NSTXU Project Update Jim Chrzanowski, Larry Dudek, Erik Perry, Tim Stevenson, Ron Strykowsky and the Project Team October 4th, 2013 NSTX-U Supported by 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 Coll of Wm & Mary Columbia U CompX General Atomics FIU INL Johns Hopkins U LANL LLNL Lodestar MIT Lehigh U Nova Photonics Old Dominion 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

NSTX-U NSTX Upgrade Project – Team Meeting– October 4 h Detailed Presentations of Progress at;

NSTX-U NSTX Upgrade Project – Team Meeting– October 4 h Excellent safety record. On schedule and cost. On track for January rough pump down. NB Cryogenic services complete 3 HVE’s installed Cable tray and diagnostic rack re-installation underway All Outer TF coils installed along with inter linkages NB DI water piping installation nearing completion Neutral beam vessel port installed on the vacuum vessel (Level II milestone) Platform installation completed Source platform installed NB Power cabling underway NSTXU Test Cell September Significant progress Umbrella structural modifications (incl legs) completed

NSTX-U NSTX Upgrade Project – Team Meeting– October 4 h Neutral Beams

NSTX-U NSTX Upgrade Project – Team Meeting– October 4 h N4ABC High Voltage Enclosure relocation completed – 3 HVEs 2425

NSTX-U NSTX Upgrade Project – Team Meeting– October 4 h N4ABC High Voltage Enclosure relocations completed 2425

NSTX-U NSTX Upgrade Project – Team Meeting– October 4 h BL2 Transmission Line relocation awaits cable and tray installation Transmission Line spool pieces ordered and received Transmission Lines in TCB awaiting completion of cable and tray installation to avoid potential damage

NSTX-U NSTX Upgrade Project – Team Meeting– October 4 h NBI Port Extension trial fit completed 2480 TF outer leg clearances maintained Maintained ¾ inch clearance to Port Extension for OL deflection per spec Maintained ¾ inch clearance to Port Extension for OL deflection per spec Awaiting NBI Duct installation…

NSTX-U NSTX Upgrade Project – Team Meeting– October 4 h NTC Access platforms modified due to BL2 placement NTC Access platforms modified due to BL2 placement After cryo line installation in TTC HVAC and Stack Duct moved and modified… After cryo line installation in TTC HVAC and Stack Duct moved and modified… …and restored to service prior to Start of Cable and Tray subcontract …and restored to service prior to Start of Cable and Tray subcontract BL2 area changes required for relocation completed

NSTX-U NSTX Upgrade Project – Team Meeting– October 4 h Cryogenics Line LN and LHe piping fabrication completed in NBI shop 2450 Cryo line fabrication Cryo line installation Cable and tray path

NSTX-U NSTX Upgrade Project – Team Meeting– October 4 h Deionized Water Piping subcontract completed (source, dump, HVE) 2450

NSTX-U NSTX Upgrade Project – Team Meeting– October 4 h NBI Armor assembly and installation in progress… 2460 Painstaking trail fit made and supports aligned. Final structural welding completed.

NSTX-U NSTX Upgrade Project – Team Meeting– October 4 h NBI Duct & TVPS duct fabrication completed … and leakchecked. Stainless circular shields complete Moly shields for rectangular bellows in progress Stainless circular shields complete Moly shields for rectangular bellows in progress

NSTX-U NSTX Upgrade Project – Team Meeting– October 4 h NBI Duct & TVPS duct fabrication completed … and leakchecked. Stainless circular shields complete Moly shields for rectangular bellows in progress Stainless circular shields complete Moly shields for rectangular bellows in progress

NSTX-U NSTX Upgrade Project – Team Meeting– October 4 h Centerstack

NSTX-U NSTX Upgrade Project – Team Meeting– October 4 h Center Stack Status Since Last Review Inner TF Bundle –(4) TF Quadrants have been VPI’d –Full TF Bundle has been VPI’d OH Solenoid –Major tooling has been delivered –Begin winding OH solenoid- October 2013 –VPI OH Solenoid- January 2014 Centerstack Casing –Delivered and studs have been installed- Outer TF Coils –(2) New TF Coils fabricated Centerstack Assembly- –Final CS assembly will occur between February- May 2014 Work was supported by Steve Raftopoulos, Mike Mardenfeld, Irv Zatz & Technician crews led by Mike Anderson and Eugene Kearns

NSTX-U NSTX Upgrade Project – Team Meeting– October 4 h Step 4- Full TF Assembly The four VPI’s quadrants were then assembled together to complete the full bundle. Quadrants are ground wrapped with layers of S-2 glass tape The full TF bundle is placed into a mold and VPI’d The quadrants will be assembled w/ S-2 between layers & pre-insulated G-10 core The full TF bundle is Ground wrapped with S-2 glass tape

