From: Hutch Neilson [hneilson@pppl.gov]
Sent: Monday, May 03, 2004 9:35 PM
To: Hutch Neilson; Phil Heitzenroeder; Mike Zarnstorff; Wayne T. Reiersen; Bob Simmons; Larry Dudek; Ronald L. Strykowsky; Brad Nelson; John Schmidt; Jim Lyon; Pamela Hampton; James H. Chrzanowski
Subject: Summary of NCSX SIT Meeting of 5/3/04
 Summary of NCSX System Integration Team (SIT) Meeting of Monday, May 3, 2004

1.   Critical FDR issues
      Update on critical issues identified at the April 26 SIT meeting. Corrections or fine-tuning of assessments requested.

• Modular coils structural performance:  Major progress last week:  tension data for the potted conductor were obtained; conductor performed well in the first cyclic fatigue test, and there were first analytical results from the model where the winding pack moves with respect to the structure.  There are still gaps in the materials properties for the cable conductor. There is some debate as to whether the correct strain range is being used in the conductor fatigue tests.  The analysis confirmed expectations that the MCWF “wings” need extra support and a design solution is being drawn up.  Assessment: margins are not everywhere as wide as we would like, properties data is not as complete as we would like, but we have enough to demonstrate that the design works at the FDR. Expect a successful FDR, but some chits to complete the materials testing and some analysis tasks
• Vacuum vessel shell deflections:  Some ideas were examined last week for reducing the calculated 1/4-inch deflections in the VV. The largest deflections are at the end of a port.  A local “patch” stiffener did not help much. Local ribs introduce fabrication risks, deemed unwise this close to the FDR.  Lashing the ports together is an idea but there is no time to evaluate it.  The deflection of the ports does not appear to be a real problem so it was decided to simply allow it to flex.  Assessment: vacuum vessel in good shape for FDR.
• Modular coil cooling concept:  A position and plan was adopted by the SIT:
  
  • The baseline winding pack design works but there are concerns about its fabrication cost and schedule, mainly having to do with the complexity of fabricating and assembling the cladding and chill plates. This is recognized by the project as a risk and needs a mitigation plan.
  • The requirements for the FDR are satisfied:  a modular coil design that works, including an MCWF specification that is ready to release for fabrication.  Mitigating the winding cost and schedule risks could affect the MC design, but  not the MCWF specifications that will be issued to the vendors for fabrication.
  • We will be prepared to discuss the risk mitigation plans for the windings at the FDR to the extent necessary: manufacturing development and demonstration on the twisted racetrack and full-scale prototype coils. We will present the minimum on this topic, but be prepared to go deeper if called upon.  We will make the point that the readiness to proceed with MCWF fabrication is not impacted, and that the comprehensive MC FDR is a still a few months away.
  • The manufacturing development plan needs to be updated to be sure it is adequately addressing the risks and technical issues of concern. Most of the effort should go into developing the baseline design. In particular, we should start fabricating chill plates ASAP. It may be prudent to devote a portion of the effort to developing an alternate cooling design, and perhaps demonstrate it on one side of the twisted racetrack.  Action: Jim Chrzanowski to propose an updated manufacturing development plan addressing the issues and risks.
  • At the Lehman review we will address risks in all work packages, what is being done about them, and their status at the time.
    

2.  FDR Preparations

• Drawings:  Brad stated that staff has been increased  to expedite promotion of drawings to final design release level for the FDR. It is expected that all MCWF and VVSA drawings will be promoted to final design release at the PDR, but other drawings may still be in process. It is thought that this will be satisfactory,
• Documents:  Good progress over the weekend: Drafts of the MCWF and VVSA design descriptions are in review. The MC and VV System Requirements Documents are in review.  MCWF and VVSA product specifications and SOWs already issued to suppliers will be available for the reviewers, possibly with updates.  Prompt turnaround on document reviews was requested. Documents will be posted on May 10.
  

3.  Preparations for IPR, June 8-9  (Neilson)

• The charge, agenda, dry run plans, and speaker guidance have been issued.
• John Schmidt will follow up on documentation other than what is already being prepared for the FDR.
  

4.  Procurement and Project Control

• April job status meeting is scheduled for Thursday morning, May 6.
• Strykowsky and Neilson will meet with procurement on May 4 to address current NCSX and QPS procurement issues needing special attention.  Action: Hutch research recent metrology procurement history with Raftopoulos.
  

5.  PAC-7 Meeting
    The following was discussed regarding the next PAC meeting:

• Week of July 12 appears to be the preferred window for PAC-7. Confirm with Director’s Office and PAC chair before finalizing the date.  Decide by Tuesday COB so it can be announced at NCSX/DOE meeting on Wednesday, May 5. Action: Mike
• Announce meeting to members and get feedback on their attendance. Make only minimum necessary changes in membership at this time.  Action: Mike review membership and issue announcement by COB Wednesday.
• The basic charge for PAC-7 should be:
  
  1. Advise on the research plans for the first 3 years of operation.
  2. Advise on the research preparations planned between now and first plasma.
     
• Update draft charge per discussion and get Rob to approve. Action: Mike.
• Agenda ideas (not exhaustive):
  
  • Update on NCSX project design and plans since PAC-6 and implications for research program (Hutch)
  • ARIES-CS progress and implications for research program (Jim)
  • Experimental results from W7-AS and elsewhere and implications etc. (Mike)
  • Research plan for first 3 years of operation.
  • Research preparation plans from now to first plasma.
    

6.  Next SIT Meeting:  Monday, May 17 at 11:00 a.m. EDT.  The current plan is for no SIT meeting on May 10.

Summary by:
Hutch Neilson