NCSX Vacuum Vessel FDR and Procurement Plan SOW

NCSX Vacuum Vessel FDR and Procurement Plan (SOW, QA, Cost & Schedule Update) Mike Viola, Paul Goranson, Tom Brown, Mike Cole, Phil Heitzenroeder, Frank Malinowski, Brad Nelson, and Larry Sutton for the NCSX Engineering Team NCSX Final Design Review May 19 -20, 2004 PPPL May 19 -20, 2004 NCSX Vacuum Vessel FDR 1

Outline NCSX § Review of the NCSX Vacuum Vessel. § Risks Mitigated through a successful PVVS program. § R&D and Vacuum Vessel Prototypes’ Status. § Cost & Schedule § Summary May 19 -20, 2004 NCSX Vacuum Vessel FDR 2

NCSX • • NCSX’s Vacuum Vessel Was Recognized as Unconventional Right from its Conception Highly shaped Formed of Inconel 625. Need for tight tolerances. Design has to accommodate assembly needs: – – May 19 -20, 2004 Vessel shape & size has to be compatible not only with plasma, but also with space needed to “slide” the modular coils over it. This also requires all ports except mid period ports to be welded in place after the coils are installed. NCSX Vacuum Vessel FDR 3

NCSX Consequently a Three-Phase Program Was Developed To Reduce Risk ü Phase I: Received inputs on the design, specification, cost and schedules in Complete limited studies during the Conceptual Design Phase. • Goal: to obtain industrial inputs on the VV design, its specification, and cost and schedule. ü Phase II: Two different vendors fabricate partial prototypes of a critical Complete region of the vessel called the Prototype Vacuum Vessel Segment (PVVS). (almost) • • • The forming, welding, machining, polishing, port removal and reattachment, and inspection processes were demonstrated and optimized. The prototype development and R&D Studies provided a solid understanding of the manufacture techniques and will reduce risk factors. Goal: to qualify suppliers for the production vacuum vessel and provide a basis for a fixed price. Ø Phase III: At the conclusion of the R&D phase, a fixed price contract will be awarded for the production vessel or the three Vacuum Vessel Subassemblies (VVSA). • May 19 -20, 2004 The two vendors that have been selected for the R&D phase will result in two qualified vendors for the production articles, and provide an extra incentive to keep production costs (and bids) low. NCSX Vacuum Vessel FDR 4

Manufacture NCSX • Dies are machined. • Panels are cold pressed. (Segmentation determined by Vendor. ) – Prototype consisted of a 20° sector which involved about 5 segments • Panels are heat treated • • • Measurements taken using CMM or gages Panels welded together on fixture Mirror every half period (60°) More measurements taken 60° segments married Ports welded on before cutting holes – permits leak check – minimizes distortion Main flanges attached Leak check entire vessel and port welds between thermal cycling Ports cut off to leave stubs – reinforces vessel – permits port alignment Holes bored Vessel and ports shipped May 19 -20, 2004 60 Degree Half-Period 6 Piece Segmentation Scheme NCSX Vacuum Vessel FDR 5

Each Team Developed Manufacturing / Inspection / Test / Quality Assurance (MIT / QA) Plans Which Clearly Document All Key Elements NCSX • A major investment was made as part of the Phase II Manufacturing / Prototype develop MIT / QA Plans to assure that we have a mutual, clear understanding of all the critical elements of manufacture: – They identify processes and materials and shows their integrated flow into end items. – They identify critical manufacturing operations, inspections, and tests. – Procedures & protocols for contamination control and cleanliness are included. • MIT / QA Plans were prepared for the VVSA as early deliverables of the Manufacturing / Prototype Development Subcontracts. – NCSX reviewed and commented on these plans. – They were then used to develop the budgetary cost estimates that were used for the PDR to assure that the costing included all essential steps. – Based on the commented MIT plans, the subcontractors developed MIT plans for their prototypes. – They were used to manufacture the prototype. – They will prepare an updated MIT / QA Plan for the VVSA after they receive the approved specification. • It will be updated to reflect what they learned during the prototype development. – During negotiations, this MIT / QA Plan will be approved and will become the basis of the manufacturing for the successful offeror. May 19 -20, 2004 NCSX Vacuum Vessel FDR 6

