Anthony Indelicato DOE-Princeton Site Office May 2012 Construction Progress Review for the NSTX Upgrade Project Construction Progress Review for the NSTX Upgrade Project U.S. DEPARTMENT OF ENERGY Office of Science Princeton Site Office 1

U.S. DEPARTMENT OF ENERGY Office of Science Princeton Site Office Increase toroidal field: 0.5T > 1.0T Increase plasma current:1 MA > 2 MA Increase pulse length:1.0 s > 5 sIncrease NB heating: 5-7MW > 10-14MW New Center Stack Inner TF bundle, TF joint, OH & inner PF coils Upgraded TF coil support structure Existing outer TF coils w/ reinstated water cooling Exst’g outer PF coils – 6 total New PF coil support structure Reinforce umbrella structure Also…modify coil power system, protection system & ancillary support systems What’s the proposed workscope? 2

U.S. DEPARTMENT OF ENERGY Office of Science Princeton Site Office Add 2 nd Beamline Decon, recondition and install Install 3 HVEs Relocate from TC basement New NB port New NB armor Modify Vacuum Vessel New Vacuum Pump Duct (below) Also…modify existing power system and ancillary support systems Workscope… continued 3

TPC=$94.3M Contingency: $15.1M (or 32% of ‘to go’) Today CD-0 CD-1 CD-2 CD-3 CD-4 Feb 09 Sep 15 Dec 11 Dec 10 Apr 10 FY09FY10FY11FY12FY13FY14FY15 $5.1$8.3$9.7$21.6$25.3$24.3$0.0 stdadv CD-3 Overdrive Budget odometer U.S. DEPARTMENT OF ENERGY Office of Science Princeton Site Office How’s spending? $47.8M to go EF 1/4 1/2 3/4 12 months of schedule contingency (or 41% of ‘to go’) 4 $31.4 spent

U.S. DEPARTMENT OF ENERGY Office of Science Princeton Site Office How’s the performance so far? SPI = 1.09 & CPI = % complete Contingency = 32% of ‘to go’ costs Budget at completion = $78.9 Estimate at completion = $79.7 Level 2 milestones:  Past = completed on or ahead of schedule  Ahead = early completion anticipated 5  All scope remains as planned.  TPC remains ‘on-target’.  CD-4 date remains ‘on-target’ with promise of early finish.  Concern: FY13+ Presidential Budget How’s the baseline?

U.S. DEPARTMENT OF ENERGY Office of Science Princeton Site Office Risks and Concerns NSTX-U future funding profile: FY 13 President’s budget provides reduced funding to PPPL...  Institutional impacts are high (possible 18% cut in lab-wide staff)  NSTX-U would be adversely impacted : -Reduction in Lab-wide human resource support... Added risk. -Slow down of schedule (due to a constrained budget profile) will add cost. Actions:  PPPL continues to work closely with PSO and FES to understand impacts of the budget cuts.  The Project developed actionable plans based on differing funding scenarios to determine the impacts on the project.  Early delivery date of the project will be significantly reduced, but project can still meet CD-4 baseline date.  Worst case: $5M of contingency will be released to cover “standing army” costs & indirect rate changes. Cost contingency will be reduced from 32% to 17% of ‘to-go’ work at about the 40% construction point. 6

U.S. DEPARTMENT OF ENERGY Office of Science Princeton Site Office Thoughts  The Budget cycle is still young and unclear for FY13 and beyond.  Too early to react ( i.e., re-baseline ).. but precautionary institutional planning must be done.  The NSTX-U Project’s performance is still the #1 priority as stated by PPPL Directorship and agreed upon by FES.  The Project has built a nice buffer in cost and schedule contingency to date... this will come in handy.  Yes... there will be added risk to the project... but, it appears that the current worst case scenario is manageable. 7

Construction Progress? U.S. DEPARTMENT OF ENERGY Office of Science Princeton Site Office 8 Overall Progress is good... Advanced procurements allowed for a good “jump start” All construction efforts are well underway Vendor performance is good Critical Path... Remains through the construction of new Center Stack assembly Center Stack Fabrication facility ready to start TF Cooling tube soldering process has been developed Management... EVMS system in place and fully functioning (CAP validation with this review). Construction proceeding well on the accelerated schedule. All CD-3 Recommendations addressed. Project is getting the resources it needs.

U.S. DEPARTMENT OF ENERGY Office of Science Princeton Site Office Post CD-3 efforts are proceeding well…  Good performance to date.  Good communication between PPPL and Site Office.  Estimates are updated and remain well within plan.  Funding and human resources are in place.  Elements of DOE Order 413.3B are met. 9 Conclusion PSO, PPPL and FES must work together as the FY13 budget evolves and assess the impact to NSTX-U and PPPL.

Back-up Slides 10

U.S. DEPARTMENT OF ENERGY Office of Science Princeton Site Office Charge Questions 1.Construction Efforts: Are construction efforts being executed safely? Does the project have adequate resources and the appropriate skills mix to execute the project per the plan? 2.Baseline Cost and Schedule: Are the current project cost and schedule projections consistent with the approved baseline cost and schedule? Is the contingency remaining adequate for the risks that remain? 3.Management: Evaluate the management structure as to its adequacy to deliver the scope within budget and schedule. Are risks being actively managed? Has the project responded satisfactorily to the recommendations from the previous SC project review? 4.Earned Value Management (EVM): Has Princeton University/PPPL implemented all required actions in the Corrective Action Plan (CAP) that was developed following the EVM system certification review from October 2011? 11

U.S. DEPARTMENT OF ENERGY Office of Science Princeton Site Office Confidence of Success Work is proceeding ahead of schedule Excellent construction progress in test cell NB work on cost and schedule Critical path work (CS upgrade) ahead of schedule Experienced staffing... Senior knowledgeable staff Strong management team PrUn and Director’s Office support the effort... Sponsor independent reviews Hiring of staff Director of Engineering & Infrastructure fully engaged Has made NSTX-U a PPPL priority Conclusion : FPD has high confidence level that PPPL will make this project a success. 12