NSTX-U NSTX-U NSTX Upgrade Project – Office of Science Review – February 4, 2014 1 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 February 4, 2014 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
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NSTX-U NSTX Upgrade Project – Office of Science Review – February 4, 2014 1 NSTX Centerstack Fabrication Status James H. Chrzanowski and the NSTX Upgrade.
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NSTX-UNSTX-U NSTX Upgrade Project – Office of Science Review – February 4, 2014 1
NSTX Centerstack Fabrication StatusNSTX Centerstack Fabrication Status
NSTX-UNSTX-U NSTX Upgrade Project – Office of Science Review – February 4, 2014 2
General Arrangement
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 – February 4, 2014 3
Upgraded Centerstack Components
Inner TF Bundle
Ohmic Heating Coil
Inner PF1c
Inner PF1b
Inner PF1a
Plasma Facing Components
CS Casing
Ceramic break assembly
NSTX-UNSTX-U NSTX Upgrade Project – Office of Science Review – February 4, 2014 4
Topics
•Progress of the Centerstack since last review
•Remaining risks and mitigation plans, Plans forward
•Address charge question #1 Critical Path Construction Efforts:
– Does the Project team have a realistic, executable schedule for Center Stack (CS) remaining construction efforts?
– Does the project have adequate resources and the appropriate skills mix to execute the remainder of the project per the plan?
NSTX-UNSTX-U NSTX Upgrade Project – Office of Science Review – February 4, 2014 5
Center Stack Status Since Last Review
• Inner TF Bundle– Complete
• Centerstack Casing– Delivered and studs have been installed
• OH Solenoid– Major tooling for OH solenoid has been
delivered & commissioned
– Aquapour and epoxy/glass base has been installed over TF bundle
– First layer of OH solenoid has been wound
– Completing layer transition 1 to 2 and resume winding layer 2
• Inner PF coils– PF1b coils have been completed
NSTX-UNSTX-U NSTX Upgrade Project – Office of Science Review – February 4, 2014 6
Involvement of ES&H Safety Department
• 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) & Construction Safety have 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• “Tool Box” Safety meeting held monthly with Technicians
• Involvement with all safety groups
NSTX-UNSTX-U NSTX Upgrade Project – Office of Science Review – February 4, 2014 7
Progress- Raising the Full TF Bundle
• Completed testing of TF Bundle• Raised TF Bundle to the vertical position
in preparation for the application of the Aquapour. √ complete
NSTX-UNSTX-U NSTX Upgrade Project – Office of Science Review – February 4, 2014 8
Progress- Installation of Aquapour Layer
• Installation of Aquapour layer was successfully completed“Aquapour” is used as a temporary spacer that will be used to maintain 0.100 inch gap between the TF OD and OH ID surfaces. It is removed post VPI of OH coil √ complete
NSTX-UNSTX-U NSTX Upgrade Project – Office of Science Review – February 4, 2014 9
OH Solenoid Winding Facility
• The OH Solenoid is being wound onto the Inner TF Bundle• Completed setup & commissioning of OH winding equipment in CS High Bay area
NSTX-UNSTX-U NSTX Upgrade Project – Office of Science Review – February 4, 2014 10
Tooling- OH Winding Station Pivot Beam
OH Winding station fully commissioned ShopsCopper Spools
Cut-off saw & Braze Station
Hydraulic Tension Unit
Dual Taping Heads
√ complete
NSTX-UNSTX-U NSTX Upgrade Project – Office of Science Review – February 4, 2014 11
Progress- Winding Preparations
Epoxy/glass layer was applied over the Aquapour surface to provide a solid winding surface
OH support structure was installed
√ complete
NSTX-UNSTX-U NSTX Upgrade Project – Office of Science Review – February 4, 2014 12
Transfer TF to OH Winding Station
• The TF bundle was transferred to the OH Winding station
√ complete
NSTX-UNSTX-U NSTX Upgrade Project – Office of Science Review – February 4, 2014 13
OH Solenoid Fabrication- 1
• Wind the OH solenoid using approved drawings and procedure D-NSTX-IP-3385
• Four layers/ 880 turns/ (2) conductors in-hand
• Co-wound turn to turn insulation (Kapton/glass)
• In-line braze joints
• Layer to layer TIG Braze joints
• Tension wound conductor
NSTX-UNSTX-U NSTX Upgrade Project – Office of Science Review – February 4, 2014 1414NSTXNSTX April 29, 2010NSTX Center Stack Upgrade Peer Review
Layer to layer TIG-Braze joint [Typical]
OH Cooling fittings- torch brazed to copper conductors
“TIG-Braze”
TIG-Brazing method minimizes annealing of conductors (use Sil-Fos)
Provides adequate joint strength
Qualified method and procedures used in previous OH solenoids
OH Solenoid Fabrication- 2
- Glass/epoxy laminate fillers between layers supports turns
- S-2 glass between fillers- Perforations in fillers will
enhance epoxy flow during VPI
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OH Winding Status and Accomplishments
• Winding operations have started• Winding station is working well• Completed first layer 240 turns• Use of “Aquapour” as winding surface is working well• Outside diameter of layer 1 turns are in spec• Successfully completed and tested 6 in line brazes• Successfully completed and tested 6 cooling fitting brazes• Completed 2- Layer to layer brazes
