1. 12/19/2006Mike Viola1 December Lehman Review December 19, 2006 Mike Viola Field Period Assembly Manager NCSX Field Period Assembly + + =

2. 12/19/2006Mike Viola2 But First: NCSX Vacuum Vessel Fabrication Complete Major Tool and Machine – S005243F VVSA #1 was delivered May 9 during the last Lehman review Final VVSA was delivered September 21 All 3 VVSA’s are completed –All passed leak check –MTM measurements confirmed by PPPL with good agreement –Tolerances acceptable 1 2 3 MTM Scan PPPL Scan 3 VVSA’s located in the NCSX Manufacturing Facility – May 9 Completed

3. 12/19/2006Mike Viola3 FPA is Accomplished in Five Stages Station 1 - VV Prep Station 2 - MC Half Period Assembly Station 3 - MCHP installation over VV Period Station 4 - TF Half Period Assembly Station 5 - Final FP Assembly Station 6 - Machine Assembly

4. 12/19/2006Mike Viola4 “SAFELY SAFELY SAFELY” Documentation and Integrated Safety Management (ISM) Work Plans –Manufacturing Facility Operation Plan (MFOP) completed for overall facility conduct using ISM as its basis. –Job Hazards Analysis (JHA) developed for FPA activity Main hazard: components must be lifted by crane – many lifts will occur in several orientations. Lift procedures with individual lift data sheets are developed for each type of lift –Activities Certification Committee (ACC) independently reviews each station setup, operations, and plans before station is activated. Station 1 review complete and declared operational

5. 12/19/2006Mike Viola5 FPA Process Definitions FPA Manufacturing, Inspection, Test, Quality Assurance Plan (MIT/QA) Complete –Input (Station specific): Dimensional Control Plan (Art Brooks) FPA Assembly Sequence Plan (Tom Brown) FPA Specification and Assembly Drawings (Mike Cole) –MIT/QA Plan provides basis for individual procedures to perform tasks then revised to include developed improvements. –FPA station 1 procedure complete and active

6. 12/19/2006Mike Viola6 FPA Concerns and Risks An International FPA peer review workshop was held. –Prove principles to mitigate risk!! –Recommendation to focus on prototyping activities and assess metrology needs and capability. We are using each first article to assess and improve assembly techniques and finalize procedures. –More time is allocated for learning curve of first time activities. –Expert Work Crew and Support – Our most highly effective and ingenious technicians assigned to perform first time tasks. 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. –Expert crew also performs dry run of tooling –Augmented as needed by cryogenic operators and NB Technicians –Train secondary support crew to perform bulk of work

7. 12/19/2006Mike Viola7 FPA Metrology Systems engineering support group formed. Addresses metrology, interferences, tolerances, datums, etc. MetrologyCriteriaResolution Equipment accuracyLaser trackers can achieve 0.0015” Capability meets needs ReliabilityStartup issues due to various combinations of software and hardware Gaining understanding of interactions Repeatability and accuracy of measurements Datums need to be chosen appropriately Systems engineering investigating best location choices AccessibilityCoil must be accessible for measurements with laser tracker Systems engineering investigating best location choices

8. 12/19/2006Mike Viola8 FPA Activity and Risk Resolution – Station 1 Station 1 (Install vacuum vessel external components diagnostic coils, cooling tubes, thermocouples using Leica laser tracker) –All three VVSA’s received by 9/21/06 –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 Technique to hold heating tapes in place on vertical ports. Technique to connect cooling hoses to vertical risers

9. 12/19/2006Mike Viola9 Station 1 Activity has begun – Metrology all the way Much was learned from VVSA fabrication Laser tracker using Verisurf® Station 1 steps: Install VVSA in Station 1 Rotating Fixture First best fit Scan performed – confirmed MTM scans!! Mark Flux Loop Templates Mark Heating Coolant Stud Locations Shoot studs – vacuum vessel #1 complete Vertical Port Component Installation –Install heating cooling manifolds –Install 29 thermocouple mounting plates on port 12’s and vacuum vessel. –Install heater tapes –Install risers Install of Magnetic Flux Loop Install Thermocouples Install H/C lines Final Loop Routing and Measurement Perform Final baseline scan Schedule to complete #1 May 3 ‘07 #2 Aug 1 ‘07 #3 Jan 30 ‘08

10. 12/19/2006Mike Viola10 RISK MANAGEMENT – test port fit-up for welding Adjust weld prep now as needed while accessibility is good

11. 12/19/2006Mike Viola11 FPA Station 1 Activities Station 1 Laser Tracker setup – Diagnostic loops & cooling studs locations

12. 12/19/2006Mike Viola12 Station 2 (3 coil preassembly – align, shim, and assembly using Leica laser tracker) –Trials have begun: Prefit individual mating coils – 3 minor interferences were found, they are all understood and straightforwardly resolved in a few days. changed adjustable platform to use fixed wedge tooling fabricated for coil form machining – stronger and reduced cost –Remaining trials (useful for Station 3 also): Install and torque bolts – assess accessibility Develop shim technique Install shims and bolt bushings in vertical orientation Install studs for nose shim Install metal shims (machined or various thicknesses) Pillow shims FPA Activity and Risk Management – Station 2

13. 12/19/2006Mike Viola13 RISK MANAGEMENT – Perform mockup alignment test Learned that positioning and leveling is simpler than expected –Simple corner plates with dial indicators Confirmed / Discovered interferences (next slide)

14. 12/19/2006Mike Viola14 RISK MANAGEMENT – Coil to Coil Fitup Perform coil to coil trial fit as soon as possible without interfering with schedule: Confirmed known tight spots Discovered small issues – tube was easily repositioned down and out of the way

15. 12/19/2006Mike Viola15 FPA Activity and Risks – Station 3 Station 3 (install coils onto vacuum vessel using Leica laser tracker) –Align and assemble the coil three packs first then onto vacuum vessel –Trial with 25,000 lb. block has resolved main concern of installing coils onto vacuum vessel Technique developed to manipulate coils onto vacuum vessel –Trials are being developed at station 2

16. 12/19/2006Mike Viola16 FPA Activity and Risks – Station 4 & 5 in NCSX test cell Station 4 (install, align and assemble TF Coils using Leica laser tracker) –Awaiting PDR –Trials to be developed Station 5 (weld ports, install TF coils, leak check, final metrology) –final assembly in NCSX test cell to enhance efficiency and reduce HP coverage –Leak check moved to final assembly –Awaiting PDR –Trials to be developed

17. 12/19/2006Mike Viola17 FPA Manpower Loading Ramp up to full complement

18. 12/19/2006Mike Viola18 Current Status Learning curve for Station 1 is behind us. To keep in the schedule box for Station 2, we may resort to selective 2 shift operation. This will be flushed out over the next couple months.

19. 12/19/2006Mike Viola19 SUMMARY Field Period Assembly has begun. Risk management and learning curves have been focus. –We have spent time to examine critical areas up front on the first articles being fabricated. Potential interferences are being addressed prior to assembly tasks are performed. –Reasonable time is allocated to perform FPA including proof of principles. –Our best technicians are assigned to the FPA tasks to identify potential problems and develop the most efficient assembly techniques. –Risks are being actively managed – communication and feedback is excellent. Required tolerances can be met. Open Issues –Stations 4 and 5 are still somewhat conceptual but will be tested out prior to actual work is performed.