2. AL-1685-4168B_SR Bifurcated Chamber SOW.pdf

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.

SR Bifurcated Chamber Statement of Work

Release Date: Mar 18 2024 9:09:57 AM PDT

Document Number: AL-1685-4168 Revision: B

Document Status: Released

Document Type: SPECIFICATION

Category Code: AL7531

ALS-U - STORAGE RING

VACUUM CHAMBERS

O ffi ci al ly R el ea se d to th e

LB

N L

D oc um en t C on tr ol

C en te r

Re le as ed

: M ar ch

8t h, D

C C

A ut h K ey : 3

2P X

7S G

V 7C

Downloaded by: Howard J Wilson at March 19, 2024 11:33:51

AL-1685-4168 Rev. B Doc. Status: Released Page 2 of 34

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.

Table of Contents

1 Revision History

2 Approvals

3 Abbreviations and Acronyms

4 Introduction

4.1 Project Overview

4.2 Description of Items

4.2.1 Chamber variants

4.2.1.1 HHL Bifurcated Chambers

4.2.1.2 HBEND BifurcateD Chambers

4.2.1.3 IR Bifurcated Chambers

4.3 Roles and Responsibilities

5 Deliverables / scope

5.1 Deliverables

5.1.1 Documentation

5.1.2 Drawings and CAD Models

5.1.2.1 LBNL provided models and drawings

5.1.3 Hardware Deliverables

5.1.3.1 Components included and delivery state

5.1.3.2 First article

5.1.3.3 Production

5.2 Scope of work

5.2.1 Management and Quality plan

5.2.2 Final Design Review Requirements

5.2.3 First article

5.2.4 First article delivery

5.2.5 Complete Production

5.2.6 Delivery

5.3 Final documentation package(s)

5.4 Government Furnished Property

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

LB

N L

D oc um en t C on tr ol

C en te r

Re le as ed

: M ar ch

8t h, D

C C

A ut h K ey : 3

2P X

7S G

V

AL-1685-4168 Rev. B Doc. Status: Released Page 3 of 34

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.

6.1 Schedule

6.2 Reporting requirements

6.3 Proposal documentation requirements

6.4 Reviews

6.5 Hold points

7 Fabrication

8 Packaging and shipping specifications

8.1 Container

8.2 Marking

8.3 Packaging

8.4 Handling and storage

9 Quality Assurance

9.1 Control plan

9.2 Type of control points

9.3 Deviation requests

9.4 Nonconformance reports

9.5 Numbering and/or Serialization

9.6 Completed ACL

10 Applicable Documents

Appendix A: Control plan ci al ly R el ea se d to th e

LB

N L

D oc um en t C on tr ol

C en te r

Re le as ed

: M ar ch

8t h, D

C C

A ut h K ey : 3

2P X

7S G

V

AL-1685-4168 Rev. B Doc. Status: Released Page 4 of 34

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.

1 REVISION HISTORY

Rev. CM Number Description of Change A Baseline B Updates to applicable documents table and reference

2 APPROVALS

The following individual(s) must approve this document:

Approver Project Role Ken Chow Chief Engineer/ Accelerator Mechanical

Systems lead Jiani Niu Project QA manager Olusola Omolayo Vacuum CAM and Technical Lead Windchill Approved / Concurred By oomolayo

3 ABBREVIATIONS AND ACRONYMS

ALS Advanced Light Source ACL Acceptance Criteria List ALS-U Advanced Light Source Upgrade AR Accumulator Ring ARO After Receipt of Order BPM Beam Position Monitor CAD Computer Aid Design CMM Coordinate Measuring Machine CP Control Plan FAT Factory Acceptance Test FDR Final Design Review HHL High Heat Load HP Hold Point

IR

KOM

InfraRed Kick Off Meeting

LBNL Lawrence Berkeley National Laboratory LCW Liquid Cooled Water NEG Non Evaporable Getter NCR Nonconformance Report NP Notification Point NTP Notification To Proceed PTL Photon Transfer Line SR Storage Ring UHV Ultra High Vacuum VC Vacuum Chamber W Witness ci al ly R el ea se d to th e

LB

N L

D oc um en t C on tr ol

C en te r

Re le as ed

: M ar ch

8t h, D

C C

A ut h K ey : 3

2P X

7S G

V

AL-1685-4168 Rev. B Doc. Status: Released Page 5 of 34

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.

4 INTRODUCTION

4.1 Project Overview

ALS-U is an upgrade project to the LBNL Advanced Light Source (ALS). The ALS is a 1.9

GeV storage ring operating at 500 mA of beam current. It is optimized to produce intense beams of soft x-rays, which offer spectroscopic contrast, nanometer-scale resolution, and broad temporal sensitivity. The ALS facility includes an accelerator complex and photon delivery system that is capable of providing the foundations for an upgrade that will achieve world-leading soft x-ray coherent flux. The existing ALS provides a ready-made foundation, including conventional facilities and also includes extensive beamlines (up to

40 simultaneously operating beamlines) and instrumentation, an experimental hall, computing resources, ancillary laboratories, offices, and related infrastructure that will be heavily utilized in an upgrade scenario.

The ALS will be upgraded with a multibend achromat (MBA) lattice design that will provide a soft x-ray source that is orders of magnitudes brighter — an up to 100-1000 times increase in brightness and will provide a significantly higher fraction of coherent light in the soft x-ray region than is currently available at ALS.

