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

**NSTX**

**SPECIFICATION**

**FOR**

**OH COIL CENTER STACK**

**NSTX-SPEC-13-040**

**Revision 0**

**DATED:** May 21, 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**

**RECORD OF CHANGE**

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**TABLE OF CONTENTS**

**1.0 SCOPE:
\...\...\...\...\...\...\...\...\...\...\...\...\...\...\...\...\... 1**

**2.0 APPLICABLE DOCUMENTS: \...\...\...\...\...\...\...\...\... 1**

2.1 DRAWINGS:
\...\...\...\...\...\...\...\...\...\...\...\...\...\...\...\...\...\...\...\...
1

2.2 STANDARDS AND CODES:
\...\...\...\...\...\...\...\...\...\...\...\...\..... 1

2.3 GENERAL STATEMENT:
\...\...\...\...\...\...\...\...\...\...\...\...\...\..... 2

**3.0 REQUIREMENTS:
\...\...\...\...\...\...\...\...\...\...\...\...\.... 2**

3.1 EQUIPMENT DEFINITION:
\...\...\...\...\...\...\...\...\...\...\...\...\..... 2

3.1.1 General Design Features:
\...\...\...\...\...\...\...\...\...\...\...\...\...\...\..... 2

3.1.2 Materials:
\...\...\...\...\...\...\...\...\...\...\...\...\...\...\...\...\...\...\...\...\...\...
2

> 3.1.2.1 Copper Conductor:
> \...\...\...\...\...\...\...\...\...\...\...\...\...\...\.... 2
>
> 3.1.2.2 Insulation System:
> \...\...\...\...\...\...\...\...\...\...\...\...\...\...\..... 3
>
> 3.1.2.3 Ground Plane:
> \...\...\...\...\...\...\...\...\...\...\...\...\...\...\...\...\....
> 4
>
> 3.1.2.4 Degreasing/Cleaning Solvent:
> \...\...\...\...\...\...\...\...\...\...\.... 4
>
> 3.1.2.5 Soldering and Braze Materials:
> \...\...\...\...\...\...\...\...\...\...\... 5
>
> 3.1.2.6 Fillers:
> \...\...\...\...\...\...\...\...\...\...\...\...\...\...\...\...\...\...\...\....
> 5
>
> 3.1.2.7 Machined Coil Lead Blocks and Electrical Flags:
> \...\...\...\... 5
>
> 3.1.2.8 Grit Blasting Materials:
> \...\...\...\...\...\...\...\...\...\...\...\...\..... 5
>
> 3.1.2.9 Tension Tube:
> \...\...\...\...\...\...\...\...\...\...\...\...\...\...\...\...\....
> 5
>
> 3.1.2.10 Copper Primer:
> \...\...\...\...\...\...\...\...\...\...\...\...\...\...\...\...\... 6
>
> 3.1.2.11 Conductor Coolant Tube
> \...\...\...\...\...\...\...\...\...\...\...\...\..... 6

3.2 COIL FABRICATION
\...\...\...\...\...\...\...\...\...\...\...\...\...\...\...\..... 6

3.2.1 Copper Conductor Delivery:
\...\...\...\...\...\...\...\...\...\...\...\...\...\...\... 6

3.2.2 Conductor Cleaning:
\...\...\...\...\...\...\...\...\...\...\...\...\...\...\...\...\...\...
6

3.2.3 Material Protection:
\...\...\...\...\...\...\...\...\...\...\...\...\...\...\...\...\...\....
6

3.2.4 Conductor Inspection:
\...\...\...\...\...\...\...\...\...\...\...\...\...\...\...\...\.... 6

3.2.5 Tension Tube Preparation:
\...\...\...\...\...\...\...\...\...\...\...\...\...\...\..... 7

3.2.6 Conductor Preparation:
\...\...\...\...\...\...\...\...\...\...\...\...\...\...\...\..... 7

3.2.7 Coil Winding:
\...\...\...\...\...\...\...\...\...\...\...\...\...\...\...\...\...\...\...\....
8

3.2.8 Layer to Layer Coil Joints:
\...\...\...\...\...\...\...\...\...\...\...\...\...\...\..... 9

> 3.2.8.1 Joint Preparation:
> \...\...\...\...\...\...\...\...\...\...\...\...\...\...\...\... 9
>
> 3.2.8.2 Braze/Solder Prerequisites:
> \...\...\...\...\...\...\...\...\...\...\...\.... 9
>
> 3.2.8.3 Joining Operation:
> \...\...\...\...\...\...\...\...\...\...\...\...\...\...\..... 10

