RFP 23-012-P.pdf

REQUEST FOR PROPOSAL (RFP) 23-012-P

TABLE OF CONTENTS

INVITATION LETTER

ACKNOWLEDGEMENT FORM

SECTION I STATEMENT OF WORK

SECTION II SAMPLE SUBCONTRACT

Sample Subcontract

Terms and Conditions

U.S. Department of Labor Employment Standards Administration

Wage and Hour Division, Washington, D.C. 20210 Wage

Determination No. 2015-4193, (Rev. 20) dated 6/27/2022

SECTION III INSTRUCTIONS FOR PROPOSAL PREPARATION

SECTION IV EVALUATION AND BASIS FOR AWARD

SECTION V FINANCIAL AND ADMINISTRATIVE INFORMATION FORMS

PPPL Offeror Information and Pricing Form * PPPL Representations and Certification Booklet * PPPL PQA Supplier Quality Survey* E-Verify Profile (Example)

SECTION I

STATEMENT OF WORK AND TECHNICAL SPECIFICATIONS

FOR OH CONDUCTOR GRIT, BLAST AND PRIMING

DRAWINGS (FOR QUOTE/BID)

REFERENCE DOCUMENTS AND DRAWINGS

PRINCETON PLASMA PHYSICS LABORATORY

P.O. BOX 451 PRINCETON, N.J. 08543

ENG-060 - SOW - STATEMENT OF WORK

STATEMENT OF WORK AND TECHNICAL

SPECIFICATIONS FOR OH CONDUCTOR GRIT,

BLAST AND PRIMING

NSTXU_1-1-3-3-2_SOW_104

Rev. 2

Work Planning #:

Effective Date: 11/22/2022

Prepared By: Richard Burke

Document Admin: Kathleen Lukazik

Reviewed By Yuhu Zhai, Preparer 11/21/2022

16:44:26 PM

Reviewed By Dang Cai, Cognizant Individual 11/22/2022

13:30:54 PM

Reviewed By Steve Raftopoulos, Responsible Engineer

09:10:06 AM

Reviewed By Richard Burke, Subject Matter Expert 11/21/2022

16:08:48 PM

Reviewed By Marlo Ramos, Quality Assurance

05:49:14 AM

Approved By Leslie Hill, Project Manager

13:50:27 PM

Approved By Robert A. Ellis, Project Engineer

13:48:00 PM

Revised 8/8/18

NSTX_1-1-3-3_2_SOW_104

FOR

OH CONDUCTOR GRIT, BLAST AND PRIMING

CAT: A1

NSTXU_1-1-3-3-2_SOW_104

REVISION 2

DATED November 21, 2022

PREPARED BY: Yuhu Zhai, Project Engineer

REVIEWED BY: Danny Cai, COG

REVIEWED BY: S. Raftopoulos, Responsible Engineer

REVIEWED BY: Richard Burke, SME

REVIEWED BY: Marlo Ramos, QA Engineer

APPROVED BY: Les Hill, Project Manager

APPROVED BY: Robert Ellis, Chief Engineer

PRINCETON UNIVERSITY

P.O. BOX 451

PRINCETON, N.J. 08542

609-243-2000

RECORD OF CHANGES

Rev. # Date Description of Changes

0 9/12/2022 Initial release of NSTXU_1-1-3-3-2_SOW_104, with Updates from the incorrectly numbered Statement of Work

(NSTXU_1-1-3-3-1_SOW_120 R0):

1) add PPPL supplier conductor spool detail and final spool dimension required 2) modified the cleanroom requirements to be consistent with the previous inner PF conductor cleanness requirements 3) update the list of documentation & deliverable 4) specify number of locations along the conductor for roughness measurements 5) Clarify final conductor shipment location 6) Clarify manual sand down of both roughness and primer thickness out of spec portions are permitted as long as final results are measured and confirmed that they meet the spec. 0.25” shall be maintained as the max allowed bare spot 7) Clarify and quantify requirements for defects, scratches, bare spots etc. 8) add “Bare Spots” requirements

9) add in Section 9.8 QA list of documents for Process History

1 11/8/2022 Added clarity to the Record of Changes table for the initial release of this SOW.

Added SI units throughout.

Section 4.1: Added information about the process development conductors and the production conductors.

Section 4.2: Added information about the delivery schedule (for Lot 1 and Lot 2) and the expected delivery location, adds information about receipt inspection requirements when raw OH conductors arrive at Subcontractor and adds that it is the Subcontractor’s responsibility to provide wooden spools to ship the processed conductors on. Added required for Subcontractor to hold weekly meetings and distribute status reports

Section 5.1: Added “PPPL approval of the Preliminary MIT Plan is required before the process development conductor can be grit blasted, primed and cured. The Final MIT Plan shall be submitted to PPPL for review 5 Days after the process development conductor is grit blasted, primed & cured. The Final MIT Plan shall incorporate lessons learned for the processing of the process development conductor. PPPL approval of the Final MIT Plan is required before the processing of the 1st Article conductor can begin. The MIT Plan shall delineate the sequence of all critical manufacturing processes and operations affecting quality, including in-process and final acceptance inspections and tests. The inspections and the characteristics/dimensions to be verified shall be detailed.”

Section 5.2: Removed the requirement for Cleanness Compliance checks and replaced with general responsibility of Subcontractor to ensure compliance with the cleanliness requirements in Section

5.2.1 to 5.2.4.

Section 5.3: Added pictures and descriptions/dimensions of the Process Development and Production OH Conductors.

Section 5.4.1 surface roughness measurement changes from 8 locations to two locations (beginning and end).

