Project OverviewProject Overview

Ron Strykowsky, J.Chrzanowski, L.Dudek, E.Perry, T.Stevenson

LSB B318January 3, 2013

NSTX-UNSTX-U Supported by

Culham Sci CtrYork U

Chubu UFukui U

Hiroshima UHyogo UKyoto U

Kyushu UKyushu Tokai U

NIFSNiigata UU Tokyo

JAEAInst for Nucl Res, Kiev

Ioffe InstTRINITI

Chonbuk Natl UNFRI

KAISTPOSTECH

Seoul Natl UASIPP

CIEMATFOM Inst DIFFER

ENEA, FrascatiCEA, Cadarache

IPP, JülichIPP, Garching

ASCR, Czech Rep

Coll of Wm & MaryColumbia UCompXGeneral AtomicsFIUINLJohns Hopkins ULANLLLNLLodestarMITLehigh UNova PhotonicsOld DominionORNLPPPLPrinceton UPurdue USNLThink Tank, Inc.UC DavisUC IrvineUCLAUCSDU ColoradoU IllinoisU MarylandU RochesterU TennesseeU TulsaU WashingtonU WisconsinX Science LLC

NSTX-UNSTX-U 2

NSTXU Test Cell – May 2012

NSTX-UNSTX-U 3

Neutral Beam Progress

NSTX-UNSTX-U 4

NSTXU Test Cell Beam Box move– 9/13/12

Photo: Elle Starkman

• Began work February 2009

• 30,000 hours (>17 person years) for decontamination, refurbishment, relocation design

• 55 people

• Safety

• >25 people at pre-job brief

• Beam box = 40 tons

• Lid = 14 tons

Stevenson

NSTX-UNSTX-U 5

NBI BL Box Relocation… TTC, South High Bay, Over the wall 2425

And on the vent stack…And on the vent stack…

Stevenson

NSTX-UNSTX-U 6

NBI BL Lid Relocation… same as Box move but more involved 2425

Stevenson

NSTX-UNSTX-U 7

NBI Duct Exit Spool Piece and BL TIV installed on Exit of BL… 24802485

Stevenson

NSTX-UNSTX-U 8

VV Modification Bay JK weldments repaired in Tech Shop…

• 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…

Stevenson

NSTX-UNSTX-U 9

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…

Neutral Beam Summary

Stevenson

NSTX-UNSTX-U 10

Construction Progress

NSTX-UNSTX-U 11

NSTXU Test Cell - CurrentUmbrella

legs being cut out and

replaced

Second beamline in

place

Vacuum Vessel cutting

for Bay J/K neutral beam cap underway

4 Outer TF coils

removed

NSTX-UNSTX-U 12

Perry

NB Bay J/K Port opening successfully plasma cut

NSTX-UNSTX-U 13

• Removal of TF outer legs that need to be repaired or replaced– Completed with minimal removal of surrounding items

– Replacements must be completed before significant re-installations can occur

Perry

Outer TF Coils -Repair

NSTX-UNSTX-U 14

Outer TF Coils -NEW

• The contract for fabricating (2) Outer TF coils was awarded to Everson-Tesla.– Soldering of the cooling tubes has started

– February 2013 delivery

Chrzanowski

NSTX-UNSTX-U 15

Dudek

Machine structural improvements well underway

NSTX-UNSTX-U 16

Dudek

Hardware Status

NSTX-UNSTX-U 17

Plan for January 2013

• Ex-vessel set-up for cutting at bay L– Installing containment and ventilation

• Vacuum vessel cutting at Bay L for new diagnostics port• Remove temporary in-vessel beams and ventilation• Leak check welds on Bays JK cap• Remove platform at Bays JKL

Perry

NSTX-UNSTX-U 18

Plan for December 2012 – March 2013

• Complete modifications to umbrella and coil supports• Complete Neutral Beam systems• Re-install items removed for centerstack work• Re-install items removed for NB work

Perry

NSTX-UNSTX-U 19

Outage Planning for Diagnostic Calibrations

• Diagnosticians have listed the calibrations they would like prior to re-starting NSTX

• Detailed schedules for these calibrations are being prepared– Schedules will be fit into the existing outage schedule– Each calibration will be scheduled as early as possible to avoid delays once the

installation work has been completed– Calibrations may be scheduled to occur after the Upgrade Outage if they are not

required for CD-4 or early operations

• All work in NSTX Test Cell being done with Engineering Work Packages (90 packages so far, 39 completed)

