technical specification for alba bellows and tapers · diagnostics or the injection components),...

ALBA Project Document No: Page: 1 of 26

END-SR-VCBLW-CC-0001 Rev. No.: 1.0

TECHNICAL SPECIFICATION FOR ALBA BELLOWS AND TAPERS

Final revision Date

Prepared by Eshraq Al-Dmour 16. Apr. 2007

Approved by Dieter Einfeld 9. May. 2007



Table of Contents

1 Introduction ...................................................................................................................................3

2 The description and the requirements of the bellows and tapers. ...............................................3

3 Scope of contract............................................................................................................................6

4 Tendering and contract management ...........................................................................................9

5 Responsibilities of the manufacturer...........................................................................................12

6 The bellows mechanical specification: ........................................................................................15

7 General requirements. .................................................................................................................19

8 Materials ......................................................................................................................................20

9 Design ...........................................................................................................................................23

10 Manufacture.................................................................................................................................25

11 Cleaning .......................................................................................................................................30

12 Inspection and testing ..................................................................................................................31

13 Documentation .............................................................................................................................37

14 Protection and transport. ............................................................................................................38

15 List of drawings............................................................................................................................39



1 Introduction

The Consortium for the Construction, Equipment and Exploitation of a Synchrotron Light Laboratory (CELLS) is responsible for the construction and the operation of a new 3rd

generation synchrotron radiation facility, named ALBA. The facility will comprise a 268.8 m circumference 3 GeV electron storage ring, injected from a 100 MeV Linac through a full energy 249.6 m booster synchrotron, and an initial complement of seven beam lines. To achieve stored beam life time of many hours, the electrons must circulate in ultra high vacuum (UHV) conditions. The pressure inside the storage ring without beam must be in the low 10-10 mbar range and with the design current of 400 mA in low 10-9 mbar range.

ALBA storage ring consists of 16 vacuum sections of two types: the matching cell and the unit cell, and the straights are between these sections. Each vacuum section is isolated with UHV sector valve and connected to the straights with bellows; these bellows will ease the assembly of the insertion devices (IDs), and will compensate for possible transverse displacement. In addition, to each side of the RF cavity straights, injection straight and diagnostics straights; there are bellows to ease the assembly of these components. At the location of the change in the inner profile of the chamber from one profile into another (e.g. IDs, pulsed magnets, RF cavities…etc), a smooth transmission implemented in the taper will be considered.

The bellows and the tapers for the storage ring of ALBA are the subject of this specification.

The documents provided for this call for tender are: this technical specification (END-SR-VCBLW-CC-0001), General Specification UHV assemblies (END-VCGS-ES-0001) and set of design drawings (see section 15).

2 The description and the requirements of the bellows and tapers.

2.1 Function: RF shielded bellows are needed on each side of the vacuum section, these bellows, will ease the installation of the straights (dummy chambers or the RF cavities or the IDs or the diagnostics or the injection components), also they will compensate for the thermal expansion due to the in-situ bake out of the straights, the bellows will also serve in compensation for the possible production and assembly imperfection.

2.2 General description: The standard bellows are shown in Figure 2-1; the bellows have an “installation length” of 160 mm and consists of two flanges, holding the RF structure which composes of the contact fingers, the spring fingers, stoppers and the inner tube. In addition, bellows cap is installed to limit their relative movement during installation and operation. The contact fingers are pressed on the inner tube from outside by the spring fingers and the electrical contact is kept at the edge of the inner tube.

2.3 As the stored electron beam passes around the synchrotron storage ring it induces eddy currents in the vacuum chamber walls. Any sudden change in cross section or gaps has a deleterious effect on beam stability and can generate damaging currents in the surrounding components. The bellows therefore have internal ‘fingers’ which maintain the vessel cross section and electrical continuity through the bellows. Each of these ‘fingers’ must remain in contact with its mating component through the full bellows assembly movements. It is these fingers and their required contact, which limit the bellows assembly movement.



Figure 2-1General layout of the RF shielded bellows of ALBA storage ring.

2.4 At the location of the RF cavity straight, a welded bellows/taper are needed, this structure has tapering to make a smooth transition from the standard profile around the ring to the circular profile of the RF cavity chamber entrance/exit flange profile. The stainless steel pumping port will be brazed to the cooled distributed absorber/taper block which is made from OFHC copper block, in addition the gauging port, the residual gas analyzer (RGA) port and a right angle vacuum valve port. A smooth cross-section transition and grilles over pumping and gauging ports are required to prevent disturbance to the circulating electron beam (see drawing SR-A-VC-4RF1-01-01, SR-A-VC-4RF3-01-01). Water cooling is required to remove the heat load from incident synchrotron light.

2.5 As the bellows and tapers are located close to the magnets, the material used for the manufacturing of the bellows and tapers must have magnetic permeability of µrel < 1.005, the final assembled bellows/taper must have magnetic permeability of µrel < 1.01 everywhere. To achieve this, the material to be used for manufacturing the bellows must be stainless steel of grade 316 LN or 316L for the bellows convolutions, 316LN for the vacuum chambers walls and pumping ports and 316 LN ESR forgings for the flanges and the pieces to be milled. OFHC copper will be used for the distributed absorbers/taper blocks of the RF cavity. The bidder may bid for other materials for the manufacture of the tender items in addition to the specified material.

2.6 The bellows/taper inlet /exit flanges are flat seal flanges or CF flanges with small gap (i.e. Spigot flanges), other connections (e.g. to the pumps and instrumentation) will be with standard Conflat flanges. No other type of flanges will be accepted; the profile of the flanges to be agreed with CELLS and CELLS approval is needed.

2.7 All the chambers and the vacuum components will be baked into 250-200°C as part of the vacuum conditioning, as a result all the bellows/taper assemblies must be bakeable up to 250°C as part of the factory acceptance tests (FAT)

The spring fingers The contact

fingers

The inner tube

Stoppers

Bellows cap



3 Scope of contract.

3.1 The manufacturer shall perform the scope of works required by this specification which includes (but not limited to): the supply of materials, all tooling, the detailed manufacturing and assembly drawings, equipment required for the manufacturing, handling and testing, manufacturing, clean-ing, inspection, vacuum conditioning, testing, packing and the delivery of the bellows and tapers to CELLS site.

3.2 This call for tender covers the supply of 57 bellows and taper assemblies (45 machine requirements + 2 prototypes + 10 spares) distributed as shown in Table 1.

Table 1 The bellows/taper assembly types, description, quantities and their corresponding drawing number.

Type #

Type name Description Qty. Drawing number note

1 BLW1 SR standard bellows 42 SR-A-VC-BLW1-01-01 35 machine requirements + 1 prototype + 6 spares.

2 BLW2 Injections straight

bellows, entrance/exit of the straight

3 SR-A-VC-BLW2-01-01 2 machine requirements

+ 1 spare

3 BLW3 Injections straight

bellows, entrance/exit of the septum magnet

4 SR-A-VC-BLW3-01-01 2 machine requirements

+ 2 spare

4 4RF1 RF cavity straight,

entrance bellows/taper assembly

4 SR-A-VC-4RF1-01-01 3 machine requirements

+ 1 prototype

5 4RF3 RF cavity straight, exit bellows/taper assembly 4 SR-A-VC-4RF3-01-01

3 machine requirements + 1 spare.

