Attachment 1_SOW_HV Stability_20221011.pdf

Administrator Stamp

1.0 INTRODUCTION & SCOPE

This SOW is coupled with the specification in Appendix 1 which covers the technical details of the Variable Phase Controller, and the SOW covers the protocols of the design reviews, documentation, safety, environment, and installation of this equipment at General Atomics, 3483 Dunhill St, San Diego CA 92121.

The Neutral Beam system injects high energy neutral atoms into the DIII-D tokamak to heat the plasma and increase its density. The atoms must be neutral in order to go through the magnetic field lines that hold the main plasma in a toroidal “magnetic bottle”. The neutral atoms are re-ionized in the main plasma chamber and then trapped in the main plasma.

The Neutral Beam atoms start off as ions and electrons in the NB source. This plasma is extracted from this chamber using a set of grids, like a vacuum tube, with the accel grid being the highest voltage 70-83kV presently. It is desirable to increase the beam energy by going to as high as 94kV but is limited by the head room on the power supply and the stability of this high voltage.

The High Voltage power supply droops when the NB pulse and to alleviate this droop the transformer/rectifier primary taps are moved to increase the charging voltage to as high as 120kV. A phased controller with feedback is desired for the input to the transformer/rectifier.

This system was analyzed in Fall 2021, see report attached, and it was determined that this type of phased controller would work to eliminate the large voltage swings using active feedback.

This Statement of Work (SOW) defines the Seller’s tasks related to the design, fabrication and testing of the VPC in the following areas:

• Design---covered by PPPL Spec 20220822 Appendix 1

• Fabrication

• Acceptance Testing

• Operation and Maintenance training for GA personnel

Acceptance Testing is intended to demonstrate the Variable Phase Controller (VPC) functionality and may be conducted at the Seller’s or Buyer’s facility. Acceptance Testing should be conducted at the Seller’s facility to the maximum extent reasonably possible.

2.0 APPLICABLE DOCUMENTS

The work requirements in this SOW shall be done:

2.1 VPC design shall be built following the specifications in SPEC 20220822 Appendix 1.

2.2 Fabrication shall be done in accordance with the specification and design proposed by the Seller in compliance with this SOW and upon approval by PPPL in conjunction with GA.

2.3 Installation and fabrication of equipment will follow the latest revisions of the documents in the list below where applicable:

2.3.1 National Electrical Code 2023

2.3.2 NFPA 70E

2.3.3 CA OSHA

2.3.4 GA Critical Lift Procedure SP-03 Appendix 4

3.0 APPLICABLE DRAWINGS

3.1 See the scanned sketch of the NB HV Power system below Appendix 2.

(The original vendor drawings were on microfiche and never transferred to paper/pdf and are no longer available.)

4.0 RESPONSIBILITIES

4.1. PRINCETON PLASMA PHYSICS LABORATORY

4.1.1. PPPL will provide a single-point contact for project management, typically the Cognizant Engineer. He will be assisted by the Responsible Engineer a General Atomics Engineer in charge of this system.

4.2. SUBCONTRACTOR

4.2.1. PPPL General Requirements

The Seller will provide a project manager who will be a single point of contact with the Buyer for programmatic direction of the Seller’s subcontract activities. The project manager will be responsible for planning, managing, monitoring, and controlling activities of the Seller’s tasks. The Seller’s project manager will report any programmatic problems or areas of high or heightened programmatic risk to the Buyer as soon as they arise or become apparent. This effort will be complete upon delivery of items detailed in Section 5.

Prior to installation activities all Seller workers must attend a safety orientation to be given by the General Atomics Safety Office.

The Seller shall provide a project schedule in a mutually agreed upon format with sufficient task detail and milestones to track progress toward project completion.

The Seller shall provide monthly program technical and schedule status to the Buyer in a written report.

The submittal schedule shall be agreed upon between the Buyer and Seller.

The Seller’s project manager or a designee will support biweekly one-hour (or mutually agreed upon) telecoms.

4.2.2 Notification Requirements Off-Normal Events and Issues

Note: Contacting the General Atomics Security Office at 858 455 2000 to obtain emergency assistance and taking immediate actions to protect workers, guests and visitors takes precedence over the notification requirements described herein.

The Subcontractor shall notify General Atomics Safety Officer, Cliff Hanna, 858-455-3610 within 15 minutes of becoming aware of off- normal events and issues; off-normal events and issues include:

• Personnel injuries of any kind

• Near misses that could have resulted in significant (recordable injury or worse) worker injuries

• Uncontrolled or unforeseen personnel exposure to radiation, chemical, biological or physical hazards (e.g., noise, laser, ultraviolet light, heat, etc.)

