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NSTXU Project UpdateNSTXU Project Update
Jim Chrzanowski, Larry Dudek, Erik Perry, Tim Stevenson, Ron Strykowsky and the
Project Team
October 4th, 2013
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 – Team Meeting– October 4h 2013 2
Detailed Presentations of Progress at;
http://evms.pppl.gov/Lehman_131002/Agenda/index.html
NSTX-UNSTX-U NSTX Upgrade Project – Team Meeting– October 4h 2013 3
•Excellent safety record.
•On schedule and cost.
•On track for January rough pump down.
NB Cryogenic services complete
3 HVE’s installed
Cable tray and diagnostic rack re-installation
underway
All Outer TF coils installed
along with inter linkages
NB DI water piping
installation nearing
completion
Neutral beam vessel port installed
on the vacuum vessel
(Level II milestone)
Platform installation completed
Source platform installed
NB Power cabling
underway
NSTXU Test Cell September 2013 -Significant progress
Umbrella structural
modifications (incl legs) completed
NSTX-UNSTX-U NSTX Upgrade Project – Team Meeting– October 4h 2013 4
Neutral Beams
NSTX-UNSTX-U NSTX Upgrade Project – Team Meeting– October 4h 2013 5
N4ABC High Voltage Enclosure relocation completed – 3 HVEs 2425
NSTX-UNSTX-U NSTX Upgrade Project – Team Meeting– October 4h 2013 6
N4ABC High Voltage Enclosure relocations completed 2425
NSTX-UNSTX-U NSTX Upgrade Project – Team Meeting– October 4h 2013 7
BL2 Transmission Line relocation awaits cable and tray installation
Transmission Line spool pieces ordered and receivedTransmission Line spool pieces ordered and received
Transmission Lines in TCB awaiting completion of cable and tray installation to avoid
potential damage
Transmission Lines in TCB awaiting completion of cable and tray installation to avoid
potential damage
NSTX-UNSTX-U NSTX Upgrade Project – Team Meeting– October 4h 2013 8
NBI Port Extension trial fit completed 2480
TF outer leg clearances maintainedTF outer leg clearances maintained Maintained ¾ inch clearance to Port Extension
for OL deflection per spec
Maintained ¾ inch clearance to Port Extension
for OL deflection per spec
Awaiting NBI Duct installation…Awaiting NBI Duct installation…
NSTX-UNSTX-U NSTX Upgrade Project – Team Meeting– October 4h 2013 9
NTC Access platforms modifieddue to BL2 placement
NTC Access platforms modifieddue to BL2 placement
After cryo line installation in TTC HVAC and Stack Ductmoved and modified…
After cryo line installation in TTC HVAC and Stack Ductmoved and modified…
…and restored to service prior to Start of Cable and Tray subcontract…and restored to service prior to
Start of Cable and Tray subcontract
BL2 area changes required for relocation completed
NSTX-UNSTX-U NSTX Upgrade Project – Team Meeting– October 4h 2013 10
Cryogenics Line LN and LHe piping fabrication completed in NBI shop2450
Cryo line fabricationCryo line fabrication
Cryo line installationCryo line installation
Cryo line installationCryo line installation
Cable and tray pathCable and tray path
NSTX-UNSTX-U NSTX Upgrade Project – Team Meeting– October 4h 2013 11
Deionized Water Piping subcontract completed (source, dump, HVE) 2450
NSTX-UNSTX-U NSTX Upgrade Project – Team Meeting– October 4h 2013 12
NBI Armor assembly and installation in progress…
2460
Painstaking trail fit made and supports aligned. Final structural welding completed.Painstaking trail fit made and supports aligned. Final structural welding completed.
NSTX-UNSTX-U NSTX Upgrade Project – Team Meeting– October 4h 2013 13
NBI Duct & TVPS duct fabrication completed 24802485
… and leakchecked.… and leakchecked.
