Progress to Date

PPPL Advisory Board Meeting May 2010 1NSTX Upgrade – R. L. Strykowsky

• CD-0 Approved February 2009• The NSTX Upgrade Project organization formally established under the Associate

Director for Engineering and Infrastructure.• Successful technical conceptual peer reviews.• Bottoms-up cost and schedule estimate prepared• Successful Independent CDR October 28-29th

• CD-1 Documentation Prepared in compliance with DOE Order 413.3• Successful OFES (Lehman) Review December 15th–16th

• Value engineering has resulted in ~$5M cost reductions in the coil support design /installation and NBI decontamination & refurbishment

• Successful technical preliminary design peer review held March 3rd for Neutral Beam #2

• Extensive iteration of project cost, schedule and scope with OFES• CD-1 Approved April 15th

• Peer Review April 21st

• CS Preliminary Design Peer Review April 29th

• NBI Decontamination

2nd Neutral Beam Decontamination in progress

PPPL Advisory Board Meeting May 2010 2NSTX Upgrade – R. L. Strykowsky

Plans for 2010

PPPL Advisory Board Meeting May 2010 3NSTX Upgrade – R. L. Strykowsky

• Preliminary Design– FMEA analysis, Design models, stress, EM,&

Thermal Analyses– Complete NBI Decontamination– R&D Activities (joint test, OH braze testing flex joint

mockup)– Update GRD for CS– Updated CD-2 Estimates– Project comprehensive PDR June 23rd – 24th

Outside reviewers

All WBS elements included

Includes Management assessment of CD-2 readiness

• Office of science review August 10th-11th

• Apply for CD-2 August 2010• CD-2 Approval September 2010• Begin Final Design after CD-2 approval

Plans for 2011

PPPL Advisory Board Meeting May 2010 4NSTX Upgrade – R. L. Strykowsky

• DOE Authorization to buy critical procurements– TF Inner Conductor (November Award)

– TF Machining (April Award)

• Begin NBI refurbishment (requires DOE authorization prior to CD-3)

• CS and NBI final design and analysis• CS and NBI Final Peer reviews mid-FY 2011• Final Design Review 3rd quarter FY 2011• OFES (Lehman review) 4th quarter FY 2011• CD-3 Approval Late FY 2011

• Complete Inner TF Fabrication (conductor machining, friction stir weld leads, procure OH conductor)

Plans for 2012

PPPL Advisory Board Meeting May 2010 5NSTX Upgrade – R. L. Strykowsky

• Begin TF/OH final assembly

• CS tile procurement

• NBI major procurements (duct, vessel cap, bellows, tiles)

• NBI Services

• Beamline relocation preparations (fixtures, procedures)

• Removal procedures and re-installation design

• Complete FY12 operations campaign and begin outage

• Start Diagnostics removals

Project Cost and Schedule Range

PPPL Advisory Board Meeting May 2010 6NSTX Upgrade – R. L. Strykowsky

• $72M being re-directed from within the NSTX Program• $3M - $21M Incremental funding required from DOE

LOW Range

FY 2010 FY 2011 FY 2012 FY 2013 FY 2014 FY 2015 FY 2016

Operations

Run Weeks 14 14 10Project Cost $9.0 $8.5 $15.8 $24.6 $11.7 $74.7 (2)

HIGH Range

FY 2010 FY 2011 FY 2012 FY 2013 FY 2014 FY 2015 FY 2016

Operations

Run Weeks 14 14 10Project Cost $9.0 $8.5 $15.8 $27.2 $25.5 $1.9 $92.9 (2)

(2) includes FY09

CS & NBI Outage PS

PDR FDRCD-4

OUTAGE 25 mos.

Begin Outage Begin Machine Ops (early start)

PDR FDRCD-4

OUTAGE 30 mos.

Begin Outage Begin Machine Ops (early start)

• Critical path through design, fabrication, installation and test of center TF/OH.• 41 month critical path from award of TF copper.• Requires early purchase of TF Copper Dec 2010

Milestones

CD-4 Definition

PPPL Advisory Board Meeting May 2010 7NSTX Upgrade – R. L. Strykowsky

Center Stack•First plasma with an ohmically heated discharge > 50 kA at a toroidal magnetic field of > 1 kG.

Second neutral beam installed and;•The beamline has been pumped to a vacuum better than 10 mTorr;•Beamline water, vacuum, cryogenics, and feedstock gas services have been attached to the beamline;•Three sources placed on alignment rails on the beamline source platform;•Power testing has demonstrated Accel High Voltage standoff to > 80 kV through the high voltage enclosure;•A Torus Isolation Valve and duct interconnects the NSTX vacuum vessel and the neutral beamline;•Armor has been reconfigured in the vacuum vessel;•Local Control Centers have been powered on to monitor power supply status, and;•Project will be verified as complete when a 40,000 electron-volt beam has been produced.

Demonstrated Performance at Completion

Risks, Issues, Opportunities

PPPL Advisory Board Meeting May 2010 8NSTX Upgrade – R. L. Strykowsky

▲ No significant jugular risk ~$3M total at time of CD-1 review.

▲ Approx 43 open risk remaining - covered by mitigation plans and contingency

▲ No large or long lead procurements─ PFC Tile $650K & 4 mos.─ Cable installation $535K and 8 mos.─ Rectangular bellows $400K and 9 mos.─ NBI Cables $422K and 5 mos.─ TF copper $242K and 5 mos.

▲ 78% of project cost for in-house labor – under PPPL control

▼ DOE fiscal pressure results in backend loading funding profiles resulting

▼ Project not funded separately thus subject to annual competition of funds from

within NSTX program.

► Purchase copper & machining desirable to leverage critical path