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Coil Winding Photos
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Coil Winding Photos -continued
• Completed 240 turns including (6) inline brazes
NSTX-UNSTX-U NSTX Upgrade Project – Office of Science Review – February 4, 2014 18
Taping Stations
• The dual taping stations had initial startup issues w/ controllers
• They are working as planned applying (3) half-lapped layers of insulation at once on two parallel conductors
NSTX-UNSTX-U NSTX Upgrade Project – Office of Science Review – February 4, 2014 19
Taping and Winding Operations
NSTX-UNSTX-U NSTX Upgrade Project – Office of Science Review – February 4, 2014 20
Winding Manpower and Shift Coverage
• Manpower:– (2) 4 man teams– Engineering coverage for both shifts
• Started teams on 1 shift until completing 1st half of layer 1• Began 2 shifts for 2nd half of layer 1• Once we reached the half way point, the actual winding and
braze times and are less than anticipated• Winding: 2nd. Half of layer 1
– Estimated- 3 shifts per quarter– Actual- 1.5 shifts per quarter
• Brazing: (2) brazes– Estimated- 3 shifts per quarter– Actual- 2 shifts per quarter
NSTX-UNSTX-U NSTX Upgrade Project – Office of Science Review – February 4, 2014 21
Winding Manpower and Shift Coverage
• Layer to Layer Transition is being done on 1 shift to understand and teach associated technical issues with all team members for future transitions
• Future Layer to layer will probably be done with 2 shifts• Resume 2 shifts once winding begins• Engineering coverage is provided for 2nd. Shift (Need will be
evaluated after second layer has been completed)
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Completion Dates
• Completion of OH winding should occur by mid to late March• VPI completed by mid April• Complete OH/TF activities: April thru May
– Continue on 2 shift operations thru completion of OH/TF activities
– Apply ground plane and diagnostics to OH surface
– Install “Micro therm” insulation
• Transport OH/TF to NSTX South bay for final assembly: June 2014
NSTX-UNSTX-U NSTX Upgrade Project – Office of Science Review – February 4, 2014 23
Crown Assembly
Field fit and drill final pins holes
Final Assembly Tasks
Purpose of Crowns: Lock conductors together & help transfer load from TF bundle through lid structure to umbrella
TF Cooling connections & bulkhead
Install Belleville Washer Assembly
Install upper and lower crowns (custom fit-up required) and TF cooling fittingsInstall Belleville washer assembly
NSTX-UNSTX-U NSTX Upgrade Project – Office of Science Review – February 4, 2014 24
Laminate Crown
Epoxy/S-2 glass construction circumferentially wound (jelly-roll)
Upper & Lower Crown Assemblies-cont’d
Pinned to Inner TF Conductors 316 SS
Fabricate in house
NSTX-UNSTX-U NSTX Upgrade Project – Office of Science Review – February 4, 2014 25
Centerstack Casing
• The Centerstack Inconel casing has been manufactured by Martinez & Turek located in California.
• Inconel studs for supporting the PFC’s have been installed & are being cut to required length (NSTX South Bay)
NSTX-UNSTX-U NSTX Upgrade Project – Office of Science Review – February 4, 2014 26
Inner PF Coils
• Contract for fabricating the Inner PF coils has been awarded to Everson-Tesla Inc. (Nazareth, Pa)
• Both inner PF1B’s have been wound and VPI’d• The first Inner PF coil has been delivered the second will be
delivered the week of Feb 10th.• Winding of the first PF1A coil will begin week of Feb 10th.• Late delivery has no impact on critical path schedule
PF1B
PF1APF1C
NSTX-UNSTX-U NSTX Upgrade Project – Office of Science Review – February 4, 2014 27
Centerstack Casing
• The Inner PF1B coils will be mounted to CS casing followed by the PFC tiles and diagnostics. (NSTX South Bay)
PF1B
Plasma Facing Component tiles
NSTX-UNSTX-U NSTX Upgrade Project – Office of Science Review – February 4, 2014 28
Miscellaneous Procurements
• TF flex buss has been completed by Zenox Corp.• Super nuts and hardware have been delivered• Outer TF Lead extensions are being manufactured by Martinez-
Turek (California) Delivery scheduled for late March
MT Torque-nut™
Flex-Bus (Cu-Cr-Zr)
OTF Lead Extensions
NSTX-UNSTX-U NSTX Upgrade Project – Office of Science Review – February 4, 2014 29
Exploded View
Assembled View
Complete Ceramic Break Sub-Assembly
- All components except for PF1C coils have been delivered for ceramic break assemblies- Assemble the ceramic break components to the Upper and Lower PF-1C coil structures. Work to be performed by PPPL
• Ceramic rings were fabricated by Kyocera in Japan
• Stainless rings manufactured by Hollis Machine (NH)
• G-11 insulators manufactured by Astro Machine Works (Pa) and Reno Machine (Conn)
• PF1C coil manufactured by Everson-Tesla Inc
NSTX-UNSTX-U NSTX Upgrade Project – Office of Science Review – February 4, 2014 30
Mount the Center Stack Support Structure to Lower PF-1A Coil
Step 1- Assemble CS Support & Lower PF-1A Together
Install “Micro-therm” insulation around outside surfaces of “Upper PF1” Coil
NSTX-UNSTX-U NSTX Upgrade Project – Office of Science Review – February 4, 2014 31
Step 2- Assemble Lower PF-1A Assy. To OH/TF Assy.