• Fire emergency of any kind

• Any unexpected discovery of an uncontrolled hazardous energy source (e.g., live electrical power circuit, etc.) not including discoveries made by zero-energy checks and other precautionary investigations made before work is authorized to begin

• Any failure to follow a prescribed hazardous energy control process (e.g., lockout/tagout)

• Damage of any kind to Laboratory property

• Damage of any kind to personal property owned by PPPL employees, guests and visitors

• Any spills of chemicals, fuels, lubricants, etc.

• Other off-normal events and issues deemed by the Subcontractor to require notification

4.2.3 Off-Normal events or issue, the SELLER and its lower-tier subcontractors SHALL:

• Notify D3D Emergency Response Team at X6161, and the

General Atomics Security Office X2000 for emergency response, if required

• Take immediate action to evacuate and post affected area, if required

• STOP related work or work in affected area

• Take actions to post and safe-off affected area

• Within 15 minutes: COG Engineer, DIII-D Responsible

Engineer, or the DIII-D High Voltage Lead Engineer, Regarding these off-normal events or issues, no recovery actions (other than those immediately required to preserve life safety) or repairs are to take place until they are reviewed by the Subcontractor and the DIII-D Technical Representative, and specifically authorized by the PPPL PTR (who has consulted with SMEs) or ESH Department Head. Resumption of work that has been stopped by DIII-D due to off-normal events and issues must follow the provisions of DIII-D Stop Work Authority.

4.2.4 Program Reviews

4.2.4.1 The Seller shall present their design at 3 levels: 1. CDR which cover the design general concept in as much detail as possible, 2. PDR which should have developed details of the design, 3. FDR which is the final review and be ready for fabrication.

4.2.4.2 In all three of these reviews the COG and Responsible Engineer (RE) approval is needed to proceed to the next review stage. The PDR review can be upgraded to an FDR if the design is matured to the point of being finalized, this is at the discretion of the COG and RE.

4.2.4.3 The Seller shall participate in, or support, periodic reviews of the program status with the Buyer including:

4.2.4.4 Biweekly reviews of the Seller’s status conducted by the Buyer through teleconferencing.

4.2.4.5 Design review of the VPC at the end of the design effort and prior to fabrication.

4.2.4.6 The design review shall be held at the Buyer’s facility and confirm the design meets the requirements of this SOW.

4.2.4.6 The Seller shall provide documentation to support the review 10 calendar days before the review.

4.2.5 VPC Tasks

• The Seller shall fabricate the VPC, according to the final approved VPC

Product Specifications and deliver the completed VPC to the Buyer’s Facility.

• The Seller shall install, test, operate, and commission the VPC into the HV

NB system in place of the autotransformer.

• The Buyer will remove the autotransformer in preparation for the new VPC.

• The Seller shall be responsible for preparation in English and delivery of

Operation and Maintenance (O&M) Manuals for the VPC. The Manuals shall include all subsystems of the VPC.

• The Seller shall provide a list of recommended spare parts.

• The Seller shall be responsible for packaging and shipment of the VPC to the

Buyer’s Facility. The packaging shall be designed to prevent damage to equipment during transport.

4.2.6 Installation

• Seller shall propose one person to provide supervision and direction to Buyer’s technicians related to the installation of the VPC.

• The Final Acceptance occurs with successful completion of acceptance tests, completion of installation and training at the Buyer’s facility, and delivery of the data package. An appropriate form shall be issued and countersigned by the Seller and Buyer.

4.2.7 VPC Training

The Seller shall train the Buyer’s personnel in all aspects of the operation and maintenance of the VPC following final acceptance testing and should identify any Buyer resources necessary to perform the training. The Seller should assume that 4 engineers / operators will be trained in the normal operation of the VPC and the handling of likely fault conditions. The Seller shall propose one person for two (2) days of training at the Buyer’s Facility. The training shall be performed within 30 days of the latest of completion of the final acceptance test and delivery to the Buyer’s facility

4.2.8 Deliverables

The Seller shall provide a Project Schedule in a mutually agreed upon format within one 10 days after award of contract. The Seller shall provide Monthly Progress Reports covering technical and schedule status. Reports shall be submitted for the entire subcontract period of performance with a delivery schedule agreed upon between the Buyer and Seller. The Seller shall provide input to the design review.

