1. NSTX-U NSTX Upgrade Project – Office of Science Review – February 4, 2014 1 NSTX Centerstack Fabrication Status James H. Chrzanowski and the NSTX Upgrade Team Princeton Plasma Physics Laboratory NSTX Upgrade Project Office of Science Review LSB B318 February 4, 2014 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

2. NSTX-U NSTX Upgrade Project – Office of Science Review – February 4, 2014 2 General Arrangement TF Flex Bus and Support Structure Centerstack Assembly Outer TF Coils Major Centerstack Components Umbrella Structure Vacuum Vessel

3. NSTX-U NSTX Upgrade Project – Office of Science Review – February 4, 2014 3 Upgraded Centerstack Components Inner TF Bundle Ohmic Heating Coil Inner PF1c Inner PF1b Inner PF1a Plasma Facing Components CS Casing Ceramic break assembly

4. NSTX-U NSTX Upgrade Project – Office of Science Review – February 4, 2014 4 Topics Progress of the Centerstack since last review Remaining risks and mitigation plans, Plans forward Address charge question #1 Critical Path Construction Efforts: –Does the Project team have a realistic, executable schedule for Center Stack (CS) remaining construction efforts? –Does the project have adequate resources and the appropriate skills mix to execute the remainder of the project per the plan?

5. NSTX-U NSTX Upgrade Project – Office of Science Review – February 4, 2014 5 Center Stack Status Since Last Review Inner TF Bundle –Complete Centerstack Casing –Delivered and studs have been installed OH Solenoid –Major tooling for OH solenoid has been delivered & commissioned –Aquapour and epoxy/glass base has been installed over TF bundle –First layer of OH solenoid has been wound –Completing layer transition 1 to 2 and resume winding layer 2 Inner PF coils –PF1b coils have been completed

6. NSTX-U NSTX Upgrade Project – Office of Science Review – February 4, 2014 6 Involvement of ES&H Safety Department The fabrication & assembly of the Centerstack is being performed by PPPL personnel at the laboratory. Safety is an important part of the PPPL culture Safety is incorporated in all aspects of the development program- carryover to production Industrial Hygiene (IH) & Construction Safety have participated in the planning and setup of the coil area Job Hazard Analysis (JHAs) are being developed for each procedure Procedures: Clearly identify safety precautions for specific operations Personnel protective equipment (PPEs) being used Tool Box Safety meeting held monthly with Technicians Involvement with all safety groups

7. NSTX-U NSTX Upgrade Project – Office of Science Review – February 4, 2014 7 Progress- Raising the Full TF Bundle Completed testing of TF Bundle Raised TF Bundle to the vertical position in preparation for the application of the Aquapour. complete

8. NSTX-U NSTX Upgrade Project – Office of Science Review – February 4, 2014 8 Progress- Installation of Aquapour Layer Installation of Aquapour layer was successfully completed Aquapour is used as a temporary spacer that will be used to maintain 0.100 inch gap between the TF OD and OH ID surfaces. It is removed post VPI of OH coil complete

9. NSTX-U NSTX Upgrade Project – Office of Science Review – February 4, 2014 9 OH Solenoid Winding Facility The OH Solenoid is being wound onto the Inner TF Bundle Completed setup & commissioning of OH winding equipment in CS High Bay area

10. NSTX-U NSTX Upgrade Project – Office of Science Review – February 4, 2014 10 Tooling- OH Winding Station Pivot Beam OH Winding station fully commissioned Shops Copper Spools Cut-off saw & Braze Station Hydraulic Tension Unit Dual Taping Heads complete

11. NSTX-U NSTX Upgrade Project – Office of Science Review – February 4, 2014 11 Progress- Winding Preparations Epoxy/glass layer was applied over the Aquapour surface to provide a solid winding surface OH support structure was installed complete

12. NSTX-U NSTX Upgrade Project – Office of Science Review – February 4, 2014 12 Transfer TF to OH Winding Station The TF bundle was transferred to the OH Winding station complete

13. NSTX-U NSTX Upgrade Project – Office of Science Review – February 4, 2014 13 OH Solenoid Fabrication- 1 Wind the OH solenoid using approved drawings and procedure D-NSTX-IP-3385 Four layers/ 880 turns/ (2) conductors in-hand Co-wound turn to turn insulation (Kapton/glass) In-line braze joints Layer to layer TIG Braze joints Tension wound conductor

14. NSTX-U NSTX Upgrade Project – Office of Science Review – February 4, 2014 14 NSTX April 29, 2010NSTX Center Stack Upgrade Peer Review Layer to layer TIG-Braze joint [Typical] OH Cooling fittings- torch brazed to copper conductors TIG-Braze TIG-Brazing method minimizes annealing of conductors (use Sil-Fos) Provides adequate joint strength Qualified method and procedures used in previous OH solenoids OH Solenoid Fabrication- 2 -Glass/epoxy laminate fillers between layers supports turns -S-2 glass between fillers -Perforations in fillers will enhance epoxy flow during VPI 14

