US ITER UWAVS Instrumentation and Control SOW (DRAFT).pdf

Statement of Work Manufacture, Inspection and Test of the UWAVS

Instrumentation and Control Subsystem

ITER Upper Wide Angle Viewing System (UWAVS)

Statement of Work for Manufacture, Inspection and Test of the Instrumentation and Control Subsystem

Princeton Plasma Physics Laboratory PO Box 451

Princeton, NJ 08543

PPPL APPROVAL

VERSION Date Author QA Engineer Approver

1.0 Ricardo Quintanilla Patrick Temple Ravinder Bhatia

SEE EDRM SEE EDRM SEE EDRM

REVISION LOG

VERSION DATE MODIFICATIONS

1.0 Statement of work

EXPORT CONTROL WARNING

This document contains technical data whose export is restricted by US law or Regulation. Release of these documents is only authorized for the use of the ITER Organization for distribution between and among duly ratified member nations and their technical representatives for the development of fusion energy for peaceful purposes, as defined under License D1146740 as EAR99.

DRAFT

Instrumentation and Control Subsystem

Contents

1. INTRODUCTION

1.1. PROJECT OVERVIEW

1.2. SUBJECT OF THIS SOW

2. DOCUMENTS

3. SCOPE OF SUPPLY

3.1. OVERVIEW OF UWAVS

3.2. INSTRUMENTATION AND CONTROLS (I&C) SUBSYSTEMS

3.3. ITEMS TO BE PROVIDED BY PPPL

3.4. OUT OF SCOPE FOR SUPPLIER

4. PHASED IMPLEMENTATION

5. PHASE 1: PREPARATION FOR MANUFACTURING

5.1. DOCUMENTATION DEVELOPMENT

5.2. SOFTWARE DEVELOPMENT

5.3. PROTOTYPING

5.4. MANUFACTURING READINESS REVIEW

6. PHASE 2: MANUFACTURING

6.1. MANUFACTURING

6.1.1. PLANNING AND PROCUREMENT

6.1.2. TEST PLAN AND SOFTWARE DEFINITION

6.1.3. FIRST ARTICLE MANUFACTURING

6.1.4. FIRST ARTICLE INSPECTION

6.1.5. FINAL MANUFACTURING AND DELIVERY

6.1.6. GENERAL REQUIREMENTS FOR ELECTRICAL COMPONENTS

6.1.7. GENERAL REQUIREMENTS FOR SOFTWARE DEVELOPMENT

6.2. FACTORY ACCEPTANCE TESTING

6.2.1. FACTORY ACCEPTANCE TEST PLAN

6.2.2. FACTORY ACCEPTANCE TEST PROCEDURE

6.2.3. FACTORY ACCEPTANCE TEST VERIFICATION REPORT

6.3. MARKING AND IDENTIFICATION REQUIREMENTS

6.4. CLEANING, PACKAGING, HANDLING, STORAGE, AND TRANSPORT

6.5. CREATION AND SUBMITTAL OF PRE-SHIPMENT DOCUMENTATION

6.6. SHIPMENT

6.7. ACCEPTANCE AND INTEGRATION SUPPORT

7. QUALITY ASSURANCE

7.1. INSPECTION / SURVEILLANCE / AUDIT BY PPPL

7.2. SUPPLIER’S RESPONSIBILITY FOR CONFORMANCE

7.3. CHANGES TO PPPL APPROVED DOCUMENTS

7.4. SUPPLIER QUALITY ASSURANCE PROGRAM

7.5. QUALITY ASSURANCE PLAN

7.6. INSPECTION PLAN

7.7. INSPECTION

7.8. DOCUMENT TRACEABILITY AND RECORDS

7.9. WITNESS / HOLD POINTS AND NOTIFICATION OF PPPL IN ADVANCE

7.10. PERFORMANCE AND DOCUMENTATION OF INSPECTIONS AND TESTS

7.11. EQUIPMENT / MATERIAL IDENTIFICATION AND STATUS

7.12. DOCUMENT REVIEW, APPROVAL AND CONTROL

7.13. NON-CONFORMANCES AND CORRECTIVE ACTIONS AND NOTIFICATION

7.14. MEASURING EQUIPMENT / CALIBRATION

7.15. SUBMITTAL OF COMPLETED RELEASE FOR SHIPMENT FORM

7.16. SUBMITTAL OF COMPLETED PROCESS HISTORY (DOCUMENTATION PACKAGE) 23

8. PROGRAM MANAGEMENT

8.1. MILESTONE FUNDING PLAN/SCHEDULE OVERVIEW

8.2. PROJECT STARTUP

8.2.1. WORK BREAKDOWN STRUCTURE (WBS) STANDARDIZATION

8.2.2. DEVELOPMENT OF SCHEDULE

8.3. REPORTING REQUIREMENTS (PROGRESS, INVOICING, ACCRUALS)

9. WARRANTY

10. DELIVERABLES

11. CONTRACT DURATION

12. ACRONYMS

List of Figures Figure 1 - View of UWAVS Ports Figure 2 - UWAVS Overview - Diagnostics Hall, In-Vessel, Ex-Vessel Figure 3 - UWAVS Design Breakdown Figure 4 - Illustration of the Instrumentation and Controls for a single port of 55.GA. Note that only one set of cameras are within the I&C Supplier’s procurement scope Figure 5 - Master Cubicle (Front View) - One Master Cubicle controls ports UP2, UP8, UP11, UP14, and

UP17

Figure 6 - Camera Cubicle (Front View) - There is one Camera Cubicle for each port (UP2, UP8, UP11, UP14, and UP17). This cubicle manages both IR and VIS camera sets and processes their data Figure 7 - Support Cubicle (Front View) - There is one Support Cubicle for each port (UP2, UP8, UP11, UP14, and UP17). The Support Cubicle manages all slow controls and data management Figure 8 - Phase 1 and Phase 2 Graphical Timeline

