1. NSTX-U Project Overview Ron Strykowsky
Supported by
Project Overview
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
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
Ron Strykowsky
Project Manager for Construction Project
Princeton Plasma Physics Laboratory
Readiness for Operations Review
LSB B318
December 9-11, 2014

2. Content
Scope
Execution Plan
Deliverables
Summary

3. NSTXU Device
The NSTX device is exploring a novel structure for the magnetic field used to contain the hot ionized gas, called “plasma”, needed to tap this source of fusion energy. 
Mission of the NSTX is to establish the potential of the ST configuration as a means of achieving practical fusion energy.
Not a steady state machine. Pulse length < 6 sec.
Design rep rate <40 minute

4. Technical Performance Baseline Parameters (defined in section 2. 2
Technical Performance Baseline Parameters (defined in section of the Project Execution Plan (PEP))
Technical Performance Baseline Parameters
To meet the mission need objective, the existing NSTX machine at PPPL will be upgraded to permit operation at the following increased levels;
• Toroidal field from 0.5 tesla to 1.0 tesla;
• Pulse length from ~1.0 second to 5.0 seconds;
• Plasma current from 1MA to 2MA;
• Neutral beam heating from 5-7MW to 10-14MW
In PEP
Design basis
Day 1 hardware capable (design and tested)
Not Day 1 planned achievement (phased in during 2-3 years)

5. NSTX Upgrade Deliverables
Double field and current
Center Stack (CS) Upgrade.
Design, build and install new CS assembly including;
a new toroidal field (TF) hub assembly,
new TF flag assemblies,
new ceramic break,
new inner TF bundle,
new ohmic heating coil,
new plasma facing component (PFC) tiles,
new poloidal field (PF) 1a, b & c coils.
Power, controls, water, services
2) Double neutral beam power & more tangential injection
2nd Neutral Beam-line (NBL).
Decontaminate and prepare a TFTR neutral beam-line (NBL) for installation on NSTX.
Evaluate and refurbish internal components as necessary (cryogenic panels, beam dumps, bending magnets, beam scrapers, calorimeter, etc.).
Relocate the NBL and
Provide a second set of beam-line services (e.g., power, water, vacuum, cryogenics, etc.).
Larry Dudek will discuss in detail
Tim Stevenson to discuss in detail
In PEP
This represents a major modification to an existing fusion device

6. CD-4 milestone completion criteria defined in section 2. 2
CD-4 milestone completion criteria defined in section of the Project Execution Plan (PEP)
Demonstrated Performance
The major milestone marking the transition from a fabrication project to an operating facility is the first plasma milestone (CD-4). First plasma is defined as an ohmically heated discharge > 50 kA at a toroidal magnetic field of > 1 kG. The operations phase will resume upon completion of the first plasma milestone.
The installation of the second neutral beam on NSTX shall be considered complete at the stage where each item below has been demonstrated:
Beamline water, vacuum, cryogenics, and feedstock gas services have been attached to the beamline;
A Torus Isolation Valve and duct interconnects the NSTX vacuum vessel and the neutral beamline;
Local Control Centers have been powered on to monitor power supply status, and;
Project will be verified as complete when a 40,000 electron-volt beam has been produced and injected into the armor for .050 seconds
In PEP

7. Project Organized to Execute Mission
Sources & Controls
M. Cropper
NB Relocation/ Services
N. Atnafu
NBI Armor
K. Tresemer
NBI Power
R. Ramakrishnan
NTC Equipment
Relocation
E. Perry
Control Sys Data Acquisition
P.Sichta
Auxiliary Systems
W. Blanchard
Construction
E.Perry
Integrated Systems Testing/Startup
C.Gentile
Centerstack Design & Procurement
S.Raftopoulos
NSTX Upgrade Project Manager
R. Strykowsky
Deputy and Construction Manager
Project Controls
S. Langish
NSTX Centerstack Manager
L. Dudek
NSTX Neutral Beam Manager
T. Stevenson
Engineering Support
Sys Analysis: P. Titus
Sys Integr: C. Neumeyer
Associate Director
M. Williams
Structures & Supports
M. Smith
Electrical Systems
Diagnostics
R.Kaita
Centerstack PFC
VPS/NB/TVPS Duct
Most staff will transition over to machine operations

