL Nationally Recognized Test Laboratory

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NSLS-II National Synchrotron Light Source II

OPI Operator Interface

PDR Preliminary Design Review

PLC Programmable Logic Controller

PPE Personnel Protection Equipment

PrFeB Praseodymium-Iron-Boron

QA Quality Assurance

RHEL Red Hat Enterprise Linux

RMS Root Mean Square; also, rms

RTD Resistance Temperature Detector

SOW Statement of Work

STP STEP file format

UHV Ultra-high Vacuum

UL Underwriters Laboratory

USB Universal Serial Bus

2 APPLICABLE DOCUMENTS

In the event of a conflict between the Technical Specification and the SOW, the Contractor shall immediately notify the BSA contractual representative, who shall in each instance determine which document takes precedence and advise the Contractor accordingly. Failure to notify BSA of a document conflict shall not relieve the Contractor’s responsibility to ensure full compliance with all requirements. All documents listed in NSLSII-6ID-SPC-003, Section

3, are incorporated into this procurement to the extent they impose requirements on the Contractor.

10CFR851 Worker Safety and Health Program

ASME B30.26 Rigging Hardware

ASME B31.3 ASME Code for Process Piping (2024 Edition)

ASME Code BTH-1 Design of Below-the-Hook Lifting Devices, Design

Category “A”

ASME Y14.5 Engineering Drawing and Related Documentation

Practices

BNL-QA-101 Supplier Quality Assurance Requirements

NSLSII-6ID-SPC-003 Cryogenic Permanent Magnet Undulator for the HRD

Beamline - Technical Specification

NSLSII-DPT-STD-002 NSLS-II Nomenclature Standard

NFPA 70 National Electrical Code (2020 Edition)

NFPA 70E Standard for Electrical Safety in the Workplace (2021)

CGA P‑12 Compressed Gas Association Guideline for Safe

Handling of Cryogenic and Refrigerated Liquids

IEEE 1202 Standard for Flame -Propagation Testing of Wire and

Cable (2023)

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3 REQUIREMENTS

In accordance with (IAW) the applicable specifications, referenced documents, and instructions as defined in this

SOW, the Contractor shall be responsible for the design, engineering, manufacturing, test, and delivery of the CPMU.

3.1 Contractor Responsibilities

3.1.1 Technical Performance

In accordance with the technical specification document NSLSII-6ID-SPC-003, and all referenced documents, the Contractor shall design and manufacture the CPMU. The Contractor shall test the

CPMU at their facility and deliver it to the BNL site. It is the Contractor’s responsibility to ensure that the specified technical performance is achieved.

3.1.2 Materials, Tools, Fixtures, and Test Equipment

The Contractor shall be responsible for supplying all materials, including (but not limited to) the construction of all tools, jigs, fixtures, and test equipment required to complete the CPMU. All special tooling and test equipment fabricated or procured by the Contractor shall be considered Government

Property and shall be accounted for by the Contractor.

3.1.3 Spare Parts

3.1.3.1 One spare connector shall be provided for each non-removable connector.

3.1.3.2 Minimum of two (2) complete sets of termination magnets and poles for the entire device.

3.1.3.3 Three (3) spare fasteners of each type where these are specialized or custom (e.g., vented screws, silver plated bolts, etc.)

3.1.3.4 The Contractor shall also provide a final list of recommended spare parts at the FDR.

This final list shall include, but not be limited to, corrector coils, linear encoders, permanent magnets, and the control system components.

3.1.3.5 The Contractor shall provide one (1) complete spare set of spare magic finger holders.

BSA will provide the required hole size, hole locations, and mounting interface requirements to the Contractor following the Preliminary Design Review (PDR). The

Contractor shall incorporate these requirements into the final design.

3.1.3.6 The Contractor shall provide one hundred (100) spare magic finger pill magnets. The required dimensions and quantity of each size shall be agreed upon between the

Contractor and BSA at the Final Design Review (FDR).

3.1.3.7 The Contractor shall provide ten (10) spare poles if they are not otherwise provided within the spare magnet supply.

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3.2 Design and Manufacturing Requirements

3.2.1 Conceptual Design Review Report

The Contractor shall provide a conceptual design for the CPMU in a Conceptual Design Report, presented at a Conceptual Design Review (CDR) meeting. The report shall include the following:

3.2.1.1 An initial assessment that shows the magnet and mechanical system layout on the basis of the specification.

3.2.1.2 A layout that consists of either 2D orthogonal views or a block 3D model. All drawings shall be to scale, but are not required to include fully detailed, dimensioned drawings.

The layout shall show sufficient detail to convey the conceptual design.

3.2.1.3 The subassembly and systems shall be identified with labels that adopt a common nomenclature and shall be in accordance with BSA document NSLSII-DPT-STD-002, NSLS-II Nomenclature Standard.

3.2.1.4 At the Conceptual Design Review (CDR), BSA will provide the required magic finger interface parameters, including the required diameter, depth, symmetry, number of rows, and number of columns. The Contractor shall incorporate these parameters into the Preliminary Design Review (PDR) design package and subsequent detailed design.

