1. NCSX Field Period Assembly (FPA) Operations, Cost and Schedule, Staffing, and Metrology Utilization Mike Viola Field Period Assembly Manager NCSX FPA Peer Review October 11-12, 2006 PPPL

2. NCSX October 12, 2006NCSX Field Period Assembly Peer Review M. Viola 2 FPA Concerns and Risks Heavy emphasis on prototyping each activity Crack Work Crew and Support –Our most highly effective and ingenious technicians assigned to perform first time tasks. More time allocated for first time. John Edwards 30 years experience (Master Support Technician), Mike Duco from Lockheed (simulations, manufacturing, coatings, vibrations), Ed Bush 20+ Quality Assurance then NB Ion Sources. –Augmented as needed by cryogenic operators and NB Technicians Learning Curve (Extra time included in schedule) –Perform all tasks first with expert crew – Prove principles to mitigate risk!! And then finalize procedures. –Train secondary support crew to perform bulk of work Tooling –Expert crew perform dry run of tooling First article takes longer and procedures cannot be finalized until techniques have been proven.

3. NCSX October 12, 2006NCSX Field Period Assembly Peer Review M. Viola 3 FPA Metrology Issues Metrology (Mike Duco with Steve Raftopoulos engineering support) Available equipment in house –Leica Laser: 0.0005” accuracy –Romer arm: 0.005-0.010” accuracy (2 other Romer Arms available) Reach/Accessibility –Coils are easy to reach but need high accuracy –VVSA is hard to reach but localized activities can use lower accuracy equipment. Availability –Hardware/Software is ~80% available. –Have days of crashing and unpredictable operations. Combination of Windows, Verisurf, MasterCAM, Leica Power Inspect, ROMER… Repeatability –Datums strategically located to provide individual activity support –May need recommendation for datum locations to be used through final machine assembly if datum shift or tolerance buildup is of concern Expert metrology support group being considered within Fabrication Division.

4. NCSX October 12, 2006NCSX Field Period Assembly Peer Review M. Viola 4 FPA Activity and Risks – Station 1 Station 1 (Install VVSA external components diagnostic coils, cooling tubes, thermocouples using Leica laser tracker or Romer arm) –All three VVSA’s received by 9/30/06 –All work performed on station 1 fixture (2 “rotisserie” stations) with Leica laser tracker & 2 men augmented with 3 technicians when needed –Most risks are identified – Installation Progressing Technique developed to locate diagnostic loop templates Technique developed to adjust interferences (cooling tube studs and thermocouples) Technique developed to install diagnostic templates Technique developed to wind diagnostic loops –Remaining trials: Technique to connect cooling hoses to vertical risers Technique to hold heating tapes in place on vertical ports.

5. NCSX October 12, 2006NCSX Field Period Assembly Peer Review M. Viola 5 FPA Activity and Risks – Station 2 Station 2 (3 coil preassembly – align, shim, and assembly using Leica laser tracker) –Some risks are identified: Prefit individual mating coils – identify any gross interferences & checkout tooling Required stiffness of adjustable platform –Remaining trials: reaming bolts - accessibility Develop shim technique and use liquid shim Install liquid shim in vertical orientation Installing studs for epoxy shim Installing metal shims (1 hole, 2 hole machined or various thicknesses) Pillow shims

6. NCSX October 12, 2006NCSX Field Period Assembly Peer Review M. Viola 6 FPA Activity and Risks – Station 3 Station 3 (install coils onto VVSA using Leica laser tracker) –Align and assemble 2 coil three packs first then onto VVSA –Some risks are identified: Technique developed to manipulate coils onto VVSA –Remaining trials: reaming bolts - accessibility Develop shim technique and use liquid shim Install liquid shim in vertical orientation Installing studs for epoxy shim Installing metal shims (1 hole, 2 hole machined or various thicknesses) Pillow shims

7. NCSX October 12, 2006NCSX Field Period Assembly Peer Review M. Viola 7 FPA Activity and Risks – Station 4 & 5 in NCSX test cell Station 4 (install, align and assemble TF Coils using Leica laser tracker) –Trials TBD Station 5 final assembly in NCSX test cell to enhance efficiency and reduce HP overhead (weld ports, install TF coils, leak check, final metrology) –Leak check moved to final assembly –Trials TBD

8. NCSX October 12, 2006NCSX Field Period Assembly Peer Review M. Viola 8 “SAFELY SAFELY SAFELY” Documentation and Integrated Safety Management (ISM) Work Plans –Manufacturing Facility Operation Plan (MFOP) covers overall facility conduct using ISM as its basis. –Activities Certification Committee (ACC) independently reviews each station setup, operations, and plans before station is activated.

9. NCSX October 12, 2006NCSX Field Period Assembly Peer Review M. Viola 9 FPA Process Definitions FPA Manufacturing, Inspection, Test, Quality Assurance Plan (MIT/QA) –Input (Station specific): Dimensional Control Plan FPA Assembly Sequence Plan FPA Specification and Assembly Drawings –MIT/QA provides basis for individual procedures to perform tasks then revised to include developed improvements.

10. NCSX October 12, 2006NCSX Field Period Assembly Peer Review M. Viola 10 FPA Roll up Schedule

11. NCSX October 12, 2006NCSX Field Period Assembly Peer Review M. Viola 11 FPA Manpower Loading Ramp up to full complement beginning FY 08

12. NCSX October 12, 2006NCSX Field Period Assembly Peer Review M. Viola 12 FPA Metrology Utilization Station 1 and Station 2 FP #1 Station 2 and Station 3 FP #1 and Tooling checks Station 1 FP #3 and Station 2 FP #2 & 3 Station 4 FP #1 & 2 Station 5 FP #1

13. NCSX October 12, 2006NCSX Field Period Assembly Peer Review M. Viola 13 FPA Station 1 Activity has begun - Metrology VVSA1_MTM_FINAL_NUMBERSVVSA1_PPPL_BEST_FIT Very good agreement.

14. NCSX October 12, 2006NCSX Field Period Assembly Peer Review M. Viola 14 FPA Metrology VVSA2_MTM_FINAL_NUMBERSVVSA2_PPPL_BEST_FIT Metrology is serving appropriate needs.

15. NCSX October 12, 2006NCSX Field Period Assembly Peer Review M. Viola 15 FPA Station 1 Active Station 1 Laser Tracker setup – Diagnostic loops & cooling studs locations Port prefit – weld preparation check

16. NCSX October 12, 2006NCSX Field Period Assembly Peer Review M. Viola 16 FPA Summary To Conclude –Our best technicians are assigned to the FPA tasks to mitigate risk. –Some assembly operations are still somewhat conceptual and will be tested out prior to actual work is performed. –Reasonable time is allocated to perform FPA including proof of principle. Open Issues –Some activities are still quite conceptual –Metrology needs augmentation –Datum transferability and tolerance buildup I invite the review team to offer their concerns and provide advice.