1. Project Overview Ron Strykowsky, J.Chrzanowski, L.Dudek, E.Perry, T.Stevenson LSB B318 January 3, 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

2. NSTX-U 2 NSTXU Test Cell – May 2012

3. NSTX-U 3 Neutral Beam Progress

4. NSTX-U 4 NSTXU Test Cell Beam Box move– 9/13/12 Photo: Elle Starkman Began work February 2009 30,000 hours (>17 person years) for decontamination, refurbishment, relocation design 55 people Safety >25 people at pre- job brief Beam box = 40 tons Lid = 14 tons Stevenson

5. NSTX-U 5 NBI BL Box Relocation… TTC, South High Bay, Over the wall 2425 And on the vent stack… Stevenson

6. NSTX-U 6 NBI BL Lid Relocation… same as Box move but more involved 2425 Stevenson

7. NSTX-U 7 NBI Duct Exit Spool Piece and BL TIV installed on Exit of BL… 2480 2485 Stevenson

8. NSTX-U 8 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… 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… Stevenson

9. NSTX-U 9 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…  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…  Neutral Beam Summary Stevenson

10. NSTX-U 10 Construction Progress

11. NSTX-U 11 NSTXU Test Cell - Current Umbrella legs being cut out and replaced Second beamline in place Vacuum Vessel cutting for Bay J/K neutral beam cap underway 4 Outer TF coils removed

12. NSTX-U 12 Perry NB Bay J/K Port opening successfully plasma cut

13. NSTX-U 13 Removal of TF outer legs that need to be repaired or replaced –Completed with minimal removal of surrounding items –Replacements must be completed before significant re-installations can occur Perry Outer TF Coils -Repair

14. NSTX-U 14 Outer TF Coils -NEW The contract for fabricating (2) Outer TF coils was awarded to Everson- Tesla. –Soldering of the cooling tubes has started –February 2013 delivery Chrzanowski

15. NSTX-U 15 Dudek Machine structural improvements well underway

16. NSTX-U 16 Dudek Hardware Status

17. NSTX-U 17 Plan for January 2013 Ex-vessel set-up for cutting at bay L –Installing containment and ventilation Vacuum vessel cutting at Bay L for new diagnostics port Remove temporary in-vessel beams and ventilation Leak check welds on Bays JK cap Remove platform at Bays JKL Perry

18. NSTX-U 18 Plan for December 2012 – March 2013 Complete modifications to umbrella and coil supports Complete Neutral Beam systems Re-install items removed for centerstack work Re-install items removed for NB work Perry

19. NSTX-U 19 Outage Planning for Diagnostic Calibrations Diagnosticians have listed the calibrations they would like prior to re- starting NSTX Detailed schedules for these calibrations are being prepared –Schedules will be fit into the existing outage schedule –Each calibration will be scheduled as early as possible to avoid delays once the installation work has been completed –Calibrations may be scheduled to occur after the Upgrade Outage if they are not required for CD-4 or early operations All work in NSTX Test Cell being done with Engineering Work Packages (90 packages so far, 39 completed) –Written procedures –Permits –Job hazard analysis –Permits: confined space, hot work, radiation work, penetration, etc –Pre-job and post-job briefings Perry

20. NSTX-U 20 Construction Summary The plan is being continuously worked –To improve safety and efficiencies –To deal with delays in getting parts –To accelerate tasks to ease pressure on critical path tasks Coordination and Control –Provided by the Work Control Center –At the Plan-of-the-day meeting –Continuously by the Field Supervisors Successfully performing the outage Perry

21. NSTX-U 21 Center Stack Progress

22. NSTX-U 22 Center Stack Fabrication & Assembly Making Good Progress Machined conductor at Major Tool being prepared for shipment to PPPL Conductor after cooling tube installation and grinding Cooling tube being soldered into conductor at PPPL Conductor being removed from oven after sandblasting and priming Conductor being wrapped with fiberglass insulation Insulated conductor being placed into mold Chrzanowski

23. NSTX-U 23 Center Stack First Quadrant ready for final assembly Conductor progress 4 quadrants of 9 conductors for full inner TF bundle 38 conductors delivered 30 cooling tube soldered 16 primed & wrapped Chrzanowski

24. NSTX-U 24 Full TF Mold The full TF mold is being manufactured by Reno Machine (Conn.) – –Scheduled for February delivery Chrzanowski

25. NSTX-U 25 Rolled Aluminum Cylinder wrapped with epoxy/glass insulation represents TF Bundle Maintains true TF OD and clearance space at top and bottom Will use actual mold segments and alignment pins Tested: 1. Filling of Aquapour √ 2. Curing of Aquapour with heating blankets √ 3. Washing Out of Aquapour √ T ESTING OF A QUAPOUR FOR OH C ONDUCTOR W INDING Chrzanowski

26. NSTX-U 26 OH Winding Station Tension unit being fabricated in house Taping machines complete OH winding support tooling complete Turning fixture delivered Induction braze station (Complete) Chrzanowski

27. NSTX-U 27 Tooling Fabrication and Procurement OH Solenoid- tooling –OH copper conductor has been received –OH conductor sandblasting & priming requisition in system –Induction braze station OH braze joints- is being commissioned OH joint braze qualification program will begin in January –Tension unit & taping machines are in fabrication –OH Mold will be out for bids in January Chrzanowski

28. NSTX-U 28 Centerstack Casing The Centerstack Inconel casing is being manufactured by Martinez & Turek located in California. Delivery is scheduled for first week in January Upon arrival of the casing 500 Inconel studs will added to the outside surfaces (original casing shown below) 696 Tiles with diagnostics will then be mounted Chrzanowski

