3) AL-1705-3156F Statement of Work.pdf

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Advanced Light Source Upgrade Project Lawrence Berkeley National Laboratory

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Printed hard copies of this document are for reference only.

SR PTL Vacuum Chamber Statement of Work

Release Date: May 21 2024 3:13:48 PM PDT

Document Number: AL-1705-3156 Revision: F

Document Status: Released

Document Type: SPECIFICATION

Category Code: AL7426

ALS-U - ACCUMULATOR TO STORAGE RING TRANSFER LINE

VACUUM CHAMBERS

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Table of Contents

1 Revision History

2 Approvals

3 Abbreviations and Acronyms

4 Introduction

4.1 Project Overview

4.2 Scope Overview

4.3 Description of Items

4.3.1 Rectangular beam Chambers

4.3.2 Pumping station Chambers

4.3.3 Bellows

4.3.4 Shipping Assembly

4.4 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

5.1.3.1 First article

5.1.3.2 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)

6 Management, Reporting, Documentation and reviews

6.1 Schedule

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6.2 Reporting requirements

6.3 Proposal documentation requirements

6.4 Reviews

6.5 Hold points

7 Packaging and shipping specifications

7.1 Container

7.2 Marking

7.3 Packaging

7.4 Handling and storage

8 Quality Assurance

8.1 Quality Plan

8.2 Control plan

8.3 Type of control points

8.4 Deviation requests

8.5 Nonconformance reports

8.6 Numbering and/or Serialization

8.7 Completed ACL

9 Applicable Documents

Appendix A: Control Plan

Appendix B: CAD Model and drawing requirements 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 Revision to section §4.4 C Fix cross reference links D Applicable Doc list revision E Fixing typo revising introduction F Fix introduction text

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 ci al ly R el ea se d to th e

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3 ABBREVIATIONS AND ACRONYMS

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.

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

FE

Final Design Review Beamline Front End

HHL High Heat Load HP Hold Point

IR

KOM

InfraRed Kick Off Meeting

LBNL Lawrence Berkeley National Laboratory LCW Liquid Cooled Water 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

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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 Scope Overview

This scope of work is for the manufacturing, design fabrication, dimensional inspection, fiducialization, vacuum testing, and delivery of vacuum chambers for the ALS-U project.

The scope includes 3 chamber types: Rectangular beam chambers, Pump station chambers, and Edge welded bellows. In total, there are 41 chamber units to be delivered.

4.3 Description of Items

The Photon Transfer Lines (PTL) are 29 separate vacuum chamber assemblies that connect the Storage Ring (SR) vacuum system with the beamlines frontends. Each sector of the storage ring may contain up to 5 beamline frontends with their corresponding PTL.

The frontends are designated X.0, X.1, X.2, X.3 and X.4 where X could be any of the 12 sectors of the storage ring. Figure 4-1 shows sector #4 of the storage ring and the associate

PTL chamber assemblies – 4.0, 4.2 & 4.3. Table 4-1 shows a complete breakdown of PTL chamber assemblies across all 12 sectors. The chambers in each PTL are designated A, B, C, … as shown.

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Each PTL assembly typically consists of 3 to 4 straight vacuum chambers with rectangular vacuum apertures. The assemblies also contain bellows and pumping station chambers. See Figure 4-2.

Table 4-1: Storage ring PTL assemblies breakdown (highlight the chambers that are part of this scope)

Sector PTL PTL Assembly Bellow Chamber B Bellow Chamber C Bellow Chamber D Bellow Chamber E Bellow

