Enclosure No. 3_SOW_BNP-II_VacuumChamberSystem_10.29.25.pdf

BioNanoProbe-II Vacuum Chamber System

APS Point of Contact (POC): Benjamin Davis Responsible Institution: TBD Responsible Institution POC: TBD Period of Performance: December 2025 – December 2026

Abstract –This document describes the technical specifications and requirements related to fabrication, testing, acceptance, and delivery of the vacuum chamber assembly used for the BioNanoProbe-II instrument at the Advanced Photon Source Sector 2-ID-D.

Rev Number Date Sections Affected Description of Changes 01 2025-08-22 All Initial Release 02 2025-10-29 5 Milestone Revision

Argonne National Laboratory | 9700 S. Cass Avenue | Argonne, IL 60439

Statement of Work APS

SOW for APS BNP-II Vacuum Chamber System

1 Table of Contents

Contents 1 Table of Contents

1 Scope of Work

1.1 Introduction

1.2 Scope of Responsibility

2 Technical Requirements and Specifications

2.1 VCS Design Concept

2.2 Final VCS Design Completion

2.2.1 Vendor-Proposed Modifications

2.2.2 Design for Manufacturability & Design for Assembly (DFM / DFA)

2.2.3 Vendor Provided Design Files

2.2.4 Exploded View – Main Chamber Sections

2.2.5 Chamber Lifting and Rigging Features & Labels

2.2.6 Stiffener Ribs

2.2.7 Base Plate Critical Interfaces & Manufacturing Plan

2.2.8 Blind Tapped Holes in Vacuum

2.2.9 Assembly Locating Features

2.2.10 Adjustable Position Panels

2.2.11 Chamber Bolts & Nuts

2.2.12 Vacuum Seal Design

2.2.13 Standard Chamber Flanges and Hardware

2.2.14 Conflat flange – Neck length

2.2.15 Feedthrough Blanks

2.2.16 Re-use two existing feedthrough panels

2.2.17 Support for Overhanging Section

2.2.18 Spherical Mount Retroreflectors

2.2.19 Structural Calculations or Simulation (completed by APS engineering)

2.2.20 Shipping configuration

2.3 Vacuum Level, Cleaning and Best Practices

3 Bid Options

3.1 BID OPTION: Invar Baseplate

3.2 BID OPTION: RGA Scan

4 Quality Assurance and Inspection

4.1 Selective Material Requirements

4.2 Pressure Safety

4.2.1 Vacuum Structural Testing

4.2.2 Rupture Disk Specification

4.2.3 Chamber Backfill Design Pressure

4.3 Machining

4.4 Finish

4.5 Welding

4.6 Operational and FAT Vacuum Pump

4.7 Critical Inspection Dimensions

4.8 FAT and SAT

4.8.1 Full Assembly & Fit-Up

4.8.2 Vacuum Leak Test

4.8.3 Site Acceptance Test

5 Milestones & Schedule

6 Reports & Documentation

6.1 Post Kickoff Meeting Documentation

6.2 Final Design Review

6.3 Manufacturing Progress Reports

6.4 Factory Acceptance Report

6.5 Shipping

6.6 Closeout

7 Warranty

8 Packaging and Shipping

9 Value Engineering Concepts

9.1 Recommendations

9.2 Investigation of Improvements

9.3 Contract Modification

10 Attachments

Abbreviations Abbreviation Definition ANL Argonne National Laboratory APS Advanced Photon Source BNP-II BioNanoProbe, 2nd generation x-ray microscope instrument CF Conflat Flange FAT Factory Acceptance Tests PDC Preliminary Design Concept POC Point of Contact PSS Personnel Safety System SOW Statement of Work VCS Vacuum Chamber System

Coordinate System

The coordinate system for all APS beamlines is shown

Figure 1. The positive Z direction points along the beam direction. The positive Y direction is a vertical axis pointing upward. The positive X direction is pointing outboard, away from the storage ring. θX, θY and θZ are the rotations about X, Y, and Z axis, respectively.

Figure 1: APS coordinate system.

1 Scope of Work

1.1 Introduction

This document is the statement of work (SOW) that specifies the design, manufacture, test, and delivery of a vacuum chamber system for the BioNanoProbe-II (BNP-II) instrument, at Sector 2ID beamline of the Advanced Photon Source (APS) at Argonne National Laboratory (ANL). The chamber will house high-resolution x-ray optics, visible light optics, numerous precision motion stages, metrology equipment, liquid nitrogen flow lines, and more.

From hereafter the combination vacuum chamber, including all features and hardware required to assemble the final designed vacuum chamber will be referred to as the vacuum chamber system (VCS). The manufacturer of the VCS shall be referred to as the vendor, the technical APS point of contact shall be referred to as the APS Technical Representative (Tech Rep), from here on.

The full scope of work includes build to specification, test, and delivery of the VCS. This SOW and supporting documentation define and fully specify these requirements.

1.2 Scope of Responsibility

The scope of responsibility split between APS and the vendor is as follows:

APS is responsible for:

• Providing specifications and a preliminary design of the desired VCS.