Any resulting Subcontract will be between the University and the party identified as the

Subcontractor and will be issued under Prime Contract No. DE-AC02-05CH11231 between the University and the United States Government (hereinafter “U.S.

Government”), represented by the Department of Energy (hereinafter “DOE”) for the management and operation of LBNL and the performance of research and related work.

4.2 Description of Items

The Bifurcated chambers is a group of vacuum chambers located in the 12 sectors of the

Storage Ring (SR). Each sector of the SR is sectioned into units consisting of 1 x straight section and 1 x arc section that further divide into 4 raft units as shown in Figure 4-1. Each raft consists of magnets, vacuum chamber assemblies, and support structures, as shown in Figure 4-3, and 4-4. The Bifurcated chambers typically consist of an electron beam chamber and a photon beam chamber that share the same upstream flange as shown in

Figure 4-2.

ci al ly R el ea se d to th e

LB

N L

D oc um en t C on tr ol

C en te r

Re le as ed

: M ar ch

8t h, D

C C

A ut h K ey : 3

2P X

7S G

V

All officially released LBNL documents are watermarked and contain LBNL Document

Figure 4-1: Sector #4 (Magnet, Vacuum chamber and support)

Straight Section Bend Section

Raft # 01

Bend Section

Raft # 02

Bend Section

Raft # 03

Bend Section

Raft # 04 Electron Beam Direction

PTL 4.3

PTL 4.2

PTL 4.0

ci al ly R el ea se d to th e

LB

N L

D oc um en t C on tr ol

C en te r

Re le as ed

: M ar ch

8t h, D

C C

A ut h K ey : 3

2P X

7S G

V

All officially released LBNL documents are watermarked and contain LBNL Document

Figure 4-2: Bifurcated Chamber example

Figure 4-1: Sector 5 Raft #3 (Bifurcated Chambers and support) ci al ly R el ea se d to th e

LB

N L

D oc um en t C on tr ol

C en te r

Re le as ed

: M ar ch

8t h, D

C C

A ut h K ey : 3

2P X

7S G

V

AL-1685-4168 Rev. B Doc. Status: Released Page 8 of 34

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.

Figure 4-2: Sector 5 Raft #3 (Magnet, Bifurcated Chambers and support)

4.2.1 Chamber variants

There are 7 chamber designs within this scope, as shown in Figure 4-5. Two of these chamber designs are non-bifurcated (VC10-2 IR Bifurcated and VC07-3 HBEND

Bifurcated) in the sense that they do not feature a separate photon and electron beam channel. However, due to their similarity to the other chambers that are bifurcated, they are included in this scope.

The bifurcated chambers have similarities including integrated beam position monitors, cooling circuits, and bakeout heater grooves. These chambers are made from copper and will be NEG coated. A further subgrouping of these chambers can be derived by their functions. HHL Bifurcated Chambers, HBEND Bifurcated Chambers, and IR Bifurcated

Chambers.

ci al ly R el ea se d to th e

LB

N L

D oc um en t C on tr ol

C en te r

Re le as ed

: M ar ch

8t h, D

C C

A ut h K ey : 3

2P X

7S G

V

All officially released LBNL documents are watermarked and contain LBNL Document

Figure 4-5: Bifurcated Chambers variants ci al ly R el ea se d to th e

LB

N L

D oc um en t C on tr ol

C en te r

Re le as ed

: M ar ch

8t h, D

C C

A ut h K ey : 3

2P X

7S G

V

All officially released LBNL documents are watermarked and contain LBNL Document

4.2.1.1 HHL BIFURCATED CHAMBERS

The HHL Bifurcated chambers are typically located between a dipole and a quadrupole magnet as shown in Figure 4-6. There are 3 chambers in this sub-group: VC07-2, VC10-4 and VC11-2. All 3 chambers feature an electron and photon beam channel. The electron beam channel is a 13mm ID tubular chamber. VC07-2 beam channel features a BPM block while VC10-4 and VC11-2 have no BPM. The beam channels are cooled while the photon channel is uncooled. The photon beam channels vary in size and cross-sectional profile.

Figure 4-6: HHL Bifurcated Chamber cross section and location overview ci al ly R el ea se d to th e

LB

N L

D oc um en t C on tr ol

C en te r

Re le as ed

: M ar ch

8t h, D

C C

A ut h K ey : 3

2P X

7S G

V

AL-1685-4168 Rev. B Doc. Status: Released Page 11 of 34

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.

Figure 4-7: HHL Bifurcated Chamber subgrouping

4.2.1.2 HBEND BIFURCATED CHAMBERS

The HBEND bifurcated chambers characteristically pass through a hard bend (HBEND) magnet, along with other magnet types. The HBEND dipole is a fixed-gap high-field permanent-magnet dipole with integral field clamps located at the beam ingress and egress ends. This is the optical source point where the electron beam generates more intense higher-energy x-ray radiation, which will be exiting two chambers downstream.

The electron beam portion of the chamber is comprised of four sections longitudinally, to accommodate for the changing pole tip profile it encounters as it passes through a quadrupole, HBEND dipole, quadrupole, and finally, a quadrupole magnet in a series.

ci al ly R el ea se d to th e

LB

N L

D oc um en t C on tr ol

C en te r

Re le as ed

: M ar ch

8t h, D

C C

A ut h K ey : 3

2P X

7S G

V

AL-1685-4168 Rev. B Doc. Status: Released Page 12 of 34

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.