3.2.9 Lead Area Turn Insulation:
\...\...\...\...\...\...\...\...\...\...\...\...\...\...\.... 10

3.2.10 Coil Leads:
\...\...\...\...\...\...\...\...\...\...\...\...\...\...\...\...\...\...\...\...\....
10

3.2.11 Electrical Connections:
\...\...\...\...\...\...\...\...\...\...\...\...\...\...\...\...\... 10

3.2.12 Coil Fillers:
\...\...\...\...\...\...\...\...\...\...\...\...\...\...\...\...\...\...\...\...\...
11

3.2.13 Coil Molding:
\...\...\...\...\...\...\...\...\...\...\...\...\...\...\...\...\...\...\...\....
11

3.2.14 Outer Ground Wall Insulation:
\...\...\...\...\...\...\...\...\...\...\...\...\...\... 11

3.2.15 Machining of Ground Wall:
\...\...\...\...\...\...\...\...\...\...\...\...\...\...\... 12

3.2.16 Post-Machining:
\...\...\...\...\...\...\...\...\...\...\...\...\...\...\...\...\...\...\....
12

3.2.17 Evaluation of Finished Surfaces:
\...\...\...\...\...\...\...\...\...\...\...\...\... 12

3.2.18 Ground Plane:
\...\...\...\...\...\...\...\...\...\...\...\...\...\...\...\...\...\...\...\...
12

**TABLE OF CONTENTS**

**4.0 TEST REQUIREMENTS: \...\...\...\...\...\...\...\...\...\..... 12**

4.1 RECEIVING INSPECTION-OH CONDUCTOR \...\...\...\...\..... 12

4.1.1 Dimensional Measurements/Inspections:
\...\...\...\...\...\...\...\...\.... 12

4.1.2 Coolant Hole Size:
\...\...\...\...\...\...\...\...\...\...\...\...\...\...\...\...\.....
13

4.2 IN-PROCESS TESTING:
\...\...\...\...\...\...\...\...\...\...\...\...\...\..... 13

4.2.1 Insulation Resistance Test Prior To Joint
\...\...\...\...\...\...\...\...\... 13

4.2.2 Hydrostat Tests During Joint Fabrication:
\...\...\...\...\...\...\...\..... 13

4.2.3 Tests After Assembly and Prior to Oven Cure:
\...\...\...\...\...\...\... 13

4.3 FINAL ACCEPTANCE TESTS:
\...\...\...\...\...\...\...\...\...\...\...\.... 14

4.3.1 Inspection:
\...\...\...\...\...\...\...\...\...\...\...\...\...\...\...\...\...\...\...\...\...
14

4.3.2 Flow/Pressure Tests:
\...\...\...\...\...\...\...\...\...\...\...\...\...\...\...\...\... 14

4.3.3 Final Electrical Tests:
\...\...\...\...\...\...\...\...\...\...\...\...\...\...\...\...\... 14

5.0 **QUALITY ASSURANCE REQUIREMENTS: \...\...\.... 15**

5.1 INSPECTION/ SURVEILLANCE/ AUDIT BY PRINCETON: .. 15

5.2 SUBCONTRACTOR'S RESPONSIBILITY

FOR CONFORMANCE:
\...\...\...\...\...\...\...\...\...\...\...\...\...\...\.... 15

5.3 QUALITY ASSURANCE PLAN:
\...\...\...\...\...\...\...\...\...\...\...\... 16

5.4 MANUFACTURING, INSPECTION AND

TEST PLAN (MIT):
\...\...\...\...\...\...\...\...\...\...\...\...\...\...\...\...\... 16

5.5 INSPECTION AND TEST PROCEDURES: \...\...\...\...\...\...\..... 16

5.6 DOCUMENT TRACEABILITY AND RECORDS: \...\...\...\...\... 16

5.7 EQUIPMENT/MATERIAL IDENTIFICATION

AND STATUS:
\...\...\...\...\...\...\...\...\...\...\...\...\...\...\...\...\...\...\...
16

5.8 DOCUMENT REVIEW, APPROVAL AND CONTROL: \...\..... 16

5.9 CALIBRATION OF TEST AND MEASURING

EQUIPMENT:
\...\...\...\...\...\...\...\...\...\...\...\...\...\...\...\...\...\...\....
17

5.10 RELEASE FOR SHIPMENT FORM:
\...\...\...\...\...\...\...\...\...\.... 17

5.11 PROCESS HISTORY:
\...\...\...\...\...\...\...\...\...\...\...\...\...\...\...\... 17

> 5.11.1 Certificate of Compliance (C of C)
> \...\...\...\...\...\...\...\..... 17
>
> 5.11.2 Material Certifications:
> \...\...\...\...\...\...\...\...\...\...\...\...\.... 17
>
> 5.11.3 Inspection/Test Documents:
> \...\...\...\...\...\...\...\...\...\...\.... 17
>
> 5.11.4 Inspection Reports:
> \...\...\...\...\...\...\...\...\...\...\...\...\...\..... 17
>
> 5.11.5 Test Reports:
> \...\...\...\...\...\...\...\...\...\...\...\...\...\...\...\...\...
> 18
>
> 5.11.6 Fabrication Drawings
> \...\...\...\...\...\...\...\...\...\...\...\...\...\... 18

6.0 **DOCUMENTATION REQUIREMENTS: \...\...\...\...\... 18**

6.1 Proposal Technical Documentation:
\...\...\...\...\...\...\...\...\...\...\... 18

6.2 Documentation After Contract Award and Prior to Fabrication:.. 18

6.3 Documentation Prior to Shipment:
\...\...\...\...\...\...\...\...\...\...\..... 19

7.0 **SHIPPING STORAGE AND HANDLING: \...\...\..... 19**

8.0 **DELIVERABLES: \...\...\...\...\...\...\...\...\...\...\...\...\...
19**

9.0 **ATTACHMENTS:**

APPENDIX I OH Center Stack Bundle drawings: \...\...\.... 20

APPENDIX II Coil Bundle/ Insulation Data: \...\...\...\...\...\... 21

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

> a\. This specification defines the manufacturing requirements for the
> National Spherical Torus Experiment (NSTX) Ohmic Heating (OH) coil
> which comprises part of the Center Stack. To minimize the risk of coil
> failure, for any reason, strict adherence to these specifications and
> the associated drawings is essential.
>
> 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, or exceptions noted herein.

