**[National Spherical Torus Experiment]{.underline}**

**NSTX**

**SPECIFICATION**

**FOR**

**TF COIL CENTER STACK BUNDLE**

**NSTX-SPEC-13-039**

**Revision 0**

**DATED:** April 12, 1997

PREPARED
BY:\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_

J.H. Chrzanowski

REVIEWED
BY:\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_

J.M. Spitzer

NSTX Tokamak Systems WBS Manager

REVIEWED
BY:\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_

Charles Neumeyer

NSTX Engineering Manager

APPROVED
BY:\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_

P.J. Heitzenroeder

Deputy NSTX Project Manager

**PRINCETON UNIVERSITY**

**PLASMA PHYSICS LABORATORY**

**(PPPL)**

**P.O. BOX 451**

**PRINCETON, N.J. 08543**

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1.0 SCOPE 5

> 2.0 APPLICABLE DOCUMENTS 5
>
> 2.1 DRAWINGS 5
>
> 2.2 STANDARDS AND CODES 5
>
> 2.3 GENERAL STATEMENT 6
>
> 3.0 REQUIREMENTS 6
>
> 3.1 EQUIPMENT DEFINITION 6
>
> 3.1.1 General Design Features 6
>
> 3.1.2 Materials 6
>
> 3.1.2.1 Copper Conductor 6
>
> 3.1.2.2 Insulation System 7
>
> 3.1.2.3 Degreasing/Cleaning Solvent 8
>
> 3.1.2.4 Copper Primer 8
>
> 3.1.2.5 Grit Blasting Materials 8
>
> 3.1.2.6 TF Coil Core 8
>
> 3.1.2.7 Conductor Coolant Tube 9
>
> 3.1.2.8 Soft Solder 9
>
> 3.1.2.9 End Caps 9
>
> 3.1.2.10 Press Mold Release Agent 9
>
> 3.1.2.11 Silicone Adhesive Sealer 9
>
> 3.2 COIL FABRICATION 9
>
> 3.2.1 Copper Conductor Delivery 9
>
> 3.2.2 Conductor Cleaning 9
>
> 3.2.3 Material Protection 10
>
> 3.2.4 Conductor Inspection 10
>
> 3.2.5 Coolant Tube Installation 10
>
> 3.2.6 Flow and Hydrostatic Tests 10
>
> 3.2.7 Conductor Grit Blasting 10
>
> 3.2.8 Cleaning After Grit Blasting 11
>
> 3.2.9 Primer Application 11
>
> 3.2.10 Turn Insulation 11
>
> 3.2.11 Lead Area Turn Insulation 11
>
> 3.2.12 Assembly of TF Coil Conductors 11
>
> 3.2.13 Quadrant Tests-Pre-Cure 12
>
> 3.2.14 Quadrant Cure 12
>
> 3.2.15 Quadrant Pre-Acceptance Tests 12
>
> 3.2.16 Assembly of TF Centerstack Quadrants 12
>
> 3.2.17 Coil Bundle Press-Molding 13
>
> 3.2.18 Ground Insulation 13
>
> 3.2.19 Machining of Ground Insulation 14
>
> 3.2.20 Post-Machining 14
>
> 3.2.21 Evaluation of Finished Surfaces 14
>
> 3.2.22 End Cap Installation 14
>
> 4.0 TEST REQUIREMENTS 14
>
> 4.1 RECEIVING INSPECTION-TF CONDUCTOR 14
>
> 4.1.1 Dimensional Measurements/Inspections 14
>
> 4.1.2 Flow and Pressure Tests: 15
>
> 4.2 IN-PROCESS TESTING 15
>
> 4.2.1 Tests After Quadrant Assembly and Prior to Oven Cure 15
>
> 4.2.2 Tests After Quadrant Cure 15
>
> 4.3 FINAL ACCEPTANCE TESTS 15
>
> 4.3.1 Inspection 15
>
> 4.3.2 Flow/Pressure Tests 16
>
> 4.3.3 Final Electrical Tests 15
>
> 5.0 QUALITY ASSURANCE REQUIREMENTS 16
>
> 5.1 INSPECTION/ SURVEILLANCE/AUDIT BY PRINCETON 16
>
> 5.2 SUBCONTRACTOR'S RESPONSIBILITY FOR CONFORMANCE 17
>
> 5.3 QUALITY ASSURANCE PLAN 17
>
> 5.4 MANUFACTURING, INSPECTION AND TEST PLAN 17
>
> 5.5 INSPECTION AND TEST PROCEDURES 17
>
> 5.6 DOCUMENT TRACEABILITY AND RECORDS 17
>
> 5.7 EQUIPMENT/MATERIAL IDENTIFICATION AND STATUS 17
>
> 5.8 DOCUMENT REVIEW, APPROVAL AND CONTROL 18
>
> 5.9 CALIBRATION OF TEST AND MEASURING EQUIPMENT 18
>
> 5.10 RELEASE FOR SHIPMENT FORM 18
>
> 5.11 PROCESS HISTORY 18
>
> 5.11.1 Certificate Of Compliance (C of C) 18
>
> 5.11.2 Material Certifications 18
>
> 5.11.3 Inspection/Test Documents 19
>
> 5.11.4 Inspection Reports 19
>
> 5.11.5 Test Reports 19
>
> 5.12 PPPL RECEIVING/INSPECTION 19
>
> 6.0 DOCUMENTATION REQUIREMENTS 19
>
> 6.1 PROPOSAL TECHNICAL DOCUMENTATION 19
>
> 6.2 DOCUMENTATION AFTER CONTRACT AWARD AND PRIOR
>
> TO FABRICATION 19
>
> 6.3 DOCUMENTATION PRIOR TO SHIPMENT 20
>
> 7.0 SHIPPING STORAGE AND HANDLING 20
>
> 8.0 DELIVERABLES 20
>
> APPENDIX I TF Center Stack Bundle drawings 21
>
> APPENDIX II Coil Bundle/ Insulation Data 22

**1.0 [SCOPE]{.underline}**

> a\. This specification defines the manufacturing requirements for the
> National Spherical Torus Experiment (NSTX) Toroidal Field (TF) Center
> Stack Bundle. The Center Stack Bundle contains the inner legs of the
> TF coil system.
>
> b\. Subcontractor shall furnish all material, labor and facilities
> necessary to complete the work as defined in the contract documents
> subject to the qualifications, conditions, and exceptions noted
> herein.