15. NSTX-U NSTX Upgrade Project – Office of Science Review – February 4, 2014 15 OH Winding Status and Accomplishments Winding operations have started Winding station is working well Completed first layer 240 turns Use of Aquapour as winding surface is working well Outside diameter of layer 1 turns are in spec Successfully completed and tested 6 in line brazes Successfully completed and tested 6 cooling fitting brazes Completed 2- Layer to layer brazes

16. NSTX-U NSTX Upgrade Project – Office of Science Review – February 4, 2014 16 Coil Winding Photos

17. NSTX-U NSTX Upgrade Project – Office of Science Review – February 4, 2014 17 Coil Winding Photos -continued Completed 240 turns including (6) inline brazes

18. NSTX-U NSTX Upgrade Project – Office of Science Review – February 4, 2014 18 Taping Stations The dual taping stations had initial startup issues w/ controllers They are working as planned applying (3) half-lapped layers of insulation at once on two parallel conductors

19. NSTX-U NSTX Upgrade Project – Office of Science Review – February 4, 2014 19 Taping and Winding Operations

20. NSTX-U NSTX Upgrade Project – Office of Science Review – February 4, 2014 20 Winding Manpower and Shift Coverage Manpower: –(2) 4 man teams –Engineering coverage for both shifts Started teams on 1 shift until completing 1 st half of layer 1 Began 2 shifts for 2 nd half of layer 1 Once we reached the half way point, the actual winding and braze times and are less than anticipated Winding: 2 nd. Half of layer 1 –Estimated- 3 shifts per quarter –Actual- 1.5 shifts per quarter Brazing: (2) brazes –Estimated- 3 shifts per quarter –Actual- 2 shifts per quarter

21. NSTX-U NSTX Upgrade Project – Office of Science Review – February 4, 2014 21 Winding Manpower and Shift Coverage Layer to Layer Transition is being done on 1 shift to understand and teach associated technical issues with all team members for future transitions Future Layer to layer will probably be done with 2 shifts Resume 2 shifts once winding begins Engineering coverage is provided for 2 nd. Shift (Need will be evaluated after second layer has been completed)

22. NSTX-U NSTX Upgrade Project – Office of Science Review – February 4, 2014 22 Completion Dates Completion of OH winding should occur by mid to late March VPI completed by mid April Complete OH/TF activities: April thru May –Continue on 2 shift operations thru completion of OH/TF activities –Removing Aquapour –Final OH testing –Fit-up and installation of laminate crowns –Finalization of TF fittings and bulkheads –Installation of Belleville washer assembly Centerstack assembly activities: May thru June: –Install lower PF1A coil –Apply ground plane and diagnostics to OH surface –Install Micro therm insulation Transport OH/TF to NSTX South bay for final assembly: June 2014

23. NSTX-U NSTX Upgrade Project – Office of Science Review – February 4, 2014 23 Crown Assembly Field fit and drill final pins holes Final Assembly Tasks Purpose of Crowns: Lock conductors together & help transfer load from TF bundle through lid structure to umbrella TF Cooling connections & bulkhead Install Belleville Washer Assembly Install upper and lower crowns (custom fit-up required) and TF cooling fittings Install Belleville washer assembly

24. NSTX-U NSTX Upgrade Project – Office of Science Review – February 4, 2014 24 Laminate Crown Epoxy/S-2 glass construction circumferentially wound (jelly-roll) Upper & Lower Crown Assemblies-contd Pinned to Inner TF Conductors 316 SS Fabricate in house

25. NSTX-U NSTX Upgrade Project – Office of Science Review – February 4, 2014 25 Centerstack Casing The Centerstack Inconel casing has been manufactured by Martinez & Turek located in California. Inconel studs for supporting the PFCs have been installed & are being cut to required length (NSTX South Bay)

26. NSTX-U NSTX Upgrade Project – Office of Science Review – February 4, 2014 26 Inner PF Coils Contract for fabricating the Inner PF coils has been awarded to Everson-Tesla Inc. (Nazareth, Pa) Both inner PF1Bs have been wound and VPId The first Inner PF coil has been delivered the second will be delivered the week of Feb 10 th. Winding of the first PF1A coil will begin week of Feb 10 th. Late delivery has no impact on critical path schedule PF1B PF1A PF1C

27. NSTX-U NSTX Upgrade Project – Office of Science Review – February 4, 2014 27 Centerstack Casing The Inner PF1B coils will be mounted to CS casing followed by the PFC tiles and diagnostics. (NSTX South Bay) PF1B Plasma Facing Component tiles

