3. AL-1685-4167B_SR Bifurcated Chamber ESD.pdf

Advanced Light Source Upgrade Project Lawrence Berkeley National Laboratory

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SR Bifurcated Chamber Engineering Specification

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

Document Number: AL-1685-4167 Revision: B

Document Status: Released

Document Type: SPECIFICATION

Category Code: AL7531

ALS-U - STORAGE RING

VACUUM CHAMBERS

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TABLE OF CONTENTS

1 Revision History

2 Approvals

3 Abbreviations and Acronyms

4 Introduction

4.1 Introduction to ALS-U

4.2 Subject of this Engineering Specification

5 Document Definitions

5.1 Specification Definition

5.2 Identification Number

5.3 Traceability

6 Description of the Bifurcated chambers

6.1 SR VC07-2 HHL Bifurcated Chamber

6.2 VC10-4 HHL Bifurcated Chamber

6.3 VC11-2 HHL Bifurcated Chamber

6.4 VC07-3 HBEND Bifurcated Chamber

6.5 VC09-2 HBEND Bifurcated Chamber

6.6 VC10-2 IR Bifurcated Chamber

6.7 VC10-3 IR Bifurcated Chamber

7 Final design

8 Environmental requirements

8.1 Codes and Standards

8.2 Cleanliness environment

8.3 Cleaning fluids

8.4 Cutting fluids

8.5 Fasteners

8.6 Flange and Gaskets

9 Technical requirement

9.1 Vacuum pressure

9.2 NEG Coating

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9.3 Manufacturing process

9.3.1 Material

9.3.2 Fabrication

9.3.2.1 Part fabrication

9.3.2.2 Cleaning after manufacturing

9.3.2.3 Part joining

9.4 Final Cleaning

9.5 Final Assembly

9.6 Final test and NEG coating

9.6.1 CMM Measurement before bakeout

9.6.2 Water pressure test

9.6.3 Bakeout

9.6.4 Residual Gas Analysis

9.6.5 NEG coating Inspection

9.6.6 Final He Leak Test

9.6.7 Final Pressure measurement

9.6.8 HPN2 Backfill

9.6.9 CMM Measurement after Bakeout

9.7 Packing and shipping

10 Applicable Documents ci al ly R el ea se d to th e

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1 REVISION HISTORY

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

2 APPROVALS

The following individual(s) must approve this document:

Approver Project Role Ken Chow Chief Engineer and System Engineer Jiani Niu Project QA manager Olusola Omolayo Vacuum CAM Windchill Approved / Concurred By oomolayo

3 ABBREVIATIONS AND ACRONYMS

ALS Advanced Light Source ALS-U Advanced Light Source Upgrade ASTM American Society for Testing and Materials AR Accumulator Ring BPM Beam Position Monitor CC Cooling Chanel CF Conflat Flange CMM Coordinate Measuring Machine COTS Commercial Off The Shelves DCC Document Control Center He Helium HPN2 High Pressure Nitrogen EN-ISO European International Organization for Standardization LBNL Lawrence Berkeley National Laboratory NEG Non Evaporable Getter PTL Photon Transfer Line

RF

US

UHV

Radio Frequency Ultra sound Ultra High Vacuum

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

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4 INTRODUCTION

4.1 Introduction to ALS-U

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

GeV storage ring operating at 500 mA of beam current. It is optimized to produce intense beams of soft x-rays, which offer spectroscopic contrast, nanometer-scale resolution, and broad temporal sensitivity. The ALS facility includes an accelerator complex and photon delivery system 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.

4.2 Subject of this Engineering Specification

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. Each raft consists of magnets, vacuum chamber assemblies, and support structures. An example of a sector, a raft unit, and details of the surrounding magnet environment for each Bifurcated chamber can be found in the SR Bifurcated Chamber Statement of Work referenced as AL-1685-

4168, §4.2. The Bifurcated chambers typically consist of an electron beam chamber and a photon beam chamber that share the same upstream flange, see the description of each chamber variant in §6.

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5 DOCUMENT DEFINITIONS

5.1 Specification Definition

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

The definitions of these terms are as follows

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

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

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

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

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

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

5.2 Identification Number

Each specification stated in this document must have a unique identification (ID) number

(NUM). Once an ID NUM has been assigned to a specific specification, the ID

NUM cannot be changed or reassigned.

