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NSTXU NBI Upgrade Overview Timothy N. Stevenson Princeton Plasma Physics Laboratory NSTX Upgrade Project Office of Science Review PPPL LSB 318 12/11/12.

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Presentation on theme: "NSTXU NBI Upgrade Overview Timothy N. Stevenson Princeton Plasma Physics Laboratory NSTX Upgrade Project Office of Science Review PPPL LSB 318 12/11/12."— Presentation transcript:

1 NSTXU NBI Upgrade Overview Timothy N. Stevenson Princeton Plasma Physics Laboratory NSTX Upgrade Project Office of Science Review PPPL LSB 318 12/11/12 & 12/12/12 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 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 Dec. 11-12, 2012 Disassemble & evaluate a TFTR BL  Decon a TFTR DT BL  Refurbish BL  Lift BL over wall – Clearance OK  Add second NBI & Services in NTC  Connect Power & Controls  Aim wider (modify VV)  Rearrange NTC to fit  Capability to run either or both  NBI Power x 2 for NSTXU  GRD Requirements for NBI System NSTX Test Cell circa May 2012 (Last Lehman Review)

3 NSTX-U NSTX Upgrade Project - Office of Science Review Dec. 11-12, 2012 NSTXU NBI Job Performance 3 * Job completed ControlNBI PlannedEarnedActual NSTXU NBI Project Cost (all k$)AccountBACEACValue CostCPISPI (through 10/31/12)Manager (BCWS)(BCWP)(ACWP) Job: 2420 - 2nd NBI Sources * Cropper 10946199 631.571.00 Job: 2425 - BL RelocationAtnafu 180315631067 9056991.290.85 Job: 2430 - 2nd NBI Decontamination * Stevenson 205720702057 20700.991.00 Job: 2440 - 2nd NBI BeamlineCropper 197915601367 152611161.371.12 Job: 2450 - 2nd NBI ServicesAtnafu 45064401684 121711131.091.78 Job: 2460 - 2nd NBI ArmorTresemer 700902392 5857170.821.49 Job: 2470 - 2nd NBI PowerRamakrishnan 33353286375 10317721.342.75 Job: 2475 - 2nd NBI ControlsCropper 26112403946 145012421.171.53 Job: 2480 - 2nd NBI/TVPS DuctBlanchard 19521938656 138214540.952.11 Job: 2485 - Vacuum Pumping SystemBlanchard 38845490 1692360.721.88 Job: 2490 - NTC Equipt RelocationsPerry 353533801442 169014401.17 Job: 7300 - NB2 ManagementStevenson 12781225616 5631.091.00 Job: 7400 - Health Physics SupportStevenson 250717061820 185410531.761.02 Total NBI Upgrade BL2 27745249491161114581125381.161.26

4 NSTX-U NSTX Upgrade Project - Office of Science Review Dec. 11-12, 2012 NSTXU Test Cell General Arrangement NSTXU BL1 BL2 Power cables TTC South Wall Helium Cryo Lines Platforms New Racks HVE NBI Duct/TVPS NSTX Gallery/DARM

5 NSTX-U NSTX Upgrade Project - Office of Science Review Dec. 11-12, 2012 NSTXU Test Cell General Arrangement NSTX Test Cell - 11/14/12

6 NSTX-U NSTX Upgrade Project - Office of Science Review Dec. 11-12, 2012 NBI Relocation in progress… 6 Complete relocation plan includes: Box Lid -90 inch Flange1Q FY13 -Source Platform1Q FY13 -Magnet & Stand1Q FY13 -Ion Dump1Q FY13 -Calorimeter1Q FY13 -DeWar1Q FY13 -High Voltage Enclosures (3) o 2-3 Q FY13 SE Door conduit removed SE Door Ducts removed SE Door Duct bypasses installed SE Shield Lintel removal BL Box modifications completed BL Lift fixture designed and approved Relocation process using air castors -Beam box and Lid o Remainder moved conventionally Moving day started in September… Complete relocation plan includes: Box Lid -90 inch Flange1Q FY13 -Source Platform1Q FY13 -Magnet & Stand1Q FY13 -Ion Dump1Q FY13 -Calorimeter1Q FY13 -DeWar1Q FY13 -High Voltage Enclosures (3) o 2-3 Q FY13 SE Door conduit removed SE Door Ducts removed SE Door Duct bypasses installed SE Shield Lintel removal BL Box modifications completed BL Lift fixture designed and approved Relocation process using air castors -Beam box and Lid o Remainder moved conventionally Moving day started in September… TFTR Test Cell & SE Door 2425 TTC 9/12/12 – a day before major relocations began

