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

**NSTX**

**SPECIFICATION**

**FOR**

**PF CENTER STACK COILS**

**NSTX-SPEC-13-041**

**Revision 0**

**DATED:** August 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 Degreasing/Cleaning Solvent:
> \...\...\...\...\...\...\...\...\...\...\.... 4
>
> 3.1.2.4 Soldering and Braze Materials:
> \...\...\...\...\...\...\...\...\...\...\... 4
>
> 3.1.2.5 Fillers:
> \...\...\...\...\...\...\...\...\...\...\...\...\...\...\...\...\...\...\...\....
> 4
>
> 3.1.2.6 Machined Coil Lead Blocks and Electrical Flags:
> \...\...\...\... 4
>
> 3.1.2.7 Grit Blasting Materials:
> \...\...\...\...\...\...\...\...\...\...\...\...\..... 4
>
> 3.1.2.8 Copper Primer:
> \...\...\...\...\...\...\...\...\...\...\...\...\...\...\...\...\... 4
>
> 3.1.2.9 Ground Plane:
> \...\...\...\...\...\...\...\...\...\...\...\...\...\...\...\...\....
> 5
>
> 3.1.2.10 Conductor Coolant Tube
> \...\...\...\...\...\...\...\...\...\...\...\...\.... 5

3.2 COIL FABRICATION
\...\...\...\...\...\...\...\...\...\...\...\...\...\...\...\..... 5

3.2.1 Copper Conductor Delivery:
\...\...\...\...\...\...\...\...\...\...\...\...\...\...\... 5

3.2.2 Conductor Cleaning:
\...\...\...\...\...\...\...\...\...\...\...\...\...\...\...\...\...\...
5

3.2.3 Material Protection:
\...\...\...\...\...\...\...\...\...\...\...\...\...\...\...\...\...\....
5

3.2.4 Conductor Inspection:
\...\...\...\...\...\...\...\...\...\...\...\...\...\...\...\...\.... 5

3.2.5 Conductor Preparation:
\...\...\...\...\...\...\...\...\...\...\...\...\...\...\...\..... 6

3.2.6 Coil Winding:
\...\...\...\...\...\...\...\...\...\...\...\...\...\...\...\...\...\...\...\....
7

3.2.7 Lead Area Turn Insulation:
\...\...\...\...\...\...\...\...\...\...\...\...\...\...\.... 7

3.2.8 Coil Leads:
\...\...\...\...\...\...\...\...\...\...\...\...\...\...\...\...\...\...\...\...\....
7

3.2.9 Electrical Connections and Coolant Tubes
\...\...\...\...\...\...\...\...\..... 7

3.2.10 Coil Fillers:
\...\...\...\...\...\...\...\...\...\...\...\...\...\...\...\...\...\...\...\...\...
8

3.2.11 Outer Ground Wall Insulation:
\...\...\...\...\...\...\...\...\...\...\...\...\...\... 8

3.2.12 Coil Molding:
\...\...\...\...\...\...\...\...\...\...\...\...\...\...\...\...\...\...\...\....
8

3.2.13 Evaluation of Finished Surfaces:
\...\...\...\...\...\...\...\...\...\...\...\...\... 9

3.2.14 Ground Plane:
\...\...\...\...\...\...\...\...\...\...\...\...\...\...\...\...\...\...\...\....
9

**4.0 TEST REQUIREMENTS: \...\...\...\...\...\...\...\...\...\..... 9**

4.1 RECEIVING INSPECTION-OH CONDUCTOR \...\...\...\...\..... 9

4.1.1 Dimensional Measurements/Inspections:
\...\...\...\...\...\...\...\...\.... 9

4.1.2 Coolant Hole Size:
\...\...\...\...\...\...\...\...\...\...\...\...\...\...\...\...\.....
10

4.2 IN-PROCESS TESTING:
\...\...\...\...\...\...\...\...\...\...\...\...\...\..... 10

4.2.1 Tests After Assembly and Prior to Oven Cure:
\...\...\...\...\...\...\... 10

4.3 FINAL ACCEPTANCE TESTS:
\...\...\...\...\...\...\...\...\...\...\...\.... 10

4.3.1 Inspection:
\...\...\...\...\...\...\...\...\...\...\...\...\...\...\...\...\...\...\...\...\...
10

4.3.2 Coil Flow Tests:
\...\...\...\...\...\...\...\...\...\...\...\...\...\...\...\...\...\.....
10

4.3.3 Hydrostat Tests:
\...\...\...\...\...\...\...\...\...\...\...\...\...\...\...\...\...\.....
11

4.3.4 Final Electrical Tests:
\...\...\...\...\...\...\...\...\...\...\...\...\...\...\...\...\... 11

**TABLE OF CONTENTS**

5.0 **QUALITY ASSURANCE REQUIREMENTS: \...\...\.... 12**

5.1 INSPECTION/ SURVEILLANCE/ AUDIT BY PRINCETON: .. 12

5.2 SUBCONTRACTOR'S RESPONSIBILITY

FOR CONFORMANCE:
\...\...\...\...\...\...\...\...\...\...\...\...\...\...\.... 12

5.3 QUALITY ASSURANCE PLAN:
\...\...\...\...\...\...\...\...\...\...\...\... 12

5.4 MANUFACTURING, INSPECTION AND

TEST PLAN (MIT):
\...\...\...\...\...\...\...\...\...\...\...\...\...\...\...\...\... 13

5.5 INSPECTION AND TEST PROCEDURES: \...\...\...\...\...\...\..... 13

5.6 DOCUMENT TRACEABILITY AND RECORDS: \...\...\...\...\... 13

5.7 EQUIPMENT/MATERIAL IDENTIFICATION

AND STATUS:
\...\...\...\...\...\...\...\...\...\...\...\...\...\...\...\...\...\...\...
13

5.8 CALIBRATION OF TEST AND MEASURING

EQUIPMENT:
\...\...\...\...\...\...\...\...\...\...\...\...\...\...\...\...\...\...\....
13

5.9 CONTROL OF SPECIAL PROCESSES \...\...\...\...\...\...\...\...\... 14

5.10 RELEASE FOR SHIPMENT FORM:
\...\...\...\...\...\...\...\...\...\.... 14

5.11 PROCESS HISTORY:
\...\...\...\...\...\...\...\...\...\...\...\...\...\...\...\... 14

> 5.11.1 Material Certifications:
> \...\...\...\...\...\...\...\...\...\...\...\...\.... 14
>
> 5.11.2 Inspection and Test Reports:
> \...\...\...\...\...\...\...\...\...\..... 14
>
> 5.11.3 Fabrication Drawings:
> \...\...\...\...\...\...\...\...\...\...\...\...\..... 14
>
> 5.11.4 Certificate of Compliance (C of C):
> \...\...\...\...\...\...\...\.... 14

5.12 PPPL RECEIVING/INSPECTION
\...\...\...\...\...\...\...\...\...\...\... 15

6.0 **DOCUMENTATION REQUIREMENTS: \...\...\...\...\... 15**

6.1 Proposal Technical Documentation:
\...\...\...\...\...\...\...\...\...\...\... 15

6.2 Documentation After Contract Award and Prior to Fabrication:.. 15

6.3 Documentation Prior to Shipment:
\...\...\...\...\...\...\...\...\...\...\..... 15

7.0 **SHIPPING STORAGE AND HANDLING: \...\...\..... 15**

8.0 **DELIVERABLES: \...\...\...\...\...\...\...\...\...\...\...\...\...
16**

9.0 **ATTACHMENTS:**

APPENDIX I PF Center Stack Bundle drawings: \...\...\.... 17

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

> a\. This specification defines the manufacturing requirements for the
> National Spherical Torus Experiment (NSTX) Poloidal Field (PF) Coils
> (PF1A upper, PF1A lower and PF1B) 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}**
>
> ASTM B260-62T (BCuP-5), Brazing Alloys
>
> ASTM B32-Sn95
>
> **[CDA Copper Development Association]{.underline}**
>
> CDA Standards Handbook, Part 2 (Wrought Products) Alloy Data, CDA
> Alloy No. 10700

**[Conductor:]{.underline}**

> Per PPPL specification ***NSTX-SPEC-13-037-0*** "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.