List of Tables Table 1 - I&C Component Procurement Responsibilities Table 2 - MRR List of Document Deliverables Table 3 - Software Milestones Table 4 – Component Verification Table Table 5 - Milestone Funding Schedule Overview Table 6 - MRR, FAT, and SAT I&C Major Deliverables Table 7 - Assembly Milestones Table 8 - Acronyms

1. INTRODUCTION

1.1. PROJECT OVERVIEW

International Thermonuclear Experimental Reactor (ITER) (http://www.iter.org) is an international project under construction in Saint Paul-lez-Durance, France (ITER St-Paul) that will demonstrate nuclear fusion at a power plant-relevant scale. ITER is a joint international research and development project with the programmatic goal to demonstrate the scientific and technical feasibility of fusion power. The ITER machine is being constructed in a collaboration with seven partners consisting of the United States, European Union, China, Russia, South Korea, Japan, and India. The US ITER Project Office (USIPO) is hosted by Oak Ridge National Laboratory (ORNL), which is located in Oak Ridge, Tennessee. ORNL works in partnership with Princeton Plasma Physics Laboratory (PPPL) and Savannah River National Laboratory (SRNL) on USIPO scope. PPPL is responsible for several diagnostic systems supplied to ITER, pursuant to direction from the Department of Energy in its role as the ITER Domestic Agency for the United States. One of the ITER diagnostic systems being provided by PPPL is the Upper Port Visible/Infrared Wide-Angle Viewing System (UWAVS).

1.2. SUBJECT OF THIS SOW

The objective of this SOW is to specify:

a. the manufacturing, procurement, and delivery of UWAVS Instrumentation and Control (I&C) components and software, to be integrated into four upper ports 2, 8, 11, 14.

b. the necessary fabrication, assembly and testing activities to validate the compliance with requirements of the supplied and manufactured parts.

c. requirements and documentation related to the review phases: Manufacturing Readiness Review (MRR), First Article Test (FAI), Factory Accept Testing (FAT), Delivery Readiness Review (DRR), and Site Acceptance Test (SAT) specification and support for the ITER Organization (IO) for Port Cell components and Diagnostic Hall components.

d. other applicable project requirements.

e. the level of effort support required from the I&C fabrication supplier to the fabrication vendors for other (non-I&C) subsystems of UWAVS.

UWAVS for Upper Port 17 is out of scope for this SOW.

2. DOCUMENTS

a. The scope of work defined herein this SOW shall be performed in accordance with all Applicable, Reference, and For Information references defined in the Current Reference List (CRL) where:

i. Applicable Documents are prefixed by V01.

ii. Reference Documents are prefixed by V02.

iii. For Information Documents are prefixed by V03.

iv. references to these documents are listed in square brackets [].

b. All document deliverables shall be created using the updated templates (where available), as defined in the Applicable Documents listed in the CRL.

c. If the vendor needs to deviate from requirements defined in the Applicable Documents, the vendor shall request approval of this deviation from PPPL prior to performing the activities affected by the deviation requested.

3. SCOPE OF SUPPLY

3.1. OVERVIEW OF UWAVS

UWAVS will provide real-time, simultaneous visible and infrared images of the ITER divertor region, via optical systems located in five upper port plugs (2, 8, 11, 14, and 17) as shown in Figure 1. Note that Port 17 is out of scope for this SOW. UWAVS provides machine protection (monitoring for overheating of surfaces), plasma control (basic and advanced), and physics measurement roles.

Figure 1 - View of UWAVS Ports

The UWAVS system is divided into three sections according to their location according to Figure 2:

● in-vessel components, comprised of FEOMS

● ex-vessel components, comprised of the BEOC, BOL, and IOT

● Instrumentation and control components, comprised of the Master Cubicle, Support

Cubicles, and Camera Cubicles DRAFT

Figure 2 - UWAVS Overview - Diagnostics Hall, In-Vessel, Ex-Vessel

3.2. INSTRUMENTATION AND CONTROLS (I&C) SUBSYSTEMS

The UWAVS control system is responsible for controlling all UWAVS subsystems, as detailed in Figure

3. This scope includes all necessary interfaces, data collection, data management, and control logic, even for functions requiring interaction with other PBS systems or their components, specialized Commercial Off-The-Shelf (COTS) components, or custom-made devices. Programmable Logic Controller (PLC) and Fast Controller software includes complex procedures like camera calibrations, complex image processing, image alignment, and measurement algorithms.

Instrumentation and controls for UWAVS manages Beam Steering, Mirror Cleaning, Camera Calibration, Shutter Control, and Camera Control. Beam Steering controls and captures data from the mirror motors, limit switches, and thermocouples for the optical path. Mirror Cleaning controls and captures data from the RF generators and RF matching units to perform the cleaning process. Calibration controls and captures data from temperature sensors and IR sources for camera calibration. Both the IR and Visible cameras require calibration, where PPPL will provide calibration sources. The shutter I&C controls and captures data from valves, pneumatic actuators, flowmeters, pressure sensors, and temperature sensors to regulate the gas valve box and shutters. DRAFT

Figure 3 - UWAVS Design Breakdown

In-Vessel and Ex-Vessel components are being procured under separate arrangements as shown in Table 1, but final control and measurement is the responsibility of the I&C supplier. The I&C Supplier is also responsible for the procurement of test equipment to ensure interoperability of each type of instrument required for testing of I&C equipment and software.

