**Statement of Work**

NCSX Modular Coil Winding Form

Manufacturing Development and Prototype Fabrication

NCSX-SOW-141-01-06

**14 March 04**

Prepared By:
\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_

D. Williamson, WBS Manager for Modular Coils (WBS 14)

Concurred By:
\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_

P. Heitzenroeder, Technical Representative for Modular Coil (WBS 14)
Procurements

Concurred By:
\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_

B. Nelson, Project Engineer for Stellarator Core Systems (WBS 1)

Concurred By:
\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_

F. Malinowski, PPPL Procurement QA Representative

Approved by:
\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_

W. Reiersen, NCSX Engineering Manager

**REVISIONS**

+----------+----------------------------------------------+-----------+
| Revision | Description of Change                        | Date      |
| No.      |                                              |           |
+----------+----------------------------------------------+-----------+
| Rev. 0   | All                                          | 10/15/02  |
+----------+----------------------------------------------+-----------+
| Rev. 1   | Added Section 4.2 on earned value reporting  | 10/18/02  |
+----------+----------------------------------------------+-----------+
| Rev. 2   | Reformatted per NCSX standards               | 1/24/03   |
|          |                                              |           |
|          | Updated prototype spec reference             |           |
|          | (NCSX-CSPEC-141-01-01 to                     |           |
|          | NCSX-CSPEC-141-01-01) throughout             |           |
|          |                                              |           |
|          | Added a task for manufacturing evaluation of |           |
|          | candidate design features (new 2.1.3) in     |           |
|          | place of copper cladding development samples |           |
|          | (old 2.1.3).                                 |           |
|          |                                              |           |
|          | Added a caveat that the coil type for the    |           |
|          | prototype might change, after discussions    |           |
|          | with the Subcontractor (2.7).                |           |
+----------+----------------------------------------------+-----------+
| Rev. 3   | Indicated that the prototype winding form    | 2/21/03   |
|          | will be Type C instead of Type A. An updated |           |
|          | specification and drawings will be provided  |           |
|          | prior to the start of prototype fabrication. |           |
+----------+----------------------------------------------+-----------+
| Rev. 4   | Tasks 2.1.3.1 and 2.1.3.2 added.             | 6/30/03   |
|          |                                              |           |
|          | Deleted date of posting for                  |           |
|          | NCSX-CSPEC-141-02-00 in Section 1.4.         |           |
+----------+----------------------------------------------+-----------+
| Rev. 5   | Pg. 4- updated Fig. 3; Pg. 5 -- updated      | 10/09/03  |
|          | specification reference. Pg. 8 -- added      |           |
|          | 2.1.3.3 concerning refinement of models for  |           |
|          | casting processing.                          |           |
+----------+----------------------------------------------+-----------+
| Rev. 6   | Pg. 7- reference concerning data for "wing"  | 03/14/04  |
|          | study was updated. Pg. 9 -- added task       |           |
|          | 2.1.3.4 " Flow Solidification Analyses of    |           |
|          | the Type A and B Winding Forms" and task     |           |
|          | 2.1.3.5 "Machining Simulations for the Type  |           |
|          | A and B Winding Forms". Pg. 10-deleted       |           |
|          | reference to HIPing.                         |           |
+----------+----------------------------------------------+-----------+
|          |                                              |           |
+----------+----------------------------------------------+-----------+
|          |                                              |           |
+----------+----------------------------------------------+-----------+
|          |                                              |           |
+----------+----------------------------------------------+-----------+
|          |                                              |           |
+----------+----------------------------------------------+-----------+

Table of Contents

# [1 GENERAL INFORMATION 1](#general-information) {#general-information-1 .TOC-1}

## [1.1 Introduction 1](#introduction) {#introduction-1 .TOC-2}

## [1.2 Background 1](#background) {#background-1 .TOC-2}

## [1.3 Scope 5](#scope) {#scope-5 .TOC-2}

## [1.4 Applicable Documents 5](#applicable-documents) {#applicable-documents-5 .TOC-2}

# [2 Work Requirements 7](#work-requirements) {#work-requirements-7 .TOC-1}

## [2.1 Technical 7](#technical) {#technical-7 .TOC-2}

[2.1.1 Manufacturing Methods for the Three Winding Form Shapes
7](#manufacturing-methods-for-the-three-winding-form-shapes)

[2.1.2 Alloy Selection 7](#alloy-selection)

[2.1.3 Manufacturing Evaluation of Candidate Design Features
7](#manufacturing-evaluation-of-candidate-design-features)

[2.1.3.1 Evaluation of the Poloidal Break and Development of CAD Details
for Proposed Poloidal Break Features
7](#evaluation-of-the-poloidal-break-and-development-of-cad-details-for-proposed-poloidal-break-features)

[2.1.3.2 Development and Evaluation of Options to Resolve "Wing"
Modeling Problems
8](#development-and-evaluation-of-options-to-resolve-wing-modeling-problems)

[2.1.4 Mold Fabrication 9](#mold-fabrication)

[2.1.5 Flow Solidification / Distortion Analyses
9](#flow-solidification-distortion-analyses)

[2.1.6 Casting details 9](#casting-details)

[2.1.7 Post-Casting Processing 9](#post-casting-processing)

[2.1.7.1 Non-Destructive Testing 9](#non-destructive-testing)

[2.1.7.2 Dimensional inspection and verification
9](#dimensional-inspection-and-verification)

