1

NCSX

TF CoilMake or Buy Evaluation

Kalish 10/14/04

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NCSX

How Did We Get Here

• TF Coils are Trapped components who’s reliability is crucial to project success.

• Coil Vendor performance in the past has been “spotty”.

• We have undergone an evaluation of in house fabrication of the TF coils to determine if it results in a net gain to the project.

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NCSXSummary

• BUY– TF Design Modifications– Vendor Issues and Risk Mitigation– Budget for Purchase of Coils

• Make– In House Tooling / Floor Plan– Schedule– Cost– Resource Loading

• Make / Buy Cost Benefit Evaluation

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NCSX

Wedge Castings Allow For Conventional Winding Pack

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NCSX

Original TF Wedged Winding Pack Cross Section vs New Design

Old Design

First Iteration

Wedge Cut and Reinsulated

Present Design

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NCSX

Risks and Risk Mitigation for Purchase of TF Coils

• Vendors attention to cleanliness and QC has been inadequate– Coils specification will be very specific. Attention to

this detail must be demonstrated at the Bid Conference

– Specification will require “clean room” upfront– Braze qualifications spelled out in detail– Approval and hold points for inspection of fixtures,

G10 fillers, winding, ground wrap, brazing etc...– PPPL Will establish a presence at the vendor. The

vendor must buy into a culture change (has not worked in the past)

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NCSX

Risks and Risk Mitigation for Purchase of TF Coils (cont.)

• Engineering at vendor has been inadequate to handle novel situations– TF design has been simplified, vendors have

experience with similar coils– All critical process parameters to be spelled out in

specification

• Vendors have been late on delivery– We will hold the actual need date in our back pocket

and require delivery three months ahead of schedule.– PPPL will monitor progress closely (may not help

schedule but removes surprises)

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NCSXDollars In Original Estimate

$1,459K in original estimate for the Wedged TF Coil including Engineering Support

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NCSXEstimate to Add Wedge Casting

Cost For Wedge Castings and Assembly    

Note: G&A and Contingency not included    

     

  Man Hrs Cost

Elimination of Coil Machining and Insulating    

Conductor Cost    

Casting Fixturing   $5,000

Castings 36 pairs   $125,000

Assembly Fixture HRS + M&S 200 $23,000

Assembly of Castings to Coil 944 $68,912

Engineering and Design, Fixture 120 $19,200

Additional Analysis 120 $19,200

Engineering and Design, Revisions 240 $38,400

Testing of Adhesion to Castings 160 $25,600

     

Total Cost   $324,312

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NCSXPresent Budget For TF Coils

• $1,326 K (with G&A no contingency) to build coils and assemble wedge castings

• -$324 K Required to add wedge castings• =$1,002K For Fabrication of Simplified TF

Compares to $1,381K using in house estimate spread sheet to develop vendor costs

• +$133K Allocated for Engineering Coverage(equivalent to1.25 man per week)

Total to compare to In house estimate =

$1,135K• Total with 20% Contingency =

$1,360K

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NCSXSummary

• BUY– TF Design Modifications– Vendor Issues and Risk Mitigation– Budget for Purchase of Coils

• Make– In House Tooling / Floor Plan– Schedule– Cost– Resource Loading

• Make / Buy Cost Benefit Evaluation

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NCSXPlan for TF Coil Fabrication at PPPL

RESA Floor Plan

Enclosed clean area created to segregate winding station from shop

TF Coil cured in autoclave Test Cell

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NCSXTF PPPL Fabrication Schedule

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NCSXTF PPPL Fabrication Schedule (cont.)

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NCSX

In House Fabrication Estimate

Engineering & Oversight $344,160.00 15.84% 17.49%

Brazing qualification $35,820.00 1.65%  

Equip. & Tooling   $295,540.00 13.61% 19.95%Equip &

Tooling

Area Preparation   $137,920.50 6.35%  

Materials & supplies $570,030.00 26.24% 26.24% M&S

Conductor prep   $72,048.00 3.32%  

Coil winding   $234,472.00 10.79% 36.31% Fabrication

Ground wrap/mold $140,936.00 6.49%  

VPI     $318,528.00 14.66%  

Testing   $22,752.00 1.05%

         

Total TF Fabrication $2,172,206 100.00%

         

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NCSXIn House Fabrication Cost Breakdown

17%

20%

26%

37%

1

2

3

4

Labor

Materials & Supplies

Equipment & tooling

Engineering & Oversight

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NCSX

TF Coil in House Man Power Requirements

Job requires dedicated team: 1 Lead Tech + 3 Techs for winding ground wrapping and mold preparation

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NCSXVPI of TF Interleaves with Mod. Coils

Parallel VPI tasks increase efficiency but remove float in critical path

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NCSXSummary

• BUY– TF Design Modifications– Vendor Issues and Risk Mitigation– Budget for Purchase of Coils

• Make– In House Tooling / Floor Plan– Schedule– Cost– Resource Loading

• Make / Buy Cost Benefit Evaluation

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NCSX

Cost Comparison Make or Buy

BUY MAKE                

                   

$1,326 $2,172 Base Costs            

-$324   Wedge Casting Fabrication and Assembly  

$133   Engineering Coverage        

  -$324 Savings to Modular Coil Fabrication    

  -$100 Brazing Unit, Infrastructure $$ (rough estimate)  

$1,135 $1,748 SUM            

    $613 Additional Cost for Fabrication In House  

                   