Section 5.4.4, 5.4.5, and 6.3 fixed Section call-out from 13.2 to 9.8.

Section 5.5.1: Change “(See Section 5.3 cleanness requirements)” to “(See Section 5.2 for cleanliness requirements)”.

Section 5.5.3: Added clarification of PPPL responsibility under the contract for touch up/rework of bare spots and thickness deviations between greater than 0.25 square inch (1.613 cm2) and less than

1.00 square inch (6.5 cm2) found by the Subcontractor during post-priming inspection. Also added the requirement that the number of “Bare Spots” shall not be more than one every 2 meters along the conductor.

Section 5.5.4: Added clearer requirements as to what will need a primer repair and the expectations of a primer repair procedure.

Section 6.2: Change to “Per Section 5.4.4 and Section 5.5.3.” from “Per Section 5.5.3”.

Section 9.8: Change to “A copy of the manufacturer’s certificate of compliance (or equivalent) and expiration dates for the CTD-450 primer, all solvents and the blasting media.” From “A copy of the manufacturer’s material certifications for the CTD-450 primer.”

Under Shipping Release change call-out of “Attachment 1” to “Attachment II”.

Section 10.0: Added more detail regarding the Subcontractor supplied wooden spool (dimensions and requirements).

Section 12.0: Added Section 12.1: Attachment I – Deliverables List and Section 12.2: Attachment II - PPPL Product Quality Certification & Shipping Release.

Section 13.2: Add “See Attachment I – Deliverables List” and Change the Deliverables List into “Attachment I – Deliverables List”. On the Physical Deliverables List – For Line Item 1 replaced “Legacy Conductor” with “Process Development Conductor”. On the Document Deliverables List – Added Section references for each line item. In Line Item 6 “Final MIT Plan” removed “5 days prior to 1st Article Processing” from when the deliverable is required.

Add Attachment II – PPPL Product Quality Certification & Shipping Release

2 11/21/2022 Section 2.0: Remove hyperlinks after each document, and split the 5 documents listed into application or reference documents.

Section 5.1: Change surplus conductors to copper conductors.

Section 4.2: Add the delivery timeline for the 28 coils to the subcontractor.

Section 7.0: Deleted N/A and added qualification information.

Section 11.0:deleted N/A and added See PPPL's Terms and Conditions.

Section 13.1: Deleted “An offer for” .

1.0 INTRODUCTION & SCOPE

This technical specification is for the surface preparation of the copper conductor that will be used in the manufacturing of the new Ohmic Heating (OH) solenoid for the new TF-OH bundle for the National Spherical Torus Experiment Upgrade (NSTX-U).

The preparation of the conductor surface in the manner described in this document provides for greater bonding strength between the copper surface and the resins that are used to impregnate the fiberglass insulation that is applied to the copper conductor during fabrication of the TF-OH bundle.

The preparation of the conductor surface consists of three main operations:

1) Media-blasting the conductor surface to remove oxides.

2) Priming, which seals the surface, preventing oxide formation, and provides a high-strength bond to the resins used during impregnation of the fiberglass.

3) Oven curing of the primer

It is imperative that the freshly sandblasted copper surface be protected against oxide formation prior to application of the primer.

2.0 APPLICABLE AND REFERENCE DOCUMENTS

2.1 APPLICABLE DOCUMENTS

1. Surface Preparation prior to Primer or Coating Application, CTD

2. CTD-450 Primer Data Sheet

3. CTD-450 Primer Safety Data Sheet

2.2 REFERENCE DOCUMENTS

1. OH and Inner PF Coil Conductor specification for NSTX-U D-NSTX-SPEC-13-129 Rev 1.

2. OH Conductor Specification, NSTXU_1-1-3-3-2_SOW_100

3.0 APPLICABLE DRAWINGS

A listing of those drawings that are part of the technical specification.

Drawing Number Description Revision

D-DC11434 OH Coil Conductor 0

4.0 RESPONSIBILITIES

4.1. PRINCETON PLASMA PHYSICS LABORATORY

PPPL will designate a technical contact, the Princeton Technical Representative (PTR), Quality Assurance (QA) as well as a back-up contact person.

PPPL will arrange for shipment of the Process Development (if required) and Production Conductors to the Subcontractor.

If needed and upon request by the Subcontractor, PPPL will provide at least four (4) copper conductor coils, 45-50 m in length, to be used in trial runs; see Section 5.3 for the configuration of coils that will be delivered to the Subcontractor.

PPPL will provide the 28 copper conductor coils, approximately 215 m in length, to be used by the Subcontractor in providing the grit blasting and priming services described herein; see Section 5.3 for the configuration of coils that will be delivered to the Subcontractor.

4.2. SUPPLIER

The Subcontractor shall designate and provide contact information for: a Project Management contact, a Technical Contact, and a Quality Assurance contact person. If any of those roles are filled by a single individual, then a backup contact shall be provided.

Weekly status meetings shall be held by the Subcontractor with PPPL representatives present unless otherwise agreed upon by the PTR. Meeting minutes delineating all action items shall be kept by the Subcontractor and distributed to all attendees as status reports.

Within ten days after contract award, 28 production copper OH coils (approximately 215 m in length each) will be shipped to the subcontractor. The Subcontractor shall grit blast and prime the 28 coils of copper OH conductor material provided by PPPL (see Section 2); the order shall be completed in two 14-unit lots and delivered to ELYTT Energy Services in Bilbao, Spain:

Lot No. 1 (14 coils) shall be delivered on or before August 15, 2023 Lot No, 2 (14 coils) shall be delivered on or before November 15, 2023

The Subcontractor shall conform to all requirements of this document and process the Conductors in full conformance with this specification. If any portion of this work is to be performed by sub-tier contractors, such plans shall be communicated to PPPL with Subcontractor’s proposal and all requirements given in this specification shall flow down to the sub-tier contractor.

