Transcript May VV FDR 4 3.ppt
May 19-20, 2004
NCSX Vacuum Vessel Manufacture
Mike Viola, Paul Goranson, Brad Nelson, Mike Cole Phil Heitzenroeder, and Tom Brown for the NCSX Engineering Team
NCSX Final Design Review May 19-20, 2004
NCSX FDR
PPPL
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Review of the NCSX Vacuum Vessel
Risks Mitigated through a successful PVVS program.
R&D and Vacuum Vessel
May 19-20, 2004 NCSX FDR
Prototypes Complete
Outline
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NCSX’s Vacuum Vessel Was Recognized as Unconventional Right from its Conception
• •
Highly shaped Forming of Inconel 625. Need for tight tolerances
•
Design has to accommodate assembly needs
–
Modular coils have to be positioned over the VV; this requires all ports except mid period ports to be welded in
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installed.
Vessel shape & size has
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Manufacture
• •
Dies are machined.
Panels are cold pressed. (Segmentation determined by Vendor.)
–
Prototype consisted of a 20 segments ° sector which involved about 5
•
Measurements taken using CMM or gages
• • • • •
Panels welded together on fixture Mirror every half period (60 °) More measurements taken
–
(Heat treatment requirements evaluated during R&D) 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
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Ports cut off to leave stubs
–
reinforces vessel
60 Degree Half-Period 6 Piece Segmentation Scheme Mike Viola 4
•
The PDR Committee considered the Technical Risks Properly Identified and Appropriately Mitigated.
Major Tool has completed its PVVS and qualified their MIT / QA Plan. Rohwedder is right behind.
–
The forming, welding, machining, polishing, port removal and reattachment, and inspection processes have all been demonstrated and optimized.
–
The prototype development and R&D Studies have provided a solid understanding of the manufacture techniques and reduced risk factors.
•
A Final Design is in hand
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The VVSA drawings and model are complete
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R&D of Vacuum Vessel Prototypes are Complete
•
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
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Tolerances Were Developed with Prototype Suppliers
•
Profile tolerance on outer vacuum surface is bilateral i.e. 0.1875 either side of reference surface.
•
Material thickness tolerance shall be per requirements set forth in ASTM B443. The minimum thickness after forming shall be 0.338. Thinning below the stock thickness shall not occur over more
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circumference of any cross-section.
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Phase II of the Manufacturing Studies Is Now Underway Goals:
•
The two Prototype suppliers Major Tool and Rohwedder submitted their MIT plans and were authorized for fabrication on August 7 th .
•
Both suppliers have completed their PVVS fabrication.
•
Initial review of Major Tools data package .
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Phase II of the Manufacturing Studies Is Now Underway (Major Tool Die/Punch set)
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Phase II of the Manufacturing Studies Is Now Underway (Major Tool Inspection Gages)
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Phase II of the Manufacturing Studies Is Now Underway (Major Tool Welding Form)
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Plans for the “Production” Subcontract
It is our intent to select one subcontractor for the (18) “production” modular coil winding forms from the two Phase II subcontractors .
•
However, we are open minded about possibly of “splitting” the subcontract between the two subcontractors if advantageous.
The selection will be based on:
•
Evaluation of the prototypes,
May 19-20, 2004 • NCSX FDR Mike Viola
“Best value” evaluation of the proposals.
12 •
Business factors, including experience in
Statement of Work (SOW) Summary
Quality Assurance Section specifically addresses:
•
Inspection / surveillance / audit by PPPL
• • • • • • • • • •
Subcontrctor’s responsibility for conformance Nonconforming items Deviations to the Apprived 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 Deliverables include:
•
Weekly reports
•
Monthly reports indicating schedule progress.
• May 19-20, 2004
(18) winding forms conforming to Spec. NCSX-CSPEC-141 03, in accordance with the supplier’s MIT/QA Plan and associated procedures.
NCSX FDR Mike Viola •
Shipping release form
13 •
Process History
Evaluation Criteria
I. Past Performance – 60%
• • • • •
Prototype Quality - performance relative to specification (40%
•
Dimensional tolerances
•
Mechanical and Physical Properties of Casting Alloy Poloidal break Magnetic permeability Non-destructive testing Surface finish Non-conformances Management (Performance relative to the SOW) 20%
•
Communication
•
Adequacy of Proj. Mgt. staff
• •
Response to technical issues & problems Reliability of estimates
•
Cost growth
•
Schedule growth
• •
Quality of the MIT/QA plan for the prototype
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Compliance with the Subcontractor’s QA documentation
Evaluation Criteria (cont’d.)
Capability for the Production Winding Forms – 40%
• −
Technical Capability (25%) Adequacy and commitment of facilities and personnel and / or subcontract arrangements.
− −
Technical approach Risk management
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Management (15%) Review of Annual Financial reports for the past 2 yrs.
Organizational structure Key personnel Letters of commitment Evidence of sufficient machine,skilled labor, and floor space to produce to the schedule and has an adequkate document control system.
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If a large business, their Small Business Subcontracting Plan.