3.2.1.5 Cursory “envelope” calculations shall be provided and presented to support the basis for the layout.

3.2.2 Preliminary Design Review Report

The Contractor shall be responsible for providing a Preliminary Design Review (PDR) report that reflects the state of the developed design evolved from the CDR. The PDR report shall consist of the following items to be addressed in detail and supported by preliminary calculations that shall be presented at the Preliminary Design Review for review and approval.

3.2.2.1 Thermal and stress analyses shall be performed using the ANSYS program, or equivalent. Analysis files shall be provided to BSA at the preliminary design review.

3.2.2.2 2D plan and elevation drawings of the Equipment (on the basis of the specification), showing the Contractor’s proposed component designs. All drawings shall be to scale, and include sufficient dimensional detail (e.g., overall height, width, length, interface details, beam height and any deflections, etc.) to confirm fit within the straight section, and component magnetic center locations. Note that in all drawings and models the beam direction shall go from Left to Right.

3.2.2.3 A PDR meeting agenda and a preliminary copy of the PDR presentation (in Microsoft™

PowerPoint or PDF format) that the Contractor will provide to BSA personnel explaining their design approach and how it will meet all BSA requirements. Written explanation shall be included with this presentation with sufficient detail to illustrate how all BSA requirements will be fully met.

3.2.2.4 A project schedule, as a Gantt chart or preferably in Microsoft™ Project, with all required tasks, milestones, and subcontractor efforts that support contractual requirements.

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3.2.2.5 All drawings and documentation of the subassemblies and systems shall be identified with titles, numbers and labels, etc., that adopt a common nomenclature, and shall be in accordance with BSA document NSLSII-DPT-STD-002, “NSLS-II

Nomenclature Standard.”

3.2.2.6 The name of the magnet supplier and the commercial name of the PrFeB alloy and specification sheet.

3.2.2.7 Details of the plating for the magnets including, but not limited to the material and thickness.

3.2.2.8 Mechanical system and subsystem descriptions with ballooned assembly drawing callouts.

3.2.2.9 Specifications, sourcing, and catalog cut-sheets for all commercially packaged components.

3.2.2.10 Final magnetic circuit design and field parameters.

3.2.2.11 Magneto-static analyses and optimizations

3.2.2.12 Output files of the ANSYS thermal and mechanical simulations.

3.2.2.13 OPERA or RADIA magnetic simulations.

3.2.2.14 Finite element analyses at part and assembly level (both input and result contour plots).

3.2.2.15 Structural, stress/deflection of the girder and the mechanical frame, thermal calculations, and vibration analysis, with accompanying finite element analysis models

(models to be provided electronically in their native ANSYS, or similar format approved by BSA in writing, as well as in hard copy form) showing effective gap and taper, vertical and rotational stiffness.

3.2.2.16 Field correction provisions and methods (coils, adjustors, mechanical/magnetic shimming).

3.2.2.17 Full package of 2D Drawings and 3D models of all assemblies, sub-assemblies, and details.

3.2.2.18 Motor, gear head, and drive train speed and sizing calculations.

3.2.2.19 Preliminary control system schematics, ladder logic printouts, flowcharts, and block diagrams.

3.2.2.20 Details of the configuration using BSA specified air casters and other transport system for the transport of the CPMU.

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3.2.2.21 Details of the lifting capability of the equipment by fixed or removable lifting eyes.

A final version of the PDR report shall be submitted to BSA which includes the minutes and agreed-to changes. These minutes shall include:

3.2.2.22 PDR comments and notes taken during the PDR meeting.

3.2.2.23 All items that require further resolution with details added explaining how these items will be acceptably resolved.

At the PDR, BSA will provide the required survey hardware standard, including the survey target/nest type, interface requirements, and the planned tunnel fiducial layout. The Contractor shall incorporate these requirements into the final design and identify the proposed locations of all survey hardware in the FDR package.

The final PDR report shall be reviewed and approved by BSA in writing before it can be considered complete. PDR approval by BSA authorizes the Contractor to begin the

Final Design.

3.2.3 Final Design Review Report

The Contractor shall be responsible for providing a Final Design Review (FDR) report that reflects the state of the developed design evolved from the PDR. The Contractor shall be responsible to develop the overall design of the CPMU in accordance with the applicable specifications and supporting documents as identified herein. The Contractor shall perform the following tasks, with the results to be included in the FDR report for review and approval as part of the FDR. The FDR Report shall be prepared by the Contractor and submitted two (2) weeks prior to the Final Design Review.

The FDR report shall include the following in addition to all of the requirements specified for the PDR in the previous section:

General Information:

3.2.3.1 A summary of any changes to the design since the PDR.

3.2.3.2 A complete schedule showing all milestones and major activities required to meet all contractual requirements.

Detailed design information:

3.2.3.3 A final 3D model (components and sub-assemblies containing Intellectual Property will not be detailed) of the system in a format defined in 3.4 of this SOW, which may also be viewed in the native CAD program on screen at the FDR meeting.