The MIT / QA Plans and Prototypes Are Excellent Investments NCSX Besides serving the multiple purposes described on the previous slide, they have been great “learning tools” for both NCSX and the Subcontractors. • • The Subcontractors gained a clear understanding of why the Specification and SOW were written the way they were; NCSX gained a clear, detailed understanding of how each team proposed to manufacture, inspect, and insure the quality of these critical components. – Very importantly, we have developed excellent working relationships with both teams through the development of these plans! • • Consequently, there has been excellent two-way communication that has been helpful in refining the designs, specifications, and statement of work. We will be able to get underway in the production phase much quicker than would otherwise be possible. – We believe this investment will more than pay for itself through reduced risks and higher product quality. May 19 -20, 2004 NCSX Vacuum Vessel FDR 7

R&D of Vacuum Vessel Prototypes is Nearly Complete NCSX Phase II Goals: • To produce a prototype VV sector. • To provide experience in manufacturing prototypical parts so firm fixed price proposals can be developed which do not have excessive contingency built in. – Prototype consisted of a 20° sector (chosen for good demonstration of shape forming) and a vacuum port assembly to demonstrate their ability to produce vacuum-quality welds. May 19 -20, 2004 NCSX Vacuum Vessel FDR 8

R&D of Vacuum Vessel Prototypes is Nearly Complete NCSX May 19 -20, 2004 NCSX Vacuum Vessel FDR Rohwedder • They both used a cold forming technique, but with different die designs and segmentation patterns. Major Tool • The two Prototype (PVVS) suppliers, Major Tool and Rohwedder, submitted their MIT plans and were authorized for fabrication on August 7, 2003. 9

R&D of Vacuum Vessel Prototypes is Nearly Complete NCSX • Major Tool pressing operation (Kirksite die set) May 19 -20, 2004 • Rohwedder / Precision Metal Works pressing operation (step die set) NCSX Vacuum Vessel FDR 10

R&D of Vacuum Vessel Prototypes is Nearly Complete NCSX • Rohwedder / PMW is at the final stages of fabrication. May 19 -20, 2004 NCSX Vacuum Vessel FDR 11

The PDR Committee considered the Technical Risks Properly Identified and Appropriately Mitigated. NCSX • Major Tool has completed its PVVS and qualified their MIT / QA Plan. • • – The forming, welding, machining, polishing, port removal and reattachment, and inspection processes have all been demonstrated. – The prototype development and R&D studies have provided a solid understanding of the manufacturing techniques and reduced risk factors. A Final Design is in hand. The VVSA drawings and model are complete. The VVSA Statement of Work and Specification is written. We are ready to receive the final proposals and award a contract. May 19 -20, 2004 NCSX Vacuum Vessel FDR 12

Major Tool Met Tolerances (For The Most Part) NCSX Tolerances: • Profile tolerance on the outer vessel surface is bilateral i. e. 0. 1875” either side of reference surface. • Material thickness tolerance is per ASTM B 443. The minimum thickness after forming shall be 0. 338”. Thinning below the stock thickness shall not occur over more than 10% of the total poloidal circumference of any crosssection. Based on Manufacturer’s data: • There is an area of points that lies outside the part True Position Tolerance band. However, these points would not have been a problem to us and we would have dispositioned the NCR "accept as is. ” May 19 -20, 2004 NCSX Vacuum Vessel FDR 13

Statement of Work (SOW) Summary NCSX-SOW-121 -03 NCSX • Deliverables include: – Weekly reports – Monthly reports indicating schedule progress – (3) vacuum vessel sub-assemblies conforming to Spec. NCSX-CSPEC-121 -02, in accordance with the supplier’s MIT/QA Plan and associated procedures – Shipping release form – Process History – Tooling (subject to disposition per direction of PPPL) • Quality Assurance Section specifically addresses: – – – May 19 -20, 2004 Inspection / surveillance / audit by PPPL Subcontractor's responsibility for conformance Nonconforming items Deviations to the Approved MIT / QA plan Subcontractor’s QA Program Inspection and Test Procedures Document Traceability and Records Equipment / Material Identification and Status Calibration of Test and Measuring Equipment Control of Special Processes PPPL Receiving and Inspection NCSX Vacuum Vessel FDR 14

Plans for the “Production” Subcontract NCSX • We shall select one subcontractor for the (3) “production” vacuum vessel subassemblies from the two Phase II subcontractors. – The Subcontract Procurement Evaluation Board (SPEB) has been selected; they have developed selection criteria, and are waiting for the final evaluation of the prototypes and the subcontractor proposals. • The selection will be based on: – Evaluation of the prototypes, – “Best value” evaluation of the proposals. – Business factors, including experience in working with them during the Phase II efforts. • Selection Criteria: – I. PAST PERFORMANCE OF PVVS FABRICATION - 60% • Prototype compliance with specification requirements (40%) • Management: Performance relative to SOW (20%) – II. CAPABILITY FOR VVSA FABRICATION - 40% • Technical capability for VVSA (25%) • Management (15%) May 19 -20, 2004 NCSX Vacuum Vessel FDR 15

