10.8.26 Update - DRAFT SOW, AL-1964-3328B.pdf

Advanced Light Source Upgrade Project Lawrence Berkeley National Laboratory

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ALS-U Statement of Work

DRAFT

Release Date:

Document Number: AL-1964-3328 Revision: B

Document Status: Working

Document Type:

Category Code:

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Table of Contents

1 Revision History

2 Approvals

3 Abbreviations and Acronyms

4 Introduction/Background

5 Objectives

6 Deliverables – SR RACKS DESIGN

7 Quality Assurance

8 Schedule

9 Applicable Documents

Appendix A: Reference Documents

1 REVISION HISTORY

Rev. CM Number Description of Change A Initial Release

2 APPROVALS

The following individual(s) shall approve this document:

Approver Project Role Alessandro Ratti ALS-U EE System Manager Alessandro Morato ALS-U PS Group Lead, CAM William Waldron ALS-U EE System Tech Deputy Windchill Approved / Concurred By

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3 ABBREVIATIONS AND ACRONYMS

A Analysis ABRV Abbreviation ALS Advanced Light Source

ALS-U

CAM

Advanced Light Source Upgrade Control Account Manager

DEMO Demonstration FLEX Flexibility ID Identification INSP Inspection LBNL Lawrence Berkeley National Laboratory METH Method N/A Not Applicable

NUM

PS

Number Power Supplies

TEST Test VERIF Verification

4 INTRODUCTION/BACKGROUND

ALS-U is an upgrade to the LBNL Advanced Light Source (ALS). It is optimized to produce intense beams of soft x-rays, which offer spectroscopic contrast, nanometer-scale resolution, and broad temporal sensitivity. Presently, the project has achieved CD-2, CD-

3A approval for long lead procurements, and CD-3 authorization to proceed to procurement and fabrication work through the execution phase of the project. The ALS-

U power supplies are based on a distributed, modular architecture of industrial 19-inch, 48U racks. A companion system of 17 racks for the new Accumulator Ring (AR) has been completed and installed; this SOW covers the remaining rack-level design work for the

Storage Ring (SR).

The SR system comprises 76 racks in 16 distinct layouts: six layouts for the SR Standard

Sectors (9 sectors, 54 racks in total), six layouts for the SR Hard Bend Sectors (3 sectors, 18 racks in total), and four unique layouts for the transfer line racks (ATS/STA, 4 racks in total). The main internal components (power supply controllers, bipolar and unipolar power converters, DCCT modules, AC distribution chassis, and COTS units) have already been designed and are in production or already procured. The subject of this SOW is the design of the complete rack assemblies integrating these components.

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Through this SOW, LBNL seeks a qualified Subcontractor to complete the rack-level design of the ALS-U SR Power Supplies system.

5 OBJECTIVES

This SOW defines the work required to complete detailed design of the ALS-U SR Power

Supplies rack assemblies and the associated documentation packages to support procurement of the components required per the detailed design including but not limited to mechanical parts, bus bars, and cable harnesses. The SOW includes an option to assess interest for assembly of the SR racks in accordance with the completed design and documentation packages. The detailed design shall include the design of each of the 16

SR rack layouts and associated internal components, interconnections, and electrical schematics.

The following design inputs will be provided by LBNL:

• Preliminary layout profiles for each of the 16 SR rack layouts.

• 3D models of the existing internal chassis and components, provided as Autodesk

Inventor libraries. Associated drawings and documentation available upon request.

• The complete Autodesk Inventor design packages for all 6 AR racks already developed, to be used as a reference.

• Architectural guidance for internal interconnections and electrical schematics, with representative block diagrams and/or high-level electrical schematics for selected rack configurations, showing the typical flow of power, control/signals, cooling-water interfaces, and the principal internal and external connections.

These diagrams are intended to establish the system architecture and design approach and are not intended to define every detailed internal interconnection.

The Subcontractor shall use these representative diagrams, together with the AR reference design package and other LBNL-furnished inputs, to develop the detailed interconnections and extend the applicable design approach to the remaining rack configurations.

Additional technical guidance or representative diagrams may be provided by LBNL, upon reasonable request and as needed, to clarify LBNL-provided design inputs, system interfaces or requirements. The Subcontractor remains responsible for developing the detailed design and for identifying and resolving design details not explicitly defined by the LBNL-provided inputs, subject to LBNL review and approval.

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A technical documentation package for a representative AR rack is included as

Attachment A and establishes the applicable reference information for the work defined in this Statement of Work.