**2.0 [APPLICABLE DOCUMENTS]{.underline}**

**[2.1]{.underline} [DRAWINGS]{.underline}**

> a\. Drawings identified in Appendix I describe the equipment to be
> provided under this specification.
>
> b\. Dimensions in drawings and specifications refer to conditions at
> room temperature (20° C/ 68° F).

**2.2 STANDARDS AND CODES**

> a\. Materials and manufacturing/test methods used in fabrication of
> the equipment covered by this specification shall comply with the
> latest revision, in effect at date of purchase order, of the following
> currently approved applicable regulations, safety codes,
> specifications and standards, including applicable technical
> definitions as acknowledged and accepted in industry.
>
> **[ASTM American Society for Testing and Materials]{.underline}**
>
> ASTM B32-Sn95
>
> **[CDA Copper Development Association]{.underline}**
>
> CDA Standards Handbook, Part 2 (Wrought Products) Alloy Data, CDA
> Alloy No. 10700

**[Conductor]{.underline}**

> Per PPPL specification ***NSTX-SPEC-13-036*** "TF Inner Bundle Copper
> Conductor".
>
> **[IEEE- Institute of Electrical and Electronic
> Engineers]{.underline}**
>
> IEEE #4, Techniques for Dielectric Tests
>
> **[NEMA-National Electrical Manufacturers Association]{.underline}**
>
> Grades and specifications for materials developed for the electric and
> electronics industries.
>
> b\. The above Standards and Codes set forth the minimum requirements.
> They may be exceeded by Subcontractor with written permission from
> PPPL, if in Subcontractor's judgment, superior or more economical
> designs or materials are available for successful and continuous
> operations, as required by the specification.

**2.3** **GENERAL STATEMENT**

Subcontractor agrees, represents and warrants that all services,
designs, equipment and material sold or otherwise provided to PPPL by
Subcontractor comply with applicable, Federal, State and Local laws,
regulations and codes, and all applicable specifications and standards
including those specified above, in each case as in effect at the date
or order placement. Subcontractor shall provide PPPL with a Certificate
of Compliance identifying the codes, standards and regulations complied
with, and any exceptions taken, in the design and fabrication of
deliverable items.