**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
of 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 the drawings identified
> in Appendix I.
>
> 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 PF coils.
>
> 3.1.2.2 [Insulation System]{.underline}
>
> a\. The turn insulation shall consist of (1) half-lapped layer
> pre-impregnated (B-stage) epoxy-glass tape with Kapton (IMI Product
> no. 2259XS) and (1) half-lapped layer pre-impregnated (B-stage)
> epoxy-glass tape without Kapton (IMI Product no. 2258XS).
>
> b\. The B-stage insulating materials shall be provided by PPPL. All
> remaining insulating materials required to manufacture the PF coils
> 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)**
>
> c\. The outer ground insulation shall be pre-impregnated (CTD-112P)
> B-stage epoxy-glass tape/without Kapton (IMI Product no.2258XS)
> applied in half-lapped layers to the outside diameter of the PF coils.
> The final radial build after final cure shall be in accordance with
> the drawings identified in Appendix I.
>
> d\. Any voids between turns or near lead areas will be filled with
> pre-impregnated (B-stage) epoxy-glass tape without Kapton (IMI Product
> no. 2258XS).
>
> e\. Details concerning the insulating materials are as follows:
>
> **[Pre-impregnated Glass/Co-wound with Kapton]{.underline} - (turn to
> turn)**
>
> **(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
>
> **[Pre-impregnated Tape]{.underline}** **- (groundwall and turn to
> turn)**
>
> **(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
>
> 3.1.2.3 [Degreasing/Cleaning Solvent:]{.underline}
>
> All conductors shall be degreased/cleaned using a solvent which has
> been pre-approved by PPPL. This solvent must be able to dissolve
> grease, tar, wax, adhesives, oils and other soils, and be residue
> free.
>
> 3.1.2.4 [Soldering and Braze Materials:]{.underline}
>
> a\. The electrical flags shall be brazed to the coil leads using
> Sil-Fos braze material a product of "Handy & Harmon". 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\. Certification of the brazing alloys shall be in accordance with
> ASTM specifications noted in section 2.2, and shall be submitted as
> part of the document package.
>
> c\. The copper coolant tubes shall be soft-soldered into the ends of
> the conductor coolant holes using 95%/5% Tin-Antimony soft-solder with
> a melt range of 453-464 °F. Subcontractor shall recommend suitable
> liquid flux. Any changes from this shall require PPPL approval.
>
> 3.1.2.5 [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.
>
> **Note:** The vendor is responsible for providing as-built drawings
> for those G-10 fillers which PPPL drawings are not provided.
>
> 3.1.2.6 [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.).
>
> 3.1.2.7 [Grit Blasting Materials:]{.underline}
>
> Grit blasting shall be performed using aluminum oxide with a grain
> size of 80-120 mesh.
>
> 3.1.2.8 [Copper Primer]{.underline}
>
> The primer shall be Araldite DZ-80-1, manufactured by Ciba-Geigy (UK)
> Limited Plastics Division. **[No substitutions
> permitted]{.underline}.**
>
> 3.1.2.9 [Ground Plane]{.underline}
>
> A dielectric ground plane shall be applied to the outside of the
> finish cured PF Coils. 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.
>
> 3.1.2.10 [Conductor Coolant Tube]{.underline}
>
> The coolant tubes which shall be soldered into the ends of the PF
> conductor shall be seamless Air Conditioning and Refrigeration (ACR)
> copper tubing with a 0.375 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 PF coils 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]{.underline}. 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 **[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 coil mandrels.

