4) AL-1705-3155F Engineering Specifications.pdf

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 Engineering Specification

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

Document Number: AL-1705-3155 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 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 PTL Assemblies

6.1 Rectangular Beam Chambers

6.2 Pump Station Chambers

6.3 Bellows

7 Environmental requirements

7.1 Codes and Standards

7.2 Cleanliness environment

7.3 Cleaning fluids

7.4 Cutting fluids

7.5 Fasteners

7.6 Flange and Gaskets

8 Technical requirement

8.1 Vacuum pressure

8.2 Manufacturing process

8.2.1 Material

8.2.2 Fabrication

8.2.2.1 Part fabrication

8.2.2.2 Cleaning after manufacturing

8.2.2.3 Part joining

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8.3 Final Cleaning

8.4 Final Assembly

8.5 Final test

8.5.1 CMM Measurement before bakeout

8.5.2 Water pressure test

8.5.3 Bakeout

8.5.4 Residual Gas Analysis

8.5.5 Final He Leak Test

8.5.6 Final Pressure measurement

8.5.7 HPN2 Backfill

8.5.8 CMM Measurement after Bakeout

8.6 Packing and shipping

9 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 Applicable Doc list revision C Applicable Doc list revision D Applicable Doc list revision E Applicable Doc list revision F Applicable Doc list revision

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 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 Photon Transfer Line (PTL) assemblies are a group of vacuum chambers connecting the storage ring vacuum systems to the beamline frontends. The PTL assembly provides a clear aperture for the beamline photons to exit the storage ring and enter the beamline frontends. There are 29 PTL assemblies across the 12 sectors of the SR. Figure 4-1 and 4-

2 shows the 4.2 PTL assembly as an example. The assembly typically consists of 4 to 5 rectangular profile beam chambers, a pump station chamber and non-RF edge welded bellows.

The PTL chambers are typically made from 316L(N) stainless steel. Some chambers feature cooling channels.

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Figure 4-1: Sector 4 Raft 3 - PTL 4.2 shown in green highlight

Figure 4-2: PTL 4.2 vacuum chambers

BEND-B

Magnet

BEND-C

Magnet

QFRC-C

Magnet

QFRC-C

Magnet QDB-B

Magne t

HBEND

Magne t

QDB-B

Magne t

Clearing Magnet -2

Bellow

PTL Chamber 4.2D

PTL Chamber 4.2C

PTL Chamber 4.2B Rotating Flange

Welded Bellow

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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 PTL ASSEMBLIES

The main functions and requirements of the PTL assemblies are:

1. Provide suitable photon beam aperture for the exiting beamline photons.

2. Provide flexibility in assembly to allow for proper alignment to the photon beam

3. Provide suitable cooling features where necessary

4. Provide ports for pumping and gauging as required

These functions and requirement has informed the detail design of each PTL assembly

6.1 Rectangular Beam Chambers

The rectangular beam chambers typically consist of two CF flanges at both ends of a rectangular aperture beam tube. There are 26 variants of this chamber in total. The variations are aperture sizes, flange sizes, overall length, presence or lack of welded bellows and presence or lack of cooling. Figure 6-1 and Figure 6-2 shows example of two

PTL rectangular beam chambers.

Figure 6-1: PTL Rectangular Straight Chamber 5.0D

Rectangular Tubes

CF DN63 Flange

Cooling Channel

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Figure 6-2: PTL Rectangular Straight Chamber 4.2B

6.2 Pump Station Chambers

Most of the PTL assemblies require pumping and thus include a section of vacuum chamber with ports for vacuum pumps and gauges. Figure 6-3 and Figure 6-4 shows examples of 2 pump station chambers. There are 6 variants of pump stations chambers in total.

Figure 6-3: PTL Pump Station Chamber 4.2C

Rectangular Tubes

Custom CF Flange

Welded Bellow

Custom Obround CF Flange

CF DN160

Flange

Custom Flange with Support

Rectangular Chamber Halves

CF DN63 Flange

CF DN40 Flange

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Figure 6-4: PTL Pump Station Chamber 4.3B

6.3 Bellows

There are 9 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. Examples of the PTL bellows is shown in figure 6-5.

Figure 6-5: Example of PTL Bellow variants

CF DN40 Flange

Support

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7 ENVIRONMENTAL REQUIREMENTS

7.1 Codes and Standards

ID NUM

(SYY-XX-) Specification

S09-94-000151

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

PTL Chamber:

EN ISO 13919 or EN ISO 5817

EN ISO 17637

ASTM E498.