4.2.9 Design Details

The VPC System Description shall contain enough detail that a review and acceptance of the VPC or subsystem can be performed by the Buyer. The documents shall contain, but are not limited to:

• Top assembly drawing

• Electrical, pneumatic, and hydraulic schematic drawings as applicable

• Bill of Materials

• Dedicated hard and software for the VPC operations

• The document(s) shall be in the Seller’s standard format.

4.2.10 Conflicting Requirements

The Seller shall advise the Buyer of any obvious, apparent, or potential conflicts in the documents incorporated within the SOW or supplied to the Seller by the Buyer, and request interpretation, resolution, and/or correction. In the case of any conflict between this SOW and any other document, this SOW shall take precedence until the conflict is resolved.

4.2.11 Approval/Disapproval and Acceptance

The Buyer reserves the right to review, approve, or disapprove any and all plans, procedures, or other data requirements necessary in the performance of this SOW and to require such revisions, additions and /or deletions deemed essential to meet the subcontract intent.

Final acceptance of the VPC will be granted, in writing, upon successful completion of all Acceptance Tests/Commissioning, approval of the VPC Data Package, and resolution of any issues (i.e. chits) formally noted during Acceptance Testing.

5.0 REQUIREMENTS

5.1. Performance Requirements and Characteristics

See Specification 20220822 Appendix 1 specifies the performance characteristics.

5.1.1. OPERATING ENVIRONMENT

All components shall be environmentally acceptable for use in this typical application per industry standards, if not the Seller shall notify the Buyer of items e.g. chemicals, oils, non-environmentally acceptable components that are to be used.

5.1.2. DESIGN LIFE

The design life shall be 10 years minimum for components and 25 years minumum for the structural enclosures.

5.1.3. RELIABILITY

Mean time to failure of subcomponents shall be 5 years minimum with required maintenance periods no less than 2 years or more.

5.1.4. MAINTAINABILITY

Access doors for internal component replacement shall be readily accessible with industry tooling, where not accessible the Seller shall obtain the Buyer’s approval.

The SCR stack in particular shall be replaceable by extraction through a hatch in the top of the enclosure without oil removal if possible.

5.1.5. HUMAN FACTORS

See Specification 20220822 Appendix 1 specifies the performance characteristics.

5.1.6. SUSTAINABILITY

6 PPPL’s prime contract requires the purchase of certain types of environmentally preferable products such as, but not limited to, EPEAT-registered electronic devices, ENERGYSTAR and FEMP-listed energy-consuming equipment, Water- Sense listed products, bio-based materials, EPA-designated recycled content products, non-ozone-depleting chemicals and non-toxic or less toxic alternatives when practical. Where such products are available and meet the technical requirements of the work, they should be specified to the maximum extent practical. In addition, SOWs for architecture and facility design, new construction, major renovations, demolition and maintenance services should conform to applicable building energy efficiency requirements and sustainable design practices, inventory, tracking and reporting of recyclables, and the specification on sustainable building materials and equipment to the maximum extent practical.

Additional information on environmentally preferable products is available online at: https://pppl.princeton.edu/PPPL_Environmentally_Preferable_Purchasing

6.1. EQUIPMENT DEFINITION

6.1.1. SPECIFICATIONS AND STANDARDS

See Specification 20220822 Appendix 1

6.1.2. GENERAL DESIGN FEATURES

See Specification 20220822 Appendix 1

6.1.3. MATERIALS

See Specification 20220822 Appendix 1

6.1.4. ELECTROMAGNETIC INTERFERENCE AND SUSCEPTIBILITY

There should be no emitted electromagnetic radiation from the equipment specified in Specification 20220822 Appendix 1

6.1.5. IDENTIFICATION AND MARKING

See Specification 20220822 Appendix 1

6.1.6. WORKMANSHIP

See Specification 20220822 Appendix 1

6.1.7. SUBCONTRACTOR EQUIPMENT USE

Subcontractors must provide their own equipment and not use government equipment. Work activities anticipated to be performed by the subcontractor shall be reviewed by D3D Safety Office and the respective Responsible Engineer, when appropriate. Subcontractors shall provide evidence of qualification and competence in the performance of their duties including the use of powered equipment.