3.3 The manufacturing of the series shall start only after all the acceptance tests have been carried out successfully on the prototypes.

3.4 The bidders are requested to comment upon the specification and are encouraged to make alternative proposals to CELLS in addition to the quotation for the given specification. The suggested alternatives to the design and fabrication methods to improve the technical performances, cost saving or to have a reduction in the delivery time.

3.5 After the contract has been placed, any deviations or modifications from the agreed specification will not be allowed, except with the written authorization of CELLS.

3.6 The manufacturer must deliver to CELLS:

a) The specified bellows and tapers assemblies (as described in section 3.1, 3.2, 3.3 and 5.6 of this specification).

b) The manufacturer must follow the time schedule as shown in 5.6 of this specification. c) The manufacturer must prepare a detailed time schedule showing all the activities

related to the fabrication and the contract.

d) Detailed and a complete set of assembly and manufacturing drawings of the bellows and tapers, the format and the standards of the manufacturing drawings to be agreed with CELLS.



e) Detailed and a complete set of manufacturing drawings for the dedicated tooling or equipments to be used for the manufacturing, assembly and testing.

f) The manufacturer shall provide a list of equipment that will be used for the manufacturing, certificates of control of some equipment could be required and to be agreed with CELLS.

g) The welding and vacuum brazing plan and drawings. h) The quality plan and the quality schedule.

i) A complete set of procurement documents for materials and bought-in items to be sent to CELLS as soon as ready and in addition a copy of each order to be sent to CELLS at the time of ordering.

j) A complete set of manufacturing, cleaning and testing procedure. In case different manufacturing, cleaning and testing procedure have been suggested from that proposed by CELLS then a complete set of manufacturing, cleaning and testing procedure is required and they have to be approved by CELLS.

k) A complete set of test certificates, factory acceptance tests results and inspection reports as required by this specification as they become available and a complete set in the form of a documentation file at the end of the contract. This documentation file shall include the results of the material and the magnetic permeability prior to work, details of the degassing procedure (pressure and temperature vs. time), results of leak tests after welding, results of the dimensional control, results of tests of permeability after welding, leakage rate, RGA scan, ultimate pressure and desorption rate of the completed bellows and tapers assemblies.

l) Reports of non conformity of the bellows and tapers assemblies (if any). m) Each bellows and taper must be supplied to CELLS with: the material certificate, the

production file, the Inspection Points Plan (IPP) documentation, welding procedure specifications (WPS), test reports, the cleaning report and the Quality Assurance Plan (QAP) results.

3.7 CELLS has the property right for all the tooling also the assembly and manufacturing drawings.

4 Tendering and contract management

4.1 Pre-tender discussions

4.1.1 All bidders are strongly encouraged to contact CELLS and discuss details of the specification so to ensure that they understand completely the requirements and implications of the specification before making an offer. Enquiries of a technical nature shall be directed to Miss. E. Al-Dmour, CELLS, tel.: 34-93-592.43.32, e-mail: [email protected] Enquiries of a contractual nature shall be directed to Mr. M. Sazatornil, CELLS, Tel: 34-93-592.43.07, e-mail: [email protected]

4.1.2 Any information supplied as a result of such enquiries that affects details of the specification will be formally distributed to all the bidders.

4.2 Information required with the tender.

The bidder shall provide with the tender documents, sufficient information to allow a satisfactory evaluation and choice of manufacturer. Two sets of the following documents should be provided:



I. A confirmation of acceptance, or detailed explanation of any departure from the conditions defined in this specification, this must be done for each clause of the present specification.

II. The bidder shall complete the price breakdown pro-forma for the equipment and services as requested in this specification. Eventual alternative technical proposals shall be described and quoted for in a clearly separated accompanying document.

III. Outline design and summary of the proposed manufacturing process and commenting on any particularly critical aspects

IV. General procedure to be followed for vacuum brazing/ welding of the bellows and tapers

V. Details of the Quality Assurance Plan (QAP) that the Manufacturer operates.

VI. The Inspection Points Plan (IPP) form to be used for the manufacturing process.

VII. The bidder shall provide a programme showing key dates for all stages of:

A. The commencement and completion of tooling design, B. Submission of documents needing CELLS approval;

C. The procurement of materials and bought-in items D. Manufacture

E. Testing

F. Delivery.

VIII. The bidder shall indicate the proposed methods and means for undertaking each of the required tests.

IX. Indications of proposed work packages to be undertaken by the manufacturer.

X. Indications of proposed work packages to be undertaken by any subcontractors.

XI. Details of the proposed subcontractors and their technical capability.

XII. A list of previous similar or comparable projects, in size and scope, to enable CELLS to assess the bidder’s viability and ability to accomplish the contract.

XIII. The proposed procedure for the cleaning of the bellows and the tapers.

XIV. The bidder shall confirm his agreement with the acceptance tests or to propose the method for carrying out the tests on the completed bellows and tapers together with the details of all means and vacuum equipment to be used (manufacturer, type, specification, and approximate date of purchase (refurbishment/calibration)), also the tools for measurements especially the dimensional checks and the vacuum tests.



XV. Brief details of the principal personnel the bidder proposes to deploy on this contract, including their position in the company, the responsibilities for this contract and the percentage of their time they will devote to it, and details of their previous experience.

XVI. The bidder shall provide CELLS with a list of raw material manufacturers he proposes as provider for this contact. He shall also provide the grade, the chemical composition and the mechanical characteristics of the materials proposed by those manufacturers. In addition the bidder must include in his bid the procedure and the tests he will follow for the inspection of the raw materials.

XVII. The bidder has to provide within the offer the applicable codes and standards applied and procedure.

XVIII. The bidder has to indicate in his bid that his subcontractor has a clean room for welding/brazing and assembly purposes and his agreement with the cleanliness indicated in this specification.

XIX. Any other information requested for submission in the bid indicated in other places within this technical specification and any other information that the bidder finds important for submission in his bid.

5 Responsibilities of the manufacturer.

5.1 At the start of the contract the manufacturer shall assign the contact person (for technical issues and for administrative matters) who will be responsible for all reporting to, and contact with CELLS.

5.2 The manufacturer will be responsible for the final design, the production methods and the correct manufacture of the bellows and the tapers, irrespective if they have been chosen by the manufacturer or suggested by CELLS. The Manufacturer is responsible for meeting all the mechanical, electrical, vacuum, thermal, and safety requirements of this specification and reference design, including testing and certification. Strict compliance with this specification is required unless specifically modified in writing by contractual amendment.

5.3 CELLS’ approval of the design and components does not release the manufacturer from his responsibilities to correct errors, oversights and omissions to ensure conformance to the specification of this documents.

5.4 The manufacturer is responsible for:

5.4.1 The preparation of a detailed time schedule for the contract this must be done within two weeks of the commencement of the contract and the control of the agreed schedule. The detailed programme covering the design; development (if necessary); manufacturing, and testing phases in sufficient detail to allow regular monthly progress monitoring against monthly reports to be produced by the manufacturer.

5.4.2 The procurement of all necessary materials and bought-in items including the preparation of all procurement documents and the provision of test and acceptance documentation.