This arrangement greatly limits the external profile of these chambers, especially at the

HBEND magnet section where the wall thickness can be as narrow as 0.5 mm.

Figure 4-8: HBEND Bifurcated Chamber cross section and location overview

There are two chamber variants under the HBEND bifurcated chamber, the bifurcated

VC09-2 (has both electron and photon beam channels) and the single channel VC07-3

(electron beam channel only).

ci al ly R el ea se d to th e

LB

N L

D oc um en t C on tr ol

C en te r

Re le as ed

: M ar ch

8t h, D

C C

A ut h K ey : 3

2P X

7S G

V

AL-1685-4168 Rev. B Doc. Status: Released Page 13 of 34

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.

Figure 4-9: HBEND Bifurcated Chamber subgrouping

4.2.1.3 IR BIFURCATED CHAMBERS

The are two variants of the IR bifurcated chambers – VC10-3 and VC10-2. Both chambers are located near the source point for the IR beamline. VC10-2 features an electron beam channel only while VC10-3 features both electron and photon beam channels. In both cases, the electron beam channel has an antechamber profile that features BPM and integrated cooling.

ci al ly R el ea se d to th e

LB

N L

D oc um en t C on tr ol

C en te r

Re le as ed

: M ar ch

8t h, D

C C

A ut h K ey : 3

2P X

7S G

V

AL-1685-4168 Rev. B Doc. Status: Released Page 14 of 34

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.

Figure 4-10: IR Bifurcated Chamber cross section and location overview

Figure 4-11: IR Bifurcated Chamber subgrouping ci al ly R el ea se d to th e

LB

N L

D oc um en t C on tr ol

C en te r

Re le as ed

: M ar ch

8t h, D

C C

A ut h K ey : 3

2P X

7S G

V

AL-1685-4168 Rev. B Doc. Status: Released Page 15 of 34

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.

4.3 Roles and Responsibilities

Two individuals will be identified in the awarded contract: a University Procurement

Specialist and a University Technical Representative. The named university personnel is responsible for the contract administration from award initiation through the receipt and acceptance of the purchased item.

University Procurement Representative – See subcontract for details.

University Technical Representative – See subcontract for details.

The selected subcontractor is required to identify a project manager to act as the single point of contact at the subcontractor. The project manager interfaces directly with the

University Technical Representative for technical, programmatic, and schedule items.

ci al ly R el ea se d to th e

LB

N L

D oc um en t C on tr ol

C en te r

Re le as ed

: M ar ch

8t h, D

C C

A ut h K ey : 3

2P X

7S G

V

AL-1685-4168 Rev. B Doc. Status: Released Page 16 of 34

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.

5 DELIVERABLES / SCOPE

This section details the required deliverables for each phase of the SR Bifurcated

Chambers build process.

5.1 Deliverables

5.1.1 Documentation

Table 5-1 provides the list of documentations to be provided by the selected Subcontractor to LBNL. Fabrication cannot start prior to the review, approval, and closure of all related FDR action items.

Table 5-1: list of documentation to be provided to LBNL.

Id Documentation Due Date

Project Documentation 1 Initial schedule 7 days ARO

2 Weekly status / progress meeting For the duration of the contract 3 Monthly Status Summary & Updated Schedule 5th of each month

Quality Documentation 4 Quality Plan 7 days ARO 5 Control plan (see Table 5-7 and §9.1) 10 days before FDR 6 Control plan duly completed and signed 10 days prior shipment

Acceptance Criteria List (AL-1685-4169)duly completed and signed 10 days prior shipment

Manufacturing Documentation 8 Manufacturing Drawing 10 days before FDR 9 Final 3D model 10 days before FDR 10 Bill of Material 10 days before FDR 11 Manufacturing plan (see Table 5-7) 10 days before FDR 12 Test Plan and Associated procedures (see Table 5-7) 10 days before FDR

Test report (dimension, He leak, etc…) AL-1685-

4167, section 8.6 10 days prior shipment

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

15 Material Certification 10 days before manufacturing

Delivery documentation 16 List of packing crates and contents 10 days prior shipment 17 Shipping plan (see §8) 10 days prior shipment

Other 18 Certificate of Conformance 10 days prior shipment 19 Final document package (see §5.3) 10 days prior shipment

*Days noted herein are based on a 5 business day work week ci al ly R el ea se d to th e

LB

N L

D oc um en t C on tr ol

C en te r

Re le as ed

: M ar ch

8t h, D

C C

A ut h K ey : 3

2P X

7S G

V

AL-1685-4168 Rev. B Doc. Status: Released Page 17 of 34

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.

5.1.2 Drawings and CAD Models

LBNL will provide the vendor with final drawings and CAD models. The fabrication must take into consideration all requirement of the Engineering Specification Document AL-

1683-3551. The vendor is able to propose changes to the design for ease of manufacture or improved performance. Such changes will be reviewed and approved/declined by

LBNL technical representative. The tolerances and dimensions stipulated in the LBNL drawings must be respected except in cases where a waiver in writing, has been explicitly provided by LBNL technical representative.