Stainless circular shields complete
Moly shields for rectangular bellows in progress
Stainless circular shields complete
Moly shields for rectangular bellows in progress
NSTX-UNSTX-U NSTX Upgrade Project – Team Meeting– October 4h 2013 14
NBI Duct & TVPS duct fabrication completed 24802485
… and leakchecked.… and leakchecked.
Stainless circular shields complete
Moly shields for rectangular bellows in progress
Stainless circular shields complete
Moly shields for rectangular bellows in progress
NSTX-UNSTX-U NSTX Upgrade Project – Team Meeting– October 4h 2013 15
Centerstack
NSTX-UNSTX-U NSTX Upgrade Project – Team Meeting– October 4h 2013 16
Center Stack Status Since Last Review
• Inner TF Bundle– (4) TF Quadrants have been VPI’d
– Full TF Bundle has been VPI’d
• OH Solenoid– Major tooling has been delivered
– Begin winding OH solenoid- October 2013
– VPI OH Solenoid- January 2014
• Centerstack Casing– Delivered and studs have been installed-
• Outer TF Coils– (2) New TF Coils fabricated
• Centerstack Assembly- – Final CS assembly will occur between
February- May 2014
Work was supported by Steve Raftopoulos, Mike Mardenfeld, Irv Zatz & Technician crews led by Mike Anderson and Eugene Kearns
NSTX-UNSTX-U NSTX Upgrade Project – Team Meeting– October 4h 2013 17
Step 4- Full TF Assembly
• The four VPI’s quadrants were then assembled together to complete the full bundle.
Quadrants are ground wrapped with layers of S-2 glass tape
The full TF bundle is placed into a mold and VPI’d
The quadrants will be assembled w/ S-2 between layers & pre-insulated G-10 core
The full TF bundle is Ground wrapped with S-2 glass tape
NSTX-UNSTX-U NSTX Upgrade Project – Team Meeting– October 4h 2013 18
Step 5- Full TF Bundle Assembly
Full TF Bundle in oven and ready for VPI
Full TF Bundle after VPI
NSTX-UNSTX-U NSTX Upgrade Project – Team Meeting– October 4h 2013 19
OH/TF Bundle Tooling
• A new CS “Tilt Fixture” has been fabricated by Astro Machine Works Inc.• Fixture will be used for up-righting the CS
to the vertical position
NSTX-UNSTX-U NSTX Upgrade Project – Team Meeting– October 4h 2013 20
Step 6- Post VPI
• Complete the electrical tests on TF bundle• Install the “Aquapour” filler over the TF bundle
surface– “Aquapour” is used as a temporary spacer that will be
used to maintain 0.100 inch gap between the TF OD and OH ID surfaces. It is removed post VPI of OH coil
• Mount TF Bundle into winding station• Begin winding operations
NSTX-UNSTX-U NSTX Upgrade Project – Team Meeting– October 4h 2013 21
Fabrication of OH Solenoid
• The OH Solenoid will be wound onto the Inner TF Bundle• The CS High Bay area is being reconfigured to wind the OH coil
NSTX-UNSTX-U NSTX Upgrade Project – Team Meeting– October 4h 2013 22
Centerstack Casing
• The Centerstack Inconel casing has been manufactured by Martinez & Turek located in California.
