NSTX Upgrade Project Final Design Review June , NSTX Supported by College W&M Colorado Sch Mines Columbia U CompX General Atomics INEL Johns Hopkins U LANL LLNL Lodestar MIT Nova Photonics New York U Old Dominion U ORNL PPPL PSI Princeton U Purdue U SNL Think Tank, Inc. UC Davis UC Irvine UCLA UCSD U Colorado U Illinois U Maryland U Rochester U Washington U Wisconsin Vac Vsl & Support Structures WBS Culham Sci Ctr U St. Andrews York U Chubu U Fukui U Hiroshima U Hyogo U Kyoto U Kyushu U Kyushu Tokai U NIFS Niigata U U Tokyo JAEA Hebrew U Ioffe Inst RRC Kurchatov Inst TRINITI KBSI KAIST POSTECH ASIPP ENEA, Frascati CEA, Cadarache IPP, Jlich IPP, Garching ASCR, Czech Rep U Quebec Mark Smith and the NSTX Upgrade Team Princeton Plasma Physics Laboratory NSTX Upgrade Project Final Design Review LSB, B318 June 22-24, 2011 NSTX Upgrade Project Final Design Review June , 2011 Outline 2 Design Overview Vessel Leg Reinforcement Pedestal Upgrade Umbrella Upgrades PF2/3 Support Upgrades PF4/5 Support Upgrades TF Outer Leg Support Upgrades Interconnections Cost & Schedule CHITs Open Items NSTX Upgrade Project Final Design Review June , 2011 Design Overview 3 Upper & Lower Umbrella Reinforcements New Umbrella Upper Lid New Umbrella Lower Lid Additional PF2 Clamp, PF2/3 Support Upgrades New Pedestal VV Foot Reinforcement Existing PF4/5 Supports Upgraded New (additional) PF4/5 Supports New Clevis & Connecting Rods New TFO Leg Support Ring Upper & Lower Umbrella Reinforcements NSTX Upgrade Project Final Design Review June , 2011 Vessel Leg Reinforcement 4 Horseshoe shaped foot reinforcement 1 reinforcement per set of VV supports. Epoxy anchor bolts attach to the concrete. NSTX Upgrade Project Final Design Review June , 2011 Pedestal Upgrade 5 Base Plate Lower Pedestal Section Upper Pedestal Section New Pedestal NSTX Upgrade Project Final Design Review June , 2011 Pedestal Upgrade 6 Epoxy anchor bolts attach to the concrete. Gap allows for height adjustment via shims. Bolt slots provide for alignment. Grouted base allows for leveling. Fiducials provided for alignment. Attachments for lower crown bolt plate and umbrella lower lid. Design provides access / clearance for equipment. Base Plate distributes load and provides attachment point for equipment. NSTX Upgrade Project Final Design Review June , 2011 Umbrella Upgrades 7 Upper & Lower Umbrellas Internal Reinforcement adjacent to Al Blocks (2 part & welded). Block threaded rods replaced. Upper & Lower Umbrellas External Reinforcement on Al Blocks (bolted). Corner bolts replaced. NSTX Upgrade Project Final Design Review June , 2011 Umbrella Upgrades 8 New Upper Lid Upper Lid Reinforcement Ring and Gussets (welded ) For installation, Upper Lid Reinforcement Ring is sectional. Upper Lid bolts to ring. Upper Lid and Crown Bolt Plate attachment (bolted) Design provides access / clearance for equipment. NSTX Upgrade Project Final Design Review June , 2011 Umbrella Upgrades 9 New Lower Lid (sectional & bolted) Lower Lid-Pedestal attachment (bolted) 1 water jet part welded Sectional lower lid aids in installation and allows maintenance access. Standoff ensures TF flex strap clearance. bolted Slots allow adjustment. welded NSTX Upgrade Project Final Design Review June , 2011 Umbrella Upgrades 10 Previous Reinforcement Scheme Outer Reinforcement to Umbrella Legs (perimeter and plug welds). Inner Reinforcement to Umbrella Legs and Arches (perimeter and plug welds). NSTX Upgrade Project Final Design Review June , 2011 Umbrella Upgrades 11 Replacement Leg (1 fabricated part) Upper & Lower Umbrella Legs removed and replaced (welded). Replace foot hardware, capture and slide with Inconel parts. Arch Reinforcement Ring (sectional & welded) To aid installation, reduce costs, and improve weld integrity the umbrella legs will be removed & replaced. NSTX Upgrade Project Final Design Review June , 2011 PF2/3 Support Upgrades 12 Additional PF2 Clamp Weld reinforcement on PF3 mount. Remove PF2/3 hardware and replace with ASTM A193 B8M Class2 Material. PF3 mount PF2 mount PF3 Clamp NSTX Upgrade Project Final Design Review June , 2011 PF4/5 Support Upgrades 13 6 New (additional) PF4/5 Supports Modifications to existing PF4/5 supports. 