5.1.2.1 LBNL PROVIDED MODELS AND DRAWINGS

LBNL is providing the vendor the design information packages, see Table 5-2.

Table 5-2: LBNL design package type

Id Drawing Description LBNL Design Information

Type

1 AL-1308-9874 SR VC07-2 Vacuum Chamber –Weldment

Reference Design1

2 AL-1305-6827 SR VC07-3 Vacuum Chamber –Weldment

3 AL-1408-1489 SR VC09-2 Vacuum Chamber –Weldment

4 AL-1496-3265 SR VC10-2 Vacuum Chamber –Weldment

5 AL-1497-6900 SR VC10-3 Vacuum Chamber –Weldment

6 AL-1413-5327 SR VC10-4 Vacuum Chamber –Weldment

7 AL-1473-5511 SR VC11-2 Vacuum Chamber –Weldment

8 AL-1663-8349 HBEND Obround Flanges blank

Final Design2

9 AL-1692-8479 Obround Flanges blank

10 AL-1582-3303 BPM Blank Flange 4mm

11 AL-1582-3280 BPM Blank Flange 4mm - Slanted

12 AL-1633-7098 Blank flange QF 40

13 AL-1633-8516 Blank flange QF 50

14 AL-1633-8521 Blank flange QF 63

15 AL-1433-2022 BPM Support Extension

1 Reference Design can be modified by Sub-contractor with approval by LBNL 2 Final Design cannot be changed by Sub-contractor ci al ly R el ea se d to th e

LB

N L

D oc um en t C on tr ol

C en te r

Re le as ed

: M ar ch

8t h, D

C C

A ut h K ey : 3

2P X

7S G

V

AL-1685-4168 Rev. B Doc. Status: Released Page 18 of 34

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.

5.1.3 Hardware Deliverables

5.1.3.1 COMPONENTS INCLUDED AND DELIVERY STATE

In addition to the vacuum chambers, each chambers delivery must include blank flanges, fittings, support brackets and chambers supports as listed in Table 5-4. LBNL will supply vacuum seals, chain clamps and fiducialization hardware as illustrated in Table 5-4, the full list and quantity of component supplied by LBNL is in AL-1685-4171.

Table 5-3: Integrated Materials provided by LBNL

Id Features Illustration LBNL ID Quantity

Flange Chain Clamps

DN50

AL-1610-0797 19

Flange Chain Clamps

DN63

AL-1589-6555 28

3 Seal, Helicoflex, DN50

HW-1000-7226

19+1 spare

4 Seal, Helicoflex, DN63

HW-1000-7225

26+4 spare

Seal, Helicoflex, BPM, 24.5OD X 19.5ID

AL-1373-1067

52+4 spare

Seal, Helicoflex, BPM, 20.5OD X 15.5ID

HW-1000-9657

16+1 spare

Seal, Helicoflex

Oval 54.54 mm x

143.92 mm

HW-1000-9647

15+1 spare

Seal, Helicoflex

Oval 34.57 mm x 192.55 mm

HW-1000-9648 6+1 spare

9 Pressure ring QF50

AL-1614-6599 72

10 Pressure ring QF63

AL-1614-6649 40

Fiducial ball

½ inch

AL-1551-3974

Lump sum ci al ly R el ea se d to th e

LB

N L

D oc um en t C on tr ol

C en te r

Re le as ed

: M ar ch

8t h, D

C C

A ut h K ey : 3

2P X

7S G

V

AL-1685-4168 Rev. B Doc. Status: Released Page 19 of 34

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.

Table 5-4 Components that subcontractor will source or manufacture ID Features Illustration LBNL ID

Bifurcated Chamber

Weldment

Multiple

QF Flange Blanks, DN40, DN50 and DN63

AL-1633-7366,

AL-1633-7098

and AL-1633-

OBROUND

END CAP, H-

BEND

CHAMBER

AL-1663-8349

OBROUND

END (CF &

QF) CAP

AL-1692-8479

and

AL-1700-1289

132mm CF

Flange Blank

AL-1700-3175

LCW

connection

AL-1582-3280

and

HW-1000-5922

7 BPM Blank

AL-1582-3280

and AL-1582-

Stainless Support struts

AL-1492-9064

and AL-1433-

Support Brackets

AL-1595-2827,

AL-1697-9682,

and

AL-1580-1197

ci al ly R el ea se d to th e

LB

N L

D oc um en t C on tr ol

C en te r

Re le as ed

: M ar ch

8t h, D

C C

A ut h K ey : 3

2P X

7S G

V

AL-1685-4168 Rev. B Doc. Status: Released Page 20 of 34

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.

5.1.3.2 FIRST ARTICLE

The selected subcontractor is required to produce the chamber listed in Table 5-5 as first article

Table 5-5: List of first article

5.1.3.3 PRODUCTION

Table 5-6 list the production articles and the respective quantities. The quantities include spares as determined for each variant by LBNL. The delivery order and batches can be proposed by the subcontractor otherwise full delivery in a single shipment applies.