> 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. A pressure of 18-20 psi is
> recommended per nozzle at a distance of approximately 5-6 inches from
> the conductor. 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}
>
> One half-lapped layer of pre-impregnated (B-stage) epoxy-glass tape
> with Kapton (IMI Product no. 2259XS) and (1) half-lapped layer
> pre-impregnated (B-stage) epoxy-glass tape without Kapton (IMI Product
> no. 2258XS) shall be applied to the conductors following application
> of the primer.
>
> **Note: Kapton side of the insulation shall face away from conductor
> during application (First layer).**
>
> *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.*
>
> 3.2.6 **[Coil Winding:]{.underline}**
>
> a\. The winding station shall include a coil winding unit; tension
> unit; copper spool station; conductor sandblast unit; portable
> insulation taping machine; pre-bend roller, mandrels plus
> miscellaneous tools and equipment.
>
> **Note: All tooling and fixturing necessary to complete the winding
> operation, is the responsibility of the Subcontractor.**
>
> b\. The PF conductor shall be tension wound directly onto suitable
> vendor supplied mandrels.

**Table 3.2.1**

**PF Coil Winding Data**

> **(approximate)**

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

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

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

  -------------- ----------- ------------------ ------------- -------------
  PF1A upper     48          178.4              214.0±1.0     430.9

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

  -------------- ----------- ------------------ ------------- -------------
  PF1A lower     48          178.4              214.0±1.0     430.9

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

  -------------- ----------- ------------------ ------------- -------------
  PF1B           28          175.9              211.0±1.0     424.9

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

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

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

> c\. [Winding Tension:]{.underline}
>
> The magnitude of the tension and method for monitoring tension value
> shall be pre-determined. The conductor tension must be sufficient to
> provide a 10% compression of the prepreg insulation during winding.
> Winding procedure to be approved by PPPL.
>
> 3.2.7 **[Lead Area Turn Insulation:]{.underline}**
>
> Turn insulation shall be tailored to fit neatly around water and
> electrical terminals.
>
> 3.2.8 **[Coil Leads:]{.underline}**
>
> The PF coil conductor leads shall be formed per approved PPPL drawings
> identified in Appendix I.
>
> 3.2.9 **[Electrical Connections and Coolant Tubes:]{.underline}**
>
> a\. The copper electrical connections shall be induction/torch brazed
> to the conductor ends during the winding process by qualified braze
> operators. Braze materials are specified in section 3.1.2.4. Braze
> process must be PPPL approved.
>
> b\. A visual inspection of the finished joint shall be made to
> ascertain complete flow of sil-fos braze material into the joint area.
> The joints shall be free from cracks and excessive porosity.
>
> c\. Soft-solder the copper coolant tubes into the ends of the
> conductor coolant holes using 95%/5% Tin-Antimony soft-solder with a
> melt range of 453-464 °F. Subcontractor shall recommend suitable
> liquid flux.
>
> d\. 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.
>
> e\. A hydrostat test shall be performed after cleaning to verify the
> water tight integrity of the newly soldered coolant tubes. (Section
> 4.3.3)
>
> 3.2.10 **[Coil Fillers]{.underline}**
>
> a\. All filler blocks shall be made with NEMA Grade G-10 glass
> reinforced epoxy which has been sanded, vacuumed and cleaned with PPPL
> approved solvent.
>
> 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.
>
> 3.2.11 **[Outer Ground Wall Insulation:]{.underline}**
>
> a\. The outer ground wall insulation shall be applied to the outside
> diameter of PF coil using half-lapped layers of pre-impregnated
> B-stage insulation (without Kapton) (IMI Product no. 2258XS)
>
> b\. All layers of ground insulation shall be applied in the same
> direction.
>
> c\. The ground wall build up shall result in achievement of the cured
> insulation thickness, specified in the coil drawings (Appendix I) and
> radial builds in Appendix II, after compression during the final cure
> process.
>
> d\. The ground insulation shall be tailored to fit neatly around the
> conductor end electrical flags.
>
> 3.2.12 **[Coil Molding]{.underline}**
>
> a\. Two (2) half-lapped layers of 2 mil non-stick (Tedlar) tape shall
> be applied around the entire PF 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\. Each PF coil 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 PF coil 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 PF coil
> to form a monolithic, void free structure with dimensions within the
> specified tolerances.
>
> f\. The subcontractor shall monitor and record cure temperature and
> time during the entire cure process. The following temperatures shall
> be monitored and continuously recorded: the copper conductor, coil
> mold and air temperature. This information shall become part of the
> Process History per section 5.11.
>
> g\. Following the insulation cure cycle, the PF coil shall be removed
> from the press-mold. The layers of Tedlar and shrinkable mylar shall
> be removed, and the coil shall be inspected for dry spots, voids or
> other surface deformations.
>
> 3.2.13 **[Evaluation of Finished Surfaces]{.underline}**
>
> The cured coils shall be checked for dimensional conformance with the
> drawings.
>
> 3.2.14 **[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 a minimum of 5 days 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- POLOIDAL FIELD (PF) 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 at the ends.