7 NSTX-U NSTX Upgrade Project - Office of Science Review Dec. 11-12, 2012 7 NBI Relocation required significant preparation… SE Door conduit removed SE Door Ducts removed SE Door Duct bypasses installed SE Shield Lintels removed BL Box modifications completed for air castors Lid Stand changes completed for air castors Sheet steel runways installed into South High Bay (not shown here)… SE Door conduit removed SE Door Ducts removed SE Door Duct bypasses installed SE Shield Lintels removed BL Box modifications completed for air castors Lid Stand changes completed for air castors Sheet steel runways installed into South High Bay (not shown here)…

8 NSTX-U NSTX Upgrade Project - Office of Science Review Dec. 11-12, 2012 8 NBI Lid Relocation: TTC 9/19/12 after the lid move Component refurbishment almost completed North side Component refurbishment almost completed North side Cleanup of TTC begun on 102’ and South side…

9 NSTX-U NSTX Upgrade Project - Office of Science Review Dec. 11-12, 2012 BL Lift fixture completed and load tested. Air castor system operational. 9 2425 Reentrant hook lift fixture design for better clearance over the NTC South Shield Wall Lift fixture fabrication in RESA Tech Shop Air castor system used on BL and Lid move from TTC to NTC South High Bay through door Show time…

10 NSTX-U NSTX Upgrade Project - Office of Science Review Dec. 11-12, 2012 NSTXU Test Cell Beam Box move– 9/13/12 Photo: Elle Starkman

11 NSTX-U NSTX Upgrade Project - Office of Science Review Dec. 11-12, 2012 NBI BL Box Relocation… TTC, South High Bay, Over the wall 11 2425 And on the vent stack…

12 NSTX-U NSTX Upgrade Project - Office of Science Review Dec. 11-12, 2012 12 NBI BL Lid Relocation… same as Box move but more involved 2425

13 NSTX-U NSTX Upgrade Project - Office of Science Review Dec. 11-12, 2012 13 NBI BL Alignment… 110, 120, 130 cm tangency radii 2425

14 NSTX-U NSTX Upgrade Project - Office of Science Review Dec. 11-12, 2012 14 NBI BL Alignment… completed 2425 Install supports Fabricate shims Install spiders Install jacking systems Setup optical alignment Survey height from BL1 and VV Install shims Survey trajectory from metrology Set and reset BL Confirm alignment Verify alignment Install supports Fabricate shims Install spiders Install jacking systems Setup optical alignment Survey height from BL1 and VV Install shims Survey trajectory from metrology Set and reset BL Confirm alignment Verify alignment “Bullseye…”

15 NSTX-U NSTX Upgrade Project - Office of Science Review Dec. 11-12, 2012 15 Calorimeter Upgrade – Parts fabrication completed Double bellows installation completed Double drive system needs replaced with correct parts External support structure work order in shop Calorimeter Upgrade – Parts fabrication completed Double bellows installation completed Double drive system needs replaced with correct parts External support structure work order in shop BL Refurbishment: Ion Dump and Calorimeter – in progress Ion Dump Replacement - Fabrication complete Leakchecking complete Reassembly in progress Thermocouples complete… Ion Dump Replacement - Fabrication complete Leakchecking complete Reassembly in progress Thermocouples complete… 2440 BL1 Calorimeter Upgrade: Double bellows double drive

16 NSTX-U NSTX Upgrade Project - Office of Science Review Dec. 11-12, 2012 16 90 inch flange refurbishment – Parts fabrication completed Feedthroughs fabricated, leakchecked, and installed OMAs reassembled and leakchecked 90 inch flange refurbishment – Parts fabrication completed Feedthroughs fabricated, leakchecked, and installed OMAs reassembled and leakchecked BL Refurbishment: 90 inch flange refurbishment in progress 2440 & Bending Magnet ready for installation…

17 NSTX-U NSTX Upgrade Project - Office of Science Review Dec. 11-12, 2012 Penetrations for water systems, power cabling, and cryogenic services 17 Penetration drilling required an articulated lift with adequate reach and ratings 6 power supply – 4 ft. 2 cryogenic piping – 6 ft. 2 water system piping (floor) – 2 ft. Penetration drilling required an articulated lift with adequate reach and ratings 6 power supply – 4 ft. 2 cryogenic piping – 6 ft. 2 water system piping (floor) – 2 ft. LN Cryo line installation Supply and Vent wall lines complete Awaiting BL platform to finish Articulated lift craned into and out of NTC… LN Cryo line installation Supply and Vent wall lines complete Awaiting BL platform to finish Articulated lift craned into and out of NTC… 2450 2470

18 NSTX-U NSTX Upgrade Project - Office of Science Review Dec. 11-12, 2012 Cryogenics Line LN and LHe piping fabrication in progress in NBI shop 18 2450 LHe Manifold & South Wall LHe Manifold & South Wall LN Pipe Nitrogen Manifold