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

**2.1** **DRAWINGS**

> 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}**
>
> B260-62T (BCuP-5), Brazing Alloys
>
> B32-Sn96, Tin/Silver solder
>
> **[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-13-037-0*** "OH/PF Coil 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.
>
> **[ASME-American Society of Mechanical Engineers]{.underline}**
>
> ASME B31.3 "Acceptance Criteria for Welds-Category D"
>
> (Tension Tube fabrication)

**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 36-38 ksi
> (0.5% elongation) and Ultimate Tensile Strength 42 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. The conductors will be supplied by
> PPPL to the Subcontractor on continual length spools for the OH coil.
>
> 3.1.2.2 [Insulation System]{.underline}
>
> a\. The turn insulation shall consist of CTD-112P pre-impregnated
> (B-stage) epoxy-glass tape with Kapton applied in half-lapped layers.
> (IMI Product no. 2259XS)
>
> b\. The tension tube shall be insulated with half-lapped layers of
> Teflon tape and CTD-112P pre-impregnated (B-stage) epoxy-glass tape
> without Kapton (IMI Product no. 2258XS) to form the inner ground wall.
>
> c\. The CTD-112P insulating materials shall be provided by PPPL. All
> remaining insulating materials required to manufacture the OH coil
> 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.
>
> **Note: The CTD products must be kept in a refrigerator or freezer to
> maintain shelf life. ( ≤ 40° F)**
>
> d\. The outer 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 OH coil. The final radial build
> after final cure and machining shall be in accordance with the
> drawings identified in Appendix I.
>
> e\. Any voids between turns or near lead areas will be filled with
> pre-impregnated CTD-112P tape.
>
> f\. Details concerning the insulating materials are as follows:
>
> **[CTD-112P Pre-impregnated Glass/Co-wound with Kapton]{.underline}**
>
> **(IMI Product No. 2259XS)** with interliner
>
> Resin Type: TGDM epoxy, aromatic amine cure agent
>
> Composite Technology Development (CTD), Boulder, Co
>
> Glass tape: S-2 ( satin weave) std. silane finish
>
> Temperature Class: 180° C
>
> Nominal Thk.: 0.006 in. (0.152 mm.) tape
>
> Nominal Width: 1.0 in. tape
>
> Barrier: Kapton
>
> Nominal Thk.: 0.002 (0.05 mm)
>
> Nominal Width: 1.0 in. tape
>
> **[CTD-112P Pre-impregnated Tape]{.underline}** (tension tube ground
> wall)
>
> **(IMI Product no. 2258XS)** with interliner
>
> Resin Type: TGDM epoxy, aromatic amine cure agent
>
> Composite Technology Development (CTD), Boulder, Co
>
> Glass tape: S-2 ( satin weave) std. silane finish
>
> Temperature Class: 180° C
>
> Nominal Thk.: 0.006 in. (0.152 mm.) tape
>
> Nominal Width: 1.0 in. tape
>
> **[3M-Scotchply #1003-]{.underline}** (Groundwall insulation)
>
> Epoxy-glass pre-preg insulation in tape form
>
> Glass Tape: Type "K" filament
>
> Nominal Thickness: 0.010 in. (0.254 mm)
>
> Nominal width: 2.0 in. tape
>
> **[Kapton]{.underline}**
>
> 1 mil Kapton with silicone adhesive
>
> Nominal Thk.: 0.0025 in. ( 0.0635 mm.)
>
> Nominal Width: 1.00 in.
>
> Dielectric Strength: 7.5 KV
>
> Tensile Strength: 37 lb./in.
>
> Temperature Class: 180° C
>
> **[Teflon (PTFE) Pessure Sensitive Tape]{.underline}** (tension tube
> application)
>
> 2 mil Teflon with silicone adhesive
>
> Nominal Thickness: 0.0035 in. (0.051 mm)
>
> Nominal Width: 1-2 inches
>
> Dielectric Strength: 4.5 kV
>
> 3.1.2.3 [Ground Plane]{.underline}
>
> A dielectric ground plane shall be applied to the outside of the
> finish cured OH Coil. Conducting Varnish #8003, thermal class F
> (155°C) shall be used as the dielectric overcoat material (Insulating
> Materials Incorp.). An equivalent product may be used with prior
> approval by PPPL.
>
> 3.1.2.4 [Degreasing/Cleaning Solvent:]{.underline}
>
> All conductors shall be degreased/cleaned using a solvent which has
> been pre-approved by PPPL. This solvent must be able to dissolve
> grease, tar, wax, adhesives, oils and other soils, and be residue
> free.
>
> 3.1.2.5 [Soldering and Braze Materials:]{.underline}
>
> a\. The ends of the layer to layer joints shall be TIG brazed using
> Sil-Fos -braze material a product of "Handy & Harmon". It shall also
> be used to braze the electrical flags to the coil leads. No flux shall
> be used with the Sil-Fos material.
>
> Composition: 15% Ag, 80% Cu, 5% P
>
> Melting Point 1185° F (640° C)
>
> Flow Point 1130° F (705° C)
>
> b\. Following step a. the layer to layer joints shall be soft-soldered
> together using 96%/ 4% Tin-Silver soft-solder with a melt temperature
> of 430°F (221°C). Subcontractor shall recommend suitable liquid flux.
> Any changes from this shall require PPPL approval.
>
> c\. Certification of the brazing and soldering alloys shall be in
> accordance with ASTM specifications noted in section 2.2, and shall be
> submitted as part of the document package.
>
> 3.1.2.6 [Fillers:]{.underline}
>
> All lead or joggle fillers shall be made of NEMA Grade G-10 glass
> reinforced epoxy meeting all NEMA (National Electrical Manufacturers
> Association) "G-10" Grade specifications.
>
> 3.1.2.7 [Machined Coil Lead Blocks and Electrical Flags:]{.underline}
>
> Machined blocks for coil leads shall be fabricated from copper bar or
> plate. Alloy shall be CDA alloy no.10200 or 10400 oxygen free copper
> having a minimum yield strength of 30,000 psi (0.5% elong.) or PPPL
> approved equivalent.
>
> 3.1.2.8 [Grit Blasting Materials:]{.underline}
>
> Grit blasting shall be performed using aluminum oxide with a grain
> size of 80-120 mesh.
>
> 3.1.2.9 [Tension Tube:]{.underline}
>
> a\. The subcontractor is responsible for the fabrication of the
> tension tube per PPPL drawing NSTX- 13-E0005.0.
>
> b\. The OH coil tension tube shall be fabricated using 304 stainless
> steel materials.
>
> c\. It is the responsibility of the coil subcontractor to verify that
> **all fabrication tolerances** are as noted on the PPPL tension tube
> drawing.
>
> d\. Subcontractor is responsible for verifying that welders are
> certified to section 9.0 of the ASME code.
>
> e\. Subcontractor must verify the permeabilty of the welds and base
> materials as noted on the above mentioned PPPL drawing.
>
> f\. The subcontractor is responsible for obtaining material
> certifications for the materials used to fabricate the OH tension
> tube.
>
> 3.1.2.10 [Copper Primer]{.underline}
>
> The primer shall be Araldite DZ-80-1, manufactured by Ciba-Geigy (UK)
> Limited Plastics Division. **[No substitutions
> permitted]{.underline}.**
>
> 3.1.2.11 [Conductor Coolant Tube]{.underline}
>
> The coolant which shall be soldered into the ends of the OH conductor
> shall be seamless Air Conditioning and Refrigeration (ACR) copper
> tubing with a 0.250 in. outside diameter and a 0.030 in. wall
> thickness.