Should the use of government equipment become absolutely necessary, that use of equipment will require a liability release covering the use of GA equipment to be defined in the subcontract. All vehicles being used for work activities on the GA site, regardless of their maximum capable speed, must be equipped with safety belts prior to entrance.

https://pppl.princeton.edu/PPPL_Environmentally_Preferable_Purchasing

6.0 TEST & INSPECTION REQUIREMENTS

6.1. PERFORMANCE and ACCEPTANCE TESTS

Acceptance tests may be conducted at Seller’s or Buyer’s facility as defined in the Buyer approved VPC Acceptance Test Plan provided by the SELLER. However, acceptance tests shall be carried out at the Seller’s facility to the maximum possible extent. The Seller shall demonstrate conformity of the complete VPC with Attachment 1. Successful performance of all tests is mandatory for VPC acceptance.

The acceptance test shall be carried out by the Seller’s personnel, at Seller’s expense and under Seller’s responsibility.

6.2. SUPPLIER HOLD POINTS

Hold Point 1---Once the Seller provides the design, a hold point will be when preliminary tests needed to confirm the design are complete. The test results shall be reviewed and approved by the Responsible Engineer. This can happen at the Seller’s facility.

Hold Point 2---Upon removal of the associated old equipment, for site inspection prior to installation.

Hold Point 3---Upon final assembly prior to oil installation and any low voltage tests

(480VAC)

Hold Point 4---Upon final assembly and ready for high power electrical testing on-site.

Hold Point 5---Upon final testing/commissioning and data review.

7.0 QUALIFICATIONS---see section 9 below

8.0 ENVIRONMENT, SAFETY, AND HEALTH

The PPPL ES&H Department will aid in developing this section. Identify requirements to preclude or limit hazards to personnel, the environment and /or equipment including necessary hold points to verify that safety requirements are satisfied prior to proceeding with work. Refer to hazards in assembly, disassembly, test, transport, storage, operations, and/or maintenance. Specify all applicable safety requirements unique to GA.

8.1 General ES&H Statement

The subcontractor shall comply with:

The specific GA ES&H safety requirements, permits and courses listed in this Statement of Work.

The completed subcontractor Integrated Safety Management (ISM) Plan, and all applicable Federal, State, and local laws, regulations and requirements whether they are specifically listed in the Statement of Work or subcontract.

All vehicles being used for work activities on the GA site, regardless of their maximum capable speed, must be equipped with safety belts prior to entrance.

GA has safety programs that include the following areas Confined Space Permits, Digging Permits, Penetration and Fire Seal permits, Flame permits, Radiation Work permits, Lock- out/Tagout of energy sources, and restrictions on working alone. The subcontractor must confirm with their GA contact person that all prerequisites have been met before initiating any activity that involves these areas.

8.2 JHA

The PPPL Job Hazard Analysis (JHA) form (see Appendix 3) can be used as a tool to help identify ES&H hazards, controls, and related PPPL requirements that potentially apply to a subcontract. Those items identified using the JHA should then be incorporated into the SOW or subcontract documents.

A GA approved lock-out tag-out procedure, and application of locks and tags by affected individuals, is required in most cases to mitigate hazards associated with any potential energy sources (electrical, mechanical, cryogenic, etc.).

8.3 Specific PPPL requirements documents

A list of GA permits that are applicable to the Seller’s work scope are:

• Confined Space Permit,

• Hot Work Permit,

• Flame Permit,

• Digging Permit,

• OSHA regulations that are applicable to the Seller’s work scope, e.g. Material Handling, Electrical Safety, Hoisting and Rigging.

A list of GA ES&H training courses that are applicable to the Seller’s work scope are listed below. The training can be provided by GA or equivalent subcontractor training can be substituted with prior GA approval.

Safety Courses at GA

Basic Electrical Safety YES

Capacitor Bank Access YES

Confined Space Entry YES

CPR YES

Crane Operator (Vendor Certs) YES

General Employee Training for Subcontractors YES

Ladder Safety YES

Lockout/Tagout YES

Personal Protective Equipment YES

8.4 Additional ES&H Controls

• The SELLER’S safety record will be considered in the proposal/bid evaluations. A copy of the company’s safety record shall be part of the proposal.

• The SELLER’S number of injury/illness cases, in the last year or even longer, will be included in the proposal/bid evaluation requirements. A copy of the injury record should be submitted with the proposal.

• Work subcontracted by PPPL is frequently subcontracted to sub-tier contractors and, at times, sub-tier contracts are not known at the time of the initial subcontract award. The Statement of Work should address the method by which PPPL ES&H Requirements (imposed on the subcontractor) are subsequently applied to work performed by their sub-tier contractors.

• This work is to be performed at General Atomics site located at 3483 Dunhill St, San Diego CA 92121, in the power yard area. A briefing by General Atomics Safety Officers on any unique safety requirements will be included at the Pre- Proposal/Pre-Bid Conference.

