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Machine Installations and Machine Installations and Construction ManagementConstruction Management
Erik D. Perry
Princeton Plasma Physics LaboratoryNSTX Upgrade Project
Office of Science ReviewLSB B318
May 2 - 3, 2012
NSTX-UNSTX-U Supported by
Culham Sci CtrYork U
Chubu UFukui U
Hiroshima UHyogo UKyoto U
Kyushu UKyushu Tokai U
NIFSNiigata UU Tokyo
JAEAInst for Nucl Res, Kiev
Ioffe InstTRINITI
Chonbuk Natl UNFRI
KAISTPOSTECH
Seoul Natl UASIPP
CIEMATFOM Inst DIFFER
ENEA, FrascatiCEA, Cadarache
IPP, JülichIPP, Garching
ASCR, Czech Rep
Coll of Wm & MaryColumbia UCompXGeneral AtomicsFIUINLJohns Hopkins ULANLLLNLLodestarMITLehigh UNova PhotonicsOld DominionORNLPPPLPrinceton UPurdue USNLThink Tank, Inc.UC DavisUC IrvineUCLAUCSDU ColoradoU IllinoisU MarylandU RochesterU TennesseeU TulsaU WashingtonU WisconsinX Science LLC
NSTX-UNSTX-U NSTX Upgrade Project – Office of Science Review – May 2nd – 3rd 2012 2
NSTX Upgrade Outage
• A plan has been developed for performing the NSTX Upgrade Outage– Based on experience from similar outages since 1984– Plan is being continually improved as opportunities arise
• A system for coordinating and controlling the outage tasks is in place– Based on the very successful Work Control Center that was used
during the TFTR D&D Project• Assuring safety, efficiency and correct performance
NSTX-UNSTX-U NSTX Upgrade Project – Office of Science Review – May 2nd – 3rd 2012 3
Outage Planning
• Outage planning based on bottoms-up estimates from Engineering– Assumes one shift, 5 days per week for almost all work
• Assigns technicians, by name, to scope to assure staffing requirements are met
• Adjust start date of tasks to assure tasks in the same area are compatible
• Accelerating tasks that make other tasks safer or more efficient• Peel back cabling and fiber optics, rather than removing them, when
access is needed to perform tasks
10/20/11 11/03/11
NSTX-UNSTX-U NSTX Upgrade Project – Office of Science Review – May 2nd – 3rd 2012 4
Outage Planning cont
• Work in Bays J, K and L most congested– Neutral beam installation, including cutting large hole in vessel– Coil supports and umbrella modifications for center stack– Diagnostic relocations, including cutting large hole in vessel
• Work crews on opposite sides of vacuum vessel or on different shifts
• Assume moving NB box into test cell will impact other activities until box can be sealed
• Pre-plan temporary storage areas to minimize handling
• Daily / hourly coordination of all field work is critical
11/17/11 11/23/11
NSTX-UNSTX-U NSTX Upgrade Project – Office of Science Review – May 2nd – 3rd 2012 5
Outage Coordination
• Use of Work Control Center (like TFTR D&D Project)• Work Control Center reviews all Engineering Work Packages for the field
– Reviews Job Hazard Analysis (JHA)– Assures pre-requisites are done– Attends pre-job and post-job briefs– Interfaces between Engineering and the field crews– Assures that the field work is done safely and correctly– Assures that the field crews are used efficiently
• Daily Plan-of-the-day meetings to coordinate activities between crews and fine tune technician assignments
12/7/11 12/14/11 Set up for machining o-ring groove in upper flange
NSTX-UNSTX-U NSTX Upgrade Project – Office of Science Review – May 2nd – 3rd 2012 6
NSTX-U Outage Plan Schedule
NSTX-UNSTX-U NSTX Upgrade Project – Office of Science Review – May 2nd – 3rd 2012 7
NSTX-U Outage Plan Schedule cont
NSTX-UNSTX-U NSTX Upgrade Project – Office of Science Review – May 2nd – 3rd 2012 8
Start of the Outage
• Established construction power
• Disconnected all power to the NSTX Test Cell (NTC)
except lighting and construction power
• Vented vacuum vessel and ventilated to the outside– No vessel entry at this time
NSTX-UNSTX-U NSTX Upgrade Project – Office of Science Review – May 2nd – 3rd 2012 9
October 2011 – January 2012
• Removed RF piping within 10’ of vacuum vessel– To permit access to east side of machine
• Removed cable tray at top of machine– To permit crane access for heavier diagnostics