4 of 6 existing PF4/5 supports free to slide radially for thermal expansion. 2 of 6 existing PF4/5 supports (180 apart) fixed radially. NSTX Upgrade Project Final Design Review June , 2011 PF4/5 Support Upgrades 14 Replace hardware with ASTM A193 B8M Class2 Material. Remove clevis. Replace column. 2 part column with spacer for installation. Studs used for installation. NSTX Upgrade Project Final Design Review June , 2011 PF4/5 Support Upgrades 15 New (additional) PF4/5 Support T-slot allows for relative motion between PF4 and PF5. Magna Plate low friction coating interface. NSTX Upgrade Project Final Design Review June , 2011 TF Outer Leg Support Upgrades 16 NSTX Upgrade Project Final Design Review June , 2011 TF Outer Leg Support Upgrades 17 Remove /replace VV clevis. Reinforce VV pad weld. Use In718 pin. Remove and replace existing TFO Leg support turnbuckles. welded Shimmed around existing TFO leg clamp. Remove /replace TFOL clevis. Use In718 pin. 26 kips shear load capacity. NSTX Upgrade Project Final Design Review June , 2011 TF Outer Leg Support Upgrades 18 4 special rods provide clearance around VV support legs. Remove /replace connecting rods. Spherical rod ends allow alignment. Length adjustment via opposite threads. Jam nuts lock position. Wrench feature for installation. NSTX Upgrade Project Final Design Review June , 2011 Interconnections 19 Upper Crown-Lid Bolt Plate High friction interface: surface coating static 0.5 In718 strain gage bolts NSTX Upgrade Project Final Design Review June , 2011 Interconnections 20 Lower Crown-Lid-Pedestal Bolt Plate High friction interface: surface coating static 0.5 In718 strain gage bolts NSTX Upgrade Project Final Design Review June , 2011 Cost & Schedule 21 ETC has been updated. Man power EAEM (analyst): 960 mn-hrs = $170 ($k) Man power EADM (designer): 986 mn-hrs = $170 ($k) Man power EMEM (CAM) : 1364 mn-hrs = $206 ($k) Total M&S is $688 ($k) Total ETC is $1,411 ($k) NSTX Upgrade Project Final Design Review June , 2011 CHITs 22 PDR 6/2010 CHIT-07 TF Outer Leg Support Bolted Joint: Are dielectric breaks (insulated joints) required? Physics checked current loops, No breaks needed Closed. How is a shear load carried? Design accommodates shear load Closed. Peer Review 5/2011 CHIT-5: Electrically Ground new PF4/5 Supports. Ground wire provided - Closed. CHIT-18: Obtain approval for use of magnetic A193 bolts. Will receive approval or use Inconel bolts. CHIT-19a: Detailed analysis of bolted connections: (supports, pedestal, test cell floor). Connections being analyzed in detail --- pending calculation completion. NSTX Upgrade Project Final Design Review June , 2011 CHITs 23 Peer Review 5/2011 CHIT-38: Analysis indicates PF 4/5 supports not stiff enough. Titus to provide updated analysis and/or ppt slides. CHIT-40: Confirm PF4 T-slide material & required travel length to prevent lock up. Magna Plate low friction surface specified. T-slide length increased. Confirmation of design pending calculation completion. CHIT-44: Ensure tolerances, friction and pinned connections consistent with analysis assumptions. Confirmation pending