[2.1.7.3 Winding Form Repairs 9](#winding-form-repairs)

[2.1.7.4 Heat Treatment 10](#heat-treatment)

[2.1.7.5 Machining and Final Finishing
10](#machining-and-final-finishing)

[2.1.7.6 Final Inspection 10](#final-inspection)

## [2.2 Subcontractor's Recommendations 10](#subcontractors-recommendations) {#subcontractors-recommendations-10 .TOC-2}

## [2.3 Additional Manufacturing Development Activities 10](#additional-manufacturing-development-activities) {#additional-manufacturing-development-activities-10 .TOC-2}

## [2.4 Preliminary Manufacturing / Inspection / Test (MIT) and Quality Assurance (QA) PLANS for Production Coils 11](#preliminary-manufacturing-inspection-test-mit-and-quality-assurance-qa-plans-for-production-coils) {#preliminary-manufacturing-inspection-test-mit-and-quality-assurance-qa-plans-for-production-coils-11 .TOC-2}

## [2.5 Budgetary Cost and Schedule Estimate 11](#budgetary-cost-and-schedule-estimate) {#budgetary-cost-and-schedule-estimate-11 .TOC-2}

## [2.6 Processing Plans for Prototype 11](#processing-plans-for-prototype) {#processing-plans-for-prototype-11 .TOC-2}

## [2.7 Prototype Manufacture 11](#prototype-manufacture) {#prototype-manufacture-11 .TOC-2}

## [2.8 Final MIT and QA Plans for Production Winding Forms 11](#final-mit-and-qa-plans-for-production-winding-forms) {#final-mit-and-qa-plans-for-production-winding-forms-11 .TOC-2}

## [2.9 Firm Fixed Price and Schedule Proposal 11](#firm-fixed-price-and-schedule-proposal) {#firm-fixed-price-and-schedule-proposal-11 .TOC-2}

# [3 Quality Assurance 13](#quality-assurance) {#quality-assurance-13 .TOC-1}

## [3.1 Inspection/ Surveillance/Audit by PPPL 13](#inspection-surveillanceaudit-by-pppl) {#inspection-surveillanceaudit-by-pppl-13 .TOC-2}

## [3.2 Subcontractor\'s Responsibility for Conformance 13](#subcontractors-responsibility-for-conformance) {#subcontractors-responsibility-for-conformance-13 .TOC-2}

## [3.3 Subcontractor's Quality Assurance Program 13](#subcontractors-quality-assurance-program) {#subcontractors-quality-assurance-program-13 .TOC-2}

## [3.4 Processing Plans 14](#processing-plans) {#processing-plans-14 .TOC-2}

[3.4.1 MIT Plan 14](#mit-plan)

[3.4.2 QA Plan 14](#qa-plan)

## [3.5 Inspection and Test Procedures 14](#inspection-and-test-procedures) {#inspection-and-test-procedures-14 .TOC-2}

## [3.6 Document Traceability and Records 14](#document-traceability-and-records) {#document-traceability-and-records-14 .TOC-2}

## [3.7 Equipment/Material Identification and Status 15](#equipmentmaterial-identification-and-status) {#equipmentmaterial-identification-and-status-15 .TOC-2}

## [3.8 Calibration of Test and Measuring Equipment 15](#calibration-of-test-and-measuring-equipment) {#calibration-of-test-and-measuring-equipment-15 .TOC-2}

## [3.9 Control of Special Processes 15](#control-of-special-processes) {#control-of-special-processes-15 .TOC-2}

## [3.10 Release for Shipment Form 15](#release-for-shipment-form) {#release-for-shipment-form-15 .TOC-2}

## [3.11 Process History 15](#process-history) {#process-history-15 .TOC-2}

[3.11.1 Material Certifications 16](#material-certifications)

[3.11.2 Inspection and Test Reports 16](#inspection-and-test-reports)

[3.11.3 Repair Documentation 16](#repair-documentation)

[3.11.4 PPPL Receiving and Inspection
16](#pppl-receiving-and-inspection)

# [4 DELIVERABLES 17](#deliverables) {#deliverables-17 .TOC-1}

## [4.1 Weekly Reports 17](#weekly-reports) {#weekly-reports-17 .TOC-2}

## [4.2 Earned Value Reporting 17](#earned-value-reporting) {#earned-value-reporting-17 .TOC-2}

## [4.3 Technical Reports 17](#technical-reports) {#technical-reports-17 .TOC-2}

## [4.4 Prototype Processing Plans 17](#prototype-processing-plans) {#prototype-processing-plans-17 .TOC-2}

## [4.5 Preliminary Production Processing Plans 18](#preliminary-production-processing-plans) {#preliminary-production-processing-plans-18 .TOC-2}

## [4.6 Prototype Winding Form 18](#prototype-winding-form) {#prototype-winding-form-18 .TOC-2}

## [4.7 Production Processing Plans 18](#production-processing-plans) {#production-processing-plans-18 .TOC-2}

## [4.8 Documentation 18](#documentation) {#documentation-18 .TOC-2}

## [4.9 Tooling 18](#tooling) {#tooling-18 .TOC-2}

# GENERAL INFORMATION

## Introduction 

Stellarators are a class of magnetic fusion confinement devices
characterized by three dimensional magnetic fields and plasma shapes and
are the best-developed class of magnetic fusion devices after the
tokamak. The stellarator concept has greatly advanced since its
invention by Dr. Lyman Spitzer, the founding director of the Princeton
Plasma Physics Laboratory (PPPL), during the 1950's. A traditional
stellarator uses only external magnetic fields to shape and confine the
plasma. The National Compact Stellarator Experiment (NCSX) is the first
of a new class of stellarators known as "compact stellarators." The
differentiating feature of a compact stellarator is the use of plasma
current in combination with external fields to accomplish shaping and
confinement. This combination permits a more compact device. The NCSX
project is managed by PPPL in partnership with the Oak Ridge National
Laboratory. This Subcontract will be administered by PPPL. Operation of
NCSX is scheduled to begin in July 2007.

