Summary of NCSX System Integration Team (SIT) Meeting of Monday, November 14, 2005

1.    Safety

• NCSX had a recordable injury case 2 weeks ago. A worker performing test cell prep work (WBS 7) cut his thumb requiring several stitches. Improper use of a power drill was the cause. The individual is now OK and it was not a DART case.  Larry reported that the incident is being discussed with NCSX manufacturing staff, with reminders to work safely and use tools properly.
• NCSX manufacturing activities are under intense cost and schedule pressure, working extended hours and extra shifts. These circumstances can increase the risk of safety violations or incidents.  The priority of safety over other goals was re-emphasized.
• The next PPPL Hazard Awareness Training will be conducted via NetMeeting with ORNL on Nov. 16. Action: Wayne and Brad coordinate teleconference arrangements. Hutch obtain the slides from ES&H and transmit to ORNL.
  

2.    Risks

• MC parts availability. (Larry)
  
  • Chill plates for C1 are at risk due to lack of drawings. Brad stated that signed-off drawings would be issued for fabrication this day (11/14). Brad to follow up.
  • Larry stated he had no way of knowing what drawings he is missing. Wayne stated that the Type C Bill of Materials should be used to identify needed drawings and parts and their need dates.  Action: Wayne and Larry review available drawings and parts procurement status versus the Bill of Materials.
  • Larry stated that he has difficulty getting drawings, dxf files, etc. to vendors. The solution is to post the data on either the manufacturing web or the FTP server. Marianne Tyrrell was identified to help with manufacturing web postings, Tom Brown for the FTP server.
  • Cladding bids have come back too high by a factor of 3. Larry is working with vendors to investigate laser cutting as a cheaper solution. Two bids for fabrication by laser cutting are anticipated.
  • Avantek and Precise Tool, sister companies in Rochester, NY, were mentioned as potential sources for NCSX fabrication jobs including machining.
    
• Cladding conformance issue. (Wayne)
  
  • Wayne summarized the issue of poor cladding conformance, which led to a decision last week to establish quantitative acceptance criteria for cladding conformance and re-work much of the C1 cladding. The schedule setback is approximately two weeks.
  • Weekend work, including the Thanksgiving holiday weekend, is authorized to ensure that we accomplish the missed FY-05 Joule target (complete the conductor installation) before the end of the year.
  • Corrective measures to prevent recurrence include:  adding a quantitative criteria for cladding conformance to the procedure, establishing specifications on the application of cladding adhesive to ensure a thinner film, training the staff to ensure uniformity of process.
  • Alternative adhesives are being looked at but at this time we are using the same product that was adopted on the TRC.
    
• MCWF Delivery (Phil)
  
  • Phil visited Major Tool last week with Jim C. and reported that the C-2 quality is significantly better than C-1. Requested changes have been incorporated. However, C-2 delivery is delayed. Phil expects delivery by December 12.
    
• Modular coil design issues (Brad)
  
  • Cladding and chill plate design is taking longer than expected. Daily meetings with the design team are planned to keep the work on track and identify/resolve issues promptly.
  • Type A&B lead block designs will be developed in parallel for efficiency.
  • Brad proposed the following priority order:  1)Type C chill plates, 2)Type A cladding & lead blocks, 3)Type C Assembly drawings. Guidance was requested.  Action: Wayne provide guidance on MC design priorities.
    
• VV design and procurement issues (Brad)
  
  • Cryostat interface flange, H/C manifolds and header, heater tapes.  I believe the flange and manifolds were in the procurement process. I did not hear anything about the heater tapes. Larry to check status.
  • Lateral supports & personnel access ports: FDR scheduled for 11/17.
  • H/C tubes: prototype ordered for testing was not received. A new plan is needed. Brad
  • Vertical supports are being fabricated, per Larry.  Titanium rod ends will be procured; price may be higher than expected.
  • Station 1 assembly fixture fabrication is progressing well at PPPL, about 75% complete.
    
• Fine-tuning of FY-06 schedule to align with work plans (Wayne, Ron)
  
  • TF: iteration on wedge castings and investigation of ASIPP option needs to be budgeted and scheduled.
  • Diagnostics: re-schedule later in time.
  • MC analysis: plan for completing and documenting needs to be developed.
  • Possible role of magnetic measurements in field period assembly needs to be settled. Peer review scheduled for Friday Nov. 18 at 2:30.
  • Additional FY-06 work to be scheduled if an additional $1.7M is provided as expected: PF/CS design, cryostat/base design, coil services design (ORNL), power cabling installation, test cell prep, VV personnel access port procurement, power systems design, contingency. (Ron)
    

3.    Management

• October job status meeting was held last week.
• Lehman review recommendation responses will be posted. Please review assignments and follow up.
  

4.  Next SIT Meeting: Nov. 21.

Summary by:
Hutch Neilson