Table 1 - I&C Component Procurement Responsibilities

Region Component Instrument Responsibility

In Vessel A10-A30 Mirror Modules Thermocouples In-Vessel Supplier

Mirror Cleaning Components

In-Vessel Supplier

IR Cal Source In-Vessel Supplier

Interspace Closure Plate Window Thermocouples Ex-Vessel Supplier

IOT Structure Thermocouples Ex-Vessel Supplier

A40 Motors Ex-Vessel Supplier

Limit Switches Ex-Vessel Supplier

Thermocouples Ex-Vessel Supplier

A50 Thermocouples Ex-Vessel Supplier

BioShiel Plug BOL Thermocouples Ex-Vessel Supplier

A60 Motors Ex-Vessel Supplier, 1

Provided by PPPL

Limit Switches Ex-Vessel Supplier

Region Component Instrument Responsibility

Thermocouples Ex-Vessel Supplier

Port Cell Valve Box Limit Switches Ex-Vessel Supplier

Electromagnetic Solenoids Ex-Vessel Supplier

Pressure Sensors Ex-Vessel Supplier

Shutter Actuation Pumps Ex-Vessel Supplier

BEOC Thermocouples Ex-Vessel Supplier

BEOC: Shielded Cabinet RF Matching Box Ex-Vessel Supplier

Fiber Media Converters Ex-Vessel Supplier

BEOC: Filter Wheel Assembly Limit Switches Ex-Vessel Supplier

Filter Wheel Motors Ex-Vessel Supplier

Visible Cameras I&C Supplier 1 Set, Ex-Vessel remaining

Linear Stage Motors Ex-Vessel Supplier

BEOC Optical Bench Thermocouples Ex-Vessel Supplier

IR Cameras I&C Supplier 1 Set, Ex-Vessel remaining

Diagnostic Hall Cubicle Area Cubicles I&C Supplier

RF Generators I&C Supplier

Fast Controllers I&C Supplier

PLCs I&C Supplier

Motor Controllers I&C Supplier

DC Power Supplies I&C Supplier

Signal Conditioners I&C Supplier mTCA Chassis I&C Supplier

Master Controller CPUs I&C Supplier

PSH I&C Supplier

Figure 4 shows the UWAVS interfaces to individual components. Items in green are within the procurement and management scope of I&C.

Components in white boxes are within the scope of I&C management, but not procurement. Grey boxes are systems with which I&C interfaces.

Black lines describe data connections that I&C uses to interface with UWAVS components.

Figure 4 - Illustration of the Instrumentation and Controls for a single port of 55.GA. Note that only one set of cameras are within the I&C

Supplier’s procurement scope

I&C diagnostic hall hardware resides in the cubicles in the form of fast/slow controllers, component controllers (ex. motor, mirror cleaning, etc.), cameras, frame grabbers, Field Programmable Gate Arrays (FPGAs), and data capturing systems. Wiring and connections within the cubicles are within the I&C scope. A single Master cubicle (Figure 5 manages the general controls of the Support (Figure 6) and Camera (Figure 7) cubicles of each port. The Camera Cubicles are in charge of data processing and management of both IR and VIs cameras for their respective ports. The Support Cubicles manage all other controls and processing required by the UWAVS subsystems.

Figure 5 - Master Cubicle (Front View) - One Master Cubicle controls ports UP2, UP8, UP11, UP14, and

UP17

Figure 6 - Camera Cubicle (Front View) - There is one Camera Cubicle for each port (UP2, UP8, UP11, UP14, and UP17). This cubicle manages both IR and VIS camera sets and processes their data

Figure 7 - Support Cubicle (Front View) - There is one Support Cubicle for each port (UP2, UP8, UP11, UP14, and UP17). The Support Cubicle manages all slow controls and data management

The software component of UWAVS I&C consists of Programmable Logic Controller (PLC), Master Controller, Slow Controller, and Fast Controller software. This includes complex procedures like camera calibrations, complex image processing, image alignment, measurement algorithms, user interfaces, network interfaces, and other support software, e.g. operating system support, driver, etc.

The supplier, via PPPL, is expected to interact with and support the efforts of the In-Vessel and Ex-Vessel suppliers, specifically regarding integration and functional test support (e.g., drivers for shutter operation, thermocouple functional testing), as necessary.

3.3. ITEMS TO BE PROVIDED BY PPPL

a. PPPL will supply prototyping and interface support in the forms of:

● Prototyping Integration Kit

● Previous prototype reports and software package

b. PPPL will provide relevant algorithms and software modules developed during early prototype testing.

c. PPPL will provide representative measurement data, as available.

d. PPPL will provide calibration sources for offline calibration of cameras.

e. PPPL will provide a commonly used motor from the other assemblies, for the purpose of testing.

3.4. OUT OF SCOPE FOR SUPPLIER

The following items are out of scope for this SOW:

a. The integration of the UWAVS I&C components in the ITER facility.

b. Procurement of all instruments, connections, and associated cables located within the Interspace, the Front-End Optical Modular Systems (FEOMS), and the Diagnostic Shield Module (DSM), unless explicitly stated in Table 1.

a. The connections, cabling, and control systems within and directly on the cubicles are within the scope of this SOW.

b. In-Vessel and Ex-Vessel components being procured under separate arrangements as shown in Table 1.

c. Cables outside of cubicle assemblies are installed at the instruction of cabling diagrams, but are the responsibility of the IO after installation.

4. PHASED IMPLEMENTATION

The Execution of this SOW is divided into two phases.

Phase 1 being Preparation for Manufacturing: generation of the documentation and build to print (BTP) drawing development required to support Manufacturing Readiness Review(s) (MRR), completion of prototyping activities proposed by the supplier and agreed to by PPPL prior to contract award and completion of MRR(s). [01-104] Phase 2 is Manufacturing: component fabrication, assembly, subassembly, factory acceptance testing, packaging, handling, storage, transport, delivery, and integration support of the subassemblies.