3.2.3.4 Drive train preloading, alignment, coupling, and braking requirements.

3.2.3.5 Nominal gap and settings for the limit switch and hard stop position.

3.2.3.6 Electrical System, Instrumentation, and Controls component specifications and cut-sheets.

3.2.3.7 Controls System schematics, flowcharts, and block diagrams, provided electronically.

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3.2.3.8 Electrical rack/cabinet assembly drawing and callouts and complete wiring diagrams including connector and cable coding and pin-outs

3.2.3.9 Details of wire routing both within the 19-in rack as well as external cables to the CPMU.

3.2.3.10 Vacuum chamber supports and adjustors design.

3.2.3.11 Critical machining and assembly stack-up tolerance calculations.

3.2.3.12 Material selections, environmental compatibility, surface and heat treatments.

3.2.3.13 Identification of any components that contain materials with a probable shorter life than defined in the specification and the details of the supplied spares for the lifetime of the CPMU.

3.2.3.14 Manufacturing and assembly planning, including any related concerns, including (but not limited to) schedule and high-risk items.

3.2.3.15 All inspection and test procedures.

3.2.3.16 Details of any assembly tooling and procedures, including but not limited to magnetic girders, magnet and pole insertion/extraction, vacuum chamber installation.

3.2.3.17 Mechanical component life cycle calculations, including (but not limited to) power screws, bearings, and motors.

3.2.3.18 Mechanical system and subsystem descriptions with ballooned assembly drawing callouts.

3.2.3.19 Fiducialization, survey, and alignment plans.

3.2.3.20 Guards, grounding, safety features, and precautions to meet applicable safety codes and standards.

3.2.3.21 Tip stability, weight, center-of-gravity, and floor load calculations.

3.2.3.22 Required utilities callouts (electrical power, compressed air, liquid nitrogen, water, where applicable).

3.2.3.23 Demonstration that all applicable safety codes and standards have been met.

3.2.3.24 Proposed design improvements and upgrades; see section 10 (Value Engineering).

3.2.3.25 The names and contact information of the contributors to the FDR report.

3.2.3.26 All detailed documentation, including (but not limited to) manufacturing drawings, top level assembly drawings, associated 3D models, parts lists, and schematics.

3.2.3.27 Acceptance Test Procedures (ATPs).

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3.2.3.28 Final list of recommended spare parts.

3.2.3.29 List of major subcontractors and the components and/or assemblies being provided.

3.2.3.30 Installation plan and procedure.

3.2.3.31 Design for electronics serviceability.

3.2.3.32 Proposed location of identification labels.

3.2.3.33 Proposed acceptance test procedures.

3.2.3.34 Detailed description of the cryogenic cooling system including connections, flow rates (if

LN2 cooled), internal and external equipment, supply lines, power consumption, and cooling capacity.

ESH Information:

3.2.3.35 Identification of hazards, and their mitigation, during all stages of the life of the

Equipment including installation, commissioning, operation, maintenance, repair, and in fault conditions. This information shall be provided to determine ESH compliance and included in the equipment manual.

3.2.3.36 On identification of hazards the Contractor shall identify methods to mitigate the hazard by substituting with something less hazardous, mitigate the severity or eliminate the hazard through engineered solutions, or require the use or Personal Protective

Equipment (least desirable).

3.2.4 Approval to Proceed (FDR Approval)

BSA must approve, in writing, the final design review report, including any modifications introduced at the Final Design Review, before the Contractor shall proceed with ordering material and components. Ordering of long-lead-time materials and components prior to the approval of the Final

Design Review Report must be reviewed and approved in writing by BSA.

3.2.5 Test Requirements

3.2.5.1 Acceptance Test Procedures

The Contractor shall develop procedures to verify and document that all requirements specified by BSA have been met, including all dimensional requirements, and to show that all applicable codes, standards, and specifications and referenced documents have been met. The proposed acceptance test procedures shall be presented at the FDR. All

ATPs must be acceptable to BSA and approved in writing prior to use.

3.2.5.2 Test Data

All test data shall be documented and delivered to BSA for review and written approval prior to delivery of the CPMU. All magnet block measurement data (Mx, My, Mz) shall be supplied to BSA.

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3.2.5.3 Survey Data Requirements

BSA will provide the Contractor with the required survey data deliverables prior to the

Factory Acceptance Test (FAT). These requirements shall define the survey coordinate system, required fiducials and reference points, measured dimensions and locations, data format, reporting format, and any associated uncertainty requirements. The

Contractor shall acquire and deliver the specified survey data as part of the FAT documentation package.

3.2.6 Magnet Blocks and Poles

The Contractor shall order a 10% excess number of magnet blocks and poles, to facilitate sorting and to allow shrinkage due to breakage. Additionally, there shall be provided a minimum of two (2) complete sets of termination magnets and poles for the entire device. Spare blocks shall be delivered to BSA upon completion of contract.

3.3 Management

3.3.1 Program Plan

Within two (2) weeks after award of contract, the Contractor shall deliver a detailed program plan which includes a milestone schedule defining the design validation, manufacturing, and testing in sufficient detail to allow regularly scheduled progress monitoring.

