Attachment C - MPEX-04-SOW-102 R0 Statement of Work.pdf

MPEX-04-SOW-102 R0

STATEMENT OF WORK FOR

INSULATING AND HEATING BLANKETS

MATERIAL PLASMA EXPOSURE EXPERIMENT

(MPEX)

Prepared by

OAK RIDGE NATIONAL LABORATORY

Oak Ridge, TN 37831-6283

Managed by

UT-BATTELLE, LLC

For the

US DEPARTMENT OF ENERGY

under contract DE-AC05-00OR22725

This report was prepared as an account of work sponsored by an agency of the United States government. Neither the United States government nor any agency thereof, nor any of their employees, makes any warranty, express or implied, or assumes any legal liability or responsibility for the accuracy, completeness, or usefulness of any information, apparatus, product, or process disclosed, or represents that its use would not infringe privately owned rights. Reference herein to any specific commercial product, process, or service by trade name, trademark, manufacturer, or otherwise, does not necessarily constitute or imply its endorsement, recommendation, or favoring by the United States government or any agency thereof. The views and opinions of authors expressed herein do not necessarily state or reflect those of the United States government or any agency thereof.

MPEX-04-SOW-102 R0 Page 2 of 15

Material Plasma Exposure Experiment Oak Ridge National Laboratory

Statement of Work for Insulating and Heating Blankets for the

Material Plasma Exposure Experiment Project

MPEX-04-SOW-102

Author(s):

Jonathan Perry, Vacuum Pumping Lead Engineer, TPO Date

Reviewer(s):

Misty Magill, Procurement Officer Date

Aftab Hussain, MPEX Lead Engineer Date

Craig Deibele, MPEX Operations Lead Date

LaTravia Harmon, Quality Assurance Representative Date

Approver:

Adam Aaron, CAM Vacuum Systems Date

Distribution:

Phil Ferguson, MPEX Project Director

Robyn Rose, MPEX Project Manager

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Revision History

Revision Date DESCRIPTION OF CHANGE

REVISION TYPE

Major Minor

0 Nov 2023 Initial Issue ☐ ☐

MPEX-04-SOW-102 R0 Page 4 of 15

CONTENTS

ACRONYMS

1. INTRODUCTION

2. SCOPE

3. APPLICABLE DOCUMENTS

4. PERFORMANCE REQUIREMENTS

4.1 TASK 1: QUALITY PLAN AND PROJECT SCHEDULE

4.2 TASK 2: PROJECT MANAGEMENT

4.2.1 Project Management Plan

4.2.2 Point of Contact

4.2.3 Variance Reporting

4.2.4 Monthly Progress Reports

4.2.5 Periodic Communications

4.2.6 Language

4.2.7 Units

4.2.8 Reporting – Kick-Off Meeting

4.3 TASK 3: DESIGN REVIEW AND PERFORMANCE SPECIFICATIONS

4.4 TASK 4: MANUFACTURING DESIGN REVIEW

4.5 TASK 5: BLANKETS FABRICATION

4.6 TASK 6: DELIVER BLANKETS

5. QUALITY ASSURANCE

5.1 QUALITY PROGRAM

5.2 ACCESS FOR SOURCE SURVEILLANCE INSPECTIONS

5.3 SELLER REQUESTED DEVIATIONS

5.4 NON-CONFORMANCES

5.5 MEASUREMENT AND TEST EQUIPMENT

5.6 SUSPECT/COUNTERFEIT ITEMS PREVENTION

6. TRANSPORTATION

7. DELIVERABLES

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ACRONYMS

MPEX Material Plasma Exposure Experiment

TPO Technical Project Officer

ISO International Organization for Standardization

NIST National Institute of Standards and Technology

NQA ASME Nuclear Quality Assurance

QAP Quality Assurance Program

SOW Statement of Work

STEP Standard for the Exchange of Product Data

PMI Plasma Material Interaction

SAS Surface Analysis Station

ECH Electron Cyclotron Heating

ICH Ion Cyclotron Heating

COTS Commercial Off The Shelf

DAP Delivered At Place

FAT Factory Acceptance Test

POC Point of Contact

PO Procurement Officer

ORNL Oak Ridge National Laboratory

CMM Coordinate Measuring Machine

VCR Swagelok VCR® Metal Gasket Face Seal Fitting

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1. INTRODUCTION

The Material Plasma Exposure eXperiment (MPEX), a superconducting magnet, steady-state device, is being built at Oak Ridge National Laboratory (ORNL) to address the harsh conditions inside a fusion reactor. This device, as designed, will have the unique feature of being able to conduct accelerated lifetime tests of plasma-facing components, including those that have experienced neutron damage. The vacuum vessels create the vacuum barrier to generate and contain the plasma. The vacuum vessels require to be baked out. To bake out the vacuum vessels, insulating and heating blankets are required.