5.4.3 Study, design, production and assembly drawings, manufacture and/or supply of tools, gauges



and all test equipment necessary to fulfil the contract.

5.4.4 Preparation of a quality assurance plan and the Inspection Points Plan (IPP).

5.4.5 Complete documentation file of manufacture and quality assurance acceptance tests.

5.4.6 The manufacturing processes including:

i. Quality schedule,

ii. Preparation of detailed manufacturing drawings, iii. Complete design of welds/vacuum brazing and the welding/vacuum brazing

process,

iv. Qualification of the welding/vacuum brazing operators and welders, v. The manufacture of the bellows and tapers as defined in 3.1 of this specification.

vi. Cleaning procedures and protection of components during manufacture and shipment.

vii. All tests necessary for the acceptance of the completed bellows and tapers including:

a) Provision of necessary equipment.

b) Dimensional checks and control.

c) Final cleaning. d) Vacuum tests.

5.4.7 The control of the quality of all materials and manufacturing processes including the provision of all agreed documentation.

5.4.8 Submission of monthly progress reports.

5.4.9 Control of all subcontractors.

5.4.10 The production file for each bellows and tapers, which include the complete documentation file of manufacture and quality assurance acceptance tests.

5.4.11 The packing and transport of the bellows and taper from the manufacturer factory to CELLS site.

5.4.12 All the above points in as much as they apply to approved subcontractors.

5.5 If after the order is placed, the Supplier discovers that he has misinterpreted the specification, this will not be accepted as an excuse and CELLS will insist that the Manufacturer delivers the equipment to specification at no extra cost. During the construction, all proposed deviations from the specification must be submitted to CELLS in writing; CELLS will give its approval or refusal also in writing. It is expected that the manufacturer shall record the changes and the approvals, and to control these changes to fulfil this specification.

5.6 The schedule which must be followed for the performance of this contract:

5.6.1 Within two weeks of the commencement of the contract the Manufacturer must issue a detailed programme covering the design; development if necessary; manufacturing, and testing phases in sufficient detail to allow regular monthly progress monitoring against monthly reports to be produced by the Manufacturer.

5.6.2 Within a month of the commencement of the contract a programme of technical and progress meetings will be agreed between the Manufacturer and CELLS.



5.6.3 Following the signature of the contract, the design stage shall not exceed one calendar month in length unless mutually agreed in writing. A full design review must take place by the end of this month.

Three phases:

Phase 1: Design review phase. Phase 2: pre-series (prototypes) production phase.

Phase 3: series production phase.

Action Time Contract placed 0

Start up meeting 0+2 weeks

Engineering design complete (end of phase 1) Nov. 2007 Start of the prototypes production (start of Phase 2) Nov. 2007

End of prototypes production (end Phase 2) Jan. 2008 Release of the series production (start of phase 3) Jan. 2008

Delivery of the first batch Mar. 2008

Delivery of the second batch May. 2008 Delivery of the third batch and completion of the series production (end of phase 3)

Jul. 2008

5.6.4 The manufacturing of phase 3 bellows will start only after the entire factory acceptance tests (FAT) and the site acceptance tests (SAT) at CELLS have been carried out successfully for the prototypes.

5.6.5 The design stage will cover the discussion of any updates for the design as request from the manufacturer side or CELLS side, the preparation of the manufacturing drawings, the progress in the procurement of the material and the tools, the detailed preparation for the testing and acceptance and the details of the manufacturing process, welding and brazing plan, details of handling, packing and shipping conditions.

5.6.6 The final acceptance of the bellows and tapers will be based on the SAT. For the series production: a provisional acceptance for bellows and tapers will be performed, this will be based on the results of the FAT according to this specification, the bellows and tapers will not be dispatched to CELLS before the provisional tests have been accepted by CELLS. CELLS is going to perform the final acceptance tests for the series production at CELLS site. CELLS has the right to perform any of the tests again.

5.6.7 The bellows and tapers will be delivered by batches which will be defined together with CELLS in accordance with the installation schedule of the storage ring and during the engineering design review phase. Each batch may be composed of different types of bellows and tapers assemblies.

5.6.8 CELLS reserves the right to delay delivery or installation at no additional cost to CELLS by up to three months in the event of unavoidable delay to the general time schedule of CELLS.

5.7 Even if CELLS gave its approval for the drawings, certificates, manufacturing process, tests…etc, the responsibility of the final design, performance and product is on the manufacturer.



6 The bellows mechanical specification:

6.1 All the bellows are of type welded bellows.

6.2 All the bellows are equipped with RF shield which keep a smooth cross section facing the beam, however is the deformation state of the bellows. The inner surface of the bellows must always provide a good electrical contact.

6.3 The RF shield is composed of two main parts:

Part 1: The RF fingers which are the sheets bended with openings to allow pumping down the space between the bellows and the RF fingers/sleeve.

Part 2: The sleeve, which is a sheet deformed with the profile needed, RF spring fingers are connected on top of the sleeve which serves in keeping the RF fingers in contact with the sleeve.

6.4 In order to avoid over compression of the bellows than required, internal rods are installed this will stop the movement of the fingers/bellows. In addition a cover is needed around the bellows in order to stop any extra expansion of the bellows and also any extra transversal movement, in addition this cover will serve in order to block completely the movement of the bellows during installation.

6.5 The bellows are connected to the neighbouring chambers using Conflat flanges (of Spigot type) or flat seal flanges, the CF of the bellows must be rotateable, and the external ring of the flange must be made of two halves.

6.6 Special attention need to taken to the surface of contact of the spring fingers/ RF finger and the sleeve, the surfaces need to be polished in order to avoid any material removal from the movement of the bellows at the location of the contact. The bidder must specify in his bid the proposed degree of the polishing and the means to be used to perform it.

6.7 Bellows type 1 and type 2:

6.7.1 Figure 2-1 shows the bellows needed for type 1; the only difference between bellows type 1 and type 2 is that there is a taper on the sleeve of type 2, which serves in making a smooth transmission from the standard profile in the bellows into the profile of the kickers magnets located in the injection straight. The profile inside have a key-hole profile as shown in Figure 6-1.

(1) (2)

Figure 6-1: (1) the profile of the standard bellows and (2) the profile of the kicker magnets.

6.7.2 The bellows must allow a total stroke in the longitudinal direction of at least 20mm, this can be by 10 mm compression and 10 mm expansion and ±2 mm in all the transverse directions, this



transverse displacement must be available all along the 20 mm of the longitudinal stroke.

6.7.3 The bellows have in one side flat seal flanges and on the other side CF spigot flanges.

6.8 Bellows type 3:

6.8.1 These bellows have the same cross section of the kicker magnets profile (see Figure 6-1) the profile is implemented in the sleeve and the RF fingers.

6.8.2 These bellows have two rotateable ConFlat (spigot type) flanges at the entrance and the exit.

6.8.3 The bellows must allow a total stroke in the longitudinal direction of at least 20mm, this can be by 10 mm compression and 10 mm expansion and the transversal movement need to be more than the other bellows, this will allow transversal movement of the septum magnets where the bellows are connect to it. It is estimated that a transversal movement in the +/-5 mm range is needed. This transverse displacement must be available all along the 20 mm of the longitudinal stroke.