**[3.0 REQUIREMENTS]{.underline}**

**3.1 EQUIPMENT DEFINITION**

> 3.1.1 **[General Design Features]{.underline}**
>
> a\. Dimensional characteristics of the coils are given in the drawings
> identified in Appendix I.
>
> b\. Coil bundle insulation builds are given in Appendix II.
>
> c\. Tolerances are indicated on the drawings identified in Appendix I.
> Strict adherence to these dimensions is critical to the assembly and
> performance of the subject equipment.
>
> 3.1.2 **[Materials]{.underline}**
>
> 3.1.2.1 [Copper Conductor]{.underline}
>
> a\. The conductor will be CDA alloy 10700, silver bearing copper, (25
> troy ounces per ton 0.085% min.) with Yield Strength of 30-36 ksi
> (0.5% elongation) and Ultimate Tensile Strength 38 ksi minimum (15%
> elongation).
>
> b\. The copper conductor will be provided by PPPL. All generated scrap
> and excess material furnished by PPPL shall remain the property of
> PPPL. A material inventory, defining quality, condition and quantity
> of excess material shall be maintained and submitted at the conclusion
> of the job. PPPL shall instruct Subcontractor as to the disposition of
> excess materials at PPPL's expense.
>
> c\. The conductors will be supplied by PPPL to the Subcontractor with
> the electrical end connections and coolant tube grooves already
> machined in each conductor, and with inserts (\"Keenserts\") already
> installed in the bolt holes.
>
> 3.1.2.2 [Insulation System]{.underline}
>
> a\. The turn insulation shall consist of \"CTD-112P\" pre-impregnated
> (B-stage) epoxy-glass tape applied in half-lapped layers.
>
> b\. All of the CTD-112P tape, sheet and roving shall be provided by
> PPPL. All remaining insulating materials required to manufacture the
> TF bundle shall be provided by the Subcontractor. All excess material
> furnished by PPPL shall remain the property of PPPL. A material
> inventory, defining quality, condition and quantity of excess material
> shall be maintained and submitted at the conclusion of the job. PPPL
> shall instruct Subcontractor as to the disposition of excess materials
> at PPPL's expense.
>
> c\. The boundary layer between the inner and outer conductors shall
> consist of a layer of CTD-112 pre-impregnated epoxy-glass sheet. An
> additional layer of Kapton polyimide film in sheet form without
> adhesive backing shall be installed between the inner and outer
> conductors in the vicinity of the outer conductor electrical joints.
>
> d\. The ground insulation shall be "Scotchply" Type No.1003
> pre-impregnated (B-stage) epoxy-glass tape applied in half-lapped
> layers to the outside diameter of the TF bundle. The final radial
> build after final cure and machining shall be in accordance with the
> drawings identified in Appendix I.
>
> e\. The barrier between quadrants shall consist of pre-impregnated
> epoxy-glass sheets (provided by PPPL) with the same resin as the
> CTD-112P tape. This insulation shall be applied in sheet form with no
> splices.
>
> f\. Any voids between turns or near lead areas will be filled with
> pre-impregnated glass rope (provided by PPPL) with the same resin as
> the CTD-112P tape.
>
> g\. The dielectric shields in the joint areas shall be Kapton
> polyimide film in sheet form without adhesive backing.
>
> h\. Details concerning the insulating materials are as follows:
>
> **[CTD-112P Pre-impregnated Tape and Sheet]{.underline}**
>
> Resin Type: TGDM epoxy, aromatic amine cure agent
>
> Glass tape: S-2 ( satin weave) std. silane finish
>
> Temperature Class: 180° C
>
> Nominal Thk.: 0.006 in. (0.152 mm.) tape
>
> 0.022 in. (0.508 mm) sheet
>
> Nominal Width: 1.0 in. tape, or sheet form
>
> **[Braided Glass Rope]{.underline} (Roving)**
>
> Glass: S-2 glass
>
> Resin Type: TGDM epoxy, aromatic amine cure agent
>
> Temperature Class: 180° C
>
> Nominal Diameter: 0.125, 0.25 and 0.375 inch
>
> **[Kapton Sheet- "Dupont" product]{.underline}**
>
> Type H polyimide film
>
> Nominal Thickness: 0.004 in. (0.102 mm)
>
> Nominal width: Sheet form
>
> Temperature Class: 180° C
>
> **[3M-Scotchply #1003- Groundwall]{.underline}**
>
> Epoxy-glass pre-preg insulation in tape form
>
> Glass Tape: Type "K" filament
>
> Nominal Thickness: .010 in. (0.254 mm)
>
> Nominal width: 2.0 in. tape
>
> 3.1.2.3 [Degreasing/Cleaning Solvent]{.underline}
>
> All conductors shall be degreased/cleaned using a solvent which has
> been pre-approved by PPPL. This solvent should be able to dissolve
> grease, tar, wax, adhesives, oils and other soils without leaving a
> residue.
>
> 3.1.2.4 [Copper Primer]{.underline}
>
> The primer shall be Araldite DZ-80-1, manufactured by Ciba-Geigy (UK)
> Limited Plastics Division. [No substitutions permitted]{.underline}.
>
> 3.1.2.5 [Grit Blasting Materials]{.underline}
>
> Grit blasting shall be performed using aluminum oxide with a grain
> size of 80-120 mesh.
>
> 3.1.2.6 [TF Coil Core]{.underline} (Reference Dwg. 13.E0015.0)
>
> The center core of the TF bundle assembly shall be made of silicone
> rubber with a Shore "A" Durometer hardness of 60. Recommended
> materials include "G.E." silicone rubber products No. RTV 31 or RTV
> 60. Subcontractor shall recommend suitable material and receive PPPL
> approval prior to fabrication of core.
>
> 3.1.2.7 [Conductor Coolant Tube]{.underline}
>
> The coolant tube which shall be soldered into the TF conductors shall
> be seamless Air Conditioning and Refrigeration (ACR) copper tubing
> with 0.312 in. outside diameter and 0.032 in. wall thickness. The
> tubing shall be procured with the outside diameter pre-tinned prior to
> soldering into the conductor.
>
> 3.1.2.8 [Soft Solder]{.underline}
>
> The copper coolant tube shall be soft-soldered into the TF conductor
> using 95%/5% Tin-Antimony soft-solder with a melt range of 453-464 °F.
> Subcontractor shall recommend suitable liquid flux. Any changes from
> this shall require PPPL approval.
>
> 3.1.2.9 [End Caps]{.underline} (Reference Drawing 13.E0042.0)
>
> The TF Bundle end caps shall be made of NEMA Grade G-10 glass
> reinforced epoxy, meeting all NEMA (National Electrical Manufacturers
> Association) "G-10" Grade specifications.
>
> 3.1.2.10 [Press-Mold Release Agent]{.underline}
>
> A suitable press-mold release agent shall be recommended by the
> subcontractor and approved by PPPL.
>
> 3.1.2.11 [Silicone Adhesive Sealer]{.underline}
>
> A suitable silicone adhesive sealer for securing the end caps in
> position shall be recommended by the subcontractor and approved by
> PPPL.

