NSTX-U_Center_Stack_Casing_Specs_(draft).pdf

TECHNICAL SPECIFICATION

FOR

CENTER STACK CASING FABRICATION

CAT: ☑ A1 ☐ A2 ☐ A3

UNIQUE PROJECT IDENTIFIER: NSTX-U-SPEC-VVIH-002-00

REFERENCE WORK PLANNING NO: 2320

REVISION 0

DATED December 13 th , 2018

PREPARED BY: C. Pagano

Engineer

REVIEWED BY: M. Viola

Cognizant Individual/PTR

REVIEWED BY: M. Safabakhsh

Fabrication Technical Authority

REVIEWED BY: G. Swider

Associate Project Manager

REVIEWED BY: D. Loesser

Responsible Engineer

REVIEWED BY:

ES&H

REVIEWED BY:

Quality Assurance

APPROVED BY: C. Neumeyer

Chief Engineer

PRINCETON UNIVERSITY

PLASMA PHYSICS LABORATORY

P.O. BOX 451

PRINCETON, N.J. 08543

609-243-2000

RECORD OF CHANGES

Rev. Date Description of Change(s)

0 12/13/2018 Initial release

NSTX-U-SPEC-VVIH-002-00

TABLE OF CONTENTS

LIST OF ACRONYMS

1.0 INTRODUCTION & SCOPE

2.0 APPLICABLE DOCUMENTS

3.0 APPLICABLE DRAWINGS

4.0 RESPONSIBILITIES

Princeton Plasma Physics Laboratory ............................................................................................................. 8 4.1

Project Management & Oversight ........................................................................................................ 8 4.1.1

PPPL Deliverables to Subcontractor .................................................................................................... 8 4.1.2

Subcontractor .................................................................................................................................................. 8 4.2

Project Management ............................................................................................................................. 8 4.2.1

Deliverables to PPPL ............................................................................................................................ 8 4.2.2

Material Acquisition ............................................................................................................................. 8 4.2.3

Manufacturing ...................................................................................................................................... 8 4.2.4

Documentation ..................................................................................................................................... 8 4.2.5

Start of Work ........................................................................................................................................ 9 4.2.6

Dimensional Verification ..................................................................................................................... 9 4.2.7

Notification Requirements .................................................................................................................... 9 4.2.8

Tooling Accountability ......................................................................................................................... 9 4.2.9

Weekly Updates ................................................................................................................................... 9 4.2.10

Photographs of Processes, Handling, Packaging & Crating ................................................................. 9 4.2.11

Shipping Release Form ......................................................................................................................... 9 4.2.12

5.0 REQUIREMENTS

Design Performance Requirements ............................................................................................................... 11 5.1

Performance Characteristics ............................................................................................................... 11 5.1.1

Equipment Definition .................................................................................................................................... 11 5.2

Specification and Standards................................................................................................................ 11 5.2.1

Subcontractor Supplied Materials ...................................................................................................... 11 5.2.2

Electromagnetic Interference and Susceptibility ................................................................................ 12 5.2.3

Identification and Marking ................................................................................................................. 12 5.2.4

Workmanship ..................................................................................................................................... 13 5.2.5

Subcontractor Use of Equipment ........................................................................................................ 13 5.2.6

Welding ......................................................................................................................................................... 13 5.3

Proposed Manufacturing Sequence ............................................................................................................... 14 5.4

Fabrication and Assembly of the Center Stack First Wall Sleeve, Vertical Sleeve, and Angled 5.4.1

Sleeve Adapter Fabrication and Installation of the Divertor Flange Assembly ........................................................... 14 5.4.2

Installation of the Heat Transfer Tube ................................................................................................ 14 5.4.3

Installation of the Organ Pipes and Divertor Flange F ....................................................................... 15 5.4.4

Installation of the Heat Transfer Plate ................................................................................................ 15 5.4.5

Installation of the Flux Loops ............................................................................................................. 15 5.4.6

Installation of the Bellows and Bellows Wrap ................................................................................... 15 5.4.7

Installation of PFC Studs .................................................................................................................... 15 5.4.8

6.0 TEST AND INSPECTION REQUIREMENTS

Performance Tests ......................................................................................................................................... 16 6.1

Dimensional Inspection ...................................................................................................................... 16 6.1.1

Non-Destructive Testing .................................................................................................................... 16 6.1.2

Leak Testing ....................................................................................................................................... 16 6.1.3

Pressure Testing ................................................................................................................................. 17 6.1.4

Magnetic Permeability Test ................................................................................................................ 17 6.1.5

Metrology ........................................................................................................................................... 18 6.1.6

Testing Sequence .......................................................................................................................................... 18 6.2

Tests After Performing CSC Welds ................................................................................................... 18 6.2.1

Tests After HTT Installation............................................................................................................... 19 6.2.2

Tests After Organ Pipe Installation .................................................................................................... 20 6.2.3

Tests After HTP Puck Installation ...................................................................................................... 21 6.2.4

Tests After HTP Installation ............................................................................................................... 22 6.2.5

Tests After Bellows Installation ......................................................................................................... 23 6.2.6

Tests After PFC Stud Installation ....................................................................................................... 23 6.2.7

Tests After Full Assembly .................................................................................................................. 23 6.2.8

Subcontractor Hold Points ............................................................................................................................ 24 6.3

7.0 QUALIFICATIONS

General Requirements ................................................................................................................................... 24 7.1

Welding ......................................................................................................................................................... 25 7.2

Specifications ..................................................................................................................................... 25 7.2.1

Personnel Qualifications ..................................................................................................................... 25 7.2.2

Critical Lifts .................................................................................................................................................. 25 7.3

8.0 ENVIRONMENT, SAFETY, AND HEALTH

Safety ............................................................................................................................................................ 25 8.1