3.3.2 Progress Teleconference

Within two (2) weeks after award of contract, weekly program technical and progress teleconferences and/or meetings between the Contractor and BSA shall be held at a mutually scheduled time. The discussions shall include the Contractor’s progress, technical and contractual questions, analyses, design reviews, value engineering, troubleshooting, material status, tooling status, resources, and manufacturing issues. Also, within two (2) weeks after award of contract, the Contractor shall establish a protected large-file-transfer site on a local server that is accessible to BSA and updated timely in accordance with the agreed upon schedule. Included on that website will be technical and contractual questions and answers, presentations of analysis or testing results, design reviews, value engineering, troubleshooting, material status, tooling status, resources, manufacturing issues and project status reporting.

3.3.3 Manufacturing, Inspection, and Test Plan

A manufacturing plan shall be developed which identifies the manufacturing processes required to complete all efforts identified in this SOW. The plan shall be submitted for review and approval by

BSA within sixty (60) calendar days after award of contract. The plan may be a single document or may make use of existing travelers or other suitable planning and control documents. It shall address the MRP and, at a minimum, shall include manufacturing, inspection, and test steps—including the identification of critical manufacturing operations and parts/subassemblies and showing integrated flow into the end item(s). If the Contractor does not have an MRP system in place, then details for purchasing all raw materials, shop loading (by work center), and a schedule for manufacturing all components and assemblies through packaging and shipping shall be provided by the Contractor.

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3.3.4 Performance Reporting

Throughout the life cycle of the contract, the Contractor shall supply a written report by the fifth of every month to the BSA technical representative and contractual representative that clearly details progress through the prior month with respect to the program. This shall include milestone charts, detailed progress, open items, problems, recommended solutions, and risk mitigation.

3.4 Documentation and Data Management

3.4.1 General Documentation Requirements

All documentation provided by the Contractor shall be in English.

3.4.1.1 All drawings shall:

• be formatted in accordance with ASME Y14.5.

• have views shown in third angle projection.

• use metric dimensions and tolerances.

• have a separate parts list.

• have part number designations in accordance with BSA Document NSLSII-DPT-

STD-002.

3.4.1.2 Manufacturing drawing CAD files of all components and assemblies shall be included in the documentation provided to BSA.

3.4.1.3 Schematics shall also be provided in a searchable PDF.

3.4.2 Drawing Format Requirements

The contractor shall provide and maintain the capability to receive and send CAD files of all components or assemblies in the following formats:

3.4.2.1 2D Formats: AutoCAD 2D drawings (.DWG format).

3.4.2.2 3D Formats: IAM, or IPT (preferable) or STP or SAT file format of all components and assemblies, at the request of BSA. IGES files are not acceptable.

3.4.3 Installation Drawings

The contractor shall supply installation drawings showing all necessary equipment dimensions required for BSA installation; all electrical and utility connections to the BSA-provided equipment and services shall be clearly shown.

3.4.4 End Item Documentation

The Contractor shall provide an electronic copy (by email, USB data storage device, or downloadable from a secure repository) of the End Item documentation package IAW the schedule set forth in this

SOW. The End Item documentation package for the CPMU shall consist of the following documentation (all provided with delivery of the CPMU):

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3.4.4.1 All documentation identified in this SOW.

3.4.4.2 All Part and Assembly solid models.

3.4.4.3 Part detail drawings.

3.4.4.4 All source codes for control system including but not limited to EPICS, CSS/Phoebus, motion and motor controllers, and programmable logic controllers. This shall include any programmable or configurable hardware configuration files.

3.4.4.5 Notification and access to new versions of software as available.

3.4.4.6 Final Tuning/Shimming Procedure.

3.4.4.7 All magnetic measurement data including final magnetic field mapping data.

3.4.4.8 Magnetic analysis files.

3.4.4.9 User/operation manual detailing: maintenance, operation, and hazard management.

3.4.4.10 All Completed travelers.

3.4.4.11 As-Built Listing (ABL) for each configurable subassembly or component.

3.4.4.12 A list of the magnets, which have been displaced during the shimming.

3.4.4.13 The number and the configuration of magnets in the magic fingers.

3.4.4.14 Material Certifications for rare earth magnetic material.

3.4.4.15 Acceptance Test Reports.

3.4.4.16 Test data for tests performed during manufacturing.

3.4.4.17 Data from incoming inspection and in-process manufacturing.

3.4.4.18 Certificate of Conformance.

3.4.4.19 Source inspection documents (inspections conducted by the Contractor at a subcontractor).

3.4.4.20 Procedure for removal and reinstallation of the taper transition assemblies, including all required tooling, alignment precautions, torque requirements, and post-installation verification.

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3.4.4.21 Procedure for removal, replacement, and reinstallation of permanent magnets, poles, and associated hardware, including all required tooling, shimming, alignment, inspection, and magnetic verification steps necessary to restore the CPMU to its specified performance.

3.5 Configuration Management

The Contractor shall establish and maintain a configuration control system to assure that all End Items

(including spares) are of the proper configuration, and that all approved configuration changes are incorporated at the specified effectivity points. Records shall be maintained verifying the configuration of each item.