8. Project Scope WBS Breakdown
Larry Dudek will discuss scope in detail
Tim Stevenson to discuss scope in detail

9. Project Scope WBS Breakdown (continued)

10. Design, Fabrication, Assembly, & Installation followed a disciplined approach
Physics Motivation and needs vetted in mission need statement
General Requirement Documents (GRD's) prepared.
Plasma parameters (equilibria) defined for 96 initial operational scenarios
Detail design parameters in the Design Point Spreadsheet
Design ENG-032 (work planning form), ENG-033 (design reviews),ENG-010 (change control)
Global model analysis and calculations ENG-033 (calculation form)
Procurement/ fabrication packages established ENG-006 (Specifications & statements of work)
Receipt inspections, testing, pre-assembly fit-ups QA-004 (PPPL Site Inspection Program) (Control of Non-conformances)
Installation Engineering Work Packages (EWP’s) ESH-004 (Job Hazard Analysis) ENG-30 (procedures), 055 (Conduct of Operations)
Testing ENG-030 (Preoperational test procedures)
Updated Failure Mode and Effects Analysis ENG-008 (FMEA )
Updated Safety Assessment Document (SAD)
Lessons learned from previous experiences design reviews & external reviewers.
Chits from design reviews independently tracked
Risk registry maintained that identified mitigation plans that were incorporated into the design where applicable
Stefan Gerhardt will elaborate
Judy Malsbury will elaborate
Erik Perry will elaborate
Jerry Levine will elaborate

11. NSTXU Design, Fabrication and Assembly vetted by a rigorous review process
Multiple design & project level reviews (per eng-033).
Chits documented and independently tracked by QA (402 total 94% closed). Remaining 6% to be closed prior to startup. Will be confirmed by the Activity Certification Committee (ACC).
69 individual external reviewers from 22 institutions
QA integral part of the design, procurement, fabrication, and inspection process.
Charlie Gentile will discuss the ACC process
Judy Malsbury will describe QA/QC oversight.

12. Larry Dudek will discuss center stack and machine scope in detail
Major Machine Components Description
Outer TF coils
New NB port
PF Coils
Larry Dudek will discuss center stack and machine scope in detail

13. Center Stack - Core of machine
Simpler Inner TF design
(single layer of TF conductors)
Improved Joint Design
Reinforced Coil Supports
OH coil wound on TF
Existing outer TF WITH water cooling
Flex joint design critical required R&D. OH winding on TF required R&D. Inner TF epoxy required R&D
Much R&D was required to vet critical design details

14. Centerstack Upgrade Scope
Bolted joints located at further radius hence lower joint current density and lower magnetic field at joint
Original CS
Two conductors types and two layers
TF Bundle contains 36 identical conductors with one-layer joint design with non zinc-chloride flux
Increased contact pressure even with higher loads.

15. Assembly of centerstack
Fabrication of center stack performed by PPPL with components supplied by industry
Assembly four quadrants of conductors
Assembling first of 4 quadrants of conductors
Final VPI of OH/TF bundle
Winding of OH conductor around TF bundle
Assembly by PPPL conductor fab by Major Tool & EWI
VPI and Testing of the OH/TF magnet successful…however

16. OH Aquapour Removal Issue
100 mill Aquapour gap TF
Coil OH
During VPI, epoxy saturated the Aquapour turning it into waster resistant substance.
• No solution for removing the remaining Aquapour- epoxy mixed material. Decision to leave Aquapour in place.
Independent peer review conducted to determine mitigation plan.
Minimal impact on Operations
Stefan Gerhardt will discuss operations considerations in detail

17. OH/TF center stack bundle assembly completed
Final sanding and clear coat applied.
Outer ground plane applied.

18. Plasma Facing Components (PFC’s) installed on center stack casing
October 2014
First row diverter tiles pre-fit then removed to prevent damage
PFC tiles installed!
PFC tiles being installed on the CS Casing

19. Casing with tiles installed over the OH/TF bundle

20. Center stack assembly installed into the NSTX Machine

21. Second Neutral Beam Scope
A TFTR Neutral Beamline was Decontaminated and relocated to the NSTX Test Cell
NSTX test cell
TFTR test cell
Tim Stevenson will discuss Neutral Beam scope in detail