4.2 **IN-PROCESS TESTING**

> 4.2.1 **[Tests After Assembly and Prior to Oven Cure:]{.underline}**
>
> a\. [DC Resistance:]{.underline}
>
> Measure and record the dc resistance and temperature of each PF coil
> and lead. The resistance shall agree with the calculated value within
> 3.0%. The calculated PF coil resistance's are:
>
> **Table 4.2.1**
>
> **PF Coil Resistance's**

+-----------------------------------+-----------------------------------+
| **Coil ID**                       | **Coil Resistance**               |
|                                   |                                   |
|                                   | **@ 20°C**                        |
+-----------------------------------+-----------------------------------+

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

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

  ----------------------------------- -----------------------------------
  PF1A upper                          0.0028 Ω

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

  ----------------------------------- -----------------------------------
  PF1A lower                          0.0028 Ω

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

  ----------------------------------- -----------------------------------
  PF1B                                0.0028 Ω

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

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

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

> b\. [Insulation Resistance to Ground]{.underline}
>
> The insulation resistance of each PF coil shall be verified by
> applying a **500 V** Megger between the coil and the ground wall. Hold
> at **500 V** until there is no change in resistance. The insulation
> resistance shall be greater than **1000 MΩ.**
>
> c\. [PF Coil Turn to Turn Tests]{.underline}
>
> Seller shall propose, based on available equipment, means for turn to
> turn testing the PF coils, subject to approval by PPPL.

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 complete visual inspection and dimensional check shall be made
> according to applicable drawings.
>
> 4.3.2 **[Coil Flow 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\. Record all test data.
>
> c\. Flow rates and pressure drops are as follows:
>
> **Table 4.3.1**

**PF Coil Flow vs. Pressure Table**

  ---------------------- ---------------- ---------------- ----------------
  **OH Winding ID**      **Flow (GPM)**   **Δ Pressure     **Coil Length
                                          (PSI)**          (ft.)**

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

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

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

  ---------------------- ---------------- ---------------- ----------------
  PF1A upper             3.07             100              214

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

  ---------------------- ---------------- ---------------- ----------------
  PF1A lower             3.07             100              214

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

  ---------------------- ---------------- ---------------- ----------------
  PF1B                   3.10             100              211