2.0 AL-1471-4140 AL-1652-5823 AL-1653-0031 AL-1652-5823 AL-1653-1087 AL-1652-8091 AL-1730-8127 AL-1440-6502

2.1 AL-1507-7007 AL-1417-2302 AL-1439-5599 AL-1589-0567 AL-1511-4050 AL-1439-5599 AL-1511-4077

3.1 AL-1507-7008 AL-1417-2302 AL-1439-5599 AL-1589-0567 AL-1511-8637 AL-1507-3328 AL-1440-6502

3.3 AL-1388-5786 AL-1635-7916 AL-1637-1009 AL-1637-3087 AL-1637-3105 AL-1442-9546

4.0 AL-1652-5823 AL-1652-5823 AL-1652-6463 AL-1652-8091 AL-1652-8177 AL-1577-0894 AL-1652-8200

4.2 AL-1391-4133 AL-1673-6336 AL-1673-5912 AL-1413-4789 AL-1633-5819 AL-1443-2551

4.3 AL-1392-8442 AL-1673-5912 AL-1633-3105 AL-1633-4474 AL-1518-1237 AL-1443-2551

5.0 AL-1577-0900 AL-1673-9115 AL-1577-0922 AL-1604-7328 AL-1454-4472 AL-1439-5599

5.1 AL-1507-7009 AL-1417-2302 AL-1439-5599 AL-1589-0567

5.3 AL-1388-5786 AL-1635-7916 AL-1637-1009 AL-1637-3087 AL-1637-3105 AL-1442-9546

6.0 AL-1512-0868 AL-1652-5823 AL-1653-0031 AL-1652-5823 AL-1653-1087 AL-1652-5823 AL-1652-8091 AL-1577-0894 AL-1730-8014

6.1 AL-1507-7010 AL-1417-2302 AL-1439-5599 AL-1589-0567 AL-1511-8637 AL-1439-5599 AL-1512-1021

6.3 AL-1388-5786 AL-1635-7916 AL-1637-1009 AL-1637-3087 AL-1637-3105 AL-1442-9546

7.0 AL-1512-1657 AL-1652-5823 AL-1652-6463 AL-1652-8091 AL-1577-0894 AL-1730-8232

7.3 AL-1388-5786 AL-1635-7916 AL-1637-1009 AL-1637-3087 AL-1637-3105 AL-1442-9546

8.0 AL-1512-1997 AL-1652-5823 AL-1652-6463 AL-1652-8091 AL-1730-9504 AL-1439-5599 AL-1731-1279

8.2 AL-1391-4133 AL-1673-6336 AL-1673-5912 AL-1413-4789 AL-1633-5819 AL-1443-2551

8.3 AL-1392-8442 AL-1673-5912 AL-1633-3105 AL-1633-4474 AL-1518-1237 AL-1443-2551

9.0 AL-1515-4747 AL-1652-5823 AL-1653-0031 AL-1652-5823 AL-1653-1087 AL-1652-8091 AL-1730-9447 AL-1440-6502

9.1 AL-1507-7011 AL-1417-2302 AL-1439-5599 AL-1589-0567 AL-1511-8637 AL-1507-3328 AL-1440-6502

9.3 AL-1388-5786 AL-1635-7916 AL-1637-1009 AL-1637-3087 AL-1637-3105 AL-1442-9546

10.0 AL-1517-8584 AL-1652-5823 AL-1652-6463 AL-1652-8091 AL-1577-0894 AL-1730-8275

10.3 AL-1388-5786 AL-1635-7916 AL-1637-1009 AL-1637-3087 AL-1637-3105 AL-1442-9546

11.0 AL-1517-8697 AL-1652-5823 AL-1653-0031 AL-1652-5823 AL-1653-1087 AL-1652-8091 AL-1577-0894 AL-1730-8014

11.1 AL-1507-7012 AL-1417-2302 AL-1439-5599 AL-1589-0567 AL-1511-8637 AL-1507-3328 AL-1440-6502

11.3 AL-1388-5786 AL-1635-7916 AL-1637-1009 AL-1637-3087 AL-1637-3105 AL-1442-9546

12.0 AL-1517-8737 AL-1652-5823 AL-1652-6463 AL-1652-8091 AL-1730-9504 AL-1439-5599 AL-1731-1279

12.2 AL-1391-4133 AL-1673-6336 AL-1673-5912 AL-1413-4789 AL-1633-5819 AL-1443-2551

12.3 AL-1392-8442 AL-1673-5912 AL-1633-3105 AL-1633-4474 AL-1518-1237 AL-1443-2551 ci al ly R el ea se d to th e

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

Figure 4-2: PTL Chamber Assembly example

Beginning of PTL, connection to SR

End of PTL; connect to gate valve and the beamline user end

Pump Station

Support s

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4.3.1 Rectangular beam Chambers

There are in total 26 variants of rectangular beam chambers. The chambers feature CF flanges on the entry and exit. Some chambers have integrated cooling channels and features for supporting the chambers. Figure 4-3 shows CAD images of all

26 rectangular beam chamber variants.

Figure 4-1: All rectangular straight chamber variants ci al ly R el ea se d to th e

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4.3.2 Pumping station Chambers

The pumping chambers for the PTL come in various geometries due to the different space constrain at each PTL locations.