29. NSTX-U 29 Plans Forward for Centerstack Components Inner TF Bundle –VPI first Quadrant- January 2013 –VPI Full Bundle- May 2013 OH Solenoid –Begin winding OH solenoid- July 2013 –VPI OH Solenoid- October 2013 Centerstack Casing –Delivery is scheduled for December 2012 Centerstack Assembly- –Final assembly will occur between November 2013 to February 2014 –Developing Assembly procedures Chrzanowski

30. NSTX-U 30 Plans Forward- continued Inner Poloidal Field Coils –Requisition has been submitted to procurement- RFQ –Delivery summer 2013 TF buss and support components –Purchase Order has been placed with Zenox Corp. (TF Flexes) –Super-nuts in procurement February 2013 –OTF Lead extensions (January procurement) Deliver completed Centerstack Assembly - February 2014 MT Torque-nut™ Flex-Bus (Cu-Cr-Zr) Chrzanowski

31. NSTX-U 31 Center Stack Summary The risks associated with the production of the TF conductors have been addressed (Major Tool/Edison Welding) The soldering trials have been completed and production nearly complete (Retired risk) The TF bundle manufacturing facility is in full operation –Awaiting delivery of molds and completion of procedures The R&D and procedures for VPI are complete & first VPI is scheduled for January The Aquapour trials are complete Tooling for the OH solenoid is being fabricated The OH conductor sandblast/priming contract is awaiting bids The Inconel casing is scheduled for delivery in January Contract for the OTF has been awarded Requisition for Inner PF coils is in procurement The production of the Centerstack Assembly has begun Chrzanowski

32. NSTX-U 32 Cost and Schedule

33. NSTX-U 33 Schedule on track for early finish Late delivery of conductors and rework of vendor supplied quadrant mold Neutral Beam relocated ahead of schedule CD-4 SEPT 30 2015 Forecast Aug 4 2014 Early Finish Sept 30 2014 Critical path based on 5 day/week, one shift no planned OT. We will implement OT, weekends and 2 shift operations where appropriate on critical path. Critical path based on 5 day/week, one shift no planned OT. We will implement OT, weekends and 2 shift operations where appropriate on critical path.

34. NSTX-U 34 Lehman Review Dec 11-12 -Conclusions 1.Construction efforts are being executed safely. 2.The project presently has adequate resources and necessary skills mix to execute the project. However, the impact of the possible loss of key personnel if a laboratory staff reduction is required is unknown. 3.The Project team has implemented the required action to update the Risk Registry resulting from the status review in May 2012. Particular emphasis has been placed on using the detailed schedule to manage and accelerate procurements. 4.The current project cost and schedule projections are consistent with the approved baseline cost and schedule. 5.Contingency remaining is adequate for the risks that remain. 6.The management structure is in place to deliver the scope within budget and schedule. 7.Risks are being actively managed.

35. NSTX-U 35 Lehman Review Dec 11-12 - Recommendations 1.Develop a comprehensive facility readiness plan and schedule including both project and non-project items. Present plan at the next review. 2.Assign adequate personnel to assure completion of the Digital Coil Protection System on the original baseline schedule. 3.Reassess the potential impacts of the loss of critical skills and personnel and update the risk registry by February 1, 2013. 4.Prepare a plan for startup readiness that is acceptable to by the Site Office prior to the next review.

36. NSTX-U 36 NSTX Upgrade Summary The project has maintained a safe working environment. The project continues to make good technical progress. The project is on schedule and cost. The project is sufficiently staffed to meet schedule. The project is on track for meeting CD-2 baseline within OFES guidance.

37. NSTX-U 37 Supplemental

38. NSTX-U 38 Lehman Review - Tour Inner TF conductor post-cooling tube soldering. Ready for grinding and cleanup. Inner TF conductor cooling tube soldering station showing setup for soldering of bar number 30 Lehman review team Chris Ackerman Tony Indelicato Tim Maier Bruce Stauss Arnie Kellman Kin Chao Ed Synakowski Steve Meador Frank Crescenzo Rick Blaisdall Barry Sullivan Will Oren

39. NSTX-U 39 Lehman Review December 11 th & 12 th - Tour Inner TF conductor sandblasting station Aqua pour mockup test. End of inner TF quadrant showing cooling tubes. Inner TF quadrant with 9 conductors in place ready for mold lid.

40. NSTX-U 40 Second Neutral Beam Safely relocated ahead of schedule 40 Beam box = 40 tons Lid = 14 tons Began work February 2009 30,000 hours (>17 person years) for decontamination, refurbishment, relocation design 55 people Safety >25 people at pre-job brief

41. NSTX-U 41 Cost –CPI = 1.00 CV = +199K Schedule –SPI = 1.06 ( Against early finish baseline) Total float = 2 months to early finish PLUS 12 months to late finish CD-4 Completion –Forecast= August 4, 2014 –CD-4 Project Baseline (Early Finish)= September 2014 –CD-4 DOE Milestone (Late Finish)= September 2015 BAC =$82.7 EAC= $83.9 TPC =94.3M Cost to date = $44.1 M 54% complete Free balance contingency 31-33% ($11.8M remaining consistent with remaining risk and uncertainty) (27% at CD-2) Performance metrics good

42. NSTX-U 42 Risk & Opportunities 42 OH Fab$1,290k FY13 Inner TF bundle fab$544k FY13 Serious injury stand-down$400k FY14 Late vendor delivery on critical path$250k/mo FY14 Other$391k FY14 I&C add’l capacity $200k FY14 Diagnostic re-installation $294k FY14 Hardware fit up issues $427k FY14 Mgmt direct allocations $216k FY14 Critical skill lost $137k FY14 Total open$4,149 Opportunities PPPL Overhead rates (baselined at conservative levels ) Schedule acceleration (by applying 2 shifts to critical path ) Risk