Notification Requirements Off-Normal Events & Issues .............................................................................. 26 8.2

Oversight ....................................................................................................................................................... 26 8.3

Safety and Hazard Mitigation Plan ............................................................................................................... 26 8.4

9.0 QUALITY ASSURANCE REQUIREMENTS

Inspection/ Surveillance/Audit By PPPL ...................................................................................................... 26 9.1

Subcontractor’s Responsibility for Conformance ......................................................................................... 27 9.2

Subcontractor Quality Assurance Program ................................................................................................... 27 9.3

Manufacturing Readiness Review ................................................................................................................. 27 9.4

Quality Assurance Plan ................................................................................................................................. 27 9.5

Manufacturing, Inspection and Test Plan ...................................................................................................... 27 9.6

Changes To PPPL Approved Documents ..................................................................................................... 28 9.7

Nonconformance and Corrective Actions and Notification Of PPPL ........................................................... 28 9.8

Measuring and Test Equipment ..................................................................................................................... 28 9.9

Submittal of Material Certifications .............................................................................................................. 28 9.10

Document Traceability and Records ............................................................................................................. 29 9.11

Inspection and Test Control .......................................................................................................................... 29 9.12

Performance and Documentation of Inspections and Tests ........................................................................... 29 9.13

Submittal of Completed Inspection and Test Reports ................................................................................... 29 9.14

Submittal Of Acceptance Test Procedures For PPPL Approval ................................................................... 30 9.15

General Requirements ................................................................................................................................... 30 9.16

PPPL Receiving/Inspection ........................................................................................................................... 30 9.17

Process Sequence .......................................................................................................................................... 30 9.18

Equipment/Material Identification And Status .............................................................................................. 30 9.19

Control of Special Processes ......................................................................................................................... 30 9.20

Submittal of Completed Release For Shipment Form ................................................................................... 30 9.21

10.0 SHIPPING STORAGE AND HANDLING

11.0 ATTACHMENTS

12.0 DOCUMENTATION & DELIVERABLES

LIST OF ACRONYMS

ASME = American Society of Mechanical

Engineers

ASTM = American Society for Testing &

Materials

CMTR = Certified Mill Test Report

CSASA = Center Stack Angled Section

Adapter

CSC = Center Stack Casing

CSFWS = Center Stack First Wall Sleeve

CSVS = Center Stack Vertical Sleeve

GD&T = Geometric Dimensioning &

Tolerancing

GFE = Government Furnished Equipment

HTP = Heat Transfer Plate

HTT = Heat Transfer Tube

JHA = Job Hazard Analysis

MIT = Manufacturing, Inspection &

Testing

NCR = Non-Conformance Report

NDT = Non-Destructive Testing

NSTX = National Spherical Torus eXperiment

PPPL = Princeton Plasma Physics

Laboratory

PTR = Princeton Technical Representative

QA = Quality Assurance

SST = Stainless STeel

1.0 INTRODUCTION & SCOPE

As part of the NSTX-U Recovery Work Plan, this Technical Specification documents all materials, labor, supervision, equipment, etc., required to perform the fabrication of the new

NSTX-U Center Stack Casing (CSC) per the drawings outlined below in §2.0. This includes, but is not limited to the following:

a. Fabrication of the Center Stack First Wall Sleeve (CSFWS), CS Angled Section Adapter

(CSASA), and the CS Vertical Sleeve (CSVS)

b. Installation of CS Case Divertor Flange-Collar Assemblies

c. Installation of Heat Transfer Tubes and Plates

d. Metrology/Validation of final CSC geometry

e. Acceptance testing (NDT, Leak, Pressure) of all joints/connections

2.0 APPLICABLE DOCUMENTS

[1] ASME B31.3 – Process Piping Code – Category D Fluid Services

[2] ASME Section IX – Welding Brazing and Fusing

[3] ASTM E498/E498M – Leaks using Mass Spectrometer Leak Detector or Residual Gas

Analyzer

[4] ASTM A 342-04 – Standard Test Methods for Permeability of Weakly Magnetic

Materials

[5] ASNT: SNT-TC-1A – Personnel Qualifications and Certification in Nondestructive

Testing

[6] ASTM B443 – Standard Specification for Nickel-Chromium-Molybdenum Columbium

Alloy (UNS N06625) Plate Sheet and Strip

[7] ASTM B444 – Standard Specification for Nickel-Chromium-Molybdenum Columbium

Alloy (UNS N06625) Pipe and Tube

[8] ASTM B446 – Standard Specification for Nickel-Chromium-Molybdenum Columbium

Alloy (UNS N06625) Rod and Bar

[9] ASTM A269 – Standard Specification for Seamless and Welded Austenitic Stainless Steel

Tubing for General Service

[10] ASTM A276 – Standard Specification for Stainless Steel Bars and Shapes

[11] ASTM B166 – Standard Specification for Nickel-Chromium-Iron Alloys (UNS N06600)

Rod, Bar

[12] AWS A5.9 – Specification for Bare Stainless Steel Welding Electrodes and Rods

[13] AWS A5.14 – Specification for Nickel and Nickel-Alloy Bare Welding Electrodes & Rods

[14] PPPL Guidelines for Procurements Involving Hoisting and Rigging (H&R) Services

3.0 APPLICABLE DRAWINGS

The drawings needed to fabricate the CSC are listed in Table 1 below. Each drawing contains not only the high-level assembly views, but all the necessary sub-component drawing views needed to fabricate the subcomponents, and the overall assembly. Current revisions are indicated, subsequent revisions will be provided to the subcontractor by change order as needed. Should the drawing notes/details conflict with this Technical Specification, the Technical Specification shall take precedence.