The 28 coils of OH conductor provided by PPPL will be in the form of 80”-100” (2032mm - 2540mm) diameter free coils(i.e., without spools) as shown below where the wider side of the conductor is facing the inner diameter (ID) of the coil form. The following figure is shown for reference only and the conductor shipped will be in a coil form without a spool.

Note: PPPL is responsible for the documentation and correction of defects found by the Subcontractor upon inspections at receipt. The Subcontractor shall document and submit the fair and reasonable labor and material costs for these additional services for restitution in accordance with the contract.

The Subcontractor shall inspect the general condition of shipping crates and conductor coils, including the in-bound shipments as received and out-bound shipments after grit, blast and priming. Outer surface of the visible Conductor supplied to the vendor shall be inspected by the Subcontractor for any abnormalities and imperfections in finish, color, or geometry, including nicks and scratches.

The Subcontractor shall promptly report Conductor finish abnormalities or visible defects/ imperfections and abnormal crate and coil conditions to PPPL.

The Subcontractor shall provide photographs of the abnormalities or visible imperfections with the report to PPPL. This information shall be included in the Subcontractor’s Process History documentation.

The Subcontractor shall include in the report whether the surface imperfections are not expected to be removed by the media-blasting process.

Where actions are required to address abnormalities or imperfections, PPPL and the Subcontractor shall agree, in writing using the Contractor’s non-conformance reporting system, on the rework or repair steps necessary.

The Subcontractor shall document the accomplishment of the processing along with the method or methods used. This information shall be included in the Subcontractor’s Process History documentation.

The Subcontractor is responsible for providing spools that are part of its manufacturing process, including the wooden spools specified in section 10.0.

PPPL reserves the ability to request final conductor shipment to locations other than PPPL and shall provide such information when available prior to shipment.

PPPL may send engineers or QA/QC representatives to provide oversight, provide authorization at hold points, etc.

The Subcontractor shall provide a working space for PPPL oversight away from the shop floor. The space shall have a desk, power, internet access, etc. enabling the PPPL representative to work and communicate with PPPL.

The Subcontractor shall provide a safe working environment for PPPL oversight personnel including any required training and briefings on Job Hazard Analysis.

5.0 REQUIREMENTS

5.1. MANUFACTURING, INSPECTION AND TEST (MIT) PLAN

Within ten days after Contract Award and before utilizing copper conductors (45-50 m in length) supplied by PPPL for Process Development only, the Subcontractor shall submit a Preliminary Manufacturing, Inspection and Test (MIT) Plan for PPPL review. PPPL approval of the Preliminary MIT Plan is required before the process development conductor can be grit blasted, primed and cured.

The Final MIT Plan shall be submitted to PPPL for review 5 Days after the process development conductor is grit blasted, primed & cured. The Final MIT Plan shall incorporate lessons learned for the processing of the process development conductor. PPPL approval of the Final MIT Plan is required before the processing of the 1st Article conductor can begin.

The MIT Plan shall delineate the sequence of all critical manufacturing processes and operations affecting quality, including in-process and final acceptance inspections and tests.

The inspections and the characteristics/dimensions to be verified shall be detailed.

Equipment to be used for all fabrication, inspections and tests shall be specified.

Relevant data for inspections include conductor unique identification, equipment unique identification and calibration status, acceptance values, actual values obtained, personnel performing the inspection, date and pass/fail determination.

The MIT Plan may include flow chart(s), Process Sheets, Shop Travelers, and inspection sheets, etc. PPPL may select steps as mandatory Witness Points.

The Subcontractor shall notify PPPL a minimum of five (5) working days in advance of these Witness Points.

Revisions or changes to the approved MIT Plan shall be reviewed and approved by PPPL prior to use.

Additional MIT plan requirements include

1. Inspection before media blasting

2. Preparation for media blasting

3. Media blasting

a. Blasting media

b. Blasting process

c. Surface finish verification technique

d. Quantity of surface roughness measurements (total number of measurements) for each conductor

4. Media removal

5. Inspection after media removal & cleaning

6. Primer application

7. Post priming cure

8. Primer thickness inspection

9. Shipping preparation

a. Conductor Crating 10.Equipment (Parts, tooling and fixturing)

5.2. CONDUCTOR PREPARATION

Freshly media blasted copper surfaces shall be protected against oxide formation prior to application of the primer to maximize its effectiveness.

During the Priming and Curing processes, the Primer shall not be contaminated with dust, debris or other foreign matter.

The Subcontractor shall use the following controls to ensure cleanliness and prevent the introduction of contamination of foreign material into the work product:

5.2.1. Gloves and Lab Coats

Latex, vinyl, rubber, nitrile or cotton lint-free gloves, hair and shoe covers, and lab coats shall be worn in the work areas during the handling of the conductors. An alternative glove material may be proposed, but needs to be approved, in writing, by PPPL prior to use. Lab coats and hair covers worn outside of the clean area, regardless of length of time, shall not be brought back into the clean area. No uncovered jewelry shall be permitted in the cleanroom. Eyeglasses when worn shall be inspected for loose screws and parts prior to entry into the clean room.

5.2.2. Markers and Pencils

The use of lead pencils or non-approved markers is prohibited in the fabrication stations due to electrical tracking concerns. Marking on coil components shall be kept to a minimum, but when needed, only blue or black ink “Sharpie” brand name permanent markers may be used. The “Sharpie” product has been electrically tested by PPPL.