• Approval of vendor-suggested changes to specifications, design, and scope for VCS.

• Approval signature for the completion of project milestone steps.

• Approval signature for both factory acceptance test and on-site acceptance test.

• Approval signature for final contract completion with the vendor

The Vendor is responsible for:

• Meeting all project milestones.

• Completing engineering of the VCS design to meet all specifications and technical requirements.

• Meeting all quality assurance and inspection requirements.

• Supplying all required documentation at the designated milestone times.

• Communicating any changes of specification, design, scope, or deliverable timelines to the APS Tech Rep for approval by way of the Supplier Disposition Form (SDR).

• Fabrication, build, and factory acceptance test (FAT) of the complete VCS.

• Supplying brief bi-weekly status updates to the APS Tech Rep, with APS retaining the option to change the frequency of these updates if needed.

• Packaging and delivering the VCS to ANL without damage to the system in transit.

• Providing any technical support should there be issues upon delivery, testing or installation.

• Final handoff of all closeout documentation to APS.

The VCS shall be fabricated and tested according to the APS procurement and technical requirements, as well as the quality assurance and acceptance requirements.

2 Technical Requirements and Specifications The following subsections define the technical requirements and specifications for the VCS.

2.1 VCS Design Concept

The VCS is comprised of a baseplate, several weldments, and all related hardware and support equipment. The design intention allows assembly and maintenance of internal components throughout the life of the system. A mature design concept model of the VCS is included with this SOW.

• 3D step file (.STP)

• 2D detailed drawing file (.PDF)

The provided files are a proposed preliminary design concept (PDC) of the chamber, where the most critical features are the locations and orientations of the different types of ports, windows, doors, and sealing interfaces. Additionally, the inside space claim allowance for in-vacuum hardware is critical. There are other design features that are required to be brought to design completion and are proposed in the rest of this section. There are also engineering details that need to be finished and are listed in the rest of this section.

2.2 Final VCS Design Completion

It is expected that the Vendor will start with the proposed VCS design concept geometry and satisfy all the requirements and deliverables in this SOW to complete the final design. The Vendor shall consider their technical expertise in manufacturing vacuum chambers when proposing value engineering changes that could help design feasibility or reduce cost of their proposal. It is left to the vendor to complete the design and create final piece part and assembly drawings and models. Any proposed deviations in the chamber geometry, or the locations, types, and orientations of ports, windows, doors, and sealing interfaces shall be communicated early to the APS for written approval before reaching the final design review.

The following subsections are specific design elements and specifications that must be brought to completion. Any vendor desired deviation from specifications in the subsections must be submitted for approval to APS before reaching the final design review.

2.2.1 Vendor-Proposed Modifications

The vendor is encouraged to propose design changes in the form of modifying existing features, adding new features, or eliminating existing features that will help to improve manufacturability and/or improve performance. These proposed modifications are encouraged but require an approval signature by the APS Tech Rep.

2.2.2 Design for Manufacturability & Design for Assembly (DFM / DFA) The Preliminary Design Concept (PDC) shows a simplified version of each weldment construction. The PDC likely has inconsistencies in the weld joint geometry for each flange, conflat port and wall features. The PDC also likely has inconsistent tube lengths for similar conflat flanges which may not be intentional or necessary.

The vendor shall examine each design feature, weld joint, o-ring geometry, etc. and optimize for easier fabrication, easier assembly, simpler design, higher rigidity, and additional clearance to nearby features. This re-configuration may include adding additional components or combining multiple PDC components into one machined part.

Some examples of poor DFM/DFA principles are as follows. The vendor shall consider these points while updating the design.

• Any design that would require special tools or processes, when a small re-design effort would simplify or mitigate

• Lack of fillet on internal corner that would require additional machining setup or time

• Excessive number of bolts on an o-ring flange, when much fewer would also suffice

• A bolt that cannot possibly be installed because of clearance issues

• Lift point location will cause rigging equipment to rub or inadvertently stress a VCS component

• A component could be installed in two different orientations or two different locations, when not intended

• O-ring falls out of groove when mating part is removed, when dovetail groove would retain

2.2.3 Vendor Provided Design Files

The vendor shall create new solid models and piece part drawings with the full design of each weld joint present. More details of the weld joint requirements can be found in Section 4.5.

2.2.4 Exploded View – Main Chamber Sections

The chamber sections are shown below.

Figure 2 – Exploded view of the eight major chamber weldment sections (including baseplate)

2.2.5 Chamber Lifting and Rigging Features & Labels

Each main chamber section shall have appropriate lifting features. A lifting interface is required for each assembly component (weldment) weighing more than 20 lbs. Larger components shall have more lifting points as necessary.

An overhead crane, lifting straps, and shackles will be provided for work done on-site at ANL. However, the vendor shall include all hardware that attaches to the VCS, i.e. provide all eye bolts, swivel hoists, etc.

All rigging equipment shall be manufactured in compliance with applicable ASME standards and have a certificate of load test from the manufacturer. Deviations from this rule require an approval signature from APS Tech Rep.