Table 1. List of PPPL Provided Drawings

Drawing No. Rev. Description

E-DC 1428 0 Center Stack Bellows Detail

E-DC 11073 0 Heat Transfer Coil Assembly, Top and Bottom

E-DC 11074 0 Cooling Coil Vertical Clamp, Top and Bottom (HTT)

E-DC 11124 0 Left & Right Cooling Plate Assembly, Top (HTP)

E-DC 11125 0 Left & Right Cooling Plate Assembly, Bottom (HTP)

E-DC 11165 0 Diagnostic Organ Pipe Weldment

E-DC 11167 0 Bellows Weldment

E-DC 11173 0 Gasket, HTP

E-DC 11174 0 Heat Transfer Coil Holding Clamps, Top & Bottom

E-DC 11198 0 HTP Clamp Support Welding Fixture

E-DC 11204 0 Center Case Assembly, Protective Tile Weld Stud Locations

E-DC 11206 0 Blank, CS Vertical Sleeve (Mat'l for E-DC11210-5 & -6)

E-DC 11208 0 Forging, CS Angled Section Adapter (Mat'l for E-DC11210-7)

E-DC 11209 0 Blank, CS First Wall Sleeve (Mat'l for E-DC11210-8)

E-DC 11210 0 Center Case Weldment, Center Stack

E-DC 11211 0 Center Case Weldment, Heat Transfer Parts

E-DC 11212 0 Center Case Weldment, Bellows

E-DC 11213 0 Forging, CS Collar Support (Mat'l for E-DC11210-3 & -4)

E-EB 1089 0 Upper Coolant Tube Stub Weldments Assembly

Figure 1. Exploded and Section views of the components of the CSC fabrication

4.0 RESPONSIBILITIES

PRINCETON PLASMA PHYSICS LABORATORY 4.1

PROJECT MANAGEMENT & OVERSIGHT 4.1.1

a. PPPL is responsible for this document, and the requirements outlined within.

b. PPPL will designate a technical contact, the Princeton Technical

Representative (PTR) and a Quality Assurance (QA) contact as well as alternate contacts for those individuals at the time of contract award.

c. PPPL will provide staff to oversee and witness various tests, including all leak tests performed as part of this test plan. The Subcontractor should provide a minimum one weeks’ notice to PPPL of the anticipated date of testing.

PPPL DELIVERABLES TO SUBCONTRACTOR 4.1.2

a. All drawings outlined in §3.0.

b. All parts/sub-assemblies and quantities listed in Table 2

c. PPPL Shipping Release Form (Attachment A)

d. Guidelines for Procurements Involving Hoisting and Rigging (H&R)

Services (Attachment B)

SUBCONTRACTOR 4.2

PROJECT MANAGEMENT 4.2.1

The Subcontractor shall provide a single-point of contact and an alternate for any communication between PPPL and the Subcontractor.

DELIVERABLES TO PPPL 4.2.2

The Subcontractor is responsible for providing the physical and document deliverables in §12.0 to PPPL when noted and as required.

MATERIAL ACQUISITION 4.2.3

Unless otherwise noted, the Subcontractor shall be responsible for purchasing all raw and shop materials necessary for the fabrication of all Subcontractor furnished components and subassemblies (see Table 3) and assembly of the final deliverable, the CSC (see Table 4).

MANUFACTURING 4.2.4

The Subcontractor is responsible for the fabrication of the components all

Subcontractor furnished components and subassemblies, see Table 3 and assembly of the final deliverable, the CSC, per the drawings supplied by PPPL, and any other instructions/standards/etc., referenced in this Technical Specification.

DOCUMENTATION 4.2.5

The Subcontractor shall thoroughly document calibration records, manufacturing plans, personnel certifications and qualifications, and all inspections performed.

Inspection reports shall be submitted to PPPL as noted in Table 6 in §12.0. This includes test reports for all NDT, Leak and Pressure tests performed in the completion of the scope of work regardless if a PPPL employee, or designee, is present to witness the test. The report shall include type of test, location or test and results and photos of the setup.

START OF WORK 4.2.6

The actual fabrication work shall not start, until the following are met:

a. PPPL has reviewed, and approved all required documents, including the

Subcontractors MIT plan.

b. Successful completion of a Manufacturing Readiness Review per §9.4.

c. PPPL’s written approval to proceed with the fabrication.

DIMENSIONAL VERIFICATION 4.2.7

The Subcontractor shall verify all dimensions noted in the drawing package and document the results throughout the component fabrication process, and the final assembly per §6.1.1.

NOTIFICATION REQUIREMENTS 4.2.8

The Subcontractor shall immediately contact PPPL regarding damage to any part or assembly. Details of the damage, including pictures, shall be discussed and documented, and a mitigation plan shall be developed. Work shall not resume on the damaged items, until an approved NCR is issued by PPPL.

TOOLING ACCOUNTABILITY 4.2.9

Any custom tool/fixture needed in the execution of the scope, including test fixtures, shall be the property of PPPL. The Subcontractor shall label, and ship these items to PPPL upon CSC completion. The Subcontractor shall make a list of this tooling and should be identified in the applicable step(s) in the MIT Plan. This list shall include the unique identifier for each tool, plus what step, and which part in the manufacturing process, it was used. Pictures shall be taken of the tool(s), showing how the tool was used to make/hold the part. The general requirements outlined in §9.16 apply to all tooling and fixture materials and hardware.

WEEKLY UPDATES 4.2.10

The Subcontractor shall submit weekly updates on the status of fabrication/assembly process. These updates shall include, which part is being worked on, the estimated completion date for each part, any delays, and the reason for the delay. These updates are to be emailed every Monday. The Subcontractor shall schedule a weekly meeting with PPPL to discuss these updates as well.