• Submittal of an ISM Plan is required within 30 days of subcontract award. The receipt of the Plan will be a condition of letting the Subcontractor begin on-site work. GA review of the ISM Plan will be by the Cog/Responsible Engineer/ and a GA Safety Officer who will approve the plan.

NOTE: An ISM Plan (Heath & Safety Plan) per ESHD 5008, Section 1, Subsection 1.4.4 (http://bp.pppl.gov/ESHD_MANUAL/safety/sm1.pdf) must be provided for review and approval for all construction projects.

This and other statements cited in Subsection 1.4.4 must be included in all SOWs for construction projects. See Appendix 5 http://bp.pppl.gov/ESHD_MANUAL/safety/sm1.pdf

8.5 The Seller must inform its employees of the contents of their ISM Plan, including hazards and controls shall also be included in the subcontract. This requires the SELLER to hold a pre-job briefing before starting on-site work

8.5.1 PPPL will monitor execution of the ISM Plan and subcontract compliance.

8.5.2 Waste that is generated from work performed, construction, installation and or cleanup efforts shall be identified and removed by the SELLER from the GA site.

9.0 QUALITY ASSURANCE REQUIREMENTS

9.1 Inspection/Surveillance/Audit By PPPL

Authorized representatives of PPPL and the U. S. Government shall have the right at all reasonable times to visit the Subcontractor's premises and those of Subcontractor's suppliers during the performance of the 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.

9.2 Subcontractor's Responsibility for Conformance

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

9.3 Changes to PPPL Approved Documents

Revisions or changes by the Subcontractor to documents approved by PPPL shall be reviewed and approved by PPPL prior to use.

9.4 Subcontractor Quality Assurance Program

The Subcontractor shall maintain an effective Quality Assurance Program to assure that the Subcontractor's work meets the required level of quality and is performed in accordance with contractual requirements.

• Subcontractor's quality assurance function shall be organized to have sufficient authority and independence to identify quality problems, verify conformance of supplied items or services to specified requirements and obtain satisfactory resolution of conflicts involving quality.

• Subcontractor’s quality assurance function shall be actively involved in the planning, processing oversight, problem resolution, and determination of acceptability of all work under this technical specification.

• Subcontractor shall perform planned, periodic audits of the various aspects of its QA

Program by persons not directly responsible for the area being audited. Written reports of these audits shall be available to PPPL.

9.5 Submittal of Quality Assurance Program Manual

The Subcontractor shall submit with the proposal, a copy of its Quality Assurance Program

Manual, describing the Subcontractor's quality capability and general approach to quality assurance. The manual shall be subject to PPPL's review and acceptance prior to contract award.

9.6 Submittal of Quality Assurance Plan for this procurement

Subcontractor shall submit within 10 working days of subcontract/purchase order award and prior to start of manufacture, unless another time period has been agreed to, a 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.

9.7 Submittal of Manufacturing/Inspection/Test (MIT) Plan

Subcontractor shall submit a Manufacturing/Inspection/Test Plan within 10 working days after receipt of order for PPPL approval prior to start of manufacture. The plan shall identify parts; show their integrated flow into end items; identify critical manufacturing operations;

and show inspections and the characteristics/dimensions to be inspected. The Plan may include flow chart(s), Process Sheets, Shop Travelers, and inspection sheets, etc. PPPL may designate selected operations as mandatory "witness" points based on the MIT Plan.

Subcontractor shall provide PPPL with notice five working days in advance of such witness points. Revisions or changes to the approved MIT shall be reviewed and approved by

PPPL prior to use.

9.8 Process Sequence

The Subcontractor shall maintain a system to define the sequence and document the performance of manufacturing, inspection, installation, and test activities. These shall provide for signoff and date by designated inspection personnel at specified process, inspection, and test points and shall be traceable to the items.

9.9 Document Traceability and Records

The Subcontractor shall maintain a system of documentation whereby the results 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, signed, and dated and shall be traceable to subject items.

9.10 Witness/Hold Points and Notification of PPPL in Advance

PPPL reserves the right to designate selected manufacturing, inspection and/or test operations as mandatory Witness or Hold points. Subcontractor shall provide PPPL with notice five working days in advance of such points. These default hold points apply, in addition to any others that may be added for this work: - When welding / brazing qualifications are specified, welding / brazing must not occur until all required welding documentation is submitted and approved by PPPL. When a Release for Shipment form is specified, shipment must not be made until the shipping release form is signed and returned by PPPL.