In preparation for fabrication of critical components, PPPL is
initiating manufacturing development activities. This Statement of Work
is for one of these activities - the coil winding forms, which are
described below.

## Background

Figure 1 is a sectional view of the NCSX device showing its major
components. Note the modular coil set with an integral shell; the
stainless steel winding forms that comprise this shell are the subjects
of this SOW.

The modular coil windings are shown in Figure 2 without their associated
winding forms to permit the complex shape of the windings to be more
readily seen. There are three distinct shapes; six of each make up the
complete modular coil set. To fabricate these windings to the precise
shapes required, stranded copper cable conductor is wound on the
machined stainless steel winding forms, as shown in Figure 3. In
addition to defining the shape of the coils, the winding forms also
provide the strong structural support necessary to react electromagnetic
loads as high as 7000 lbs. / in. Figure 4 shows the final assembly of
the NCSX modular coil set.

*Note: Figures in this section are only for illustration and should not
be used in the performance of this Scope of Work.*

![](media/image1.png){width="6.041666666666667in"
height="4.384027777777778in"}

Figure 1 - The NCSX Device and Definition of its Major Components

*Note in particular the Modular Coil Set with Integral Shell. This
integral shell is comprised of the (18) winding forms that are the
subject of this SOW. A typical winding form is shown in Figure 3.*

![](media/image3.wmf){width="5.498611111111111in"
height="3.823611111111111in"}![](media/image4.wmf){width="5.999305555555556in"
height="1.961111111111111in"}

Figure 2 - NCSX modular coil windings

*The windings are shown without their associated winding forms so their
complex shapes can be easily seen. In order to manufacture these
windings to their precise shapes, stranded copper conductor is wound on
the machined winding forms (shown in Figure 3), which are the subject of
this Statement of Work. Six of each of the three winding form shapes are
required. (Dimensions in meters)*

![](media/image5.png){width="3.101968503937008in"
height="3.5952755905511813in"}![](media/image6.wmf){width="3.1110236220472443in"
height="2.0326771653543307in"}

Figure 3 - Modular coil details

*Shown is one of the three winding form shapes. The right view shows a
sectional view of the form with the stranded cables conductors wound in
place on both sides of the "T" section. The winding form serves two very
important functions: it defines the precise shape of the winding and
provides the required structural support.*

![](media/image8.png){width="5.355555555555555in"
height="3.3444444444444446in"}

Figure 4 - Final assembly of the NCSX modular coil set

*Shown above is the final assembly of the eighteen modular coils (six
each of three coil shapes).*

## Scope

The scope of this SOW includes manufacturing development for all three
winding form shapes, the production of a full-scale prototype of one
winding form, and, based on these activities, a firm fixed price and
schedule proposal for the eighteen production castings. The SOW tasks
focus on the difficult aspects of manufacturing these shapes: tolerance
control; maintenance of low magnetic permeability; machining of the
complex geometry; control of distortion during heat treatment; and
timely, low-cost fabrication. The production of the full-scale prototype
is meant to give the Subcontractor the experience needed to develop and
submit a firm fixed price and schedule proposal as a final deliverable
of this effort.

## Applicable Documents

[Product Specification for the Prototype Modular Coil Winding Form
(NCSX-CSPEC-141-01-02)]{.underline} is the complete specification for
the prototype modular coil winding form. The specification identifies
applicable Pro/Engineer drawings and models that define the geometry of
the prototype modular coil winding form.

[Product Specification for the Modular Coil Winding Forms
(NCSX-CSPEC-141-02-00)]{.underline} will be the complete specification
for the modular coil winding forms. The initial version of this
specification will be similar in content to the specification for the
prototype modular coil winding form (NCSX-CSPEC-141-01-01) and will be
provided prior to the Subcontractor providing a firm fixed price bid and
schedule proposal. The specification identifies applicable Pro/Engineer
drawings and models that define the geometry of the modular coil winding
forms. Preliminary drawings and models of the modular coil winding
forms, to be used until revised versions are provided, are currently
available on the PPPL FTP server. Drawings and models that are released
for fabrication will be provided prior the Subcontractor providing a
firm fixed price bid and schedule proposal.

# Work Requirements

The tasks described below should be performed approximately in the order
indicated. It is expected that the Subcontractor may be working on
several in parallel. Schedule requirements are described in the
Subcontract.

## Technical

### Manufacturing Methods for the Three Winding Form Shapes

The Subcontractor shall describe the manufacturing methods for
fabricating, inspecting, and machining the modular coil winding forms
and proposed Quality Assurance provisions. (Ref. Specification \#
NCSX-CSPEC-141-01-01, Sects. 3 and 4).