PHOTOGRAPHS OF PROCESSES, HANDLING, PACKAGING & CRATING 4.2.11

Photographs shall be submitted to PPPL of each step of the various processes (i.e.

machining, handling, welding, inspection, packaging, and crating). If the part is moved during the process, new photos shall be taken.

SHIPPING RELEASE FORM 4.2.12

Before shipping, the Subcontractor must complete the Shipping Release Form, see

§9.21 and Attachment A, and send it to PPPL’s QA department. The Subcontractor shall not ship the physical deliverables back to PPPL until PPPL returns the signed form and provides written authorization.

Table 2. List of GFE Provided by PPPL

Part No. Description Quantity Material

E-DC 1428-1 Center Stack Bellows 2 Inconel 625

E-DC 11073-01 Heat Transfer Coil Assembly, Top 1 Ass'y

E-DC 11073-02 Heat Transfer Coil Assembly, Bottom 1 Ass'y

E-DC 11073-03 Heat Transfer Inlet Tube Assembly, Top 1 Ass'y

E-DC 11073-04 Heat Transfer Outlet Tube Assembly, Top 1 Ass'y

E-DC 11073-05 Heat Transfer Inlet Tube Assembly, Bottom 1 Ass'y

E-DC 11073-06 Heat Transfer Outlet Tube Assembly, Bottom 1 Ass'y

E-DC 11074-

1 thru 24

Vertical Clamp Segments 1 thru 24 1 EA

(24 Tot.)

Inconel 625

E-DC 11198-01 HTP Clamp Support Ring Welding Fixture 1 Ass'y

E-DC 11124-01 Left Cooling Plate Assembly, Top 1 Ass'y

E-DC 11124-02 Right Cooling Plate Assembly, Top 1 Ass'y

E-DC 11125-01 Left Cooling Plate Assembly, Bottom 1 Ass'y

E-DC 11125-02 Right Cooling Plate Assembly, Bottom 1 Ass'y

E-DC 11174-

1 thru 2

Clamp, Vertical Tube, Top & Bottom 1 EA Inconel 625

E-DC 11174-3 Clamp, Tube Holder 8 Inconel 625

E-DC 11174-

4 thru 15

Lower HTP Clamps 1 EA

(12 Tot.)

Inconel 625

E-DC 11174-16 Feedthru 4 Inconel 625

E-EB 1089-01 Divertor Flange Coolant Tube Stub Weldment –

Type "A1"

1 Ass'y

E-EB 1089-02 Divertor Flange Coolant Tube Stub Weldment –

Type "A2"

1 Ass'y

E-EB 1089-03 Divertor Flange Coolant Tube Stub Weldment –

Type "A3"

1 Ass'y

E-EB 1089-04 Divertor Flange Coolant Tube Stub Weldment –

Type "A4"

1 Ass'y

Flux Loops 2 N/A

Table 3. List of Vendor Fabricated Components

Part No. Description Quantity Material

E-DC 11165-1 Diagnostic Organ Pipe 34 Inconel 625

E-DC 11165-2 1/8" Non-Rotatable Tapped Conflat Flange – Modified 34 316 SST

E-DC 11167-1 Bellows Support Flange, Lower 1 Inconel 625

E-DC 11167-2 Bellows Support Flange, Upper 1 Inconel 625

E-DC 11168-4 Wrap, Upper Outer PF-1B Support 2 Microtherm

E-DC 11204-1 Weld Stud, 5/16-18 UNC-2B Inconel 625

E-DC 11204-2 Weld Stud, 1/4-20 UNC-2B Inconel 625

E-DC 11210-1 CS Divertor Flange, Upper 1 Inconel 625

E-DC 11210-2 CS Divertor Flange, Lower 1 Inconel 625

E-DC 11210-3 Collar Support Assembly, Upper 1 Inconel 625

E-DC 11210-4 Collar Support Assembly, Lower 1 Inconel 625

E-DC 11210-5 Center Case Vertical Sleeve, Upper (CSVS) 1 Inconel 625

E-DC 11210-6 Center Case Vertical Sleeve, Lower (CSVS) 1 Inconel 625

E-DC 11210-7 Center Case Sleeve Adapter Flange (CSASA) 2 Inconel 625

E-DC 11210-8 Center Case First Wall Sleeve (CSFWS) 1 Inconel 625

E-DC 11210-9 Wrap, Upper Outer Collar 1 Microtherm

E-DC 11210-10 Wrap, Lower Outer Collar Support 1 Microtherm

5.0 REQUIREMENTS

DESIGN PERFORMANCE REQUIREMENTS 5.1

PERFORMANCE CHARACTERISTICS 5.1.1

a. All components installed on the CSC shall be positioned to within the tolerances defined in the drawing package.

b. All welded joints/connections shall pass all Non-destructive testing, leak and pressure tests as outlined in §6.1.

EQUIPMENT DEFINITION 5.2

SPECIFICATION AND STANDARDS 5.2.1

A copy of the most recent calibration certificates for each of the machining, metrology and other appropriate equipment/instruments that will be used for critical measurements or manufacturing processes shall be submitted for PPPL approval, at least a week prior to the beginning of fabrication. The Subcontractor must maintain the equipment calibration throughout the duration of the scope of work. The calibration standards must be traceable to the National Institute of

Standards and Technology (NIST) or equivalent.

SUBCONTRACTOR SUPPLIED MATERIALS 5.2.2

General Requirements 5.2.2.1

a. All materials shall meet the magnetic permeability limits outlined in §5.2.3.

b. Misc. Hardware ‒ All hardware shall meet requirements defined in the associated drawings. Hardware shall also incorporate a locking device (wire or tack weld) where noted. All hardware must meet the requirements outlined in §9.16.