Table 5-6: List of production articles Id Drawing ID Description Qty Due Date

1 AL-1308-9874 SR VC07-2 HHL Bifurcated Chamber 7

30 weeks After First

Article Approval

2 AL-1305-6827 SR VC07-3 HBEND Bifurcated Chamber 3

3 AL-1408-1489 SR VC09-2 HBEND Bifurcated Chamber 2

4 AL-1496-3265 SR VC10-2 IR Bifurcated Chamber 1

5 AL-1497-6900 SR VC10-3 IR Bifurcated Chamber 3

6 AL-1413-5327 SR VC10-4 HHL Bifurcated Chamber 4

7 AL-1473-5511 SR VC11-2 HHL Bifurcated Chamber 3

5.2 Scope of work

5.2.1 Management and Quality plan

The selected subcontractor will be responsible for supplying an initial Schedule and a

Quality Plan 7 days ARO. This must include organizational policy on quality, controlled documents for Non-conformance, material inspection, and subcontractor qualification.

Id 2D drawing Description Qty Due Date

1 AL-1408-1489 VC09-2 HBEND Bifurcated Chamber 1 16 weeks After FDR Approval ci al ly R el ea se d to th e

LB

N L

D oc um en t C on tr ol

C en te r

Re le as ed

: M ar ch

8t h, D

C C

A ut h K ey : 3

2P X

7S G

V

AL-1685-4168 Rev. B Doc. Status: Released Page 21 of 34

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.

5.2.2 Final Design Review Requirements

A final design review is required once the subcontractor has completed the detail manufacturing design for all chambers and tooling. The selected subcontractor must be responsible for supplying all documentations related to the FDR prior to fabrication of the SR Bifurcated Chambers. Documentations must take into account the SR Bifurcated

Chambers engineering specification (AL-1685-4167).

CAD model and drawing requirements are dictated by LBNL document AL-1265-6612.

The FDR is required to include of the following documentation:

1. Control Plan and Manufacturing plan for the Bifurcated Chambers

2. Final manufacturing drawings (Required if Reference Design was modified)

3. Final CAD model (Required if Reference Design was modified)

4. Test plan and associated procedures

5. Bill of material

Close out of the FDR includes review, written approval, and resolution of all related FDR action items prior to fabrication. This is also required to satisfy the Notice to Proceed, reference §9.2.

ci al ly R el ea se d to th e

LB

N L

D oc um en t C on tr ol

C en te r

Re le as ed

: M ar ch

8t h, D

C C

A ut h K ey : 3

2P X

7S G

V

AL-1685-4168 Rev. B Doc. Status: Released Page 22 of 34

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.

Table 5-7: Documentation description Documents Description

Manufacturing plan

The manufacturing plan documents step-by-step all the manufacturing process from the procurement of raw material to the delivery (except tests for FAT, which are covered in the test plan). The manufacturing plan has to contain at least the following details:

Standards required for the procurement of raw material

Description of each step of the fabrication

Internal procedures applicable to this effort

Procedures and/or standards used for fabrication must be referenced in the manufacturing plan.

Test Plan

The test plan at a minimum documents step-by–step activities of all tests prior to the FAT to validate the vacuum hardware such as:

He leak test

Bakeout

RGA

Outgassing rate

Beam center measurement in reference to fiducials

All criteria relative to tests performed have to be mentioned in the test plan. Procedures and/or standards used for tests must be referenced in the test plan.

Control plan

The control plan must describe all steps of the fabrication, including, verification of materials, manufacturing/execution operations, inspection, tests and delivery and any work to be performed by subcontractor.

LBNL will provide a template to the selected subcontractor

5.2.3 First article

Following approval of the FDR, a first article will be produced. The first article will be subjected to the same testing and quality assurance processes as the production units.

After assessments of the first article, LBNL will give the selected subcontractor approval for the rest of the production. Reference §5.1.3.2 First Article, and §9.2 Notice to Proceed for additional information.

ci al ly R el ea se d to th e

LB

N L

D oc um en t C on tr ol

C en te r

Re le as ed

: M ar ch

8t h, D

C C

A ut h K ey : 3

2P X

7S G

V

AL-1685-4168 Rev. B Doc. Status: Released Page 23 of 34

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.

5.2.4 First article delivery

The selected subcontractor will be responsible for the delivery of the first article to LBNL in accordance with the parameters provided within this document.

5.2.5 Complete Production

In accordance with section 5.2.3 LBNL will give final approval for the commencement of fabrication of the production units once the first article unit has been received and satisfactorily tested.

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

1. Complete SR Bifurcated Chambers packed in an appropriate crate.

2. Completed FAT and associated reports

3. Final and completed CP

4. Final and completed ACL

5. Quality assurance receipts and certifications

6. Nonconformance or deviation documentation pertaining to each individual assembly

7. Final, approved shipping plan

8. Written authorization from LBNL to proceed with shipping

LBNL personnel reserve the right to perform an evaluation of hardware, documentation, and shipping scheme at the subcontractor’s production site prior to authorizing shipment.

5.2.6 Delivery

The selected subcontractor will be responsible for the packing, shipping and delivery of the production units to LBNL in accordance with the requirements provided herein.

5.3 Final documentation package(s)

LBNL will be provided a full and complete documentation package at the end of the production. Reference LBNL document AL-1265-6612 for specific file requirements. The documentation package must contain the items listed below.

ci al ly R el ea se d to th e

LB

N L

D oc um en t C on tr ol

C en te r

Re le as ed

: M ar ch

8t h, D

C C

A ut h K ey : 3

2P X

7S G

V

AL-1685-4168 Rev. B Doc. Status: Released Page 24 of 34

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.

