NSTXU NBI Upgrade Overview

NSTXU NBI Upgrade OverviewNSTXU NBI Upgrade Overview

Timothy N. Stevenson

Princeton Plasma Physics LaboratoryNSTX Upgrade Project

Office of Science ReviewPPPL LSB 318

12/11/12 & 12/12/12

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 PhotonicsORNLPPPLPrinceton 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 Dec. 11-12, 2012

Disassemble & evaluate a TFTR BL

Decon a TFTR DT BL

Refurbish BL

Lift BL over wall – Clearance OK

Add second NBI & Services in NTC

Connect Power & Controls

Aim wider (modify VV)

Rearrange NTC to fit

Capability to run either or both

NBI Power x 2 for NSTXU

GRD Requirements for NBI System

NSTX Test Cell circa May 2012

(Last Lehman Review)


NSTXU NBI Job Performance

3

* Job completed

Control NBI NBI Planned Earned Actual

NSTXU NBI Project Cost (all k$) Account BAC EAC Value Value Cost CPI SPI

(through 10/31/12) Manager (BCWS) (BCWP) (ACWP)

Job: 2420 - 2nd NBI Sources* Cropper 1094 61 99 99 63 1.57 1.00

Job: 2425 - BL Relocation Atnafu 1803 1563 1067 905 699 1.29 0.85Job: 2430 - 2nd NBI Decontamination* Stevenson 2057 2070 2057 2057 2070 0.99 1.00

Job: 2440 - 2nd NBI Beamline Cropper 1979 1560 1367 1526 1116 1.37 1.12

Job: 2450 - 2nd NBI Services Atnafu 4506 4401 684 1217 1113 1.09 1.78

Job: 2460 - 2nd NBI Armor Tresemer 700 902 392 585 717 0.82 1.49

Job: 2470 - 2nd NBI Power Ramakrishnan 3335 3286 375 1031 772 1.34 2.75

Job: 2475 - 2nd NBI Controls Cropper 2611 2403 946 1450 1242 1.17 1.53

Job: 2480 - 2nd NBI/TVPS Duct Blanchard 1952 1938 656 1382 1454 0.95 2.11Job: 2485 - Vacuum Pumping System Blanchard 388 454 90 169 236 0.72 1.88Job: 2490 - NTC Equipt Relocations Perry 3535 3380 1442 1690 1440 1.17 1.17

Job: 7300 - NB2 Management Stevenson 1278 1225 616 616 563 1.09 1.00Job: 7400 - Health Physics Support Stevenson 2507 1706 1820 1854 1053 1.76 1.02

Total NBI Upgrade BL2 27745 24949 11611 14581 12538 1.16 1.26


NSTXU Test Cell General Arrangement

NSTXUNSTXU

BL1BL1

BL2BL2

Power cablesPower cablesTTC South WallTTC South Wall

Helium Cryo LinesHelium Cryo Lines

PlatformsPlatforms

New RacksNew Racks

HVEHVE

NBI Duct/TVPSNBI Duct/TVPS

NSTX Gallery/DARMNSTX Gallery/DARM


NSTXU Test Cell General Arrangement

NSTX Test Cell - 11/14/12NSTX Test Cell - 11/14/12


NBI Relocation in progress…

6

• Complete relocation plan includes: Box Lid- 90 inch Flange 1Q FY13- Source Platform 1Q FY13- Magnet & Stand 1Q FY13- Ion Dump 1Q FY13- Calorimeter

1Q FY13- DeWar 1Q FY13- High Voltage Enclosures (3)

o 2-3 Q FY13 SE Door conduit removed SE Door Ducts removed SE Door Duct bypasses installed SE Shield Lintel removal BL Box modifications completed BL Lift fixture designed and approved Relocation process using air castors

- Beam box and Lido Remainder moved conventionally Moving day started in September…

• Complete relocation plan includes: Box Lid- 90 inch Flange 1Q FY13- Source Platform 1Q FY13- Magnet & Stand 1Q FY13- Ion Dump 1Q FY13- Calorimeter

1Q FY13- DeWar 1Q FY13- High Voltage Enclosures (3)

o 2-3 Q FY13 SE Door conduit removed SE Door Ducts removed SE Door Duct bypasses installed SE Shield Lintel removal BL Box modifications completed BL Lift fixture designed and approved Relocation process using air castors

- Beam box and Lido Remainder moved conventionally Moving day started in September…

TFTR Test Cell & SE Door

2425

TTC 9/12/12 – a day before major relocations began

NSTX-UNSTX-U NSTX Upgrade Project - Office of Science Review Dec. 11-12, 2012 7

NBI Relocation required significant preparation…

SE Door conduit removed

SE Door Ducts removed

SE Door Duct bypasses installed

SE Shield Lintels removed

BL Box modifications completed for air castors

Lid Stand changes completed for air castors

Sheet steel runways installed into South High Bay (not shown here)…

SE Door conduit removed

SE Door Ducts removed

SE Door Duct bypasses installed

SE Shield Lintels removed

BL Box modifications completed for air castors

Lid Stand changes completed for air castors

Sheet steel runways installed into South High Bay (not shown here)…


NBI Lid Relocation: TTC 9/19/12 after the lid move

Component refurbishment almost completedNorth side

Component refurbishment almost completedNorth side

Cleanup of TTC begun on 102’ and South side…

Cleanup of TTC begun on 102’ and South side…


BL Lift fixture completed and load tested. Air castor system operational.