Specific Requirements 5.2.2.2

a. CSFWS – Shall be Inconel 625 plate meeting ASTM B443.

b. CSVSs – Shall be Inconel 625 plate meeting ASTM B443.

c. CSASA – shall be made out of a forging of Inconel 625 per

ASTM B446-03 Grade 1 Annealed Material capable of

Ultrasonic Inspection per AMS-STD-2154 Class A.

d. CS Divertor Flanges ‒ shall be machined out of Inconel 625 plate meeting ASTM B443.

e. CS Divertor Flange Collar ‒ shall be made out of a forging of

Inconel 625 per ASTM B446-03 Grade 1 Annealed Material capable of Ultrasonic Inspection per AMS-STD-2154 Class A.

f. Bellows Flanges ‒ shall be machined out of Inconel 625 plate meeting ASTM B443.

g. Diagnostic Organ Pipes ‒ shall be Inconel 625 tube meeting

ASTM B444.

h. Conflat Flanges ‒ shall be 316 SST meeting ASTM A276 and meet the magnetic permeability limits outlined in §5.2.3.

i. PFC Studs – Shall be machined out of Inconel 600 per ASTM

B166.

j. Weld Filler – Shall meet the AWS A5.9 or AWS A5.14 specifications for steel and Inconel 625 weldments respectively.

ELECTROMAGNETIC INTERFERENCE AND SUSCEPTIBILITY 5.2.3

All work performed in the execution of this Technical Specification shall meet the

Magnetic Permeability Limits listed on the drawing. If the drawings do not list a magnetic permeability limit, then use the following:

Base Material:

≤ 1.2μ for 316SST

≤ 1.02μ for all other materials

Welds:

≤ 1.2μ for 316 Stainless-to-Stainless

≤ 2.0μ for 316 Stainless-to-Inconel

≤ 1.02μ for Inconel-to-Inconel

≤ 1.2μ for all other welds, and attaching hardware (e.g. nuts, bolts, etc.)

IDENTIFICATION AND MARKING 5.2.4

Add identifications and markings per the supplied drawings.

WORKMANSHIP 5.2.5

a. General shop cleanliness and housekeeping shall be adequately maintained to prevent tracking contamination of vessel components.

b. Careful handling of the CSC is required so as not to damage machined surfaces.

c. All fabricated parts shall be free from sharp edges and burrs.

d. All surfaces shall be cleaned to remove all oil, grease, dirt, loose mill scale, residue from protective covering and other foreign substances. Cleaning shall be performed using acetone and then finished with alcohol.

e. In the event of ferritic contamination of stainless steel, pickling and passivation shall be required.

f. The all parts and assemblies shall be free from weld spatter.

g. Tubing shall be bent with care to avoid kinking.

SUBCONTRACTOR USE OF EQUIPMENT 5.2.6

Subcontractors must provide their own equipment and not use government equipment. It is the Subcontractor’s responsibility to qualify/calibrate all equipment necessary to perform the work outlined in this document.

WELDING 5.3

a. Unless otherwise noted on the drawing, all full penetration weld joints shall be of the double-beveled joint type with a minimum included angle of 45 degrees. The sequence of the welding shall be performed to allow easy access to view the weld root prior to applying the second weld. For example, when welding the CSC sleeves, the inner diameter should be welded first and the root background from the outside until sound metal is visible. Exceptions require written PPPL concurrence.

b. Edges or surfaces of parts to be joined by welding shall be prepared by machining, grinding, or plasma arc cutting.

c. Where thermal cutting is used, all scale must be removed by grinding. Any grinding shall be performed using rubber or resin bonded aluminum oxide or silicon carbide grinding wheels. The grinding wheels shall not have been previously used on other than stainless steel materials and identified accordingly

(e.g. color coded).

d. Prior to welding, the joint edges and immediate weld area of the parts to be joined shall be cleaned of all oil, grease, scale or other foreign materials. For degreasing, swab the weld region with acetone or other PPPL approved solvent.

No residual cleaning compounds shall be left on the surfaces prior to welding.

These steps shall be documented in the MIT plan described in §9.6.

e. All filler material must be compatible with the base metals of the components that shall be welded together and have equal or greater strength than the base material and meet the specifications outlined in §5.2.2.2j. Filler material must be added in all weld passes. Filler materials which are dirty, damaged or inadequately identified shall not be used. Filler material shall be stored in a clean and dry space. The filler material shall be properly identified by type or grade.

f. Magnetic permeability may increase at the base material because of thermal processing. If the permeability increase exceeds the criteria of §5.2.3, additional grinding will be required.

g. Welding shall be accomplished per the welding standards listed in §2.0, in particular ASME B&PV Code, Section IX.

h. Welding sequence and techniques shall be closely controlled in order to minimize distortion. Subcontractor's welding sequence and distortion control methodology shall be provided to PPPL for review and approval as part of the

Manufacturing/Inspection/Test Plan. Subcontractor may propose alternate methods of welding and weld types (e.g. MIG) other than those indicated on the drawings. These alternate methods must be fully documented and approved by

PPPL prior to use. The method proposed should maximize position and tolerance control.

i. All welds shall be subject to non-destructive testing. Leak and pressure testing shall be performed as necessary on vacuum-boundaries and pressure lines as outlined in §6.1.3 and §6.1.4.

PROPOSED MANUFACTURING SEQUENCE 5.4

The following sequence of operations is the recommended fabrication and installation sequence for the assembly of the new Center Stack Casing highlighting key steps. The

Subcontractor shall provide a process flow via their MIT plan which shall be submitted to

PPPL for approval prior to the start of work. All welded joints associated with the fabrication and installation below are subject to the testing outlined in §6.0. PPPL required hold points for this process are listed in §6.3.