6 DELIVERABLES – SR RACKS DESIGN

The work can be performed in different phases, prioritizing the delivery of the SR

Standard Sector Racks, then the Hard Bend Sector Racks and eventually the ATS/STA

Racks. Phases can proceed in parallel if the earliest delivery of the Standard Sector Racks at 6.1 is ensured. The preferred approach is proceeding with all designs in parallel to complete design January 31, 2027.

6.1 3D models (x6 models – source project files) and detailed rack assembly and production drawings of the SR Standard Sector racks;

6.2 3D models (x6 models - source project files) and detailed rack assembly and production drawings of the SR Hard Bend Sector racks;

6.3 3D models (x4 models - source project files) and detailed rack assembly and production drawings of the ATS/STA racks.

Each of these deliverables shall include 3D mechanical models with a level of detail adequate to: (i) validate the rack layouts and design choices, including component fit, internal airflow and thermal management, internal cable routing, and maintainability;

(ii) support the design of the ancillary mechanical components (mechanical supports, copper bus bars, auxiliary chassis) and of the internal cables and connectors; and (iii) support the generation of the fabrication drawings and documentation for the to-be-designed rack components.

The 3D models shall have a level of detail sufficient to support rack-level design and integration, including verification of component fit, mounting and interface locations, required clearances, internal airflow and thermal management, cable routing, maintainability, and assembly/disassembly. The required level of geometric detail shall be limited to what is necessary to complete the detailed design and generate the technical documentation required for the missing rack components, including mechanical parts, bus bars, cable harnesses and associated fabrication documentation.

Detailed geometric representation of individual components beyond what is necessary to define their external envelope, mounting features, interfaces, connection points, and integration within the rack is not required. LBNL-furnished component models may be used as provided and are not required to be recreated at a higher level of detail.

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All models shall be delivered including native source files. 3D models (16 in total when summing all three deliverables) are complete once finalized, reviewed and accepted by

LBNL. Note: the level of detail in these models is only to sufficiently inform the design of components in the racks, such as wire harnesses or support brackets, and the ability to assemble and disassemble the racks.

A. Documentation derived from 3D files, capturing the technical specifications to be shared with vendors to manufacture parts. Documentation is complete once finalized, reviewed and accepted by the CAM.

• Drafting documentation packages for SR rack bus bars

• Drafting documentation packages for SR mechanical parts and enclosures

B. Electrical diagrams are complete once finalized, reviewed and accepted by the

CAM.

• Electrical diagrams of SR Standard Sector racks; x6 models

• Electrical diagrams of SR Hard Bend Sector racks; x6 models

• Electrical diagrams of ATS/STA racks; x4 models

C. Interconnects and cable harnesses are considered complete once the drawings are finalized, reviewed and accepted by the CAM. The drawings will be shared with vendors to manufacture parts.

• Design of interconnect and Cable Harness SR Standard Sector Racks

• Design of interconnect and Cable Harness SR Hard Bend Sector Racks

• Design of interconnect and Cable Harness ATS/STA Racks

6.4 The following deliverables shall be provided in support of SR mechanical parts, bus bars, and cable harness procurements and production:

• Responses to design clarification requests and vendor questions.

• Reviews of vendor-submitted materials and documentation.

• Revised drawings and documentation, as required during fabrication.

Deliverables shall be provided on an as-needed basis through completion of the associated procurements, up to a maximum of 200 hours and for a period of up to one year following completion of the design.

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6.5 Progress updates shall be provided in the following manner:

• Weekly status updates via Zoom and email

• Updates should include status on design progress, technical challenges, and schedule updates compared to the original agreed upon schedule

• Suggested improvements of the rack assembly and ways to expedite the schedule as applicable

6.6 OPTIONAL: Interest may be indicated in supporting a future production, assembly and testing phase for all or a portion of the following racks: 54 SR Standard

Sector Racks, 18 SR Hard Bend Sector Racks, 4 ATS/STA Racks. This optional deliverable is intended to assess interest, capabilities and preliminary approach to a potential subsequent production and testing phase. Any production, assembly, testing, FAT requirements, acceptance criteria, schedule and associated scope would be defined in detail under a separate SOW.

If there is interest, a preliminary, non-binding production concept shall be provided for the rack types and quantities that could be supported, including:

• A preliminary production approach, including indicative schedule, available resources, staffing, production capacity and facilities that could be allocated to the work.