5.2.3. Conductive Contaminants

Filing, grinding, or any other operation that generates any kind of electrically conductive chips shall not be allowed in the clean area for priming without a PPPL-approved enclosure to contain such chips. Clamping and tooling design must preclude conductive debris from being generated. For example, any fixtures or clamps that could possibly abrade and form conductive chips are not allowed.

5.2.4. Material Protection

Material controls shall be addressed in the QA Plan or MIT Plan. Copper conductor and all materials used for grit blasting and priming shall be stored and processed in controlled areas free from metallic dust or other contaminants. All materials shall be protected from contamination by skin oil, etc. All materials shall be cleaned with approved degreaser using a lint-free cloth prior to entry into the clean room. Once cleaned, the parts shall be protected to keep them clean, until ready for use. Tools shall be chosen so as to assure that they do no damage to the coil components (conductor, insulation, filler, etc.).

5.3. CONDUCTOR HANDLING

The configurations of the Process Development and Production OH coils are provided below:

Process Development Coil The inner diameter of the trial coil is approximately 47” (1194 mm).

Production Coil The diameter of the production coils (loose coils) is 80”-100” (2032mm - 2540mm). They are free coils (i.e., without spools) with the wider side of the conductor keystone facing inwards.

The OH conductor handling shall be accomplished so that equipment - forks, cradles and or slings used - do not contact the conductor surface or protective wrap during unloading and reel handling.

If using a forklift, the forks shall lift the spool at 90 degree to the flanges and the forks shall be long enough to make complete lifting contact with both flanges.

Care should be taken to not permanently deform or twist the conductor during handling.

Conductors should be carefully handled and separated when processing to protect the surface from nicks, scratches or gouges.

The maximum separation of conductor turns shall be 4 inches (100 mm) in pitch to ensure no additional cold-work hardening of the copper Conductor.

An identification number shall be provided/assigned and affixed to each continuous length conductor for traceability.

5.3.1. INSPECTION BEFORE MEDIA BLASTING

The Subcontractor shall inspect all four sides of the conductor’s surface for any abnormalities and imperfections in finish, color, or geometry, including nicks and scratches.

The inspection process shall be detailed in the Subcontractor’s MIT Plan.

The Subcontractor shall promptly report conductor finish abnormalities or imperfections to

PPPL.

The Subcontractor shall provide photographs of the abnormalities or imperfections with the report to PPPL. This information shall be included in the Subcontractor’s Process History documentation (Per Section 9.8).

The Subcontractor shall include in the report whether the surface imperfections are not expected to be removed by the media-blasting process. This information shall be included in the Subcontractor’s Process History documentation).

Subcontractor shall agree, in writing using the Subcontractor’s non-conformance system, on the rework or repair steps necessary.

5.3.2. CLEANING BEFORE MEDIA BLASTING

The Subcontractor shall flush the Conductor cooling passage with Trisodium Phosphate followed by ethanol, isopropyl alcohol or a (nominally) 85%/15% IPA/Ethanol solution to remove traces of oil or grease remaining from the extrusion process.

All traces of liquid shall be removed from the conductor prior to further processing. The Subcontractor’s MIT Plan shall detail the method to eliminate moisture and verify that the cooling passage is dry.

If both conductor ends are not accessible before media blasting, the conductor cooling passage shall be cleaned after media blasting, media removal and media cleaning. After the conductor cooling passage has been cleaned and dried, conductor surface Inspection per 5.4.4 shall be performed. Extensive care shall be used to ensure the conductor surface is not contaminated with chemicals, solvents or other foreign matter.

The Subcontractor shall clean the Conductor surface with acetone followed by ethanol, isopropyl alcohol or a (nominally) 85%/15% IPA/Ethanol solution to remove traces of oil or grease remaining from the extrusion and cold roll hardening processes performed by others (i.e., the conductor fabricator).

5.3.3. PREPARATION FOR MEDIA BLASTING

The Subcontractor shall plug the conductor cooling passage prior to media-blasting.

Cutting off or removal of material from conductors shall be performed in a manner that minimizes debris such as copper chips, slivers and dust.

Cutting and removal operations of material from conductors shall concurrently utilize a vacuum system.

The method of plugging shall be included in the MIT Plan.

5.4. MEDIA BLASTING, MEDIA REMOVAL, CLEANING & INSPECTION

5.4.1. MEDIA BLASTING

All four sides of the Conductor surface shall be Media Blasted to obtain a uniform Surface Finish of nominally 100 Micro-Inches Root Mean Square (RMS) (2.5 Microns RMS)

Note: RMS Roughness, is the root mean square average of the profile heights over the evaluation length

The CTD-450 Primer vendor recommends the following which are the PPPL requirements for acceptance:

80 Grit alumina Pressure of 80 p.s.i (5.5 bar) Media-blasting nozzle 1 in to 2 in (2.5 cm to 5.0 cm) from the copper surface Media-blasting nozzle at an angle of 75 degrees to 105 degrees to the copper surface.

The Subcontractor shall include details of the Media Blasting Process and Blasting Media in the MIT Plan. This information shall be included in the Subcontractor’s Process History

Conductor Surface Roughness measurements shall be provided in Microns (millionths of a meter).

The Subcontractor shall include details of the Conductor Surface Finish Measurement instrument in the MIT Plan.

The Surface Finish Roughness Measurements shall be taken on all four sides and be identified as “TOP”, “BOTTOM”, “AA”, and “BB”.

For the OH conductor, the surface roughness measurements shall be located nominally:

At the beginning of each Conductor At the end of each Conductor

The approximate Conductor Measurement locations shall be recorded with the Roughness Data in the Process History Documentation.