calculation completion. NSTX Upgrade Project Final Design Review June , 2011 Open Items 24 Analysis/Calculations: Finalized and checked. COG/CAM sign off. Recent open items Contact vendor for high friction coating. Contact vendor for In718 strain gage bolts. TFO Leg Support: VV pad, clevis, rods, weldment, revised & validated. NSTX Upgrade Project Final Design Review June , NSTX Supported by College W&M Colorado Sch Mines Columbia U CompX General Atomics INEL Johns Hopkins U LANL LLNL Lodestar MIT Nova Photonics New York U Old Dominion U ORNL PPPL PSI Princeton U Purdue U SNL Think Tank, Inc. UC Davis UC Irvine UCLA UCSD U Colorado U Illinois U Maryland U Rochester U Washington U Wisconsin Bus Bars & Supports WBS Culham Sci Ctr U St. Andrews York U Chubu U Fukui U Hiroshima U Hyogo U Kyoto U Kyushu U Kyushu Tokai U NIFS Niigata U U Tokyo JAEA Hebrew U Ioffe Inst RRC Kurchatov Inst TRINITI KBSI KAIST POSTECH ASIPP ENEA, Frascati CEA, Cadarache IPP, Jlich IPP, Garching ASCR, Czech Rep U Quebec Mark Smith and the NSTX Upgrade Team Princeton Plasma Physics Laboratory NSTX Upgrade Project Final Design Review LSB, B318 June 22-24, 2011 NSTX Upgrade Project Final Design Review June , 2011 Outline 26 Description & Features Installation Layout CHI Ring Bus PF 1a, b, c Bus OH Coaxial Bus TF Bus Cost & Schedule CHITs Open Items NSTX Upgrade Project Final Design Review June , 2011 Description & Features 27 Replace CHI Ring: accommodate new pedestal. New Upper and Lower PF1a,b,c Bus New Coaxial OH Bus & Standard Bus Replace existing TF cables with solid bus bar. Oxygen free copper 2 mil Kapton, Fiberglass wrap, Epoxy Coated Bolted Connections: silver plated flat surfaces, bevel washers, minimum contact 2 ksi. G10 isolators, clamps, and supports. SS supports NSTX Upgrade Project Final Design Review June , 2011 Installation Layout 28 Bus Tower CHI Ring Bus TF Bus Upper PF1 Bus NSTX Upgrade Project Final Design Review June , 2011 Installation Layout 29 Bus Tower Pedestal OH Bus CHI Ring Bus TF Bus Upper PF1 Bus Lower PF1 Bus NSTX Upgrade Project Final Design Review June , 2011 CHI Ring Bus 30 G10 spacer Support/mount Clamp Water cooled. NSTX Upgrade Project Final Design Review June , 2011 PF 1a, b, c Bus 31 Support/mount Clamp Upper PF1 Bus Runs Bus Tower NSTX Upgrade Project Final Design Review June , 2011 OH Coaxial Bus 32 G10 spacer Support/mount Water cooled rectangular bus section. Air cooled Coaxial Bus section. Connection to OH coil. NSTX Upgrade Project Final Design Review June , 2011 TF Bus 33 G10 spacer Support/mount Water cooled section. Bus Tower Support/mount G10 spacer NSTX Upgrade Project Final Design Review June , 2011 TF Bus 34 G10 spacer Support/mount Water cooled section. Bus Tower Support/mount G10 spacer NSTX Upgrade Project Final Design Review June , 2011 Cost & Schedule 35 ETC completed. 1 st pass analysis is completed. Assembly and detailed drawings mostly completed. Note: Since bus runs are field fit, design finalization & validation occurs during installation. M&S = $109 ($k) ETC = $ 995 ($k) includes installation. NSTX Upgrade Project Final Design Review June , 2011 CHITs 36 Peer Review 5/2011 CHIT-20: Prepare designs for the bus supports for all new bus runs. Supports already included, modifications per updated analysis - Closed. CHIT-21: Prepare designs for the cooling water of new bus runs. Designs to be prepared. CHIT-29: Fault modes required when analyzing bus bar supports. Future analysis will include fault modes. NSTX Upgrade Project Final Design Review June , 2011 Open Items 37 Update models per calculations, FDR CHITs. Update analysis. Finalize design during field fit up / installation.