9.11 Inspection and Test Control

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.

9.12 Submittal of Acceptance Test Procedures (ATPs) For PPPL Approval

The Acceptance Test Procedures (ATPs), including pass/fail criteria, required to demonstrate conformance to PPPL's requirements shall be submitted to PPPL for review and approval prior to use of such procedures.

9.13 Performance and Documentation of Inspections & Tests

Each item to be delivered to PPPL shall be inspected and tested by the Subcontractor to verify that they meet PPPL's requirements. All produced parts must be inspected and tested unless an alternate plan is agreed upon with PPPL in writing. Results shall be documented and reported to PPPL. Any exceptions to PPPL requirements must be approved by PPPL in writing.

The inspection/test report(s) shall indicate the results of all tests and compliance with all drawing notes

Actual values for all drawing dimensions, including Basic, but excluding Reference, must be reported. Either a drawing copy or an inspection report may be used as the report, but the drawing zone and actual measured values must be clearly indicated. Regardless of format, the report must be dated and signed.

9.14 Equipment/Material Identification and Status

Material and equipment identification shall be maintained throughout processing 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.

9.15 Prototype Quality Assurance Requirements

All work on items or services designated as prototypes shall be performed at the level of quality assurance stipulated in these quality requirements unless specified otherwise by

PPPL.

9.16 First Article Inspection Qualification

Subcontractor shall provide for inspection/test of a first article to provide objective evidence of the conformance of the item, documentation, and process to PPPL requirements. PPPL reserves the right to designate the first article inspection a mandatory witness point. After acceptance of first article, the remaining units required by the purchase order shall be produced using the same design, materials, processes, methods, and tooling that were used to manufacture the approved first article. Any changes must have prior approval from

PPPL.

9.17 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 and qualifications shall be available for review by PPPL and submitted to PPPL for acceptance if requested.

9.18 Document Review, Approval and Control

The Subcontractor shall implement a system 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. The system shall also control PPPL-furnished design documents, shall ensure that any models are in sync with the applicable drawings, and that obsolete information is not used.

9.19 Design Reviews and Notification of PPPL for Design Reviews Subcontractor shall perform Design Reviews as required and PPPL shall have the right, at its option, to participate in these reviews. Subcontractor shall give PPPL notice five working days prior to each Review.

9.20 Interchangeability

Subcontractor shall assure that like deliverable end items are interchangeable.

Acceptability of Purchased Items and Services (Procurement Control) The Subcontractor shall verify conformance of purchased and PPPL-furnished items or services to drawing and specification requirements and shall provide objective evidence of such verifications to PPPL if requested.

9.21 Nonconformances & Corrective Actions and Notification

Nonconforming items or services shall be identified, and, where possible, segregated to prevent use. The Subcontractor shall document each nonconformance. The written approval of PPPL is required prior to the use of the nonconforming item or service. The

Subcontractor's system shall provide not only for timely resolution of nonconformances but also for analysis of nonconformances to determine causes and to implement appropriate corrective actions (determination of cause and corrective action may be waived by PPPL for specific situations).

9.22 Configuration Control

Subcontractor shall completely document the configuration of delivered end items or services, using drawing revisions, specification revisions, unique part numbers, or other suitable means.

9.23 Measuring Equipment/Calibration

Acceptance inspections and tests shall be performed using properly calibrated measuring equipment. Calibration standards shall be traceable to the National Institute for Standards and Technology (NIST) or equivalent. Where such standards do not exist, the basis used for calibration shall be documented. Standards used for calibration shall not be used for shop inspections and shall be protected against damage or degradation.

9.24 Submittal of Reliability and Maintainability Document

Subcontractor shall submit one copy of its Reliability and Maintainability Document, addressing such issues as failure modes effects and criticality analysis (FMECA), fault tree analysis, mean-time-to-failure (MTTF), mean-time-to-repair (MTTR), confidence levels, modular construction, design for ease of repair access, etc., to meet the requirements of this particular Subcontract, for PPPL review and approval prior to the Preliminary Design

Review (PDR).

9.25 Welding & Brazing

Unless otherwise specified on the drawings:

• Welder(s) and welding procedure(s) shall be qualified to ASME B&PV Code Section IX or to AWS D1.1.

• Brazer(s) and brazing procedure(s) shall be qualified to ASME B&PV Code Section IX.

• Flame brazing procedures shall minimize the embrittlement of copper in copper-to-copper joint.

9.26 Printed Circuit Board Fabrication

The fabrication of bare printed circuit boards shall meet the requirements of ANSI/IPC-A-

600, or PPPL approved equivalent.