6.8.4 The manufacturer is responsible of the detailed design of this type of bellows and to achieve the specified strokes. The final values of the longitudinal and transversal movements will be agreed with the manufacturer during the design review phase.

6.9 Type 4 (RF straight entrance Bellows/taper assembly):

6.9.1 This type of assembly has the standard bellows structure and the structure is brazed into the taper/cooled absorber copper block. The taper serves in changing the profile from the profile of the standard bellows into a circular profile which is needed at the entrance of the RF cavity entrance flange.

6.9.2 In addition, stainless steel (316LN) pumping port will be brazed to the cooled absorber/taper block which is made from OFHC copper block, in addition the gauging port, the residual gas analyzer (RGA) port and a right angle vacuum valve port. A smooth cross-section transition and grilles over pumping and gauging ports are required to prevent disturbance to the circulating electron beam. Water cooling is required to remove the heat load from incident synchrotron light.

6.9.3 The bellows must allow a total stroke in the longitudinal direction of at least 20 mm, this can be by 10 mm compression and 10 mm expansion and ±2 mm in all the transverse directions, this transverse displacement must be available all along the 20 mm of the longitudinal stroke.

6.10 Type 5 (RF straight exit Bellows/taper assembly):

6.10.1 This type of assembly has the standard bellows structure and the structure is welded into the taper. The taper serves in changing the profile from the profile of the standard bellows into a circular profile which is needed at the exit of the RF cavity exit flange. The taper structure is made of stainless steel 316LN block or from 316LN deformed sheets, and the shape is machined in that block.

6.10.2 In addition, stainless steel (316LN) pumping port will be welded to the taper, also the gauging port, the residual gas analyzer (RGA) port and a right angle vacuum valve port. A smooth cross-section transition and grilles over pumping and gauging ports are required to prevent disturbance to the circulating electron beam.

6.10.3 The bellows must allow a total stroke in the longitudinal direction of at least 20mm, this can be by 10 mm compression and 10 mm expansion and ±2 mm in all the transverse directions, this



transverse displacement must be available all along the 20 mm of the longitudinal stroke.

6.11 Summary of the different types is shown in Table 2.

Table 2 summary of the bellows and tapers.

Type #

Describtion

Total longitudinal stroke (Compression/expansion)

(mm)

Transversal movement (mm)

profile Flanges

with taper

1 Standard bellows 20mm

(-10/+10) ± 2

Standard profile No

2 Entance/exit of

injection straight 20mm

(-10/+10) ± 2

Standard profile Yes

3 Entrance/exit of septum magnet

20mm (-10/+10)

± 5 Septum profile

No

4 RF straigth entrance

taper bellows assembly

20mm (-10/+10)

± 2

Bellows Standard

profile/copper tapers

Yes

5 RF straigth exit taper bellows

assembly

20mm (-10/+10)

± 2

Bellows Standard

profile/316LN tapers

Yes

7 General requirements.

7.1 The manufacturer should have an adequate and currently operational Quality Assurance Organisation like ISO 9000.

7.2 All equipment should use ISO metric Fasteners and Fittings.

7.3 The Manufacturer shall follow a quality assurance program compliant with ISO 9001 for the design, manufacture and testing of all systems and equipment provided by them

7.4 All equipment shall be manufactured in accordance with the best existing techniques and recognised good engineering practices available at the time of construction. The bellows and tapers shall be designed and constructed with an expected operational lifetime longer than 20 years. The bellows and tapers shall be designed and constructed for continuous use.

8 Materials

8.1 Construction materials are specified on the drawings accompanying this tender and, unless otherwise specified on the drawings, must generally be as follows:

Bellows Walls: stainless steel grade 316LN or 316L.

Sleeves, pumping ports, RF fingers and spring fingers: stainless steel grade 316 LN.

Bellows and tapers assemblies Flanges/blanking flanges, milled parts: AISI 316LN Electro-slag Re-melted (ESR) forgings.

Taper bodies: OFHC Copper.



Cooling water pipe fittings: Stainless steel AISI 316.

Bellows Cap: AISI 304.

The bidder may suggest other materials in addition to the material specified here in his bid.

8.2 Each piece of stainless steel or Copper must be identified. The manufacturer will propose an adequate system to ensure the traceability of each piece of material during manufacture. The manufacturer must have a storage area dedicated to the materials necessary for this contract.

8.3 The material used for the manufacturing of the bellows and tapers must have magnetic permeability of µrel < 1.005.

8.4 The stainless steel specification:

8.4.1 The production and remelting of the 316 LN steel material has to be done by electro-slag refined (ESR).

8.4.2 All forgings have to be forged in all axes in order to arrive to grain sizes of 3.5 according to ASTM E 112-88. After forging the forged parts are to be quenched in water. The material shall have a maximum of 1 inclusion of type A, B or C and a maximum of 1.5 inclusions of type D according to ASTM E 45-87. Every tenth forging (apart from the standard flanges) shall be tested by ultra-sound testing over the entire volume according to ASME V 23, SA-745. For acceptance, the acceptance criteria QL 1 and QA1 will be used. In case of non-compliance the follow-up has to be decided together with CELLS.

8.5 Where the CF flanges are manufactured in house, the manufacturer will send to CELLS a detailed drawing for each type of flange used together with the full material specification for CELLS approval. Where the CF flanges are purchased from another company CELLS approval at the proposed flange manufacturer must be sought prior to purchase.

8.5.1 Flanges and other pieces to be milled are to be manufactured from forgings. The structure of these forgings shall be homogeneous, free from porosity and fully austenitic with less than 1% ferrite. The presence of sigma phase of precipitated carbide is not permitted. The material must show a Brinell hardness of 170-300 in the area of the sealing edge of the Conflat flanges and the sealing surface of the Flat-seal flanges.

8.6 The OFHC copper specification:

8.6.1 The material designation is Cu OFE as per 150 431.OFE (Oxygen Free Electronic) as per standard ASTM B 224 - Material reference number C 101.

8.6.2 The raw material must be sufficient to provide the required final required dimension. The manufacturer will be responsible for machining the OFHC material to the final dimensions.

8.6.3 In order to guarantee the thermal properties, the material used for manufacture of these bellows and tapers assemblies must comply with standard ASTM F 68-82, Cu min: 99.99 %,

• Impurities present in copper Max content (ppm): Bi: 10, Cd: 1, Hg: 1, O2: 10, P: 3, Pb: 10, S: 18, Se: 10, Te:1, Zn: 1.

• The content of any other single impurity shall not exceed 25 ppm, with As, Bi, Mn, Sb, Se, Sn, Te, O2, ≤ 40 ppm.

• Total impurity (Ag, As, Bi, Cd, Fe, H, Hg, Mn, Ni, O2, P, Pt, S, SB, Se, Sn, To, Zn,... )≤ 100 ppm.



• The thermal conductance for the OFHC copper must be around 400 W/m.°C (at room temperature).

8.6.4 The Manufacturer need to provide material test certificates showing: the physical and chemical analysis, mechanical/thermal properties, ultrasonic examination, metallographic, Hydrogen embrittlement, inclusions, grain size, dimensional check…etc, and the standards being used for these analysis and tests. It is the responsibility of the manufacturer to guarantee the homogeneity of the raw material in order to detect any continuity defaults. The testing procedure will be discussed during the call for tender process.