There are 6 sub-variants of pumping station chamber. The chambers ports for vacuum pumps and gauges. They also feature structures for supporting the chamber. Figure 4-4 shows CAD images of all pump station chamber variants.

Figure 4-4: All pumping chamber variants ci al ly R el ea se d to th e

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4.3.3 Bellows

There are 8 variants of bellows used across all the PTL assemblies. These bellows are non-

RF and are designed with or without a reducer flange at one end. All variants are circular bellows except for one obround-shaped variant, as shown in Figure 4-5.

Figure 4-5: PTL bellow variants

4.3.4 Shipping Assembly

Each individual vacuum chamber and bellows must be delivered with all ports sealed with the corresponding blank flanges. The selected vendor is responsible for producing or providing the blank flanges as well as LCW connections and copper gaskets. Table 4-1 lists the flanges and LCW fittings the selected vendor must supply. The quantity to be produced is as needed to fulfill the scope of work. LBNL will supply Helicoflex seals for applicable chambers as illustrated in Table 4-2, the full list and quantity of component supplied by LBNL is in AL-1714-6191.

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Table 4-1: Components that subcontractor will source or manufacture ID Features Illustration LBNL ID

DN200,

Blank flange

HW-1001-2984

DN160,

HW-1000-9327

DN100,

HW-1001-

DN63, Blank

Flange

HW-1000-

DN50, Blank

Flange

AL-1652-5792

132 OD,

Blank Flange

AL-1633-4492

Obround

Blank Flange

AL-1695-6771

Long

Obround Blank Flange

AL-1635-7929

Stadium

Shape Blank Flange

AL-1604-9130

Fitting compression 6mm x 8mm

OD tube

HW-1000-6992

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Table 4-2: Materials to be Integrated provided by LBNL

Id Features Illustration LBNL ID Quantity

Seal, Helicoflex

Oval 49.87 mm x 92 mm

HW-1001-

4.4 Roles and Responsibilities

The subcontract will name two University specialists to oversee the contractual and technical aspects of the procurement:

The University Procurement Specialist is responsible for contract administration from solicitation to subcontract award, and any contractual issues that arise thereafter.

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

The Subcontractor must identify a project manager who will act as the single point of contact for the University representatives. The project manager must be available for the duration of the subcontract to resolve issues and provide technical, programmatic, and schedule updates as specified in this SOW and in the subcontract.

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5 DELIVERABLES / SCOPE

This section details the required deliverables for each phase of the SR PTL 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 5-5 and §9.2) 10 days before FDR 6 Control plan duly completed and signed 10 days prior shipment

Acceptance Criteria List (AL-1708-1515) 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 5-5) 10 days before FDR 12 Test Plan and Associated procedures (see Table 5-5) 10 days before FDR

Test report (dimension, He leak, etc…) AL-1705-3155, 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 §7) 10 days prior shipment

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

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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 requirements of the SR PTL chamber Engineering

Specification Document AL-1705-3155. 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 the 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 the LBNL technical representative.

5.1.2.1 LBNL PROVIDED MODELS AND DRAWINGS

LBNL is providing the vendor with the design information packages. See Table 5-2.