3.6 Software Requirements

3.6.1.1 The Contractor shall have and maintain an effective software configuration management system. The Contractor’s system shall establish requirements for placing software under configuration control and provide for the positive identification of software and the control of all software baseline changes.

3.6.1.2 The Contractor shall develop written procedures describing the controls applied to the design of software and the validation of the design through independent technical review. The procedures shall provide for documentation of review activities, including requirements for documenting comments and resolutions of comments. Contractor software designs and review documentation shall be subject to review and approval by the BSA.

3.6.1.3 The Contractor shall test and verify computer software developed or modified to fulfill the requirements in the procurement documentation. The validation testing shall be accomplished by a comparison of test results with those from other verified software, or by a comparison with results from analytical solutions or BSA-approved alternatives.

3.6.1.4 File format requirements: The Contractor shall provide and maintain the capability to receive and send CAD files of all components or assemblies in STP, SAT, IAM, or IPT file format.

3.6.1.5 The Contractor shall perform magnetic analyses using Radia, Tosca/Opera3D, or an equivalent software package approved in writing by BSA; the analysis source files shall be provided to BSA.

3.6.1.6 The EPICS IOC and CSS/Phoebus GUI shall be provided by the Contractor for control during troubleshooting and tuning. It will either be integrated into a rack-mount PC residing in a standard BSA rack or be a standalone application running on a laptop system that communicates to the standard BSA rack via Ethernet connections.

3.6.1.7 Documentation shall be provided by the Contractor, detailing the components, structure, and operation of the system software.

3.7 Environment, Safety, and Health (ESH)

The Contractor shall design and build all equipment IAW ESH requirements in the appropriate Specifications, codes, standards, and other documents listed in this SOW and the associated SPC.

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3.7.1 Electrical Safety

3.7.1.1 All electrical distribution must be in accordance with U.S. standards and must comply with NFPA70. All COTS components shall be approved by a NRTL, http://www.osha.gov/dts/otpca/nrtl/nrtlmrk.html. CE is not an approved NRTL. In the event the equipment cannot be NRTL approved, exceptions must be approved in writing by BSA, and the Contractor shall determine the equipment to be safe for the intended use. The determination must be documented and approved by a trained BSA inspector upon delivery to BNL.

3.7.1.2 All exposed uninsulated electrical connections ≥50 volts shall be covered to comply with

UL Standard 508 so that all uninsulated charged surfaces protect workers from the hazards of electrical shock. Plexiglas® is not allowed; Lexan® may be used. All electrical insulation outside of the 19-in rack must be Low Smoke, Zero Halogen, Fire Retardant and radiation resistant unless otherwise approved in writing by BSA. Teflon insulation is not allowed.

3.7.1.3 All cables to be installed in a cable tray shall be rated for cable tray use. The cable shall have the TC (Tray Cable) and NRTL markings. If a Contractor elects to use a cable not marked for tray cable use, then the Contractor shall use a cable that will meet IEEE

1202 or equivalent approved by BSA in writing. BSA shall approve the use of all non

NRTL marked tray cables in advance of the Contractor ordering the cable.

3.7.2 Pressure Safety

All components shall comply with ASME B31.3 process piping requirements, as applicable.

3.7.3 Lifting Fixtures

3.7.3.1 The Contractor shall provide lifting eyes, either permanent or removable, on the equipment in sufficient capacity and number to allow the equipment to be safely lifted in the fully assembled condition. Acceptable manufactures of lifting eyes are Columbus

McKinnon, Chicago Hardware & Fixture Company, and RUD Lifting, alternatives must be approved in writing by BSA.

3.7.3.2 All CPMU lifting fixtures must meet the requirements specified in ASME B30.26

(Rigging Hardware) and ASME BTH-1 (Design of Below-the-Hook Lifting Devices, Design Category “A”) for above center of gravity lifts. Below center of gravity lifts are discouraged.

3.7.4 Cryogenic Safety

The contractor shall ensure compliance with all applicable Cryogenic Systems Standards including but not limited to:

3.7.4.1 Installation/operation conforming to NFPA 55, NFPA 45, and CGA P‑12 guidance.

3.7.4.2 Pressure containment vessels: ASME Section VIII of the Boiler and Pressure

Vessel Code.

3.7.4.3 Internal and external piping systems to ASME B31.3 Process Piping Code.

http://www.osha.gov/dts/otpca/nrtl/nrtlmrk.html

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The contractor shall:

3.7.4.4 Use only cryogenic compatible material. The use of materials that become brittle at cryogenic temperatures is prohibited.