The ID NUM formant is as follows SYY-XX-QQQQQQ, where S indicates that this is a specification, YY identifies the Major Systems Level within the ALS-U project, XX is a unique identifier within the Major Systems Level, and QQQQQQ is a unique six digit number.

The unique ID numbers are assigned by the ALS-U Lead System Engineer.

5.3 Traceability

Each specification stated in this document must have a traceability to determine the relationship between different requirements and specifications not only within this document, but also for the entire project.

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6 DESCRIPTION OF THE BIFURCATED CHAMBERS

6.1 SR VC07-2 HHL Bifurcated Chamber

The main functions and requirements of the SR VC07-2 are:

1. Provide a circular aperture through a dipole and quadrupole magnet.

2. Provide an appropriate aperture for the existing photon beam.

3. Host a BPM in the gap between the dipole and quadrupole magnets

4. Support features to allow stability and positioning requirements to be met.

5. NEG coating of the internal surface in accordance to the vacuum design stipulated to meet vacuum requirements

6. Provide suitable flange interface along the beam path to adjoining chambers

7. Provide suitable cooling system

The VC07-2 Bifurcated chamber has been designed by LBNL to meet these requirements and perform these functions. The chamber has 3 sections as shown in Figure 6-1.

1. Dipole section

2. BPM section

3. Quadrupole section

Each section’s geometry is unique and optimized to the space constraints of each section.

The BPM section is achieved from a monolith block of copper, CNC machine on the outside, and EDM on the inside. The two tubular sections along the beam path are made from extruded C10700 copper and shaped to follow the beam path. The photon beam channel is machined from a single piece of C18150 copper. Both the electron and photon channels share a custom obround upstream flange that uses Helicoflex seal. The downstream flange on the electron beam channel is also a custom QF type Helicoflex sealed flange while the photon beam side is a CF flange.

The primary joining method for the chamber sections is Electron beam welding.

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Figure 6-1: VC07-2 HHL Bifurcated Chamber

6.2 VC10-4 HHL Bifurcated Chamber

VC10-4 HHL bifurcated chambers have similar function and construction to the afore-described VC07-2 HHL bifurcated chamber. The primary differences are that VC10-4:

1. Has no BPM

2. The photon beam channel is made in two sections joined together about halfway the length of the channel.

3. The downstream flange on the photon beam channel is a custom obround flange that uses CF gasket

Figure 6-2: VC10-4 HHL Bifurcated Chamber ci al ly R el ea se d to th e

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6.3 VC11-2 HHL Bifurcated Chamber

VC11-2 HHL bifurcated chambers has similar function and construction to the afore described VC10-4 HHL bifurcated chamber. The primary differences are that VC11-2:

1. Is shorter

2. The downstream flange on the photon beam channel is a CF style rotating flange

Figure 6-3: VC11-2 HHL Bifurcated Chamber

6.4 VC07-3 HBEND Bifurcated Chamber

VC07-3 is grouped with bifurcated chambers but the chamber only has an electron beam channel and no separate photon beam channel.

The main functions and requirements of the SR VC07-3 are:

1. Provide a required aperture through a series of 5 magnet: QDB, HBEND dipole, QDB and QFRD-C magnets.

2. Host a BPM in the gap between the QDB and QFRD-C quadrupole magnets

3. Support features to allow stability and positioning requirements to be met.

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4. NEG coating of the internal surface in accordance to the vacuum design stipulated to meet vacuum requirements

5. Provide suitable flange interface along the beam path to adjoining chambers

6. Provide suitable cooling system

The VC07-2 Bifurcated chamber has been designed by LBNL to meet these requirements and perform these functions. The chamber has 4 sections as shown in Figure 6-4.

1. QDB Section

2. HBEND Section

3. QDB Section

4. BPM + QFRD-C Section

Each section’s geometry is unique and optimized to the space constraints of each section.

Each section is machined from a monolith block of copper C18150, EDM on the inside and conventional CNC on the outside. The sections are joined by electron beam welding.

The entry and exit flanges are custom QF flanges sealed with Helicoflex seals.