**3.2 COIL FABRICATION**

> This section describes a recommended procedure for fabricating the
> subject equipment. The Subcontractor shall submit for approval by
> PPPL, a Manufacturing, Inspection, and Test (MIT) plan. No deviations
> from the MIT plan will be accepted without PPPL approval.
>
> 3.2.1 **[Copper Conductor Delivery]{.underline}**
>
> The copper conductors shall be delivered to the Subcontractor with the
> electrical contact face of each conductor end individually wrapped for
> protection. The crates shall be inspected for visual damage by the
> Subcontractor and condition of crates documented.
>
> 3.2.2 **[Conductor Cleaning]{.underline}**
>
> Each conductor shall be wiped down with degreasing solvent to remove
> excess oil, lubricant and grease.
>
> 3.2.3 **[Material Protection]{.underline}**
>
> Cleaned copper, whether bare or insulated, shall be stored and
> processed in an environment free from metallic dust or other
> contaminants. The copper surface and insulating materials shall be
> protected from skin oil, etc., by requiring shop personnel to handle
> conductors only while wearing clean, lint free, white cotton gloves.
> Insulation and in-process subassemblies shall be processed and stored
> in controlled clean areas. The electrical joint faces at each end of
> the conductors shall be protected from damage.
>
> 3.2.4 **[Conductor Inspection]{.underline}**
>
> The copper conductors shall be moved to an inspection table where they
> shall be inspected per requirements in Section 4.0 paragraph 4.1.
>
> 3.2.5 **[Coolant Tube Installation]{.underline}**
>
> a\. The pre-tinned copper coolant tube shall be positioned and
> soft-soldered into the groove provided in each conductor. The copper
> tube shall be continuous with no splices. ( Reference Drawing
> 13.E0016.0)
>
> b\. [Caution:]{.underline} Extreme care must be taken to ensure that
> the heating process used for soldering does not effect the hardness of
> the copper extrusion. Pre and post Rockwell hardness measurements
> shall be taken by subcontractor to ensure compliance. This information
> shall be included in the Process History.
>
> c\. Following the soldering operation, the excess solder shall be
> removed from the conductor so that the cross-section of the conductor
> conforms to the PPPL drawings. Care should be taken so that the
> coolant tube is not damaged. The conductor must also be cleaned to
> remove flux residue.
>
> 3.2.6 **[Flow and Hydrostatic Tests:]{.underline}**
>
> Flow and hydrostatic tests of the soft-soldered coolant tube shall be
> performed per requirements in section 4.1.2 to verify integrity of the
> coolant tube and to provide a base line for future tests.
>
> 3.2.7 **[Conductor Grit Blasting]{.underline}**
>
> Following the installation and testing of the coolant tubes, the
> conductor shall be grit blasted to remove any surface oxidation and
> promote insulation bonding. This process must be performed in a
> controlled manner which will expose the conductor to grit blasting at
> a recommended rate of 12 seconds/ inch2. It is essential that water
> and oil filters are located in the main air supply line to minimize
> the risk of introducing contaminants onto the conductors.
>
> 3.2.8 **[Cleaning After Grit Blasting]{.underline}**
>
> After grit blasting, the conductor shall be vacuum cleaned and wiped
> to remove all residue remaining from the grit blasting.
>
> 3.2.9 [**Primer Application**]{.underline}
>
> A layer of DZ-80-1 primer will be applied by brushing or spraying. The
> final method for application and curing must be approved by PPPL. It
> is important that the primer be applied with a thin uniform thickness.
> Primer shall be air dried before proceeding. The final cure of the
> primer shall occur during the insulation cure cycle.
>
> 3.2.10 **[Turn Insulation]{.underline}**
>
> a\. The half-lapped layers of turn insulation shall be applied to the
> conductors to achieve the cured insulation thickness specified on the
> drawings and in appendix II.
>
> b\. Care shall be taken to avoid damage to the insulation in
> subsequent handling. Damaged insulation shall be replaced with new
> insulation in accordance with a Subcontractor Prepared/ PPPL approved
> repair procedure which will maintain insulation continuity.
>
> 3.2.11 **[Lead Area Turn Insulation]{.underline}**
>
> Turn insulation shall be tailored to fit neatly around water and
> electrical terminals.
>
> 3.2.12 **[Assembly of TF Coil Conductors]{.underline}**
>
> a\. Insulated TF conductors shall be assembled in accordance with
> approved drawings to form a quadrant of the TF bundle. Joint surfaces
> at each end of the bundle shall be precisely located in angular
> position by bolting a tooling fixture (designed and supplied by
> Subcontractor, approved by PPPL) into the inserts (\"Keenserts\")
> provided in the bolt holes. Fixture shall be designed to provide
> angular alignment and to permit, or assist in, the application of
> inward radial compression during cure. Maximum allowable bolt tension
> is TBD pounds.
>
> b\. All voids between turns shall be filled with B-stage roving.
>
> c\. A layer of CTD-112 pre-impregnated epoxy-glass sheet shall be
> placed between the inner and outer row of insulated conductors. In the
> vicinity of the outer TF electrical connection areas (2) locations an
> additional layer of Kapton polyimide film, in sheet form without
> adhesive backing, shall be positioned between the inner and outer row
> of insulated conductors.
>
> d\. Kapton dielectric shields shall be positioned between the TF
> conductors at the electrical connection areas. (Reference Drawing
> 13.E0016.0)
>
> e\. Two (2) half-lapped layers of 2 mil non-stick (Tedlar) tape shall
> be applied around the entire quadrant.
>
> f\. Two (2) half-lapped layers of shrinkable mylar tape shall be
> applied over the Tedlar layer.
>
> 3.2.13 **[Quadrant Test- Pre-Cure]{.underline}**
>
> Each conductor within the TF Coil quadrant shall be electrically
> tested against all other conductors shorted together and grounded per
> test requirements given in section 4.
>
> 3.2.14 **[Quadrant Cure]{.underline}**
>
> a\. Internal surfaces of a press mold (design and supplied by
> Subcontractor, approved by PPPL) shall be coated with pre-approved
> mold release agent. The TF quadrant shall be installed into the press
> mold. The press mold shall be designed to provide sufficient
> compression of the B-stage insulating materials to insure that the
> resin flows into all voids and that the dimensions of the finished
> assembly are within the specified tolerances.
>
> b\. The quadrant bundle and press mold shall be heated in an oven, and
> cured at 170° C for a period of (2) two hours. During this time the
> press mold shall apply sufficient compression (10% of nominal B-stage
> insulation thickness) to the quadrant to allow the conductors to form
> a monolithic, void free structure with dimensions within the specified
> tolerances.
>
> c\. The subcontractor shall monitor and record cure temperature and
> time during the entire cure process. This information shall become
> part of the Process History per section 5.11.
>
> d\. Following the insulation cure cycle, the quadrant shall be removed
> from the press mold. The layers of Tedlar and shrinkable mylar shall
> be removed and the quadrant bundle inspected.
>
> 3.2.15 **[Quadrant Pre-Acceptance Tests]{.underline}**
>
> Each conductor within the TF Coil quadrant shall be electrically
> tested against all other conductors shorted together and grounded per
> test requirements given in section 4.
>
> 3.2.16 **[Assembly of TF Centerstack Quadrants]{.underline}**
>
> a\. The four quadrants shall be assembled together to form the
> complete bundle assembly. Joint surfaces at each end of the bundle
> shall be precisely located in angular and axial position by bolting a
> tooling fixture (designed and supplied by Subcontractor, approved by
> PPPL) into the inserts (\"Keenserts\") provided in the bolt holes.
> Fixture shall be designed to provide angular alignment and axial
> location and to permit, or assist in, the application of inward radial
> compression during cure. Maximum allowable bolt tension is TBD pounds.
>
> b\. Two (2) layers of CTD-112P Prepreg insulation shall be applied
> between each quadrant. This barrier shall be applied in sheet form to
> provide a continuous bond surface.
>
> c\. The silicone rubber core in the center of the TF bundle shall be
> included during the assembly operation. Care shall be taken to ensure
> that the surfaces of the silicone rubber core have been cleaned prior
> to installation.
>
> d\. All voids between turns shall be filled with prepreg roving.
>
> 3.2.17 **[Coil Bundle Press-Molding]{.underline}**
>
> a\. Two (2) half-lapped layers of 2 mil non-stick (Tedlar) tape shall
> be applied around the entire TF bundle.
>
> b\. Two (2) half-lapped layers of shrinkable mylar tape shall be
> applied over the Tedlar layer.
>
> c\. The internal surfaces of the press mold shall be coated with
> pre-approved mold release agent.
>
> d\. The TF coil bundle shall be transported to the oven area and
> placed in a press mold. The press-mold shall be designed to provide
> sufficient compression of the B-stage insulating materials to insure
> that the resin flows into all voids and that the dimensions of the
> finished assembly are within the specified tolerances.
>
> e\. The coil bundle and mold shall be heated and cured to the
> following times and temperatures.
>
> 2 hours @ 177°C
>
> 7 hours @ 200°C
>
> During this time the press mold shall apply sufficient compression
> (10% of nominal uncured B-stage insulation thickness) to the TF bundle
> to allow the quadrants to form a monolithic, void free structure with
> dimensions within the specified tolerances.
>
> f\. Following the insulation cure cycle, the TF coil bundle shall be
> removed from the press-mold. The layers of Tedlar and shrinkable mylar
> shall be removed, and the coil bundle shall be inspected.
>
> 3.2.18 **[Ground Insulation]{.underline}**
>
> a\. The ground insulation shall be applied to the outside diameter of
> the assembled TF bundle using half-lapped layers of pre-preg Scotchply
> #1003 insulation.
>
> b\. All layers of ground insulation shall be applied in the same
> direction.
>
> c\. The ground insulation build up shall result in an oversized
> diameter allowing additional insulation thickness for machining.
> Subcontractor shall determine the required buildup with PPPL approval.
>
> d\. The ground insulation shall be tailored to fit neatly around the
> conductor end electrical flags.
>
> e\. The "Scotchply" ground insulation shall be cured to mutually
> agreed upon specifications.
>
> 3.2.19 **[Machining of Ground Insulation]{.underline}**
>
> a\. After the "Scotchply" has cured, the TF coil ground insulation
> shall be machined to achieve the final dimensions as specified in the
> drawings.
>
> b\. The method for machining the ground insulation of the TF Bundle
> shall be proposed by Subcontractor and approved by PPPL. Care must be
> taken not to machine below the specified dimensions in the drawings.
>
> 3.2.20 **[Post-Machining]{.underline}**
>
> Subcontractor shall evaluate the machined coil bundle surfaces to
> verify freedom from defects such as cracks, dry spots, voids, etc. The
> coil bundle surfaces shall not be patched or mechanically processed
> without written approval of PPPL. There shall be no voids or
> delaminations. Surface cracks shall be reviewed with PPPL for
> disposition.
>
> 3.2.21 **[Evaluation of Finished Surfaces]{.underline}**
>
> The cured coils shall be checked for dimensional conformance with the
> drawings.
>
> 3.2.22 **[End Cap Installation]{.underline}**
>
> Subcontractor shall install G-10 End Caps on each end of the TF
> Bundle. Silicone adhesive sealer (RTV) shall be used to secure the end
> caps in position.