### Alloy Selection

Describe in detail the composition and mechanical and physical
properties (at 77 K and at room temperature) of the chosen alloy and
your experience with using this alloy. (Ref. Specification \#
NCSX-CSPEC-141-01-01, Sect. 3.2.1)

### Manufacturing Evaluation of Candidate Design Features

[Background Information for 2.1.3.1 and 2.1.3.2]{.underline}: The
Subcontractor shall perform Tasks 2.1.3.1 and 2.1.3.2 using drawings
based on the E04 coil geometry. This data was placed NCSX Manufacturing
ftp site in a folder entitled MC_wing_study on 02 July 03..

#### Evaluation of the Poloidal Break and Development of CAD Details for Proposed Poloidal Break Features

Concerns have been expressed about the details of the poloidal break in
the present design:

-   The lack of positive locating features such as pins to ensure
    alignment of the casting after the cut is made for the poloidal
    break.

-   The number, size, and location of bolts currently shown may not be
    strong enough to restrain the casting after the break is cut.

A complete plan has to be developed for the breaks which covers how the
casting will be restrained during cutting of the break, how the casting
will be cut, how the G11 CR insulation sheets will be installed, how the
break will be protected during the manufacturing processes, and how an
insulation sheet will be replaced if it failed electrical tests.

The goal of this task is to develop improved designs for the poloidal
breaks that would address these concerns. This will help reduce
uncertainties, which would otherwise be reflected in higher
contingencies incorporated in the firm fixed price and schedule
proposals. Specifically, the Subcontractor will:

-   Perform a detailed evaluation of the current design, identifying
    concerns with the current design.

-   Develop CAD models of improved design concepts. Manufacturing
    details such as materials, tolerances, and procedures should be
    addressed.

-   Provide a report that includes the evaluation of the current design
    and descriptions of improved design concepts.

#### Development and Evaluation of Options to Resolve "Wing" Modeling Problems

The NCSX team has had difficulty developing acceptable CAD models of the
modular coil winding form in the regions where the "wings" from one
winding form nest into the adjacent winding form. The goal of this task
is to develop acceptable CAD models (without interferences) of the
winding forms in these regions. The CAD models must address design
constraints, which include:

-   Assembly of the modular coils into three-coil modules (Type B to
    Type A and Type C to Type B prior to field period assembly) and
    six-coil modules (Type A to Type A during field period assembly).

-   Assembly of the three six-coil modules during final assembly (Type C
    to Type C).

-   Providing toroidal insulating breaks between adjacent modular coils.

-   Preserving structural continuity between adjacent modular coils.

-   Preserving a height of \~2.5" for the base of the tee for the clamps
    and for sealing the mold for vacuum pressure impregnation.

-   Accommodating vacuum vessel port extensions.

Specifically, the Subcontractor will:

-   Review the current design to understand the problem areas.

-   Develop CAD models that resolve the problem areas while addressing
    design constraints.

-   Provide a report that describes proposed design improvements.

PPPL will provide support for the Subcontractor by supplying the CAD
models, communicating design constraints, and providing feedback on
proposed options to the Subcontractor.

2.1.3.3 [Refinement of Prototype Pro-E]{.underline} [Models]{.underline}
[to Meet]{.underline} [Subcontractor's]{.underline} [Casting
Requirements]{.underline}: The Subcontractor shall refine the Pro-E
models defined in Sect. 1.4 to add fillets, draft angles, "padding" of
surfaces, and other such features that are necessary for their casting
process. The refined models shall be submitted to PPPL in Pro-E or STEP
format for verification of essential geometry features. PPPL's written
approval of the use of these models is required before contractors can
proceed. It is anticipated that the Subcontractor will require 2 working
weeks for the refinement step and PPPL will require 2-3 working days for
the verification step.

2.1.3.4 [Flow Solidification Analyses of the Type A and B Winding
Forms:]{.underline} The Subcontractor shall perform flow solidification
analyses of the Type A and B winding forms. The data for these analyses
are available at the NCSX Manufacturing ftp site in the **production­**
**winding­** **form** folder. The goal of this task is to verify that the
proposed designs of these winding forms are acceptable from the point of
view of casting. The Subcontractor shall summarize their findings in a
report and shall also use the results of this study in the preparation
of their fixed cost and schedule proposal for the production winding
forms. The data has been placed in a zip file
(type_ab_for_sol_study.zip) which contains the following files:
Pro/Engineering part files se141-114v.prt.2 (Type "A"), se141-114v.drw.1
drawing file, se141-115v.prt.1 (Type "B"), se141-115v.drw.1 drawing file
and ornl_ncsx_e-size_part.frm.2 format.  STEP files are included along
with Adobe PDF drawing files.  These models are complete except for the
future addition of a local boss that may be added to the mid plane
region (inboard and outboard) of the type "B" prototype for assembly
purposes.

2.1.3.5 [Machining Simulations for]{.underline} [the Type A and B
Winding Forms:]{.underline} The Subcontractor shall perform machining
simulations of the Type A and B winding forms. The machining data for
the Type A and B winding forms will be available on or about March 30,
2004 at the NCSX Manufaturing ftp site. These parts will contain most of
the expected features; however, the final production parts are likely
contain some minor changes in details which should not affect the goal
of this task, which is to verify that the proposed designs of these
winding forms are acceptable from the point of view of machining. The
Subcontractor shall summarize their findings in a report and shall also
use the results of this study in the preparation of their fixed cost and
schedule proposal for the production winding forms. The files will be
identified in an e-mail which will be sent to you as soon as the files
are available.