NSTX-U NSTX Upgrade Project – Team Meeting– October 4 h Step 5- Full TF Bundle Assembly Full TF Bundle in oven and ready for VPI Full TF Bundle after VPI

NSTX-U NSTX Upgrade Project – Team Meeting– October 4 h OH/TF Bundle Tooling A new CS “Tilt Fixture” has been fabricated by Astro Machine Works Inc. Fixture will be used for up-righting the CS to the vertical position

NSTX-U NSTX Upgrade Project – Team Meeting– October 4 h Step 6- Post VPI Complete the electrical tests on TF bundle Install the “Aquapour” filler over the TF bundle surface –“Aquapour” is used as a temporary spacer that will be used to maintain inch gap between the TF OD and OH ID surfaces. It is removed post VPI of OH coil Mount TF Bundle into winding station Begin winding operations

NSTX-U NSTX Upgrade Project – Team Meeting– October 4 h Fabrication of OH Solenoid The OH Solenoid will be wound onto the Inner TF Bundle The CS High Bay area is being reconfigured to wind the OH coil

NSTX-U NSTX Upgrade Project – Team Meeting– October 4 h Centerstack Casing The Centerstack Inconel casing has been manufactured by Martinez & Turek located in California. Inconel studs for supporting the PFC’s have been installed

NSTX-U NSTX Upgrade Project – Team Meeting– October 4 h Construction and Machine Assembly

NSTX-U NSTX Upgrade Project – Team Meeting– October 4 h Outage Progress in 2013 Install new umbrella legs / feet / slides Install umbrella arch reinforcements

NSTX-U NSTX Upgrade Project – Team Meeting– October 4 h Outage Progress in 2013 Install reinforcements for TF to umbrella interface

NSTX-U NSTX Upgrade Project – Team Meeting– October 4 h Outage Progress in 2013 Replace PF2/3 clamp hardware and install additional PF2 clamps Install new PF4/5 supports and replace existing hardware (still in progress)

NSTX-U NSTX Upgrade Project – Team Meeting– October 4 h Outage Progress in 2013 Modify vacuum vessel legs to clear new TF turnbuckles

NSTX-U NSTX Upgrade Project – Team Meeting– October 4 h Outage Progress in 2013 Re-silverplated leads on TF outer legs

NSTX-U NSTX Upgrade Project – Team Meeting– October 4 h Outage Progress in 2013 Installed new cable tray around top of machine –Walking surface included in top of tray

NSTX-U NSTX Upgrade Project – Team Meeting– October 4 h Outage Progress in 2013 Installed most of the TF outer leg upper support structure –Successfully proven out this very challenging installation procedure

NSTX-U NSTX Upgrade Project – Team Meeting– October 4 h Remaining Structural Work Finish installing new PF4/5 supports and replace existing columns Install new TF outer leg lower supports Install new centerstack pedestal Install TF outer support turnbuckles Add extensions and anchors to vacuum vessel leg struts

NSTX-U NSTX Upgrade Project – Team Meeting– October 4 h Work Once Centerstack is in NSTX Test Cell 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

NSTX-U NSTX Upgrade Project – Team Meeting– October 4 h Tasks to Prepare for Return to Operations Clean, photo and close the vacuum vessel Pumpdown Leak check Bakeout All routine tasks at the end of an outage

NSTX-U NSTX Upgrade Project – Team Meeting– October 4 h CD-4 SEPT Forecast November 2014 CD-3 Dec 2011 Schedule on track for early finish ~3/4 the way through the Centerstack fabrication ! Key to meeting CD-4 and cost containment  Complete and deliver the centerstack to the test cell for installation by May 2014! ~3/4 the way through the Centerstack fabrication ! Key to meeting CD-4 and cost containment  Complete and deliver the centerstack to the test cell for installation by May 2014! Deliver CS to Test Cell May 2014

NSTX-U NSTX Upgrade Project – Team Meeting– October 4 h Lehman Review-Recommendations 1.Construction Efforts: Are construction efforts being executed safely? Does the project have adequate resources and the appropriate skills mix to execute the project per the plan? YES..but $ 2.Baseline Cost and Schedule: Are the current project cost and schedule projections consistent with the approved baseline cost and schedule? Is the contingency remaining adequate for the risks that remain? YES..but $ 3.Management: Evaluate the management structure as to its adequacy to deliver the scope within budget and schedule. Are risks being actively managed? Has the project responded satisfactorily to the recommendations from the previous project reviews? YES..but $ 4.Transition to Operations: Is the Project appropriately aligned for completion of construction efforts and transitioning to NSTX-U for CD-4 approval? YES.

NSTX-U NSTX Upgrade Project – Team Meeting– October 4 h Summary The project has 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 sufficiently staffed to meet schedule. The project is on track for meeting CD-2 baseline within OFES budgetary guidance. The project is preparing for transitioning into operations.