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71-971205-CLN-01

***TO: DISTRIBUTION***

***FROM: C NEUMEYER***

***SUBJECT: CLARIFICATION OF NSTX DESIGN REVIEW OBJECTIVES &
PROCEDURES***

This memo provides clarification of the objectives of, and procedures
for, NSTX design reviews.

The governing procedure is NSTX-PROC-004-01, \"NSTX Design
Verification\". While the procedure establishes general guidelines, this
memo provides more specific information. It is the intention of the
writer to revise the procedure to include the more specific information
contained herein. This memo provides interim guidance.

*Project Elements Subject To Review*

The WBS structure provides the high level division of the project scope
into elements at various levels. The depth of the WBS definition varies
within each WBS element. On NSTX, WBS 1 is divided up down to Level 5 in
the WBS parlance (e.g. the OH coil is WBS 1332). Further subdivision of
the project scope beyond the formal WBS definition is possible and in
many cases appropriate in terms of deciding which elements of the
project scope require formal individual review. For example, WBS 21 HHFW
is not further subdivided by the WBS definition. However, it makes sense
to review the antenna scope separately from the transmitter/transmission
line scope.

[The grouping of WBS elements into individual reviews, and/or the
partitioning of WBS elements into pieces subject to individual review,
is negotiable and subject to agreement between the WBS Manager and the
NSTX Project Engineering Manager (C Neumeyer).]{.underline}

All NSTX Level 3 WBS elements were reviewed together at the conceptual
level (Conceptual Design Review - CDR) at the Engineering Cost &
Schedule Review in July 1996. After the move of NSTX to D-site, those
WBS elements which are significantly site dependent (WBS 3 - Auxiliary
Systems, WBS 5 - Power Systems, WBS 6 - Central I&C) were subject to a
second CDR in February 1997.

Typically the higher level elements of the project scope are subject to
three reviews, namely the CDR, Preliminary Design Review (PDR), and
Final Design Review (FDR). However, the [PDR is optional, subject to
agreement between the WBS manager and the NSTX Project Engineering
Manager]{.underline} (in retrospect skipping the PDR step has caused
some difficulties in the past and will generally be avoided in the
future).

History of subsystem reviews and future plans are as indicated in the
following table.

  ------------- --------------- --------------- -------------- ------ ------- -------
                                                               CDR    PDR     FDR

  1X-Torus Sys                                                 7/96           

                11-PFCs                                               5/97    7/97

                12-VV                                                         7/97

                13-Magnets                                                    

                                131-PF Outer                                  

                                132-TF Outer                                  7/97

                                133-Center Stk                                

                                                1331-TF Inner         10/96   2/97

                                                1332- OH              10/96   2/97

                                                1333-PF1a/1b          10/96   2/97

                                                1334-CS Casing        10/96   2/97

  2X-Htg & CD                                                  7/96           

                21- HHFW                                                      

                                Antenna                               12/97   2/98

                                Xmitter/Lines                         TBD     6/98

                22- CHI                                                       

                23- ECH                                               TBD     TBD

                24- NBI                                               TBD     TBD

  3X-Aux Sys                                                   2/97           

                31- Vacuum                                            9/97    11/97

                32- Cooling                                           1/98    3/98

                33- Bakeout                                           10/97   1/98

                34- Gas                                               12/97   2/98

                35- GDC                                               TBD     3/98

  4X-                                                          7/96           
  Diagnostics                                                                 

                Magnetic Diag.                                        9/97    1/98

                CHERS                                                 2/98    4/98

                Installations                                                 1/98

  5X- Power Sys                                                2/97           1/98

                Power Cable                                                   8/97

                PS Control                                            TBD     TBD

  6X- I&C                                                      2/97           

                61- Process                                           2/98    6/98
                Cntl                                                          

                62- Data Acq                                          2/98    6/98

  8X-                                                                         
  Facilities                                                                  

                Platform                                              7/97    8/97

                Test Cell GA                                                  10/97
  ------------- --------------- --------------- -------------- ------ ------- -------

As the project moves forward there will arise the need for additional
lower level reviews, typically for individual components rather than
integrated subsystems. The procedure NSTX-PROC-004-01 allows for such
reviews and sets forth general guidelines for Peer, CDR, PDR, and FDR
reviews.

*Design Review Objectives and Deliverables*

The following table outlines the objectives and deliverables for the
high level reviews.

