Tom Egebo PPPL Review of the NSTX TF Coil Repair Effort September 3 - 4, 2003 Cost & Schedule to Completion Supported by Columbia U Comp-X General Atomics INEL Johns Hopkins U LANL LLNL Lodestar MIT Nova Photonics NYU ORNL PPPL PSI SNL UC Davis UC Irvine UCLA UCSD U Maryland U New Mexico U Rochester U Washington U Wisconsin Culham Sci Ctr Hiroshima U HIST Kyushu Tokai U Niigata U Tsukuba U U Tokyo Ioffe Inst TRINITI KBSI KAIST ENEA, Frascati CEA, Cadarache IPP, Jülich IPP, Garching U Quebec

NSTX TF Coil Repair-Cost & Schedule Contents  Background  Issues/Actions  Schedule  Projected Cost  Basis for Estimate to Complete (ETC)  Conclusion

NSTX TF Coil Repair-Cost & Schedule-Background When failure occurred separate cost accounts were opened to accrue costs associated with repair  Analysis & Testing  New TF Inner Bundle & Components  Assembly & Installation of TF Inner Bundle  Instrumentation Funding accommodated within the NSTX Facility Operations Budget Schedule established in May forecast return to operation in February 2004 Project Execution Plan (PEP) prepared in June to formalize repair project. Final Design Review held August 7 th 2003

NSTX TF Coil Repair-Cost & Schedule-Issues  Placed contract with single vendor for critical path machining of conductor bars. In retrospect too much effort for this shop. Risk would have been mitigated by dividing the order. Direct Impact on Critical Path ( lost 5 weeks )  Final Design and testing of hub assembly parts delayed release for fabrication  Final design of torque collar is only remaining issue Allowing 2 weeks for procurement and 5 weeks for fabrication, design has less than 1 week float. (Fabrication in-house will increase float)

NSTX TF Coil Repair-Cost & Schedule-Actions Actions Taken (Back on Schedule with some cost growth)  Subsequent procurements broken down for fabrication by multiple vendors and early delivery incentives are offered.  Increased resources for design and testing  Increased resources for conductor preparation  Increased resources for insulating and molding conductor bars (+ 2 weeks)  Assigned two crews during hub fit-up so that the upper and lower hub fit-up can occur in parallel. (+ 2 weeks)  Reduced pre-op test activity from 3 weeks to 2 (+ 1 week)  Added explicit schedule contingency of 2 weeks  Increased contingency on ETC from 15% to 25%

NSTX TF Coil Repair-Cost & Schedule - Schedule Resource Loaded Schedule organized by cost account Focus on Critical Path  Assemble/Mold/Test inner TF Bundle  Reconstruct upper hub & fit-up lower hub  Re-install TF bundle into center stack  Reconstruct lower hub  Re-fit bus-work & cooling lines  Re-install umbrella lids  Machine area scrub  Test

NSTX TF Coil Repair-Cost & Schedule - Schedule Closely Monitoring Vendor Fabrications (incentives offered on deliveries)  Outer Flags and Flag Studs ~ 2 weeks float  Inner Flags ~ 3 weeks float  Flag Boxes > 4 weeks float  Hub assembly parts > 4 weeks float PPPL shop giving very high priority to NSTX TF repair support

NSTX TF Coil Repair-Cost & Schedule – Project Milestones DescriptionBaselineForecastActual 1.TF Coil Repair ReviewApr ’03Apr ’03 2.Complete 24 Outer Conductor MachiningJun ‘03Jun ’03 3.Complete 12 Inner Conductor MachiningJul ’03Aug ‘03 4.Complete Insulating TF ConductorsAug ’03Sep ‘03 5.TF Repair FDRAug ’03Aug ‘03 6.Complete Assembly/Mold of TF BundleSep ’03Oct ‘03 7.Test Inner TF BundleOct ’03Nov ‘03 8.Reinstall TF Bundle into center stackNov ’03Nov ‘03 9.Begin Pre-Op ISTPsJan ’04Feb ‘04 10.Ready for Plasma OperationsFeb ’04Feb ‘04 11.Project CompletionFeb ‘’04Feb ‘04

NSTX TF Coil Repair-Cost & Schedule – Projected Cost Costs through July close = $1426.1K Estimate to Complete = $1,725.8 K Total projected cost without contingency = $ 3,151.9K Contingency on 25% = $431.5K Facility Operations consumable budget diverted to procurements Facility Operations staff diverted to repair activities

NSTX TF Coil Repair-Cost & Schedule – Budget Profile

NSTX TF Coil Repair-Cost & Schedule – Tech Support

NSTX TF Coil Repair-Cost & Schedule – Basis for ETC ETC organized by cost account broken down by Labor and Material & Supplies Each remaining task on the schedule was assigned required resources: hours of labor and $’s for expenses (Materials & Supplies etc…).

NSTX TF Coil Repair-Cost & Schedule – Basis for ETC Resources were assembled and priced out using current labor and overhead rates The ETC for M&S is mainly based on contracts already in place or vendor input.

NSTX TF Coil Repair-Cost & Schedule – Conclusions Schedule and Resources are in place to execute this plan. Status meetings held weekly. Cost data reviewed monthly. Vendor deliveries are crucial and being closely monitored. 2 week activity following ISTP’s to allow schedule contingency. Have not taken credit for OT and Weekends after October 25% contingency applied on the remaining scope work.