9

2425

Reentrant hook lift fixture design for better clearance over the NTC

South Shield Wall

Lift fixture fabrication in RESA Tech Shop

Air castor system used on BL and Lid move from TTC to NTC South High Bay through door

Show time…


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

Photo: Elle Starkman


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

11

2425

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


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


NBI BL Alignment… 110, 120, 130 cm tangency radii 2425


NBI BL Alignment… completed 2425

• Install supports

• Fabricate shims

• Install spiders

• Install jacking systems

• Setup optical alignment

• Survey height from BL1 and VV

• Install shims

• Survey trajectory from metrology

• Set and reset BL

• Confirm alignment

• Verify alignment

• Install supports

• Fabricate shims

• Install spiders

• Install jacking systems

• Setup optical alignment

• Survey height from BL1 and VV

• Install shims

• Survey trajectory from metrology

• Set and reset BL

• Confirm alignment

• Verify alignment

“Bullseye…”“Bullseye…”


Calorimeter Upgrade –

• Parts fabrication completed

• Double bellows installation completed

• Double drive system needs replaced with correct parts

• External support structure work order in shop

Calorimeter Upgrade –


• Double bellows installation completed

• Double drive system needs replaced with correct parts

• External support structure work order in shop

BL Refurbishment: Ion Dump and Calorimeter – in progress

Ion Dump Replacement -

• Fabrication complete

• Leakchecking complete

• Reassembly in progress

• Thermocouples complete…

Ion Dump Replacement -

• Fabrication complete

• Leakchecking complete

• Reassembly in progress

• Thermocouples complete…

2440

BL1 Calorimeter Upgrade: Double bellows double drive


90 inch flange refurbishment –


• Feedthroughs fabricated, leakchecked, and installed

• OMAs reassembled and leakchecked

90 inch flange refurbishment –


• Feedthroughs fabricated, leakchecked, and installed

• OMAs reassembled and leakchecked

BL Refurbishment: 90 inch flange refurbishment in progress 2440

& Bending Magnet ready for installation…& Bending Magnet ready for installation…


Penetrations for water systems, power cabling, and cryogenic services

17

Penetration drilling required an articulated lift with adequate reach and ratings6 power supply – 4 ft.2 cryogenic piping – 6 ft.2 water system piping (floor) – 2 ft.

Penetration drilling required an articulated lift with adequate reach and ratings6 power supply – 4 ft.2 cryogenic piping – 6 ft.2 water system piping (floor) – 2 ft.

LN Cryo line installationSupply and Vent wall lines completeAwaiting BL platform to finish Articulated lift craned into and out of NTC…

LN Cryo line installationSupply and Vent wall lines completeAwaiting BL platform to finish Articulated lift craned into and out of NTC…

24502470


Cryogenics Line LN and LHe piping fabrication in progress in NBI shop

18

2450

LHeManifold& South

Wall

LHeManifold& South

Wall

LNPipe

NitrogenManifold


Liquid Nitrogen and Vent installation in NTC completed along walls…

19

2450

• Extend existing LN System service for BL2

• Connects to BL1 now

• Build scaffold catwalk to access

• Cut into system

• Tee for BL2

• Piping supply and vent lines on North and West wall

• Connections to BL2 LN manifolds & LHe deWar

• LHe lines will connect to existing system in TFTR TC with penetrations into NTC…

• Extend existing LN System service for BL2

• Connects to BL1 now

• Build scaffold catwalk to access

• Cut into system

• Tee for BL2

• Piping supply and vent lines on North and West wall

• Connections to BL2 LN manifolds & LHe deWar

• LHe lines will connect to existing system in TFTR TC with penetrations into NTC…

NTC North Wall & Catwalk NTC North Wall & Catwalk LN Supply

Nitrogen Vent line


NBI Mechanical: Cryogenics Services & SF6 line

NTC

South Wall Cryo LHe valvesSouth Wall Cryo LHe valves

Operate either BL1 or BL2 or both…

Liquid Helium manifold fabrication in progress and ready for S wall…


NSTXU NBI Power & Controls

Routing, Penetrations, Installation Procedures revisedfor improved penetration locations. All 6 Penetrations completed.

Routing, Penetrations, Installation Procedures revisedfor improved penetration locations. All 6 Penetrations completed.