3.7.4.5 Use ASME rated over-pressure relief devices sized for nitrogen expansion.

3.7.4.6 Use CGA-compliant fittings, valving, and vacuum jacketed transfer lines (low boil-off and ice formation).

3.7.4.7 Use certified and tested NFPA-compliant pressure relief valves on all isolated containment volumes.

3.7.4.8 Ensure there are no trapped volumes for liquid accumulation to avoid pressure buildup on rapid boil-off

The contractor shall include in the operation manual descriptions of

3.7.4.9 Operating temperature and pressure and maximum cryogen capacity.

3.7.4.10 All system points with seals, O-rings, and valves that may undergo cryogenic induced wear.

3.7.4.11 Maintenance requirements and record log of nitrogen transfers and system inspections

3.7.4.12 Special procedure and precautions for slow, controlled filling with venting.

3.7.4.13 Recommended PPE to be used for service or refill.

3.7.4.14 Cautionary signage and warning for potential ODH and burn risk.

3.8 Design Reviews

3.8.1 Conceptual Design Review Meeting

A CDR meeting shall be held IAW the schedule set forth in this SOW. The Contractor shall provide, no later than five (5) working days prior to the scheduled meeting, a draft Conceptual Design Report that meets the requirements set forth in section 3.2.1. The contents of this report shall be reviewed at the CDR, to be held via teleconference. The Contractor shall be responsible for maintaining and submitting the minutes of the CDR and shall also incorporate any agreed-to changes into the conceptual design report as required. CDR minutes are to be submitted within five (5) working days of the CDR for subsequent review and approval by BSA. Upon written approval of the CDR Report, the

Contractor may proceed to the preparation of the preliminary design.

3.8.2 Preliminary Design Review Meeting

A PDR meeting shall be held IAW the schedule set forth herein. To ensure that the requirements are compliant with this SOW, applicable specifications, and interface control drawings, the Contractor shall provide, no later than five (5) working days prior to the scheduled meeting, a draft PDR Report that shall consist of the requirements set forth herein. The contents of this report shall be reviewed at the PDR to be held at the Contractor location, BSA, or in video conference format (at the discretion of

BSA) and shall cover the tasks cited in 3.2.2. The Contractor shall be responsible for maintaining and

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submitting the minutes of the PDR and shall also incorporate any agreed-to changes into the final comprehensive PDR Report, both of which are to be submitted within five (5) working days of the

PDR for subsequent review and written approval by BSA. Upon written approval of the PDR Report, the Contractor may proceed to the preparation of the final design.

3.8.3 Final Design Review

A FDR meeting shall be held IAW the schedule set forth herein. The Contractor shall provide, no later than ten (10) working days prior to the scheduled meeting, a draft Final Design Review Report that shall consist of the requirements set forth in section 3.2.3. The findings of the FDR Report shall be reviewed at the FDR to be held at BSA or in video conference format (at the discretion of BSA) and shall cover all pertinent issues relating to the final detailed design of the CPMU The Contractor shall be responsible for maintaining and submitting minutes of the FDR and shall also incorporate any agreed-to changes into the final comprehensive FDR Report, both of which are to be submitted to BSA within five (5) working days of the

FDR for subsequent review and written approval. Upon written approval of the FDR Report, the Contractor may proceed to procurement and manufacturing phase.

3.9 Serialization

Each individual magnet and holder combination shall be marked indelibly with a 4-digit serial number on the holder or vacuum-tight package of each magnet. These marking shall be compatible with the ultra-high vacuum specification. These serial numbers must be assigned to the parent part through the use of the ABL and travelers. The naming protocol shall be IAW BSA Document “NSLS-II Nomenclature Standard NSLSII-

DPT-STD-002.”

3.10 Packaging

3.10.1.1 In preparation for shipping, the CPMU shall be covered or wrapped for protection against weather elements, dust, and damage to projections, shock loads, impacts, and rubbing. The CPMU shall be properly braced and cushioned within its own packing so that it will not shift during handling and shipment. The packaging shall be designed to withstand a mechanical shock in excess of 2 Gs.

3.10.1.2 Added protection shall be given to the magnet surfaces, electrical connections, and limit switches. Durable material, such as clean wood, bubble wrap, or similar non-contaminating material, shall be used to support and protect the components from one another during transit and storage. Peanut-type material shall not be used for packaging.

3.10.1.3 Prior to shipment, all liquid nitrogen shall be removed from the system and lines appropriately capped to prevent contamination.

3.10.1.4 The magnet gap must be locked in a magnetically stable open gap position with the vertical gap motion carriage assembly supported externally to the vacuum chamber for the purpose of transferring the magnet loads away from the gap drive. The vacuum chamber shall then be back-filled with dry nitrogen of at least 99.999% Ultra High

Purity for transport.

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3.10.1.5 The container shall be appropriately labeled with the listing of contents, destination, gross weight, location of center of gravity, Department of Transportation labeling for magnetic fields, purchase order/Contract number, and contact information.

3.10.1.6 The Contractor shall affix BSA provided sensors to the CPMU structure to record the temperature, humidity, maximum tilt angle, and acceleration experienced by the CPMU during transport to BNL. Each container shall have G-force shock indicators.

3.10.1.7 Each container shall be palletized and include provisions to permit access for a forklift to lift the container.

