NCSX Weekly Update of 12/15/05

1. Modular Coil fabrication (PPPL)

C-1 Coil

• Winding of side A was completed.
• The part was turned around, the lower leads for side B were set into position, and winding of side B started. As of Tuesday afternoon, one turn was installed on Side B.
• We expect to finish the conductor installation before the holidays.
• We expect to complete the C1 coil by 2/28, or 29 days ahead of schedule for the Level II milestone scheduled for March.
  

2. MCWF procurement (Energy Industries of Ohio)

Machining operations (Major Tool and Machine):

• The C-2 winding form completed final inspection operations. After review of the inspection data by EIO and project staff, it was released for shipment on Dec. 14. It is expected to arrive at PPPL on Friday, 12/16.  The quality of the part is good, and while some non-critical non-conformances were accepted as was the case for C-1, it is a significant improvement over C1.
  

• The C-3 casting is nearly finished with 3-axis operations on the 40-ft. Mitsu, and is expected to move to the U5 on Dec. 15 or 16.  During a meeting with NCSX staff at Major Tool on Dec. 14, Major Tool forecast delivery of C-3 on 1/28/06.
  

• The C-4 completed rough machining on the Lucas-40T machine.  It will move to the Mitsu-40 as soon as the C-3 comes off. Delivery is forecast for 3/10/06.
  

• The C-5 is in rough machining operations on the Lucas-40T.
  

• The A-1 casting is at Major Tool.
  

Foundry operations (MetalTek International):

• The A-2 is completing its weld repairs. It has passed LP inspection, and is expected to ship to MQS for final radiographic inspection this weekend.
  

• The A-3 is undergoing weld repairs.
  

• The B-1 casting had a dimensional scan by 3D ScanCo on Dec. 5-6. Following review of the results, it was to be sent for radiographic testing.
  

• The C-6 was heat treated and the gates and risers are being removed.
  

• The A mold is being set up in preparation for pouring the A-4 next week.
  

3. VVSA procurement (Major Tool and Machine)

• Welding of ports into the first 120-degree segment was completed. Installation of bosses for the support hangers and polishing of the interior are in progress.
  

• The second 120-degree segment is in the queue for the milling machine, behind another job.
  

• Fabrication of the fifth and sixth 60-degree half-segments continues.
  

• Fabrication of the first spacer and the large ports for segments 2 and 3 continues.
  

• During a meeting with NCSX staff at Major Tool on Dec. 14, Major Tool provided updated forecasts for the delivery of the 3 VVSA segments:  3/27/06, 5/15/06, and 6/16/06.  The schedule has been analyzed in greater detail, based on the schedule performance and experience gained on VVSA#1 so far. While the delivery dates are delayed relative to the forecasts as of 11/1/05, the final sector delivery forecast date is 2.5 months ahead of schedule for the Level II milestone scheduled for September.
  

Hutch Neilson