– Written procedures

– Permits

– Job hazard analysis

– Permits: confined space, hot work, radiation work, penetration, etc

– Pre-job and post-job briefings

Perry

NSTX-UNSTX-U 20

Construction Summary

• The plan is being continuously worked– To improve safety and efficiencies

– To deal with delays in getting parts

– To accelerate tasks to ease pressure on critical path tasks

• 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

Perry

NSTX-UNSTX-U 21

Center Stack Progress

NSTX-UNSTX-U 22

Center Stack Fabrication & Assembly Making Good ProgressMachined conductor at Major Tool being prepared for shipment to PPPL

Conductor after cooling tube installation and grinding

Cooling tube being soldered into conductor at PPPL

Conductor being removed from oven after sandblasting and priming

Conductor being wrapped with fiberglass insulation

Insulated conductor being placed into mold

Chrzanowski

NSTX-UNSTX-U 23

Center Stack First Quadrant ready for final assembly

Conductor progress4 quadrants of 9 conductors for full inner TF bundle

• 38 conductors delivered• 30 cooling tube soldered• 16 primed & wrapped

Chrzanowski

NSTX-UNSTX-U 24

Full TF Mold

• The full TF mold is being manufactured by Reno Machine (Conn.) –

– Scheduled for February delivery

Chrzanowski

NSTX-UNSTX-U 25

•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 OH CONDUCTOR WINDING

Chrzanowski

NSTX-UNSTX-U 26

OH Winding Station

Tension unit being fabricated in house

Taping machines complete

OH winding support tooling complete

Turning fixture delivered

Induction braze station (Complete)

Chrzanowski

NSTX-UNSTX-U 27

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

Chrzanowski

NSTX-UNSTX-U 28

Centerstack Casing

• The Centerstack Inconel casing is being manufactured by Martinez & Turek located in California.

• Delivery is scheduled for first week in January

• 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

Chrzanowski

NSTX-UNSTX-U 29

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

Chrzanowski

NSTX-UNSTX-U 30

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)Chrzanowski

NSTX-UNSTX-U 31

Center Stack Summary

• 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 January• Contract for the OTF has been awarded • Requisition for Inner PF coils is in procurement

• The production of the Centerstack Assembly has begunChrzanowski

NSTX-UNSTX-U 32

Cost and Schedule

NSTX-UNSTX-U 33

Schedule on track for early finish

Late delivery of conductors and rework of vendor supplied quadrant mold

Late delivery of conductors and rework of vendor supplied quadrant mold

Neutral Beam relocated ahead of scheduleNeutral Beam relocated ahead of schedule

CD-4 SEPT 30 2015

CD-4 SEPT 30 2015

Forecast Aug 4 2014

Forecast Aug 4 2014

Early Finish Sept 30 2014

Early Finish Sept 30 2014

• Critical path based on 5 day/week, one shift no planned OT.

• We will implement OT, weekends and 2 shift operations where appropriate on critical path.

• Critical path based on 5 day/week, one shift no planned OT.

• We will implement OT, weekends and 2 shift operations where appropriate on critical path.

NSTX-UNSTX-U 34

Lehman Review Dec 11-12 -Conclusions

1. Construction efforts are being executed safely.

2. The project presently has adequate resources and necessary skills mix to execute the project. However, the impact of the possible loss of key personnel if a laboratory staff reduction is required is unknown.

3. The Project team has implemented the required action to update the Risk Registry resulting from the status review in May 2012. Particular emphasis has been placed on using the detailed schedule to manage and accelerate procurements.

4. The current project cost and schedule projections are consistent with the approved baseline cost and schedule.

5. Contingency remaining is adequate for the risks that remain.

6. The management structure is in place to deliver the scope within budget and schedule.

7. Risks are being actively managed.

1. Construction efforts are being executed safely.

2. The project presently has adequate resources and necessary skills mix to execute the project. However, the impact of the possible loss of key personnel if a laboratory staff reduction is required is unknown.

3. The Project team has implemented the required action to update the Risk Registry resulting from the status review in May 2012. Particular emphasis has been placed on using the detailed schedule to manage and accelerate procurements.