9.27 Printed Circuit Board Soldering and Assembly

Soldering and printed circuit board assembly workmanship shall meet the requirements of

ANSI/PC-A-610, Class 2, or PPPL approved equivalent.

9.28 Submittal of Instruction Manuals

Subcontractor shall provide, prior to or with delivery, PPPL with copies of Subcontractor's documents describing equipment installation, operation, maintenance, repair, etc., of the type, format and number of copies as required by PPPL.

9.29 Submittal of Completed Release for Shipment Form

Subcontractor shall not ship without a "Product Quality Certification and Shipping Release"

Form (Exhibit 1) signed by PPPL's Representative. Subcontractor shall complete and sign the certification section, fax or email the form to PPPL’s Quality Assurance (QA)

Representative along with the Process History, and hold shipment until PPPL signs and returns the form, authorizing shipment. A copy of the fully executed form shall accompany each full or partial shipment.

9.30 Submittal of Completed Process History (Documentation Package) Subcontractor shall deliver, along with the completed item(s), one digital or two hard copies of the Process History, a compilation of documents, detailing the objective evidence of the acceptability of the work performed. Some parts of the Process History, typically inspection and test reports, will be required with the Shipping Release request. The

Process History shall include as a minimum, the following:

• Subcontractor's CofC, signed by the Quality Manager, stating that the work performed conforms in every respect to PPPL the physical configuration and functional inspection/test requirements and that personnel performing or interpreting the results of special processes

(i.e., welding, soldering, electronic assembly, brazing, nondestructive examination, etc.)

were properly trained and qualified. Subcontractor’s Quality Assurance (QA) Manager shall sign the CofC. Where the Subcontractor has used PPPL-furnished material, such certification shall also include the statement: "Material furnished by PPPL has been inspected by the Subcontractor and used by the Subcontractor as specified by PPPL with no unauthorized substitutions".

• The Subcontractor must submit a list of drawings, if more than one, and the actual as-built drawings of each delivered item. Electronic drawings, in DXF or IGES format, are preferred. When hardcopies are used, each drawing shall be reproducible, black on white, hardcopy. All drawings must be fully approved with revision level, signatures, and date.

• The Subcontractor shall submit the manufacturer's Material Test Reports (MTR) showing actual relevant chemical, mechanical, and electrical properties of materials used and providing traceability to the actual material. Submitted MTRs must be linked to the specific part by referencing the parts list on the drawing. One copy is to be submitted to PPPL upon

Subcontractor acceptance for use. Note: For specialty materials, typically non-metals, where test reports are not readily available from the manufacturer, their certificate of analysis or certificate of grade, as appropriate, may suffice, subject to PPPL concurrence.

• Copies of completed process planning and control documents (travelers, etc.) that verify controlled execution of the required work.

• Signed and dated reports for all required inspections and tests.

• Copies of Nonconformance Reports

• Proof of Qualification for Welding, Brazing, and other Special Processes defined.

9.31 Handling, Packaging, Shipping and Storage

Subcontractor shall control items during handling and shipping and while in storage, including PPPL-furnished items, and shall assure that materials and items are adequately protected from damage or deterioration, with special attention to packaging for shipment.

Such protection shall include special environmental packaging requirements as specified.

Packaging, shipping and storage procedures shall provide for adequate marking or labeling to clearly and readily identify the items. Release from storage shall be controlled to prevent accidental or inadvertent use of incorrect or unacceptable items. Procedures may be subject to PPPL review and approval.

9.32 Age/Shelf Life Storage Control and Records

Subcontractor shall maintain records that verify that materials with a specified limited shelf life shall have been stored in accordance with manufacturer's recommendations. Materials shall possess at least 35% (or higher if specified elsewhere by PPPL) of the initial 100% shelf life at the time they are used in the respective manufacturing process.

9.33 Princeton 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.

9.34 General Purchase Order Requirements

Material(s) and/or product(s), including those components, parts, and materials that are permanently installed into systems, sub-systems, and/or assemblies, etc. furnished under this purchase order/subcontract shall be new. Parts and components that have been rebuilt, refurbished, or modified are specifically prohibited unless approved by PPPL in writing. Evidence of deliberate misrepresentation of any item(s)/component(s)/material(s) provided under this order may result in an investigation by the Office of the Inspector

General, U.S. Department of Energy. Examples of such misrepresentation include:

• Remanufactured, rebuilt, or used parts represented as new

• Counterfeit parts (fraudulently labeled or marked with another manufacturer’s name). •

Misrepresented parts.