OH Conductor Surface Roughness Measurement Locations

Surface Finish Roughness Measurements shall be between 60 and 240 Micro-Inches Root Mean Square (RMS) (1.5 and 6.0 Microns RMS), inclusive. Values less than 60 Micro-Inches (1.5 Microns RMS) or greater than 240 Micro Inches (6.0 Microns RMS) shall be discussed with PPPL. PPPL and the Subcontractor shall agree, in writing using the Subcontractor’s non-conformance system, on the rework or repair steps necessary before proceeding to the Primer application.

The location on the Processing Line where the Surface Roughness Measurement was performed shall be recorded with the Roughness Data in the Process History Documentation.

The approximate Conductor Measurement location, from the Conductor upper or lower ends, shall be recorded with the Roughness Data in the Process History Documentation.

The Subcontractor shall perform additional Surface Roughness Measurements if there is an opportunity to do so at other Conductor Locations.

5.4.2. MEDIA REMOVAL

After Media Blasting, the Subcontractor shall clean all four sides of the copper Conductor to remove any embedded Media and other particulate matter.

The CTD-450 Primer vendor recommends Media Removal with clean, dry nitrogen gas at 100 p.s.i. (7.0 bar) with the nozzle approximately 1 inch (2.54 cm) from the copper surface.

The Subcontractor shall include the Media Removal Process in the MIT Plan.

5.4.3. CLEANING AFTER MEDIA REMOVAL

Gloves and long sleeves and hair net shall be worn while handling, cleaning, priming and inspecting Conductors.

The Conductor surfaces shall be cleaned with ethanol, isopropyl alcohol, or a (nominally) 85%/15% IPA/Ethanol solution to remove visible contaminants.

A minimum of 10 minutes shall be allowed for drying prior to further processing.

If both Conductor Ends are not accessible before Media Blasting, the Conductor Cooling Passage shall be cleaned after Media Blasting, Media Removal & Media Cleaning. After the Conductor Cooling Passage has been cleaned and dried, Conductor surface Inspection shall be performed. Extensive care shall be used to ensure the conductor surface is not contaminated with chemicals, solvents or other foreign matter. (see Section 5.4.4)

5.4.4. INSPECTION AFTER MEDIA REMOVAL & CLEANING

The Subcontractor shall inspect all four sides of the Conductor’s surface for any abnormalities

The Inspection process shall be detailed in the Subcontractor’s MIT Plan.

The Subcontractor shall promptly report the Conductor finish abnormalities or imperfections to

PPPL.

If the Conductor has surface contamination, such as being touched with bare hands, the Subcontractor shall clean the area with acetone.

Subcontractor shall agree, in writing using the Subcontractor’s non-conformance system, on the rework or repair steps necessary.

5.4.5. DOCUMENTATION

The Subcontractor shall provide information specified in the Process History documentation Per Section 9.8.

5.4.6. BAGGING

If the Priming will not begin within 8 hours from the completion of the Media Blasting, the Conductor shall be bagged. The bag shall be filled with either gaseous Nitrogen or Argon to minimize oxidation.

The Subcontractor shall record the time between the completion of Media Blasting and the beginning of Priming if longer than 8 hours. This time shall be reported in the Subcontractor’s Process History documentation. Permission to proceed from PPPL is required if the delay is more than 8 hours.

The Subcontractor shall provide PPPL photographs of the bagged Conductors. This information shall be reported in the Subcontractor’s Process History documentation.

5.5. PRIMING

5.5.1. PRIMER APPLICATION

Priming should be performed as soon as practical after media-blasting and cleaning in order to reduce oxidation of the Conductor surface.

CTD-450 primer shall be applied along all four surfaces of the entire Conductor length. The Primer application technique, tools and materials shall be included in the MIT Plan.

Nominal Cured Primer thickness is 0.007 mm (7 Microns; 0.3 mils). Maximum cured primer thickness is .025 mm (25 Microns; 1 mil).

For Reference and from the CTD-450 1-Part Toughened Primer Use Instructions Document (CTD-450 Primer Use Instructions_4-28-08.pdf):

“Apply minimum and uniform thickness of CTD-450. Typical thickness is on the order of 0.007 mm to 0.025 mm. Remove any primer build-up or excess.”

If primers begin to “pool up” above 0.012 mm the preference is to keep the thickness less than

0.012 mm and avoid the necessity of removing extra material.

Primer shall be applied in a controlled environment, indoors, under temperature & humidity control (see Section 5.2 for cleanliness requirements).

The Conductor temperature shall be no less than 3 Degrees Centigrade above the Dew Point during the Priming Process. See Carboline Technical Guide “How to Specify Blasting” for Dew Point Calculation Chart.

The Relative Humidity, Ambient Air and Conductor Temperature shall be recorded and reported to PPPL as part of the Process History documentation package.

Gloves and long sleeves shall be worn while handling, cleaning, priming and inspecting Conductors.

Steps shall be taken so that foreign material does not contaminate the primer before it is Cured.

5.5.2. CURING

The primer shall be Cured following CTD’s “CURE” process detailed in their “CTD-450 1-Part Toughened Primer” document (CTD-450 Primer User Instructions_4-28-08.pdf):

1. Ramp for 3 hours from room temperature to 110°C

2. Hold at 110°C for 8 hours

3. Ramp for 2 hours from 110°C to 150°C

4. Hold at 150°C for 4 hours

5. Cool to room temperature

The Subcontractor shall record Time vs. Oven Temperature for each Conductor’s Cure cycle.

This record of the Oven Temperature profile shall be provided in the Subcontractor’s Process History documentation.