Table 5-2: LBNL design package type

Id Drawing Description LBNL Design

Information Type

1 AL-1653-0031 PTL VC 2/6/9/11.0B

Reference Design1

2 AL-1652-6463 PTL VC 4/7/8/10/12.0B

3 AL-1653-1087 PTL VC 2/6/9/11.0C

4 AL-1652-8200 PTL VC 4.0E

5 AL-1652-8177 PTL VC 4.0D

6 AL-1730-8232 PTL VC 7.0E

7 AL-1730-8014 PTL VC 6/11.0E

8 AL-1511-4077 PTL VC 2.1E

9 AL-1507-3328 PTL VC 3/9/11.1E

10 AL-1512-1021 PTL VC 6.1E

11 AL-1730-8127 PTL VC 2.0E

12 AL-1730-9447 PTL VC 9.0E

13 AL-1417-2302 PTL VC 2/3/5/6/9/11.1B

14 AL-1577-0922 PTL VC 5.0B

15 AL-1454-4472 PTL VC 5.0D

16 AL-1730-9504 PTL VC 8/12.0D

1 Design can be modified by Sub-contractor with approval by LBNL ci al ly R el ea se d to th e

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LBNL Design

Information Type

17 AL-1730-8275 PTL VC 10.0D

Reference Design

18 AL-1511-4050 PTL VC 2.1D

19 AL-1511-8637 PTL VC 3/6/9/11.1D

20 AL-1673-6336 PTL VC 4/8/12.2B

21 AL-1633-5819 PTL VC 4/8/12.2.D

22 AL-1518-1237 PTL VC 4/8/12.3D

23 AL-1633-4474 PTL VC 4/8/12.3C

24 AL-1637-3087 PTL VC 3/5/6/7/9/10/11.3CX

25 AL-1637-3105 PTL VC 3/5/6/7/9/10/11.3DX

26 AL-1731-1279 PTL VC 8/12.0E

27 AL-1413-4789 PTL VC 4/8/12.2C

28 AL-1652-8091

PTL VC

2/4/6/7/8/9/10/11/12.0C/D

29 AL-1604-7328 PTL VC 5.0C

30 AL-1589-0567 PTL VC 2/3/5/6/9/11.1C

31 AL-1633-3105 PTL VC 4/8/12.3B

32 AL-1637-1009 PTL VC 3/5/6/7/9/10/11.3BX

33 AL-1652-5823 Bellow, DN50 Rotatable

34 AL-1673-9115 Bellow, Stadium Flange

35 AL-1577-0894 Bellow, DN63 to DN50

36 AL-1439-5599 Bellow, DN 63Rotatable

37 AL-1440-6502 Bellow, DN63 to DN160

38 AL-1635-7916 Bellow, Obround

39 AL-1443-2551 Bellow, DN160

40 AL-1442-9546 Bellow, DN200

41 HW-1001-2984 DN200, Blank flange

Final Design2

42 HW-1000-9327 DN160, Blank flange

43 HW-1001-0102 DN100, Blank flange

44 HW-1000-3595 DN63, Blank Flange

45 AL-1652-5792 DN50, Blank Flange

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LBNL Design

Information Type

46 AL-1633-4492 132 OD, Blank Flange

Final Design 47 AL-1673-5846 Obround Blank Flange

48 AL-1635-7929 Long Obround Blank Flange

49 AL-1604-9130 Stadium Shape Blank Flange

5.1.3 Hardware

The selected subcontractor is responsible for the manufacture of all variants of the PTL chambers and all its features.

5.1.3.1 FIRST ARTICLE

The selected subcontractor must produce chamber AL-1413-4789, PTL VC 4.2C Chamber, quantity of 1, as the first article.

Table 5-3: First articles

5.1.3.2 PRODUCTION

Table 5-4 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 5-4: List of production articles

Id Drawing ID Description Qty Due Date

1 AL-1653-0031 PTL VC 2/6/9/11.0B 4

35 weeks After

First Article Approval

2 AL-1652-6463 PTL VC 4/7/8/10/12.0B 5

3 AL-1653-1087 PTL VC 2/6/9/11.0C 4

4 AL-1652-8200 PTL VC 4.0E 1

Id Drawing ID Description Qty Due Date

1 AL-1413-4789 PTL VC 4.2C 1

10 weeks After

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5 AL-1652-8177 PTL VC 4.0D 1