5. PHASE 1: PREPARATION FOR MANUFACTURING

5.1. DOCUMENTATION DEVELOPMENT

a. The supplier shall prepare a manufacturing plan covering the full scope of manufacturing, inspection, conduct of factory acceptance tests, cleaning, packaging and shipment, and site acceptance at ITER.

b. The supplier shall develop an MRR document package containing detailed information on how the supplier intends to execute documentation required for each MRR [V02-07]. The supplier shall provide documents shown in T for each MRR.

Table 2 - MRR List of Document Deliverables

Document Expected Contents

System Requirements Specification (SRS)

a. The SRS shall be updated to consolidate I&C requirements, which are to include software requirements, and define use cases. For each requirement, a specific verification method shall be defined at each phase (Manufacturing/FAT, Acceptance/SAT). This document shall be processed into EA.

b. This document shall also include:

• High-Level Operation Procedure Diagram

• High-Level Hardware Architecture Diagram

• High-Level Operating State

EA Project The supplier shall update the EA project from FDR with any changes and updates from the MRR phase.

Self-Description Data (SDD) Project

The supplier shall create an SDD project containing the design information loaded from the EA project, including:

• Signals

• Components

• Functions

• Variables

• Process control for any plant system operation state.

• Process failure detection and strategy for process control.

• I/O treatments.

• Data exchanges required for slow and fast controls.

• Feedback controls.

• HMI, alarms and events.

• Software architecture for these items with identification of related software modules and data exchange links.

Quality Plan

The supplier shall produce a Quality Plan that addresses and encompasses the tasks and deliverables defined within this SOW and its references. The supplier’s Quality Plan will be reviewed by the Company and the ITER Organization (IO) for acceptance. [V02-09]

System Manufacturing Specification (SMS)

a. The supplier shall complete an SMS, consolidating all details for the manufacturing of the Diagnostic Plant I&C.

b. The SMS shall outline all technical, procedural, and quality requirements necessary to initiate and control the manufacturing phase, including hardware and software components.

c. The SMS shall include details regarding standards compliance, inspection protocols, component traceability, PCDH deliverables, and logistics.

d. The SMS shall include an I&C spare parts list with appropriate specification of storage space and conditions

Software Quality Assurance Plan

a. The supplier shall provide a Software Quality Assurance Plan, within the Software Manufacturing Specification (SMS), in accordance with the Quality Assurance methods described in [V01- 102]. This quality assurance plan shall cover:

• Requirement / architecture documents

• Unit and integration testing

• Standard release / deployment procedures

• User and developer documentation

b. The supplier shall provide, as part of the Software Quality

Assurance Plan, a plan of support for mitigating software obsolescence through the system’s projected lifespan, including necessary updates, patches, and version control to maintain system functionality and security.

I&C Cubicle Wiring Diagrams

The supplier shall complete the final electrical enclosure wiring diagrams and interconnection diagrams, developed in SEE Electrical Expert (SXP).

The diagram shall serve as the reference for cubicle manufacturing, cable installation, and ongoing maintenance and will require input from th SXP technician, Diagnostic TRO, Plant I&C designer, Plant I&C manufacturer, and IO-CT experts.

Inspection Plan (IP)

Inspection Plan shall include definition of cleaning points between integration, testing and assembly operations, sample form provided as [V02- 120] to include but not limited to the following:

a. Manufacturing sequence for the fabrication of parts and sub-assemblies. The manufacturing sequence shall cover the manufacturing processes, (bending, connectors, inspections, etc.) and operations (internal handling, transportation, etc.).

b. Description for each step of the manufacturing sequence including a short explanation, images, 3D views, possible issues or risks with proposed solutions and detailed design of jigs and fixtures to be used during fabrication and handling.

c. Description of each inspection activity for each manufacturing step, indicating the tools and procedures that will be used for the inspection.

d. Assembly sequence of the sub-parts or sub-assemblies up to complete the sub-assembly.

Manufacturing Inspection Plan (MIP)

The supplier shall generate a Manufacturing Inspection Plan that focuses on hardware in the form of a spreadsheet.

Software Development and Inspection Plan

(SDIP)

The supplier shall deliver a Software Development Inspection Plan at MRR. This plan focuses solely on software quality for the purpose of inspection during the Manufacturing Phase. From the document’s own introduction:

The purpose of the Software development and inspection document is to track the progress of software development and perform intermediate inspections. The reference of this document will be given in the SMS document. This document needs to be updated during software development at regular intervals and eventually software inspection will be performed by IO.

Assembly Instructions

A detailed assembly sequence for all sub-assemblies including a short explanation, images, views, possible issues or risks with proposed solutions, detailed design of Test, Measurement and diagnostics equipment, fixtures or tooling necessary during assembly and handling.

Marking and Labelling plan.

a. The plan shall be in accordance with the requirements for marking, labelling, cleaning, handling and packaging described in sections 5.3 and 5.4.

Cleaning, Packaging, and Transportation plan

a. Updated BOM, if required.

b. Updated Assembly Plan for System Acceptance.

c. Qualification report (if needed).

d. Risk plan.

e. Personnel qualifications.

Factory Acceptance Test (FAT) Plan

a. Hardware Test Plans and verifications that will be carried out during the manufacturing process, in accordance with the classification of the component with respect to Quality, Safety, including Functional tests to be performed.

b. Software Test Plans and verifications that will be carried out during the manufacturing process, in accordance with the classification of the component with respect to Quality, Safety, including Functional tests to be performed.

c. Detailed description and procedures of each test to be made, including acceptance criteria.

d. Identification for each operation of the place where it will be carried out (i.e. Workshop or Clean area).

System Test Plan A system test plan shall be developed for each major milestone, including use cases and test criteria.

Site Acceptance Plan

a. Receipt Inspection

b. Functional tests and acceptance criteria include required test measurement diagnostic equipment, test fixtures, and interface components to be conducted at the port integrator facility.