Figure 6-4: VC07-3 HBEND Bifurcated Chamber ci al ly R el ea se d to th e

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6.5 VC09-2 HBEND Bifurcated Chamber

VC09-2 is similar to VC07-3. There are 3 primary differences:

1. Presence of a photon channel.

2. Custom obround entry flange

3. Support brackets connecting the electron beam channel to the photon beam channel.

Figure 6-5: VC09-2 HBEND Bifurcated Chamber

6.6 VC10-2 IR Bifurcated Chamber

VC10-2 is grouped with bifurcated chambers but the chamber only has an electron beam channel and no separate photon beam channel.

The main functions and requirements of the SR VC10-2 are:

1. Provide the required aperture through BENDC dipole and QFRC-A quadrupole magnets.

2. Host a BPM in the gap between the dipole and quadrupole magnets

3. Support features to allow stability and positioning requirements to be met.

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4. NEG coating of the internal surface in accordance to the vacuum design stipulated to meet vacuum requirements

5. Provide suitable flange interface along the beam path to adjoining chambers

6. Provide suitable cooling system

The VC10-2 Bifurcated chamber has been designed by LBNL to meet these requirements and perform these functions. The chamber has three sections as shown in Figure 6-6.

1. Dipole section

2. BPM section.

3. Quadrupole section

Each section is geometry is unique and optimized to the space constraints of each section.

The BPM sections, and both chamber sections are all made in their respective monolith block of cooper, CNC machine on the outside and EDM on the inside. A custom QF flange with a shadowing feature sits at the electron beam egress, a custom CF flange in the photon beam egress, and a custom obround CF flange is at the ingress of the chamber.

The material of choice for this chamber is Copper C18150. The welding method is Electron beam welding.

Figure 6-6: VC10-2 IR Bifurcated Chamber ci al ly R el ea se d to th e

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6.7 VC10-3 IR Bifurcated Chamber

VC10-3 is similar to VC10-2, the main differences are:

1. Presence of a photon channel.

2. Custom obround entry flange

3. Support brackets connecting the electron beam channel to the photon beam channel.

Figure 6-7: VC10-3 IR Bifurcated Chamber ci al ly R el ea se d to th e

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7 FINAL DESIGN

ID NUM

(SYY-XX-) Specification

S09-05-000376 The center axis through the BPM section must be fiducialised

S09-05-000377 The chamber is in very close proximity to magnets, therefore the overall footprint of the chamber must be maintained unless otherwise approved by the ALS-U vacuum systems technical lead.

S09-05-000378 The electron beam channel must be void on any abrupt geometry change through the chamber.

S09-05-000379 The final design must include features to aid careful handling of the chambers during fabrication, transportation and assembly

8 ENVIRONMENTAL REQUIREMENTS

8.1 Codes and Standards

ID NUM

(SYY-XX-) Specification

S09-94-000151

The following standards must apply for the fabrication and test of the SR

Bifurcated Chamber:

EN ISO 13919 or EN ISO 5817

EN ISO 17637

ASTM E498.

EN ISO 17640

ASTM E2734/E2734 M − 10.

8.2 Cleanliness environment

ID NUM

(SYY-XX-) Specification

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

8.3 Cleaning fluids

ID NUM

(SYY-XX-) Specification

S09-94-000153 The cleaning fluids must comply with UHV Chamber and Component Production Requirements AL-1220-7841, §7.3 ci al ly R el ea se d to th e

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8.4 Cutting fluids

(SYY-XX-) Specification

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

8.5 Fasteners

ID NUM

(SYY-XX-) Specification

S09-94-000155 The fasteners of the of vacuum chambers must comply with AL- 1220-7841, §7.6

8.6 Flange and Gaskets

(SYY-XX-) Specification

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

AL-1220-7841, §7.7

9 TECHNICAL REQUIREMENT

9.1 Vacuum pressure

ID NUM

(SYY-XX-)

Specification

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

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

9.2 NEG Coating

ID NUM

(SYY-XX-)

Specification

S09-94-000292 The thickness of the NEG coating must be between 0.5 to 1.5 micron

S09-94-000293 The NEG material must be 30%,30%,40% atomic weight. TiZrV +/- 10%

S09-94-000294 The NEG film must be deposited using PVD process using Krypton gas ci al ly R el ea se d to th e

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(SYY-XX-)

Specification

S09-94-000295 The vacuum pressure achieved on the NEG coating station prior to NEG coating must be better than 1e-8 Torr and a clean RGA scan

S09-94-000296 The NEG coated chamber must be free of surface oxides and sufficiently cleaned prior to NEG coating to ensure adhesion

S09-94-000297 The NEG coating coverage on the internal surface of the chamber along the electron beam path channel must be greater than 99%

S09-94-000298 The NEG coating must be carried out at a chamber temperature of 100oC +40 oC /- 0oC

S09-94-000301 The coating recipe must be maintained from the first article to the production chamber coatings

9.3 Manufacturing process

9.3.1 Material

The procurement of the raw material by the Sub-contractor must comply with the following requirements

ID NUM

(SYY-XX-) Specification

S09-94-000163 All materials must be new.