• A preliminary logistics approach addressing shipment of completed racks and the receipt, storage, handling, and management of material already procured by

LBNL. Material required for rack assembly is currently located in Berkeley and includes, among other items:

o All 76 empty racks, with ancillary components o More than 1,000 rack-mounted chassis, including 1U-2U power supplies, controllers and power distribution units

• A preliminary description of the area and infrastructure that could be made available for electrical testing and Factory Acceptance Testing (FAT), including the capability to provide the required electrical utilities (120 V, 208 V, and 480 V), cooling water (non-LCW), and suitable dummy loads for the power channels.

• In case of interest in supporting a substantial portion or the entirety of the production scope, examples of comparable production, assembly, and testing activities completed within the last five years.

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7 QUALITY ASSURANCE

The Subcontractor shall apply its standard engineering QA/QC practices throughout the detailed design effort. Prior to formal submittal, design deliverables shall be internally reviewed for completeness, technical consistency, and compliance with the applicable requirements, codes, standards, and LBNL-provided design inputs. The Subcontractor shall maintain appropriate document and revision control for submitted design files and shall address comments and required corrections identified during LBNL PDR/FDR reviews. Acceptance of the submitted design deliverables will be performed by LBNL using the applicable Attachment C - Acceptance Criteria List (ACL) for SR Rack Design.

Final acceptance requires that the applicable ACL criteria be satisfied or otherwise formally dispositioned by LBNL. LBNL review and acceptance do not relieve the

Subcontractor of responsibility for the completeness and technical adequacy of the submitted design.

8 SCHEDULE

The work shall be performed in accordance with the following schedule requirements.

The detailed schedule shall identify the planned dates for each design review, LBNL review and approval period, and final design deliverable.

• Kickoff Meeting: A project kickoff meeting shall be conducted no later than one

(1) week after contract award.

• Detailed Schedule: A detailed project schedule shall be submitted to LBNL no later than two (2) weeks after contract award. The schedule shall identify the activities, milestones, design reviews, LBNL review and approval periods, and deliverables necessary to achieve completion of the full design and documentation packages by January 31, 2027.

• Preliminary Design Reviews: A Preliminary Design Review (PDR) shall be conducted for each of the following rack design types:

o Standard o Hard Bend o ATS/STA

The planned date for each PDR shall be established in the detailed schedule based on the design delivery schedule.

At PDR, the design shall be sufficiently mature to establish and review the proposed rack architecture and major design decisions. The review package shall

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include the applicable 3D rack models, preliminary electrical diagrams and interconnections, identification of major mechanical components and interfaces, and the proposed approach for cable routing, thermal management, and maintainability. Major open design items, assumptions, and interfaces shall be identified. Fabrication documentation is not expected to be final at PDR.

Following each PDR, two (2) weeks shall be provided for LBNL review and approval of the preliminary design.

• Final Design Reviews: A Final Design Review (FDR) shall be conducted for each rack design type identified above. The planned date for each FDR shall be established in the detailed schedule based on the design delivery schedule.

At FDR, the detailed design shall be substantially complete and suitable for final technical review. The applicable 3D models, electrical diagrams, interconnect and cable-harness documentation, and mechanical/bus-bar fabrication documentation shall be sufficiently complete and mutually consistent to demonstrate that the design can proceed to final documentation release. Major design issues and interfaces shall be resolved. Remaining changes following FDR should be limited to incorporation of LBNL review comments and minor corrections required for final acceptance.

Following each FDR, two (2) weeks shall be provided for LBNL review and approval of the final design.

• Final Design and Documentation Packages: LBNL's preferred target date for the completion and submission of the full design and documentation packages is January 31, 2027. However, LBNL recognizes the aggressive timeline and is open to considering alternative completion dates and phased deliveries. Offerors shall propose their earliest realistic and achievable delivery schedule, including intermediate milestones and proposed delivery dates for each rack family. The proposed schedule will be considered as part of the overall proposal evaluation.

Offerors may also propose alternative accelerated delivery options, identifying the associated schedule benefits and any additional costs, which shall be quoted separately.

The detailed schedule shall account for the required LBNL review and approval periods and shall demonstrate the sequencing necessary to meet the January 31, 2027, final design and documentation completion date. Any changes to the approved schedule shall be communicated to LBNL and shall not affect the required January 31, 2027, completion date without prior LBNL approval.

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9 APPLICABLE DOCUMENTS

Attachment A - Reference technical documentation package for a representative AR rack

(3D model, fabrication drawings, electrical diagrams, and supporting documentation), provided for information to support the preparation of the proposal.

Attachment B - Layout files for the 16 SR rack configurations

Attachment C - SR Rack Design Acceptance Criteria List (ACL)

APPENDIX A: REFERENCE DOCUMENTS

Autodesk Inventor 3D models and parts library used in the corresponding work completed for the AR (6 racks).