In recognition of the fact that the nature of the subsystems vary
considerably, it is allowed that each review can have a specific set of
deliverables which may differ somewhat from what is listed. [For each
review the specific deliverables are subject to negotiation between the
Cognizant Engineer, WBS manager, Design Review Chair, and the NSTX
Project Engineering Manager.]{.underline}

+------+-------------------------------+-------------------------------+
| L    | Objectives                    | Deliverables                  |
| evel |                               |                               |
| of   |                               |                               |
| Re   |                               |                               |
| view |                               |                               |
+------+-------------------------------+-------------------------------+
| Conc | Conceptual review \...        | Documentation Package to      |
| ept( |                               | Design Review Board & NSTX    |
| CDR) | • Establish technical         | File ≥ 3 full working days    |
|      | feasibility of one or more    | prior to review\...           |
|      | implementation options        |                               |
|      |                               | • Draft SRD (unsigned pending |
|      | • Establish interface         | outcome of CDR and chit       |
|      | definitions and requirements  | resolution)                   |
|      |                               |                               |
|      | • Establish cost & schedule   | • Draft SDD                   |
|      |                               |                               |
|      | NOTE: Following resolution of | • Results of preliminary      |
|      | CDR chits the SRD shall be    | calculations to demonstrate   |
|      | signed and placed under       | performance vs. requirements  |
|      | configuration control.        |                               |
|      |                               | • Sketch level drawings,      |
|      |                               | P&IDs, schematics             |
|      |                               |                               |
|      |                               | • Cost & Schedule Estimate    |
+------+-------------------------------+-------------------------------+
| Pr   | Preliminary review\...        | Documentation Package to      |
| elim |                               | Design Review Board & NSTX    |
|      | • Assessment of design        | File ≥ 3 full working days    |
| (    | progress                      | prior to review\...           |
| PDR) |                               |                               |
|      | • Establish firm definition   | • Resolution of CDR chits     |
|      | of configuration              |                               |
|      |                               | • SRD Revisions, if any       |
|      | • Confirm global/integrated   |                               |
|      | performance vs. requirements  | • Updated Draft SDD           |
|      | via preliminary analysis of   |                               |
|      | all aspects (electrical,      | • Results of preliminary      |
|      | thermal, mechanical,          | calculations to demonstrate   |
|      | structural, seismic, etc. as  | performance vs. requirements  |
|      | applicable)                   |                               |
|      |                               | • Assembly/system level       |
|      | • Refine interface            | drawings, P&IDs, schematics   |
|      | definitions and Requirements  |                               |
|      |                               | • Updated Cost & Schedule     |
|      | • Refine Cost & Schedule      | Estimate                      |
|      | estimate                      |                               |
|      |                               |                               |
|      | NOTE: Selection of            |                               |
|      | implementation scheme from    |                               |
|      | multiple options shall be     |                               |
|      | made prior to PDR; multiple   |                               |
|      | options shall                 |                               |
|      | [not]{.underline} be          |                               |
|      | presented. This includes      |                               |
|      | material selection.           |                               |
+------+-------------------------------+-------------------------------+
| F    | Final review of               | Documentation Package to      |
| inal | subsystems\...                | Design Review Board & NSTX    |
| (    |                               | File ≥ 3 full working days    |
| FDR) | • Confirmation of successful  | prior to review\...           |
|      | completion of detailed design |                               |
|      | prior to release for          | • Resolution of PDR chits     |
|      | procurement, fabrication,     |                               |
|      | assembly, installation as     | • SRD Revisions, if any       |
|      | applicable                    |                               |
|      |                               | • Final Draft SDD (unsigned   |
|      | • Establish final definition  | pending outcome of review and |
|      | of configuration              | chit resolution)              |
|      |                               |                               |
|      | • Confirm with complete       | • Documented and Checked      |
|      | assurance the                 | Calculations to demonstrate   |
|      | global/integrated             | performance vs. requirements  |
|      | performance, as well as       |                               |
|      | performance of detailed       | • Supporting design basis     |
|      | elements, vs. requirements    | documentation such as memos,  |
|      | via completed analysis of all | reports, etc. referenced by   |
|      | aspects (electrical, thermal, | SDD, as appropriate           |
|      | mechanical, structural,       |                               |
|      | seismic, etc. as applicable)  | • Formal drawings, to level   |
|      |                               | required to proceed with      |
|      | • Confirm the                 | pro                           |
|      | constructability, safety and  | curement/fabrication/assembly |
|      | operability of the design     | as applicable, P&IDs,         |
|      |                               | schematics (checked but       |
|      | • Finalize interface          | unsigned pending outcome of   |
|      | definitions and requirements  | review and chit resolution)   |
|      |                               |                               |
|      | • Refine cost & schedule      | • Updated Cost & Schedule     |
|      | estimate                      | Estimate                      |
|      |                               |                               |
|      | NOTE: Following resolution of |                               |
|      | FDR chits, the SDD and        |                               |
|      | drawings shall be signed off. |                               |
+------+-------------------------------+-------------------------------+

