1. Machine Installation and Construction Management Erik D. Perry Princeton Plasma Physics Laboratory NSTX Upgrade Project Office of Science Review LSB B318 October 2 nd & 3 rd, 2013 NSTX-U Supported by Culham Sci Ctr York U Chubu U Fukui U Hiroshima U Hyogo U Kyoto U Kyushu U Kyushu Tokai U NIFS Niigata U U Tokyo JAEA Inst for Nucl Res, Kiev Ioffe Inst TRINITI Chonbuk Natl U NFRI KAIST POSTECH Seoul Natl U ASIPP CIEMAT FOM Inst DIFFER ENEA, Frascati CEA, Cadarache IPP, Jülich IPP, Garching ASCR, Czech Rep Coll of Wm & Mary Columbia U CompX General Atomics FIU INL Johns Hopkins U LANL LLNL Lodestar MIT Lehigh U Nova Photonics Old Dominion ORNL PPPL Princeton U Purdue U SNL Think Tank, Inc. UC Davis UC Irvine UCLA UCSD U Colorado U Illinois U Maryland U Rochester U Tennessee U Tulsa U Washington U Wisconsin X Science LLC

2. NSTX-U NSTX Upgrade Project – Office of Science Review – October 2-3,, 2013 2 Topics Outage Planning Outage Coordination Installation Risks and Mitigations Outage Progress in 2013 Remaining Structural Work Work Once Centerstack is in NSTX Test Cell Tasks to Prepare for Return to Operations

3. NSTX-U NSTX Upgrade Project – Office of Science Review – October 2-3,, 2013 3 Outage Planning Outage planning based on bottoms-up estimates from Engineering –Assumes just 5 days per week for almost all tasks Assigns technicians, by name, to critical scope to assure staffing requirements are met Adjust start dates of tasks to assure tasks in the same area are compatible Accelerate tasks that make other tasks safer or more efficient Work crews on opposite sides of vacuum vessel or on different shifts Daily / hourly coordination of all field work is critical

4. NSTX-U NSTX Upgrade Project – Office of Science Review – October 2-3,, 2013 4 Outage Coordination Use of Work Control Center (like TFTR D&D Project) to oversee and coordinate all activities in the NSTX Test Cell All work in the NSTX Test Cell being done with Engneering Work Packages (EWPs) Work Control Center reviews all EWPs for the field –Reviews removal/installation procedures –Reviews Job Hazard Analysis (JHA) –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 the field crews are used efficiently

5. NSTX-U NSTX Upgrade Project – Office of Science Review – October 2-3,, 2013 5 Outage Coordination Daily Plan-of-the-day meetings to coordinate activities between crews and fine tune technician assignments –Includes field crew leaders, QA, Safety, Health Physics, Industrial Hygiene, DOE –Adjustments based on actual progress and manpower availability Flexibility for adjustments comes from –Second shift work –Multiple crews working on opposite sides of the vessel –Having many work packages ready for field work Safety and efficiency from –Temporary platforms to improve efficiency –Trial fit-ups to verify handling techniques and minimize time spent on NSTX –Temporary platforms to improve access and safety (inspected every shift) –Plan work so crews are on opposite sides of machine

6. NSTX-U NSTX Upgrade Project – Office of Science Review – October 2-3,, 2013 6 Installation Risks and Mitigations Delays in getting parts delivered to installation crews –Re-schedule work sequence –Schedule work on two shifts once parts arrive Scope creep –Engineering Change Proposal process –Review of engineering estimates by division heads (WAF review) Fit-up of new centerstack –Estimate includes three fit-ups

7. NSTX-U NSTX Upgrade Project – Office of Science Review – October 2-3,, 2013 7 Outage Progress in 2013 Install new umbrella legs / feet / slides Install umbrella arch reinforcements

8. NSTX-U NSTX Upgrade Project – Office of Science Review – October 2-3,, 2013 8 Outage Progress in 2013 Install reinforcements for TF to umbrella interface

9. NSTX-U NSTX Upgrade Project – Office of Science Review – October 2-3,, 2013 9 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)

10. NSTX-U NSTX Upgrade Project – Office of Science Review – October 2-3,, 2013 10 Outage Progress in 2013 Modify vacuum vessel legs to clear new TF turnbuckles

11. NSTX-U NSTX Upgrade Project – Office of Science Review – October 2-3,, 2013 11 Outage Progress in 2013 Move two TF outer legs to new locations (to make room for other work) Install two new TF outer legs to replace ones taken out of service

12. NSTX-U NSTX Upgrade Project – Office of Science Review – October 2-3,, 2013 12 Outage Progress in 2013 Re-silverplated leads on TF outer legs

13. NSTX-U NSTX Upgrade Project – Office of Science Review – October 2-3,, 2013 13 Outage Progress in 2013 Installed new cable tray around top of machine –Walking surface included in top of tray

14. NSTX-U NSTX Upgrade Project – Office of Science Review – October 2-3,, 2013 14 Outage Progress in 2013 Installed most of the TF outer leg upper support structure –Successfully proven out this very challenging installation procedure

15. NSTX-U NSTX Upgrade Project – Office of Science Review – October 2-3,, 2013 15 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

16. NSTX-U NSTX Upgrade Project – Office of Science Review – October 2-3,, 2013 16 Work Once Centerstack is in NSTX Test Cell Lift centerstack casing over the OH/TF bundle Install PF1A upper coil Install kapton/G10 flash shields Lift centerstack into vacuum vessel Install TF flex bus support rings Install ceramic break assemblies Install organ pipes Install instrumentation cables to centerstack Install CHI flags Install edge tiles in-vessel

17. NSTX-U NSTX Upgrade Project – Office of Science Review – October 2-3,, 2013 17 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

18. NSTX-U NSTX Upgrade Project – Office of Science Review – October 2-3,, 2013 18 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

19. NSTX-U NSTX Upgrade Project – Office of Science Review – October 2-3,, 2013 19 Summary The Upgrade 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 continually worked –To improve safety and efficiency –To deal with delays in getting parts –To accelerate tasks to make full use of resources 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 (SPI= 0.97, CPI= 1.09) –Will turn over NSTX to Operations in a fully ready condition