NSTX Centerstack Fabrication Status NSTX Centerstack Fabrication Status James H. Chrzanowski and the NSTX Upgrade Team Princeton Plasma Physics Laboratory NSTX Upgrade Project Office of Science Review LSB B318 December 11-12, 2012 NSTX-U 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. Supported by. NSTX Centerstack Fabrication Status. 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 - PowerPoint PPT Presentation
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NSTX Centerstack Fabrication StatusNSTX Centerstack Fabrication Status
NSTX-UNSTX-U NSTX Upgrade Project – Office of Science Review – December 11-12, 2012 2
Progress Since Last Review
• A great deal of work and accomplishments have been achieved since the last review.– TF Conductor Sub-assembly procurement is proceeding smoothly– Soldering of cooling tubes in TF conductor (Full TF Bundle) is nearly
complete– Centerstack Casing fabrication is nearly complete– Coil manufacturing area for Centerstack is in full operation– Final tooling fabrication and procurement for OH is underway– OH and PF conductor has been completed– Completed testing of the Aquapour– Outer TF Coils procurement has been awarded – Inner PF coil contract requisition has been submitted– Delivery of Centerstack Assembly is scheduled for February 2014
NSTX-UNSTX-U NSTX Upgrade Project – Office of Science Review – December 11-12, 2012 3
General Arrangement
3
TF Flex Bus and Support Structure
Centerstack Assembly
Outer TF CoilsMajor Centerstack Components
Umbrella Structure
Vacuum Vessel
NSTX-UNSTX-U NSTX Upgrade Project – Office of Science Review – December 11-12, 2012 4
Critical Path Schedule
NSTX-UNSTX-U NSTX Upgrade Project – Office of Science Review – December 11-12, 2012 5
TF Conductor Assembly
• Major Tool and Edison Welding Institute are manufacturing the TF conductor assemblies.
• Initially a slow start due to the final development of the Friction Stir Welding (FSW) procedures and the necessary NDT testing, but production is now moving smoothly.
• 36 conductors required for the full TF bundle have been delivered• Quadrant #5 conductors in January• Quadrant #6 conductors in February.
NSTX-UNSTX-U NSTX Upgrade Project – Office of Science Review – December 11-12, 2012 6
TF Solder Operations
• From Solder Trials to Operations:– Solder trials were successfully completed
at PPPL with assistance of a Solder Consultant
– Solder operations are now moving along smoothly
– 29 conductors have already been soldered
• Materials:– Solder paste- 96.5 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~ 270-300 degrees
C to ensure wetting
NSTX-UNSTX-U NSTX Upgrade Project – Office of Science Review – December 11-12, 2012 7
Area Setup- TF Fabrication
VPI Station
NSTX-UNSTX-U NSTX Upgrade Project – Office of Science Review – December 11-12, 2012 8
Safety Involvement
• The fabrication & assembly of the Centerstack is being 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 (JHA’s) are being developed for each
procedure• Procedures: Clearly identify safety precautions for specific
operations• Personnel protective equipment (PPE’s) being used• Involvement of all safety groups
NSTX-UNSTX-U NSTX Upgrade Project – Office of Science Review – December 11-12, 2012 9
Tooling Fabrication and Procurement
• Inner TF Bundle- Tooling and Fabrication– Operations are moving ahead smoothly– All stations are in full operation
• Post solder bake √
• Sandblast √
• Priming and cure √
• Application of turn insulation √
• Install conductors in mold √
• Align conductors and complete assembly of mold- In process– Awaiting lid for Quadrant mold
• Vacuum Pressure Impregnation of TF Quadrant- January 2013
– Full TF bundle mold has been awarded to Reno Machining- delivery in late January
NSTX-UNSTX-U NSTX Upgrade Project – Office of Science Review – December 11-12, 2012 10
TF Conductor Preparation
Sandblasting
PrimingTurn Insulation
Post Solder Bake
NSTX-UNSTX-U NSTX Upgrade Project – Office of Science Review – December 11-12, 2012 11
TF Quadrant Assembly
• Install conductors into mold
NSTX-UNSTX-U NSTX Upgrade Project – Office of Science Review – December 11-12, 2012 12
VPI Operations
• Developed procedures and tooling for VPI operations• Trial VPI was successful
NSTX-UNSTX-U NSTX Upgrade Project – Office of Science Review – December 11-12, 2012 13
VPI Process Cycle
NSTX-UNSTX-U NSTX Upgrade Project – Office of Science Review – December 11-12, 2012 14
J.H. Chrzanowski 9/7/12
NSTX-U Center Stack Coils VPI Cycle [CTD-425]
3024 45 7562520
Coil Fill Period [Fill/soak & remove lines]
Cure Time
