NSTX-U FY2014 Q3 progress report: Upgrade Construction Progress Ron Strykowsky, Erik Perry, Tim Stevenson, Larry Dudek, Jim Chrzanowski, Steve Langish,

NSTX-U FY2014 Q3 progress report:NSTX-U FY2014 Q3 progress report:Upgrade Construction ProgressUpgrade Construction Progress

Ron Strykowsky, Erik Perry, Tim Stevenson, Larry Dudek, Jim Chrzanowski, Steve Langish,

Jon Menard, Stefan Gerhardt, Mike Williams

August 15th, 2014

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-U FY2014 Q3 Report - Construction Progress - July 29th, 2014 2

Significant progress this quarter


Good progress on construction, assembly, & installation

Centerstack Fabrication & Assembly

Visual inspection of VPI = no dry spots

Hydro and flow test cooling passages (200 psi operating pressure)

Megger to = 13kv (oper voltage 6kv)

Major risk retired !

Sanding complete to remove excess resin

Aqua pour removal – UNSUCCESSFUL

Epoxy resin infiltrated the porous aqua pour

Could not flush out with water

Used mechanical chisels on ends in an attempt to break through end-plug

Attempted heating/cooling the OH/TF respectively to open gap and demonstrate the OH moved independent of the TF

Decision to live with the “Aquament”


Good progress on construction, assembly, & installation

Centerstack Fabrication & Assembly – Moving forward

Dry out center stack and re-megger

Install upper & lower crown assemblies

Silver plating leads

Install Belleville washer assembly

Install (paint on) outer ground plane

Transport to NSTXU TC Mid-September


• Install PF 1a coils• Install Microtherm blanket• Insert CS magnet assy into casing

• Install Centerstack Assy – October• Install bus inside umbrella and back to racks• Install new TF flex bus• Field measure space between centerstack and all TF flags• Fabricate 72 unique centerstack to TF flag links• Install umbrella lid support rings• Install new umbrella lids• Clean, photo and close

the vacuum vessel• Pumpdown • Leak check • Bakeout

Remaining Construction Work in NSTX Test Cell


Good progress on construction, assembly, & installation (cont)

Test Cell Construction

Flux loops being installed and outer protective “cans” on PF1c coils.TF lead extensions being re-fabricated by Martinez-Turlits . Partial

delivery of the Lead Extensions with the first batch shipping August 12th and the last parts shipping September 2nd.

TF bus is being installed in the tower in the NTC and CHI bus is being trial fit under the machine

PF1b coils being installedPF1a coils being fit-up CS pedestal pre-fit up completed PFC Tile installation on CS casing to begin next week Fabrication and wrapping of coil bus continues in the Tech Shop and the

C-site test cell,Trial fit-up of the CHI bus has been started under the machine CHERS and tFIDA calibrations have been completed. RF antenna installations have been completed. New RWM coils installed Coil support modifications complete



DCPS

Validation (Testing through simulation)

96 plasma equilalibia simulated through autotester. Additionally , last two years of NSTX ops data run through the autotester.

Testing continues as needed to support changes arising from these studies and to investigate discrepancies found in output data. Component installation and bench testing continues

Verification ( Design, completeness)

Code Peer Review conducted last week (=20 hours). 9 minor chits most of which were directed at interfacing or operational DCPS issues and not the code itself. DCPS at present runs to approximately 12,000 lines of code

Next step - move to Junction area



Neutral Beam

Duct installed between NB and vacuum vessel

High Voltage Transmission Line support and ground wire installation is complete. With Transmission Lines now in their final positions, BL2 High Voltage Enclosures have been bolted to the floor

Armor Installed

3 Sources Installed

TVPS installation work continues including water piping modifications and instrumentation.

Service installations continue on BL2 including dry nitrogen and air lines.

NB Controls fabrication and installation cabling work on rack connections, cable runs, and BL wiring continued in NTC and gallery.


Center stack Coil Winding Operations Completed

Excess epoxy resin being sanded.

Excess epoxy resin being sanded.


Center stack Coil Winding Operations Completed

• OH/TF bundle Successfully tested. • Assembly of conductors began May 2012.• First quadrant VPI February 2013

• Job well done.• Now for the final assembly.

• OH/TF bundle Successfully tested. • Assembly of conductors began May 2012.• First quadrant VPI February 2013

• Job well done.• Now for the final assembly.


Neutral beam component installation nearing completion

Neutral Beam & TIV valve

Neutral Beam & TIV valve

• Neutral Beam connecting duct assembly (bellows(2) ,VPS duct) being lowered into position

• Entire assembly leak tested prior to installation

• Neutral Beam connecting duct assembly (bellows(2) ,VPS duct) being lowered into position

• Entire assembly leak tested prior to installation

Vacuum Vessel Bay J/K port

Vacuum Vessel Bay J/K port


NB component installation nearing completion (cont)

Transmission line installation underway

Transmission line installation underway

Neutral Beam Armor InstalledNeutral Beam

Armor Installed


Readiness review planning underway


NSTX Upgrade – Milestones on track

Level MilestoneDOE

Commitment Date

Forecast Actual

Months ahead

(behind) DOE

milestoneLevel I Receive CD-2 Approval Jan-11 Dec-10 1.4 Level II Project FDR Jun-11 Jun-11 0.3 Level I Receive CD-3 Approval Jan-12 Dec-11 1.4 Level II Receive First Delivery Machined Inner Tf Conductor Jun-12 Apr-12 2.7 Level II Nstx Complete Operations Jul-12 Sep-11 11.1 Level II Begin Upgrade Outage Aug-12 Sep-11 11.8 Level II Award Neutral Beam (NB) Vessel Cap Jun-13 Feb-11 28.9 Level II Begin Inner Tf Quadrant Fab (Apply Turn Insul #1 Apr-13 Jun-12 10.6 Level II Complete Assy and Pot Of 4th Inner TF Quadrant Oct-13 Jun-13 4.8

Install NB Sources Aug-14 Aug-14Level II Complete Fabricate & Test Inner TF/OH Coil Assy Jul-14 Jul-14 - Level II NB Cap Installed Oct-14 Jan-13 22.2

Deliver Center Stack to the NSTX TC Sep-14Level II Lift In New Centerstack Jan-15 Nov-14 3.0

Pumpdown Dec-14Level II Complete ISTP Aug-15 Feb-15 6.0 Level II Resume Operations Sep-15 Feb-15 7.0 Level I CD-4 Sep-15 Feb-15 7.0


Summary

• Project personnel have maintained a safe working environment.

• The project continues to make good technical progress.

• The project is on schedule and cost with adequate contingency to finish.

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

• Project personnel have maintained a safe working environment.

• The project continues to make good technical progress.

• The project is on schedule and cost with adequate contingency to finish.

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

Documents

NSTX-U FY2014 Q3 progress report: Upgrade Construction Progress Ron Strykowsky, Erik Perry, Tim Stevenson, Larry Dudek, Jim Chrzanowski, Steve Langish,