NB Switchyard

NBPC Bldg

138’

100’

Pumproom

TFTR TC

TFTR TC Basement

MER

AccelDecelFil&ArcMagPLC F/OPS F/O

All new cabling here…All new cabling here…

24702475

NSTX TC


… and high voltage triax cable successfully tested here to 150 kV.

Temporary hipot testing area in D site MG BuildingTemporary hipot testing area in D site MG Building


Update NB N4ABC Power Supply controls to current status – done

Mimic existing NSTX BL1 Controls scheme for BL2 but move NTC racks - done

Reactivate N4 Local Control Centers, Hardwired Interlock System – in progress

Turn BL2 Plasma Current Interlocks on (chassis still in use for BL1) - OK

Add additional plasma interlock to prevent long pulse into armor- Ip & IpR - OK

Expand I/O for PLC control of BL and Services but use existing PLC – I/O received

Expand Thermocouple Scanning System to include BL2 & the ARMOR - OK

Fold BL2 into EPICS & timing pages – in progress

Update NBOS LabView Operator interface so existing staff can run 2 BLs - software in progress

No new problems - many new drawings completed

Update NB N4ABC Power Supply controls to current status – done

Mimic existing NSTX BL1 Controls scheme for BL2 but move NTC racks - done

Reactivate N4 Local Control Centers, Hardwired Interlock System – in progress

Turn BL2 Plasma Current Interlocks on (chassis still in use for BL1) - OK

Add additional plasma interlock to prevent long pulse into armor- Ip & IpR - OK

Expand I/O for PLC control of BL and Services but use existing PLC – I/O received

Expand Thermocouple Scanning System to include BL2 & the ARMOR - OK

Fold BL2 into EPICS & timing pages – in progress

Update NBOS LabView Operator interface so existing staff can run 2 BLs - software in progress

No new problems - many new drawings completed

NSTXU NBI Controls System modifications in progress…

Work Scope very similar to BL1 with updates to current status


NSTXU NBI Power Supply Controls - One Line Diagram

NBI NBPS One Line Diagram

Update electronics & control circuits completeUpdate electronics & control circuits complete 2475


N4ABC Local Control Center upgrade and wiring in progress

25

2475

• New NI chassis and LabView adds BL operator control purview

• Software upgrades designed and coded

• Additional NI and computing interfaces provide timing and data transfer with NSTX central computing and eliminates CAMAC

• Wiring changes in progress…

• New NI chassis and LabView adds BL operator control purview

• Software upgrades designed and coded

• Additional NI and computing interfaces provide timing and data transfer with NSTX central computing and eliminates CAMAC

• Wiring changes in progress…


N4ABC High Voltage Power Supply controls modifications completed

26

NBI Switchyard Disconnect Switch Remote Control Mod/Reg Grad Grid Divider and Controls chassis modifications

2475

New GGD here


Mod/Reg: Grad Grid Divider fabrication and assembly completed

27

2475


NBI Duct and Torus Vacuum Pumping System (TVPS) PROGRESS…

28

40” Torus Isolation (Gate) Valve received

24802485

TVPS valves, hardware, TMPs, and

shields on order

TVPS valves, hardware, TMPs, and

shields on orderCutting flanges…

Spool section & supports

Circular bellowsExit spool piece


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

29

24802485


VV Modification Bay JK weldments repaired in Tech Shop…

30

• 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…


VV Bay JK Modification in progress…

31

2480

• Bay JK and port extension weldments final machining completed;

• Final metrology performed

• JK Pieces ready for installation on VV

• Lift fixture fabricated and tested

• Rectangular bellows completed; rectangular flange on order – due Jan. 13

• Full duct assembly and leacheck off line planned 2-3 Q FY 13

• Install after testing…

• Bay JK and port extension weldments final machining completed;

• Final metrology performed

• JK Pieces ready for installation on VV

• Lift fixture fabricated and tested

• Rectangular bellows completed; rectangular flange on order – due Jan. 13

• Full duct assembly and leacheck off line planned 2-3 Q FY 13

• Install after testing…Bay JK Weldment and

Port Extension

Rectangular Bellows FlangesOn order and progressing at

vendor


NBI Armor fabrication done and installation in progress…

32

2460

Bay H supports need to befield fit and aligned using backing platesbefore final welding…

OKOK

• Backing plates fabricated

• Manifolds complete

• Carbon tiles machined

• Stiffener pieces fabrication done

• Braze/weld in shop

• Align/assemble/install/leakcheck

• Backing plates fabricated

• Manifolds complete

• Carbon tiles machined

• Stiffener pieces fabrication done

• Braze/weld in shop

• Align/assemble/install/leakcheck

Supports aligned using metrology and tack welded in place to determine field fit changes…

Bay H Port cover modifications for feedthroughs in progress.

Bay H


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…

NSTXU NBI: Conclusion

NSTXU NBI Upgrade Overview

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