When a component is removed, it shall maintain its orientation. Therefore, the lifting point locations shall be designed to put an overhead crane hook directly above the center of gravity of the component.

Lifting provisions shall prevent slippage of straps & minimize interference in assembly & disassembly operations. Consider the use of adjustable lifting beams to keep the straps oriented vertically and minimize damage to equipment due to lifting straps. In addition, the baseplate shall accommodate a potential combined lift of all assembled VCS sections together.

The lifting features must have appropriate justifications or calculations to verify the structural integrity of the features implemented in the chamber sections and of the lift hardware itself given the way it will be used. Appropriate thread length engagement of at least 2.5 thread diameters shall be implemented if threaded lifting features are incorporated by the vendor. See the ANL-407 (APS Project Procurement Quality Requirements Form which is included in the Procurement package) for more specific requirements on lifting devices.

Each component shall be labeled with a tag indicating its weight, along with the configuration it is expected to be in, if multiple components shall be lifted concurrently. See Figure 3 for an example.

Figure 3 – Proposed lifting points and rigging hardware types

Figure 4 – Proposed combined lift of the entire VCS, used for removing from shipping container and transportation

Figure 5 – Example of rigging weight label, which clearly indicates the weight for various expected lift configurations

2.2.6 Stiffener Ribs

The vendor shall examine the structure and determine where stiffener ribs can be added throughout the vacuum chamber. Communication with APS to ensure the ribs do not affect functionality and will improve stability performance or safety.

2.2.7 Base Plate Critical Interfaces & Manufacturing Plan

The baseplate of the vacuum chamber also has critical interfaces to internal components.

Refer to the provided detail drawing regarding mounting holes and features. Please note the inspection dimensions for locating features, as well as flatness and parallelism callouts for critical interfaces. The vendor is encouraged to provide a detailed manufacturing plan for how the proposed critical dimensions and GD&T specifications will be met. The flatness specifications may require annealing step/s to relieve internal stresses before or during machining. It is the vendor’s responsibility to handle all potential heat treatment, machining, measurement, and logistical processes necessary to achieve the specifications. If the specifications are not met, the vendor shall prepare a mitigation plan to remain on schedule.

2.2.8 Blind Tapped Holes in Vacuum

The VCS, and particularly the baseplate, includes numerous blind tapped holes in vacuum.

The vendor shall carefully clean each hole to remove swarf, burrs, cutting fluid remnants, and any other possible contamination. Note: APS will use vented hardware on all blind tapped holes to avoid trapped air volumes.

Figure 6 – Numerous blind tapped holes in vacuum on the baseplate, highlighted in green

2.2.9 Assembly Locating Features

Locating guide pins are required to locate components throughout the system. Refer to the 3D CAD model for all positions. Each assembly step requires consideration of the type and size of locating feature. APS recommends using engineered guide pins, that have a smooth gradual chamfer from small diameter to large diameter, and are removable if necessary (threaded) after the assembly step is complete. The preferred interface is two guide pins on the “lower” component, and a hole/slot combination on the mating component. The appropriate hole shaft tolerance shall also be considered to balance the ease of assembly while minimizing tolerance stackup. Refer to detailed drawings of critical interfaces to determine tolerance stackup requirements.

Figure 7 – Proposed locating features for component interfacing

2.2.10 Adjustable Position Panels

To align the critical conflat ports with the beamline components, both upstream and downstream panels shall be manually adjustable in position by ±2mm, in both vertical and horizontal directions. A proposed method is included in the PDC, which uses M8 screws to push the panel while the vacuum chamber is vented, and the corresponding flange screws are loose. The vendor shall ensure the fixed flange geometry, moving panel geometry and o-ring interface is properly designed to accommodate this manual alignment motion.

Figure 8 –Two panels with adjustable position. Downstream panel shown here

2.2.11 Chamber Bolts & Nuts

Silver-plated stainless steel bolts shall be used throughout the VCS. Each bolt shall be ASTM A193 grade B8 class 1 equivalent strength or better. Plate nuts are preferred over individual nuts for chamber section interfaces. Common conflat plate nuts are required for all conflat ports unless a specific exception is made. Metric hardware is strongly preferred throughout.

The PDC includes a representation of bolts and custom plate nuts at the interface of all weldments. However, the spacing shown in the PDC is arbitrary. The Vendor shall calculate and document the sizing and spacing of bolts at each interface. This documentation shall demonstrate the effectiveness to properly form a vacuum seal and provide structural stability during lifting and rigging operations. Industry standard conflat flange joints are exempt from this documentation.

2.2.12 Vacuum Seal Design

The vendor shall design o-ring sealing interfaces between all weldment sections. The PDC demonstrates a double o-ring seal for the large flanges, with differentially pumped volume between the o-rings at all three large interfaces. The other smaller interfaces may also require a double o-ring seal, if agreed upon during the design phase.

All vacuum seal design geometry must be brought to final design completion. This includes, for example, ensuring appropriate o-ring diameters, groove cross sections, groove turning radii, and appropriate o-ring practices throughout. APS requires every o-ring and custom metal gaskets in the design to include a piece part drawing. Two spare seals per interface shall be provided by vendor.