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

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

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

> ***Pressure drop shall be ± 10% of values indicated above.***
>
> 4.3.3 **[Hydrostat Tests:]{.underline}**
>
> A hydrostat test shall be performed after the coolant tubes have been
> soldered into position 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. The pressure
> gauge shall have increments no greater than 2 psi.
>
> b\. After the ten minute period, the pressure shall 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.
>
> 4.3.4 **[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 each coil and
> lead. The resistance shall agree with the measurement of section
> 4.2.1, within 10.0%.
>
> b\. [Insulation Resistance to Ground]{.underline}
>
> The insulation resistance of the PF coil shall be verified by applying
> a **1 kV** Megger between the coil and the ground plane. The
> insulation resistance shall be greater than **1000 MΩ.** (Perform
> prior to 9 kV Hipot test.)
>
> c\. [DC Hipot Tests]{.underline}
>
> The insulation between the coil bundle and ground shall be verified by
> applying a **9 kV** DC Hipot between all turns 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**.
>
> d\. [PF Coil Turn to Turn Tests]{.underline}
>
> Subcontractor shall propose, based on available equipment, means for
> turn to turn testing the PF coils, subject to approval by PPPL.

**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 within 30 days of contract 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. (Reference Section 6.2)

**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. Each
> inspection and test shall be documented.

**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 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.

**5.9 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.

**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 **[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.
>
> 5.11.2 **[Inspection and Test Reports]{.underline}**
>
> Copies of the original reports of all required inspections, tests and
> examinations, properly validated by authorized personnel.
>
> 5.11.3 **[Fabrication Drawings]{.underline}**
>
> Copies of the final fabrication "as built" drawings that include all
> approved changes made during the fabrication.
>
> 5.11.4 **[Certificate of Compliance (C of C)]{.underline}**
>
> Subcontractor\'s CofC, stating that the work performed conforms in
> every respect to the physical configuration and functional
> inspection/test requirements. The CofC shall be signed by
> Subcontractor\'s Quality Assurance (QA) Manager. Where
> Princeton-furnished material has been used by the Subcontractor, such
> certification shall also include the statement: \"Material furnished
> by Princeton has been inspected by the Subcontractor and used by the
> Subcontractor as specified by Princeton with no unauthorized
> substitutions.

**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**

**6.1 PROPOSAL TECHNICAL DOCUMENTATION**

> a\. Subcontractor shall submit as part of his proposal documentation
> in preliminary or outline form, the QA Plan (refer to section 5.3),
> the Manufacturing/Inspection/Test Plan (refer to section 5.4), and
> procedures for tests (refer to section 5.5).
>
> b\. Subcontractor shall submit as part of the proposal a preliminary
> description of the press mold, and winding tooling (refer to sections
> 3.3.7 and 3.3.12).

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

> a\. Subcontractor shall submit (2 copies) final versions of the QA
> Plan (refer to section 5.3), the Manufacturing/Inspection/Test Plan
> (refer to section 5.4), and procedures for tests (refer to section
> 5.5) for PPPL review and approval within 30 days of contract award.
>
> b\. Subcontractor shall submit (2 copies) a final description of the
> press mold and winding tooling (refer to sections 3.2.6 and 3.2.12)
> 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, flushed
> with electrical grade ethylene glycol, drained of glycol and sealed
> for storage and subsequent shipment.
>
> b\. The PF coils shall be individually 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 PF coils 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 PF
> coils at PPPL in Princeton , New Jersey, USA.
>
> d\. The PF coils 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 ea.) completed PF1A upper, PF1A lower and PF1B 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
> PF coils.

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

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

**PF Center Stack Coil drawings**

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

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

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

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

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

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

  ----------------------------------- -----------------------------------
  PF1A Coil Final Assembly            EDC1012

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

  ----------------------------------- -----------------------------------
  PF1A Transitions and leads          EDC1013

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

  ----------------------------------- -----------------------------------
  PF1A Coil Lead Details and Assembly EDC1009

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

  ----------------------------------- -----------------------------------
  PF1B Coil Final Assembly            EDC1006

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

  ----------------------------------- -----------------------------------
  PF1B Coil Winding Details Sht.1     EDC1007

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

  ----------------------------------- -----------------------------------
  PF1B Coil Lead Details and Assembly EDC1008

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

  ----------------------------------- -----------------------------------
  PF1A and 1B Copper Conductor        13.A0011.0

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

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

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