### Mold Fabrication

Describe details of the proposed mold design and fabrication (including
modeling).

### Flow Solidification / Distortion Analyses

Describe analyses, plans, and schedules.

### Casting details

Describe the details of the proposed casting process.

### Post-Casting Processing

#### Non-Destructive Testing

Describe the non-destructive testing methods proposed for evaluating the
castings for defects. (Ref. Specification \# NCSX-CSPEC-141-01-01,
Sects. 4.2.8-4.2.10).

#### Dimensional inspection and verification

Describe measuring instrumentation, proposed details of measurements and
how these measurements will be used to verify that the cast part meets
the requirements. (Ref. Specification \# NCSX-CSPEC-141-01-01, Sect.
4.2.7)

#### Winding Form Repairs

Describe expected defects, proposed repair methods, and impact on
winding form material properties. (Ref. Specification \#
NCSX-CSPEC-141-01-01, Sect. 3.3.2.2).

#### Heat Treatment

Describe heat treatment(s) and fixtures required for chosen alloy.
Describe methods for controlling distortion during heat treatment. (Ref.
Specification \# NCSX-CSPEC-141-01-01, Sect. 3.3.2.1).

#### Machining and Final Finishing

Describe details of proposed machining methods and any final finishing
operations (including any mechanical surface finishing methods and final
cleaning methods). (Ref. Specification \# NCSX-CSPEC-141-01-01, Sect.
3.2.1.5)

#### Final Inspection

Describe the final inspection methods proposed to assure that the
winding forms meet all of the requirements of NCSX-CSPEC-141-01-01.

## Subcontractor's Recommendations

The Subcontractor shall recommend changes to the design or Specification
that could make the winding forms easier to manufacture, reduce costs,
improve the fabrication schedule, or reduce risk. PPPL reserves the
right to accept or reject any or all of the Subcontractor's change
recommendations, or to incorporate them into the specification in whole
or in part, even in the event that the contract award for production
winding forms is to another supplier.

## Additional Manufacturing Development Activities

The Subcontractor shall perform and document any additional agreed upon
manufacturing development activities that are necessary to develop the
knowledge required to produce the three winding form shapes and reduce
the technical, cost, and schedule risk. (These additional activities are
to be defined in the Subcontractor's Proposal and shall be set forth in
a revised Statement of Work.)

## Preliminary Manufacturing / Inspection / Test (MIT) and Quality Assurance (QA) PLANS for Production Coils

The Subcontractor shall produce preliminary MIT and QA Plans for all
three winding shapes. (See Section 3.4 of this SOW for plan
descriptions.)

## Budgetary Cost and Schedule Estimate

The Subcontractor shall prepare a Budgetary Cost and Schedule Estimate
for all (18) production winding forms and required tooling in the format
provided in the subcontract based on the MIT plan developed in Section
2.4.

## Processing Plans for Prototype

The Subcontractor shall develop MIT and QA Plans (see Section 3.4) for
the Prototype Winding Form.

## Prototype Manufacture

The Subcontractor shall manufacture a full-scale prototype winding form,
including any required tooling. Drawings have been provided for a
prototype based on the Type A coil. However, the prototype has been
changed from Type A to Type C. Revised drawings will be provided with
the revised specification prior to the start of prototype fabrication.

## Final MIT and QA Plans for Production Winding Forms

The Subcontractor shall develop final MIT and QA Plans (see Section 3.4)
for production of all three winding form shapes based on these supplied
documents. Thirty days before final MIT and QA Plans for Production
Winding Forms are due, PPPL will provide an approved specification
(NCSX-CPEC-141-02-00) and associated Pro/Engineer models and drawings
that are released for fabrication. These are expected to be similar to
those used in the performance of this SOW, but with updates based on the
manufacturing development activities and the production of the Prototype
performed under this SOW.

## Firm Fixed Price and Schedule Proposal

The Subcontractor shall provide a firm fixed price and schedule proposal
for the (18) production winding forms in the format provided in the
Subcontract based on Section 2.8. Thirty days before the Firm Fixed
Price and Schedule Proposal for Production Winding Forms are due, PPPL
will provide an approved specification (NCSX-CPEC-141-02-XX, where XX
reflects the current approved version at that time) and associated
Pro/Engineer models and drawings that are released for fabrication.
These are expected to be similar to those used in the performance of
this SOW, but with updates based on the manufacturing development
activities and the production of the Prototype performed under this SOW.

# Quality Assurance

## Inspection/ Surveillance/Audit by PPPL

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
Subcontract 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*.*

## Subcontractor\'s Responsibility for Conformance

Neither PPPL review and/or approval of Subcontractor\'s documents nor
PPPL inspection of Subcontractor\'s items or services shall relieve the
Subcontractor of responsibility for full compliance with requirements of
the purchase order/contract. The Subcontractor is responsible for
assuring that all requirements and restrictions are imposed on any
sub-tier suppliers.

## Subcontractor's Quality Assurance Program

The Subcontractor shall establish and maintain an effective Quality
Assurance Program to assure that the Subcontractor's work meets the
required quality and is performed in accordance with contractual
requirements. Subcontractor's quality assurance function shall be
organized to have sufficient authority and independence to identify
quality problems, verify conformance of supplied items or services to
specified requirements and obtain satisfactory resolution of conflicts
involving quality.