FABRICATION AND ASSEMBLY OF THE CENTER STACK FIRST WALL SLEEVE, 5.4.1

VERTICAL SLEEVE, AND ANGLED SLEEVE ADAPTER

The Subcontractor shall fabricate the CSFWS, CSVSs and Sleeve Adapter Flanges at the quantities outlined in drawing E-DC11210. The CSVS and Sleeve Adapters shall be welded together and metrology measurements shall be taken to look for any distortion. Using the results of the metrology, the two CSVS/Sleeve Adapter subassemblies shall be welded on either end of the CSFWS. Another set of metrology measurements shall be taken after this second weldment in order to verify the assembly meets the tolerance requirements. Post machining of the CSC can be performed if necessary. For all welds, when switching between the inner and outer passes, back grinding shall be performed in order to achieve the desired full penetration welds.

FABRICATION AND INSTALLATION OF THE DIVERTOR FLANGE ASSEMBLY 5.4.2

The Subcontractor shall fabricate the divertor flanges with collar assemblies as outlined in the associated drawing E-DC11210. Once completed, the assemblies shall be welded to either end of the CSC. All surfaces of the divertor flange and collar shall be turned to meet the GD&T requirements outlined on the drawings.

Certain features on the divertor flange are to be machined after weldment to the

CSC to avoid potential distortion. These features include the outer ring of HTP mounting and organ pipe holes.

INSTALLATION OF THE HEAT TRANSFER TUBE 5.4.3

The Subcontractor shall install the HTT and associated vertical clamps into the groove on the inner surface of the CSVSs per drawing E-DC11211. [NOTE: The

HTT shall be provided with unbent ends that are to be bent to fit in the field. Once the tube is inside the CSVS groove, the 1/4" return line shall be inserted and welded in field using the 3/8" to 1/4" union. The inlet and return stub tube weldments shall then be welded to the HTT assembly making sure that the ends pass through the windows in the divertor flange collar.] Next the Vertical clamps shall be welded to the ID surface of the CSVS. PPPL shall provide an installation fixture (E-DC11198-01) for assistance with the installations of the clamps to achieve the required 1000lb preload. If warping/dimpling occurs due to the welding process, the outer diameter of the CSVSs shall be turned after welding to meet the tolerance requirements. [NOTE: Once the vertical clamps are installed, the subcontractor shall weld the remaining individual tube clamps followed. Finally the subcontractor shall bolt on the tube holders.]

INSTALLATION OF THE ORGAN PIPES AND DIVERTOR FLANGE F 5.4.4

The Subcontractor shall weld the organ pipes to the CSC, and the HTP feedthrus to the Divertor Flange per drawing E-DC11211. Once installed, the Subcontractor shall perform all necessary NDT and leak testing per this Technical Specification.

INSTALLATION OF THE HEAT TRANSFER PLATE 5.4.5

The Subcontractor shall install the HTP, and weld the thru tubes, to the pucks in the divertor flanges per drawing E-DC11211. [NOTE: Prior to installing the HTP, Grafoil shims shall be placed on the divertor flange to match the CSC metrology with the perpendicularity indicated on the drawings. Once shimmed, the HTP is installed utilizing the associated bolts preloaded to 1000lb. Metrology shall then be performed to guarantee the positioning matches the drawing. With the HTP aligned, the tube adapters are welded to the HTP shall be welded to the feedthrus in the divertor flanges. The HTP inlet and return lines shall then be welded to the exposed ends of the HTP tube adapters. Finally, the shear pin holes in the HTP and divertor flange shall be match-machined to achieve the appropriate diameter and positioning, and the pins shall be inserted and tack welded in place.]

INSTALLATION OF THE FLUX LOOPS 5.4.6

The Subcontractor shall weld the flux loops to the outer surfaces of the divertor flanges using the appropriate clamps as shown in the associated drawing.

INSTALLATION OF THE BELLOWS AND BELLOWS WRAP 5.4.7

The Subcontractor shall weld the bellows to the divertor flange and turn its surface to the dimensional tolerances indicated in drawings E-DCE-DC11212. All features shall then be machined into the bellows flange. Once completed, the bellows shall be wrapped in insulation as shown in the associated drawing.

INSTALLATION OF PFC STUDS 5.4.8

The Subcontractor shall install all 648 CSC studs per drawing E-DC11204.

6.0 TEST AND INSPECTION REQUIREMENTS

PERFORMANCE TESTS 6.1

The Subcontractor shall perform each test in the sequence outlined in §6.2, unless suggested changes are submitted and approved in writing by PPPL.

DIMENSIONAL INSPECTION 6.1.1

Tolerances are indicated on the manufacturing drawings. Strict adherence to these dimensions and tolerances are critical to the assembly and performance of the subject equipment. All dimensional measurements shall be performed in a temperature controlled environment.

On all large surface features (e.g. the outer surface of the CSFWS), the measurements shall be taken with a maximum allowable spacing of 2" between measured points. For all remaining surfaces/features, it is the Subcontractors responsibility to provide adequate point density to verify the drawing tolerances have been achieved.

The Subcontractor shall include the sequence and measurement methodology as part of their MIT Plan. The Subcontractor shall also note what best-fit methodology is used to confirm compliance with the drawing tolerances.

Dimensional inspections shall be performed at the following steps:

a. Pre-Weld/Component Measurements ‒ inspect all components per their respective drawings and document the results.

b. Post-Weld Measurements ‒ inspect the weldments per their respective drawing and document the results.

c. Final Metrology Survey Data ‒ when all other weld, leak and other inspections have been completed, take a final metrology point cloud of the finished work to confirm GD&T compliance with all drawings. The positional accuracy of all assembled components shall fall within the tolerances specified in the associated drawings.

NON-DESTRUCTIVE TESTING 6.1.2

All welds performed as part of this work scope shall be subjected to non-destructive testing in accordance with the severe cyclic condition acceptance criteria of ASME B31.3. All welds shall be subjected to visual inspections.