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

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

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

1.01 and for welds or braze joints 1.04

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

S09-94-000169 The material must be compatible with synchrotron radiation

9.3.2 Fabrication

9.3.2.1 PART FABRICATION

The fabrication of the SR Bifurcated Chamber must comply with the following requirements

Cutting fluids

ID NUM

(SYY-XX-) Specification

S09-94-000170 A water-soluble and non-halogenated cutting fluids must be used for fabrication ci al ly R el ea se d to th e

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Cutting fluids

(SYY-XX-) Specification

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

9.3.2.2 CLEANING AFTER MANUFACTURING

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

ID NUM

(SYY-XX-) Specification

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

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

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

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

9.3.2.3 PART JOINING

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

General requirement

ID NUM

(SYY-XX-) Specification

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

S09-94-000177 All parts must be cleaned prior to welding (See §9.4)

S09-94-000178 A WPS is not required

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

ISO 5817

S09-94-000181 All requirements relative to brazing must comply with AL-1220- 7841, §10.4

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

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Inspection of welded joints

(SYY-XX-) Specification

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

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

Component leak check

ID NUM

(SYY-XX-) Specification

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

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

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

9.4 Final Cleaning

The final cleaning of the SR Bifurcated Chamber must comply with the following requirements

General requirement

ID NUM

(SYY-XX-) Specification

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

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

Cleaning

ID NUM

(SYY-XX-) Specification

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

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

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9.5 Final Assembly

(SYY-XX-) Specification

S09-94-000192 All requirement with final assembly must comply AL-1220-7841, §13

9.6 Final test and NEG coating

The final tests to ensure the performance of the SR Bifurcated Chamber must be performed in the sequence shown in Figure 9-1.

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

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General requirement

(SYY-XX-) Specification

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

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

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

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

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

9.6.1 CMM Measurement before bakeout

ID NUM

(SYY-XX-) Specification

S09-94-000198 A CMM measurement must be performed, on all SR Bifurcated Chamber

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

9.6.2 Water pressure test

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

ID NUM

(SYY-XX-) Specification

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

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

Criteria

ID NUM

(SYY-XX-) Specification

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

9.6.3 Bakeout

ID NUM

(SYY-XX-) Specification

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

9.6.4 Residual Gas Analysis

ID NUM

(SYY-XX-) Specification

S09-94-000205 Residual Gas Analysis must comply with AL-1220-7841, §14.2 ci al ly R el ea se d to th e

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AL-1685-4167 Rev. B Doc. Status: Released Page 21 of 23

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.

9.6.5 NEG coating Inspection

(SYY-XX-) Specification

S09-94-000299 NEG coating coverage must be inspected on the first article by insertion of a camera probe through the chamber

S09-94-000300

A short copper ribbon sample must be placed in the extension chamber in series with every coated chamber. The thickness of coating on the ribbon sample must be reported in a least 3 locations around the circumference of the ribbon.

9.6.6 Final He Leak Test

ID NUM

(SYY-XX-) Specification

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

9.6.7 Final Pressure measurement

ID NUM

(SYY-XX-) Specification

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

9.6.8 HPN2 Backfill

(SYY-XX-) Specification

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

9.6.9 CMM Measurement after Bakeout

ID NUM

(SYY-XX-) Specification

S09-94-000328 A CMM measurement must be performed on all SR Bifurcated Chamber with the same critical dimension given in §8.6.1 after the bakeout

9.7 Packing and shipping

ID NUM

(SYY-XX-) Specification

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

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

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

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

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

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

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

16 AL-1692-8479 A Obround Flanges blank Drawing

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

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

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

20 AL-1433-2022 B BPM Support Extension

21 AL-1700-3175 A OBROUND END CF CAP

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

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