8.6.5 If explosion-bonded material being used, then they must be 100% ultrasonically tested to prove that the bond is complete over the entire material interface.

8.7 For all materials forming part of the bellows/ tapers, the manufacturer shall supply CELLS with material certificates confirming the material specification, chemical analysis and room temperature mechanical properties.

8.8 The manufacturer shall supply CELLS with a test certificate giving the measured permeability for at least three samples widely spaced from each batch of material. The manufacturer shall demonstrate that the magnetic permeability of each completed bellows and taper is less than 1.01 in a magnetic field strength of 80000 A/m.

8.9 All the bellows and tapers assemblies and their flanges have to be bakeable at a temperature up to 250 °C, bake out at the factory shall be performed at 250 °C as part of the vacuum testing (see section 12.2.5).

8.10 Metal gaskets (copper OFHC silver plated) shall be used to seal all vacuum joints wherever is required (e.g. blanking flanges); all blanking flanges, gaskets, fasteners and washers are to be provided by the manufacturer.

8.11 Material for the bellows and tapers shall only be ordered when the manufacturer has submitted and obtained CELLS approval in writing.

8.12 Acceptance of the test certificates by CELLS shall not relieve the manufacturer of his responsibilities under the contract for ensuring that all material meet CELLS specification.

8.13 CELLS reserves the right to reject any material or component not completely fulfilling the conditions laid down in this specification.

9 Design

9.1 Manufacture of the bellows and tapers will be in accordance with the drawings supplied by CELLS in this specification or as agreed in writing with CELLS.

9.2 Although these drawings and associated data are available for use by the manufacturer, the manufacturer will be responsible for the adopted designs meeting the required performance criteria.

9.3 The drawings issued with this tender are assembly drawings. The manufacturer must submit the detailed assembly drawings and the manufacturing drawings based on the drawings of this specification for CELLS approval.

9.4 The regular supply of work in progress drawings will be required during the design process, rather than fully checked and approved drawings.



9.5 The geometrical tolerances on the drawings prescribe mainly shape and position tolerances to achieve a bellows and tapers. The manufacturer will define the tolerances to achieve on isolated components and sub-assemblies to meet the requested tolerances on the assembly according to his manufacturing processes, tooling and assembly sequence.

9.6 The space between the bellows interior and the electron beam and the emitted radiation fan is limited. Dimensions and tolerances are therefore critical where indicated on the drawings referred to in this specification.

9.7 The manufacturer must provide two full sets of paper copies for the detailed manufacturing drawings. In addition, the Manufacturer must provide two full sets of electronic copies of detail drawings on a CD or DVD, the preferred format for the drawings to be as DWG or DXF, non-scalable formats are not acceptable, for the 3D models the preferable format is IGS, STEP or VDA. The final format of the drawings and 3D models to be submitted electronically to be agreed with CELLS.

9.8 Drawing tolerances shall be interpreted in accordance with ISO/R 1101-2004. Tolerance values according to ISO 2768 unless specified in the drawings. Tolerances are subject to negotiation with CELLS.

9.9 The tolerances are specified in the drawings.

9.9.1 The general tolerance for the dimensions is according to the tolerance interval of IT10 and the general angular tolerance is ± 0.1°.

9.9.2 The surface finish of the flat seal flange after machining is N7 and the surface finish for the flat seal flanges after grinding is N4.

9.10 Deflection of the bellows and tapers walls both during manufacture and under load must be carefully limited. To this end, a finite element analysis (FEA) based on the manufacturing drawing of the bellows and tapers must be performed by the manufacturer. The actual deformation under vacuum load of the prototype bellows and taper at normal room temperature when the interior is under vacuum must be measured and reported in writing to CELLS, the maximum deflection must be proved by analysis and acceptance testing of the prototype.

9.11 The manufacturer shall be responsible for the detailed specification of the welding/brazing procedures and plan and shall make such test pieces and trials as are necessary and record the details in the welding procedure specification.

9.12 The manufacturer must consider in his manufacturing drawings and in the manufacturing the space to be equipped by the Flat flange seal, as CELLS consider a full length of the bellows without this gap.

9.13 In general the bellows will be installed in the expansion position (in order to get 20 mm total stroke during the in-situ bakeout of the vacuum straights) and for maximum reliability, it is expected that the bellows will operate at all times in this state – longer than the bellows free length. The bidder must consider this issue in his design.

9.14 It is anticipated that one design review meeting will be required to approve the proposed fabrication methods.

9.15 Where deviations from the information or dimensions contained in the manufacturing drawings is authorised by CELLS during manufacture, the Manufacturer must note the changes. A final



set of ‘as-built’ drawings must be provided in the same manner as for the manufacturing drawings described above.

9.15.1 The body of the taper is manufactured from OFHC copper block with brazed on vacuum flanges, bellows structure and fittings. Cooling is by deionised water flowing through water channels.

9.15.2 If the manufacturer offers an alternative design they must validate their design by conducting a Finite Element Analysis to confirm that it satisfies the required performance criteria.

10 Manufacture

10.1 General

10.1.1 Manufacture of bellows and tapers and tooling shall commence only after the manufacturer has submitted and obtained CELLS approval in writing of the following documents:

a) The start up meeting:

I. Detailed time schedule showing the duration of all major activities such as the procurement of materials, manufacture of tools, manufacture of components, fabrication, cleaning, testing, inspection and delivery,

II. The overall quality schedule listing quality control procedures at all stages of procurement, manufacture, assembly and testing.

III. The Inspection Points Plan (IPP).

IV. The manufacturer must prepare in the start up meeting a list of the items and raw materials which he expect to have long delivery time and he would like to have CELLS approval for these items in an early stage.

b) Design review meeting:

I. The detailed manufacturing process documentation including: the welders’ certificates, QAP, the IPP and the welding procedure specifications (WPS).

II. The detail manufacturing drawings for the component parts of the bellows and tapers,

III. The detail and assembly drawing for tooling,

IV. The detailed welding/brazing plan for the tapers/bellows assemblies.

10.1.2 CELLS will give approval or otherwise comment on documents submitted for approval within two weeks after receipt. The manufacturer should allow sufficient time in his schedule for review of documents.

10.1.3 All vacuum joints shall be of metal type sealed; the use of elastomer seals is prohibited.

10.1.4 The plastic deformation of any part of the bellows must never reached, the manufacturer must take attention that during the detailed design, manufacturing and testing, that he did not exceed the yield stress of any part of the assembly, this is valid at room temperature, during bakeout and during normal operation.

10.2 Cleanliness



10.2.1 For the bellows and tapers to be compatible with the ultra high vacuum requirements of the modern synchrotron light sources, a high degree of cleanliness will be necessary at all stages of production to guarantee an acceptable low outgassing rate and weld integrity.

10.2.2 All machining work is to be carefully controlled to ensure that no foreign material is embedded in the surface of the material.

10.2.3 All mechanical cold working operations must exclude the use of heavy organic lubricants since these can be retained to some extend in the surfaces after the process.

