Equilibrium and Stability Modeling of NSTX-Upgrade Scenarios with Free-Boundary TRANSP and DCON
NSTX Centerstack Fabrication James H. Chrzanowski and the NSTX Upgrade Team Princeton Plasma Physics...
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Transcript of NSTX Centerstack Fabrication James H. Chrzanowski and the NSTX Upgrade Team Princeton Plasma Physics...
NSTX Centerstack FabricationNSTX Centerstack Fabrication
James H. Chrzanowskiand the NSTX Upgrade Team
Princeton Plasma Physics LaboratoryNSTX Upgrade Project
Office of Science ReviewLSB B318
May 2 - 3, 2012
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 NSTX Upgrade Project – Office of Science Review – May 2nd – 3rd 2012 2
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-UNSTX-U NSTX Upgrade Project – Office of Science Review – May 2nd – 3rd 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 – May 2nd – 3rd 2012 4
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-UNSTX-U NSTX Upgrade Project – Office of Science Review – May 2nd – 3rd 2012 5
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-UNSTX-U NSTX Upgrade Project – Office of Science Review – May 2nd – 3rd 2012 6
TF Conductor Production Videos
TF Machining Video.movEWI Friction Stir Production.mov
NSTX-UNSTX-U NSTX Upgrade Project – Office of Science Review – May 2nd – 3rd 2012 7
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- 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 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-UNSTX-U NSTX Upgrade Project – Office of Science Review – May 2nd – 3rd 2012 8
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 9-20-12
NSTX-UNSTX-U NSTX Upgrade Project – Office of Science Review – May 2nd – 3rd 2012 9
Area Setup- TF Fabrication
VPI Station
NSTX-UNSTX-U NSTX Upgrade Project – Office of Science Review – May 2nd – 3rd 2012 10
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 (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 – May 2nd – 3rd 2012 11
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 1st. week of
May– Priming station complete √– VPI station- complete √– Full TF mold- Requisition in system
NSTX-UNSTX-U NSTX Upgrade Project – Office of Science Review – May 2nd – 3rd 2012 12
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-UNSTX-U NSTX Upgrade Project – Office of Science Review – May 2nd – 3rd 2012 13
OH Solenoid Winding Facility
NSTX-UNSTX-U NSTX Upgrade Project – Office of Science Review – May 2nd – 3rd 2012 14
10.5”
92”
8.5”
15.788”
“Mock TF Bundle” with 3x Mold SegmentsCenter 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 Aquapour2. Curing of Aquapour with heating blankets3. Washing Out of Aquapour
TESTING OF AQUAPOUR FOR CENTER STACK FABRICATION
Trials will be performed this summer
NSTX-UNSTX-U NSTX Upgrade Project – Office of Science Review – May 2nd – 3rd 2012 15
Lehman Review Recommendation dispositon log
• 201110 - L02 from October 2011 Lehman Review– Item:2.2 Evaluate 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-UNSTX-U NSTX Upgrade Project – Office of Science Review – May 2nd – 3rd 2012 16
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-UNSTX-U NSTX Upgrade Project – Office of Science Review – May 2nd – 3rd 2012 17
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-UNSTX-U NSTX Upgrade Project – Office of Science Review – May 2nd – 3rd 2012 18
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