For reviews which cover only a part of the scope contained within the
governing SRD/SDD (e.g. Vacuum Pumping Systems, WBS 31, is part of the
SRD which covers all of WBS 3), only the effected sections are
considered to be part of the deliverables in the above table.

For lower level reviews (e.g. components instead of subsystems) where
the SRD/SDD do not apply, appropriate documentation of requirements and
design description should be included in their place.

*Criteria for Successful Review*

At present, any and all shortcomings (e.g. calculations not documented
and checked) can be covered by submittal of a chit at a review, while
not rendering the review \"unsuccessful\". This loophole has led to
problems. Therefore in the future [the practice of allowing chits to be
written to cover the absence of deliverables shall not be permitted,
unless approved by the NSTX Project Director (M Ono).]{.underline} If
any of the agreed to deliverables are missing then the review shall be
declared unsuccessful.

*Design Review Follow Up*

Design Review Chairperson shall submit a report to NSTX File, signed by
WBS manager following review, containing\...

• summary

• list of attendees

• recommendations

• chits and dispositions

*Procedural Steps*

The governing procedure, NSTX-PROC-004-01, outlines in detail the steps
to be taken in arranging for and conducting a review. In addition to the
steps outlined therein two new steps shall be added (and incorporated
into the governing procedure) as follows:

[1) At least twenty working days prior to the review date a meeting
shall be convened between the Cognizant Engineer, WBS manager, Design
Review Chair, and the NSTX Project Engineering Manager, at which time
the specific set of deliverables for the review shall be agreed
to.]{.underline}

[2) At least five working days prior to the review date a meeting shall
be convened between the Cognizant Engineer, WBS manager, Design Review
Chair, and the NSTX Project Engineering Manager, at which time the
Cognizant Engineer shall report on his readiness for the review. If it
is judged that he is not ready, then the review shall be postponed. In
addition, the review board membership and invitees shall be agreed
to.]{.underline}

*Essential Features of the Process*

The following features are essential to the success of the process:

• Clear definition of deliverables for review well in advance of review
date

• Check of status of work one week prior to review to ensure readiness

• Option to postpone review if not ready, rather than proceeding on an
incomplete basis

• Advance distribution of documentation package (at least three full
working days) to review board to ensure adequate time and detail of
their preparations in advance of the meeting

• Elimination of loophole allowing chits to be written against absence
of deliverables

*Relationship to OP-AD-104*

Per previous agreement (71-970728-CLN-01, \"NSTX & D-SITE Configuration
Control\"):

• Global DCAs shall be submitted for each of the NSTX Level 3 WBS
elements to introduce the NSTX work to the D-Site system;

• Supplemental DCAs, issued under the global DCA numbers, can be used to
cover pieces of the work covered under the global DCAs, and these will
use the global DCA numbers with an additional three digit code attached
(e.g. DCA-174-001);

• NSTX procedures for requirements and design documentation, and for
design reviews, satisfy the spirit of the recommendations given in
OP-AD-104 and can therefore be followed during the conduct of the NSTX
design process;

• When the time comes to make physical changes at D-Site the Design
Change Release Package called out by OP-AD-104 will be prepared in
addition to the NSTX Installation Procedure, and will be subject to
approval by the D-Site Engineering Manager prior to implementation.

cc:

J Chrzanowski

R Wilson

L Dudek

R Kaita

S Ramakrishnan

G Oliaro

E Perry

T Egebo

P Heitzenroeder

J Malsbury

M Ono

G Pitonak

J Schmidt

R Strykowsky

M Williams

NSTX File