From: Hutch Neilson
Sent: Wednesday, August 09, 2006
10:18 PM
To: Jeffrey Makiel; Barry Sullivan; Ronald L. Strykowsky; Jim
Lyon
Cc: James H. Chrzanowski; Michael E. Viola; Pamela Hampton; Phil
Heitzenroeder; Wayne T. Reiersen; Richard J. Hawryluk; Sam Barish; Robert J.
Goldston; Gene Nardella; Bradley E. Nelson; Michael R. Kalish; Gregory
Pitonak
Subject: 20060809 NCSX weekly update
There will be no telecon on Thursday due to the all-day
meeting with EIO. How about Friday at 9:30? Hutch
NCSX Weekly
Update of 08/09/06
1. Modular Coil fabrication
(PPPL)
MC Fabrication summary status:
3 coils through VPI
to date
3 coils in winding form prep and winding operations
2 in
the queue
C-1 Coil
- Lead area repairs
completed, followed by successful meggar test.
C-2
Coil
- In queue for post-VPI
cleanup.
C-3 Coil
- In queue for post-VPI
cleanup
C-4 Coil
- Bag mold and epoxy shell
completed.
- Scheduled to move to the
autoclave this week.
- VPI prep completion
milestone was July 20. Currently 14 working days behind
schedule.
C-5 Coil
- Conductor winding is
complete, winding pack dimensional adjustments are in progress.
- VPI prep completion
milestone is August 16. Currently 8 working days behind
schedule.
A-1 Coil
- Cladding installation
complete
- VPI prep completion
milestone is October 2. Currently 9 working days behind
schedule.
A-2 Coil
- In the queue for winding
operations.
- VPI prep completion
milestone is November 10. Currently on
schedule.
A-3 Coil
- In the queue for winding
operations.
Summary comment: As expected, critical-path winding
operations continue to experience schedule slippages throughout the summer
months, and are currently 8-14 working days behind. The two main causes,
and how they are being addressed, are as follows:
- Understaffing: four new
technicians have been hired and are joining the winding crew as they complete
new-employee training. It will bring the total crew size to 18 technicians.
Vacations also are having an impact which will continue at some level through
September, although we believe the peak is behind us for this year.
- Facility backups: an
additional winding station will be procured. When installed (by Dec. 1)
this will provide greater operational flexibility and should improve flow of
coils through the facility.
2. MCWF procurement (Energy Industries of
Ohio)
MCWF summary status:
All 18 castings
have completed foundry operations
5 in active machining operations
5 in
the machining queue
8 shipped to PPPL
Machining operations (Major Tool
and Machine):
B-1
- The B-1 is in 3-axis
operations on the Mitsu-40.
- The project’s delivery
milestone is September 20.
B-2
- The B-2 is being machined
on the Mitsu-30. The poloidal break has been cut.
- The project’s delivery
milestone is November 29 for B2.
A-4
- The A-4 has completed Lucas
40T operations and is in the queue for the Mitsu-40.
- The project’s delivery
milestone is October 24 for A-4.
B-3 and
B-4
- The B-3 and B-4 are
alternating in rough machining operations on the Lucas 40T.
- The project’s delivery
milestone is January 11 for B-3
- The project’s delivery
milestone is February 14 for B-4.
The expected delivery sequence for
the next few coils is A-3, B-1, B-2, A-4. All are on or ahead of
schedule.
A-5, A-6, B-5, B-6, and C-6
- The A-5, A-6, B-5, B-6, and
C-6 are in the queue for machining.
- Machining operations are
performed on the C-6 whenever time and resources
permit.
EIO and Major Tool personnel will visit PPPL for a
MCWF Contract Status Meeting on August 10.
3. VVSA procurement
(Major Tool and Machine)
- VVSA #3: Completed vacuum
testing, and now on the DSI for final machining of the end
flanges.
4. TF Assemblies procurement (Everson Tesla,
Incorporated)
- Tesla has signed a contract
with Österby (Sweden) to supply wedge castings, superseding previous tentative
arrangements with other suppliers. The NCSX project is pleased with this
decision because it reduces risks in a number of ways. Österby has relevant
experience, having supplied the modular coil castings for W7-X and performed
well. The material comfortably meets project requirements. The casting will be
supplied close to net shape, reducing the amount of machining required at
Tesla and the attendant risk of distortion.
- A detailed project schedule
was provided to PPPL. The new wedge casting plan eliminates a key schedule
uncertainty. The schedule meets project requirements.
- Some winding equipment
loaned by PPPL has arrived at ETI, with the balance due to arrive this week.
ETI personnel stated that the equipment loan will improve the manufacturing
process and reduce technical risks.
- ETI plans to build a clean
room similar to those in the NCSX manufacturing facility at PPPL. The
components are due this week.
- The winding mandrel and the
brazing head are being fabricated.
- Hutch Neilson joined Mike
Kalish on the weekly visit to ETI on August 9.
Hutch
Neilson