## Processing Plans

The Subcontractor shall prepare Manufacturing/Inspection Test (MIT) and
Quality Assurance (QA) Plans for PPPL review and approval.

### MIT Plan

Within the MIT plan, the Subcontractor shall identify processes and
materials and show their integrated flow into end items. The plan shall
also identify critical manufacturing operations and inspections and
tests. Procedures and/or protocols for contaminant control and
cleanliness shall be included with the MIT. 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 a minimum of five (5)
working days notice in advance of witness points described in the MIT
plan. Such witness points shall be mutually planned to minimize delays.

### QA Plan

The Quality Assurance Plan shall describe the specific quality assurance
and quality control procedures and practices to meet the requirements of
this subcontract and associated specification.

## Inspection and Test Procedures

Inspections and tests shall be performed in accordance with written
procedures referencing criteria for acceptance or rejection. Actual data
and accept/reject status for each inspection and test shall be
documented for each winding form.

## 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.

## 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.

## 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 acceptable to PPPL and
shall not be used for shop inspections, but instead be protected against
damage or degradation.

## Control of Special Processes

Subcontractor shall use trained and qualified personnel and qualified
written procedures in accordance with specified requirements for the
performance of certain special processes, including but not limited to,
soldering, electronic assembly, brazing, welding, plating, heat
treatment, nondestructive examination, etc. Copies of special process
procedures shall be available for review by Princeton and submitted to
Princeton for review and approval if requested.

## Release for Shipment Form

Subcontractor shall have a signed \"Product Quality Certification and
Shipping Release\" Form (Attachment 1 of this SOW) prior to NCSX Project
acceptance of procured items or services for full or partial shipment.
NCSX Project reserves the right to refuse to accept shipments unless
accompanied by a signed \"Shipping Release Form".

## Process History

Subcontractor shall provide to PPPL, with the shipment release request,
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:

### Material Certifications

The Subcontractor shall submit Material Test Reports showing actual
relevant chemical, mechanical, and electrical properties of materials
used and providing traceability to the actual material. Material
certifications from sub-tier suppliers shall also be submitted. One copy
is to be submitted upon Subcontractor acceptance for use.

### Inspection and Test Reports

Copies of the original reports of all required inspections, tests and
examinations, which have been properly validated by authorized
personnel.

### Repair Documentation

Repair documentation specified in NCSX-CSPEC-141-01-01, Section 3.3.2.2.

### PPPL Receiving and 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 at the Subcontractor's expense.

# DELIVERABLES

## Weekly Reports

Weekly status reports covering technical, administrative, and Quality
activities shall be provided to Princeton's Technical and Administrative
Representatives by e-mail every Friday during the period of performance.

## Earned Value Reporting 

The Contractor shall prepare and submit monthly e-mail reports
indicating earned value achieved. This will be a simplified earned value
reporting requirement that will require the following actions by the
contractor in preparation for earned value reporting:

-   The Contractor will submit a resource-loaded (fully loaded dollars
    only) schedule that clearly indicates the tasks to be accomplished,
    the time frame over which each task will be accomplished, and the
    resources assigned to that task. This schedule will be submitted
    within three (3) weeks of contract award.

-   The Contractor will monthly (e-mail report satisfactory) report
    costs (accrued and actual) against each task on the resource-loaded
    schedule. The first report shall be submitted at the end of the
    first calendar month of the contract award (i.e., if contract
    awarded in January 2003, the first report will be provided at the
    end of January 2003).

-   The Contractor shall monthly report percent complete on each task
    (e-mail report satisfactory). PPPL will then use this percent
    complete to determine the earned value based on the total resources
    applied to each task.

-   On an exception basis, PPPL will request explanation and proposed
    corrective action plan on those tasks that develop significant
    unfavorable schedule or cost variances.

## Technical Reports

Provide (3) printed copies or (1) electronic copy in Adobe Acrobat .pdf
format of all technical reports by the dates specified in the
Subcontract.

## Prototype Processing Plans

MIT & QA Plans for the prototype Winding Form (Section 2.6)

## Preliminary Production Processing Plans

Production processing plans as described in Section 2.4.

## Prototype Winding Form

Fabrication of the prototype winding form per Section 2.7. Packaging and
shipping details shall be subject to prior PPPL approval.

## Production Processing Plans

MIT & QA Plans and a firm fixed price and schedule proposal for the
production winding forms as described in Sections 2.8 and 2.9 of this
document.

## Documentation

Documentation is described in Section 3.11 of this SOW.

## Tooling

All tooling specially fabricated for the performance of this SOW shall
become the property of the United States Government. Disposition will be
per direction of PPPL. In the preparation of a fixed price proposal for
the production coils, Subcontractor shall assume that the tooling is not
a deliverable.