5.5.3. PRIMER INSPECTION

Following Oven Curing, the Primer coating shall be visually inspected by the Subcontractor to verify uniform coverage of the Conductor surface.

The Subcontractor shall inspect all four sides of each Conductor’s surface for any abnormalities

The Inspection process shall be detailed in the Subcontractor’s MIT Plan.

Any foreign material and or areas of scuffed, missing or excess Primer, visible to the naked eye, shall be documented by including photographs and other applicable information and reported in the Subcontractor’s Process History documentation.

The Subcontractor shall Document any visible defects / scratches during handling whenever noticed and promptly report the Conductor finish abnormalities or imperfections to PPPL.

There shall be no inclusions and foreign objects and defects can be defined as a) any visible scratch deeper than 0.003” (76.2 micron) shall be recorded and documented, b) any visible protrusion shall be no more than 0.001” (25.4 micron).

The Cured Primer Thickness measurement instrument shall be specified in the MIT Plan.

Cured Primer Thickness measurements shall be provided in Micrometers (um). Cured Primer Thickness measurements shall alternate between the four sides of the Conductor (labeled “Top”, “AA”, “Bottom”, & “BB”).

Selection of alternating measurement locations shall be guided by the following:

The capability of the instrument to reliably measure Cured Primer Thickness on curved surfaces.

Measurements shall start at the end location of Conductor.

Subsequent measurements shall be taken every 1 ¼ turns for the OH conductor.

Additional measurements shall be taken at any locations identified via visual inspection as potentially exceeding the maximum primer thickness.

Cured Primer Thickness Measurements shall be recorded in Process History documentation.

Note: The maximum Conductor surface area without Primer coverage (“Bare Spot”) shall be

0.25 square inch (1.613 cm2).

PPPL is responsible for the documentation and correction of bare spots greater than 0.25 square inch (1.613 cm2) and less than 1.00 square inch (6.5 cm2) found by the Subcontractor during post-priming inspection. The Subcontractor shall document and submit the fair and reasonable labor and material costs for these additional services for restitution in accordance with the contract. The subcontractor is responsible for the documentation and correction of any bare spot areas larger than 1.00 square inch (6.5 cm2)

The maximum Conductor surface area with primer thickness exceeding the specified maximum of 25 microns (1.0 mils) shall not exceed 0.25 square inch (1.613 cm2). The primer thickness at any such region shall not exceed 60 Microns (2.4 mils).

Note: PPPL is responsible for the documentation and correction of thickness deviations in any areas greater than 0.25 square inch (1.613 cm2) area and less than 1.00 square inch (6.5 cm2) found by the Subcontractor during post-priming inspection. The Subcontractor shall document and submit the fair and reasonable labor and material costs for these additional services for restitution in accordance with the contract. Subcontractor is responsible for the documentation and correction of thickness deviations in any areas greater than 1.00 square inch (6.5 cm2) found by the Subcontractor during post-priming inspection.

The approximate location, approximate surface area, and maximum primer thickness of any such region shall be documented in the Traveler.

The subcontractor shall provide photographs of any regions with a primer thickness between 25 and 60 microns that do not exceed 0.25 square inch (1.613 cm2) and showing the highest thickness reading to PPPL. These photos shall be included in the Subcontractor’s Process History documentation (Section 9.8).

The Subcontractor shall provide photographs of regions with “Bare Spots” and/or a primer thickness between 25 and 60 microns that exceed 0.25 square inch (161.3 mm2) with the report to PPPL. This information shall be included in the Subcontractor’s Process History documentation. The number of “Bare Spots” shall not be more than one every 2 meters along the conductor.

5.5.4. PRIMER REPAIR

Per section 5.5.3, the Subcontractor shall inspect all four sides of the Conductor’s surface for any abnormalities and imperfections in finish, color, or geometry, including nicks and scratches.

If the Conductor has surface contamination, such as being touched with bare hands, the Subcontractor shall clean the area with acetone.

If the Primer and or the Conductor surface have any abnormalities or imperfections other than surface contamination that can be removed by acetone, the subcontractor shall promptly report the defect to PPPL.

Where actions are required to address other abnormalities or imperfections other than surface contamination removable by acetone, the repair by the Subcontractor shall only be performed after PPPL and the Subcontractor agree, in writing, on the rework or repair steps necessary.

Subcontractor shall provide a “touch-up” repair procedure for areas that do not meet these criteria in Section 5.5.3 for PPPL approval. Manual sand down of both roughness and the out of spec primer thickness are permitted as long as final results are measured and confirmed that they meet the specifications. After performing approved applicable Touch-Up Procedure steps, the Subcontractor shall document the Touch-Up by including photographs and other applicable information in the Process History documentation (Per Section 9.8).

5.5.5. POST-PRIME CLEANING AND BAGGING

Gloves and long sleeves and hair net shall be used. After Post Priming Inspection and Primer Touch-Up actions are completed, the Subcontractor shall clean and bag the Conductor after repair, and place the Conductor on the wooden spool in preparation for shipment.

6.0 TEST & INSPECTION REQUIREMENTS

6.1. PERFORMANCE TESTS

N/A

6.2. ACCEPTANCE AND INSPECTION TESTS

Per Section 5.4.4 and Section 5.5.3.

6.3. SUPPLIER HOLD POINTS

Hold Points shall be determined upon PPPL review and acceptance of the Final MIT Plan (Per Section 5.1).

The Subcontractor shall incorporate Hold Points specified by PPPL in the Traveler.

In the event that a PPPL onsite representative is unavailable to provide Traveler clearance of a Hold Point, photographs of the conductor’s condition at the time of the Hold Point shall be taken and included in the Process History documentation (Per Section 9.8) and the hold point can be approved by PPPL remotely.