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 conductor for the OH solenoid will be delivered to the
> Subcontractor as one continuous conductor per coil layer in spool form
> **(No joints/splices in copper spool allowed)**. The shipping
> containers shall be inspected upon receipt for shipping damage by the
> Subcontractor and condition of containers documented.
>
> 3.2.2 **[Conductor Cleaning]{.underline}:**
>
> The copper conductors spools shall be removed from their containers
> and the inner conductor coolant path shall be flushed with the
> degreasing solvent to remove all traces of oil or grease remaining
> from the extrusion process. The visible surfaces of the copper spool
> shall be clean and free of slivers, burrs, scale and other injurious
> defects. Note: The balance of the copper surfaces shall be cleaned
> during the winding operation.
>
> 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.
>
> 3.2.4 **[Conductor Inspection:]{.underline}**
>
> The conductors shall then be moved to an inspection station where they
> will be inspected per requirements in Section 4.0 paragraph 4.1,
> including a check of the coolant hole uniformity.
>
> 3.2.5 **[Tension Tube Preparation:]{.underline}**
>
> a\. [Surface Preparation:]{.underline}
>
> The tension tube shall be inspected for any burrs or sharp edges which
> may exist. If any are found, they shall be removed using a file or
> sanding methods.
>
> b\. [Cleaning Operation:]{.underline}
>
> The tension tube shall be thoroughly cleaned using clean rags and
> approved degreasing/cleaning solvent.
>
> c\. [Tension Tube Support:]{.underline}
>
> The OH coil tension tube must be supported internally to prevent
> distortion to the tube during winding, and to provide the necessary
> end supports for mounting to the winding equipment.
>
> d\. [Application of Inner Ground Wall :]{.underline}
>
> Two half-lapped layers of Teflon tape shall be applied directly onto
> the Tension Tube. This shall provide both a dielectric insulator and a
> slip plane for the OH Coil. An inner ground wall of Prepreg (IMI
> Product no. 2258XS) insulation shall be applied directly over the
> Teflon insulation prior to starting winding operation (See Appendix II
> for insulation build), providing the inner radius ground wall of the
> OH coil.
>
> 3.2.6 **[Conductor Preparation:]{.underline}**
>
> a\. [Conductor Spools:]{.underline}

The copper conductor spools shall be mounted onto support stands to
allow the copper conductor to be fed freely onto the tension tube.

