Anthony Indelicato DOE-Princeton Site Office October 2013 Construction Progress Review for the NSTX Upgrade Project Construction Progress Review for the NSTX Upgrade Project 1

Increase toroidal field: 0.5T > 1.0T Increase plasma current:1 MA > 2 MA Increase pulse length:1.0 s > 5 sIncrease NB heating: 5-7MW > 10-14MW New Center Stack Inner TF bundle, TF joint, OH & inner PF coils Upgraded TF coil support structure Existing outer TF coils (2 new, 2 refurbished flag joints) w/ reinstated water cooling Exst’g outer PF coils – 6 total New PF coil support structure Reinforce umbrella structure Also…modify coil power system, protection system & ancillary support systems What’s the proposed workscope? 2

Add 2 nd Beamline Decon, recondition and install Install 3 HVEs Relocate from TC basement New NB port New NB armor Modify Vacuum Vessel New Vacuum Pump Duct (below) Also…modify existing power system and ancillary support systems Workscope… continued 3

TPC=$94.3M Today CD-0 CD-1 CD-2 CD-3 CD-4 Feb 09 Sep 15 Dec 11 Dec 10 Apr 10 FY09FY10FY11FY12FY13FY14FY15 $5.2$9.0$9.9$20.5$22.8$23.7$3.2 stdadv CD-3 Overdrive Budget odometer How’s spending? $22.6M available EF 1/4 1/2 3/4 10 months of schedule contingency 4 $63.4M spent $8.3M

How’s the performance so far? SPI = 0.97 & CPI = % complete Contingency = 28% of ‘to go’ costs (variances zeroed ) Budget at completion = $85.6M Estimate at completion = $87.6M Level 2 milestones:  Two level 2 milestones completed since last review  Ahead = on time to slightly late anticipated 5  All scope remains as planned.  TPC remains ‘on-target’.  CD-4 date remains ‘on-target’ but a cost issue would exist.  Concern: Rate of Contingency Usage/Schedule How’s the baseline?

 Gradual drawdown indicates that over-cost trend will likely continue…due to estimate uncertainty.  Drawdown not a function of the risk registry items…but $4M of specific risk items do remain.  6 months acceleration gained from old CS failure is gone.  2 of 12 months of planned schedule contingency has been used. Take away: Project is currently in OK shape…but much of the padding has been used up. Need to push schedule…further schedule dilation has increasing concern. CD-4 date of Sep 15 can not be achieved before running out of funds.

FPD Analysis  PPPL developed detailed forensics of where contingency was used and what were the underlying causes  Center Stack construction efforts account for 53% of contingency usage to date, many reasons (vendor deliveries, technology problems, etc.)  Center Stack construction efforts still critical path, most future activities are series activities, schedule slippage still a risk  Project Manager brief covers the details of where contingency was used, what efforts the Lab has taken to mitigate schedule risks going forward. Further detail in break-out sessions. 7 The Project has realized significant cost/schedule contingency usage in completion of the Center Stack work-scope; at least eight months remaining in these efforts. Quality has been excellent.

Transition to Operations Progress? 8 Operational Readiness Assessment Planned The ORA will cover all NSTX-U systems: project upgrades, research upgrades and restart of existing systems that have been dormant. Pete Kelly (BHSO), an experience DOE Fac Rep, to lead the team Focus on safety of personnel and equipment PPPL Activity Certification (ACC) Process being used to return NSTX-U to operations – Princeton Site Office direct participation Full presentation on the plan by Al VonHalle

Construction Progress? 9 Overall Progress is satisfactory... All construction efforts are well underway Safety performance has been excellent to date Critical Path... Remains through the construction of new Center Stack assembly Center Stack Fabrication facility has been reconfigured for Ohmic Heating (OH) coil winding Five of six high risk Vacuum Pressure Impregnation (VPI) efforts completed satisfactory (4 TF inner quadrant, full TF; only OH VPI remains) Management... EVMS system in place and fully functioning (Annual Internal Surveillance complete) Construction proceeding well in NSTX Test Cell All previous Review Recommendations addressed Project is getting the resources it needs

 Project needs to reduce its contingency usage rate going forward by driving schedule performance.  Good communication between PPPL and Site Office.  Estimates are updated regularly.  Funding and human resources are in place.  Elements of DOE Order 413.3B are met.  Technical quality remains high… This is very important. 10 Conclusion

Back-up Slides 11

Office of Science Princeton Site Office Charge Questions 1.Construction Efforts: Are construction efforts being executed safely? Does the project have adequate resources and the appropriate skills mix to execute the project per the plan? 2.Baseline Cost and Schedule: Are the current project cost and schedule projections consistent with the approved baseline cost and schedule? Is the contingency remaining adequate for the risks that remain? 3.Management: Evaluate the management structure as to its adequacy to deliver the scope within budget and schedule. Are risks being actively managed? Has the project responded satisfactorily to the recommendations from the previous project reviews? 4.Transition to Operations: Is the Project appropriately aligned for completion of construction efforts and transitioning NSTX-U for CD-4 approval? 12

13 Project Status K. Chao, DOE/SC*/ SC-2 PROJECT STATUS Project TypeMIE CD-1Planned: Dec 09Actual: Apr 10 CD-2Planned: Dec 10Actual: Jan 11 CD-3Baseline: Jan 12Actual: Dec 11 CD-4Baseline: Sep 15Forecast: Nov 14 TPC Percent CompletePlanned: 74.3%Actual: 72% TPC Cost to Date $63.4M TPC Committed to Date $65.1M TPC $94.3M TEC $83.5M Contingency Cost (w/Mgmt Reserve) $ 8.3M 28% to go Contingency Schedule on CD-4b 10 months 77% to go CPI Cumulative 0.98 SPI Cumulative 0.97