From: Hutch Neilson
Sent: Wednesday, August 17, 2005 4:15 PM
To: Barry Sullivan; Gregory Pitonak; Jeffrey Makiel; Sam Barish; Gene Nardella
Cc: Michael E. Viola; Phil Heitzenroeder; Wayne T. Reiersen; Richard J. Hawryluk; Jim Lyon; Pamela Hampton
Subject: 20050817 NCSX procurement status
Folks,  I have jury duty Thursday and will be on vacation Friday and all next week.  I propose we forego this week’s teleconference.  Please call me this afternoon if there are any questions, or call Phil thereafter.  I will ask Phil to handle next week’s report.   hn

NCSX Procurement Update of 8/17/05

1. MCWF procurement

• Machining of the C-1 casting (MCWF#1) continues at Major Tool. They completed the second of four set-ups on the 5-axis machining. They decided to move to the fourth set-up next, and the third after that.
  

• The C-2 casting (MCWF#2) continues making good progress progress in machining at Major Tool.  
  

• Processing of the A-1 casting (MCWF#3) continues at MetalTek.  It has undergone a round of weld upgrades, but subsequent radiographic testing (RT) indicated several areas still in need of weld repair. The repairs are being done this week. It may need to be sent out again for RT after the repairs, but that has not yet been decided.
  

• EIO continues its investigation into the cause of the thin-section wall on the A-1 casting.  The CAD model and the laser scan measurements of the pattern were reviewed and found to be OK. A partial re-scan of the pattern is under consideration and the A-1 casting itself will be re-measured before shipment to Major Tool.  Note that PPPL’s analysis has confirmed that the A-1 can be accepted as is with no impact on performance. The analysis supporting this disposition was presented at a special meeting the NCSX IPT on August 8.
  

• The C-3 (MCWF#4) casting has undergone weld upgrades and was sent out for RT this week.
  

• The C-4 (MCWF#5) casting is undergoing its initial RT.
  

• The C-5 (MCWF#6) casting was poured on August 8.
  

• Fabrication and assembly of the Type B pattern (the third and last) is proceeding very well. Forecast delivery date is 9/15.
  

2. VVSA procurement

• The first 60-degree sector is completed.  PPPL analyzed Major Tool’s in-process dimensional inspection data, which showed some out-of-tolerance areas. PPPL determined that these areas are not critical to the clearance for modular coil installation
  

• Welding of the second 60-degree sector was completed. This sector appears to be fully within tolerance.
  

• This week, the first two 60-degree sectors are being mounted on the fixtures in preparation for joining into a 120-degree sector.  Additional measurement and processing steps are being taken for this first full sector fabrication.
  

• All of the 6, 8, and 10-in. dia. round ports have arrived at Major Tool.  The smaller round ports and the larger custom-shape ports are in process.
  

Hutch Neilson