• Installed new 119” EL platform on west side– To permit moving racks to new location, not just temporary storage
– To provide space to re-work passive plates
• Started rack removals to make room for NB2
• 10/20/11 1/27/12
NSTX-UNSTX-U NSTX Upgrade Project – Office of Science Review – May 2nd – 3rd 2012 10
October 2011 – January 2012
• Removed old pump duct
NSTX-UNSTX-U NSTX Upgrade Project – Office of Science Review – May 2nd – 3rd 2012 11
October 2011 – January 2012cont
• Removed old centerstack• Removed diagnostics from the machine
– Stored in upper DARM located by the bay they came from– Larger items stored in TFTR basement
NSTX-UNSTX-U NSTX Upgrade Project – Office of Science Review – May 2nd – 3rd 2012 12
October 2011 – January 2012cont
• Coiled up cables, tubing and fibers from around machine– Did not remove cables etc – too costly and time consuming to
replace
NSTX-UNSTX-U NSTX Upgrade Project – Office of Science Review – May 2nd – 3rd 2012 13
February 2012 – April 2012
• Installed extensive scaffolding to facilitate access to the upper and lower domes of the vacuum vessel– Improved safety for workers
– Improved efficiency of removal and welding tasks
– Inspected every shift as required by OSHA
NSTX-UNSTX-U NSTX Upgrade Project – Office of Science Review – May 2nd – 3rd 2012 14
February 2012 – April 2012 cont
• Added additional welding to ribs on upper and lower vacuum vessel domes– Utilized a crew to prep welding area and parts to minimize welder time (since
welders in short supply)
• Removed passive plates from in-vessel for replacement of hardware• Removed old outer TF support structure
– Permitted fit-up of prototype parts of the new design to verify design
NSTX-UNSTX-U NSTX Upgrade Project – Office of Science Review – May 2nd – 3rd 2012 15
Plan for May 2012
• Change mounting hardware for passive plates
NSTX-UNSTX-U NSTX Upgrade Project – Office of Science Review – May 2nd – 3rd 2012 16
Plan for May 2012
• Cut off vessel nozzles at Bays J, K and L• Upper vessel work at Bays J, K, and L
– Umbrella legs, TF clevis pads PF2/3 clamps
NSTX-UNSTX-U NSTX Upgrade Project – Office of Science Review – May 2nd – 3rd 2012 17
Plan for June 2012
• In-vessel set-up for vacuum vessel cutting– Installing support beams, containment and ventilation
• Ex-vessel set-up for vessel cutting– Installing containment and ventilation
• Vessel cutting at Bays J and K for new neutral beam port• Weld JK cap onto vessel
NSTX-UNSTX-U NSTX Upgrade Project – Office of Science Review – May 2nd – 3rd 2012 18
Plan for July 2012
• Ex-vessel set-up for cutting at bay L– Installing containment and ventilation
• Vacuum vessel cutting at Bay L for new diagnostics port• Remove temporary in-vessel beams and ventilation• Leak check welds on Bays JK cap• Remove platform at Bays JKL
NSTX-UNSTX-U NSTX Upgrade Project – Office of Science Review – May 2nd – 3rd 2012 19
Plan for August – October 2012
• Move Neutral Beam #2 enclosure into NSTX Test Cell (NTC)• Assemble Neutral Beam #2 in NTC• Decon exterior of Neutral Beam #2 and all affected areas in NTC
NSTX-UNSTX-U NSTX Upgrade Project – Office of Science Review – May 2nd – 3rd 2012 20
Plan for October 2012 – September 2013
• Complete modifications to umbrella and coil supports• Complete Neutral Beam systems• Re-install items removed for centerstack work• Re-install items removed for NB work
NSTX-UNSTX-U NSTX Upgrade Project – Office of Science Review – May 2nd – 3rd 2012 21
Plan for October 2013 – March 2014
• Install Centerstack• Pumpdown / leakcheck vacuum vessel• Bakeout• ISTP
NSTX-UNSTX-U NSTX Upgrade Project – Office of Science Review – May 2nd – 3rd 2012 22
Summary
• The NSTX Outage has been planned based on– Bottoms-up estimates from Engineering
– Identifying staff to do the work
– Scheduling work to avoid conflicts
• The plan is being continuously worked– To improve safety and efficiencies
– To deal with delays in getting parts
– To accelerate tasks to ease pressure on critical path tasks
• Coordination and Control– Provided by the Work Control Center
– At the Plan-of-the-day meeting
– Continuously by the Field Supervisors
• Successfully performing the outage