> PRINCETON UNIVERSITY
>
> PLASMA PHYSIC LABORATORY---PPPL

+-----------------+----+--------+--------------+----+---+---+-------------+
| PRODUCT QUALITY |    |        |              |    |   |   |             |
| CERTIFICATION   |    |        |              |    |   |   |             |
| AND SHIPPING    |    |        |              |    |   |   |             |
| RELEASE         |    |        |              |    |   |   |             |
+-----------------+----+--------+--------------+----+---+---+-------------+
| PROJECT         | IT |        |              |    |   | S |             |
|                 | EM |        |              |    |   | H |             |
|                 | D  |        |              |    |   | I |             |
|                 | ES |        |              |    |   | P |             |
|                 | CR |        |              |    |   | M |             |
|                 | IP |        |              |    |   | E |             |
|                 | TI |        |              |    |   | N |             |
|                 | ON |        |              |    |   | T |             |
|                 |    |        |              |    |   | N |             |
|                 |    |        |              |    |   | U |             |
|                 |    |        |              |    |   | M |             |
|                 |    |        |              |    |   | B |             |
|                 |    |        |              |    |   | E |             |
|                 |    |        |              |    |   | R |             |
+-----------------+----+--------+--------------+----+---+---+-------------+
| PPPL            | RE | ITEM   | SUPPLIER     |    | R |   | QUANTITY    |
| SUBCONTRACT/    | V. | NO.    | REFERENCE    |    | E |   | SHIPPED     |
|                 |    |        | NO.          |    | V |   |             |
| ORDER NO.       |    |        |              |    | . |   |             |
+-----------------+----+--------+--------------+----+---+---+-------------+
| [SUPPLIER\'S    |    |        |              |    |   |   |             |
| CERTIFICATI     |    |        |              |    |   |   |             |
| ON]{.underline} |    |        |              |    |   |   |             |
|                 |    |        |              |    |   |   |             |
| > This is to    |    |        |              |    |   |   |             |
| > certify that  |    |        |              |    |   |   |             |
| > the products  |    |        |              |    |   |   |             |
| > and services  |    |        |              |    |   |   |             |
| > identified    |    |        |              |    |   |   |             |
| > herein have   |    |        |              |    |   |   |             |
| > been produced |    |        |              |    |   |   |             |
| > under a       |    |        |              |    |   |   |             |
| > controlled    |    |        |              |    |   |   |             |
| > quality       |    |        |              |    |   |   |             |
| > assurance     |    |        |              |    |   |   |             |
| > program and   |    |        |              |    |   |   |             |
| > are in        |    |        |              |    |   |   |             |
| > conformance   |    |        |              |    |   |   |             |
| > with the      |    |        |              |    |   |   |             |
| > procurement   |    |        |              |    |   |   |             |
| > requirements  |    |        |              |    |   |   |             |
| > including     |    |        |              |    |   |   |             |
| > applicable    |    |        |              |    |   |   |             |
| > codes,        |    |        |              |    |   |   |             |
| > standards and |    |        |              |    |   |   |             |
| >               |    |        |              |    |   |   |             |
|  specifications |    |        |              |    |   |   |             |
| > as identified |    |        |              |    |   |   |             |
| > in the        |    |        |              |    |   |   |             |
| > a             |    |        |              |    |   |   |             |
| bove-referenced |    |        |              |    |   |   |             |
| > documents     |    |        |              |    |   |   |             |
| > unless noted  |    |        |              |    |   |   |             |
| > below. Any    |    |        |              |    |   |   |             |
| > supporting    |    |        |              |    |   |   |             |
| > documentation |    |        |              |    |   |   |             |
| > will be       |    |        |              |    |   |   |             |
| > retained in   |    |        |              |    |   |   |             |
| > accordance    |    |        |              |    |   |   |             |
| > with the      |    |        |              |    |   |   |             |
| > procurement   |    |        |              |    |   |   |             |
| > requirements. |    |        |              |    |   |   |             |
|                 |    |        |              |    |   |   |             |
| SIGNED:         |    |        |              |    |   |   |             |
| \_\_\_\         |    |        |              |    |   |   |             |
| _\_\_\_\_\_\_\_ |    |        |              |    |   |   |             |
| \_\_\_\_\_\_\_\ |    |        |              |    |   |   |             |
| _\_\_\_\_\_\_\_ |    |        |              |    |   |   |             |
| \_\_\_\_\_\_\_\ |    |        |              |    |   |   |             |
| _\_\_\_\_\_\_\_ |    |        |              |    |   |   |             |
| DATE:           |    |        |              |    |   |   |             |
| \_\_\_\         |    |        |              |    |   |   |             |
| _\_\_\_\_\_\_\_ |    |        |              |    |   |   |             |
| \_\_\_\_\_\_\_\ |    |        |              |    |   |   |             |
| _\_\_\_\_\_\_\_ |    |        |              |    |   |   |             |
|                 |    |        |              |    |   |   |             |
| TITLE:          |    |        |              |    |   |   |             |
| \_\_\_          |    |        |              |    |   |   |             |
| \_\_\_\_\_\_\_\ |    |        |              |    |   |   |             |
| _\_\_\_\_\_\_\_ |    |        |              |    |   |   |             |
| \_\_\_\_\_\_\_\ |    |        |              |    |   |   |             |
| _\_\_\_\_\_\_\_ |    |        |              |    |   |   |             |
| COMPANY:        |    |        |              |    |   |   |             |
| \_              |    |        |              |    |   |   |             |
| \_\_\_\_\_\_\_\ |    |        |              |    |   |   |             |
| _\_\_\_\_\_\_\_ |    |        |              |    |   |   |             |
| \_\_\_\_\_\_\_\ |    |        |              |    |   |   |             |
| _\_\_\_\_\_\_\_ |    |        |              |    |   |   |             |
+-----------------+----+--------+--------------+----+---+---+-------------+
| [PPPL           |    |        |              |    |   |   |             |
| (AUTHORIZED     |    |        |              |    |   |   |             |
