NCSX Field Period Assembly FPA Operations Cost and

NCSX Field Period Assembly (FPA) Operations, Cost and schedule, staffing, and metrology utilization Mike Viola Field Period Assembly Manager October 12, 2006 NCSX FPA Peer Review October 11 -12, 2006 PPPL NCSX Field Period Assembly Peer Review

NCSX 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 crack crew – Prove principles to mitigate risk!! And then Finalize Procedures. – Train secondary support crew to perform bulk of work • Tooling – Crack Crew perform dry run of tooling • Metrology (Mike Duco with Steve Raftopoulos Support) – Leica Laser: 0. 0005” accuracy – Romer arm: 0. 005 -0. 010” accuracy (2 other Romer Arms available) October 12, 2006 NCSX Field Period Assembly Peer Review 2

FPA Metrology Issues NCSX • Available Equipment in house – Leica Laser: 0. 0005” accuracy – Romer arm: 0. 005 -0. 010” accuracy (2 other Romer Arms available) • Reliability – Hardware/Software is ~80% reliable. – Have days of crashing and unpredictable operations. • Combination of Windows, Verisurf, Master. CAM, Leica Power Inspect, ROMER… • Reach/Accessibility – Coils are easy to reach but need high accuracy – VVSA is hard to reach but localized activities can use lower accuracy equipment. • 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 support group being considered within Fabrication Division. October 12, 2006 NCSX Field Period Assembly Peer Review 3

NCSX “SAFELY” • Documentation and ISM Work Plans – Manufacturing Facility Operation Plan (MFOP) covers overall facility conduct using ISM as its basis. – Activities Control Committee (ACC) independently reviews each station setup, operations, and plans before station is activated. October 12, 2006 NCSX Field Period Assembly Peer Review 4

FPA Process Definitions NCSX • FPA Manufacturing, Inspection, Test, Quality Assurance Plan (MIT/QA) – Input: • Dimensional Control Plan • FPA Assembly Sequence Plan • FPA Specification and Assembly Drawings – Output: • Individual procedures to perform tasks then revised to include developed improvements. October 12, 2006 NCSX Field Period Assembly Peer Review 5

NCSX FPA Cost and Schedule • FPA Cost and Schedule – Station 1 $744 K 6/30/06 – 1/17/08 – Station 2 $336 K 10/5/06 – 1/31/08 – Station 3 $300 K 7/31/07 – 4/7/08 – Station 4 $214 K 10/4/07 – 6/3/08 – Station 5 $647 K 9/14/07 – 7/11/08 • Total FPA Cost $2. 241 M October 12, 2006 NCSX Field Period Assembly Peer Review 6

FPA Metrology NCSX VVSA 1_MTM_FINAL_NUMBERS VVSA 1_PPPL_BEST_FIT Very good agreement. October 12, 2006 NCSX Field Period Assembly Peer Review 7

FPA Metrology NCSX VVSA 2_MTM_FINAL_NUMBERS VVSA 2_PPPL_BEST_FIT Metrology is serving appropriate needs. October 12, 2006 NCSX Field Period Assembly Peer Review 8

FPA Station 1 Active NCSX Port prefit Station 1 setup October 12, 2006 NCSX Field Period Assembly Peer Review 9

FPA Schedule NCSX October 12, 2006 NCSX Field Period Assembly Peer Review 10

FPA Station 1 NCSX • Station 1 Schedule (VVSA) – All three VVSA’s received by 9/30/06 – All work performed on station 1 fixture (2 “rotisserie” stations) with Leica & 2 men augmented with 3 technicians when needed – Install VVSA external components (Diagnostic Coils, Cooling Tubes, Thermocouples) Laser or Romer • • October 12, 2006 Tooling Checks and Metrology Training 5/15/06 – FP#1 6/30/06 – 5/3/07 FP#2 (VVSA #3) 9/30/06 – 8/31/07 FP#3 (VVSA #2) 8/1/06 – 1/17/08 NCSX Field Period Assembly Peer Review 11

FPA Station 2 NCSX • Station 2 Schedule (3 Coil preassembly) – Perform crude prefit – any gross interferences & Tooling checkout 10/30/06 – 6/19/07 – Perform prefit – shim and alignment – Align and Assembly Laser Tracker • • October 12, 2006 Tooling checks 10/5/06 – 3/4/07 FP#1 3/5/07 – 9/6/07 FP#2 9/7/07 – 11/15/07 FP#3 11/16/07 – 1/31/08 NCSX Field Period Assembly Peer Review 12

FPA Station 3 NCSX • Station 3 Schedule (Coils onto VVSA) (Laser Tracker or Internal GPS) – Align and Assembly 2 coil three packs • • Tooling checks 7/31/07 – 8/27/07 FP#1 9/7/07– 10/4/07 FP#2 11/16/07 – 12/10/07 FP#3 2/1/08 – 2/21/08 – Align and Assembly Coils onto VVSA • • October 12, 2006 Tooling checks 7/31/07 – 8/27/07 FP#1 8/28/07– 11/7/07 FP#2 11/8/07 – 1/16/08 FP#3 1/17/08 – 4/7/08 NCSX Field Period Assembly Peer Review 13

FPA Station 4 NCSX • Station 4 Schedule (TF Coils) Laser • Align and Assembly TF Coils • • October 12, 2006 Tooling checks 10/4/07 – 11/14/07 FP#1 11/15/07 – 1/15/08 FP#2 1/16/08 – 2/19/08 FP#3 2/20/08 – 6/3/08 NCSX Field Period Assembly Peer Review 14

FPA Station 5 NCSX • Station 5 Final Assembly Schedule in NCSX Test Cell to enhance efficiency and reduce HP overhead (Weld ports, Install TF Coils, Leak Check, Final metrology) – Align and Assembly Laser Tracker and Laser on Target for port welding • • October 12, 2006 Tooling checks 9/14/07 – 10/4/07 FP#1 11/8/07 – 4/4/08 FP#2 1/17/08 – 5/20/08 FP#3 4/11/08 – 7/11/08 NCSX Field Period Assembly Peer Review 15

FPA Summary NCSX • To Conclude – Our best technicians are assigned to these FPA tasks. – 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 – – I invite the review team to offer their concerns or provide advice. Some activities are still quite conceptual Datum transferability and tolerance buildup Very limited machine serviceability October 12, 2006 NCSX Field Period Assembly Peer Review 16

And if all else fails NCSX We found this guy October 12, 2006 NCSX Field Period Assembly Peer Review 17