2.2.13 Standard Chamber Flanges and Hardware

Some flanges or vacuum hardware in the PDC have specific vendor off the shelf part number references. It is not required to use the specific vendor for sourcing these industry standard components, but the vendor shall use a technically equivalent component for each replacement. Metric hardware throughout is strongly preferred, unless a specific exception is made.

2.2.14 Conflat flange – Neck length

The PDC includes numerous industry standard conflat flanges. The PDC model may have inconsistent neck lengths and typically is not critical. The vendor shall ensure each neck length is sufficient to easily install plate nuts by hand without difficulty. It’s also preferred to have a consistent and uniform plane of all conflat faces on each side of the chamber. Refer to the detailed drawing to determine if any conflat positions are critical.

2.2.15 Feedthrough Blanks

Unless otherwise noted, the Vendor shall provide standard blanks on all conflat flanges and other flanges throughout the VCS. APS will replace most of the blanks during instrument commissioning with various types of feedthroughs. If appropriate, the vendor may arrange to ship the blanks back to their facility after APS has completed installation, in order deduct the purchased part cost and reduce the overall bid cost. APS does not need most of the blanks long term.

2.2.16 Re-use two existing feedthrough panels

APS will install two pre-existing feedthrough panels on the vacuum chamber. The vendor may decide to either arrange for shipping to their facility for reverse engineering and testing purposes, or design aluminum plate blanks to close up the chamber for testing.

Figure 9 – Two feedthrough panels will be harvested and installed. Vendor choice how to handle.

2.2.17 Support for Overhanging Section

APS strongly encourages the use of a frame to support the weight of the overhanging section of the VCS during factory assembly and testing, in order to avoid undue stress on the joint.

The final installation at APS will also include a permanent frame to support the cantilever load of the chamber section and internal components.

Figure 10 – Support frame for overhang section. Left – Temporary at vendor site. Right – Permanent at APS

2.2.18 Spherical Mount Retroreflectors

After final assembly, APS survey and alignment equipment will be used to measure the installed final positions of the vacuum chamber in the beamline. To facilitate this operation, several strategic drilled holes shall be made in a few components of the VCS. The vendor does not need to provide any survey equipment, just needs to accommodate in the design phase by confirming all locations with APS Tech Rep.

Figure 11 – Survey targets to be installed on three red components, multiple locations each. Vendor shall work with Tech Rep during the design phase to determine final locations.

2.2.19 Large ISO Viewport

The vendor shall provide a large viewport on the top chamber. Commercial product Ideal Vac P1011604 or similar, along with associated seal and clamps. The vendor may also need to provide a metal blank for shipping and handling purposes, to be decided during the design phase.

Figure 12 – Vendor provides large ISO viewport.

2.2.20 Structural Calculations or Simulation (completed by APS engineering) The vendor shall work with APS Tech Rep during the design phase to confirm that the VCS is properly designed to sustain vacuum forces. APS does not expect major revisions to be required based on prior chambers of approximately the same size, also with half inch wall thickness. However, the vendor shall submit 3D CAD to APS, two weeks before the final design review, so that APS can perform a structural analysis and confirm the structural integrity of the chamber.

Figure 13 – An example structural simulation performed by APS

2.2.21 Shipping configuration

APS encourages the vendor to ship the VCS with highlighted blue section mounted securely inside the main chamber, with the goal of reducing number of shipping crates and reducing overall cost. Vendor shall design shipping brackets and associated features to secure inside, and shall also devise a way to maintain cleanliness of the system. Likely will require dry nitrogen filled bagging. The vendor shall also include an aluminum plate cover over the flange where this section mounts, for testing purposes with it removed.

Figure 14 – An example structural simulation

2.3 Vacuum Level, Cleaning and Best Practices

The vacuum vessel must be able to reach High Vacuum, in this case meaning

<1.0x10-7 Torr. Fabrication and cleaning procedures shall be chosen appropriately by the vendor to achieve HV. A summary of best practices is given in attachment APS Engineering Standard - Vacuum Designs (APS_2018473).

The vendor shall clean each weldment / component following this guideline, which typically requires submerging in heated water/detergent solution and ultrasonication. The vendor shall include a plan for this process in their bid, including equipment model numbers available, and process documentation.

The vendor shall maintain cleanliness after cleaning following industry best practices.

Contact with only UHV aluminum foil, gloved hands, mitigation of dust and particulates, etc.

Each component shall also be electropolished. Refer to Section 4.4 Finish for more details.

The assembled VCS chamber shall be baked out before Factory Acceptance Testing.

The temperature and ramp rate of the bakeout shall be proposed by the vendor and approved by the APS prior to testing. The vacuum performance will be determined by the acceptance testing, where the chamber must meet the desired vacuum quality at factory acceptance and at APS site acceptance. Unsuccessful achievement of this vacuum level will require a vendor mitigation and is the vendors responsibility to pass acceptance testing.