3.11 Rigging

The Contractor shall supply all necessary rigging hardware (crates, palettes, fork receptacles on shipping crate, lifting fixtures, lifting eyes, shackles, slings or spreader bars, etc.), whether integral or detached from the

CPMU structure, in accordance with the codes cited in section 2. The Contractor’s rigging hardware shall be inspected and approved by BSA personnel prior to use at BNL. For lift operations outside the climate-controlled Environmental Enclosure of BSA’s Magnet Lab, a certified 30-ton crane is available.

4 ACCEPTANCE TEST REQUIREMENTS

4.1 Magnet Acceptance Test

The following magnet acceptance tests shall be conducted before assembling the CPMU at the Contractor’s facility according to the ATPs:

4.1.1.1 The main overall dimensions of each magnet shall be measured at several points to ensure that they meet tolerances.

4.1.1.2 The thickness of the magnet coating at the center of its largest face must be measured on a sample quantity of 1% of the magnet blocks.

4.1.1.3 The three magnetic components of each magnet shall be measured at the same temperature ± 0.5ºC in a thermally controlled area between 20 and 25°C with a

Helmholtz coil having a precision of 0.1% or better. A minimum of four (4) separate measurements shall be made. The magnet should be stabilized in a thermally controlled area at least 24 hours before measurements. The contractor shall provide a calculation to show what the measured values convert to at the final operating cryogenic temperature. Ultimately, the contractor will be required to measure and guarantee the magnetic field at cryogenic operating temperature for the assembled CPMU. All magnets must be measured at the same temperature.

4.1.1.4 All measured test data shall be documented and submitted to BSA for review and written approval prior to CPMU assembly and shimming.

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4.2 Mechanical Acceptance Test

Each piece of the mechanical support shall be tested to ensure that it was designed with a tolerance so as to keep the fully assembled CPMU within the mechanical tolerances given in Table 2 of the technical specification. As part of the ATPs, the Contractor shall provide:

4.2.1.1 A local field measurement system to perform the CPMU horizontal and vertical magnetic field mapping at the operating cryogenic temperature and under vacuum. An accuracy and reproducibility of ±1G over the full measurement range is required. The positioning accuracy and reproducibility of the probes shall be in X, Y of ±10 μm and in

Z of ±2.5 μm. If the local field measurement bench uses Hall probes, they shall be calibrated prior to use with sufficient sensitivity to verify compliance with the tolerance requirements.

4.2.1.2 A field integral measurement system to measure the vertical and horizontal, first field integral at Y = 0.0 mm; 0.0 ≤ |X| ≤15 mm. The step should be ≤ 0.2 mm. The repeatability of each first field integral measurement shall be ≤5.0 G-cm, and the repeatability of each second field integral measurement shall be ≤200 G-cm2. The positioning accuracy and reproducibility shall be ±25 μm in the X direction and ±10 in μm in the Y direction.

4.2.1.3 The length of both measurement systems shall be sufficient to include the fringe field regions (below 1 Gauss) of the CPMU magnetic array.

4.2.1.4 The magnetic measurements shall be performed at room temperature as well as in vacuum and at the operating cryogenic temperature. The CPMU shall thermally equilibrate a minimum of 24 hours to before final measurements are performed. The following additional magnetic measurements shall be conducted on the CPMU at the

Contractor’s facility according to the ATPs, prior to delivery to BNL. The magnetic measurements shall be done for magnetic gaps of 4.5 mm, 5.5 mm, 5.97 mm, 6.25 mm,

6.5 mm, 7.0 mm, 7.5 mm, 8.0 mm, 8.5 mm, 9.0 mm, 9.5 mm, 10.0 mm, 12.0 mm, 14.0 mm, 16.0 mm, 20.0 mm, 25.0 mm. Measurements from 5.97 mm to 7.0 mm shall be repeated each five (5) times and recorded:

1. Local field mapping: The Contractor shall provide the mapping of the horizontal and vertical on-axis field. The longitudinal step shall be less than or equal to

0.2 mm

2. Field integral measurement: the Contractor shall provide the measurement of the horizontal and vertical first field integral at Y = 0.0 mm; 0.0 mm ≤ |X| ≤15 mm.

3. Second field integral: The second field shall be computed from the on-axis field local field measurement. Specification verification through the use of a field integral bench may be acceptable but is subject to BSA written approval.

4. Root Mean Square (RMS) Phase error: Using longitudinal Hall probe scans with zero taper, the Contractor shall compute the RMS phase error for every gap listed above. The repeatability of each measurement shall be ≤ 0.2 degree.

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5. Multipole coefficients: The Contractor shall determine the integrated skew and normal multipole component up to the octupole included at Y= 0.0 mm and

|X|<10 mm. A horizontal step of 1.0 mm is required.

6. Phase Error Repeatability: The gap shall be closed to 5.97mm and opened to 8.0

mm. The RMS phase error shall be computed at the 8.0 mm gap. The gap shall be opened to 15.0 mm and closed to 8.0 mm. The RMS phase error computation shall be repeated at the 8.0 mm gap. The change in RMS phase error shall be recorded. Repeat this gap change-measurement cycle three times. The phase error shall not differ by more than 0.2 degree.

The contractor shall provide to BSA all of the measurement data and results mentioned herein.