9.35 High Strength Fasteners

Subcontractor shall provide high strength fasteners (tensile strength equal to or greater than 100 ksi) in accordance with the Fastener Quality Act. Fasteners shall exhibit grade marks and the manufacturer’s identification symbol (headstamp) as specified in the referenced Material Specification. Fasteners having a headmark shown on the suspect fastener list will not be accepted. Certified Material Test Reports (CMTR), showing actual material composition and physical properties and traceable to the actual fasteners, are required for each lot supplied. Results must be on the original letterhead of the entity performing the tests and not transferred to alternate letterhead. Where high strength fasteners are not required, it is recommended that they not be used. If used, the requirements above shall be implemented.

9.36 Electrical Items

Electrical Items shall exhibit manufacturer’s labels and identification as specified in the referenced specification or in the body of this purchase order/subcontract.

No mixed manufacturer’s production lots within a single shipment will be accepted.

PPPL’s receipt inspection activities may include but are not limited to:

(1) dimensional inspection

(2) functional and operational testing

(3) comparison of the manufacturer’s test reports to applicable specification requirements

(4) visual inspection for evidence of used or reworked components, parts, or materials.

9.37 Mechanical Items

Mechanical Items shall exhibit manufacturer’s labels and identification as specified in the referenced specification or in the body of this purchase order/subcontract.

No mixed manufacturer’s production lots within a single shipment will be accepted.

PPPL’s receipt inspection activities may include but are not limited to:

(1) dimensional inspection

(2) functional and operational testing

(3) comparison of the manufacturer’s test reports to applicable specification requirements

(4) visual inspection for evidence of used or reworked components, parts, or materials.

9.38 Manufacturing Readiness Review

A Manufacturing Readiness Review with PPPL approval is required prior to the start of

Manufacturing.

10.0 SHIPPING STORAGE AND HANDLING

The VPC Equipment shall be packaged and shipped to GA using methods determined by the SELLER to not damage the equipment in transit.

Temporary storage of the equipment can be requested at GA with concurrence of the

COG.

Receipt inspection shall be performed by the GA Quality Assurance for any shipping associated damage.

11.0 WARRANTY

The equipment shall be warrantied for a period of 2 years from the date of installation/testing completion for workmanship and premature component failure.

12.0 ATTACHMENTS

YPC Specification (includes system analysis) Appendix 1

NB HV Power system Diagram Appendix 2

JHA form Appendix 3

GA Lift Procedure Appendix 4

ESHC 5008 Section 6 Appendix 5

13.0 DOCUMENTATION & DELIVERABLES

Deliverables List

PO / Subcontract / BOA / BPA #:

# Document Deliverables Required

When Deliverable Is Required

Deliverabl e format (paper, electronic etc.)

Storage Location for Deliverab le

Deliverabl e

Received (ü)

1 CDR Package Upon completion of the event

2 PDR Package Upon completion of the event

3 FDR Package Upon completion of the event

4 As-built Drawings Upon completion of the event

5 Test Data from all acceptance tests

Upon completion of the event

Exceptions (Add justification for any missing document deliverables that will not be received):

Princeton Technical Representative/COG:

(Sign-off and provide to the Operations Center when job is completed and deliverables are dispositioned and placed/filed in Operations Center (or other Project, Department or Division designated file center)

Statement of Work Deliverables Worksheet

Hardware

1. CDR • Non-Conformance Reports

2. • PDR • Disposal Plan/Clean Up Plan

3. • FDR • Material Certifications

4. • Installation Plan • User Manuals

5. • Qualifications and Certifications • Repair Manuals

6. • Equipment Calibration History • Maintenance Manuals

7. • Visual Inspections • QA Plan

8. • Electrical Test Reports • Design data/calculations

9. • Performance Test Reports • As-Built Drawings

10. • Performance Graphs / Charts

11. • Weld Inspection Reports

12. • Completed Travelers/Process sheets

13. • Preliminary Drawings

14. • Environmental Preferred Products documents Software:

1. • Source Code

2. • Testing Verifications

3. • Code Documentation

4. • Training Material

5. • User Manual Research:

1. • Research Results Report

2. • Analysis

3. • Status Reports

(Weekly/Monthly)

4. • Proposed Next Steps Safety and Health:

1. • ISM Plan

2. • QA Plan

3. • Lift Plan

4. • Hot Work Permit

5. • Flame Permit

6. • Inspection/Test Plans

7. • Installation Plan