> b\. [Conductor Cleaning:]{.underline}
>
> The conductor shall be cleaned as it is unwound from the copper
> storage spools using a pre-approved degreasing solvent to remove all
> traces of oil or grease remaining from the extrusion process.
>
> c\. [Grit Blasting:]{.underline}
>
> After degreasing, the conductor shall be aluminum oxide blasted to
> remove any surface oxidation and assist kapton bonding. This must be
> performed in a control manner which will expose the conductor to grit
> blasting at a 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 getting contaminants onto the conductors.
>
> d\. [Cleaning After Grit Blasting:]{.underline}
>
> After grit blasting, the conductor shall be vacuum cleaned and wiped
> to remove all aluminum oxide grit remaining from the grit blasting.
>
> e\. [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.
>
> f\. [Turn to Turn Insulation:]{.underline}
>
> Two half-lapped layers of pre-preg w/Kapton (IMI Product no. 2259XS)
> insulation shall be applied to the conductors following application of
> the primer.
>
> **Note: Kapton side of the insulation shall face away from conductor
> during application.**
>
> *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 approved repair procedure which will maintain
> insulation continuity.*
>
> 3.2.7 **[Coil Winding:]{.underline}**
>
> The OH coil is constructed of four layers of windings with the
> conductors wound two-in-hand. These conductors are connected in series
> with one set of power supply leads at the upper end of the coil.
>
> a\. The winding station shall include a coil winding unit; tension
> units; copper spool stations; conductor sandblast units; portable
> insulation taping machines; pre-bend rollers; OH Tension Tube support
> structure plus miscellaneous tools and equipment.
>
> **Note: All tooling and fixturing necessary to complete the winding
> operation, is the responsibility of the Subcontractor.**
>
> b\. The OH conductor shall be tension wound directly onto the
> centerstack tension tube, with the crown side of the conductor facing
> away from the tension tube per PPPL approved fabrication drawings.
>
> c\. There are four (4) layers of conductor turns in the OH coil. Each
> layer shall be wound with OH conductors (2 -in-hand) per PPPL approved
> fabrication drawings.
>
> d\. [Winding Tension:]{.underline}
>
> The magnitude of the tension and method for monitoring tension value
> shall be pre-determined and tension details to be approved by PPPL.
> The conductor tension must be sufficient to provide a 10% compression
> of the prepreg insulation during winding. The radial measurements
> shown on the OH coil drawings includes the 10% compression. The
> recomended winding tension is 1800-2200 psi.

**Table 3.2.1**

**OH Coil Winding Data**

+-------------+----------+-----------------+------------+------------+
| **OH        | **No.    | **Coil          | **Spool    | *          |
| Winding**   | of**     | Conductor       | Length     | *Conductor |
|             |          | Length (Ft.)**  | (Ft.)**    | Wt.        |
| **ID**      | *        |                 |            | (LBS.)**   |
|             | *Turns** |                 |            |            |
+-------------+----------+-----------------+------------+------------+

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

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

  -------------- ----------- ------------------ ------------- -------------
  OH 1X          122.5       289.0              319.0         271.0

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

  -------------- ----------- ------------------ ------------- -------------
  OH1Y           122.7       289.5              319.0         271.0

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

  -------------- ----------- ------------------ ------------- -------------
  OH2X           121.0       314.4              347.0         294.8

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

  -------------- ----------- ------------------ ------------- -------------
  OH2Y           121.0       314.4              347.0         294.8

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

  -------------- ----------- ------------------ ------------- -------------
  OH3X           119.5       339.2              376.0         319.4

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

  -------------- ----------- ------------------ ------------- -------------
  OH3Y           120.3       341.3              376.0         319.4

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

  -------------- ----------- ------------------ ------------- -------------
  OH4X           118.0       363.2              401.0         340.7

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

  -------------- ----------- ------------------ ------------- -------------
  OH4Y           118.0       363.2              401.0         340.7