Software Architecture and Design Description

The supplier shall produce a SADD to capture lower-level software architecture and design information.

I&C System Test Plan

(STP)

The supplier shall produce a Software Test Plan that outlines the test cases and their validation criteria.

Interface Sheets The supplier shall recommend updates and maintenance to Interface Sheets, as required.

c. The supplier shall use the following Codes and Standards for Manufacturing, Inspection and

Testing:

● For conventional parts: American Society of Mechanical Engineers ASME.

● For non-conventional parts: Technical Specifications including requirements derived from design activities, see Section 6.2.3 of Codes and Standards for ITER Mechanical Components (latest version).

● Electrical equipment and components use Code selected from Electrical Design Handbook (EDH): Part 3 [V02-20].

● Material certificates and traceability compliant with EN 10204 type 3.1, REC 3000.

d. Prior to MRR, the supplier shall provide specifications for purchasing necessary COTS items and materials not provided by PPPL (ex. software licenses, prototyping hardware, etc).

e. The final manufacturing drawings produced by the supplier shall be submitted to MRR for review and approval by PPPL before any manufacturing activity starts. The supplier shall review and comment on provided drawings AD-01 to AD-13.

f. Technical, procedural, and quality requirements for the Manufacturing Phase shall be covered in the

I&C SMS.

5.2. SOFTWARE DEVELOPMENT

a. For Beam Steering, the I&C supplier shall develop control software/algorithms for the mirror motors and limit switches. The software shall check the quality of the image alignment through the IR and VIS cameras.

b. For Mirror Cleaning, the I&C supplier shall develop control software/algorithms to control the RF generators and RF matching units to perform the cleaning process. This process includes assessing the success of the mirror cleaning.

c. For the Calibration process, the I&C supplier shall develop control software/algorithms for temperature sensors, heating of the IR sources, and measurement through the cameras. Both the IR and Visible cameras require calibration, where PPPL will provide calibration sources.

d. For shutter control, the I&C supplier shall develop control software/algorithms for valves, flowmeters, pressure sensors, and temperature sensors to provide pneumatic control of the shutters.

e. The I&C supplier shall develop control software/algorithms to the motors, switches, fiducials of filter wheel assembly, cameras, and supporting camera electronics. Both infrared and visible cameras shall be interfaced through frame grabbers to the processing electronics.

f. The software development life cycle runs in parallel with the development of the other parts of UWAVS, including the cubicles.

g. As a SWIL-2 class system, the supplier shall provide the intermediate milestones from Table 3 in the software development process. Software development milestones dates shall be set by PPPL, with the agreement of IO and the supplier, in preparation for MRR.

h. The supplier shall adhere to the use of Software Development Standard Documents (SDSDs), where applicable.

i. The supplier shall include testing equipment/tooling and test stand software sections in all documentation.

Table 3 - Software Milestones

Milestone SWIL-2 Deliverable Software Requirements Review Update to SRS to include software Preliminary Software Design Review

Final Software Design Review

- MRR

Software Architecture and Design Description (SADD), Software Test Plan (STP)

Preliminary Software Implementation Review

Final Software Implementation Review and Acceptance

- DRR

Source Code with change tracking (SRC), Software Test Report (STR), Software User/Development Manual (SUM)

5.3. PROTOTYPING

a. Prototypes are sub-systems of UWAVs that are built for the purpose of risk mitigation, verification of component functionality, validation of I&C software and control algorithms, and refinement of the final design and manufacturing processes.

b. The supplier shall develop plans for approved prototyping activities.

c. Following PPPL’s approval, the supplier shall conduct manufacturing prototyping on high-risk components and capture lessons learned and/or best practices.

d. Following PPPL’s approval, the supplier shall conduct software prototyping on high-risk components and capture lessons learned and or best practices.

5.4. MANUFACTURING READINESS REVIEW

a. The supplier shall present its readiness for manufacture at formal MRRs.

b. The supplier may propose to split the MRR into several either full or simplified, for the different subassemblies/components.

c. The supplier shall submit all documents, drawings/models and prototype results in support of

MRR as defined in [V02-07].

d. The supplier shall prepare presentations to support MRRs.

e. The supplier shall address findings and recommendations in an MRR panel report.

6. PHASE 2: MANUFACTURING

The supplier shall under no circumstances start Phase 2 Manufacture activities until written authorization has been granted by PPPL, after closeout of the MRR. PPPL will provide the supplier with authorization to proceed with manufacturing by email.

6.1. MANUFACTURING

6.1.1. PLANNING AND PROCUREMENT

a. The supplier shall provide specifications for purchasing necessary COTS items and materials not provided by PPPL.

b. The supplier shall be responsible for purchasing all necessary hardware required for First Article Inspection (FAI), Factory Acceptance Testing (FAT), and software development.

c. The supplier shall collaborate with the In-Vessel and Ex-Vessel suppliers through PPPL, as required, to define functional test interfaces.

d. The completion of the first article shall not be a limiting milestone for the procurement of COTS of the other articles.

6.1.2. TEST PLAN AND SOFTWARE DEFINITION

e. The supplier shall develop a functional system-level test plan.

f. The supplier shall develop unit test plan with sufficient granularity to separately test all layers of a hierarchical software design, including high level algorithms, sensor data input, data logging, actuator controls, and other major aspects of the software functions.

g. The test plan shall indicate what signals or devices are required and whether they must be provided or may be simulated.

h. Where acquiring data is not possible, data shall be generated by the supplier to meet testing requirements.

i. The supplier shall include in all test plans a method of providing remote and in-person support as applicable.

j. Software development shall not be a limiting milestone for first article FAT or FAI.