3 Bid Options The following sections describe optional additional work for the vendor to decide if they will bid this optional bid scope. The exclusion of these options from a bid will not disqualify or dissuade the procurement selection. A Vendor shall pursue these options only if the work does not significantly affect the schedule of the required sections. Both a separate line item, as well as an estimated number of labor hours, shall be generated in the vendor’s bid for each option the vendor chooses to pursue. For options that the vendor chooses not to pursue, accommodations shall still be made to coordinate the interface design with other vendors or

APS.

3.1 BID OPTION: Invar Baseplate

Rather than 304L Stainless Steel, the vendor may include a bid option of Invar 36, with the goal of improved thermal stability for components in vacuum mounted on the baseplate. The vendor shall maintain all other requirements listed in other sections including GD&T specs, cleanliness, etc.

3.2 BID OPTION: RGA Scan

The vendor shall test the VCS chamber with a high sensitivity quadrupole type residual gas analyzer (RGA), scanning from 1 amu to at least 80 amu. The RGA spectrum shall be consistent with a contamination-free vacuum chamber at room temperature, defined as having only the following peaks:

Mass Peak (AMU) Suspected Gas 2 H2

12, 13, 14, 15, 16 CH4

17, 18 H2O

28 CO or N2

44 CO2

For reference, the following mass peaks represent common unacceptable residual gases Mass Peak (AMU) Suspected Gas Likely Cause

6 Li contamination 12 – 14 air leak (real or virtual)

32 O2 leak (real or virtual) 19, 35, 37 Halogen gases Shall be investigated

36 H2S Incorrect machining coolant 40 Ar leak (real or virtual)

• High Vacuum – RGA scan acceptance criteria

AMU Range Maximum Allowable Partial Pressure Sum of entire range 5x10-8 torr

Sum of peaks above 44 2.5x10-9 torr Any single peak above 44 5x10-9 torr

The RGA scan results shall be provided to the APS POC for review and must be approved in writing by the APS POC prior to shipment.

4 Quality Assurance and Inspection The vendor shall adhere to all quality control requirements as specified in this document and the accompanying Procurement Quality Requirements form ANL-407 (see attachments).

Any deviations from this Statement of Work or the ANL-407 must be approved in writing using the APS supplier disposition report (SDR) form included in the Argonne purchase order.

APS reserves the right to inspect all materials, parts, and testing that required for completion of this contract with respect to quality requirements. APS personnel shall have access to the vendor’s facilities at reasonable times for inspection of the progress of work if necessary. In the case where physical meetings are not possible, virtual meetings and inspections can be an appropriate substitute and are at the discretion of the APS.

The following subsections are additional quality requirements that must be met in addition to those in ANL-407.

4.1 Selective Material Requirements

The following list is inclusive of material standards specified for non-standard machined piece parts of the chamber:

• Stainless steel, Type 304L ASTM A240.

o Stainless steel 316 or 316L ASTM A240 is an appropriate alternative if needed.

The following list is inclusive of material specifications or standards of off the shelf or standard hardware:

• Viton o-rings

• Silver-plated stainless steel bolts, see section 2.2.6 Organic adhesives and sealants, which could result in contamination of the VCS, shall not be incorporated into the in-vacuum assembly. Material that degrades under the radiation environment encountered in an APS undulator beamline shall not be used for the mounting fixtures and attachments. All materials used must be disclosed to and approved by the APS technical representative.

The following elements of alkali metals, zinc, tin, lead, sulfur, halogen gases, phosphorous and selenium are NOT allowed in the APS vacuum system.

All other material selections made by the vendor for remaining components not listed, such as locating and guiding components, shall be submitted to the APS for approval before or at the final design review.

4.2 Pressure Safety

4.2.1 Vacuum Structural Testing

The chamber shall be tested by pumping out the vacuum volume to medium vacuum level (1x10-5 torr) or lower, with full atmospheric pressure differential. Following the test, the vendor shall examine the vessel and determine that no effect in excess of limits established by the vendor and approved by the APS was experienced.

All vacuum tests shall be documented with a brief description of the test and include two signatures: the responsible person and one witness. Records of these tests shall be provided to the APS.

4.2.2 Rupture Disk Specification

Appropriate rupture disks shall be incorporated to satisfy the chamber as Category I, according to attached document Vacuum Systems Consensus Guideline for Department of Energy Accelerator Laboratories (APS_1273737). These rupture disks shall rupture if the internal pressure exceeds a set pressure. This allows for safe helium backfill of both sections separately for operation, storage, or shipping. The disk shall have a rupture diameter of 2 inches with a nominal set internal rupture pressure of 5 psig.

Each disk shall be able to handle vacuum with full atmospheric pressure externally to the chamber. Should there be a vacuum cycle limit to the rupture disk design, this shall be communicated to the APS for written approval or potential specification iteration.

Each rupture disk shall be mounted on a flange that allows for replacement in the future should a relief event occur. The integration of the rupture ports onto the chamber design shall be proposed by the vendor, in addition to the proposed ports in the PDC. Each rupture disk shall have a cap that prevents accidental poking of the rupture disk. This cap must be easily removed should a rupture event occur.