10.2.4 The plate material is to be cleaned before any cutting or forming operation commences. It will be sufficient to swab with acetone or similar solvent. If a guillotine or press is to be used, the blades should also be cleaned with this solvent.

10.2.5 When the plate material or any other component forming part of or within the vacuum envelope has been cut, formed, finally machined and cleaned, the vacuum surfaces must never be in contact with oily or greasy objects (including bare hands leaving finger prints), unless a thorough cleaning operation is scheduled to follow immediately afterwards.

10.2.6 Identification of components (such as with their drawing numbers) should be by engraving on non vacuum surfaces. Components which will be immersed in vacuum should be wrapped in aluminium foil and kept separately in polythene bags. The bags must be suitably labelled when the components are too small to be inscribed with their drawing numbers.

10.2.7 For all welding/brazing or assembling processes, a clean room shall be provided with partition walls and a clean washable floor. Covers shall be provided to keep the room dust free. The room shall be kept free from carbon steel contamination. Class 10000 clean room conditions, to U. S. Federal standard 209a would be preferred.

10.2.8 Final machining after welding of the bellows and tapers will be carried out in an area protected by, at the minimum, a plastic sheet enclosure.

10.2.9 All machining coolants shall be water soluble and sulphur free.

10.2.10 Where stainless steel fasteners are used in-vacuum, and mate with stainless steel threaded components, the threads of the fasteners must be silver plated. A minimum layer thickness of 5µm must be achieved; the maximum layer thickness must be limited to a thickness that will not cause interference between the mating threads. All threaded fasteners located in blind holes must have a central, coaxial vent hole. UHV flange bolts must be silver plated; no additional thread lubricant is permitted.

10.3 Welding/vacuum brazing.

10.3.1 The bellows and tapers assemblies must be manufactured so as to have extremely low leak (the leak rate must be lower than 1.10-10 mbar.l/s) and outgassing rate and, due to the potential inconvenience of a failure in service, exhibit a high degree of reliability. The bellows and tapers must be delivered to meet fixed assembly and installation programmes and therefore delays due to unforeseen problems in manufacture must be avoided. These requirements mean that the welding and brazing processes must be correctly determined and then controlled during production.

10.3.2 Welding and Brazing Plan will be left to the manufacturer’s discretion, but must contain all the necessary information in order that the correct controls are exercised. This also enables clear identification of the welds, weld type and WPSs used.



10.3.3 A weld plan must be produced together with the welding procedure specifications (WPS); the manufacturer must qualify this specification by the welding of test specimens and record the welding data and results. The test results must be documented in (the procedure qualification record PQR). CELLS retain the right to request weld samples and the WPS as well as the PQR at this stage before design review approval can be given. The WPS must be according to ISO standards: ISO 15609-3, ISO 15609-1

10.3.4 The welding/brazing plan must contain all necessary information to qualify the weld to be performed for the bellows and tapers assemblies.

10.3.5 Welding/brazing shall not induce contamination of the bellows or the tapers assemblies.

10.3.6 All longitudinal welds (if any) shall be continuous and performed by electron beam welding; other welds shall be performed by TIG welding.

10.3.7 All parts to be welded must be cleaned prior to welding.

10.3.8 To prevent undue oxidation of vacuum surfaces, all welds are to be backed by an inert gas purge to be maintained until the part has cooled down to 60°C.

10.3.9 All welds shall be internal. Where vacuum sealing welds made externally (with CELLS approval) must have full penetration leaving a smooth surface on the vacuum inside (d< 0.3 mm). Any later brushing or other finish work on the welds is prohibited.

10.3.10 Inspection and testing of the welds are to be according with ISO standards: ISO 15614-1, ISO 15614-11.

10.3.11 The quality of the weld must be according to the ISO standards: ISO 13919-1, ISO 5817, quality level B: Stringent.

10.3.12 The manufacturer must qualify the welders for each process according to ISO standards: 9606-1.

10.3.13 If, at any stage of manufacture, a weld is shown to be defective, no rectification shall be done without the prior written approval of CELLS.

10.3.14 The use of dye penetrant testing is strictly prohibited.

10.3.15 Filler material shall not be used.

10.3.16 The vacuum brazing has to be executed under vacuum. During the pre-treatment and with the selection of the vacuum brazing alloy it is to be made certain that the magnetic permeability (µr) 1.01 of the bellows and tapers assemblies is not exceeded.

10.3.17 The vacuum brazing have to take place in such a way that no breaks, inclusions, caverns etc. in the soldering zone occur, which work as virtual leakages.

10.3.18 The Manufacturer is responsible for the design of the vacuum brazing interface. He shall define all the necessary clearances and special grooves required for the vacuum brazing.

10.3.19 The brazing quality shall be tested on a sample assembly.

10.3.20 The following acceptance tests shall be conducted on the brazing sample described above:

* Visual inspection,

* Ultrasonic test for the brazing,



* Micro-examination (4 sections).

The testing procedure will be discussed during the call for tender process.

10.3.21 Acceptance tests on fabrication braze shall be made as follows:

* Visual inspection.

* Ultrasonic test for the brazing (100%).

The testing procedure will be discussed during the call for tender process.

10.3.22 In order to fulfil the ultra high vacuum requirements, the quality of the brazing is of prime importance. The brazing process shall therefore guarantee a complete homogeneous braze, without any trapped volume.

10.3.23 The Manufacturer shall provide to CELLS with dummy samples proving the success of the vacuum brazing process or a recent experimental proof (less than a year) respectful of the CELLS requirements. The specifications of this dummy sample and the tests CELLS will undertake will be discuss before the contract has been placed.

11 Cleaning

11.1 Standard UHV practices must be adopted through all stages of the manufacturing, handling, assembly…etc of the bellows and the tapers assemblies, to guarantee the highest level of cleanliness. Document END-VCGS-ES-0001 describes a general procedure and UHV practice to be followed for handling UHV components and assemblies.

11.2 The basic requirement is to remove surface contamination such as grease, tenacious oil, etc. without etching the surface. Therefore, generally, the cleaning process should not include an acid etch or treatment.

11.3 The following is a general procedure for cleaning the stainless steel parts and assemblies:

Wash with hot (80 °C) pressurized water mixed with mild detergent, then rinsed with hot pressurised water to remove the traces of the detergent, then to be dried with dry hot air.

To immerse the assembly in an ultrasonic bath of hot solvent for 15 min. then to be exposed to the vapour of the solvent, then cleaned with hot (80 °C) pressurised demineralised water.

The assembly to be immersed in an ultrasonic bath (5 min.) of alkaline degreaser and then cleaned immediately with hot (80 °C) pressurised demineralised water.

The assembly to be dried with dry clean hot air.

11.4 The following sequence is a general procedure for cleaning copper and copper alloys:

Perchlorethylene vapour at 120°C.

Alkaline bath (sodium carbonate +...) at 80°C.

Rinsing in industrial water.

Pickling in a solution containing sulfamic acid and oxygenated water or equivalent products.



Rinsing in industrial water.

Rinsing in deionised water at 80°C.

Rinsing in alcohol.

Drying in air at 110°C.

Packing in Al foil then in polythene bag filled with dry nitrogen.