**[4.0 TEST REQUIREMENTS]{.underline}**

> Mechanical and electrical inspections and tests shall be performed on
> each quadrant. Test points, test methods, acceptance criteria, and
> PPPL witness points shall be described in the Manufacturing Inspection
> Test (MIT) Plan.

**4.1 RECEIVING INSPECTION-TF CONDUCTOR**

> 4.1.1 **[Dimensional Measurements/Inspections]{.underline}**
>
> a\. Conductors shall be checked to verify that length and cross
> sectional dimensions are within the required tolerance on the approved
> PPPL drawings. They will also be inspected for twist, warp and camber.
>
> b\. The dc resistance and temperature of each conductor shall be
> measured and recorded.
>
> 4.1.2 **[Flow and Pressure Tests:]{.underline}**

Following the installation of the coolant tubes into the conductors the
following flow and pressure test shall be performed.

> a\. The soft-soldered edge coolant tube in each TF conductor must be
> tested for flow, and hydrostatic tests to verify the integrity of the
> coolant tube and to provide a base line for future tests. These tests
> shall be performed using potable water.
>
> b\. Operational flow rates and pressure drops are as follows:
>
> **16 gpm 35 ± 5 psi pressure drop**
>
> c\. The hydrostatic pressure shall be 600 psi for 30 minutes with no
> leaks. The pressure vs. time data shall be recorded.