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Source Selection Schedule Overview
Initial meeting of SPEB 18 March 04 Draft copies of Specification & SOW released to subcontractors for comment Specification and SOW updated to reflect subcontractor’s comments Prototypes due at PPPL Firm fixed price and schedules proposals due PPPL inspections of prototypes complete Oral Presentations by Offerors
May 19-20, 2004 NCSX FDR
SPEB completes report on their evaluations 23 April 04 14 May 04 28 June 04 02 July 04 19 July 04 21-22 July 04
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29 July
Statement of Work (SOW) Summary
Quality Assurance Section specifically addresses:
•
Inspection / surveillance / audit by PPPL
• • • • • • • • • •
Subcontrctor’s responsibility for conformance Nonconforming items Deviations to the Apprived 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 Deliverables include:
•
Weekly reports
•
Monthly reports indicating schedule progress.
• May 19-20, 2004
(18) winding forms conforming to Spec. NCSX-CSPEC-141 03, in accordance with the supplier’s MIT/QA Plan and associated procedures.
NCSX FDR Mike Viola •
Shipping release form
17 •
Process History
Vacuum Vessel Phase II Manufacturing Studies / Prototype Fabrication Schedules
Prototypes Completed •
The Phase II manufacturing studies are well underway.
•
The expected delivery for both prototypes is
March 04
provide technical input for the Final Design Review.
to
•
The FDR on the Vacuum Vessel is scheduled for
April 04
.
Produce a Final Manufacturing / Inspection / Test / Quality Assurance Plan for the “Production” Vacuum Vessel • Mid 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 May 04
.
• • May 19-20, 2004
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
.
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This will lead to the Production Subcontract Award in
July
Phase III of the Vessel Fabrication Is Upcoming
• • •
Goal:
To build the Vacuum Vessel within Specification, On Time & Within Budget.
Scheduled to begin fabrication in
July 04
with delivery in
September 05
The detailed manufacturing studies have yielded a composite (i.e., neither the highest or lowest cost was chosen) projected budgetary cost of the VVSA of
$2.729M
before overhead.
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WBS2 12 Budget (loaded $ based on ECP6) Sum of Budget (loaded $) PHASE
1) Title I & II
Resource
LABOR M&S 1) Title I & II Total 2) R&D LABOR
WBS 121 122
$1,004,275 $42,922 $50,552 $1,054,828 $42,922 $339,628
123 124 125 Grand Total
$31,127 $21,574 $20,979 $31,127 $21,574 $20,979 $1,120,878 $50,552 $1,171,430 $339,628 M&S 2) R&D Total 3) Fabrication & Assembly May 19-20, 2004 3) Fabrication & Assembly Total LABOR M&S Grand Total $120,357 $459,985 $228,057 $21,461 $4,743,286 $6,258,098 $131,954 $174,876 $22,939 $321,761 $344,700 $375,827 $9,601 $31,451 $41,052 $62,626 $2,608 $3,132 $5,740 $26,720 $120,357 $459,985 $284,667 $6,898,147
Vacuum Vessel Phase II Manufacturing Studies / Prototype Fabrication Cost & Schedules
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Bases of Winding Form Production Costs and Schedules
The baseline cost of the (18) winding forms is $ 4.84 M. This is a composite (i.e., neither the highest or lowest cost was chosen) of the two subcontractor’s budgetary estimates developed during the Phase II manufacturing studies.
The baseline schedule is 18 months. This
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developed during the manufacturing
Modular Coil Winding Form Cost Summary
Labor (covers all Title I, Title II, and Title III): PPPL: 2163 hrs. 341,000 ORNL: 8172 hrs. $1,055,000 $ Materials & Supplies: Manufacturing Development (Phase II Studies) 2 suppliers: 1,175.000
Production Winding Forms 4,839,300 Travel for contract monitoring:
May 19-20, 2004
48,000 G&A & Escalation on non labor
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Winding Form Cost Breakdown
May 19-20, 2004
29.2 %
Estimated Cost / Winding Form: $270 K
7.4 % 11.4 %
52.1% Mfg. Anal/Patterns Casting/HT/Inspection Machining Proj. Mgt. NCSX FDR Mike Viola 24
Winding Form Schedule Breakdown for Production
The production time for the (18) winding forms is projected to be 18 months. • Manufacturing analyses and pattern making is the first task required for each of the (3) casting types (task time: ~12 wks. – most sub-tasks can be performed in parallel) • Casting / inspection / repair / heat treatment during the production phase is estimated to take ~4 wks. / winding form. • Machining on a 5 axis milling machine is May 19-20, 2004 NCSX FDR Mike Viola required; for the production phase, this is 25 estimated to take ~4 wks. / winding form.
Summary
We are completing the manufacturing development and prototype fabrication phase . During this phase:
[1] we demonstrated that the proposed design is manufacturable [2] we are on track to qualify two suppliers for building the production articles and [3] 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.
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Summary
We are following a sound acquisition plan.
completing the manufacturing development and prototype fabrication phase. During this phase, [1] we demonstrated that the proposed design is manufacturable [2] we are on track to qualify two suppliers for building the production articles and We are [3] 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.
We have a well documented design.
comment. 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
We are ready to enter into a contract for the production articles.
NCSX FDR Mike Viola A SOW has been developed which defines the work to be performed. We have agreement 27
Summary
• • • •
Phase I is complete.
Risks have been identified and steps put in place to mitigate them.
Phase II - The Prototype Vacuum Vessel is under construction.
–
The experience gained from this 20 ° segment will provide the experience and knowledge to build the Vacuum Vessel Subassembly with great confidence in the design and cost factors.
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Major Tool has fabricated several die components Rohwedder is vigorously working a solution that
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Phase III is anticipated with great confidence.
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