AL-1852-0746_SOW_C.pdf

SR DCCT-Module Procurement_SOW

Release Date: May 14 2026 6:12:29 PM PDT

Document Number: AL-1852-0746 Revision: C

Document Status: Released

Document Type: STANDARD

Category Code: LS229504

ALS-U STORAGE RING

Power Supply Systems

DCCT Packaged

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Advanced Light Source Upgrade Project Lawrence Berkeley National Laboratory

All officially released LBNL documents are watermarked and contain LBNL Document

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

Printed hard copies of this document are for reference only.

Table of Contents

Revision History

Approvals

Abbreviations and Acronyms

1 Introduction

1.1 Project Overview

1.2 Description of Items

1.3 Roles and Responsibilities

2 Scope of Work

3 Deliverables and Schedule (batches)

3.1 Deliverables

3.2 Production

3.3 Verification summary

4 Management

4.1 Reporting/Communication requirements

4.2 Documentation requirements

4.3 Reviews

4.4 Hold points and what’s required

5 Fabrication / Assembly

5.1 Furnished Materials

5.2 Packaging

5.3 Serialization

6 Quality Assurance

6.1 Quality reporting requirements

6.1.1 Subcontractor Quality program

6.1.2 Deviation requests

6.1.3 Nonconformance reports

6.2 Required Factory Inspections and Tests

6.3 ACL upon receipt at LBNL

7 Applicable Documents

8 References ci al ly R el ea se d

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REVISION HISTORY

Rev. CM Number Description of Change A Initial Release B PRR Recommendations; Revisited Approval Table C PRR Recommendations (Spares)

APPROVALS

The following individual(s) shall approve this document:

Approver Project Role Approver Name Project Role (ex. Project Manager) Alessandro Ratti Accelerator Electrical Eng. Systems Lead Alessandro Morato ALS-U PS CAM/Tech Lead Danny Padrazo BNL Technical Representative William Waldron Accel. Electr. Eng. Systems Tech Deputy Jiani Niu ALS-U QA Manager Kelly Hanzel ALS-U Technical Procurement Lead Windchill Approved / Concurred By wlwaldron,jianiniu,aratti,amorato,al_padrazo,khanzel

ABBREVIATIONS AND ACRONYMS

Short list of acronyms that are applicable to the SOW only (Thinking for example UHV, or component specific items)

ALS Advanced Light Source ALS-U Advanced Light Source Upgrade BNL Brookhaven National Laboratory LBNL Lawrence Berkeley National Laboratory University

ACL

The Regents of the University of California Acceptance Criteria List ci al ly R el ea se d

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1 INTRODUCTION

1.1 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.

1.2 Description of Items

The purpose of this statement of work is to define the production work required to provide completed assemblies for a custom model of DCCT Module, critical to the ALS-U Power

Supply system. In accordance with the referenced documents as defined in this document, the subcontractor must manufacture, assemble and deliver the DCCT Modules as set forth in this document:

• Model: DCCT-BPC-2CH

Production QTY 910 (the total quantity includes 10 spares)

1.3 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 the contract administration full lifecycle, from solicitation, to subcontract award, post award administration, and any contractual issues that arise thereafter.

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

The selected 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.

2 SCOPE OF WORK

Provide completed assemblies for the custom model of the DCCT Module, including all components as specified in each sub-assembly drawing, respectively. Design documentation package was prepared by Brookhaven National Laboratory on behalf of

Lawrence Berkeley National Laboratory (LBNL) for the U.S. Department of Energy

(DOE) Advanced Light Source Upgrade (ALS-U) Project.

3 DELIVERABLES AND SCHEDULE (BATCHES)

Item No.

Name Qty Delivery Schedule (*)

DCCT-BPC-2CH

1st Delivery

Delivery date requirements are specified in subcontract documentation.

DCCT-BPC-2CH

2nd Delivery

DCCT-BPC-2CH

3rd Delivery

DCCT-BPC-2CH

4th Delivery

DCCT-BPC-2CH

5th Delivery

DCCT-BPC-2CH

6th Delivery

DCCT-BPC-2CH

7th Delivery

160 (*)

(*) 10 units are spares ci al ly R el ea se d

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3.1 Deliverables

Description of product deliverables:

DCCT-BPC-2CH: Dual Current Transducer Module for Bi-Polar Power Converter, P/N LT-EL-SR-PS-CTP-6302-50

3.2 Production

The subcontractor will begin fabrication of production units upon award of the subcontract.