**4.2 IN-PROCESS TESTING**

> 4.2.1 **[Tests After Quadrant Assembly and Prior to Oven
> Cure]{.underline}**
>
> Once the TF conductors have been assembled into a TF Quadrant bundle,
> the insulation between each inner leg within the quadrant shall be
> verified by applying a **500 Volt** Megger for a minimum of 2 minutes
> between each individual turn and the remainder of the turns, which
> shall be shorted and grounded. Insulation resistance shall be greater
> than **1000 MΩ.**
>
> 4.2.2 **[Tests After Quadrant Cure]{.underline}**
>
> Once the conductors for a TF coil center stack quadrant have been
> cured and prior to being assembled into the full bundle, the
> insulation between each inner leg within the quadrant shall be
> verified by applying a **3 kV** Megger between each individual turn
> and the remainder of the turns, which shall be shorted and grounded.
> Insulation resistance shall be greater than **1000 MΩ.**

**4.3 FINAL ACCEPTANCE TESTS**

These tests and inspections shall be performed once the TF Center Stack
Bundle is in a deliverable configuration.

> 4.3.1 **[Inspection]{.underline}**
>
> A careful visual inspection and dimensional check shall be made
> according to applicable drawings. All dimensions shall be in
> conformance with the drawings.
>
> 4.3.2 **[Flow/Pressure Tests]{.underline}**
>
> A final flow and hydrostatic pressure test of the soft-soldered edge
> coolant conductor tubes shall be performed to verify that no tube
> damage has been done to the soft-soldered tube as a result of final
> processing of the TF Center Stack Bundle. These tests shall be
> performed using potable water. Operational flow rates and pressure
> drops shall be within 10% of the data collected in section 4.1.2.
>
> 4.3.3 **[Final Electrical Tests]{.underline}**
>
> a\. Coils shall be temporarily wrapped with conducting material (e.g.
> Al foil) to provide a ground plane.
>
> b\. The insulation between each inner leg within the quadrant, and to
> ground, shall be verified by applying a **3 kV** Megger between each
> individual turn and the remainder of the turns, which shall be shorted
> and grounded. Insulation resistance shall be greater than **1000 MΩ.**
>
> c\. The insulation between the coil bundle and ground shall be
> verified by applying a **3 kV** DC Hipot between all turns, shorted
> together, and ground. Voltage shall be ramped up in 10 seconds, held
> for 60 seconds, and ramped down in 10 seconds. Leakage current shall
> be recorded during ramping up and down, and once every 10 seconds
> during the 60 second interval. Leakage current shall not exceed **10 µ
> Amps**.

**5.0 [QUALITY ASSURANCE REQUIREMENTS]{.underline}**

**5.1 INSPECTION/ SURVEILLANCE/AUDIT BY PRINCETON**

Authorized representatives of PPPL and the U. S. Government shall have
the right at all reasonable times to visit the Subcontractor\'s premises
and those of Subcontractor\'s suppliers during the performance of the
procurement for the purposes of inspection, surveillance, audit and/or
obtaining any required information as may be necessary to assure that
items or services are being furnished in accordance with specified
requirements. Such visits shall be coordinated with the Subcontractor\'s
personnel to minimize interference with the normal operations of said
premises. The Subcontractor shall make available records and
documentation necessary for this function and shall provide all
reasonable facilities and assistance for the safety and convenience of
PPPL and/or U. S. Government representatives in the performance of their
duties. PPPL and the U. S. Government recognize the Subcontractor\'s
right to withhold information concerning proprietary processes. The
Subcontractor agrees to insert the paragraph above in each lower tier
procurement issued hereunder.

**5.2 SUBCONTRACTOR'S RESPONSIBILITY FOR CONFORMANCE**

Neither PPPL\'s review and/or approval of Subcontractor\'s documents nor
PPPL\'s inspection of Subcontractor\'s items or services shall relieve
the Subcontractor of responsibility for full compliance with
requirements of the purchase order/contract.

**5.3 QUALITY ASSURANCE PLAN**

Subcontractor shall submit as soon as practical after the
subcontract/purchase order award, two (2) copies of its Quality
Assurance Plan, describing the specific quality assurance and quality
control procedures and practices to meet the requirements of this
particular subcontract/purchase order, for PPPL review and approval.

**5.4 MANUFACTURING, INSPECTION AND TEST PLAN (MIT)**

Subcontractor shall prepare and submit for PPPL review and approval a
Manufacturing/Inspection/Test Plan which identifies parts,
sub-assemblies, etc.; shows their integrated flow into end items; and
identifies critical manufacturing operations as well as inspections and
tests. Preparing the Plan may include developing a flow chart and
generating Process Sheets/Shop Travelers, etc. PPPL may designate
selected manufacturing, inspection and/or test operations as mandatory
"witness" points based on the MIT plan. Subcontractor shall provide PPPL
with five (5) working days notice in advance of such witness points.

**5.5 INSPECTION AND TEST PROCEDURES**

> Inspections and tests shall be performed in accordance with written
> procedures referencing criteria for acceptance or rejection. Adequate
> records shall be maintained and available for PPPL\'s review.

**5.6 DOCUMENT TRACEABILITY AND RECORDS**

The Subcontractor shall maintain a system of documentation whereby
objective evidence of required operations, inspections, examinations,
and tests is systematically compiled, indexed and stored. Such objective
evidence may include \"travelers\"; and material test, certification,
inspection, examination, test and discrepancy reports; which shall be
complete, legible, and validated by responsible personnel and shall be
traceable to subject items.

**5.7 EQUIPMENT/MATERIAL IDENTIFICATION AND STATUS**

Material and equipment identification shall be maintained throughout the
program and be traceable to the records. Status of acceptability shall
be readily discernible through the Subcontractor\'s use of tags, stamps,
serial numbers or other positive means.