5 SITE ACEPTANCE

The CPMU, related hardware, and spares are only considered to pass site acceptance after inspection after shipment, review of transport sensors, vacuum condition and testing, verification of cryogenic operation, electrical safety inspection, controls checkout, motion checkout, documentation acceptance, and BNL magnetic measurement confirming field requirements are met.

6 WARRANTY

The Contractor shall provide a warranty for the Equipment, against failure and defects for a period of two (2) years from final acceptance.

7 QUALITY ASSURANCE

The Contractor shall maintain and apply an effective QA program for the design, manufacture, and testing of all systems and equipment provided. The system shall comply with the requirements of the ISO-9001 Standard, “Quality

Management System Requirements.” The Contractor shall supply the necessary documentation to demonstrate this compliance. Post-award surveys may be required and shall be supported.

7.1 Quality Assurance Requirements

As set forth in BSA Form BNL-QA-101, “Brookhaven National Laboratory Supplier Quality Assurance

Requirements,” as amended herein, forms a part of this statement of work. Specifically, this includes the following sections: 1, 2, 3, 3.1, 3.1.2, 3.2 to 3.22, 4.0, 4.1, 4.2, 4.3, 4.4, 4.4.1, 4.4.2, 4.4.3, 4.5 as modified below, 4.6, 4.7, 4.7.1, 4.7.3, 4.10, 4.10.1, 4.10.2, 4.10.4, 4.13, 4.14 as modified below, 4.15, 4.16, 4.19, 4.21, 4.28, 4.31, 4.34, 4.35 and 4.39. With each Component delivered, the Contractor shall supply to BSA a

Certificate of Conformance, IAW section 4.16 of BNL-QA-101.

7.1.1.1 Clause 4.5: “Witness” Points, is modified as follows: The supplier shall provide BNL with thirty (30) days’ notice in advance of reaching such witness points during the manufacturing and test cycle of each item.

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7.1.1.2 Clause 4.14: Source Inspection/Surveillance is modified as follows: Items to be delivered require inspection, test, or surveillance by the Buyer’s representative at the Suppliers facility. Thirty (30) days’ notice, for acceptance inspections and tests, shall be given by the Supplier to the Buyer to permit scheduling of source inspection.

7.2 Inspection and Test Requirements

7.2.1 Test Plan

The Contractor shall prepare and maintain a Manufacturing/Inspection/Test Plan (as noted in section 3 herein), which shall be submitted to the BSA technical representative for written approval by BSA prior to its required use. This shall consist of a plan in the Contractor’s format listing components, subassemblies, and assemblies; identifying inspections and tests planned for the verification of quality;

and identifying documentation/planning to be used for such accomplishment.

7.2.2 Testing

The systems shall be tested by the Contractor at the Contractor’s facility, the Contractor’s subcontractor’s facility, or a pre-approved BSA collaborator prior to shipment, using an ATP generated by the Contractor and approved by BSA in writing. Final acceptance of the CPMU shall take place following the successful completion of final testing at BNL.

7.3 Material Review Board (MRB) Authority

7.3.1.1 Unless, and until, Material Review Board (MRB) authority has been requested and received, the Contractor shall be restricted to dispositions of rework, scrap, and return-to-vendor; i.e., the contractor shall not use nonconforming materials via unique or standard repair processes, nor via use-as-is-dispositions.

7.3.1.2 The Contractor shall not delegate MRB authority to suppliers without the prior knowledge and written approval of BSA.

7.3.1.3 BSA may delegate MRB Authority to the Contractor, when requested by the

Contractor. Such request shall be accompanied by: 1) the Contractor’s procedure for the identification, evaluation, disposition, and control of nonconformances; and 2) the resumes of personnel to be assigned as MRB members.

7.3.1.4 All nonconformances requiring MRB action shall be documented and sent to the BNL technical representative within five (5) working days of the decision.

7.4 QA Flow-Down

The Contractor shall ensure a proper and complete flow-down of all applicable QA requirements, as described in section 5.1 herein, to its suppliers and sub-tier suppliers.

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8 DELIVERABLES

The Contractor shall supply the following:

Item Deliverable Due Approval

Required

1 Program Plan 2 weeks after award of contract Yes

2 Technical & Progress Teleconference 2 weeks after award/weekly thereafter No

3 Performance Reports 5th of each month Yes

4 Manufacturing/Inspection/Test Plan 60 calendar days after award of contract Yes

5 Draft Conceptual Design Report 5 working days prior to Conceptual Design Review

(CDR)

Yes

6 Conceptual Design Report and CDR Minutes 5 working days after CDR Yes

7 Draft Preliminary Design Report 5 working days prior to Preliminary Design Review

(PDR)

Yes

8 Preliminary Design Report and PDR Minutes 5 working days after PDR Yes

9 Draft Final Design Report 10 working days prior to Final Design Review (FDR) Yes

10 Final Design Report and FDR Minutes 5 working days after FDR Yes

11 Acceptance Test Report and test Certificates 14 calendar days after completion of FAT and prior to shipment of equipment

Yes

12 Delivery…