1. A complete, as-built bill of materials identifying both fabricated and commercially available components

2. A complete, as built CAD model in an editable format

3. Complete, as built drawings in English, and in an editable format.

4. Other documentation as requested

5.4 Government Furnished Property

No Government furnished property will be provided under this effort. LBNL will provide components that will be integrated into the end item deliverables and returned to LBNL as a part of the deliverable. Detail is provided in the subcontract document. Reference

Table 4-2.

6 MANAGEMENT, REPORTING, DOCUMENTATION AND REVIEWS

6.1 Schedule

The following table provides the main schedule items and hold points.

Table 6-1 : timetable of the project

Section # Designation Schedule Responsibility

§5.2.1 Management and

Quality plan 7 days ARO subcontractor

§5.2.2 Final SR Bifurcated

Chambers design review

(FDR)

6 weeks ARO subcontractor

HP#1 Approval of the FDR 2 weeks after completion of

FDR

LBNL.

§5.2.3 Completion of Manufacturing (First article)

8 weeks after approval of FDR subcontractor

§5.2.4 Delivery

(First article) 2 weeks after completion of manufacturing subcontractor ci al ly R el ea se d to th e

LB

N L

D oc um en t C on tr ol

C en te r

Re le as ed

: M ar ch

8t h, D

C C

A ut h K ey : 3

2P X

7S G

V

AL-1685-4168 Rev. B Doc. Status: Released Page 25 of 34

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.

HP#2

Approval of the first article 2 weeks after delivery

LBNL.

§5.2.5 Completion of Manufacturing (Production)

14 weeks after approval of first article subcontractor

HP#3

Approval of the production 2 weeks after completion of each manufacturing batch

LBNL.

§5.2.6 Delivery 2 weeks after each approval of manufacturing batch subcontractor

6.2 Reporting requirements

Upon award of the subcontract, the LBNL technical representative will contact the selected subcontractor to set up a Project Kick-off meeting. This meeting will establish the requirements for communication and introduce the portal that will be used for data exchange.

Written progress updates are required on before the fifth of each month. This may include drawings, manufacturing plans, test plans, QA plans, schedule updated or other documents upon request in any state.

Visits by LBNL personnel, including access to the factory where the units are being built, as the discretion of LBNL, may be required.

Subcontractor must be responsible for maintaining an action item list for documenting the actions resulting from each meeting, identifying the responsible party and providing an anticipated completion date for each action.

Other reports or data as requested in writing.

6.3 Proposal documentation requirements

Upon subcontract award, a Windchill Project portal will be established by LBNL and access provided to the subcontractor. Windchill will be used as the repository for all information, QA data, and drawing transference related to the magnet development and production. A brief overview of Windchill will be provided at the kickoff meeting.

Additional training may be available upon request.

ci al ly R el ea se d to th e

LB

N L

D oc um en t C on tr ol

C en te r

Re le as ed

: M ar ch

8t h, D

C C

A ut h K ey : 3

2P X

7S G

V

AL-1685-4168 Rev. B Doc. Status: Released Page 26 of 34

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.

An electronic copy of all required documentation noted in the Deliverables section of this document is required.

LBNL document AL-1265-6612: ALS-U BUILD TO SPECIFICATION CAD MODEL AND

DRAWING REQUIREMENTS, specifies acceptable file formats for the final drawings and

CAD models.

Other document formats include .docx, .xlsx, and other editable file formats may be used with advance written approval from the LBNL technical representative.

6.4 Reviews

A final design review is required for this project. The LBNL technical representative will work with the subcontractor to establish an appropriate timeline and location for all reviews. Reviews may be conducted at either the subcontractor’s or the LBNL site or via web/video conference tools. External, non-LBNL reviewers may be included at LBNL’s discretion.

Review drawings, documentation, and presentations are required to be delivered to the

LBNL technical representative a minimum of 10 business days prior to the scheduled review.

6.5 Hold points

The Table 6-2 provides the list of control points. Additional control points may be identified following review of the Acceptance Criteria List reference section 9.2.

Table 6-2 : List of hold points

Section Activity Control point Type §5.2.2 Closeout of FDR NTP §5.2.3 Approval of fabrication (before NEG Coating) NTP §5.2.3 Approval of first article NTP §5.2.5 Approval of complete production NTP

Control point types are defined in §9.

ci al ly R el ea se d to th e

LB

N L

D oc um en t C on tr ol

C en te r

Re le as ed

: M ar ch

8t h, D

C C

A ut h K ey : 3

2P X

7S G

V

AL-1685-4168 Rev. B Doc. Status: Released Page 27 of 34

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.

7 FABRICATION

The selected subcontractor must follow the SR - Bifurcated Chambers - Engineering Specification referenced as AL-1685-4167 for the fabrication of all SR Bifurcated Chambers.

8 PACKAGING AND SHIPPING SPECIFICATIONS

The selected subcontractor must submit to LBNL a shipping plan and be approved in writing by LBNL before the first shipment. The following points must be described in the shipping plan:

8.1 Container

Containers or crates for the SR Bifurcated Chambers may be used for both shipping and storage. Construction of the containers must be sufficient to adequately support and protect the SR Bifurcated Chambers throughout shipping.