**5.8 DOCUMENT REVIEW, APPROVAL AND CONTROL**

The Subcontractor shall provide a system for distribution and control of
approved documents and changes thereto. The system shall use procedures
which provide for review and approval of design documents (drawings,
specifications, etc.), prior to issuance for use, and for approval and
incorporation of changes in a formal and orderly manner. The system
shall control obsolete documents to prevent inadvertent use.

**5.9 CALIBRATION OF TEST AND MEASURING EQUIPMENT**

Inspections and tests shall be performed using properly calibrated
measuring and test equipment. Subcontractor shall have in its possession
the necessary equipment to perform the required inspections and tests.
Calibration standards shall be traceable to the National Institute for
Standards and Technology (NIST) or equivalent. Subcontractor shall
impose these calibration requirements on subtier suppliers.

**5.10 RELEASE FOR SHIPMENT FORM**

Subcontractor shall have a signed \"Product Quality Certification and
Shipping Release\" Form to be provided by PPPL\'s Quality Assurance
Representative prior to PPPL acceptance of procured items or services
for full or partial shipment. PPPL reserves the right to refuse to
accept shipments unless accompanied by a signed \"Shipping Release\"
Form .

**5.11 PROCESS HISTORY**

Subcontractor shall provide to PPPL a Process History which includes a
compilation of documents, detailing the objective evidence of the
acceptability of the work performed. The Process History shall include
as a minimum, but not be limited to, the following:

> 5.11.1 **[Certificate Of Compliance (C of C)]{.underline}**
>
> Subcontractor\'s C of C, stating that the work performed conforms in
> every respect to the physical configuration and functional
> inspection/test requirements. The C of C shall be signed by
> Subcontractor\'s Quality Assurance (QA) Manager.
>
> 5.11.2 **[Material Certifications]{.underline}**
>
> The Subcontractor shall submit copies of inspection reports, test
> data, and/or certifications from vendors, showing relevant chemical,
> mechanical and electrical properties of materials used, where
> applicable, as well as documents showing adherence to in-process
> requirements. Material certifications from sub-tier suppliers shall
> also be submitted.
>
> 5.11.3 **[Inspection/Test Documents]{.underline}**
>
> Copies of filled in and completed process planning and control
> documents (travelers, etc.) which verify controlled execution of the
> required work. (Records shall be available for review but may not be
> required for delivery.)
>
> 5.11.4 **[Inspection Reports]{.underline}**
>
> Copies of the original reports of all required inspections and
> examinations, properly validated by authorized personnel.
>
> 5.11.5 **[Test Reports]{.underline}**
>
> Copies of the original test data sheets or reports of all required
> tests, both in-process and acceptance, properly validated by
> authorized personnel.

**5.12 PPPL RECEIVING/INSPECTION**

PPPL will perform Receiving Inspection on items or services supplied by
Subcontractor, using either a sampling plan or 100% inspection.
Discrepant items or services will be rejected and returned to
Subcontractor or reworked by PPPL. Costs caused by rejects will be
charged to Subcontractor.

**[6.0 DOCUMENTATION REQUIREMENTS]{.underline}**

**6.1 PROPOSAL TECHNICAL DOCUMENTATION**

> a\. Subcontractor shall submit as part of his proposal documentation
> in preliminary or outline form, the QA Plan (refer to section 5.3),
> the Manufacturing/Inspection/Test Plan (refer to section 5.4), and
> procedures for tests (refer to section 5.5).
>
> b\. Subcontractor shall submit as part of the proposal a preliminary
> description of the press mold and conductor alignment fixtures (refer
> to sections 3.2.12, 3.2.14, 3.2.16 and 3.2.17).

**6.2 DOCUMENTATION AFTER CONTRACT AWARD AND PRIOR TO FABRICATION**

> a\. Subcontractor shall submit (2 copies) final versions of the QA
> Plan (refer to section 5.3), the Manufacturing/Inspection/Test Plan
> (refer to section 5.4), and procedures for tests (refer to section
> 5.5) for PPPL review and approval within 30 days of contract award.
>
> b\. Subcontractor shall submit (2 copies) a final description of the
> press mold and conductor alignment fixtures (refer to sections 3.2.12,
> 3.2.14, 3.2.16 and 3.2.17) for PPPL review and approval within 30 days
> of contract award.
>
> c\. Subcontractor shall submit (2 copies) of final fabrication
> drawings for PPPL review and approval within 30 days of contract
> award.

**6.3 DOCUMENTATION PRIOR TO SHIPMENT**

> a\. Subcontractor shall submit (2 copies) all documents identified in
> section 5.11, Process History.
>
> b\. Subcontractor shall submit an inventory of excess materials
> provided by PPPL.

**7.0 [SHIPPING STORAGE AND HANDLING]{.underline}**

> a\. The conductor coolant tubes shall be drained of all water and
> sealed for storage and subsequent shipment.
>
> b\. The center stack bundle shall be crated for shipment. The crate
> shall be built for moving on rollers, handling with slings from
> overhead cranes and forklifts.
>
> c\. The crate shall protect the center stack bundle from shock and
> weather conditions, including precipitation and protection against
> freezing. Subcontractor's name, shipper, purchase order number,
> contents and gross weight shall be marked on the shipping container.
> Subcontractor is responsible arranging shipment, and for the safe
> arrival of the TF Center Stack Bundle at PPPL in Princeton , New
> Jersey, USA.
>
> d\. The TF Bundle shall be prepared for shipment is such a manner as
> to ensure acceptance by common carrier for transportation at the
> lowest applicable rate and to afford protection from normal hazards of
> transportation.