Included in the PDC is a selection of commercially available burst disks. Ancorp 9100041 Low Pressure Burst Disk CF275 Flange w/ QF50 Gas Recovery Port, 5 psig.

Final rupture disk specifications, locations, ports, mounting, and life information must be approved in writing by the APS POC.

4.2.3 Chamber Backfill Design Pressure

Despite having 5 psig rupture disks, the chamber and all components when assembled shall be justified by the vendor to have appropriate structural integrity when a positive backfill pressure of 15 psig is reached. Vendor shall reach agreement with APS about the structural integrity for both vacuum and overpressure, communicating expected behavior from the structural analysis described in Section 2.2.17.

4.3 Machining

The use of silicone, sulfur, phosphorus, or halogen based cutting fluids and abrasives is strictly prohibited. Use of water-soluble sulfur-free/silicone-free cutting fluids like trim sol® or equivalent are acceptable. Grinding, sanding, or other machining operations that can cause contaminants to be embedded into the surface are prohibited.

Machining operations that can cause contaminants to be embedded into the surface like rolling or sandblasting is prohibited. If glass bead blasting is thought to be required, approval from APS-POC will be required. Grinding with resin bonded wheels, rouge, emery cloth, crocus cloth or similar abrasives are prohibited.

4.4 Finish

Unless otherwise specified, all vacuum-side surfaces must have a surface roughness of 63 microinches Ra or better prior to electropolish. All vacuum-sided surfaces to be electropolished with a final surface roughness of 32 microinches Ra or better. Processes such as grinding and/or polishing that may result in contamination of the part are prohibited.

4.5 Welding

All components are to be appropriately cleaned prior to welding. The vessel must be fabricated with vacuum tight internal gas tungsten arc welds. All continuous welds are to be helium leak tight. Structural skip welds are encouraged on air side interfaces. All post-weld machining shall be performed dry or using a water-soluble coolant fluid that is free of silicone, sulfur, phosphorous, and halogens.

The required type of weld is an internal weld. If geometry does not allow an internal weld, then a full penetration weld will be required.

4.6 Operational and FAT Vacuum Pump

The HV chamber will use a scroll roughing pump in operation to pull rough vacuum. After rough vacuum has been achieved, a large turbo pump (Pfeiffer HiPace 700M or similar) will be used to reach the desired vacuum threshold during operation. These pumps will be used in APS site acceptance. Equivalent or worse performance pumps shall be used to determine final vacuum level performance at the vendor.

4.7 Critical Inspection Dimensions

The vendor and the APS will come to an agreement on the total critical dimensions to be inspected, how they are measured, and the tolerances of those critical dimensions. The final summary of this agreement will be submitted by the vendor to APS at the time of the final design review for final approval. These critical dimensions will be verified at both the FAT and at ANL onsite acceptance. It is recommended that the vendor initiate the discussion of this early in the design process. The proposed list of critical dimensions features is as follows:

Vertical distance between top face of base plate and center of both x-ray upstream and downstream window flanges, as shown in drawing. Nominally 405.0 mm, with a tolerance of ±0.3 mm, while the adjustable panel is in the nominally centered location.

Figure 15 – Critical inspection dimension #1

It is left to the discretion of the APS to add critical dimensions to inspect as the design progresses, typically but not limited to the case when the vendor communicates design and or manufacturing challenges. An inspection certificate will be required from the vendor.

4.8 FAT and SAT

Prior to shipping, the vendor shall clean, assemble, pump down, leak check the entire VCS.

Calibrated vacuum instruments and equipment are required for factory acceptance testing at the fabrication facility. The Vendor shall provide a list of equipment and instruments to be used for factory acceptance testing for approval by the APS prior to use. The vacuum instruments and equipment shall be calibrated and traceable to the U.S. National Institute of Standards and Technology or equivalent standards laboratory. The Vendor shall provide copies of the calibration certificates or records for the equipment being used to perform the acceptance tests.

The vendor shall give at least 8-weeks-notice of any FAT date to allow the necessary travel arrangement to be made should APS decide they want to be present during testing.

4.8.1 Full Assembly & Fit-Up

The vendor shall perform a full assembly of overall vacuum system to verify fit up of the complete VCS.

4.8.2 Vacuum Leak Test

The chamber shall be successfully tested at the vendor for vacuum quality during the Factory Acceptance Test. A successful receipt leak test inspection must occur during SAT. A helium leak detector shall be connected to the evacuation system after the chamber reaches base pressure. The leak detector must be checked against calibrated leak before and after testing.

For approval, a leak check must provide all data as required by the AES-MOM Leak Test Form

(APS_1192756).

The leak check is considered a pass when no leak is detected using a leak detector with a minimum sensitivity of 1x10-9 std cc/sec (helium) per leak meter division with a signal to noise ratio greater than one.

4.8.3 Site Acceptance Test

After receiving the VCS, APS will conduct a site acceptance test (SAT) to confirm the form and function after shipping. The vendor shall be responsible to mitigate any issues uncovered during SAT. The acceptance criteria are the same as FAT acceptance criteria.