Additionally, the seam welds between the CSFWS, CSASA and CSVS shall be subjected to radiographic inspection. Liquid Penetrant NDT is not allowed.

LEAK TESTING 6.1.3

All Helium Leak testing shall be performed following ASTM E498/E498M utilizing Test Method A. The maximum allowable helium leak rate, unless otherwise noted, is 1×10 -9

ATM cc/sec (air equivalent) on all vacuum boundary welds. It is required that a global test of the entire weld with 1 atmosphere of helium be completed (see §10.8 of ASTM E498/498M). Helium detection shall be performed utilizing a Helium Mass Spectrometer Leak Detector (HMSLD).

All leak testing shall be witnessed by a qualified PPPL employee (as designated by

PPPL). The Subcontractor shall give one week’s notice to PPPL for any upcoming leak tests.

This testing shall be performed on all welded joints including, but not limited to the following:

a. CSC sleeve seams

b. Diverter Flange to CSVSs on CSC

c. Bellows to Bellows Support Flange, Upper

d. Bellows to Bellows Support Flange, Lower

e. Bellows Support Flange, Lower to Divertor Flanges

f. HTP Puck to Divertor Flanges

g. HTP Assembly to HTP Puck

h. All joints part of HTT assemblies

i. HTP Assembly to HTP Tube Stud Weldments

PRESSURE TESTING 6.1.4

All Pressure testing shall be done to 2 times the maximum expected operating pressure, which exceeds the requirements of to ASME BPVC I – XII and to the acceptance criteria of ASME B31 after performance of any required leak testing.

The test shall be conducted for 8 hours, or overnight.

a. For all joints of the HTT, pressure testing shall be performed to 2 times the maximum operating pressure: 120PSIG × 2 = 240PSIG.

b. For all joints of the HTP, pressure testing shall be performed to 2 times the maximum operating pressure: 300PSIG × 2 = 600PSIG.

Failure of connections tested cause damage/debris to be ejected to the surround area. The Subcontractor shall be required to have a clean work area in which to perform the tests, and include such provisions in their Job Hazard Analysis (JHA).

This testing shall be performed on the following joints:

a. All joints part of HTT assemblies

b. HTP Assembly to HTP Tube Stud Weldments

The Subcontractor shall give one week’s notice to PPPL for any upcoming pressure tests.

MAGNETIC PERMEABILITY TEST 6.1.5

To verify conformance, magnetic permeability shall be measured in accordance with the requirements of ASTM A 342, Test Method No. 3.

a. The magnetic permeability limits shall be per §5.2.3.

b. Testing shall use a Severn Engineering Low Mu Permeability Indicator

(Available from Severn Engineering Co. Auburn, Alabama), which has been calibrated within the past 12 months.

c. The drawing shall designate where to measure permeability. If the drawing does not designate where to measure permeability, then contact the PPPL

PTR for clarification. Record on the drawing only those values, and their locations, that are out-of-tolerance. Include dimensions to the nearest edge/surface so that it can be double-checked by the PTR or designee.

d. All welds shall be checked every 1/2" (both inside and outside surfaces wherever possible). Actual values shall be recorded only for any out-of-tolerance conditions.

http://www.severnengineering.com/lomu.htm

METROLOGY 6.1.6

Prior to shipping, PPPL requires a metrology data set (e.g. a point cloud) of the finished work confirming GD&T compliance with all drawings. The positional accuracy of all assembled components shall meet or exceed the tolerances specified in the associated drawings. Additional metrology steps may be required throughout the fabrication process in order to verify the dimensional tolerances outlined in the drawing package of individual components and subassemblies.

TESTING SEQUENCE 6.2

The Subcontractor shall perform all of the tests outlined in this test plan in the following sequence. Should the Subcontractor’s approved MIT plan conflict with this sequence, the

Subcontractor shall contact PPPL to discuss and receive written approval for any changes

TESTS AFTER PERFORMING CSC WELDS 6.2.1

The subcontractor shall perform NDT and leak testing at all seam welds, see Figure

2:

a. Weld 1 – CSVS to CSASA, upper and lower

b. Weld 2 – CSVS-CSASA Assemblies (Step a.) to CSFWS, upper and lower

c. Weld 3 – CS Divertor Flange-Collar Assemblies to CS Sleeve Assemblies, upper and lower

The leak testing requires a fixture to enclose the entire inner volume of the CS

Sleeve Assembly.

Prior to welding the divertor flange assembly to the CS Sleeve assemblies, the

Subcontractor shall perform NDT on the CS Divertor Flange-Collar weld, see

Figure 3.

Figure 2. Vacuum-Air Boundary Welds to be NDT and leak tested on the CSC

Figure 3. Weld to be tested between the divertor flange and collar

TESTS AFTER HTT INSTALLATION 6.2.2

The Subcontractor shall perform NDT, leak and pressure testing on the HTT return tube to tube adapter joint per §6.1.3 and §6.1.4, see Figure 4. The clamps used to hold the tube in the CSVS groove shall only be subject to NDT, see Figure 5.

Figure 4. Welds to be tested during the installation of the HTT Return Tube

Figure 5. HTT Lower Clamp Welds to be subjected to NDT

The HTT to HTT Stub Assemblies, see Figure 6, shall be subject to NDT, leak testing and pressure testing per §6.1.3 and §6.1.4.

Figure 6. Welds to be tested during the installation of the HTT Inlet and Outlet Stubs

TESTS AFTER ORGAN PIPE INSTALLATION 6.2.3

The Subcontractor shall perform NDT and leak testing on each weld between the diagnostic organ pipe tubes and Conflat Flanges, see Weld 1 of Figure 7.