A note documenting the use of this provision shall be included in the traveler in the appropriate Hold Point section.

7.0 QUALIFICATIONS

Personnel performing the work defined herein shall have relevant qualifications as defined in the Subcontractor’s Training and Qualification program. Records of training shall be maintained and shall be available to PPPL upon request.

8.0 ENVIRONMENT, SAFETY, AND HEALTH

N/A

9.0 QUALITY ASSURANCE REQUIREMENTS

9.1 INSPECTION/SURVEILLANCE 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 Subcontract 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.

The Subcontractor 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 recognizes 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 SUBCONTRACTORS RESPONSIBILITY FOR CONFORMANCE

Neither PPPL review and/or approval of Subcontractor’s documents nor PPPL inspection of Subcontractor’s items or services shall relieve the Subcontractor of responsibility for full compliance with 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 SUBCONTRACTOR’S QA PROGRAM

The Subcontractor shall maintain an effective Quality Assurance Program to assure that the Subcontractor’s work meets the standards in this document and the conductor drawings and is performed in accordance with contractual requirements. 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 specification. The 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.

9.4 EQUIPMENT/MATERIAL IDENTIFICATION AND STATUS

Material and equipment identification shall be maintained throughout the program and be traceable to records. Status of acceptability shall be readily discernible through the Subcontractor’s use of tags, stamps, serial numbers or other positive means.

9.5 CALIBRATION OF TEST AND MEASURING EQUIPMENT

Inspections and tests shall be conducted using calibrated measuring and test equipment.

Calibration standards shall be traceable to the National Institute for Standard and Technology (NIST) or equivalent acceptable to PPPL and shall not be used for shop inspections, but instead be protected against damage or degradation.

9.6 INSPECTION

Inspections shall be conducted in accordance with written instructions referencing criteria for acceptance or rejection. Reports shall clearly identify the item inspected, the performing individual, the date performed, and the signature of the authorized individual.

9.7 NON-CONFORMING ITEMS

Non-conforming items shall be positively identified, and, where possible, segredated to prevent use. PPPL must be notified of non-conformances within one (1) business day. The Subcontractor shall document each nonconformance, identifying the extent and location of the non-conformance and proposing a disposition. The written concurrence of PPPL is required prior to implementing the disposition. The Subcontractor’s system shall provide not only for timely resolution of non-conformances but also for analysis of non-conformances to determine root causes and to implement appropriate and effective corrective actions.

9.8 PROCESS HISTORY

The Subcontractor shall maintain a system of documentation whereby objective evidence of required operations, inspections, examinations, and tests is systematically compiled, indexed, stored and ultimately provided to PPPL. This documentation or “Process History” shall include but not limited to:

Inspection Documents: Completed process planning and control documents (procedures, travelers, etc.) which verify controlled execution of the required work.

Material Certifications: A copy of the manufacturer’s certificate of compliance (or equivalent) and expiration dates for the CTD-450 primer, all solvents, and the blasting media.

Oven Chart: A legible copy of the oven chart with the start and stop times clearly denoted shall be provided for each cure cycle.

Shipping Release: The Subcontractor shall not ship without a "Product Quality Certification and Shipping Release" Form (Attachment II) signed by PPPL's Representative. Subcontractor shall complete and sign the certification section, fax or email the form and the inspection reports to PPPL’s Quality Assurance (QA) Representative, 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.

A Sub-Tier Contractor shall not be utilized by the Subcontractor without prior approval and qualification by PPPL

10.0 SHIPPING STORAGE AND HANDLING

Prior to shipment but after priming is complete, the Subcontractor shall store all Conductors in a fashion which protects the Conductors and their Primed Surfaces.

The Subcontractor shall store Conductors in a temperature and humidity controlled area.

The Subcontractor’s storage area should be away from activities that could potentially damage the Conductor.

The primed conductor coils shall be spooled in a single layer on the wooden spool; a detailed description of the spool configuration is provided below (unit in mm):

Subcontractor Supplied Conductor Spool Size

As shown above, the inner diameter (drum diameter) of the wooden spool shall be 1500 +/-20

mm. The maximum overall width is 863 mm. All conductors shall be spooled in one layer only.

The final spool after grit, blast and priming shall be the wider side of the conductor facing the ID of the spool so the direction of the keystone feature on the conductor is the same as the received raw conductor before the grit, blast and priming; see illustration provided below:

Final Spooled Conductor Orientation

Plastic bagging and wrapping: Conductor spools shall be bagged and wrapped in wooden crates that are clean of dust, debris, oil and grease. The shipping crates should be in good repair and serviceable for shipment; shipping crate design is to be approved by PPPL. See the illustration provided below for the suggested configuration:

Shipping Crate and Conductor Plastic Bagging and Wrapping Suggestion

The delivery destination is ELYTT Energy Services in Bilbao, Spain.

During packaging and shipment, the Primer and Conductor surface require protection from damage while in contact with the spool. Tape with silicon-based adhesives could contaminate the Conductor and shall not be used. An acceptable alternative is polyimide film tape having acrylic pressure-sensitive adhesive. Any proposed alternative adhesive shall be approved by PPPL prior to use.

The method of packaging the conductor on the spool shall be detailed in the MIT Plan.

The Subcontractor shall inform PPPL of an upcoming shipment at least one week prior to the shipment. Shipping may not occur without a "Product Quality Certification and Shipping Release" Form.

Partial shipments shall be acceptable

11.0 WARRANTY

See PPPL's Terms and Conditions

12.0 ATTACHMENTS

A list of drawings and specifications will be provided.