35 weeks After First Article

Approval

6 AL-1730-8232 PTL VC 7.0D 1

7 AL-1730-8014 PTL VC 6/11.0E 2

8 AL-1511-4077 PTL VC 2.1E 1

9 AL-1507-3328 PTL VC 3/9/11.1E 3

10 AL-1512-1021 PTL VC 6.1E 1

11 AL-1730-8127 PTL VC 2.0E 1

12 AL-1730-9447 PTL VC 9.0E 1

13 AL-1417-2302 PTL VC 2/3/5/6/9/11.1B 6

14 AL-1577-0922 PTL VC 5.0B 1

15 AL-1454-4472 PTL VC 5.0D 1

16 AL-1730-9504 PTL VC 8/12.0D 2

17 AL-1730-8275 PTL VC 10.0D 1

18 AL-1511-4050 PTL VC 2.1D 1

19 AL-1511-8637 PTL VC 3/6/9/11.1D 4

20 AL-1673-6336 PTL VC 4/8/12.2B 3

21 AL-1633-5819 PTL VC 4/8/12.2.D 3

22 AL-1518-1237 PTL VC 4/8/12.3D 3

23 AL-1633-4474 PTL VC 4/8/12.3C 3

24 AL-1637-3087 PTL VC 3/5/6/7/9/10/11.3CX 7

25 AL-1637-3105 PTL VC 3/5/6/7/9/10/11.3DX 7

26 AL-1731-1279 PTL VC 8/12.0E 2

27 AL-1413-4789 PTL VC 4/8/12.2C 2

28 AL-1652-8091

PTL VC

2/4/6/7/8/9/10/11/12.0C/D

29 AL-1604-7328 PTL VC 5.0C 1

30 AL-1589-0567 PTL VC 2/3/5/6/9/11.1C 6

31 AL-1633-3105 PTL VC 4/8/12.3B 3

32 AL-1637-1009 PTL VC 3/5/6/7/9/10/11.3BX 7

33 AL-1652-5823 Bellow, DN50 Rotatable 14

34 AL-1673-9115 Bellow, Stadium Flange 1

35 AL-1577-0894 Bellow, DN63 to DN50 5

36 AL-1439-5599 Bellow, DN 63Rotatable 12 ci al ly R el ea se d to th e

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37 AL-1440-6502 Bellow, DN63 to DN160 5 35 weeks After

First Article Approval

38 AL-1635-7916 Bellow, Obround 7

39 AL-1443-2551 Bellow, DN160 6

40 AL-1442-9546 Bellow, DN200 7

5.2 Scope of work

5.2.1 Management and Quality plan

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

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

(see §7.1)

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 PTL Chambers. Documentations must take into account the SR PTL Chambers

Engineering Specification AL-1705-3155. CAD model and drawing requirements are dictated by LBNL document AL-1265-6612 (also see Appendix B).

The FDR is required to include the following documentation:

1. Control Plan and Manufacturing plan for the PTL 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 §8.3.

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Table 5-5: 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 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 §5.1.3.1 First Article, and §8.3 Notice to Proceed for additional information.

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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 PTL Chambers packed in appropriate crates

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 parameters outlined in this document.

5.3 Final documentation package(s)

The selected subcontractor must provide 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.

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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 ci al ly R el ea se d to th e

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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

§6.2 Kick-off Meeting 1 week ARO subcontractor

§5.2.2 Final SR PTL 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)

10 weeks after approval of FDR subcontractor

§5.2.4 Delivery

(First article) 2 weeks after completion of manufacturing subcontractor

HP#2

Approval of the first article 2 weeks after delivery

LBNL

§5.2.5 Completion of Manufacturing (Production)

35 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 ci al ly R el ea se d to th e

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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.

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.

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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 §10.

Table 6-2 : List of hold points

Section Activity Control point Type

§5.2.2_Final_Design_Review Closeout of FDR NTP §5.2.3 Approval of first article NTP §5.2.5 Approval of complete production

NTP

Control point types are defined in §8.3.

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7 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:

7.1 Container

Containers or crates for the SR PTL Chambers may be used for both shipping and storage.

Construction of the containers must be sufficient to adequately support and protect the

SR PTL 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 PTL Chambers. The crates must be strapped on all sides prior to and during shipment.

7.2 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 PTL Chambers contained therein.

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

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7.3 Packaging

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

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

Each chamber must to be assembled along with each associated LCW fitting, steel support(s), and flange blanks in accordance with their associated, FDR approved

ASM drawings.

Each bellow must be packaged individually in accordance with their associated, FDR approved ASM drawings.

Placement of eco-friendly packing foam between the SR PTL Chambers (if crate contains multiple SR PTL Chambers)

Placement of eco-friendly packing foam between the SR PTL Chambers and the sides of the crate to assist in minimizing movement during transportation.

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

The packaging must be compliant with the Toxics in Packaging Prevention Act, AB-4553.

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

7.4 Handling and storage

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

Should the SR PTL 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.

3 Reference: https://dtsc.ca.gov/toxics-in-products/toxics-in-packaging-law/ This AB 455 act prohibits intentional introduction of cadmium, lead, mercury, or hexavalent chromium, and/or incidental presence of those metals above 100 parts per million (ppm) by the combined weight of all of the above metals.

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8 QUALITY ASSURANCE

The SR PTL 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.

8.1 Quality Plan

As part of our project requirements, we are requesting that the vendor provide a comprehensive quality plan to ensure the successful execution and delivery of the project.

The quality plan should encompass various essential components to guarantee adherence to high standards throughout the project lifecycle. Below are the specific elements that should be included:

Quality Manual: The vendor must provide a detailed quality manual outlining the company's quality management system (QMS). This manual should encompass all relevant quality procedures, standards, and methodologies adopted by the company to ensure consistency and effectiveness in delivering quality products or services.

