DF-1001-8363.pdf

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Statement of Work

Supply of Magnet Half Shells for the

Test Facility Dipole

DF-1001-8363

Abstract

This statement of work concerns the supply of two aluminum half shells for the

Test Facility Dipole (TFD).

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Table of Contents

1. INTRODUCTION

2. SCOPE OF THE SUPPLY

2.1 Deliverables and Activities Included in the Supply

2.2 Activities at the Subcontractors’ Premises

3. TECHNICAL REQUIREMENTS

3.1 General Description

3.2 Material

3.3 Applicable Standards, Rules, and Regulations

3.4 Dimensions and Tolerances

3.5 Technical Drawings

3.6 Traceability of individual half shells

3.7 Information and Documentation

4. PERFORMANCE OF THE SUBCONTRACT

4.1 Delivery Schedule

4.2 Tests

4.2.1 Dimensional Test Specifications

4.2.2 Tests Carried Out at LBNL

4.3 Packing and Shipping

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1. INTRODUCTION

The large-bore Nb3Sn “cable test facility magnet” designed to test advanced cables and inserts in a high transverse background field is a project funded by the U.S. Department of Energy (DOE) Office of

Science (SC), as a joint effort between the offices of Fusion Energy Sciences and High Energy Physics.

The test facility dipole magnet (TFD), Figure 1, that creates the background field is developed at the

Lawrence Berkeley National Laboratory (LBNL).

Figure 1. Cross section of the Test Facility Dipole.

2. SCOPE OF THE SUPPLY

The subcontractor shall supply the aluminum half shells (hereinafter referred to, in whole or in part, as the “supply”) as defined in this technical specification and drawings attached to it.

2.1 Deliverables and Activities Included in the Supply

The supply shall include:

• Half shells summarized in Table 1.

• All reports and records of inspections, tests, and measurements carried out within the scope of this

Technical Specification (see § 3.7 and § 4.2);

Table 1: Summary of parts.

Drawing number Version Name Number of half shells [units]

DF-1001-0333 A Half Shell 2

2.2 Activities at the Subcontractors’ Premises

The subcontractor shall perform the following activities at their premises:

• The complete study, manufacturing process, deburring process, cleaning procedures and drying process, including manufacturing drawings;

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• Acquisition of all raw material;

• Tests as specified in § 4.2;

• Complete reporting and recording of inspections, tests and measurements and production carried out within the scope of this Technical Specification (see § 4.2);

• Identification and traceability of the half shells and safe packing (see § 4.3);

• Shipping to LBNL (see § 4.3).

3. TECHNICAL REQUIREMENTS

3.1 General Description

The half shells shall be made of Aluminum 7075-T6 in accordance with the technical drawing listed in

Table 1.

3.2 Material

The subcontractor shall procure and use AL 7075-T6 for fabrication. The subcontractor shall provide

ASM 4310E material certifications for the material used for fabrication. The material certificates shall be sent to LBNL for approval before the start of manufacturing. All reports shall be sent to LBNL before shipping.

3.3 Applicable Standards, Rules, and Regulations

The applicable standards for the manufacturing are detailed in the technical drawing.

3.4 Dimensions and Tolerances

The dimensions of the finished shells shall be within the tolerances given by the technical drawing.

3.5 Technical Drawings

The drawing listed in Table 1 is part of this Technical Specification and shall be used for the manufacturing of the individual components.

3.6 Traceability of individual half shells

Each half-shell shall be accompanied by a copy of the following documents:

• Material certificates for the material used;

• Results of the dimensional checks;

• Date of production.

The original of the above-mentioned documents shall be sent to LBNL before shipping the half shells.

The transportation to LBNL will be authorized only after LBNL’s written approval of the transmitted documents.

3.7 Information and Documentation

The subcontractor shall document the results of all the tests and inspections carried out within the scope of this supply. The same information shall be transmitted to LBNL with the complete measuring files.

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4. PERFORMANCE OF THE SUBCONTRACT

Unless specifically mentioned otherwise, the subcontractor shall apply the most restrictive clause in case of ambiguity between the clauses of the subcontract, including its incorporated documents. After the subcontract signature, a Kick-off meeting shall be arranged to discuss the execution of the subcontract.

4.1 Delivery Schedule

After the subcontract signature, the subcontractor shall submit to LBNL a detailed subcontract execution schedule, detailing the manufacturing and testing schedules. The place of manufacture may only be changed after written approval by LBNL.

4.2 Tests

The subcontractor shall give at least ten working days notice of the proposed date of any tests. LBNL reserves the right to request additional inspections.

The dimensional inspections will be carried out using a coordinate measuring machine (CMM). CMM scanning capability is required for continuous measurements of the surface profiles of the inner and outer diameters. The surface profile shall be measured by scanning probe. The CMM scanned profile data shall be delivered as a table of measured features, and shall include a graphical representation showing the surface profile data.

ASTM B594 Ultrasonic testing shall be performed on the final part after machining. The part shall satisfy the requirements of class AA as defined in ASTM B594. Ultrasonic reports shall be made available to

LBNL without delay.

4.2.1 Dimensional Test Specifications

The geometry of the half shells shall be checked with respect to the specific technical drawing. All checks shall be made on deburred pieces. All geometrical measurements shall be made at 20 °C ± 1 °C in a room with controlled temperature. The dimensions of all components shall be measured with a ball probe using a three-dimensional CMM, or an equivalent device ensuring an accuracy of measurements of at least

± 5 µm over the volume of the part.

All geometrical measurements shall be made according to a dimensional inspection procedure. These procedures shall be agreed upon between the subcontractor and LBNL, aiming to specify the definition of reference systems, main dimensions to be measured and required number of measurements for specific features. The final dimensional inspection procedure shall be approved by LBNL before the start of manufacturing.

4.2.2 Tests Carried Out at LBNL

LBNL reserves the right to carry out dimensional measurements to demonstrate the conformity of the half shells to the respective reference drawings before giving its final approval of delivered half shells.

The dimensional inspections at LBNL will be carried out according to the dimensional inspection procedure.

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4.3 Packing and Shipping

The subcontractor shall arrange for the safe and efficient packing, transport and delivery to the LBNL premises of the half shells in agreement with the schedule and procedures defined by LBNL in § 4.1. The

Shipping Terms are defined in the subcontract. The packing of the half shells shall not start before LBNL has given its formal approval of all required documentation and inspection reports.

The subcontractor is responsible for the packing. The orientation of the half shells with respect to gravity within the crate or transport packing used for shipping shall be approved by LBNL before the start of packing or procurement of boxes. In all cases, subcontractor shall ensure that half shells are delivered to

LBNL without damage and any possible deterioration in performance due to transport conditions.

The size and shape of the crates or transport packing option used for shipping shall be defined in agreement with LBNL. A suitable protection against transport and storage damage shall be provided.

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