2. SCOPE

This Statement of Work (SOW) applies to the fabrication, assembly, testing, inspection, packaging, and delivery of the insulating and heating blankets identified in Table 1 and Table 2 as defined in the Technical Specification for MPEX Insulating and Heating Blankets [1].

Table 1 Insulating Blankets to be Procured

Vacuum Vessel/Component Order Qty

Dump Tank 1

Drift Pipe:

Dump Tank Vessel to Helicon Transport and Helicon to ECH Transport

Diagnostic chamber:

Upstream and Downstream

Helicon Fueling Ring 1

Helicon Launcher 1

Limiter 1

Skimmer:

Upstream and Downstream

Bellows:

Helicon to ECH, ECH to ICH, and ICH to PMI

Microwave Absorber:

Upstream and Downstream

ECH Launcher 1

ICH Launcher 1

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Vacuum Vessel/Component Order Qty

ICH to PMI Transport Drift Pipe 1

Upstream PMI to Autocoupler Half 1

Downstream PMI to Autocoupler Half 1

Autocoupler to PMI Transport Conical Reducer 1

PMI Chamber 1

PMI Pumping Chamber 1

Table 2 Heating Blankets to be Procured

Vacuum Vessel/Component Order

Qty

Target Exchange Chamber 1

Gate Valve to Autocoupler Half 1

SAS 5-Way Cross 1

SAS Stage Housing 1

SAS Chamber 1

Dump Tank Pump Ducting 1

ECH/Helicon Pump Ducting 1

PMI Roughing Pump Ducting 1

PMI Turbo Pump Ducting 1

3. APPLICABLE DOCUMENTS

[1] MPEX-04-SPC-102, Technical Specification for MPEX Insulating and Heating

Blankets

[2] MPEX-04-DES-00-I004, Vacuum Chamber Internal Volumes

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4. PERFORMANCE REQUIREMENTS

4.1 TASK 1: QUALITY PLAN AND PROJECT SCHEDULE

The Seller shall prepare a quality plan and a project schedule for the manufacture, test, inspection, packaging, and delivery of the insulating and heating blankets. The quality plan shall address how the Seller's Quality Program will be applied to the work in this SOW, and identify procedures and other documentation for all special processes, measurements, etc. The quality plan shall also identify the planned work to be outsourced, list the planned or expected subcontractors and

Suppliers, and address how the quality requirements of this SOW will be flowed down to these subcontractors and Suppliers.

The project schedule shall contain sufficient detail so that ORNL may track design, procurement, fabrication, assembly, testing, inspection, packaging, and shipping activities. The Seller shall propose milestones for tracking progress and payments.

For this task, the Seller shall provide ORNL with:

• Quality plan

• Project Schedule

• Factory Acceptance Test Plan

• Complete final documentation

• Commissioning and Site Acceptance Test Plan (if applicable)

4.2 TASK 2: PROJECT MANAGEMENT

The Seller will prepare a Project Management Plan that integrates each element of this task into a concisely written document. The Seller will submit the Project Management Plan to ORNL for comment within one week after the award of contract (AoC) and before the Kickoff Meeting.

4.2.1 Project Management Plan

The Project Management Plan will include, as a minimum:

• Seller’s Point of Contact

• List of Seller’s Contractors

• List of Seller’s Project Team

• Project Schedule including key milestones and dates for contract deliverables

• Monthly Progress Reports

• Periodic Progress Meetings

• List of Action Items

4.2.2 Point of Contact

The Seller will designate an official Point of Contact (PoC) to interface with ORNL for discussions, clarification, or other technical issues. The PoC Designation will be in the form of an

MPEX-04-SOW-102 R0 Page 9 of 15 e-mail sent to ORNL with a copy to the Procurement Officer. The PoC Designation will be completed within five (5) working days after AoC.