12.1 Attachment I – Deliverables List

12.2 Attachment II – PPPL Product Quality Certification & Shipping Release

13.0 DELIVERABLES

13.1. ITEMS

A total of 28 spools shall be provided and delivered as finished product after grit, blasting and priming.

13.2. DOCUMENTATION & DELIVERABLE

See Attachment 1: Deliverables List

Attachment I: Deliverables List PO / Subcontract / BOA / BPA #:

# Physical Deliverables Required When Deliverable Is Required Deliverable

Received

1 Process Development Conductor (155’ loose spool x 6) Trial run before production conductor priming

2 Primed OH Conductor (28 spools) After PPPL signed shipping release

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

# Document Deliverables Required When

Deliverable Is Required

Deliverable format (paper, electronic etc.)

Deliverable Received

1 Weekly Status Reports (Section 4.2) After Contract Award electronic

2 Preliminary MIT Plan (Section 5.1) 10 Days After Contract Award electronic

3 Material Certificate of Compliance & Expiration Dates for Primer (Section 9.8)

5 Days After Receipt of Material

Paper or electronic

4 Material Certificate of Compliance & Expiration Dates for Solvents (Section 9.8)

5 Material Certificate of Compliance & Expiration Dates for Blasting Media (Section 9.8)

6 Final MIT Plan (Section 5.1) 5 Days After Process Development Blast, Prime & Curing is completed

7 Process History (Section 9.8) With Shipping Release request

8 Repair Procedure (Section 5.5.4) With Shipping Release request

9 Product Quality Certification and Shipping Release (Section 9.8 and Attachment II)

Prior to Shipping Paper or electronic

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)

ATTACHMENT II: PRINCETON UNIVERSITY PLASMA PHYSICS LABORATORY—

PPPL PRODUCT QUALITY CERTIFICATION & SHIPPING RELEASE

To be completed by supplier and submitted to PPPL with the Documentation package. Shipment (full or partial) is not authorized until PPPL returns this form signed.

PPPL SUBCONTRACT/ ORDER # ITEM #(s) QUANTITY SHIPPED

ITEM DESCRIPTION

SUPPLIER REFERENCE # SHIPMENT #

Co m pl et ed b y Su pp lie r

SUPPLIER'S CERTIFICATION

This is to certify that the products and services identified herein have been produced under a controlled quality assurance program and are in conformance with the procurement requirements including applicable codes, standards and specifications as identified in the above-referenced documents unless noted below. Any supporting documentation will be retained in accordance with the procurement requirements.

SIGNED: _________________________________________ DATE: __________________________

TITLE: _________________________________ COMPANY: _______________________________

PPPL (AUTHORIZED REPRESENTATIVE) SHIPPING RELEASE

This is to certify that evidence supporting the above Supplier's Certification statement has been reviewed and no product/service non-conformances from procurement requirements have been identified unless noted below. This product/service is hereby released for shipment.

This section serves as the Quality Assurance release for the above-described product for shipment. It does not constitute an acceptance thereof and does not relieve the Supplier, Manufacturer or Contractor of any and all responsibility or obligation imposed by the purchase contract. It does not waive any rights the Purchaser may have under the purchase contract, including the Purchaser's right to reject the above described material upon discovery of any deviations from requirements of the purchase contract, drawings and specifications.

NONCONFORMANCES FROM PROCUREMENT QUALITY REQUIREMENTS:

REMARKS/PRODUCT SERIAL NUMBERS:

, s ig ne d, a nd ur d by P

PP

L be fo re s hi pm en t

BY PPPL QA REPRESENTATIVE (OR DESIGNEE) DATE

2600 CAMPUS DRIVE, SUITE D | LAFAYETTE, CO 80026 | PHONE: 303-664-0394 | FAX: 303-664-0392| WWW.CTD-MATERIALS.COM

Surface Preparation prior to Primer or Coating Application

The use of CTD-450 primer is solely at the discretion of the manufacturer. However, as most people who have tried to bond to Copper know, it is notoriously difficult to bond to, so proper surface preparation followed by the application of the primer immediately after the surface has been prepared/cleaned, produces the best bond adhesion results in most instances. Therefore, we recommend the use of the CTD-450 primer whenever practical in the manufacturing process.

For surface preparation of the Copper, you can use the following as a guideline for prepping the surface of any metallic. This is taken from ASTM D2651 which covers the “Preparation of

Metal Surfaces for Adhesive Bonding.” We realize that it is often not possible or practical to perform all of these steps, but we recommend doing as many of the steps as possible.

Note that steps 6-8 are not usually practical for conductors.

1. Degrease all bond surfaces with IPA or equivalent

2. Sand blast with 80 grit alumina at 80 psi. Gun should be 1-2 inches from surface at a 70-90° angle. Visually, make sure the surfaces are sandblasted evenly

3. Nitrogen blast - Blast surfaces with clean N2 gas, 100 psi, about 1 inch from surface, to remove all embedded sand.

4. Rinse with IPA

5. Inspect surface for any embedded sand (microscope sometimes used)

6. Ultrasonic Clean in IPA for 1 hour

7. Vapor Degrease in IPA for 15-30 minutes

8. Water Break Test

9. Prime

In talking with our COO (Chief Engineer) it appears that grit blasting with 80 grit sand or alumina particles, which is what we recommend, generally translates into a surface roughness of

80 micro-inch RMS or around 2 microns RMS. We have not done any studies on various surface roughness levels to determine the optimum surface roughness.

2600 CAMPUS DRIVE, SUITE D | LAFAYETTE, CO 80026 | PHONE: 303-664-0394 | FAX: 303-664-0392|…