22. Second Neutral Beam - Scope (continued)
NBL2 Duct w/ new TIV
Torus Vessel Pump System Duct
Port Extension
Bay J-K Cap
(Required NSTX Vessel Modification)
NBI Armor addition

23. Second Neutral Beam Relocated
Beam box = 40 tons
Lid = 14 tons
Began work February 2009
30,000 hours (>17 person years) for decontamination, refurbishment, relocation design

24. Neutral beam component installation
Neutral Beam & TIV valve
Vacuum Vessel Bay J/K rectangular port
Neutral Beam connecting duct assembly being lowered into position
Round bellows and duct
Turbo molecular vacuum Pumps
Rectangular Bellows

25. NB component armor installed

26. Neutral Beam High Voltage Enclosures & Transmission Lines Installed

27. Construction Coordination
Use of a Work Control Center for all work in the test cell. Project in-charge during assembly and testing (Erik Perry). Handoff to Operations (Al vonHalle) for start of ISTP
System pre-operational tests conducted as part of the WBS scope.
Work Control Center reviews all Engineering Work Packages for the field
Daily Plan-of-the-Day meetings to coordinate activities between crews and fine tune technician assignments
Erik Perry to discuss in detail

28. Current machine status
Neutral Beam (NB) #1
NB #1 duct in place.
Existing RF pipes
New Centerstack
Machine Ready for pump down
Neutral Beam (NB) #2
Neutral Beam Duct/TVPS
High Voltage Enclosures (HVE)
New Platforms

29. Summary
Technical Performance Baseline Parameters as documented in the PEP and GRD’s were the basis for the project design.
Execution of project scope followed a disciplined and auditable process following mature PPPL Procedures.
Startup of NSTX (OP-NSTX-02) and start of ISTP (OP-NSTX – ISTP-01) marks the turnover from construction to operations.
Conclusion of the construction project will be achieved as defined in the PEP Demonstrated Performance.
Construction is almost complete. We will be ready to operate

30. Backup slides

31. Analysis & Value Engineering – An Iterative process
96 Plasma Equilibria (Physics)
Design Point SS (Magnetic loads)
Analysis (ANSYS, Workbench)
Design (CAD Models)
Field Assembly (Field Experience)
TF Inner Leg and Flex Joint Qualification
Concept, Initial Analysis
TF Inner Joint Stress, Contact Pressures
TF Current Diffusion
TF Torsional Shear
TF Stress, Insulation Tension Stress
TF Tooth Interface w/Umbrella Structure
Vessel and Umbrella Structure
Original, Early Upgrade
Full 360 degree Model from Pro E, Reinforcements
TF Loading on Alum Blocks, hang,
Vessel Lid and Bottom Cover Connection, Central Column to Umbrella
Vacuum loading with neutral beam ports
Pushing the structural limits of the existing machine required significant analytical modeling in concert with Physics, engineering and field input to optimize the design.
Additional inspections and instrumentation requirements added (Larry Dudek, Steve Raftopoulos to discuss)
Outer TF Leg Analysis
Torsional OOP Loads
Stress, Insulation Tension Stress
Outer Leg Support
Other
Center Stack
Plasma Facing Components
Inner PF Supports
Outer PF Supports
Lower Support Pedestal
HHFW Antenna Analyses
Disruption
OPERA Axisymmetric
Vessel and Passive Plates, Early Upgraded Loads +DLF
Detailed Vessel and Passive Plates
EMAG Transient Dynamic Analysis
Center Stack Casing with Halo Currents

32. Princeton Plasma Physics Laboratory-NSTXU
Field Coil Power Conversion Bldg
Motor Generators
RF Transmission lines
Magnet Power Rectifiers
Neutral Beam Power Conversion Bldg
138kV electric transmission line to PPPL
NSTXU Test Cell
Centerstack Fabrication area
Mockup Bldg
D-Site
Tunnel from NSTXU control room to D-Site
C-Site
RF Bldg
NSTXU Control Room (basement level)
You are here