4.2.3 Variance Reporting

The Seller shall notify ORNL and the PO immediately in writing when it is determined the actual cost may exceed the Agreement price. In no case shall the Seller continue work without authorized funding if it is determined that actual cost may exceed the Agreement price. The Seller’s schedule, with changes, will be delivered monthly, at a minimum, to ORNL.

4.2.4 Monthly Progress Reports

Monthly progress reports will be submitted in the first week of each calendar month to ORNL throughout the contract period. These reports, which are an important part of ORNL management information system, will address the following, unless otherwise directed by ORNL:

• Main scheduled task and milestones during the reporting period

• Progress, results, achievements, and issues encountered on each task during the reporting period

• Scheduled tasks for the following period, including updates because of issues encountered during the reporting period

• Outstanding issues and action items from the reporting period and previous periods

• Percent complete per task through the period

• Variance explanation and corrective actions with cause and impact description

• Anticipated variance in cost or schedule associated with added scope or issues encountered

4.2.5 Periodic Communications

The Seller shall participate in a bi-weekly phone conference to be held with ORNL to discuss any technical issues and schedule, personnel, and any other items pertinent to the work activities. The bi-weekly phone conference will serve as a mechanism to get early visibility of potential problems and issues arising during the performance of this subcontract. The Seller shall prepare written meeting minutes and submit these to ORNL within five (5) working days after the meeting.

4.2.6 Language

The working language of the project is English. In the subsequent execution of the contract, misunderstandings, and their consequences due to mistranslations into or from the Seller’s or

Manufacturer’s preferred language other than English are the responsibility of the Seller.

4.2.7 Units

The International System of units (SI units) will be used throughout the project. In the subsequent execution of the contract, misunderstandings, and their consequences due to mis-conversion of units into or from the Seller’s and/or Manufacturer’s preferred unit system other than SI are the responsibility of the Seller.

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4.2.8 Reporting – Kick-Off Meeting

The kickoff meeting will be scheduled at a mutually agreed time as soon as practical after award of the subcontract. The Seller is responsible for recording meeting minutes and submitting them to ORNL within five (5) working days after the meeting.

If the meeting is held at the Seller’s and/or the Manufacturer’s facility, and if requested by ORNL, the Seller will arrange for a tour of the facility where the items listed within this Statement of Work will be manufactured, as well as where testing occurs.

The following topics will be discussed:

• Seller’s scope of work

• Flow down of requirements.

• Work activities, schedules, and deliverables

• Expectations for satisfying quality standards and documentation

• Fabrication and/or Manufacturing Processes and Methods

4.3 TASK 3: DESIGN REVIEW AND PERFORMANCE SPECIFICATIONS

A formal design review meeting will be conducted and hosted by the Seller and/or Manufacturer with ORNL. The purpose of the review meeting will be to assure that the detailed design solution is complete, verified, and properly documented.

The Seller shall review MPEX-04-DES-00-I004 [2], the vacuum vessels three dimensional (3D)

CAD models provided to the seller, and the performance specifications of the insulating and heating blankets found in [1]. The seller can propose deviations or changes to these specifications.

ORNL will review these change requests and update relevant project documentation as necessary.

Any deviation request shall be submitted by the Seller and approved by ORNL for all process or specification deviations. The seller shall provide a list of analysis and drawings for all components and assemblies that are part of the deviation request. ORNL must review and approve analysis and drawing documents. The documents must be under revision control after ORNL approval.

The seller shall provide ORNL with all released documents. The seller shall provide ORNL updated documents whenever a revision is made and shall provide a final set of documents for all analysis and manufacturing drawings to ORNL prior to delivery. Approval of the Design

Package shall be listed as an ATPP (Authorization to Proceed Point) hold point in the IP

(Inspection Plan).

4.4 TASK 4: MANUFACTURING DESIGN REVIEW

With the completion of Task 2 and with authorization from ORNL, the Seller shall prepare a manufacturing design package of the insulating and heating blankets to demonstrate how the design specifications given in [1] and [2] will be satisfied. The package shall include all applicable design analysis calculations to support deviation requests as well as all Seller drawings that will be used to fabricate the insulating and heating blankets. The Seller shall prepare a design report and participate in a design review. The expectation is that the design analysis supporting deviation requests identified in Task 2 shall be complete and Seller generated fabrication drawings shall be

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> 60% completed for this review. The Manufacturing design review will be held by videoconferencing or at the Seller's site based on agreement between the Seller and ORNL.