28. NSTX-U NSTX Upgrade Project – Office of Science Review – February 4, 2014 28 Miscellaneous Procurements TF flex buss has been completed by Zenox Corp. Super nuts and hardware have been delivered Outer TF Lead extensions are being manufactured by Martinez- Turek (California) Delivery scheduled for late March MT Torque-nut Flex-Bus (Cu-Cr-Zr) OTF Lead Extensions

29. NSTX-U NSTX Upgrade Project – Office of Science Review – February 4, 2014 29 Exploded View Assembled View Complete Ceramic Break Sub-Assembly - All components except for PF1C coils have been delivered for ceramic break assemblies - Assemble the ceramic break components to the Upper and Lower PF-1C coil structures. Work to be performed by PPPL Ceramic rings were fabricated by Kyocera in Japan Stainless rings manufactured by Hollis Machine (NH) G-11 insulators manufactured by Astro Machine Works (Pa) and Reno Machine (Conn) PF1C coil manufactured by Everson-Tesla Inc

30. NSTX-U NSTX Upgrade Project – Office of Science Review – February 4, 2014 30 Mount the Center Stack Support Structure to Lower PF-1A Coil Step 1- Assemble CS Support & Lower PF-1A Together Install Micro-therm insulation around outside surfaces of Upper PF1 Coil

31. NSTX-U NSTX Upgrade Project – Office of Science Review – February 4, 2014 31 Step 2- Assemble Lower PF-1A Assy. To OH/TF Assy. Position the Lower PF-1A coil assembly over the OH/TF Assembly

32. NSTX-U NSTX Upgrade Project – Office of Science Review – February 4, 2014 32 Step 3 – OH Diagnostics & Thermal Blanket Mount the OH surface diagnostics and the Micro-Therm Insulation Blanket around the outer surfaces of the OH Solenoid -Flux loops -Thermocouples -Rogowski Coils Micro-Therm Insulation Lower PF-1A Coil Assy. TRANSPORT OH/TF BUNDLE TO NSTX SOUTH HIGH BAY AREA

33. NSTX-U NSTX Upgrade Project – Office of Science Review – February 4, 2014 33 Lower the CS Casing over the OH/TF Assembly Step 4 – Install CS Casing to CS Assembly Upper Assembly Lower Assembly Lower the Upper PF1A coil over the OH/TF Assembly & secure to Upper PF1B coil

34. NSTX-U NSTX Upgrade Project – Office of Science Review – February 4, 2014 34 Step 5- Install Flash Shields Install the Kapton shields and vertical motion instrumentation Flash Shields

35. NSTX-U NSTX Upgrade Project – Office of Science Review – February 4, 2014 35 Pre-position the lower Ceramic Break Assembly and Rotatable Flange prior to lowering CS assembly into the VV Install the completed Center Stack Assembly into the Vacuum Vessel (July 2014) Step 6- Install Completed CS Assembly

36. NSTX-U NSTX Upgrade Project – Office of Science Review – February 4, 2014 36 Critical Path Schedule The OH Manufacturing steps are series activities w/ very few parallel activities

37. NSTX-U NSTX Upgrade Project – Office of Science Review – February 4, 2014 37 Charge Question Address charge question #1 Critical Path Construction Efforts: –Does the Project team have a realistic, executable schedule for Center Stack (CS) remaining construction efforts? –The project feels that the schedule to complete the center stack assembly is realistic and achievable. Most of the high risk tasks or operations have been addressed during the performance of the manufacturing. OH winding is proceeding well taking fewer days than anticipated The layer 1 diameter is being maintained and is in tolerance The Aquapour is performing as expected providing a stable base for winding the OH turns In-line brazing operations are going well –The remaining high risks are associated with the final vacuum pressure impregnation of the OH solenoid

38. NSTX-U NSTX Upgrade Project – Office of Science Review – February 4, 2014 38 Charge Question –Does the project have adequate resources and the appropriate skills mix to execute the remainder of the project per the plan? –The four man teams operating on 2 shifts provide the necessary manpower to complete the winding of the OH solenoid. –Additional manpower is available to cover illness or vacation –3 engineers plus project management (RLM) are assigned to the center stack through completion.

39. NSTX-U NSTX Upgrade Project – Office of Science Review – February 4, 2014 39 Conclusion The full TF bundle have been VPId and tested (Retired risks) –Five of the 6 required VPIs have been completed The Inconel casing has been delivered & studs installed Major tooling for the OH solenoid has been completed The OH coil manufacturing facility has being setup & commissioned –There was a delay in commissioning the OH winding station (taping stations) Production has started with winding of first layer completed Times for winding and brazing are less than anticipated Inner PF coils are being fabricated by Everson Tesla with first (2) coils completed Anticipate completion of the Centerstack components and installation into NSTX in July 2014