Organizational Chart: An organizational chart specific to the project should be included, illustrating the hierarchical structure of the team involved. This chart will help delineate roles, responsibilities, and reporting lines within the project team, ensuring clarity and accountability.

Key Personnel: A list of key personnel involved in the project, along with their respective roles and responsibilities should be provided. This includes project managers, quality assurance personnel, technical experts, and any other relevant stakeholders critical to the project's success.

Subcontractor Information: If any subcontractors are engaged in the project, their names, roles, and scope of work should be clearly stated in the quality plan.

Additionally, measures to ensure the quality and performance of subcontracted work should be outlined.

Project-Specific Procedures: The quality plan must outline specific procedures and protocols to be applied within the context of the project. This may include quality ci al ly R el ea se d to th e

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control measures, inspection processes, testing methodologies, and any other relevant procedures tailored to the project's requirements.

QA Documentation Presentation: A presentation of the quality assurance (QA) documentation should be included, highlighting the key documents, records, and forms utilized to manage and track quality throughout the project lifecycle. This must include Control Plans (see §8.2), inspection reports, non-conformance reports (see

§8.5), deviation request (see §8.4) and corrective action plans.

8.2 Control plan

The Control Plan (see Table 5-5) 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 §9).

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.

8.3 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.

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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.

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.

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8.4 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.

8.5 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.

8.6 Numbering and/or Serialization

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

Designation Serialization

AL-1637-3087

AL-1637-3087-0001

AL-1637-3087-0002

AL-1637-3087-0006

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

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Figure 8-1: Location of the serialization

8.7 Completed ACL

The subcontractor must provide a completed ACL to LBNL technical representative before shipping each SR PTL 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. HPN2 backfill

7. 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-1708-1515.

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9 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 9-1: Applicable documents ID Document ID Title

1 AL-1705-3155F SR PTL Chamber Engineering Specification 2 AL-1708-1515A SR PTL Chamber ACL 3 AL-1714-6191A SR PTL Vacuum Chamber Furnished Materials 4 AL-1220-7841F UHV Chamber and Component Production Requirements 5 AL-1405-1295A Control plan template 6 AL-1208-0209C ALS-U supplier quality evaluation survey 7 AL-1265-6612B ALS-U Build to Specification CAD Model and Drawing Requirements

8 AL-1653-0031B WLDMT, PTLX.0B, 43X11, LONG

9 AL-1652-6463C WLDMT, PTLX.0B, 47.5X13.5

10 AL-1653-1087B WLDMT, PTLX.0C, 47.5X16.5, LONG

11 AL-1652-8200A WLDMT, PTL4.0E, 47.5X16.5, COOL

12 AL-1652-8177A WLDMT, PTL4.0D, 45X15

13 AL-1730-8232A WLDMT, PTL7.0E, 47.5X16.5, COOL

14 AL-1730-8014A WLDMT, PTL6.0E, 47.5X16.5, COOL

15 AL-1511-4077A WLDMT, PTL2.1E

16 AL-1507-3328B WLDMT, VC3.1E

17 AL-1512-1021B WLDMT, VC6,1E

18 AL-1730-8127A WLDMT, PTL,2.0E, 42X13.6, COOL

19 AL-1730-9447A WLDMT, PTL9.0E, 36.6X13.6

20 AL-1417-2302B WLDMT, VC3.1B

21 AL-1577-0922B CHAMBER, PHOTON TRANSFER LINE, VC5.0B

22 AL-1454-4472A CHAMBER, PHOTON TRANSFER LINE, VC5.0D

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23 AL-1730-9504B WLDMT, PTL8.0D / PTL12.0D, 36.6X13.6

24 AL-1730-8275A WLDMT, PTL10.0D, 36.6X13.6

25 AL-1511-4050A WLDMT, VC2.1D

26 AL-1511-8637B WLDMT, VCX.1D

27 AL-1673-6336A WLDMT, PTLX.2B, S4,8,12

28 AL-1633-5819B WLDMT, PTLX.2D, S4,8,12

29 AL-1518-1237B WLDMT, PTLX.3D, S4,8,12

30 AL-1633-4474A TAPERED, CHAMBER VC04.3

31 AL-1637-3087A WLDMT, PTLX3XC

32 AL-1637-3105A WLDMT, PTLX3XD

33 AL-1731-1279A WLDMT, 45X13.6, PTL8.0E/12.0E

34…