The Subcontractor shall then perform NDT and leak testing on each weld between the diagnostic organ pipe assemblies and the divertor flange, see Weld 2 of Figure

7.

Figure 7. Welds to be tested during the fabrication and installation of the organ pipes

TESTS AFTER HTP PUCK INSTALLATION 6.2.4

The Subcontractor shall perform NDT and leak tests on the welds connecting the

HTP feedthrus to the divertor flange, see Figure 9. This leak test shall require a fixture to create an enclosed pump-down volume. One such proposed fixture is shown in Figure 9.

Figure 8. Welds between the HTP feedthrus and the casing flange to be tested

Figure 9. Proposed leak testing setup and equipment for qualifying the weld between the feedthrough and divertor flange

TESTS AFTER HTP INSTALLATION 6.2.5

The Subcontractor shall perform NDT and leak tests on the welds joining the HTP tube adapters to the feedthrough installed on the CS Divertor Flange, see Figure 10.

Figure 10. Welds to be leak tested during installation of the HTP

The Subcontractor shall then perform NDT, leak and pressure testing per §6.1.3 and §6.1.4 on the HTP tube stud weldments to the HTP tube adapters see Figure

11.

Figure 11. Welds to be tested during the installation of the HTP Inlet and Outlet Stubs

TESTS AFTER BELLOWS INSTALLATION 6.2.6

The Subcontractor shall perform NDT and leak testing per §6.1.2 and §6.1.3 on the welds joining the bellows to the bellows skirt and flange, see welds 1 and 2 in

Figure 12.

The Subcontractor shall also perform NDT and leak testing on the weld joining the bellows assembly to CS Divertor Flange, see Weld 3 in Figure 12.

TESTS AFTER PFC STUD INSTALLATION 6.2.7

After installing each stud on the CSC, the Subcontractor shall perform a visual inspection of each stud weld and be reinforced as necessary with additional weld passes.

TESTS AFTER FULL ASSEMBLY 6.2.8

Upon completion of the assembly (E-DC11204-01), the entire CSC shall be subjected to a leak test. Both ends of the CSC shall be capped with fixtures designed and provided by the Subcontractor and the whole volume shall be pumped down.

Figure 12. Welds to be tested as part of the Bellows and Bellows Flange Weldment

SUBCONTRACTOR HOLD POINTS 6.3

Hold work and contact PPPL for inspection/approval prior to proceeding at the following process steps:

a. After fabrication/machining of the CSFWS, CSASA, CSVS as part of a trial fit-up.

b. After welding the divertor flange to the CSC Sleeve Assembly and machining surfaces.

c. After testing of the Organ Pipe, Puck and HTT installation welds

d. After testing the HTP tube to puck welds

e. After the testing the bellows weld

f. After installing flux loop, and bellows insulation on the CSC.

g. After performing the preliminary testing of the entire CSC assembly

h. After performing the post temperature gradient simulation testing

i. Before final packing and crating

j. After final packing and crating when ready for shipment.

7.0 QUALIFICATIONS

GENERAL REQUIREMENTS 7.1

Personnel are required to be trained in the operation of the equipment such that time is not lost, and material is not damaged, due to preventable mistakes. A copy of training certifications for Personnel performing the operations listed below shall be provided, and approved by PPPL, in writing, before the manufacturing work begins. The training must be up-to-date and maintained by each individual throughout the fabrication performed in the execution of this scope. The certifications shall be per the requirements listed in §2.0, or by a PPPL approved alternative.

a. Welders

b. Non-Destructive Testing Operators

c. Magnetic Permeability

d. Leak Tester

e. Pressure Tester

WELDING 7.2

SPECIFICATIONS 7.2.1

Welding Procedure Specifications (WPSs), Welding Procedure Qualification

Records (PQRs), and Welding Personnel qualifications (WPQs) shall be provided for all work being performed through the execution of this Statement of Work. All documentation must be approved by PPPL prior to the start of welding.

PERSONNEL QUALIFICATIONS 7.2.2

All welders, welder operators and welding procedures shall be qualified in accordance with the requirements of the ASME Boiler and Pressure Vessel Code, Section IX, and this scope of work. Welding procedure qualification test results shall demonstrate that the resulting weldments are compatible with the base materials and meet or exceed the base material mechanical properties, with relative magnetic permeability less than or equal to 1.7.

CRITICAL LIFTS 7.3

Due to the criticality of the work executed as part of this scope (Category A1), all rigging

& lifts of the CSC shall require a lift plan to be reviewed and approved by PPPL before execution. The lift plan shall include:

a. The current equipment inspection report for equipment being used, such as the crane.

b. Equipment manual and load charts.

c. New wire rope shall be used.

d. Lift data sheet detailing loads, center of gravity, attachment points, component capacities, calculations, lift angle, and swing location. Requires approval by the

PPPL Lift Engineer and signature by the Subcontractor’s Lift Engineer.

e. Qualifications of the Rigger and Signal Person. An officer from the

Subcontractor’s firm shall sign that the stated Rigger and Signal Person are qualified per OSHA.

The subcontractor shall review the PPPL Guidelines for Hoisting & Rigging (see

Attachment B) to comply with these requirements. This guideline includes the recommended template for the required Lift Data sheet. The Lift Procedure and a JHA should be prepared, reviewed and approved prior to performing the lift.

8.0 ENVIRONMENT, SAFETY, AND HEALTH

SAFETY 8.1

Work shall be performed under an established safety program including documented policies and procedures subject to PPPL review. Workers shall be trained to these policies and procedures and records of their training shall be auditable.

NOTIFICATION REQUIREMENTS OFF-NORMAL EVENTS & ISSUES 8.2

The Subcontractor is required to provide, for PPPL review and approval, a procedure that details…