6.1.3. FIRST ARTICLE MANUFACTURING

k. First Article subassemblies are the first build of a complete cubicle, cabinet, or other stand-alone component.

a. The First Article assembly consists of the Master Cubicle, a Camera Cubicle, and a Support Cubicle.

b. The First Article assembly includes all controlling and processing softwares to be run on each cubicle.

l. The supplier shall manufacture the First Article subassemblies to be produced in accordance with the manufacturing drawings, plans, and procedures approved at MRR, the technical requirements stated in this SOW and applicable/reference documents.

m. The supplier shall prioritize the reuse of purchased hardware in the final manufacturing and operational build whenever practical.

n. The supplier shall integrate the subassemblies, with simulated IO networking and CODAC systems.

6.1.4. FIRST ARTICLE INSPECTION

o. The supplier shall conduct first article inspection (FAI) of each of the first article subassemblies.

p. The supplier shall conduct a Factory Acceptance Test of each first article.

q. The supplier shall conduct an integrated test of a complete cubicle set, with software systems, to the level of the following, in accordance with Table 4:

a. Verification of inter-cubicle data flows.

b. Verification of individual and inter-cubicle functions.

c. Verification of inter-cubicle command and control.

d. The use of input and output simulations to the In-Vessel and Ex-Vessel components.

e. Other possible tests identified in the System Test Plan.

r. The supplier shall conduct the tests and deliver test reports as they become available.

6.1.5. FINAL MANUFACTURING AND DELIVERY

s. Once the FAI and FAT has completed, and upon authorization to proceed from PPPL, the Supplier shall then manufacture the remaining subassemblies.

t. The supplier shall deliver source code of any software developed for the plant system I&C including:

a. Source code of any software developed for the plant system I&C for operation, tooling during manufacturing, factory acceptance test, site acceptance test, integrated commissioning and maintenance, in the scope of this delivery. Configuration data for any plant system I&C controller shall be delivered.

b. Mini-CODAC configuration developed in the Mini-CODAC environment required for factory acceptance test, site acceptance test and integrated operation.

u. The supplier shall be responsible for the transport of all Supplier-procured hardware and software between the Supplier's location and the facilities of the In-Vessel and Ex-Vessel Suppliers, and the final delivery location when deemed necessary by PPPL for prototyping or assembly.

6.1.6. GENERAL REQUIREMENTS FOR ELECTRICAL COMPONENTS

a. Electrical equipment shall be in accordance with the electrical design handbook (EDH) as defined in V02-24, V02-25, V02-26, & V02-27.

b. Thermocouples shall comply with ASTM E2846.

6.1.7. GENERAL REQUIREMENTS FOR SOFTWARE DEVELOPMENT

a. The supplier shall develop UWAVS software in compliance with the system software definitions in [V01-103].

b. Requirements for ITER software development are provided in the PCDH [V01-101].

c. The supplier shall use the prescribed configuration, development, and documentation tools required by the IO.

d. The supplier shall follow the software development cycle explained in [V01-103], including iterative test cycles, documentation, and standards.

e. The supplier shall develop a Factory Acceptance Test plan for the software. The FAT shall be submitted to PPPL for review and approval.

f. The system software shall be submitted to PPPL for review and approval.

g. The supplier shall ensure the delivered software package includes all source code, build scripts, necessary compilers, and detailed documentation required for the independent rebuilding of all software.

h. The supplier shall update the EA model, as necessary. Refer to the user manual as [V02-123].

6.2. FACTORY ACCEPTANCE TESTING

6.2.1. FACTORY ACCEPTANCE TEST PLAN

a. The supplier shall consider the verification approach provided in Table 4.

Table 4 – Component Verification Table

Item Figure(s) Supplier Verification Approach

Master Cubicle Figure 5 Factory Acceptance Test Camera Cubicle Figure 6 Factory Acceptance Test Support Cubicle Figure 7 Factory Acceptance Test I&C Integrated Test Figure 5, Figure

6, Figure 7 System Level Test

b. The supplier shall develop and submit the Factory Acceptance Test (FAT) Plan for approval at the

MRR, detailing the assembly sequence, test strategy, and acceptance criteria for all UWAVS components.

c. The supplier may propose alternative assembly, test, and acceptance criteria to the ones summarized in this SOW.

d. The Supplier shall present alternative test assemblies and test benches to avoid dependencies on In-Vessel and Ex-Vessel hardware, including extra hardware, alternative/equivalent hardware, and custom builds.

e. The supplier shall include detailed assembly sequences for all sub-assemblies including a short explanation, images, views, possible issues or risks with proposed solutions, detailed design of jigs, fixtures, tooling, or test equipment necessary during assembly and handling.

f. The supplier shall prepare a functional system-level test plan for assemblies as shown in Table 4.

g. Where reasonable, the Ex-Vessel and In-Vessel suppliers shall procure their own testing equipment and develop testing software.

6.2.2. FACTORY ACCEPTANCE TEST PROCEDURE

h. The supplier shall provide the Factory Acceptance Test Procedure based on the approved FAT

Plan, detailing the step-by-step execution sequence.

i. The supplier shall travel, as required at the approval of PPPL, to support the Ex-Vessel and In-

Vessel Supplier’s FAT testing to provide I&C support software and hardware support and integration expertise.

a. Travel shall be limited to the minimum required personnel, travel days, and number of trips to perform full testing. A maximum of two trips is expected when all suppliers are prepared for final FAT tests.

j. The Supplier shall prepare, package, and ship all necessary test equipment, tools, and specialized hardware/software interfaces required to execute the PPPL approved I&C support activities at the Ex-Vessel and In-Vessel Supplier’s FAT location, as required.

k. The Supplier shall develop and provide necessary specialized software tools, scripts, or interface simulations required to conduct Ex-Vessel and In-Vessel FAT testing.

l. The supplier shall execute the FAT strictly following the approved FAT Plan and Procedure.