**8.0 [DELIVERABLES]{.underline}**

> The Subcontractor is responsible for delivering to PPPL the following:
>
> a\. All documentation listed in section 6.0.
>
> b\. One (1) completed TF Coil Center Stack Bundle which has
> successfully passed all acceptance tests and criteria.
>
> c\. Balance of materials supplied by PPPL or which were procured by
> Subcontractor solely for this contract.
>
> d\. Fixtures or tooling fabricated solely for the fabrication of the
> TF Center Stack Bundle.

**[APPENDIX I]{.underline}**

**TF Center Stack Bundle drawings**

  ----------------------------------- -----------------------------------
  **Description**                     **PPPL Drawing Number**

  ----------------------------------- -----------------------------------

  ----------------------------------- -----------------------------------
                                      

  ----------------------------------- -----------------------------------

  ----------------------------------- -----------------------------------
  Inner TF Conductor                  NSTX 13.E0025.0

  ----------------------------------- -----------------------------------

  ----------------------------------- -----------------------------------
  Outer TF Conductor                  NSTX 13.E0026.0

  ----------------------------------- -----------------------------------

  ----------------------------------- -----------------------------------
  Conductor/Insulation Arrangement    NSTX 13.E0100.D

  ----------------------------------- -----------------------------------

+-----------------------------------+-----------------------------------+
| Inner Coil Quadrant Assembly      | NSTX 13.E0016.0                   |
|                                   |                                   |
| Conductor Insulation Arrangement  | NSTX 13.E0015.0                   |
|                                   |                                   |
| Protective End Cap Details        | NSTX-13.E0042.0                   |
+-----------------------------------+-----------------------------------+

**[APPENDIX II]{.underline}**

**Coil Bundle/ Insulation Data**

+-------------------------+----------+----------+----------+----------+
|                         | **Dim    | **       | **Dim    | **       |
|                         | ension** | Radius** | ension** | Radius** |
|                         |          |          |          |          |
|                         | *        | *        | *        | *        |
|                         | *(in.)** | *(in.)** | *(cm.)** | *(cm.)** |
+-------------------------+----------+----------+----------+----------+

  -------------------------- ----------- ----------- ----------- -----------
  **TF Quadrant Radial                                           
  Build**                                                        

  -------------------------- ----------- ----------- ----------- -----------

  -------------------------- ----------- ----------- ----------- -----------
  TF Centerbore              0.250       0.250       0.635       0.635

  -------------------------- ----------- ----------- ----------- -----------

  -------------------------- ----------- ----------- ----------- -----------
  1st. layer turn Insulation 0.032       0.282       0.081       0.716
  (IR cu)                                                        

  -------------------------- ----------- ----------- ----------- -----------

  -------------------------- ----------- ----------- ----------- -----------
  1st. layer copper          1.936       2.218       5.634       5.634
  conductor (OR)                                                 

  -------------------------- ----------- ----------- ----------- -----------

  -------------------------- ----------- ----------- ----------- -----------
  1st. layer turn insulation 0.032       2.250       0.081       5.715

  -------------------------- ----------- ----------- ----------- -----------

  -------------------------- ----------- ----------- ----------- -----------
  TF Layer Insulation        0.020       2.270       0.051       5.766

  -------------------------- ----------- ----------- ----------- -----------

  -------------------------- ----------- ----------- ----------- -----------
  2nd. layer turn insul.     0.032       2.282       0.081       5.847
  (copper)                                                       

  -------------------------- ----------- ----------- ----------- -----------

  -------------------------- ----------- ----------- ----------- -----------
  2nd. layer (conductor      1.546       3.828       3.268       9.774
  face)                                                          

  -------------------------- ----------- ----------- ----------- -----------

  -------------------------- ----------- ----------- ----------- -----------
  2nd. layer turn insulation 0.032       3.860       0.081       9.855

  -------------------------- ----------- ----------- ----------- -----------

  -------------------------- ----------- ----------- ----------- -----------
                                                                 

  -------------------------- ----------- ----------- ----------- -----------

  -------------------------- ----------- ----------- ----------- -----------
  **TF Bundle Build**                                            

  -------------------------- ----------- ----------- ----------- -----------

  -------------------------- ----------- ----------- ----------- -----------
  *At (0°, 90°, 180° &                                           
  270°)*                                                         

  -------------------------- ----------- ----------- ----------- -----------

  -------------------------- ----------- ----------- ----------- -----------
  Allowance for Segment      0.020       3.900       0.051       9.906
  insulation                                                     

  -------------------------- ----------- ----------- ----------- -----------

  -------------------------- ----------- ----------- ----------- -----------
  TF Groundwall              0.062       **3.962**   0.157       10.064

  -------------------------- ----------- ----------- ----------- -----------

  -------------------------- ----------- ----------- ----------- -----------
  *At (45°, 135°, 225° &                                         
  315°)*                                                         

  -------------------------- ----------- ----------- ----------- -----------

  -------------------------- ----------- ----------- ----------- -----------
  Allowance for Segment      0.028       3.908       0.072       9.927
  insulation                                                     

  -------------------------- ----------- ----------- ----------- -----------

  -------------------------- ----------- ----------- ----------- -----------
  TF Groundwall              0.054       **3.962**   0.137       10.064

  -------------------------- ----------- ----------- ----------- -----------

  -------------------------- ----------- ----------- ----------- -----------
                                                                 

  -------------------------- ----------- ----------- ----------- -----------

  -------------------------- ----------- ----------- ----------- -----------
                                                                 

  -------------------------- ----------- ----------- ----------- -----------

**Note:** Turn to Turn Insulation builds are based upon 10% compression
of nominal B-stage insulation thickness.