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

> 3.2.8 **[Layer to Layer Coil Joints:]{.underline}**
>
> There are seven layer to layer coil joints in the OH coil assembly.
> Two of these are locking joints which must be made once the conductors
> have been wound in place onto the tension tube. The detail and
> location of these joints are shown in the approved PPPL drawings
> identified in Appendix I.
>
> 3.2.8.1 [Joint Preparation:]{.underline}
>
> a\. The layer to layer joint shall always occur on the outer most of
> the two layers being joined.
>
> b\. The ends of each conductor shall be machined per the PPPL approved
> drawings identified in Appendix I.
>
> c\. The conductors shall be pre-formed to proper layer radius prior to
> joining.
>
> d\. The ends of the conductors shall be properly cleaned prior to
> soldering.
>
> e\. Prior to joining each OH coil layers an [insulation
> resistance]{.underline} test shall be performed (see section 4.2.1).
>
> 3.2.8.2 [Brazing/Soldering Prerequisites]{.underline}
>
> a\. Brazing and soldering procedures are required for fabricating the
> OH joints. These procedures shall be reviewed and approved by PPPL.
>
> b The Subcontractor's braze/soldering operator must be qualified and
> demonstrate his ability to perform the TIG brazing and
> silver-soldering operations with skill and efficiency.
>
> c\. The braze operator must fabricate a minimum of three OH sample
> joints which shall then be tested at PPPL to determine their
> mechanical integrity. These tests must be successfully completed prior
> to the operator becoming qualified.
>
> 3.2.8.3 [Joining Operation:]{.underline}
>
> a\. The overlapping joint surfaces shall be pre-tinned using the 96%/4
> % silver-tin soft-solder. A liquid flux is required during the
> soldering operation. The conductors **shall not be heated above
> 500°F**.
>
> b\. The conductors shall be overlapped forming a four inch single lap
> joint and clamped in position.
>
> c\. Each end of the conductors shall be TIG brazed, by a qualified
> operator, using Sil-Fos braze material with helium shield gas. (6-10
> seconds at 180 amps per end)
>
> **Note: TIG brazing time MUST be carefully controlled to minimize
> softening of the copper conductor.**
>
> d\. The maximum joint temperature and the time required to complete
> the TIG operation must be monitored and documented.
>
> e\. Remove the clamps from the previous operation. Apply flux to the
> pre-tinned joint and solder using pre-approved procedure and
> technique. The copper coolant tubes shall be soldered into the
> conductor coolant holes during this step.
>
> f\. Carefully clean the joint with hot water, **making sure that no
> water gets into the surrounding insulation**, and remove excess solder
> using a file and hand sanding.
>
> g\. A hydrostat test shall be performed after cleaning and prior to
> insulating to verify the water tight integrity of the newly soldered
> coolant tubes. (Section 4.2.2)
>
> h\. A visual inspection of the joint shall be made and findings
> documented.
>
> i\. Sandblast the conductor surface and apply primer. Install the G-10
> fillers at each end of the joined conductors and apply turn insulation
> per section 3.2.6. Care must be taken to blend the turn insulation
> with the existing insulation on the conductors.
>
> 3.2.9 **[Lead Area Turn Insulation:]{.underline}**
>
> Turn insulation shall be tailored to fit neatly around water and
> electrical terminals.
>
> 3.2.10 **[Coil Leads:]{.underline}**
>
> The OH coil conductor leads shall be formed per approved PPPL drawings
> identified in Appendix I.
>
> 3.2.11 **[Electrical Connections:]{.underline}**
>
> The copper electrical connections shall be induction/torch brazed to
> the conductor ends during the winding process. Braze materials are
> specified in section 3.1.2.5. Braze process must be PPPL approved.
>
> 3.2.12 **[Coil Fillers]{.underline}**
>
> a\. All filler blocks shall be made with NEMA Grade G-10 glass
> reinforced epoxy which has been sanded and vacuum cleaned.
>
> b\. Pre-impregnated (IMI Product no. 2258XS) insulation without Kapton
> shall be installed between adjacent G-10 fillers to bond fillers
> together during the coil molding process.
>
> 3.2.13 **[Coil Molding]{.underline}**
>
> a\. Two (2) half-lapped layers of 2 mil non-stick (Tedlar) tape shall
> be applied around the entire OH coil.
>
> 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 OH 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 OH coil
> to form a monolithic, void free structure with dimensions within the
> specified tolerances.
>
> f\. Following the insulation cure cycle, the OH coil shall be removed
> from the press-mold. The layers of Tedlar and shrinkable mylar shall
> be removed, and the coil shall be inspected.
>
> 3.2.14 **[Outer Ground Wall Insulation:]{.underline}**
>
> a\. The outer ground wall insulation shall be applied to the outside
> diameter of OH coil 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 outer ground insulation shall extend over the G-10 split
> pressure ring collars located at each end of the OH coil assembly.
>
> f\. The "Scotchply" ground insulation shall be cured to mutually
> agreed upon specifications.
>
> 3.2.15 **[Machining of Ground Insulation]{.underline}**
>
> a\. After the "Scotchply" has cured, the OH 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 OH coil
> shall be proposed by Subcontractor and approved by PPPL. Care must be
> taken not to machine below the specified dimensions in the drawings.
>
> 3.2.16 **[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.
>
> 3.2.17 **[Evaluation of Finished Surfaces]{.underline}**
>
> The cured coils shall be checked for dimensional conformance with the
> drawings.
>
> 3.2.18 **[Ground Plane:]{.underline}**
>
> After the cured coil has been inspected, the outer surfaces of the
> coils shall be painted with a conductive paint, providing a ground
> plane on the outer wall of the coil insulation.

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

Mechanical and electrical inspections and tests shall be performed on
each coil. Reports of required tests are to be provided to PPPL for
acceptance in accordance with manufacturers inspection and test (MIT)
plan, approved by PPPL. Seller shall notify PPPL in advance to permit
PPPL's representatives to witness any of the inspections or tests,
either in-process or final acceptance.