6.2.3. FACTORY ACCEPTANCE TEST VERIFICATION REPORT

m. The supplier shall deliver all SWIL-2 deliverables presented in Table 3.

n. The supplier shall complete documentation to the levels described in Table 4 for the FAT milestone.

o. The supplier shall deliver FAT reports for all tests performed, which shall include at a minimum:

● Overview of the test performed in accordance with the FAT procedure

● Summary of results: Test forms filled with the measured or observed values of each test

● List of Non-Compliance during Acceptance test and actions taken to resolve the Non-

Compliance

● List of as-built drawings of the manufactured components

● FAT packaging, delivery and final shipment report

6.3. MARKING AND IDENTIFICATION REQUIREMENTS

a. The supplier shall mark and label deliverable items in accordance with ITER Numbering

System for Components and Parts [V02-05] and Procedure for Labelling on Physical Items [V02-06].

b. Marked items shall include but are not limited to:

● Title of Product

● Functional Reference Number (provided by PPPL)

● Part Number of ITER (provided by PPPL).

● Serial Number (SN) (generated by the Supplier).

● Safety Classification, e.g. Non-PIC, ESPN, etc.

● Quality Class.

● CE marking, if applicable.

c. The supplier shall ensure that any marking is in a visible area after the production, packing, storage and installation.

d. The supplier shall provide certificates of conformity for I&C procurement to any regulation applicable on ITER site and proof of compliance to ITER I&C standards, in particular CE marking and NFC-15100.

e. The supplier is required to mark each crate with the following:

● Subcontract number

● Delivery address

● Consignor (Seller’s name, address, and contact information)

● Package number (as identified on the packing list)

● ITER Equipment Identification Number(s) (if applicable)

● Gross Weight (kg)

● Net Weight (kg)

● Handling instructions

● Lifting/Lashing/Jacking points

● Center of Gravity (in 3 dimensions)

● Compliance marks (if applicable)

6.4. CLEANING, PACKAGING, HANDLING, STORAGE, AND TRANSPORT

a. After final cleaning, the handling of vacuum equipment shall be strictly controlled to preserve cleanliness complying with the requirements. Items shall under no circumstances be delivered by the supplier before formal approval of the DRR is granted by PPPL.

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

c. The supplier shall provide a package design document which includes the proposed packaging design as well as analysis showing the deliverable can withstand air, land, and sea transport.

d. The supplier shall include environmental packaging, as necessary.

e. The supplier shall control release from storage to prevent accidental or inadvertent use of non-compliant items.

f. The supplier shall control release from storage to prevent accidental or inadvertent use of non-compliant items.

g. The supplier shall provide packaging to protect the equipment from any conditions (e.g., shock, impact, weather, etc.) which could cause damage to the equipment resulting in nonconformity with applicable requirements.

h. The supplier shall package and prepare each piece of equipment for shipment to the port integration facility.

6.5. CREATION AND SUBMITTAL OF PRE-SHIPMENT DOCUMENTATION

a. Transportation and Shipment of the Ex-Vessel Assemblies will be conducted by the ITER

Project's Global Logistical Services Provider (LSP), Daher International and/or its United States partner, St. Germain Heavy Industrial Projects (SHIP), and is therefore not part of this Agreement. However, Task Orders will be generated with these logistics service providers.

b. The pre-shipment documentation consists of four pre-shipment packages each containing differing documents and timelines for delivery.

c. The supplier shall prepare material for a Delivery Readiness Review in accordance with the Procedure for the Transportation of Components to the ITER Site [V02-38].

d. The supplier shall provide a pre-shipment deliverable package #1 no later than 60 business days prior to the delivery readiness review, and contain the following items:

● Written notice of the planned date on which the goods will be packaged and available for shipment.

● Contact information for supplier’s shipping/logistics coordinator.

● Technical characteristics of the packaged components as follows:

o Physical data and drawings showing dimensions, total and distributed weights, center of gravity (in 3 dimensions), shipping orientation;

o Address of the location where items are to be picked up by the Logistics Service Provided

(LSP).

● Documentation (e.g., material safety data sheet) regarding relevant compliance regimes, such as export control, transportation of dangerous goods, and environmental protection.

● Identification of any items that have been identified as Safety Important Components (SIC) or Protection Important Components (PIC).

● Conditions or precautions to be respected when moving, loading/offloading, handling/slinging, and storing/marshaling to include, when required, specific provisions and controls to be performed and recorded while under the control of the LSP.

● Documentation confirming that packaging is designed to protect components from damage and contamination, considering anticipated environmental conditions and multimodal (e.g., highway, ocean) handling/transit accelerations.

● Packaging specification including confirmation of compliance with international packing standards (e.g., International Standard for Phytosanitary Measures (ISPM)-15, Conformity European/CE certification for relevant package lifting appurtenances such as eyes/rings), agree barcoding requirements and regulations relating to packaging materials used.

● Definition of packaging/frame, when the components are packed or trapped, including any procedures for handling, moving, clean-up, maintenance, storage.

● Specification for securing and hanging packages/frames including jacking/lifting/lashing conditions, procedures, and acceptable securing points.

● Identification of specialized equipment/hardware (e.g., custom lifting fixture) interface requirements between each point of use within the supply chain.

● Description of Interface between Supplier and LSP (e.g., release conditions for loads, Supplier’s loading means, etc.).

● Technical data concerning monitors (e.g., shock, vibration, tilt, acceleration, temperature) utilized to detect events during transit which may cause damage to components.

e. The supplier shall provide pre-shipment deliverable package #2 no later than 90 days prior to planned date of shipment, and contain the following items:

● Written confirmation of the date goods will be ready for shipment or submit revised shipment date for approval.

● Contact information for supplier’s shipping/logistics coordinator.

● Fabrication value of goods (for insurance purposes-should not include destination site support services).

