1. NCSX May 12, 2005 ACC Review- Station 5 J.H. Chrzanowski - 1 ACC Review Of Modular Coil Manufacturing Facility Station No. 5 [VPI] the NCSX Manufacturing Team

2. NCSX May 12, 2005 ACC Review- Station 5 J.H. Chrzanowski - 2 General Overview- Station No. 5  This ACC review is reviewing the safe guards and controls that are planned and implemented on the VPI Station No. 5.  Station 5 will be used to epoxy impregnate the modular and Toroidal Field coils following winding activities.  Quantity of coils to use Station 5  (18) modular coils  (18) Toroidal field coils  (1) Twisted Racetrack coil

3. NCSX May 12, 2005 ACC Review- Station 5 J.H. Chrzanowski - 3 Modular Coil Types Modular Coils TF Coils TRC Coil

4. NCSX May 12, 2005 ACC Review- Station 5 J.H. Chrzanowski - 4 Moderate Hazard Facility  The NCSX Coil Manufacturing Facility has been designated a “Moderate” Hazard Facility”  This a result of the autoclave usage and the activities associated with the VPI of the MC  “NCSX-PHA-142-01” approved document, documents all of the known hazards associated with then MCWF

5. NCSX May 12, 2005 ACC Review- Station 5 J.H. Chrzanowski - 5 NCSX R&D – Safety is Integrated in All Aspects  Safety is an important element of the PPPL culture and is incorporated in all aspects of the development program and will be carried over to production  Integrated Safety Management (ISM)  Job Hazard Analysis survey (JHA’s) is being developed to identify hazards associated with the various tasks and the personnel protective equipment required with Station 5  Involvement of all safety groups in developing plans for manufacturing- IH, Construction safety, HP

6. NCSX May 12, 2005 ACC Review- Station 5 J.H. Chrzanowski - 6 STATION 1 STATION 2 STATION 3 STATION 4 STATION 5 Modular Coil Manufacturing Facility Location of Station 5

7. NCSX May 12, 2005 ACC Review- Station 5 J.H. Chrzanowski - 7 General Description of Station #5 Activities Station 5 Activities -Install coil in autoclave and prep for VPI -Mixing of epoxy -Vacuum leak checking systems -Working with vacuum/heat/pressure [autoclave] -Filling coil with epoxy (VPI) -Heat curing filled coil -Remove coil from autoclave Work is covered by Procedure No. D- NCSX-MCF-003

8. NCSX May 12, 2005 ACC Review- Station 5 J.H. Chrzanowski - 8 Safety Related Activities  The following items are being addressed in the procedures and JHA  Confined space- working in the autoclave  Working on elevated surfaces- upper catwalks  Working around hot surfaces  Working with vacuum and pressure chamber  General safety concerns-house cleaning, etc.  Crane Operations

9. NCSX May 12, 2005 ACC Review- Station 5 J.H. Chrzanowski - 9 Safety Controls  Personal protective equipment- face, gloves  Confined space permits  Training  Approved procedures

10. NCSX May 12, 2005 ACC Review- Station 5 J.H. Chrzanowski - 10 NCSX Coil Manufacturing Organizational Chart Indicates a communication link, and not a management link between the participants * Note: Designates primary station responsibility as well as sharing overall field management responsibilities. Construction Safety Representative Quality Control Representative Coil Manufacturing Facility Manager Jim Chrzanowski Industrial Hygiene Representative Health Physics (HP) Representative PPPL Responsible Line Manager Larry Dudek NCSX WBS 14 Manager Dave Williamson NCSX WBS 13 Manager Mike Kalish Field Supervisor * Steve Raftopoulos METROLOGY Field Supervisor * Jim Chrzanowski Station No. 1 Winding Form Preparation (1) Lead Tech. + [1] crew Station No. 2, 3 & 4 Winding stations (3) Lead Techs + [4] crew Station No. 5 VPI (1) Lead Tech. + [3] crew Station No. 6 Coil Testing (1) Lead Tech. + [TBD] crew Coil Test Director Geoff Gettelfinger Field Supervisor Mike Kalish Field Supervisor * Tom Meighan

11. NCSX May 12, 2005 ACC Review- Station 5 J.H. Chrzanowski - 11 Manufacturing Documents- Station 5  NCSX-PLAN-CMFOP-00 [NCSX Manufacturing Facility Operations Plan]  Approved NEPA 1283  WP’s- 1188 (TRC),1138 (MC) and 1231 (TF)  NCSX-MIT/QA-142-01-00 [MC MIT/QA Plan]  Manufacturing Procedures  D-NCSX-MCF-003 [MC VPI Activities]  D-NCSX-OP-EO-41 [Emergency Response Procedure]  D-NCSX-OP-G-162 [Autoclave Operating procedure]

12. NCSX May 12, 2005 ACC Review- Station 5 J.H. Chrzanowski - 12 Modular Coil VPI Flow Diagram

13. NCSX May 12, 2005 ACC Review- Station 5 J.H. Chrzanowski - 13 VPI Delivery System  Epoxy Delivery System  Supply & return manifolds  Epoxy control valves  Epoxy Filters  Valves assemblies are disposable

14. NCSX May 12, 2005 ACC Review- Station 5 J.H. Chrzanowski - 14 Autoclave

15. NCSX May 12, 2005 ACC Review- Station 5 J.H. Chrzanowski - 15  During the VPI process, the Modular Coil will be divided into 3 zones  Zone 1- supply only  Zone 2- supply and return  Zone 3- return only  The autoclave will initially be maintained at vacuum matching the vacuum inside of the “bag mold” [minimize potential leaks]  As the coil reaches the ½ fill mark, the autoclave atmosphere will slowly shift from vacuum to pressure (5 psig max) to support the bag mold  Once filled, autoclave will return to atmospheric pressure prior to beginning the ramp up of temperature to cure the epoxy Zone 1 [Fill] (12) sprues Zone 3 [Return] (12) sprues Zone 2 [Fill/return] (24 sprues) Vacuum-Pressure Impregnation (VPI)

16. NCSX May 12, 2005 ACC Review- Station 5 J.H. Chrzanowski - 16 NCSX MODULAR COIL VPI CYCLE 10 20 30 40 60 50 70 80 90 130 100 110 140 0 120 61212 1818 2424 3030 3636 60544848 4242 0 10 20 30 40 60 50 70 80 90 130 100 110 140 120 Coil Fill Period Cure Time Ramp down Period Ramp up period Post Cure Time Ramp up period 5 hours 18 hours 16 hours 6 hours @ 10 ° C ramp up per hour 11 hours @ 10 ° C ramp down per hour Temperature degrees C Hours “Scrambled Egg” test to verify Gel temperature Viscosity measurements Epoxy component mixing