• Repeat measurement of Critical Inspection Dimensions as described in Section 4.7

• Repeat full assembly & fit-up, as described in Section 4.8.1

• Repeat vacuum leak test, as described in Section 4.8.2

• Repeat RGA scan, as described in Section 4.8.3

5 Milestones & Schedule There are 6 major milestones required to complete this scope of work. A percentage is given for each deliverable as a metric to determine project completion.

• Kickoff Meeting (at the APS or virtual) o APS POC written approval of timeline and to proceed with final design.

o This milestone is NOT eligible for progress payment.

• Final Design Review o APS POC written approval to proceed with manufacturing.

o This milestone is eligible for progress payment less than or equal to 10% of the award total.

• Factory Acceptance Test (FAT) o APS POC written approval that FAT is acceptable.

• Shipping of device from the vendor to ANL o APS POC written approval that delivery has occurred.

• Site acceptance testing (SAT) at ANL o APS POC written approval that acceptance testing is acceptable and complete.

• Closeout Documentation Delivered o APS POC written approval that all documents are delivered and are acceptable and that the project is complete.

It is required that any Vendor-proposed deviations in the design from the proposed preliminary design concept geometry (Section 2.1) must be communicated as early as possible to the APS POC by email for written approval. This avoids getting to the final design review with an undesirable change that requires mass rework and engineering to mitigate.

The vendor shall only initiate fabrication after APS has provided written approval of the VCS final design review via email to ensure that an agreement to begin fabrication has been documented.

The vendor shall propose a schedule to APS such that all items will be received, accepted, and tested not more than 52 weeks after receipt of order. An example schedule is given below. It is encouraged that the vendor proposes an aggressive timeline where all requirements of this project can be satisfied.

6 Reports & Documentation This section gives more details as to the required reports, documentation, and updates to be delivered for each milestone. All documentation must be emailed to the APS.

In addition to the milestone documentation below, general bi-weekly progress updates are required from the vendor to the APS after the initial project kickoff documentation is completed. These updates must be a brief bulleted list in an email that details progress, issues and mitigations, potential and actual delays and forecast delivery information.

For each milestone the Vendor shall provide the following documents and/or reports:

6.1 Post Kickoff Meeting Documentation

• A report including a concept sketch, main challenges, and summary of ANL visit (or virtual meeting) discussion points and responses.

Line Item Description Weeks Weeks

ARO*

Contract Award Project Start 0 0 Kickoff Meeting Discuss deliverables, finalize project schedule 1 1 Kickoff Meeting Documentation

Vendor supplies summary and responses to recommendations of the kickoff meeting. 2 3

Vendor Final Design Report & Supporting Documents

Documents to be provided to APS for review 8 11

APS Final Design Review Vendor to present:

1. Review of Final Design Report

2. Review of FAT Planning Document

3. Review of the Lifting and Rigging Plan

Document APS written approval to proceed after recommendations have been addressed.

2 13

Vendor Fabrication Vendor fabrication. 30 43 Vendor Factory Acceptance Tests

Acceptance tests to be performed at vendor 2 45

Ship to ANL Item in transit to ANL 2 47 Receipt, Installation, and Acceptance Testing at ANL

ANL receive, unpacking, assembly, and on-site acceptance testing 4 51

Closeout All documentation handed off from vendor to

ANL 1 52

• A vendor proposed schedule for APS written approval.

6.2 Final Design Review

Final Design Report, including the following:

• How ALL Technical Requirements and Specifications section will be achieved in the design.

• All drawings for production of parts.

• A complete 3D cad model of the VCS for APS verification and approval of dimensionality

vs. initial proposed design concept geometry.

Additionally, the following documents must be submitted with the Final Design Report:

• The vendor will deliver a FAT Planning Document detailing how the required tests at the vendor of section 3.8 will be performed for APS verification and approval. This shall also include the agreed upon critical inspection dimensions that will be measured at both the FAT and at onsite acceptance.

• The vendor will deliver a preliminary Lifting and Rigging Plan Document detailing the steps and equipment needed to assemble and disassemble the VCS for APS verification and approval.

6.3 Manufacturing Progress Reports

• When fabrication begins, a manufacturing progress report shall be submitted to APS every two weeks. This will replace the general bi-weekly reporting during the fabrication period.

• Any issues in manufacturing or timeline shall be reported to the APS Tech Rep and Procurement Specialist immediately upon discovery by separate email and must also be documented in the bi-weekly progress reports.

• Pictures shall be supplemental to the progress report of relevant manufacturing activities. The APS may request specific pictures that must be included in the progress reports.

• Include details of actions completed, issues arising, and open actions in the progress report.

6.4 Factory Acceptance Report

• A summary of FAT results. All tests shall be summarized into one report for review by the APS POC.

6.5 Shipping

• See Section 8 for details.

6.6 Closeout

Final documentation must be submitted as a package including the following elements:

• As built drawings.

• Manufacturing drawings in PDF format.

• 3D models in either Creo or STEP format.

