NSTX Centerstack Fabrication James H. Chrzanowski and the NSTX Upgrade Team Princeton Plasma Physics Laboratory NSTX Upgrade Project Office of Science Review LSB B318 May 2 - 3, 2012 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

NSTX-U NSTX Upgrade Project – Office of Science Review – May 2 nd – 3 rd Progress Since Last Review A great deal of work and accomplishments have been achieved since the last review. –TF Conductor Sub-assembly operations are underway –Solder trials for TF conductor have been completed –Centerstack Casing fabrication is underway –Area preparation for Centerstack fabrication has been completed –Tooling fabrication and procurement is underway –OH conductor has been shipped –Outer TF Coils procurement now underway –Final Centerstack Assembly on schedule for October 2013 completion

NSTX-U NSTX Upgrade Project – Office of Science Review – May 2 nd – 3 rd General Arrangement 3 TF Flex Bus and Support Structure Centerstack Assembly Outer TF Coils Major Centerstack Components Umbrella Structure Vacuum Vessel

NSTX-U NSTX Upgrade Project – Office of Science Review – May 2 nd – 3 rd TF Conductor Assembly Major Tool and Edison Welding Institute have successfully delivered to PPPL four (4) TF conductors. The balance of the conductors for first Quadrant will be delivered by mid May. Final development of the Friction Stir Welding (FSW) procedures and the necessary NDT testing has started slowly. However these delays have now ended and production has started.

NSTX-U NSTX Upgrade Project – Office of Science Review – May 2 nd – 3 rd TF Fabrication Sequence Bars shipped to Major Tool Bars shipped back to PPPL Bars are shipped to Major Tool Bars shipped to EWI Leads extensions are FSW to conductors Bars inspected at Major Tool & preliminary machining performed FSW joints are Non Destructively TestedFinal machining of TF Assemblies

NSTX-U NSTX Upgrade Project – Office of Science Review – May 2 nd – 3 rd TF Conductor Production Videos

NSTX-U NSTX Upgrade Project – Office of Science Review – May 2 nd – 3 rd TF Solder Trials Solder Trials: –Trials have been performed with the assistance of Solder Consultant to verify materials and heating processes –Successful heat runs w/actual TF bar Materials: –Solder paste Sn /3.5 Ag w/ GMS based R flux [Glyceryl Mono-stearate, Terigitol (a detergent) and Cyclohexlamine Hydro-bromide] Solder Temperatures: –Liquidus ~221º C (430º F) –Soludus~ 246º C (475ºF) –TF solder temperature~ 270 degrees C to ensure wetting Heating Method: –Power supply w/heating plate –Torch heat to complete process Begin production soldering first week of May

NSTX-U NSTX Upgrade Project – Office of Science Review – May 2 nd – 3 rd Centerstack Casing The contract for manufacturing the Inconel casing has been awarded to Martinez & Turliz in California. They have been making good progress in the manufacturing –Raw material has all been received –Main components have been rolled and welded –Flanges have been machined –Inconel forgings for the transition sections will arrive in mid May PPPL team will revisit in May Delivery scheduled

NSTX-U NSTX Upgrade Project – Office of Science Review – May 2 nd – 3 rd Area Setup- TF Fabrication VPI Station

NSTX-U NSTX Upgrade Project – Office of Science Review – May 2 nd – 3 rd Safety Involvement The fabrication & assembly of the Centerstack will be performed by PPPL personnel at the laboratory. Safety is an important part of the PPPL culture Safety is incorporated in all aspects of the development program- carryover to production Industrial Hygiene (IH) has participated in the planning and setup of the coil area Job Hazard Analysis (JHAs) are being developed for each procedure Procedures: Clearly identify safety precautions for specific operations Personnel protective equipment (PPEs) being used Involvement of all safety groups

NSTX-U NSTX Upgrade Project – Office of Science Review – May 2 nd – 3 rd Tooling Fabrication and Procurement Inner TF Bundle- tooling –Soldering station- complete –Grit blasting station complete –Turn insulation station complete –Oven commissioned- complete –Quadrant mold- Delivery 1 st. week of May –Priming station complete –VPI station- complete –Full TF mold- Requisition in system

NSTX-U NSTX Upgrade Project – Office of Science Review – May 2 nd – 3 rd Tooling Fabrication and Procurement OH Solenoid- tooling –OH copper conductor has been procured-delivery early May –OH conductor sandblasting & priming will be sub-contracted –October 2012 –Induction braze station has been procured to support OH braze joints- delivery end of May Braze qualification program scheduled for this summer –Aquapour mold fabrication- complete Trials have been scheduled for later this summer –Tension unit & taping machines are scheduled for fabrication this summer –OH Mold has been designed, but will not be procured until October 2012 –OH Winding station- winder delivered

NSTX-U NSTX Upgrade Project – Office of Science Review – May 2 nd – 3 rd OH Solenoid Winding Facility

NSTX-U NSTX Upgrade Project – Office of Science Review – May 2 nd – 3 rd Mock TF Bundle with 3x Mold Segments Center Stack Immediately Before Washing Aquapour Rolled Aluminum Cylinder Represents TF Bundle Maintains true TF OD and clearance space at top and bottom Will use actual mold segments and alignment pins Will test: 1. Filling of Aquapour 2. Curing of Aquapour with heating blankets 3. Washing Out of Aquapour T ESTING OF A QUAPOUR FOR C ENTER S TACK F ABRICATION Trials will be performed this summer

NSTX-U NSTX Upgrade Project – Office of Science Review – May 2 nd – 3 rd Lehman Review Recommendation dispositon log L02from October 2011 Lehman Review –Item:2.2Evaluate procuring spare key fabrication tooling ( e.g. induction heater) to reduce schedule risk from failures prior to start of fabrication. –Status: The project has procured induction braze unit- delivery end of May –Spare parts: investigated purchase of spare parts. Parts are readily available so only spare work coil procured. A total of 24 production induction brazes are needed for OH solenoid

NSTX-U NSTX Upgrade Project – Office of Science Review – May 2 nd – 3 rd Plans Forward for Centerstack Components Inner TF Bundle –VPI first Quadrant- July 12, 2012 –VPI Full Bundle- January 15, 2013 OH Solenoid –Begin winding OH solenoid- March 20, 2013 –VPI OH Solenoid- July 1, 2013 Centerstack Casing –Delivery is scheduled for September 2012 Outer TF Coils –Requisition has been submitted to procurement –Delivery two (2) OTF coils- December 2012

NSTX-U NSTX Upgrade Project – Office of Science Review – May 2 nd – 3 rd Plans Forward- continued Inner Poloidal Field Coils –Place purchase order for PF coils- October 2012 –Delivery spring/summer 2013 TF buss and support components –Place requisitions in procurement- October 2012 –> $946.0 k procurements Centerstack Assembly- –Assembly will occur between May to October 2013 –Developing Assembly procedures Deliver completed Centerstack Assembly October 2013 MT Torque-nut Flex-Bus (Cu-Cr-Zr)

NSTX-U NSTX Upgrade Project – Office of Science Review – May 2 nd – 3 rd Conclusion The risks associated with the production of the TF conductors have been addressed and conductors are being delivered The soldering trials have been completed and the first conductor is ready to be soldered The TF bundle manufacturing facility has been setup and ready to begin production –Awaiting delivery of molds and completion of procedures The Inconel casing has been ordered and is on schedule The OH conductor has been shipped Tooling for the OH winding has been developed. Some has been delivered the balance will be ordered this summer The production of the Centerstack Assembly is ready to begin