19 NSTX-U NSTX Upgrade Project - Office of Science Review Dec. 11-12, 2012 Liquid Nitrogen and Vent installation in NTC completed along walls… 19 2450 Extend existing LN System service for BL2 Connects to BL1 now Build scaffold catwalk to access Cut into system Tee for BL2 Piping supply and vent lines on North and West wall Connections to BL2 LN manifolds & LHe deWar LHe lines will connect to existing system in TFTR TC with penetrations into NTC… Extend existing LN System service for BL2 Connects to BL1 now Build scaffold catwalk to access Cut into system Tee for BL2 Piping supply and vent lines on North and West wall Connections to BL2 LN manifolds & LHe deWar LHe lines will connect to existing system in TFTR TC with penetrations into NTC… NTC North Wall & Catwalk LN Supply Nitrogen Vent line

20 NSTX-U NSTX Upgrade Project - Office of Science Review Dec. 11-12, 2012 20 NBI Mechanical: Cryogenics Services & SF6 line NTC South Wall Cryo LHe valves Operate either BL1 or BL2 or both… Liquid Helium manifold fabrication in progress and ready for S wall…

21 NSTX-U NSTX Upgrade Project - Office of Science Review Dec. 11-12, 2012 21 NSTXU NBI Power & Controls Routing, Penetrations, Installation Procedures revised for improved penetration locations. All 6 Penetrations completed. Routing, Penetrations, Installation Procedures revised for improved penetration locations. All 6 Penetrations completed. NB Switchyard NBPC Bldg 138’ 100’ Pumproom TFTR TC TFTR TC Basement MER Accel Decel Fil&Arc Mag PLC F/O PS F/O All new cabling here… 2470 2475 NSTX TC

22 NSTX-U NSTX Upgrade Project - Office of Science Review Dec. 11-12, 2012 22 … and high voltage triax cable successfully tested here to 150 kV. Temporary hipot testing area in D site MG Building

23 NSTX-U NSTX Upgrade Project - Office of Science Review Dec. 11-12, 2012 23 Update NB N4ABC Power Supply controls to current status – done Mimic existing NSTX BL1 Controls scheme for BL2 but move NTC racks - done Reactivate N4 Local Control Centers, Hardwired Interlock System – in progress Turn BL2 Plasma Current Interlocks on (chassis still in use for BL1) - OK Add additional plasma interlock to prevent long pulse into armor- Ip & IpR - OK Expand I/O for PLC control of BL and Services but use existing PLC – I/O received Expand Thermocouple Scanning System to include BL2 & the ARMOR - OK Fold BL2 into EPICS & timing pages – in progress Update NBOS LabView Operator interface so existing staff can run 2 BLs - software in progress No new problems - many new drawings completed Update NB N4ABC Power Supply controls to current status – done Mimic existing NSTX BL1 Controls scheme for BL2 but move NTC racks - done Reactivate N4 Local Control Centers, Hardwired Interlock System – in progress Turn BL2 Plasma Current Interlocks on (chassis still in use for BL1) - OK Add additional plasma interlock to prevent long pulse into armor- Ip & IpR - OK Expand I/O for PLC control of BL and Services but use existing PLC – I/O received Expand Thermocouple Scanning System to include BL2 & the ARMOR - OK Fold BL2 into EPICS & timing pages – in progress Update NBOS LabView Operator interface so existing staff can run 2 BLs - software in progress No new problems - many new drawings completed NSTXU NBI Controls System modifications in progress… Work Scope very similar to BL1 with updates to current status

24 NSTX-U NSTX Upgrade Project - Office of Science Review Dec. 11-12, 2012 24 NSTXU NBI Power Supply Controls - One Line Diagram NBI NBPS One Line Diagram Update electronics & control circuits complete 2475

25 NSTX-U NSTX Upgrade Project - Office of Science Review Dec. 11-12, 2012 N4ABC Local Control Center upgrade and wiring in progress 25 2475 New NI chassis and LabView adds BL operator control purview Software upgrades designed and coded Additional NI and computing interfaces provide timing and data transfer with NSTX central computing and eliminates CAMAC Wiring changes in progress… New NI chassis and LabView adds BL operator control purview Software upgrades designed and coded Additional NI and computing interfaces provide timing and data transfer with NSTX central computing and eliminates CAMAC Wiring changes in progress…

26 NSTX-U NSTX Upgrade Project - Office of Science Review Dec. 11-12, 2012 N4ABC High Voltage Power Supply controls modifications completed 26 NBI Switchyard Disconnect Switch Remote ControlMod/Reg Grad Grid Divider and Controls chassis modifications 2475 New GGD here