The Seller shall prepare written meeting minutes and submit them to ORNL for review within 3 working days after the meeting. Completion of the Manufacturing design review and closure of all chits (action items) shall constitute a project milestone. Approval of the Manufacturing Design

Review meeting minutes shall constitute an ATPP hold point in the IP.

4.5 TASK 5: BLANKETS FABRICATION

After completion of Task 4 and with approval of ORNL, the Seller shall provide an updated manufacturing schedule and begin construction. The Seller and ORNL shall establish a recurring fabrication update meeting not to exceed 1 month between meetings. The Seller shall prepare a current manufacturing status report and identify any fabrication issues or logistics that will affect the agreed upon delivery date. ORNL will review and generate findings with actionable items for the Seller or ORNL. Finding status shall be reviewed at all fabrication status meetings.

Fabrication status meetings shall be held by videoconferencing or at the Seller's site based on agreement between the Seller and ORNL. The Seller shall prepare written meeting minutes and submit them to ORNL for review within 3 working days after each meeting.

At a minimum, the meeting minutes shall include:

• Project schedule update o Fabrication status o Delivery status o Testing status o Inspection status

• Quality plan update o Quality Control Inspection reports o Non-conformance reports o Procedure changes o Revisions

• Status of old findings

• New findings

• Report any variances or deviations from the agreed upon specifications

• Summary of main discussion topics

• Summary of decisions and agreements between the Seller and ORNL.

4.6 TASK 6: DELIVER BLANKETS

Upon successful completion of Task 5 and with authorization of ORNL, the Seller shall perform factory acceptance testing, generate quality plan compliance documentation and deliver the insulating and heating blankets in accordance with the approved design from Task 3 meeting the specifications in [1]. The Seller shall provide installation supervision and commissioning support at ORNL's site, including participation in the site acceptance testing.

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Final acceptance of the insulating and heating blankets will occur upon successful completion of the site acceptance tests at ORNL's facility.

5. QUALITY ASSURANCE

5.1 QUALITY PROGRAM

The Seller shall have a Quality Assurance Program (QAP) that, at a minimum, is ISO 9001 certified, but preferably compliant with NQA-1 2008/2009a or equivalent. The Seller shall be able to demonstrate that it can fulfill the quality assurance requirements in this SOW and in [1]. At a minimum, the prospective supplier shall have an established, documented, and effectively implemented quality assurance program describing controls for: work processes (controlled by instructions/procedures), personnel training and qualification, document and records control, design, procurement, inspection and testing; including the use of measuring and test equipment when used, corrective action, and assessments (audits).

Prior to subcontract award, the seller’s QAP shall be evaluated to determine the degree of effective implementation of the quality program. Deficiencies, if any, identified during the evaluation shall be addressed and corrected to the satisfaction of ORNL and shall occur prior to award.

All suppliers/sub-suppliers, subcontractors and fabricators (as applicable) shall have a Quality

Assurance Program that meets or exceeds the requirements listed above.

For electrical equipment, assemblies, or items that are not NRTL listed or field evaluated by an

OSHA Recognized NRTL (https://www.osha.gov/dts/otpca/nrtl/), the Seller shall provide documentation to assist ORNL with safety inspections and evaluations of the equipment, assembly, or item. Documentation shall be submitted with the equipment and shall include the following:

• Schematics and/or elementary diagrams

• Wiring diagrams, if applicable

• Detailed results of factory tests. Certificates of compliance or conformity alone are not acceptable.

• Operating instructions

ORNL will use the submitted information to conduct a post-receipt safety evaluation of the equipment, assembly, or item against appropriate code(s) and standard(s) ORNL may reject the equipment, assembly, or item if ORNL concludes it does not satisfy requirements of the applicable codes(s) or standard(s).

5.2 ACCESS FOR SOURCE SURVEILLANCE INSPECTIONS

As part of ORNL’s quality assurance program, ORNL reserves the right to perform source surveillance activities and may be conducted at the Seller’s facility or any sub-tier seller facility that ORNL determines necessary to ensure that quality objectives are met.