Crates must be reusable with sides that attach using clips or other standard attachments that allow for ease of disassembly and/or reuse. LBNL must evaluate and approve shipping crate designs prior to fabrication of the crates or utilizing them for shipping.

Crates can contain multiple SR Bifurcated Chambers. The crates must be strapped on all sides prior to and during shipment.

8.2 Marking

The exterior of the crates must have markings that clearly identify tie-downs, lifting points, and the crate center of gravity.

Mark the exterior of the crate with clear and obvious labels indicating the presence of fragile contents. Shipments originating outside of the United States must have pictorial labels or labels written in both the originating native language and English.

The exterior of the crate must have up arrows indicating the appropriate crate orientation.

Crates must be marked with the serial numbers of each SR Bifurcated Chambers contained therein.

All shipping containers must be labeled with all subcontract information including subcontract number, LBNL point of contact individual, and delivery information.

ci al ly R el ea se d to th e

LB

N L

D oc um en t C on tr ol

C en te r

Re le as ed

: M ar ch

8t h, D

C C

A ut h K ey : 3

2P X

7S G

V

AL-1685-4168 Rev. B Doc. Status: Released Page 28 of 34

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.

8.3 Packaging

All SR Bifurcated Chambers including cooling channels must be free of any liquid prior to shipping. The use of desiccant is strictly forbidden.

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

Each chamber needs to be assembled along with each associated LCW fitting, copper cooling tube loops, steel support(s), flange blanks and chain clamps, in accordance with their associated, FDR approved ASM drawings.

Placement of foam between the SR Bifurcated Chambers (if crate contains multiple

SR Bifurcated Chambers)

Placement of foam between the SR Bifurcated Chambers and the sides of the crate to assist in minimizing movement during transportation.

SR Bifurcated Chambers shipping containers should incorporate a moisture barrier to prevent condensation during air shipment.

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

8.4 Handling and storage

The subcontractor must pay particular attention during phases of lifting operation to avoid damage on SR Bifurcated Chambers

Should the SR Bifurcated Chambers require storage, the storage location must be a temperature and moisture controlled, secured storage facility. Ambient air temperature during storage is between 10 C and 40 C.

ci al ly R el ea se d to th e

LB

N L

D oc um en t C on tr ol

C en te r

Re le as ed

: M ar ch

8t h, D

C C

A ut h K ey : 3

2P X

7S G

V

AL-1685-4168 Rev. B Doc. Status: Released Page 29 of 34

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.

9 QUALITY ASSURANCE

The SR Bifurcated Chambers must follow the quality plan during first article and production fabrication

The selected subcontractor must provide a single point of contact for Quality Items. This may be the project manager or another individual.

9.1 Control plan

The Control Plan must cover the entire scope of the phase/task, including any work to be performed by subcontractors like verification of materials, manufacturing/execution operations, inspection and test and delivery. LBNL will provide the selected subcontractor the template of Control Plan (see Appendix A: Control plan and applicable document in §10).

Each activity once finished must be dated and signed by the subcontractor and the LBNL technical representative. The identification of the records released during activity execution (test report, dimensional report, NCR) must be registered with the Control Plan. The Control Plan must be delivered to and approved by the University prior to the FDR. Notification points (NP, W, HP) will be added by LBNL before returning to the selected subcontractor.

9.2 Type of control points

Notification point (NP): means that a notification must be sent to the entity before a task is performed. The notified can decide to visit or not. NP does not affect the production flow of the selected subcontractor. Notification sent to LBNL 10 working days before scheduled operation, LBNL will respond to the subcontractor within 5 working days of the scheduled operation of its intention.

Witness (W): means a visit/presence at the action to witness/monitor. Action cannot occur without the presence or without a written waiver. The production flow is interrupted (before the action) in order to allow the mandatory inspection/surveillance.

Notification sent to LBNL 10 working days before scheduled operation, LBNL will respond to subcontractor within 5 working days of schedule operation of its intention.

In case of “no-show” of a technical representative or delegate: the subcontractor must formally notify the technical representative and may proceed with production after 2 working days.

ci al ly R el ea se d to th e

LB

N L

D oc um en t C on tr ol

C en te r

Re le as ed

: M ar ch

8t h, D

C C

A ut h K ey : 3

2P X

7S G

V

AL-1685-4168 Rev. B Doc. Status: Released Page 30 of 34

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.

Hold point (HP): the process and all related activities cannot continue (work cannot proceed beyond this point) without the relevant HP being cleared. This can be a record of acceptance, an event or a written waiver. Production flow for the associated process is interrupted (after the action) until clearance is given.

Notification sent to LBNL 10 working days before scheduled operation, LBNL notifies the selected subcontractor within 10 working days of the result on the HP activity:

o On rejection: The selected subcontractor has 5 working days to propose a recovery plan, o On objection (duly justified): The selected subcontractor has 10 working days to answer (and if applicable propose a recovery plan).

For HP requiring witness by LBNL, in case of “no-show” of a technical representative or delegate: the subcontractor must formally notify the technical representative and may proceed with production after 2 working day.

Notice to Proceed (NTP): the current process cannot continue (next tasks) without the relevant NTP being cleared. The NTP notification point for this contract must be the following:

Successful completion and acceptance of the FDR. LBNL will provide a written approval to the selected subcontractor indicating the NTP that has been satisfied.