4.1 **RECEIVING INSPECTION- OH CONDUCTOR**

> 4.1.1 **[Dimensional Measurements/Inspections]{.underline}**
>
> Conductors shall be checked to verify that the cross-sectional
> dimensions are within the required tolerance. They will also be
> inspected for surface conditions.
>
> 4.1.2 **[Coolant Hole Size:]{.underline}**
>
> The coolant hole size shall be checked for uniform diameter throughout
> the entire length of the bar by means of a ball bearing which will be
> 1/16 inch diameter undersize of the nominal diameter. The centering of
> the hole shall be checked.

4.2 **IN-PROCESS TESTING**

> 4.2.1 **[Insulation Resistance Test Prior To Joint]{.underline}**
>
> An insulation resistance test shall be performed of each wound
> conductor prior to making up the layer to layer joint. The insulation
> resistance shall be verified by applying a **500 V** Megger to the
> layer be tested with the adacent conductors grounded. Hold at **500
> V** until there is no change in resistance. The insulation resistance
> shall be greater than **1000 MΩ.**
>
> 4.2.2 **[Hydrostat Tests During Joint Fabrication:]{.underline}**
>
> A hydrostat test shall be performed on each soldered coolant tube
> after the soldering operation, but prior to the joint being insulated
> using calibrated pressure gauges.
>
> a\. The test pressure shall be maintained at **600 psi** without any
> change for at least ten minutes from the time the system was isolated
> from the pressure source, during which time there shall be no change
> in the pressure reading on the calibrated pressure gauge.
>
> b\. After the ten minute period, the pressure may be reduced to the
> **200 psi**, and held for a sufficient time to permit inspection of
> the newly soldered coolant tube. Record all test data.
>
> 4.2.3 **[Tests After Assembly and Prior to Oven Cure:]{.underline}**
>
> a\. [DC Resistance:]{.underline}
>
> Measure and record the dc resistance and temperature of the OH coil
> and lead. The resistance shall agree with the calculated value within
> 3.0%. The calculated OH coil resistance is: **0.0932 Ω** ( 93.18 mΩ )
>
> b\. [Insulation Resistance to Ground]{.underline}
>
> The insulation resistance of the OH coil shall be verified by applying
> a **500 V** Megger between the coil and the ground plane. Hold at
> **500 V** until there is no change in resistance. The insulation
> resistance shall be greater than **1000 MΩ.**

4.3 **FINAL ACCEPTANCE TESTS**

These tests and inspections shall be performed once the coils are in a
deliverable configuration.

> 4.3.1 **[Inspection:]{.underline}**
>
> A careful visual inspection and dimensional check shall be made
> according to applicable drawings.
>
> 4.3.2 **[Flow/Pressure Tests:]{.underline}**
>
> a\. The coil coolant circuits shall be tested for flow vs. pressure
> drop and hydrostatic pressure tested. These tests shall be performed
> using potable water.
>
> b\. Operational flow rates and pressure drops are as follows:

**Table 4.3.1**

**OH Coil Flow vs. Pressure Table**

  ----------------------- ----------------------- -----------------------
  **OH Winding ID**       **Flow (GPM)**          **Pressure (PSI)**

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

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

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

  ----------------------- ----------------------- -----------------------
  OH 1X                   0.64                    210.9

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

  ----------------------- ----------------------- -----------------------
  OH 1Y                   0.64                    211.4

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

  ----------------------- ----------------------- -----------------------
  OH 2X                   0.70                    268.5

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

  ----------------------- ----------------------- -----------------------
  OH 2Y                   0.70                    268.5

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

  ----------------------- ----------------------- -----------------------
  OH 3X                   0.76                    334.4

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

  ----------------------- ----------------------- -----------------------
  OH 3Y                   0.76                    336.5

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

  ----------------------- ----------------------- -----------------------
  OH 4X                   0.81                    401.2

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

  ----------------------- ----------------------- -----------------------
  OH 4Y                   0.81                    401.2

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

> ***Pressure drop shall be +/- 10% of values indicated above.***
>
> b\. [Hydrostatic Pressure Tests:]{.underline}
>
> A hydrostat test shall be performed on the entire OH coil per section
> 4.2.1. The test results shall be documented.
>
> 4.3.3 **[Final Electrical Tests:]{.underline}**
>
> If any of the following electrical tests show evidence of disruptive
> discharges indicating insulation failure or weakness, (i.e., excessive
> current leakage, flashover), this shall be cause for rejection. It is
> the Seller's responsibility to insure that the specified test voltage
> levels are not exceeded, and that proper testing safeguards are taken
> to prevent test equipment and circuitry malfunctions which could
> result in over-voltage and/or switching transients.
>
> a\. [DC Resistance:]{.underline}
>
> Measure and record the dc resistance and temperature of the coil. The
> resistance shall agree with the measurement of section 4.2.2, within
> 10.0%.
>
> b\. [Insulation Resistance to Ground]{.underline}
>
> The insulation resistance of the OH coil shall be verified by applying
> a **5 kV** Megger between the coil and the ground plane. The
> insulation resistance shall be greater than **1000 MΩ.** (Perform
> prior to 13 kV Hipot test.)
>
> c\. [DC Hipot Tests]{.underline}
>
> The insulation between the coil bundle and ground shall be verified by
> applying a **13 kV** DC Hipot between all turns (start and finish
> leads jumpered together) and ground. Voltage shall be ramped up in 30
> seconds, held for 60 seconds, and ramped down in 30 seconds. Leakage
> current shall be recorded during ramp 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.
>
> 5.11.6 **[Fabrication Drawings]{.underline}**
>
> Copies of final fabrication drawings including all approved changes
> made during fabrication.

