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NSTXU NBI Upgrade Overview

NSTX-U. Supported by. NSTXU NBI Upgrade Overview. Timothy N. Stevenson. Coll of Wm & Mary Columbia U CompX General Atomics FIU INL Johns Hopkins U LANL LLNL Lodestar MIT Lehigh U Nova Photonics ORNL PPPL Princeton U Purdue U SNL Think Tank, Inc. UC Davis UC Irvine UCLA

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NSTXU NBI Upgrade Overview

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  1. NSTX-U Supported by NSTXU NBI Upgrade Overview Timothy N. Stevenson Coll of Wm & Mary Columbia U CompX General Atomics FIU INL Johns Hopkins U LANL LLNL Lodestar MIT Lehigh U Nova Photonics ORNL PPPL Princeton U Purdue U SNL Think Tank, Inc. UC Davis UC Irvine UCLA UCSD U Colorado U Illinois U Maryland U Rochester U Tennessee U Tulsa U Washington U Wisconsin X Science LLC Culham Sci Ctr York U Chubu U Fukui U Hiroshima U Hyogo U Kyoto U Kyushu U Kyushu Tokai U NIFS Niigata U U Tokyo JAEA Inst for Nucl Res, Kiev Ioffe Inst TRINITI Chonbuk Natl U NFRI KAIST POSTECH Seoul Natl U ASIPP CIEMAT FOM Inst DIFFER ENEA, Frascati CEA, Cadarache IPP, Jülich IPP, Garching ASCR, Czech Rep Princeton Plasma Physics Laboratory NSTX Upgrade Project Office of Science Review PPPL LSB 318 12/11/12 & 12/12/12

  2. GRD Requirements for NBI System 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  NSTX Test Cell circa May 2012 (Last Lehman Review)

  3. NSTXU NBI Job Performance * Job completed

  4. NSTXU Test Cell General Arrangement New Racks NSTX Gallery/DARM BL1 Platforms NSTXU HVE NBI Duct/TVPS BL2 Helium Cryo Lines Power cables TTC South Wall

  5. NSTXU Test Cell General Arrangement NSTX Test Cell - 11/14/12

  6. NBI Relocation in progress… 2425 • 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) • 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 Lid • Remainder moved conventionally • Moving day started in September… TFTR Test Cell & SE Door TTC 9/12/12 – a day before major relocations began

  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)…

  8. NBI Lid Relocation: TTC 9/19/12 after the lid move Component refurbishment almost completed North side Cleanup of TTC begun on 102’ and South side…

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

  10. NSTXU Test Cell Beam Box move– 9/13/12 Photo: Elle Starkman

  11. NBI BL Box Relocation… TTC, South High Bay, Over the wall 2425 And on the vent stack…

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

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

  14. 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 “Bullseye…”

  15. BL Refurbishment: Ion Dump and Calorimeter – in progress 2440 BL1 Calorimeter Upgrade: Double bellows double drive • Ion Dump Replacement - • Fabrication complete • Leakchecking complete • Reassembly in progress • Thermocouples complete… • Calorimeter Upgrade – • Parts fabrication completed • Double bellows installation completed • Double drive system needs replaced with correct parts • External support structure work order in shop 15

  16. BL Refurbishment: 90 inch flange refurbishment in progress 2440 • 90 inch flange refurbishment – • Parts fabrication completed • Feedthroughs fabricated, leakchecked, and installed • OMAs reassembled and leakchecked & Bending Magnet ready for installation… 16

  17. Penetrations for water systems, power cabling, and cryogenic services 2450 2470 Penetration drilling required an articulated lift with adequate reach and ratings 6 power supply – 4 ft. 2 cryogenic piping – 6 ft. 2 water system piping (floor) – 2 ft. LN Cryo line installation Supply and Vent wall lines complete Awaiting BL platform to finish Articulated lift craned into and out of NTC…

  18. Cryogenics Line LN and LHe piping fabrication in progress in NBI shop 2450 LN Pipe Nitrogen Manifold LHe Manifold & South Wall

  19. Liquid Nitrogen and Vent installation in NTC completed along walls… LN Supply NTC North Wall & Catwalk 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… Nitrogen Vent line

  20. Liquid Helium manifold fabrication in progress and ready for S wall… NBI Mechanical: Cryogenics Services & SF6 line NTC South Wall Cryo LHe valves Operate either BL1 or BL2 or both…

  21. NSTXU NBI Power & Controls 2470 2475 Routing, Penetrations, Installation Procedures revised for improved penetration locations. All 6 Penetrations completed. NBPC Bldg Accel Decel Fil&Arc Mag PLC F/O PS F/O 138’ TFTR TC NSTX TC 100’ NB Switchyard Pumproom TFTR TC Basement MER All new cabling here… 21

  22. … and high voltage triax cable successfully tested here to 150 kV. Temporary hipot testing area in D site MG Building

  23. NSTXU NBI Controls System modifications in progress… Work Scope very similar to BL1 with updates to current status • 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 23

  24. NSTXU NBI Power Supply Controls - One Line Diagram Update electronics & control circuits complete 2475 X 3 NBI NBPS One Line Diagram 24

  25. N4ABC Local Control Center upgrade and wiring in progress 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… X 3

  26. N4ABC High Voltage Power Supply controls modifications completed 2475 New GGD here NBI Switchyard Disconnect Switch Remote Control Mod/Reg Grad Grid Divider and Controls chassis modifications X 3

  27. Mod/Reg: Grad Grid Divider fabrication and assembly completed 2475 X 3

  28. NBI Duct and Torus Vacuum Pumping System (TVPS) PROGRESS… 2480 2485 40” Torus Isolation (Gate) Valve received Circular bellows Exit spool piece TVPS valves, hardware, TMPs, and shields on order Spool section & supports Cutting flanges…

  29. NBI Duct Exit Spool Piece and BL TIV installed on Exit of BL… 2480 2485

  30. 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…

  31. VV Bay JK Modification in progress… 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… Rectangular Bellows Flanges On order and progressing at vendor Bay JK Weldment and Port Extension

  32. NBI Armor fabrication done and installation in progress… 2460 Supports aligned using metrology and tack welded in place to determine field fit changes… Bay H supports need to be field fit and aligned using backing plates before final welding… Bay H Port cover modifications for feedthroughs in progress. Bay H OK OK • Backing plates fabricated • Manifolds complete • Carbon tiles machined • Stiffener pieces fabrication done • Braze/weld in shop • Align/assemble/install/leakcheck

  33. NSTXU NBI: Conclusion 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…  33

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