From: Hutch Neilson
Sent: Monday, April 09, 2007 9:48 PM
To: Bradley E. Nelson; Hutch Neilson; Jim Lyon; Lawrence E. Dudek; Mike Williams; Michael C. Zarnstorff; Phil Heitzenroeder; Wayne T. Reiersen; Ronald L. Strykowsky; Mike Cole
Subject: Summary of NCSX SIT Meeting of 04/09/07
Summary of NCSX System Integration Team (SIT) Meeting of Monday, April 9, 2007

1. Readiness start MC assembly in May: Schedule Risks

• We reviewed the schedule risks for starting MC assembly.  The schedule issued at last week’s SIT forecast that we would start at the end of July.  This would meet our Level II milestone if achieved, but has zero schedule float so risk of failure is high.  Moreover it does not satisfy our management goal to start in May, which is important for underpinning our new ETC (due in June) and demonstrating convincing progress at the July Lehman review.  We need to take measures to recover this schedule slippage, by working on the two main critical path activities
  
  • Modular coil prep
  • Inboard shim
    
• Modular coil prep  Larry
  
  • Drawings for the additional flange holes have been issued. The C2 coil has been taken to the RESA building for machining and grinding operations to start.
  • Overtime is an option for managing schedule risks, but will proceed deliberately at first to be sure process is worked out.
    
• Inboard shim. Wayne
  
  • Stresses in the fillet weld (shear puck design) have been analyzed.  Need to check applied loads and allowables. Mike C.
  • Weld test will be performed to check distortion and determine how good a fit-up can be obtained around the shear puck.  Parts for the test have been fabricated and the test will be carried out this week. A significant risk is seen that the weld distortion will be too large to obtain satisfactory fit-up.  Larry.
  • New alumina friction tests will be performed with the mating steel surface finish more representative of the actual modular coil flanges. (Friction shim design) Earlier tests may have had too smooth a finish.  Gettelfinger.
  • It was observed that the shear puck design has high schedule risks because of the need for development trials, the risk that those trials will have unsatisfactory outcomes or require multiple iterations, and demanding assembly requirements.  The friction shim design (“Plan B” introduced by Wayne over the weekend) appears to offer reduced schedule risks and therefore may be more attractive.  Fit-up issue should be resolved via A-A fit-up trials.
  • We need to converge this week on a design that has acceptable schedule risks.  Hutch
    
• A-A fitup trials  Larry
  
  • After some delays, trials should proceed tomorrow. Crane operators are booked.
  • This test expected to confirm that constant-thickness shims are acceptable, and establish the range and gradation of shim thicknesses.
    

2.  ETC Update Issues

• Status summary was issued by Ron. A few more reviews  were conducted last week, including WBS 18 and 7.  Estimates for about 2/3 of the work have been submitted as of last week, and are in various stages of review.
• Additional submissions and reviews are planned for this week.  Ron
  

3.  New FY09-11 budget guidance from DOE

• We will focus primarily on FY-09 for our initial response due April 18. Beyond that depends on the outcome of our ETC activity.
  

Summary by:
Hutch Neilson