11.5 The bidder is requested to submit in his bid a detailed description of the proposed cleaning process for copper and stainless steel (with the cleaning agents to be used and the sequence) with the tender and at which stages he will perform the cleaning; attention needs to be taken as some degreasers which may leave stains on the bellows or the tapers surfaces.

11.6 A written approval for the cleaning procedure must be submitted from CELLS before being used for cleaning the bellows and the tapers assemblies during the design review meeting.

11.7 After cleaning the vacuum surfaces must be protected against accidental contamination.

12 Inspection and testing

12.1 General

12.1.1 The manufacturer shall submit a detailed quality schedule specifying the intermediate tests and checks that will be made during the whole manufacturing, testing and assembly procedure. The manufacturer shall provide all the equipment, facilities, funds and personnel for carrying out the tests. For each test mentioned below, a procedure must be submitted.

12.1.2 The manufacturer shall inspect and vacuum test bellows and tapers assemblies to ensure that they conform to this specification. He shall provide all equipment and measuring instruments necessary to carry out these tests and inspections.

12.1.3 The manufacturer shall inform CELLS at least one week in advance of factory acceptance tests and inspections to allow CELLS to witness the tests.

12.1.4 All components, equipments, tools, gauges, fittings… etc used to carry out the tests must be according to UHV standards, which will guarantee the cleanliness and performance of the final product according to this specification.

12.1.5 All bellows and tapers assemblies must be labelled and given a serial number for reference inscribed at a straight part of the bellows and tapers assemblies close to the flange at the upper outer wall. The marking process must be carried out by dry scribers vibrating engravers or laser engravers. This serial number will be used to identify the bellows and tapers assemblies during the testing procedure and results recording.

12.1.6 Acceptance of any component will only be given when it has met the full requirements of this specification. In the event of a test failure, the manufacturer shall document the failure and submit a proposal for correcting any fault or failures. Written approval from CELLS shall be required before any corrective action is taken.

12.1.7 CELLS by its authorised representatives shall have free access to the manufacturer’s works and the premises of any subcontractor for the purpose of inspection and progress during all stages of manufacture, testing, assembly…etc.



12.1.8 A written progress report shall be sent to CELLS every month after the contract has been placed.

12.1.9 The manufacturer shall supply CELLS with a quality assurance document for each item delivered, certifying that it conforms to this specification and listing the results of tests and inspections, and include it in the production file of the bellows and tapers assemblies.

12.1.10 The bellows and tapers assemblies shall only be dispatched to CELLS after the manufacturer has been notified in writing that the factory acceptance tests of that bellows or tapers assemblies have been accepted by CELLS.

12.1.11 The final decision to accept or reject a bellows or taper assembly will be made by CELLS after the delivery. Before making its decision CELLS may, at its discretion, repeat any of the tests and inspections detailed in this specification. The final acceptance of a bellows or taper assembly will be made at CELLS site within one month after delivery. If the final acceptance test is accepted, the two years guarantee period starts.

12.1.12 The tests at the factory and on-site together must establish that all items of the manufactured equipment completely meet the performance requirements as described in this specification. CELLS reserves the right to require additional or more extensive tests to be conducted in the event of marginal design or performance.

12.2 Inspection and testing sequence (FAT)

The sequence of operations for the factory acceptance test (FAT) on each completed and cleaned bellows and tapers assemblies shall be as follows:

1) Visual internal and external inspection.

2) Dimensional and tolerances check. 3) Hydraulic testing for the cooling system for the cooled tapers.

4) Movement tests. 5) Vacuum leak test and desorption test after a bakeout of the bellows and tapers

assemblies to 250 °C. A He-leakage rate of < 1·10-10 mbar.l/sec and a specific desorption rate of < 1·10-12 mbar.l/(sec.cm2) is to be demonstrated. Also partial pressure measurement.

6) Visual inspection of the sealing surfaces of flanges immediately prior to protective packing for dispatch.

12.2.1 Visual inspection

12.2.1.1 The manufacturer shall visually inspect the bellows and tapers assemblies internally and externally to ensure that there are no defects which might render them unfit for service. Particular attention shall be paid to the form and state of the vacuum surfaces of the bellows and tapers assemblies, the quality of welded joints and the sealing surfaces of flanges. Inner surfaces will be controlled in order to detect any surface defect, e.g. incrustation, grooves, traces of pollution, dust…etc.

12.2.1.2 The quality of the welds/braze will be controlled in particular the size of the shape defect generated by the weld/braze to detect any defect which might render the bellows and tapers assemblies unfit for service.

12.2.1.3 The sealing flanges shall be inspected; any defect on the knife edge of the flanges is a cause of rejection of the bellows and tapers assemblies.

12.2.1.4 Special attention need to be taken for the cooling channels for the tapers, to guarantee that there



is no blockage or particles inside.

12.2.2 Dimensional check.

12.2.2.1 Depending on the equipment at his disposal the manufacturer is invited to describe in his bid the method proposed by him to check all dimensions and tolerances indicated on the corresponding drawings. A quality assurance document listing all measurements against the tolerances specified in the drawing shall be established and transferred to CELLS. Mechanical measurements to ensure tolerances are met, should be performed in a temperature-controlled environment at 23 °C ± 2°C.

12.2.2.2 Where geometric tolerances are requested and are on the agreed inspection drawings, these must be measured and recorded. If any of the specified dimensions on the manufacturing or inspection drawings are not achieved, no rectification is to be made without prior approval from CELLS.

12.2.2.3 The final dimensional check shall be done after vacuum testing (which includes the bake out process), in order to control an eventual stress relaxation during the bake out. The final dimensional check must be within the tolerances of this specification.

12.2.2.4 To control the deformation of the bellows and tapers assemblies under vacuum, the manufacturer must measure the maximum deformation and report it for each bellows and tapers assembly, this test will be performed at room temperature and after the bake out of the bellows and tapers assemblies to 250 °C for 24 hours and under UHV, the value of the maximum deformation must be according to section 9 of this specifications.

12.2.3 Hydraulic tests

12.2.3.1 The hydraulic cooling circuits shall be tested with high pressure circulating water. The water cooling circuits shall be filled with water, pressurised to 16 bars and sealed. The pressure shall be recorded at intervals of 5 minutes for a period of 30 minutes. For acceptance there must be no evidence of water leakage.

12.2.3.2 The measurement of the flow rate at the exit of each circuit and the pressure drop must be performed, these must be carried out using a clean, filtered (10µm) water supply. The values of the mass flow and the pressure drop of each circuit will be given to the manufacturer during the design review meeting. A record of the valve settings and flow rates achieved must be provided.

12.2.4 Movements’ tests.

12.2.4.1 The ability of the internal features to move through the required normal operating range and maintain electrical continuity through each ‘finger’ and on subsequent return to the centre position must be tested.

12.2.4.2 The ability of the edge-welded bellows to remain undamaged and functional after the extremes of the maximum design movements must also be tested. Also the maximum movement for the internal assemblies to remain undamaged and functional after return to the normal operating range must also be tested.

12.2.4.3 Full continuity through every contact face must be tested without manual adjustment or intervention (manufacturer must specify the testing procedure to be followed); this must be maintained after the tests have been completed.

