May 12, 2005 ACC Review- Station 5 J.H. Chrzanowski - 1

NCSX

ACC Review ACC Review OfOf

Modular Coil Modular Coil Manufacturing FacilityManufacturing Facility

Station No. 5 [VPI]Station No. 5 [VPI]the NCSX Manufacturing Team the NCSX Manufacturing Team

May 12, 2005 ACC Review- Station 5 J.H. Chrzanowski - 2

NCSXGeneral Overview- Station No. 5

This ACC review is reviewing the safe guards and controls that are planned and implemented on the VPI Station No. 5.

Station 5 will be used to epoxy impregnate the modular and Toroidal Field coils following winding activities.

Quantity of coils to use Station 5 (18) modular coils (18) Toroidal field coils (1) Twisted Racetrack coil

May 12, 2005 ACC Review- Station 5 J.H. Chrzanowski - 3

NCSXModular Coil Types

Modular Coils

TF Coils

TRC Coil

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NCSXModerate Hazard Facility

The NCSX Coil Manufacturing Facility has been designated a “Moderate” Hazard Facility”

This a result of the autoclave usage and the activities associated with the VPI of the MC

“NCSX-PHA-142-01” approved document, documents all of the known hazards associated with then MCWF

May 12, 2005 ACC Review- Station 5 J.H. Chrzanowski - 5

NCSXNCSX R&D – Safety is Integrated in All AspectsNCSX R&D – Safety is Integrated in All Aspects

Safety is an important element of the PPPL culture and is incorporated in all aspects of the development program and will be carried over to production

Integrated Safety Management (ISM)Job Hazard Analysis survey (JHA’s) is being developed

to identify hazards associated with the various tasks and the personnel protective equipment required with Station 5

Involvement of all safety groups in developing plans for manufacturing- IH, Construction safety, HP

May 12, 2005 ACC Review- Station 5 J.H. Chrzanowski - 6

NCSX

STATION 1

STATION 2

STATION 3

STATION 4

STATION 5

Modular Coil Manufacturing Facility

Location of Station 5

May 12, 2005 ACC Review- Station 5 J.H. Chrzanowski - 7

NCSXGeneral Description of Station #5 ActivitiesGeneral Description of Station #5 Activities

Station 5 Activities-Install coil in autoclave and prep for VPI-Mixing of epoxy-Vacuum leak checking systems-Working with vacuum/heat/pressure [autoclave]-Filling coil with epoxy (VPI)-Heat curing filled coil-Remove coil from autoclave

Work is covered by Procedure No. D-NCSX-MCF-003

May 12, 2005 ACC Review- Station 5 J.H. Chrzanowski - 8

NCSXSafety Related Activities

The following items are being addressed in the procedures and JHA Confined space- working in the autoclave Working on elevated surfaces- upper catwalks Working around hot surfaces Working with vacuum and pressure chamber General safety concerns-house cleaning, etc. Crane Operations

May 12, 2005 ACC Review- Station 5 J.H. Chrzanowski - 9

NCSXSafety ControlsSafety Controls

Personal protective equipment- face, glovesConfined space permitsTrainingApproved procedures

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NCSXNCSX Coil Manufacturing Organizational ChartNCSX Coil Manufacturing Organizational Chart

Indicates a communication link, and not a management link between the participants

* Note: Designates primary station responsibility as well as sharing overall field management responsibilities.

Construction Safety Representative

Quality Control Representative

Coil Manufacturing Facility Manager

Jim Chrzanowski Industrial Hygiene Representative

Health Physics (HP) Representative

PPPL Responsible Line Manager

Larry Dudek

NCSX WBS 14 Manager

Dave Williamson

NCSX WBS 13 Manager

Mike Kalish

Field Supervisor *Steve RaftopoulosMETROLOGY

Field Supervisor *Jim Chrzanowski

Station No. 1Winding Form

Preparation(1) Lead Tech. + [1]

crew

Station No. 2, 3 & 4Winding stations

(3) Lead Techs + [4] crew

Station No. 5VPI

(1) Lead Tech. + [3] crew

Station No. 6Coil Testing

(1) Lead Tech. + [TBD] crew

Coil Test DirectorGeoff Gettelfinger

Field Supervisor Mike Kalish

Field Supervisor *Tom Meighan

May 12, 2005 ACC Review- Station 5 J.H. Chrzanowski - 11

NCSXManufacturing Documents- Station 5

NCSX-PLAN-CMFOP-00 [NCSX Manufacturing Facility Operations Plan]

Approved NEPA 1283 WP’s- 1188 (TRC),1138 (MC) and 1231 (TF) NCSX-MIT/QA-142-01-00 [MC MIT/QA Plan] Manufacturing Procedures

D-NCSX-MCF-003 [MC VPI Activities]D-NCSX-OP-EO-41 [Emergency Response

Procedure]D-NCSX-OP-G-162 [Autoclave Operating procedure]

May 12, 2005 ACC Review- Station 5 J.H. Chrzanowski - 12

NCSXModular Coil VPI Flow Diagram

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NCSXVPI Delivery System

Epoxy Delivery System Supply & return

manifolds Epoxy control valves Epoxy Filters Valves assemblies are

disposable

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NCSXAutoclave

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NCSX

During the VPI process, the Modular Coil will be divided into 3 zones Zone 1- supply only Zone 2- supply and return Zone 3- return only

The autoclave will initially be maintained at vacuum matching the vacuum inside of the “bag mold” [minimize potential leaks]

As the coil reaches the ½ fill mark, the autoclave atmosphere will slowly shift from vacuum to pressure (5 psig max) to support the bag mold

Once filled, autoclave will return to atmospheric pressure prior to beginning the ramp up of temperature to cure the epoxy

Zone 1 [Fill]

(12) sprues

Zone 3[Return] (12) sprues

Zone 2 [Fill/return]

(24 sprues)

Vacuum-Pressure Impregnation (VPI)

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NCSX

NCSX MODULAR COIL VPI CYCLE

10

20

30

40

60

50

70

80

90

130

100

110

140

0

120

6 12

18

24

30

36

605448

42

0

10

20

30

40

60

50

70

80

90

130

100

110

140

120

Coil Fill Period

Cure Time

Ramp down Period

Ramp up

period

Post Cure Time

Ramp up period

5 hours

18 hours

16 hours

6 hours @ 10 ° C ramp up per hour

11 hours @ 10 ° C ramp down per hour

Temperature degrees C

Hours “Scrambled Egg” test to verify Gel temperature

Viscosity measurementsEpoxy component

mixing