Position the Lower PF-1A coil assembly over the OH/TF Assembly
NSTX-UNSTX-U NSTX Upgrade Project – Office of Science Review – February 4, 2014 32
Step 3 – OH Diagnostics & Thermal Blanket
Mount the OH surface diagnostics and the “Micro-Therm” Insulation Blanket around the outer surfaces of the OH Solenoid-Flux loops-Thermocouples-Rogowski Coils
Micro-Therm Insulation
Lower PF-1A Coil Assy.
TRANSPORT OH/TF BUNDLE TO NSTX SOUTH HIGH BAY AREA
NSTX-UNSTX-U NSTX Upgrade Project – Office of Science Review – February 4, 2014 33
Lower the CS Casing over the OH/TF Assembly
Step 4 – Install CS Casing to CS Assembly
Upper Assembly Lower Assembly
Lower the Upper PF1A coil over the OH/TF Assembly & secure to Upper PF1B coil
NSTX-UNSTX-U NSTX Upgrade Project – Office of Science Review – February 4, 2014 34
Step 5- Install Flash Shields
Install the Kapton shields and vertical motion instrumentation
Flash Shields
NSTX-UNSTX-U NSTX Upgrade Project – Office of Science Review – February 4, 2014 35
Pre-position the lower Ceramic Break Assembly and Rotatable Flange prior to lowering CS assembly into the VV
Install the completed Center Stack Assembly into the Vacuum Vessel (July 2014)
Step 6- Install Completed CS Assembly
NSTX-UNSTX-U NSTX Upgrade Project – Office of Science Review – February 4, 2014 36
Critical Path Schedule
The OH Manufacturing steps are series activities w/ very few parallel activities
NSTX-UNSTX-U NSTX Upgrade Project – Office of Science Review – February 4, 2014 37
Charge Question
• Address charge question #1 Critical Path Construction Efforts: – Does the Project team have a realistic, executable schedule for
Center Stack (CS) remaining construction efforts? – The project feels that the schedule to complete the center stack
assembly is realistic and achievable. Most of the high risk tasks or operations have been addressed during the performance of the manufacturing.
• OH winding is proceeding well taking fewer days than anticipated
• The layer 1 diameter is being maintained and is in tolerance
• The Aquapour is performing as expected providing a stable base for winding the OH turns
• In-line brazing operations are going well
– The remaining high risks are associated with the final vacuum pressure impregnation of the OH solenoid
NSTX-UNSTX-U NSTX Upgrade Project – Office of Science Review – February 4, 2014 38
Charge Question
– Does the project have adequate resources and the appropriate skills mix to execute the remainder of the project per the plan?
– The four man teams operating on 2 shifts provide the necessary manpower to complete the winding of the OH solenoid.
– Additional manpower is available to cover illness or vacation– 3 engineers plus project management (RLM) are assigned to the
center stack through completion.
NSTX-UNSTX-U NSTX Upgrade Project – Office of Science Review – February 4, 2014 39
Conclusion
• The full TF bundle have been VPI’d and tested (Retired risks)– Five of the 6 required VPI’s have been completed
• The Inconel casing has been delivered & studs installed• Major tooling for the OH solenoid has been completed• The OH coil manufacturing facility has being setup &
commissioned– There was a delay in commissioning the OH winding station (taping stations)
• Production has started with winding of first layer completed• Times for winding and brazing are less than anticipated• Inner PF coils are being fabricated by Everson Tesla with first (2)
coils completed
• Anticipate completion of the Centerstack components and installation into NSTX in July 2014