3.3 Verification summary

At the time of delivery, the subcontractor must provide a dated, and numbered receipt indicating the unit model and serial numbers.

4 MANAGEMENT

Within two (2) weeks after award of subcontract, the subcontractor must deliver a detailed program plan for each phase which includes a milestone schedule by batch defining a production readiness review, manufacturing, assembly, QA inspection, shipment & delivery dates in sufficient detail to allow regularly scheduled progress monitoring.

4.1 Reporting/Communication requirements

Upon award of the subcontract, the University Technical Representative will contact the selected subcontractor to set up a Project Kick-off meeting within one week of award date.

This meeting will establish the requirements for communication and introduce the portal that will be used for data exchange.

Visits by LBNL personnel or selected designee, including access to the factory where the manufacturing and assembly work is performed may be required. Visits are at the discretion of LBNL with reasonable notice to the subcontractor.

Action item tracking is recommended and may be required based upon LBNL’s discretion.

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Throughout the life of the contract, the subcontractor must supply a written report by the fifth of every month to LBNL's project technical lead, procurement representative, and

LBNL Technical Representative, clearly detailing the progress through the prior month with respect to the program. This must include a schedule update comparing progress to the contractual delivery dates, detailed progress with photos, planned work for the upcoming month, open actions, problems, recommended solutions, and risk mitigation.

Within two (2) weeks after award of contract, bi-weekly program technical and progress teleconferences and/or meetings between the subcontractor and an authorized representative of the University must be held at a mutually scheduled time. The discussions must include the subcontractor's progress, adherence to schedule and cost, technical and contractual questions, presentations of analysis or inspection results, material status, tooling status, resources, and manufacturing issues. The frequency of these meetings may be adjusted at the discretion of the University, based on project needs or by mutual agreement.

4.2 Documentation requirements

Upon subcontract award, a Windchill Project portal will be established by LBNL and/or

BNL. Windchill will be used as the repository for all documentation, QA data, certificates of conformance, test results, models, and drawings.

An electronic copy of all required documentation as noted in this document is required and must be transmitted to LBNL via the designated Windchill portal.

Acceptable document formats include .docx, .xlsx, and other editable Office file formats or as noted in this document.

All engineering drawings provided by LBNL include:

▪ PDF and native file format where applicable

▪ Document Control List

▪ Parts list

▪ Assembly Drawing

▪ Pick and Place

▪ Gerber Data for PCB Fabrication

▪ Part number syntax in accordance with format as LT-EL-SR-PS-xxx ci al ly R el ea se d

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4.3 Reviews

Designs and specifications have previously been reviewed by an authorized representative of the University. This is a build-to-print procurement.

A Production Readiness Review (PRR) is required prior to the start of production. The

PRR must review the production plan and include a summary/documentation of the manufacturing process (status & delivery plan for subcomponent procurements, key manufacturing steps, assembly or work instructions, QC checks & templates for planned

QC documentation to be provided to LBNL), the status of production tooling, testing equipment, and components, and an updated production schedule per Section 4 above.

The subcontractor will develop a PRR presentation. The form and content of the PRR must be acceptable to the University Technical Representative.

4.4 Hold points and what’s required

Written approval from an authorized representative of the University is required to proceed beyond any identified hold points.

The completed assemblies must not be shipped until the University provides written authorization to ship. The Subcontractor must first provide details and photos of the

DCCT packaging along with relevant QC data detailed in Section 6.2.

5 FABRICATION / ASSEMBLY

IPC / J-Std Class 2 – Printed Circuit Assembly Materials

All fabrication and assembly must meet IPC 610 Class 2

Lead solder must be used for component-to-printed circuit board soldering.

5.1 Furnished Materials

LBNL will provide 1,820 Current Coils (P/N DX200IH-CP01) for incorporation into the

DCCT module assembly. Any unused coils must be returned to LBNL upon subcontract work completion.