• Inconel studs for supporting the PFC’s have been installed
NSTX-UNSTX-U NSTX Upgrade Project – Team Meeting– October 4h 2013 23
Construction and Machine
Assembly
NSTX-UNSTX-U NSTX Upgrade Project – Team Meeting– October 4h 2013 24
Outage Progress in 2013
• Install new umbrella legs / feet / slides• Install umbrella arch reinforcements
NSTX-UNSTX-U NSTX Upgrade Project – Team Meeting– October 4h 2013 25
Outage Progress in 2013
• Install reinforcements for TF to umbrella interface
NSTX-UNSTX-U NSTX Upgrade Project – Team Meeting– October 4h 2013 26
Outage Progress in 2013
• Replace PF2/3 clamp hardware and install additional PF2 clamps
• Install new PF4/5 supports and replace existing hardware (still in progress)
NSTX-UNSTX-U NSTX Upgrade Project – Team Meeting– October 4h 2013 27
Outage Progress in 2013
• Modify vacuum vessel legs to clear new TF turnbuckles
NSTX-UNSTX-U NSTX Upgrade Project – Team Meeting– October 4h 2013 28
Outage Progress in 2013
• Re-silverplated leads on TF outer legs
NSTX-UNSTX-U NSTX Upgrade Project – Team Meeting– October 4h 2013 29
Outage Progress in 2013
• Installed new cable tray around top of machine– Walking surface included in top of tray
NSTX-UNSTX-U NSTX Upgrade Project – Team Meeting– October 4h 2013 30
Outage Progress in 2013
• Installed most of the TF outer leg upper support structure– Successfully proven out this very challenging installation procedure
NSTX-UNSTX-U NSTX Upgrade Project – Team Meeting– October 4h 2013 31
Remaining Structural Work
• Finish installing new PF4/5 supports and replace existing columns
• Install new TF outer leg lower supports
• Install new centerstack pedestal
• Install TF outer support turnbuckles
• Add extensions and anchors to vacuum vessel leg struts
NSTX-UNSTX-U NSTX Upgrade Project – Team Meeting– October 4h 2013 32
Work Once Centerstack is in NSTX Test Cell
• Install bus inside umbrella and back to racks
• Install new TF flex bus
• Field measure space between centerstack and all TF flags
• Fabricate 72 unique centerstack to TF flag links
• Install umbrella lid support rings
• Install new umbrella lids
NSTX-UNSTX-U NSTX Upgrade Project – Team Meeting– October 4h 2013 33
Tasks to Prepare for Return to Operations
• Clean, photo and close the vacuum vessel
• Pumpdown
• Leak check
• Bakeout
All routine tasks at the end of an outage
NSTX-UNSTX-U NSTX Upgrade Project – Team Meeting– October 4h 2013 34
CD-4 SEPT 30 2015
CD-4 SEPT 30 2015
Forecast November 2014
Forecast November 2014
CD-3 Dec 2011CD-3 Dec 2011
Schedule on track for early finish
• ~3/4 the way through the Centerstack fabrication !
• Key to meeting CD-4 and cost containment Complete and deliver the centerstack to the test cell for installation by May 2014!
• ~3/4 the way through the Centerstack fabrication !
• Key to meeting CD-4 and cost containment Complete and deliver the centerstack to the test cell for installation by May 2014!
Deliver CS to Test Cell May 2014Deliver CS to Test Cell May 2014
NSTX-UNSTX-U NSTX Upgrade Project – Team Meeting– October 4h 2013 35 35
Lehman Review-Recommendations
1. Construction Efforts: Are construction efforts being executed safely? Does the project have adequate resources and the appropriate skills mix to execute the project per the plan? YES..but $
2. Baseline Cost and Schedule: Are the current project cost and schedule projections consistent with the approved baseline cost and schedule? Is the contingency remaining adequate for the risks that remain? YES..but $
3. Management: Evaluate the management structure as to its adequacy to deliver the scope within budget and schedule. Are risks being actively managed? Has the project responded satisfactorily to the recommendations from the previous project reviews? YES..but $
4. Transition to Operations: Is the Project appropriately aligned for completion of construction efforts and transitioning to NSTX-U for CD-4 approval? YES.
NSTX-UNSTX-U NSTX Upgrade Project – Team Meeting– October 4h 2013 36
Summary• The project has maintained a safe working
environment.
• The project continues to make good technical progress.
• The project is on schedule and cost with adequate contingency to finish.
• The project is sufficiently staffed to meet schedule.
• The project is on track for meeting CD-2 baseline within OFES budgetary guidance.
• The project is preparing for transitioning into operations.
• The project has maintained a safe working environment.
• The project continues to make good technical progress.
• The project is on schedule and cost with adequate contingency to finish.
• The project is sufficiently staffed to meet schedule.
• The project is on track for meeting CD-2 baseline within OFES budgetary guidance.
• The project is preparing for transitioning into operations.