Ramp down Period
Ramp up period
Post Cure Time
Ramp up period
15 hours
24 hours
10 hours
Ramp up 6 hours @ 10 ° C / hour
Ramp down 13 hours @ 10 ° C per hour
Hours
Temperature degrees C
10
20
30
40
60
50
70
80
90
130
100
110
140
0
120
150
160
170
10
20
30
40
60
50
70
8090
130
100
110
140
0
120
150
160
170
Ramp up 7 hours @ 10 ° C per hour
Temperature degrees C
NSTX-UNSTX-U NSTX Upgrade Project – Office of Science Review – December 11-12, 2012 15
Full TF Mold
• The full TF mold is being manufactured by Reno Machine (Conn.) –
– PPPL is planning a visit in December– Scheduled for February delivery
NSTX-UNSTX-U NSTX Upgrade Project – Office of Science Review – December 11-12, 2012 16
Tooling Fabrication and Procurement
• OH Solenoid- tooling– OH copper conductor has been received
– OH conductor sandblasting & priming requisition in system
– Induction braze station OH braze joints- is being commissioned
• OH joint braze qualification program will begin in January
– Tension unit & taping machines are in fabrication
– OH Mold will be out for bids in January
NSTX-UNSTX-U NSTX Upgrade Project – Office of Science Review – December 11-12, 2012 17
OH Solenoid Winding Facility
NSTX-UNSTX-U NSTX Upgrade Project – Office of Science Review – December 11-12, 2012 18
OH Winding Station
Tension unit being fabricated in house
Taping machines complete
OH winding support tooling complete
Turning fixture delivered
Induction braze station (Complete)
NSTX-UNSTX-U NSTX Upgrade Project – Office of Science Review – December 11-12, 2012 19
•Rolled Aluminum Cylinder wrapped with epoxy/glass insulation represents TF Bundle•Maintains true TF OD and clearance space at top and bottom•Will use actual mold segments and alignment pins•Tested:
1. Filling of Aquapour √2. Curing of Aquapour with heating blankets √3. Washing Out of Aquapour √
TESTING OF AQUAPOUR FOR CENTER STACK FABRICATION
NSTX-UNSTX-U NSTX Upgrade Project – Office of Science Review – December 11-12, 2012 20
Centerstack Casing
• The Centerstack Inconel casing is being manufactured by Martinez & Turek located in California.
• They have been making good progress
– PPPL visited facility in November just prior to final welding
• Delivery is scheduled for December 2012
NSTX-UNSTX-U NSTX Upgrade Project – Office of Science Review – December 11-12, 2012 21
Centerstack Casing
• Upon arrival of the casing 500 Inconel studs will added to the outside surfaces (original casing shown below)
• 696 Tiles with diagnostics will then be mounted
3.4 3.4
5.8
5.8
NSTX-UNSTX-U NSTX Upgrade Project – Office of Science Review – December 11-12, 2012 22
Plans Forward for Centerstack Components
• Inner TF Bundle– VPI first Quadrant- January 2013
– VPI Full Bundle- May 2013
• OH Solenoid– Begin winding OH solenoid- July 2013
– VPI OH Solenoid- October 2013
• Centerstack Casing– Delivery is scheduled for December 2012
• Centerstack Assembly- – Final assembly will occur between November
2013 to February 2014
– Developing Assembly procedures
NSTX-UNSTX-U NSTX Upgrade Project – Office of Science Review – December 11-12, 2012 23
Plans Forward- continued
• Inner Poloidal Field Coils– Requisition has been submitted to
procurement- RFQ
– Delivery summer 2013
• TF buss and support components– Purchase Order has been placed with Zenox
Corp. (TF Flexes)
– Super-nuts in procurement February 2013
– OTF Lead extensions (January procurement)
• Deliver completed Centerstack
Assembly - February 2014
MT Torque-nut™
Flex-Bus (Cu-Cr-Zr)
NSTX-UNSTX-U NSTX Upgrade Project – Office of Science Review – December 11-12, 2012 24
Outer TF Coils
• The contract for fabricating (2) Outer TF coils was awarded to Everson-Tesla.– Soldering of the cooling tubes has started
– February 2013 delivery
NSTX-UNSTX-U NSTX Upgrade Project – Office of Science Review – December 11-12, 2012 25
Conclusion
• The risks associated with the production of the TF conductors have been addressed (Major Tool/Edison Welding)
• The soldering trials have been completed and production nearly complete (Retired risk)
• The TF bundle manufacturing facility is in full operation– Awaiting delivery of molds and completion of procedures
• The R&D and procedures for VPI are complete & first VPI is scheduled for January
• The Aquapour trials are complete• Tooling for the OH solenoid is being fabricated• The OH conductor sandblast/priming contract is awaiting bids• The Inconel casing is scheduled for delivery in December• Contract for the OTF has been awarded • Requisition for Inner PF coils is in procurement
• The production of the Centerstack Assembly has begin