33. Requirements documented in 2 GRD’s
NSTX CENTER STACK UPGRADE
GENERAL REQUIREMENTS DOCUMENT
NSTX_CSU-RQMTS-GRD
Revision 5
June 14, 2012
This General Requirements Document (GRD) defines:
The Machine Parameters (Table 1-1)
The overall engineering requirements for the Center Stack Upgrade as well those specific to each major element of the Work Breakdown Structure (WBS) (Table 1-2)
The Machine Planned Pulse duty (Table 2-4)
Performance and plasma shape including disruption modes

34. Design Point Spreadsheets
Physics
Radial Build
Center Stack Dimensions
TF Coil
OH Coil
Inner PF Coils
PF/OH Coil Summary
Power Systems
Coil Circuit Summary
Coil Insulation Summary
PF/OH Coil Forces
Coil Combination Forces and Moments
PFC Heat Loads
TF Current Waveform
Force Influence Matricies
Circuit Impedances
Pulse Spectrum
Design Point Spreadsheets
Example for OH Coil
Provides detail design parameters that need to be met to satisfy the GRD and 96 plasma equilibria.
Larry Dudek to discuss in detail

35. Calculations & analysis form the basis of our design
67 calculations independently checked
Example for OH Coil
Larry Dudek to discuss in detail

36. Reinforcement of the TF outer leg support structure
Extensive analysis and reinforcements required for magnet supports and vacuum Vessel
Reinforcement of the TF outer leg support structure

37. Design/Build Process we followed
Concept through reality roadmap

38. Initial experimental modes defined
Defined experimental modes yields base case 96 plasma equilibria that quantified the operating parameters for each coil
Stefan Gerhardt to discuss in detail

39. National Spherical Torus Experiment – NSTX
Umbrella Structure
Neutral Beam #1 operating since Sept 2000
TF Coil
Plasma
PF Coil
Time consuming low technical risk.
Center-stack Assy
Vacuum Vessel
NSTX Device operating since February 1999
CS Pedestal

40. Remaining Construction Work in NSTX Test Cell
Pumpdown - November
Leak check - December
Install bus inside umbrella and back to racks - November
Install new TF lead extensions - January
Install TF flex bus - January
Install new umbrella lids - February
Install umbrella lid support rings - February
Bakeout - February
ISTP - March

41. Engineering Design Implementation
Work Planning
Work Planning Form ENG-032)
Calculation Form (ENG-033)
Engineering / Software Change Notice (ENG-010)
Design Review Doc (ENG-033)
Chit form
(ENG-033)
Procedure Cover Sheet
(ENG-030)
Procedure review and Approval Matrix
Procedure Revision Sheet
Record of Training
Job Hazard Analysis
(ESH-004)
Design Verification
Drawing/Software Control
Installation/Operations

42. NSTX History OP-NSTX-02 “Startup of NSTX” executed for each start-up
NSTX First Plasma February 1999
NSTXU First Plasma March 2015
NSTX History
1996
1997
1998
1999
2000
2001
2002
2003
2004
2005
2006
2007
2008
2009
2010
2011
2012
2013
2014
2015
2016
2017
NSTX Design &
Construction
Operations
Neutral
Build New
NSTXU
Fabrication and
Beam #1
Inner TF
Design
Assembly
Bundle
RWM Coils, PF1A Upgr
Litium Evaporator
Diagnostic Upgrades
= Operations
HHFW Antenna Upgrade
= Outage
HHFW & Diag Upgrades
Enhanced LLD
OP-NSTX-02 “Startup of NSTX” executed for each start-up
(13 times)

43. Reconciliation between Demonstrated Performance
Deliverables and GRD Baseline Parameters
NSTX
(Max.)
FY 2015 NSTX-U
Operations
FY 2016 NSTX-U
FY 2017 NSTX-U
Ultimate Goal
IP [MA]
1.2
~1.6
2.0
BT [T]
0.55
~0.8
1.0
Allowed TF I2t [MA2s]
7.3 80
120
160
IP Flat-Top at max. allowed I2t, IP, and BT [s]
~0.4
~3.5 ~3 5
1st year goal: operating points with forces up to ½ the way between NSTX and NSTX-U, ½ the design-point heating of any coil
Will permit up to ~5 second operation at BT~0.65
2nd year goal: Full field and current, but still limiting the coil heating
Will revisit year 2 parameters once year 1 data has been accumulated
3rd year goal: Full capability
Stefan Gerhardt will discuss in detail