12.2.4.4 For the bellows prototype (type 1) cycling tests must be performed, the test for their ability to remain leak tight for the appropriate number of operating cycles must be tested. Using a suitable jig with an actuator, the bellows must be set at their neutral position and then axially cycled between 10mm compression and the neutral position for 100 cycles, then between 5mm



compression and 5mm expansion for 10,000 cycles. The cycle rate in operation is very slow; there is no need to test cycle at a rate greater than 0.5Hz.

12.2.4.5 Testing for the transverse displacement must be performed and the tests must guarantee that this transversal movement is available all along the 20 mm of the longitudinal stroke.

12.2.5 Vacuum testing

Depending on the equipment at his disposal, the manufacturer is invited to describe in his bid the method and means proposed by him to measure the leak tightness and the desorption rate of the completed bellows and tapers assemblies.

12.2.5.1 The leak testing:

Will be carried out on the completed bellows and tapers assemblies as the first vacuum test according to UHV practice. The manufacturer is invited to perform leak tests at any stage of the production. The leak test must be carried out by spraying all the surfaces, welds/brazing, and the sealing flanges with helium.

The leak detection shall be done in a clean area, the bellows and tapers assemblies shall be put on a clean support or table, the contact surface between the bellows and tapers assemblies and the support must be covered with a clean aluminium foil.

The leak detection shall be done with a suitable helium leak detector, the pumping system of the leak detector must be composed of dry (oil free) pumps; the leak detector must not include any contamination to the tested bellows and tapers assemblies. No vacuum grease shall be used to guarantee the leak tightness of the connection of the bellows and tapers assemblies on the leak detector.

The leak tightness of the completed bellows and tapers assemblies has to be below 1·10-10 mbar.l/sec (the measurement must include the background). The upper limit of the leak rate has to be documented for each bellows and taper assembly in the quality assurance document.

The leak test need to be performed before bakeout, during bakeout (with leak rate of 1·10-9 mbar.l/sec during bakeout) and after bakeout.

Leak tightness of the cooling tubes shall also be checked by injecting helium at a 10 bar pressure. The maximum leak rate recorded for each chamber has to be documented in the quality assurance document.

12.2.5.2 The desorption rate:

The desorption rate of the completed and cleaned bellows and taper assembly has to be below 1·10-12 mbar.l/(sec.cm2) after cooling down to room temperatures from a 24 h bakeout at 250 °C. The bellows and taper assembly must be pumped down with a dry (oil free) pumps. After bakeout, the desorption rate is measured when the bellows and taper assembly is pumped down. Precautions must also be taken to avoid oxidation of the internal surfaces of copper water pipes and absorbers and to limit oxidation of external copper surfaces.

12.2.5.3 Total and partial pressure (residual gas analysis from 1-200 AMU) must be performed after cooling down to room temperature from a 24h bake out at 250 °C. The residual gas analysis of each bellows and taper assembly must show that hydrocarbons contamination defined by the total partial pressure of all masses greater than 28 (with exception of mass 44) is less than 1.0% of the total pressure. The total pressure measurement after the bake out must be in the low 10-10 mbar range.



12.2.6 All roughing pumps used at anytime in the testing process must be oil fee.

12.3 These tests must be performed, documented and submitted to CELLS for each bellows and taper assembly.

12.4 If additional cleaning is required to allow the equipment to meet the acceptance standards then the Manufacturer must undertake to pay for all costs associated with additional cleaning carried out by CELLS or subcontractor.

12.5 The Final Acceptance Tests will be carried out by CELLS and will take place within 3 months from receipt of delivery of each bellows and taper assembly.

12.6 The final acceptance tests will include any or all of the tests specified in the preceding sections of this specification, under the vacuum conditions described above.

13 Documentation

13.1 The manufacturer shall provide 2 (two) sets of paper copies of the following documentation as soon as it becomes available and in accordance with the schedule presented:

o Schedule o Construction drawings

o Travellers of control executed at each step of the manufacturing

o A manufacturing booklet for each piece of equipment o The Manufacturer must provide two full sets of paper and electronic copies for the detailed

assembly and manufacturing drawings as described in 9.7 of this technical specification.

All the technical documents delivered by the manufacturer shall be in English.

13.2 Guarantee

The manufacturer shall guarantee the bellows and taper assemblies against failure due to either faulty components or faulty manufacture for the period indicated in the Administrative Terms and Conditions after the bellows and taper assemblies have been accepted by CELLS. This guarantee shall not be invalidated by the opening of the components for visual examination and diagnostic tests. It is warranted that no modifications will be undertaken without the written permission of the manufacturer.

14 Protection and transport.

14.1 The bellows and taper assemblies are to be supplied ultra-high vacuum cleaned and conditioned, under dry high-purity nitrogen and in a state ready for immediate installation into the CELLS storage ring.

14.2 All bellows and taper assemblies must be labelled and given a serial number for reference inscribed close to the flange. The marking process must be carried out by dry scribers vibrating engravers or laser engravers.

14.3 The manufacturer will include in his tender the transport from the factory: • to the site where CELLS may perform some tests on the bellows and taper assemblies. This place will not be necessarily in the CELLS site, but within the distance to CELLS. • or to the storage area that CELLS will indicate. This storage area will be at CELLS site or nearby.



14.4 Shock detectors shall be fixed on the containers at visible places.

14.5 The bellows and taper assemblies will be delivered by in three batches, the type of bellows and taper assemblies in each batch which will be defined together with CELLS in accordance with the installation schedule of the storage ring equipment.

14.6 All packages must be supplied with lifting hooks and be compatible with fork-lift trucks or crane. The manufacturer will be responsible for providing special purpose lifting equipment if necessary.

14.7 Any water in cooling circuits must be completely removed and the circuits dried out before shipment.

14.8 The bellows and taper assemblies must be supplied in appropriate packaging and with all the appropriate closing for the flanges (to be agreed with CELLS). For storage and shipping each bellows and taper assemblies must be backed filled with dry pure nitrogen at a slightly above atmospheric pressure, according to the standards of UHV practice.

14.9 The bellows must be secured using the cover of the bellows in order to block any possible movement of the bellows or the RF fingers during transportation.

14.10 Details of the shipment procedures and methods must be approved by CELLS before any shipments are made.

14.11 The bellows and taper assemblies shall be properly supported and contained to prevent damage and contamination during transport. Packing-cases shall be non-returnable and of a stout and robust nature suitable for lifting and transportation without damage using a forklift truck or crane. The manufacturer must supply to CELLS the conditions of the package and the lifting tools needed and procedure, which guarantees safe unloading at CELLS site.

14.12 Where air transport is to be used the packing and protection against contamination shall be suitable for use in an un-pressurized cargo hold.

14.13 The following is to be displayed clearly on the outside of the container:

1) Shipping address as specified within the contract.

2) CELLS contract number. 3) Manufacturer name and address.

4) The components contained within the container. 5) Labels like “FRAGILE”, “TOP”… are required.

6) The weight of the loaded container.

7) Support points for transport and lifting.

15 List of drawings.

1) SR-A-VC-BLW1-01-01.

2) SR-A-VC-BLW2-01-01 3) SR-A-VC-BLW3-01-01.

4) SR-A-VC-4RF1-01-01.

5) SR-A-VC-4RF3-01-01

technical specification for alba bellows and tapers · diagnostics or the injection components),...

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