$133   Additional Engineering Coverage      

$18   Travel            

$1,286 $1,748              

    $462 Additional Cost for Fabrication In House  

      If Cost of Increased Oversight at Vendor is Considered

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NCSX

Make or Buy Advantages vs Risk / Cost

• Advantages1. PPPL has total control of

process. Higher quality coils likely**

2. Valuable experience gained at PPPL. Increased capabilities for future projects (winding, brazing).

3. Pay for facility improvements out of infrastructure $$$ ($100K for braze unit)

4. Resources optimized during gaps in modular coil VPI schedule.

• Risks / Cost1. Net additional cost of

roughly $613K to laboratory

2. Float in VPI schedule for modular coils is reduced / lost

3. Labor Conflicts, 4.5 additional technicians Required in FY06

4. Quality for in house fabrication at risk if resources are spread thin. Must have dedicated staff

5. Moves $$$ for TF coil procurement from FY06 into into FY05

**Note: Additional steps will be taken to mitigate risks and maximize quality from vendors

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NCSX

Alpha Magnetics, Inc

1876 Saber Street Hayward, CA 94545510 732-6698 Ken Wadsworthken@alphamag.com

*Site Visit by Fred Dahlgren, "Capable, and experienced coil shop with a casual (but probably effective) management style. House-keeping did not appear to be a high priority on the shop floor. In-house expertise in coil winding, machining, Tig and Mig welding, torch brazing, He-leak checking, etc (see trip report)." *Dick Thome at General Atomics has been happy with their work but have had issues with schedule*Brookhaven Laboratories has rated Alpha "Good to Very Good" (per Tom Paterson at Columbia)*Greg Hartwell at Auburn 42cm dia coil was 2mm too wide when the tolerance was +/- 2mm, they were 4 months on a 3 month delivery, coil looks good, as of yet untested, shifted in shipping but packaging did not necessarily look bad*Tom Paterson at Columbia, building small but complicated coils includes welded package, job in progress, alpha has been responsive and knowledgeable but slow to begin work*Teleconference with Ken Wadsworth- Reviewed techniques used to build two large coils one D Shaped 15 feet high by 20 ft long with 1.5"x2" aluminum conductor and 12"x12" cross section for Fermi Lab. The other water cooled copper conductor 12' ID with a 14" square cross section built to a 1/16" tolerance for "Archimedes". A third 60 ft long coil was made by building in place a convection oven. They have a large horizontal boring mill adequate for machining the NCSX TF coils. Ken Wadsworth reviewed the NCSX PF and TF Coil drawings posted on the web and indicated that they are both capable and interested in building any or all of these coils. *Lee Severe (858 642-9170 x208) at Archimedes (purchased the 12' ID coils) would choose EversonTesla over Alpha even at a higher price the next time they purchase large coils. Alpha took about 13 months on an 8 month schedule and was non responsive even when offered additional money to get back on schedule. Alpha had limited or no QA, instrument calibrations were 4 yrs old, Alpha bid 3/4 of the cost of EversonTesla, Archimedes had an engineer on full time who caught bad torch braze joints that would have been buried in the middle of the coil, the end watter fittings were over toqued and distorted at Alpha. The coils are now in service and are working to spec but Lee feels that without the Archimedes oversight the bad braze would have led to a failed coil.There may be "Staffing" issues at Alpha, the company lost it's president and brought back the founder who is competent but temporaryAlpha will require a very high level of oversight a by PPPL to ensure they deliver a quality product but appears to have the basic capability to build any or all of the Conventional Coils

Potential TF Coil Vendors

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NCSX

Everson Tesla, Inc

615 Daniels RoadNazareth, PA 18064610 746-1520Greg Naumovichwww.eversontesla.com

PPPL's experience with Everson is mixed. Generally a well run operation with good controls on paper however there were some avoidable quality problems with the NSTX Coils fabricated at Everson (TF Bundle, and OH Coil). The remnants of Everson have been bought out by Tesla and renamed EversonTesla. Greg Naumovich in a meeting at PPPL did provide some assurances that some of the past issues with QC oversight and attention to detail have been addressed in the reorganization. While they are well positioned to produce any or all of the NCSX coils, to minimize risk there will have to be careful oversight by PPPL and a review and commitment by EversonTesla to put in place procedural improvements to avoid past problems.

Stangenes Industries

1052 East Meadow CirclePalo Alto, CA 94545Lance Thompson650 494-7303lthompson@stangenes.comwww.stangenes.com

Teleconference with Lance Thompson, 30 yrs in the business, two buildings each about 15,000 sq. feet, about 100 employees, ISO Certification is in process, have QC department, Built 14' long by 6' wide rectangular coil with 1"x2" conductor for Brookhaven, Built 13' diameter coil with 2cm sq conductor for EBCO Labs in Canada, these jobs were within the last 4 yrs, they No Bid the Columbia job, they have a 10ft oven they no longer use because there aren't very many large coils and they prefer to build an oven in place, Lance said they are capable of building all of the NCSX conventional coils and that he would speak with the CEO. Stangenes looks like a possible player and will get further scrutiny. To be considered for the Bidders list

National Electric Coil

Columbus OhioHoward MoodyHmoudy@national-electric-coil.comTony Mcconnnon

Large industrial supplier as well as supplier for Nuclear Navy. Produce hollow solid copper conductor windings mostly for power generation. Generator Rotor Coils (.25”x1” conductor) Use a lot of CDA 107 copper. Familiar with torch, resistance and induction brazing. Work with clean rooms. Familiar with VPI process. 300,000 sq foot facility. Howard Moody worked the industrial side of Everson up until 10 yrs ago. Will Plan Visit

General Atomics

Dick Thome858 455-3127

Capabilities exist at GA to build any or all of the NCSX Coils. They are limited by the capacity of the 10 Ton Crane which is not an issue for these coils. Dick Thome indicated that GA would not be competitive with industry due to their cost structure and for that reason would not want to expend the effort to bid the job. He did however say that we could consider GA a backup option if we failed to find a satisfactory industrial vendor.

Potential TF Coil Vendors