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
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