Oversight for the “Production” Subcontract NCSX • Technical oversight for the production phase will continue using the practices established during R&D which worked well: – Tracking of technical performance through weekly e-mail status updates and monthly earned value updates (which, for the fixed price production phase, will be schedule updates). – Regular telecons and on-site visits by the technical representative, QA, and contract administrator. May 19 -20, 2004 NCSX Vacuum Vessel FDR 16

NCSX Source Selection Schedule Overview Initial meeting of SPEB 3 February 04 Draft copies of Specification & SOW released to subcontractors for comment 21 April 04 Specification and SOW updated to reflect subcontractor’s comments 11 May 04 Major Tool prototype arrived at PPPL 22 April 04 SOW, SPEC, drawings and model released to subcontractor 26 May 04 PPPL inspections of prototypes complete 31 May 04 Request For Proposal Issued 1 June 04 Firm fixed price and schedules proposals due 25 June 04 Oral Presentations by Offerors 14 -16 July 04 SPEB completes report on their evaluations and recommendations 23 July 04 SSO approval of SPEB recommendation; submit to DOE - PSO for approval 26 July 04 Negotiations with subcontractor completed 10 August 04 Vacuum Vessel production subcontract signed 24 August 04 May 19 -20, 2004 NCSX Vacuum Vessel FDR 17

Vacuum Vessel Phase II Manufacturing Studies / Prototype Fabrication Schedules (Near Completion) NCSX ü Prototypes Completed (almost) – The Phase II manufacturing studies are nearly complete. – Evaluations not yet complete • Produce a Final Manufacturing / Inspection / Test / Quality Assurance Plan for the “Production” Vacuum Vessel – End of May 04 – This will be refined based on their experience in manufacturing the prototype. – Their Firm Fixed Price and Schedule Proposal will be developed based on this. • Produce a Firm Fixed Price and Schedule Proposal – To be completed by the end of June 04. – A Subcontract Proposal Evaluation Board (SPEB) will begin evaluations of the two teams’ Prototype performance in June 04. – They will evaluate the two teams’ Proposals when received in late June and submit their findings and recommendations for the Production Subcontractor to the Procurement Official by July 04. – This will lead to the Production Subcontract Award in August 04. May 19 -20, 2004 NCSX Vacuum Vessel FDR 18

Phase III of the Vessel Fabrication Is Upcoming NCSX Goal: • To build the Vacuum Vessel within Specification, On Time, & Within Budget. Cost and Schedule: • The baseline schedule is 14 months. This is the higher of the schedule estimates developed during the manufacturing studies and has not changed. • Scheduled to begin fabrication in September 04 with delivery in November 05 • The baseline cost of the (3) VVSA’s is $ 2. 873 M. This was a composite (i. e. , neither the highest or lowest cost was chosen) of the two subcontractor’s budgetary estimates developed during the Phase I manufacturing studies. However, a 20% increase is forecast due to additional effort to control tolerances during forming and heat treatment as well as the increased number of CMM checks. Also there is concern about distortion control while welding the two 60° segments together. • Finally, about 30 ports have been added to meet project needs which are expected to cost another $300 K bringing the current projected total to $ 3. 75 M or 30% above the baseline. May 19 -20, 2004 NCSX Vacuum Vessel FDR 19

Summary NCSX • We are completing the manufacturing development and prototype fabrication phase. During this phase: – – – we demonstrated that the proposed design is manufacturable; we are on track to qualify two suppliers for building the production articles; and these two suppliers should be in an excellent position to provide a leaner bid (lower contingency in both cost and schedule) based on their experience fabricating the prototypes. • Our design is well documented in a product specification and accompanying Pro/E models and drawings. – Pre-proposal versions have been provided to our suppliers for their review and comment and are reflected in the final versions. • We are ready to enter into a contract for the production articles. – – A SOW has been developed which defines the work to be performed. We have agreement with the suppliers on the process and quality assurance requirements for fabricating the production articles. Detailed MIT/QA Plans were developed for the prototypes that are prototypical of what is required for the production articles. We have developed a good working relationship with our suppliers. • Cost increases are expected due to the additional ports and the manufacturing challenges identified by the subcontractors during the fabrication of the prototypes. A 30% overall increase is forecast compared with the 40% contingency assigned due to the assumed risks associated with the vacuum vessel. May 19 -20, 2004 NCSX Vacuum Vessel FDR 20