• 2D assembly drawings in DWG or DXF format.

• BOM of all hardware comprising the chamber system.

• FAT procedures and report.

• User’s manuals and procedures for system operation, maintenance, assembly, disassembly, lifting and rigging, on-site installation.

• Manuals and warranties for all 3rd party components.

• All warranty information.

• Quality Assurance Documents for the completed systems, including a list of used materials with their description, copies of material certificates, details of all quality control checks and intermediate test results, or anything else as specified in the accompanying Quality Assurance Procurement Requirements Form ANL-407.

7 Warranty The VCS and sub-components shall be warranted for 12 months after final acceptance at APS or 18 months from delivery, whichever comes first.

8 Packaging and Shipping Estimated packing and shipping charges shall be explicitly included as part of the vendor proposal quote.

Four weeks prior to expected shipping, the vendor shall submit a plan to APS for written approval describing the shipping, packaging, lifting, and rigging of all assemblies for the VCS.

The vendor is responsible for proper packing and shipping of all components. This includes:

• Assembly status shall be proposed by vendor and confirmed with APS POC, whether that be all major chamber sections assembled together or separated.

• All internal exposed vacuum areas on the VCS parts shall be configured and packaged in such a way such that they are backfilled with dry nitrogen against the vacuum side surfaces. This includes the upper and lower chamber sections, lid, and base plate. The backfill pressure shall not exceed 0.5 psig.

• All flanges must be hermetically sealed to atmosphere using conflat or o-ring style blanks.

One of these blanks on each section of chamber must have a tube to allow for a dry nitrogen backfill which will then be crimped shut or shall house a small valve which can be sealed closed when backfilling is completed.

• All sealing surfaces must be protected from potential dents, nicks, and scratches.

• Chamber ports shall be covered in new oil free aluminum foil.

• Silver-plated stainless-steel screws must be used to secure the flanges. ONLY silver-plated stainless-steel screws are acceptable.

• All assemblies shall be bagged or wrapped in Tyvek (or equivalent).

• Each assembly shipped shall be identified by the purchase order number, assembly number and sequential identity or serial number.

• Assemblies must be secured for shipment in a fashion that protects the assembly from dust, dirt and weather or water damage. The assemblies must be securely fastened, padded, boxed and/or crated for shipment in a suitable manner for prevention of shipment damage to any assembly and its weather/dust protection and ensure their safe delivery to the Laboratory.

• Shipping containers shall be suitable for lifting and transportation without damage using a forklift with a max capacity of 5000 lbs. Each shipping container shall also contain the appropriate quality assurance records specified in the ANL-407 form.

• Shipping crates shall be attached to a pallet so that it can be moved using standard handling devices (forklift or pallet jack).

• Shipping containers shall have an orientation arrow. Irreversible indicators that record vertical shock loads of more than 10 G and tilt indicators shall be attached to the shipping crates.

Each crate shall be labeled on the outside with the information shown below:

• Part numbers and quantities of enclosed parts

• Recipient: Argonne National Laboratory, Advanced Photon Source Upgrade

• Address: 9700 South Cass Avenue, Argonne, IL 60439

• Gross weight of each crate

• Conspicuous arrows to indicate its upright position

The packaging and crating of the VCS components shall be such that they can be stored for a period of 6 months in an indoor environment without causing damage (including rust or mold) or loss of vacuum performance to the VCS. Desiccant packets are recommended inside crates.

9 Value Engineering Concepts Throughout performance of this PO, the Vendor is requested to identify alternative materials, products, systems, equipment, or methods that could lead to project cost savings through the Value Engineering Processes. Once these value engineering cost savings are identified, a written report of suggested value engineering strategies shall be submitted to ANL’s Tech Rep for improving the efficiency of the PO award. A formalized cost sharing mechanism will be implemented on the PO award document.

9.1 Recommendations

The vendor is encouraged to make recommendations for changes, including design, components, and specifications, that might lead to an improvement in performance, reliability, quality, safety, or significant reduction in cost.

9.2 Investigation of Improvements

Where it appears a substantial improvement in simplicity of design, performance, safety, ease of maintenance, efficiency, or reliability will result from the use of materials, parts, processes, and specifications other than those specified, it is strongly suggested that these value engineering strategies be submitted to the POC/Technical Rep for further investigation and potential reduction in total project cost.

9.3 Contract Modification

Any change of scope to the contract will need to be submitted to the APS Procurement Specialist and Technical Representative prior to change of design/process/etc. The change will be reviewed, and if approved, new pricing and/or scheduling will be renegotiated, and the contract modified accordingly.

10 Attachments

• 3D Model of the VCS

• Detailed drawing package of the VCS

• APS Procurement Quality Requirements Form (APS_2016776)

• APS Engineering Standard - Vacuum Designs (APS_2018473)

• Vacuum Systems Consensus Guideline for Department of Energy Accelerator

Laboratories (APS_1273737)

• AES MOM Leak Test Form (APS_1192756)

• APS Supplier Disposition Report (SDR) form

2.3 Vacuum Level, Cleaning and Best Practices

10 Attachments