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5.2 Packaging

After completion of each assembly at the subcontractor’s facility, assemblies must be packaged individually using adequate ESD-compliant packing material by the subcontractor. Assemblies must be hand-delivered to BNL in boxes that are durable enough to facilitate subsequent storage at BNL after completion of the incoming inspection.

5.3 Serialization

Where labeling is required, the position of serialization and/or labeling of the identification number/nameplate as per assembly drawing for each unit.

6 QUALITY ASSURANCE

6.1 Quality reporting requirements

The subcontractor must retain objective evidence, including records, of the inspections and tests performed in the course of manufacturing, testing, inspecting, preserving, packaging, and preparation for shipment of procured items. These records must be made available to LBNL's representative for review upon request. These records must be maintained for a minimum of three (3) years, unless otherwise specified in the procurement documentation, after the completion of the contract.

6.1.1 Subcontractor Quality program

Supplier must maintain a quality system that meets the requirements of the ISO 9001 standard: "Quality Management Systems - Requirements" (Latest revision as of the date of issuing the procurement documentation).

6.1.2 Deviation requests

Any deviations from the dictating LBNL documents must be requested by the subcontractor in writing and approved by LBNL procurement and the LBNL Technical

Representative prior to implementation. LBNL will provide a standard deviation request ci al ly R el ea se d

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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.

6.1.3 Nonconformance reports

The authorized University representative must be notified in writing, of all non-conformance within 48 hours of their occurrence.

A nonconformance report (NCR) provides a written summary that describes how a particular product does not conform to defined specifications or how a procedure does not conform to defined requirements. A nonconformance may be determined and reported by either the Subcontractor or the University.

The University uses their standard NCR form that the Subcontractor can request. Or, with prior University approval, the Subcontractor can use their own customary NCR documentation.

The University will provide a written dispensation establishing a path forward for each nonconformance. However, once a nonconformance has been identified, no further operation may be performed on the nonconforming item without the University’s written approval to proceed. Additionally, if any process is found to produce nonconforming components, all work utilizing that process must immediately cease upon discovery until the process can be reviewed with input from the University. Resumption of the process is at the discretion of the University.

6.2 Required Factory Inspections and Tests

The subcontractor is responsible for performing the following visual inspections prior to shipment, using the applicable drawings and BOM as reference.

Exterior inspection

Verify that the enclosure, front panel, rear panel, covers, ventilation slots, mounting features, connectors, bushings, and labels are present, clean, free of visible damage, and consistent with the applicable drawings.

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Internal inspection

Verify that the current transducer heads, boards, ribbon cables, tubes, supports, fasteners, washers, standoffs, and other internal components are installed, properly seated, visibly secure, and consistent with the applicable drawings and BOM.

Wiring and connections inspection

Verify that wiring, ribbon cables, and connectors are consistent with the wiring diagrams, properly seated, correctly oriented, neatly routed, and free of visible damage, pinching, excessive strain, loose strands, or unintended contact.

Final cleanliness and hardware check

Verify that the assembly is free of loose hardware, metal shavings, debris, foreign material, sharp burrs, or other visible conditions that could affect installation, handling, or operation.

Inspection record

Document the inspection result for each module, including unit identification, applicable drawing revision, inspection date, inspector name, and any nonconformance or deviation.

6.3 ACL upon receipt at LBNL

The acceptance criteria list, AL-1876-8204, will be used by LBNL to evaluate and accept all deliverables. Acceptance of the assemblies is contingent upon successful completion of these evaluations.

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7 APPLICABLE DOCUMENTS

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

Document Number Title AL-1752-7584 DCCT-BPC-2CH ALS-U Tech Note Document AL-1876-8204 ALS-U SR DCCT-Module ACL

8 REFERENCES

Documents listed in this section are considered reference documents that can be used to better describe, clarify intent, or provide information on where the information was obtained from.

IPC standards for printed circuit board fabrication, assembly, and chassis construction, including quality meeting the requirements of ISO-9001 standards, as well as the IPC/J-

Std Class 2 standards for printed circuit assembly material, and IPC 610 Class 2 for fabrication and assembly.

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