4. The current project cost and schedule projections are consistent with the approved baseline cost and schedule.

5. Contingency remaining is adequate for the risks that remain.

6. The management structure is in place to deliver the scope within budget and schedule.

7. Risks are being actively managed.

NSTX-UNSTX-U 35

Lehman Review Dec 11-12 - Recommendations

1. Develop a comprehensive facility readiness plan and schedule including both project and non-project items. Present plan at the next review.

2. Assign adequate personnel to assure completion of the Digital Coil Protection System on the original baseline schedule.

3. Reassess the potential impacts of the loss of critical skills and personnel and update the risk registry by February 1, 2013.

4. Prepare a plan for startup readiness that is acceptable to by the Site Office prior to the next review.

1. Develop a comprehensive facility readiness plan and schedule including both project and non-project items. Present plan at the next review.

2. Assign adequate personnel to assure completion of the Digital Coil Protection System on the original baseline schedule.

3. Reassess the potential impacts of the loss of critical skills and personnel and update the risk registry by February 1, 2013.

4. Prepare a plan for startup readiness that is acceptable to by the Site Office prior to the next review.

NSTX-UNSTX-U 36

NSTX Upgrade Summary

• The project has maintained a safe working environment.

• The project continues to make good technical progress.

• The project is on schedule and cost.

• The project is sufficiently staffed to meet schedule.

• The project is on track for meeting CD-2 baseline within OFES guidance.

• The project has maintained a safe working environment.

• The project continues to make good technical progress.

• The project is on schedule and cost.

• The project is sufficiently staffed to meet schedule.

• The project is on track for meeting CD-2 baseline within OFES guidance.

NSTX-UNSTX-U 37

Supplemental

NSTX-UNSTX-U 38

Lehman Review - TourInner TF conductor post-cooling tube soldering.

Ready for grinding and cleanup. Inner TF conductor post-cooling tube soldering.

Ready for grinding and cleanup. Inner TF conductor cooling tube soldering station

showing setup for soldering of bar number 30Inner TF conductor cooling tube soldering station

showing setup for soldering of bar number 30

Lehman review teamLehman review team

Chris AckermanChris Ackerman

Tony IndelicatoTony Indelicato

Tim MaierTim Maier

Bruce StaussBruce Stauss

Arnie KellmanArnie Kellman

Kin ChaoKin ChaoEd SynakowskiEd Synakowski

Steve MeadorSteve Meador

Frank CrescenzoFrank Crescenzo

Rick BlaisdallRick Blaisdall

Barry SullivanBarry Sullivan

Will OrenWill Oren

NSTX-UNSTX-U 39

Lehman Review December 11th&12th - Tour

Inner TF conductor sandblasting stationInner TF conductor sandblasting station

Aqua pour mockup test.Aqua pour mockup test.End of inner TF quadrant showing cooling tubes.End of inner TF quadrant showing cooling tubes.

Inner TF quadrant with 9 conductors in place ready for mold lid.

Inner TF quadrant with 9 conductors in place ready for mold lid.

NSTX-UNSTX-U 40

Second Neutral Beam Safely relocated ahead of schedule

40

• Beam box = 40 tons• Lid = 14 tons

• Began work February 2009• 30,000 hours (>17 person years) for decontamination,

refurbishment, relocation design• 55 people• Safety

• >25 people at pre-job brief

NSTX-UNSTX-U 41

• Cost – CPI = 1.00 CV = +199K

• Schedule– SPI = 1.06 ( Against early finish baseline) Total float = 2 months to early

finish PLUS 12 months to late finish CD-4

• Completion– Forecast = August 4, 2014– CD-4 Project Baseline (Early Finish) = September 2014– CD-4 DOE Milestone (Late Finish) = September 2015

• BAC =$82.7 EAC= $83.9 TPC =94.3M

• Cost to date = $44.1 M 54% complete

• Free balance contingency 31-33% ($11.8M remaining consistent with

remaining risk and uncertainty) (27% at CD-2)

Performance metrics good

NSTX-UNSTX-U 42

Risk & Opportunities

42

OH Fab $1,290k FY13

Inner TF bundle fab $544k FY13

Serious injury stand-down $400k FY14

Late vendor delivery on critical path $250k/mo FY14

Other $391k FY14

I&C add’l capacity $200k FY14

Diagnostic re-installation $294k FY14

Hardware fit up issues $427k FY14

Mgmt direct allocations $216k FY14

Critical skill lost $137k FY14

Total open $4,149

Opportunities PPPL Overhead rates (baselined at conservative levels)Schedule acceleration (by applying 2 shifts to critical path)

Risk