● Transport drawings with sufficient detail to facilitate lifting / lashing / stowage and approval of the operators (e.g., steamship line, air carrier).

● Business documents shall be written in the English language.

● The transportation Incoterm rule is FCA (Free Carrier) Incoterms 2010. The supplier shall be responsible for packaging and loading of all hardware/equipment in accordance with this

SOW.

● For shipments subject to United States export control law, the supplier shall comply with the Export Administration Regulations (EAR) and Foreign Trade Statistics Regulations (FTSR).

● The supplier shall serve as both the Exporter (Shipper of Record) according to the EAR and the U.S. Principal Party of Interest (USPPI) according to the FTSR.

● For shipments originating from foreign locations, the supplier shall serve as the Exporter according to the origin country's export control regulations.

● The supplier shall be responsible for assisting Company and LSP in coordination of the transportation and shipping arrangements. The supplier may interface directly with the LSP, if written authorization is given in advance by the PPPL.

● Equipment will be shipped to the following address or alternate designated by PPPL:

ITER Organization Route de Vinon sur Verdon, CS 90 046 13067 St. Paul lez Durance, CEDEX France

● Declaration of Integrity

The undersigned hereby certifies that the components and package(s) described on this Packing List meet the contractual requirements except for any approved deviations and non-conformance reports specified in the associated documentation.

● The supplier shall provide pre-shipment deliverable package #3 no later than two weeks prior to planned date of shipment, and contain the following items:

● Evidence of appropriate proof testing and certification for any custom lifting apparatus that will travel with the item and be utilized during loading and unloading operations.

● The supplier shall provide pre-shipment deliverable package #4 no later than one week prior to planned date of shipment, and contain the following:

● Any remaining information needed to facilitate appropriate completion of transport documents such as bills of lading or air waybills.

● Data elements and authorizations (e.g., shipper’s letter of Instruction, power of attorney) required for Logistics Service Provider submission of electronic filings in the automated export system, when necessary.

● Dangerous goods declaration if required for transport.

e. Pre-shipment deliverable package #3 is to be provided no later than two weeks prior to planned date of shipment and contains the following items:

● Evidence of appropriate proof testing and certification for any custom lifting apparatus that will travel with the item and be utilized during loading and unloading operations.

f. Pre-shipment deliverable package #4 is to be provided no later than one week prior to planned date of shipment and contains the following:

● Any remaining information needed to facilitate appropriate completion of transport documents such as bills of lading or air waybills.

● Data elements and authorizations (e.g., shipper’s letter of Instruction, power of attorney) required for LSP submission of electronic filings in the automated export system when necessary.

● Dangerous goods declaration if required for transport.

g. Items shall under no circumstances be delivered by the supplier before formal written approval by PPPL following the DRR.

6.6. SHIPMENT

a. If requested by PPPL, the supplier shall withhold shipment for up to 60 days to allow preparations at destination for Site Acceptance by the port integrators.

b. The supplier shall submit a Release for Shipment form [V02-13].

c. The supplier will issue Task Orders directly to the logistics service provider for transportation, shipment, logistics, and customs clearance associated with finished products under this Agreement. To facilitate the transportation activities being undertaken by the LSP and Company, the supplier is responsible for the timely provision of all transport documentation and information listed in this section. Transportation/freight costs associated with the finished products/deliverables required by the SOW are expressly unallowable under this Agreement.

d. The supplier shall load packaged components to be transported onto the Logistics Service Provider conveyance (e.g., truck, van, trailer, vessel, ocean container, air freight container, rail car) at the factory.

e. When a Release for Shipment form is specified, shipment must not be made until the shipping release form is signed and returned by PPPL.

f. Requirements for software development and delivery are provided in the PCDH as guidelines. The software shall be submitted to PPPL for review and approval, within the SVN as defined in V01-24.

g. Electronic distribution will be the standard method of transmitting all software and documentation deliverables including reports, meeting minutes, drawings, general correspondence, software, etc.

6.7. ACCEPTANCE AND INTEGRATION SUPPORT

a. The supplier shall rectify any non-conformances during receipt inspections in accordance with QA

Section 6.1 with non-conformances identified by the IO during acceptance testing.

b. The supplier shall attend and support PPPL and IO during the Site Acceptance (SA) using the Site

Acceptance Plan presented at the MRR after delivery to the IO for the verification and final acceptance of UWAVS subassemblies.

c. The supplier shall support the port integrator and IO with SMEs in integration questions or issues related to manufacturing. If design issues are identified during this integration process, the supplier will raise this to PPPL for adjudication.

d. The supplier shall provide, as deliverables to the SA:

● Interface Sheet updates and maintenance, as necessary

● I&C STP, specific to SA

● I&C SMS updates and maintenance, as necessary

● I&C SADD updates and maintenance, as necessary

● I&C Cubicle Wiring Diagram updates and maintenance, as necessary

● I&C Operations and Maintenance Manual, to a detailed/consolidated level

● I&C STR, specific to SA

● EA project updates and maintenance, as necessary

7. QUALITY ASSURANCE

7.1. INSPECTION / SURVEILLANCE / AUDIT BY PPPL

a. With prior written notification, PPPL may conduct source surveillance activities at the supplier’s facility to ensure quality objectives are met.

b. Authorized representatives of PPPL, the U. S. Government, and ITER Organization (IO) shall have the right at all reasonable times to visit the supplier's premises and those of supplier's sub-tier vendors 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.

c. Such visits shall be coordinated with the supplier's personnel to minimize interference with the normal operations of premises.

d. The supplier shall make available records and documentation necessary for this function and shall provide all reasonable facilities and assistance for the safety and convenience of PPPL and/or U.

S. Government representatives in the performance of their duties. PPPL and the U. S. Government recognize the supplier's right to withhold information concerning proprietary processes.