nstxu project update jim chrzanowski, larry dudek, erik perry, tim stevenson, ron strykowsky and the...

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


•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


Neutral Beams


N4ABC High Voltage Enclosure relocation completed – 3 HVEs 2425


N4ABC High Voltage Enclosure relocations completed 2425


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


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…


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


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


Deionized Water Piping subcontract completed (source, dump, HVE) 2450


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.


NBI Duct & TVPS duct fabrication completed 24802485

… and leakchecked.… and leakchecked.

Stainless circular shields complete

Moly shields for rectangular bellows in progress




NBI Duct & TVPS duct fabrication completed 24802485

… and leakchecked.… and leakchecked.






Centerstack


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


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


Step 5- Full TF Bundle Assembly

Full TF Bundle in oven and ready for VPI

Full TF Bundle after VPI


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


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


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


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


Construction and Machine

Assembly


Outage Progress in 2013

• Install new umbrella legs / feet / slides• Install umbrella arch reinforcements



• Install reinforcements for TF to umbrella interface



• Replace PF2/3 clamp hardware and install additional PF2 clamps

• Install new PF4/5 supports and replace existing hardware (still in progress)



• Modify vacuum vessel legs to clear new TF turnbuckles



• Re-silverplated leads on TF outer legs



• Installed new cable tray around top of machine– Walking surface included in top of tray



• Installed most of the TF outer leg upper support structure– Successfully proven out this very challenging installation procedure


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


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


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


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.


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.

nstxu project update jim chrzanowski, larry dudek, erik perry, tim stevenson, ron strykowsky and the...

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