Successful completion and acceptance of the First article. LBNL will provide a written approval to the selected subcontractor indicating the NTP that has been satisfied

Successful completion and acceptance of production articles test report prior to shipment. LBNL will provide a written approval to the selected subcontractor indicating the NTP that has been satisfied

9.3 Deviation requests

Any deviations from the LBNL documents must be requested by the subcontractor and approved by LBNL prior to implementation. LBNL will provide a standard deviation request form however; a subcontractor’s existing or internal document may be utilized with LBNL approval. Deviation requests apply to requests to modify processes or documented drawings. Deviation requests DO NOT apply to hardware that is built and does not conform to the specification.

ci al ly R el ea se d to th e

LB

N L

D oc um en t C on tr ol

C en te r

Re le as ed

: M ar ch

8t h, D

C C

A ut h K ey : 3

2P X

7S G

V

AL-1685-4168 Rev. B Doc. Status: Released Page 31 of 34

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.

9.4 Nonconformance reports

A nonconformance report provides a summary for products or procedures, which do not conform to the defined requirements. Nonconformance may be determined and reported by either the subcontractor or LBNL staff. LBNL will provide a standard nonconformance report form however; a subcontractor’s existing or internal document may be utilized with LBNL approval. Nonconformance reports are to be submitted to LBNL within 2 business days of the nonconformance identification.

Nonconformance reports apply to hardware that is built and does not conform to the specification(s). LBNL will provide a written disposition establishing a path forward for each nonconformance. No operations may be performed on the nonconforming item without LBNL’s written disposition or approval to proceed.

9.5 Numbering and/or Serialization

Each SR Bifurcated Chamber must be serialized. The following indicate the methodology of serialization

Designation Serialization

AL-1308-9874

AL-1308-9874-0001

AL-1308-9874-0002

AL-1308-9874-0003

AL-1304-7560-0006

The serialization must be laser etched on the fixed flanged of all chamber. See location of the serialization on the picture below.

Figure 9-1: Location of the serialization ci al ly R el ea se d to th e

LB

N L

D oc um en t C on tr ol

C en te r

Re le as ed

: M ar ch

8t h, D

C C

A ut h K ey : 3

2P X

7S G

V

AL-1685-4168 Rev. B Doc. Status: Released Page 32 of 34

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.

9.6 Completed ACL

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

1. Visual Inspection

2. CMM measurement after bakeout

3. Water Pressure Test

4. RGA scan

5. He leak test

6. NEG Coating inspection

7. HPN2 backfill

8. All Required Documentation

The ACL must include the criteria of the requirements and the results of the test related to the requirement. See doc AL-1685-4169.

ci al ly R el ea se d to th e

LB

N L

D oc um en t C on tr ol

C en te r

Re le as ed

: M ar ch

8t h, D

C C

A ut h K ey : 3

2P X

7S G

V

All officially released LBNL documents are watermarked and contain LBNL Document

10 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).

Table 10-1: Applicable documents ID Document ID Title

1 AL-1685-4167 B SR Bifurcated Chamber Engineering Specification 2 AL-1685-4169 A SR Bifurcated Chamber ACL 3 AL-1685-4171 C SR Bifurcated Chamber Furnished Material 4 AL-1220-7841 F UHV Chamber and Component Production Requirements 5 AL-1405-1295 A Control plan template 6 AL-1265-6612 B ALS-U Build to Specification CAD Model and Drawing Requirements 7 AL-1308-9874 D SR VC07-2 Vacuum Chamber –Weldment Drawing 8 AL-1305-6827 C SR VC07-3 Vacuum Chamber –Weldment Drawing 9 AL-1408-1489 B SR VC09-2 Vacuum Chamber –Weldment Drawing 10 AL-1496-3265 B SR VC10-2 Vacuum Chamber –Weldment Drawing 11 AL-1497-6900 E SR VC10-3 Vacuum Chamber –Weldment Drawing

12 AL-1413-5327 B SR VC10-4 Vacuum Chamber –Weldment Drawing

13 AL-1473-5511 B SR VC11-2 Vacuum Chamber –Weldment Drawing

14 AL-1582-3303 B BPM Blank Flange 4mm Drawing

15 AL-1582-3280 B BPM Blank Flange Slanted 4mm Drawing

16 AL-1663-8349 A HBEND Obround Flanges blank Drawing

17 AL-1692-8479 A Obround Flanges blank Drawing

18 AL-1633-7098 A Blank flange QF 40 Drawing

19 AL-1633-7366 A Blank flange QF 50 Drawing

20 AL-1633-8533 A Blank flange QF 63 Drawing

21 AL-1433-2022 B BPM Support Extension

22 AL-1700-3175 A OBROUND END CF CAP

23 AL-1700-1289 A 132mm CF Flange Blank ci al ly R el ea se d to th e

LB

N L

D oc um en t C on tr ol

C en te r

Re le as ed

: M ar ch

8t h, D

C C

A ut h K ey : 3

2P X

7S G

V

All officially released LBNL documents are watermarked and contain LBNL Document

APPENDIX A: CONTROL PLAN

Extract of the control plan to be completed by the subcontractor ci al ly R el ea se d to th e

LB

N L

D oc um en t C on tr ol

C en te r

Re le as ed

: M ar ch

8t h, D

C C

A ut h K ey : 3

2P X

7S G

V