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5.3 SELLER REQUESTED DEVIATIONS

The Seller shall propose any deviations to the specifications, drawings, or other technical requirements and obtain ORNL’s approval prior to invoking the deviation. Any Deviation

Requests arising from the fabrication phase shall adhere to the Seller's Quality Program procedure and must be approved by ORNL.

5.4 NON-CONFORMANCES

When a nonconformance is identified, the Seller shall notify ORNL to determine what actions are required and document the nonconformance following the Seller's Quality Program procedure. All nonconformances shall be summarized in the Final Report. Items that do not conform to specified requirements shall be controlled to prevent inadvertent installation or use. Controls shall provide for identification, documentation, evaluation, segregation when practical, disposition of the nonconforming items, and for notification to ORNL.

5.5 MEASUREMENT AND TEST EQUIPMENT

Tools, gages, instruments, and other measurement and test equipment used for activities affecting quality shall be controlled, calibrated at specified periods, adjusted, and maintained to required accuracy limits.

Measurement and test equipment used by the Seller to perform work under this Statement of Work must be calibrated and traceable to NIST standards. Calibrations must be current. Calibration records must be provided to ORNL.

5.6 SUSPECT/COUNTERFEIT ITEMS PREVENTION

The Seller’s QAP must include an S/CI Program that is compliant with DOE O 414.1D, Quality

Assurance or approved equivalent. Although there is a provision in the contract describing SCI prevention; we have found many vendors don’t focus on the details of SCI nor the impact long-term with respect to counterfeit items prevention.

6. TRANSPORTATION

The equipment shall be packaged in a manner that protects the equipment from damage and, facilitates movement, loading, and unloading by fork truck or crane. Any special lifting fixtures or related hardware that are required to move, load, or unload the equipment shall be considered part of the equipment. The Seller shall package and prepare each piece of equipment for shipment to the ORNL Facility in Oak Ridge, Tennessee. The packaging shall protect the equipment from any conditions (e.g., shock, impact, weather, etc.) which could cause damage resulting in nonconformity with applicable requirements. The Seller shall be responsible for all shipping activities.

7. DELIVERABLES

The Seller shall supply the following:

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Deliverable 1 – Within 2 weeks of subcontract award, provide to ORNL the Seller's Quality

Assurance Program documentation, a project specific Quality Plan, and project schedule.

Deliverable 2 – The Kick-Off Meeting, as defined by Section 4.2.8, shall occur as soon as reasonably possible following the contract award. The Seller shall provide the Kick-Off Meeting

Minutes to ORNL no more than five (5) days following the Kick-Off Meeting.

Deliverable 3 – Manufacturing design review shall be held no more than 8 weeks after subcontract award and shall include the following documents:

• Manufacturing design review report

• Engineering calculations if required by Section 4.3 and 4.4

• All manufacture drawings and information called for in Section 4.4

• Presentation slides and documents

• Chit resolution documentation

• Fabrication procedures if required

Deliverable 4 – Insulating and heating blankets shall be delivered to ORNL site no more than 24

Weeks after contract award and shall include:

• Quality inspection data required for all components

• Test data required for all components

• Completed factory acceptance test report for each blanket

• As built mechanical drawings

• As built 3D CAD files preferred in CREO CAD system format

Deliverable 5 – On Site acceptance testing shall be performed to verify FAT at ORNL site. The seller shall have a representative available as necessary to support on site testing outlined in the

On Site Acceptance Test Plan.

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Table 1: Documentation Deliverables

Document Deliverable

Identifier Document Name

DD1 Project Kick-Off Meeting Minutes

DD2 Project Plan

DD3 Progress Meeting Notes

DD4 Inspection Plans

DD5 Design Package

DD6 Manufacturing Design Review and Meeting Minutes

DD7 Validation Plan and Reports

DD8 Maintenance and Operations Manuals

DD9 Wiring Diagrams and Assembly Instructions

(if applicable)

DD10 Certificate of Conformity or NRTL Certification and Inspection Report

DD11 Packaging Design

DD12 Pre-Shipment Documentation

DD13 Quality Plan

DD14 Deviation Requests (if Applicable)

DD15 Non-Conformance Reports (if applicable)