27 NSTX-U NSTX Upgrade Project - Office of Science Review Dec. 11-12, 2012 Mod/Reg: Grad Grid Divider fabrication and assembly completed 27 2475

28 NSTX-U NSTX Upgrade Project - Office of Science Review Dec. 11-12, 2012 NBI Duct and Torus Vacuum Pumping System (TVPS) PROGRESS … 28 40” Torus Isolation (Gate) Valve received 2480 2485 TVPS valves, hardware, TMPs, and shields on order Cutting flanges… Spool section & supports Circular bellows Exit spool piece

29 NSTX-U NSTX Upgrade Project - Office of Science Review Dec. 11-12, 2012 NBI Duct Exit Spool Piece and BL TIV installed on Exit of BL… 29 2480 2485

30 NSTX-U NSTX Upgrade Project - Office of Science Review Dec. 11-12, 2012 VV Modification Bay JK weldments repaired in Tech Shop… 30 Bay JK and port extension weldments procured and received; HOWEVER… No weld prep and poor weld quality from vendor SO… PPPL Tech Shop repair and rewelding completed Additional welds added for better integrity Vacuum prep and annealing heat cycle complete Leakchecking done… Bay JK and port extension weldments procured and received; HOWEVER… No weld prep and poor weld quality from vendor SO… PPPL Tech Shop repair and rewelding completed Additional welds added for better integrity Vacuum prep and annealing heat cycle complete Leakchecking done…

31 NSTX-U NSTX Upgrade Project - Office of Science Review Dec. 11-12, 2012 VV Bay JK Modification in progress… 31 2480 Bay JK and port extension weldments final machining completed; Final metrology performed JK Pieces ready for installation on VV Lift fixture fabricated and tested Rectangular bellows completed; rectangular flange on order – due Jan. 13 Full duct assembly and leacheck off line planned 2-3 Q FY 13 Install after testing… Bay JK and port extension weldments final machining completed; Final metrology performed JK Pieces ready for installation on VV Lift fixture fabricated and tested Rectangular bellows completed; rectangular flange on order – due Jan. 13 Full duct assembly and leacheck off line planned 2-3 Q FY 13 Install after testing… Bay JK Weldment and Port Extension Rectangular Bellows Flanges On order and progressing at vendor

32 NSTX-U NSTX Upgrade Project - Office of Science Review Dec. 11-12, 2012 NBI Armor fabrication done and installation in progress… 32 2460 Bay H supports need to be field fit and aligned using backing plates before final welding… OK Backing plates fabricated Manifolds complete Carbon tiles machined Stiffener pieces fabrication done Braze/weld in shop Align/assemble/install/leakcheck Backing plates fabricated Manifolds complete Carbon tiles machined Stiffener pieces fabrication done Braze/weld in shop Align/assemble/install/leakcheck Supports aligned using metrology and tack welded in place to determine field fit changes… Bay H Port cover modifications for feedthroughs in progress. Bay H

33 NSTX-U NSTX Upgrade Project - Office of Science Review Dec. 11-12, 2012 33 NBI BL2 Upgrade GRD Requirements achieved General Arrangement maintained by Construction Manager to avoid interferences BL refurbishment almost completed… Tech Shop, Health Physics, and Work Control Center support has been excellent Relocation to NTC – major BL and Lid moves completed Services fabrication and installation has begun – water line S/C planned later this FY Power - cables received & installation S/C planned later this FY Controls progress has been tremendous on BL and NBPS Floor space has been achieved by use of gallery and new elevated platforms Duct procurements, shop work orders, and fabrication going strong VV modifications have begun – parts are here and ready Armor support installation has started and armor fabrication progressing well Preoperational testing planned to begin in FY 14 Cost and schedule indices have tracked well to date – CPI and SPI greater than 1.1 Schedule still adequate for NBI activities – not critical path NSTXU NBI project is progressing on task, under cost, on time…  NBI BL2 Upgrade GRD Requirements achieved General Arrangement maintained by Construction Manager to avoid interferences BL refurbishment almost completed… Tech Shop, Health Physics, and Work Control Center support has been excellent Relocation to NTC – major BL and Lid moves completed Services fabrication and installation has begun – water line S/C planned later this FY Power - cables received & installation S/C planned later this FY Controls progress has been tremendous on BL and NBPS Floor space has been achieved by use of gallery and new elevated platforms Duct procurements, shop work orders, and fabrication going strong VV modifications have begun – parts are here and ready Armor support installation has started and armor fabrication progressing well Preoperational testing planned to begin in FY 14 Cost and schedule indices have tracked well to date – CPI and SPI greater than 1.1 Schedule still adequate for NBI activities – not critical path NSTXU NBI project is progressing on task, under cost, on time…  NSTXU NBI: Conclusion

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