EN ISO 17640

ASTM E2734/E2734 M − 10.

7.2 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

7.3 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

7.4 Cutting fluids

ID NUM

(SYY-XX-) Specification

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

7.5 Fasteners

ID NUM

(SYY-XX-) Specification

S09-94-000155 The fasteners of the of vacuum chambers must comply with AL- 1220-7841, §7.6 ci al ly R el ea se d to th e

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7.6 Flange and Gaskets

ID NUM

(SYY-XX-) Specification

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

AL-1220-7841, §7.7

8 TECHNICAL REQUIREMENT

8.1 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

8.2 Manufacturing process

8.2.1 Material

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

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

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8.2.2 Fabrication

8.2.2.1 PART FABRICATION

The fabrication of the SR PTL 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

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

8.2.2.2 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 §7.2).

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

8.2.2.3 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 §8.3)

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

S09-94-000180 All requirements relative to welding stainless steel shall comply with UHV Chamber and Component Production Requirements AL-1220- 7841_Rev B §10.2 ci al ly R el ea se d to th e

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General requirement

(SYY-XX-) Specification

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.

Inspection of welded joints

ID NUM

(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

8.3 Final Cleaning

The final cleaning of the SR PTL 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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8.4 Final Assembly

(SYY-XX-) Specification

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

8.5 Final test

The final tests to ensure the performance of the SR PTL Chamber must be performed in the sequence shown in Figure 8-1.

General requirement

ID NUM

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

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Figure 8-1: Final test sequence ci al ly R el ea se d to th e

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8.5.1 CMM Measurement before bakeout

(SYY-XX-) Specification

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

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

8.5.2 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

8.5.3 Bakeout

ID NUM

(SYY-XX-) Specification

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

8.5.4 Residual Gas Analysis

ID NUM

(SYY-XX-) Specification

S09-94-000205 Residual Gas Analysis must comply with AL-1220-7841, §14.2

8.5.5 Final He Leak Test

ID NUM

(SYY-XX-) Specification

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

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

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8.5.7 HPN2 Backfill

(SYY-XX-) Specification

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

8.5.8 CMM Measurement after Bakeout

ID NUM

(SYY-XX-) Specification

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

8.6 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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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-1705-3156F SR PTL Chamber Statement of Work 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 AL-1413-4789B WLDMT, PTLX.2C, S4,8,12

35 AL-1652-8091A WLDMT, PTLX.0C/D, PUMP STATION

36 AL-1604-7328B CHAMBER, PHOTON TRANSFER LINE, PUMP, VC5.0C

37 AL-1589-0567A PUMP MANIFOLD, VC3.1

38 AL-1633-3105B WLDMT, PTLX.3B, PUMP STATION

39 AL-1637-1009A WLDMT, PTLX3XB

40 AL-1673-5912A BELLOW, 132OD, 102ID

41 AL-1652-5823A BELLOW, DN50, 51MM ID, 76MM, 79MM LG

42 AL-1673-9115A BELLOW, DN50 TO OBROUND, 51MM ID, 84MM LG, ROTATABLE

43 AL-1577-0894B BELLOWS ASSY, LBL CF DN63R - DN50, 51 MM ID

44 AL-1439-5599A DN63CF BELLOW, 65MM ID, 90MM OD, 20MM STROKE

45 AL-1440-6502A DN63CF-DN160 BELLOW, 65MM ID, 90MM OD, 25MM STROKE

46 AL-1635-7916B ASM, PTLX3X BELLOW, OBROUND

47 AL-1443-2551A BELLOW, DN160CF, 148ID, 104L

48 AL-1442-9546A DN200CF BELLOW, 200MM ID, 235MM OD, 24.5MM STROKE

49 HW-1001-2984A DN200, Blank flange 50 HW-1000-9327A DN160, Blank flange 51 HW-1001-0102A DN100, Blank flange 52 HW-1000-3595A DN63, Blank Flange ci al ly R el ea se d to th e

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53 AL-1652-5792A DN50, Blank Flange 54 AL-1633-4492A 132 OD, Blank Flange 55 AL-1695-6771A Obround Blank Flange, knife edge 56 AL-1635-7929A Obround Blank Flange, seal 57 AL-1604-9130A Stadium Shape Blank Flange 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 ci al ly R el ea se d to th e

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D oc um en t C on tr ol

C en te r

Re le as ed

: M ay

1s t, C A ut h

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: U O

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