| REPRESENTATIVE) |    |        |              |    |   |   |             |
| SHIPPING        |    |        |              |    |   |   |             |
| RELEA           |    |        |              |    |   |   |             |
| SE]{.underline} |    |        |              |    |   |   |             |
|                 |    |        |              |    |   |   |             |
| > This is to    |    |        |              |    |   |   |             |
| > certify that  |    |        |              |    |   |   |             |
| > evidence      |    |        |              |    |   |   |             |
| > supporting    |    |        |              |    |   |   |             |
| > the above     |    |        |              |    |   |   |             |
| > Supplier\'s   |    |        |              |    |   |   |             |
| > Certification |    |        |              |    |   |   |             |
| > statement has |    |        |              |    |   |   |             |
| > been audited  |    |        |              |    |   |   |             |
| > and no        |    |        |              |    |   |   |             |
| >               |    |        |              |    |   |   |             |
| product/service |    |        |              |    |   |   |             |
| >               |    |        |              |    |   |   |             |
| nonconformances |    |        |              |    |   |   |             |
| > from          |    |        |              |    |   |   |             |
| > procurement   |    |        |              |    |   |   |             |
| > requirements  |    |        |              |    |   |   |             |
| > have been     |    |        |              |    |   |   |             |
| > found unless  |    |        |              |    |   |   |             |
| > noted below.  |    |        |              |    |   |   |             |
| > This          |    |        |              |    |   |   |             |
| >               |    |        |              |    |   |   |             |
| product/service |    |        |              |    |   |   |             |
| > is hereby     |    |        |              |    |   |   |             |
| > released for  |    |        |              |    |   |   |             |
| > shipment.     |    |        |              |    |   |   |             |
| >               |    |        |              |    |   |   |             |
| > This section  |    |        |              |    |   |   |             |
| > serves as the |    |        |              |    |   |   |             |
| > Quality       |    |        |              |    |   |   |             |
| > Assurance     |    |        |              |    |   |   |             |
| > release for   |    |        |              |    |   |   |             |
| > the above     |    |        |              |    |   |   |             |
| > described     |    |        |              |    |   |   |             |
| > product for   |    |        |              |    |   |   |             |
| > shipment. It  |    |        |              |    |   |   |             |
| > does not      |    |        |              |    |   |   |             |
| > constitute an |    |        |              |    |   |   |             |
| > acceptance    |    |        |              |    |   |   |             |
| > thereof and   |    |        |              |    |   |   |             |
| > does not      |    |        |              |    |   |   |             |
| > relieve the   |    |        |              |    |   |   |             |
| > Vendor,       |    |        |              |    |   |   |             |
| > Manufacturer  |    |        |              |    |   |   |             |
| > or Contractor |    |        |              |    |   |   |             |
| > of any and    |    |        |              |    |   |   |             |
| > all           |    |        |              |    |   |   |             |
| >               |    |        |              |    |   |   |             |
|  responsibility |    |        |              |    |   |   |             |
| > or obligation |    |        |              |    |   |   |             |
| > imposed by    |    |        |              |    |   |   |             |
| > the purchase  |    |        |              |    |   |   |             |
| > contract. It  |    |        |              |    |   |   |             |
| > does not      |    |        |              |    |   |   |             |
| > waive any     |    |        |              |    |   |   |             |
| > rights the    |    |        |              |    |   |   |             |
| > Purchaser may |    |        |              |    |   |   |             |
| > have under    |    |        |              |    |   |   |             |
| > the purchase  |    |        |              |    |   |   |             |
| > contract,     |    |        |              |    |   |   |             |
| > including the |    |        |              |    |   |   |             |
| > Purchaser\'s  |    |        |              |    |   |   |             |
| > right to      |    |        |              |    |   |   |             |
| > reject the    |    |        |              |    |   |   |             |
| > above         |    |        |              |    |   |   |             |
| > described     |    |        |              |    |   |   |             |
| > material upon |    |        |              |    |   |   |             |
| > discovery of  |    |        |              |    |   |   |             |
| > any           |    |        |              |    |   |   |             |
| > deviations    |    |        |              |    |   |   |             |
| > from          |    |        |              |    |   |   |             |
| > requirements  |    |        |              |    |   |   |             |
| > of the        |    |        |              |    |   |   |             |
| > purchase      |    |        |              |    |   |   |             |
| > contract,     |    |        |              |    |   |   |             |
| > drawings and  |    |        |              |    |   |   |             |
| >               |    |        |              |    |   |   |             |
| specifications. |    |        |              |    |   |   |             |
+-----------------+----+--------+--------------+----+---+---+-------------+
| NONCONFORMANCES |    |        |              |    |   |   |             |
| FROM            |    |        |              |    |   |   |             |
| PROCUREMENT     |    |        |              |    |   |   |             |
| QUALITY         |    |        |              |    |   |   |             |
| REQUIREMENTS:   |    |        |              |    |   |   |             |
+-----------------+----+--------+--------------+----+---+---+-------------+
| REMARKS/PRODUCT |    |        |              |    |   |   |             |
| SERIAL NUMBERS: |    |        |              |    |   |   |             |
+-----------------+----+--------+--------------+----+---+---+-------------+
| BY PPPL QA      |    |        |              | DA |   |   |             |
| REPRESENTATIVE  |    |        |              | TE |   |   |             |
| (OR DESIGNEE)   |    |        |              |    |   |   |             |
+-----------------+----+--------+--------------+----+---+---+-------------+