**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, tension tube support fixture and
> winding setup (refer to sections 3.2.5, 3.2.6, 3.2.7 and 3.2.13).

**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, tension tube support fixture and winding setup (refer to
> sections 3.2.5, 3.2.6, 3.2.7 and 3.2.13) 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 OH Coil Assembly (OHCA) 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 OHCA 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
> OHCA at PPPL in Princeton , New Jersey, USA.
>
> d\. The OHCA 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 OH Coil Assembly 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
> OHCA.

**9.0 [ATTACHMENTS:]{.underline}**

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

**OH Coil drawings**

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

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

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

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

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

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

  ---------------------------------------- ------------------------------
  OH Coil Final Assembly-1                 NSTX 13.E0001.0

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

  ---------------------------------------- ------------------------------
  OH Coil Final Assembly-2                 NSTX 13.E0002.0

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

  ---------------------------------------- ------------------------------
  Tension Tube Assembly                    NSTX-13.E0005.0

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

  ---------------------------------------- ------------------------------
  Turn Transitions at Bottom               NSTX-13.E0014.0

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

  ---------------------------------------- ------------------------------
  Turn Transitions at Top                  NSTX-13.E0040.0

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

  ---------------------------------------- ------------------------------
  OH Coil Conductor                        NSTX 13.A0010.0

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

  ---------------------------------------- ------------------------------
  OH Coil and Buss Connections             NSTX 13.E0041.0

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

  ---------------------------------------- ------------------------------
  Split Pressure Ring Asembly              NSTX-13.D0043-01

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

  ---------------------------------------- ------------------------------
  Trans. Piece Between Turn and Coolant    NSTX-13.D0047.0
  Tube                                     

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

  ---------------------------------------- ------------------------------
  Schematic of Winding turns               NSTX-13.E0055.0

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

  ---------------------------------------- ------------------------------
  Current Path Schematic                   NSTX-13.E0058.0

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

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

**Coil Bundle/ Insulation Data**

  -------------------------- --------------- ------------ --------------- ------------
                             **Dimension**   **Radius**   **Dimension**   **Radius**

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

  -------------------------- ----------- ----------- ----------- -----------
                             **(in.)**   **(in.)**   **(cm.)**   **(cm.)**

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

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

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

  -------------------------- ----------- ----------- ----------- -----------
  **OH Build**                                                   

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

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

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

  -------------------------- ----------- ----------- ----------- -----------
  Tension Tube               0.118       4.208       0.300       10.688

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

  -------------------------- ----------- ----------- ----------- -----------
  Teflon                     0.014       4.222       0.036       10.723

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

  -------------------------- ----------- ----------- ----------- -----------
  OH Groundwrap              0.054       4.276       0.137       10.860

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

  -------------------------- ----------- ----------- ----------- -----------
  OH 1st.layer turn          0.032       4.308       0.081       10.942
  insul.(IR of cu)                                               

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

  -------------------------- ----------- ----------- ----------- -----------
  OH 1st. Layer OR of copper 0.394       4.702       1.001       11.942

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

  -------------------------- ----------- ----------- ----------- -----------
  OH 1st. Layer turn insul.  0.032       4.734       0.081       12.024

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

  -------------------------- ----------- ----------- ----------- -----------
  OH 2nd layer turn insul.   0.032       4.766       0.081       12.105
  IR of cu                                                       

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

  -------------------------- ----------- ----------- ----------- -----------
  OH 2nd. Layer OR of copper 0.394       5.160       1.001       13.106

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

  -------------------------- ----------- ----------- ----------- -----------
  OH 2nd. Layer turn insul.  0.032       5.192       0.081       13.187

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

  -------------------------- ----------- ----------- ----------- -----------
  OH 3rd. layer turn insul.  0.032       5.224       0.081       13.268
  IR of cu                                                       

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

  -------------------------- ----------- ----------- ----------- -----------
  OH 3rd. Layer OR of copper 0.394       5.618       1.001       14.269

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

  -------------------------- ----------- ----------- ----------- -----------
  OH 3rd. Layer turn insul.  0.032       5.650       0.081       14.350

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

  -------------------------- ----------- ----------- ----------- -----------
  OH 4th. layer turn insul.  0.032       5.682       0.081       14.432
  IR of cu                                                       

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

  -------------------------- ----------- ----------- ----------- -----------
  OH 4th. Layer OR of copper 0.394       6.076       1.001       15.432

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

  -------------------------- ----------- ----------- ----------- -----------
  OH 4th. Layer turn insul.  0.032       6.108       0.081       15.514

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

  -------------------------- ----------- ----------- ----------- -----------
  OH Groundwrap              0.054       6.162       0.137       15.651

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

  -------------------------- ----------- ----------- ----------- -----------
  OH Groundplane paint       0.005       6.167       0.013       15.664

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