1. NSTX Upgrade Project – Final Design Review June 22 - 24, 2011 1 NSTX Supported by College W&M Colorado Sch Mines Columbia U CompX General Atomics INEL Johns Hopkins U LANL LLNL Lodestar MIT Nova Photonics New York U Old Dominion U ORNL PPPL PSI Princeton U Purdue U SNL Think Tank, Inc. UC Davis UC Irvine UCLA UCSD U Colorado U Illinois U Maryland U Rochester U Washington U Wisconsin Machine Installations and Outage Coordination Culham Sci Ctr U St. Andrews York U Chubu U Fukui U Hiroshima U Hyogo U Kyoto U Kyushu U Kyushu Tokai U NIFS Niigata U U Tokyo JAEA Hebrew U Ioffe Inst RRC Kurchatov Inst TRINITI KBSI KAIST POSTECH ASIPP ENEA, Frascati CEA, Cadarache IPP, Jülich IPP, Garching ASCR, Czech Rep U Quebec Erik D. Perry Princeton Plasma Physics Laboratory NSTX Upgrade Project Final Design Review LSB B318 June 22-24, 2011

2. NSTX Upgrade Project – Final Design Review June 22 - 24, 2011 NSTX Upgrade Outage As we shift from engineering the NSTX Upgrades to the installation of the hardware, we need to plan the installations in such a way that success is assured A plan has been developed for performing the NSTX Upgrade Outage –Based on experience from similar outages since 1984 A system for coordinating and controlling the outage tasks has been identified –Based on the very successful Work Control Center that was used during the TFTR D&D Project 2

3. NSTX Upgrade Project – Final Design Review June 22 - 24, 2011 Outage Planning Outage planning based on bottoms-up estimates from Engineering –Assumes one shift, 5 days per week for almost all work Assign technicians, by name, to scope to assure staffing requirements are met –Identify early where temporary staff additions are needed 6 Electricians (from existing BOA), 1 welder, 4 safety watch technicians Adjust start date of tasks to assure one task at a time in each area Accelerate tasks that make other tasks more efficient Work toward peeling back cabling and fiber optics, rather than removing them when access is needed to perform tasks 3

4. NSTX Upgrade Project – Final Design Review June 22 - 24, 2011 Outage Planning cont Work in the Bays J, K and L most congested –Neutral beam installation, including cutting large hole in vessel –Coil supports and umbrella modifications for center stack –Diagnostic relocations, including cutting large hole in vessel Work crews on opposite sides of the vacuum vessel Assume moving NB box into test cell will impact other activities until box can be sealed Pre-plan temporary storage areas –Minimize material handling whenever possible Daily / hourly coordination of all field work is critical 4

5. NSTX Upgrade Project – Final Design Review June 22 - 24, 2011 Outage Coordination Use of a Work Control Center ( like TFTR D&D Project ) Work Control Center reviews all Engineering Work Packages for the field –Reviews Job Hazard Analysis (JHA) –Assures pre-requisites are done –Arranges for permits –Assigns work to field crews once package is ready –Runs pre-job and post-job briefs –Interfaces between Engineering and the field crews –Assures that the field work is done safely and correctly –Assures that the field crews are used efficiently –Coordinates storage and lay-down areas as well as crane use Daily Plan-of-the-Day meetings to coordinate activities between crews and fine tune technician assignments 5

6. NSTX Upgrade Project – Final Design Review June 22 - 24, 2011 NSTX-U Work Control Center 6

7. NSTX Upgrade Project – Final Design Review June 22 - 24, 2011 Work Control Center Flow Chart 7

8. NSTX Upgrade Project – Final Design Review June 22 - 24, 2011 NSTX-U Outage Plan Schedule 8

9. NSTX Upgrade Project – Final Design Review June 22 - 24, 2011 NSTX-U Outage Plan Schedule cont 9

10. NSTX Upgrade Project – Final Design Review June 22 - 24, 2011 NSTX Test Cell 10

11. NSTX Upgrade Project – Final Design Review June 22 - 24, 2011 Outage Plan - Start of the Outage Establish construction power Disconnect all power to NSTX Test Cell (NTC) except lighting and construction power Vent vacuum vessel and ventilate to the outside –No vessel entry at this time 11

12. NSTX Upgrade Project – Final Design Review June 22 - 24, 2011 First Month Remove cable tray at top of machine –Improves crane access for heavier diagnostics Remove RF piping within 10’ of vacuum vessel –Permits access to east side of machine Install new 118’ EL platform on west side –Permits moving racks to new location, not just temporary storage Start rack removals to make room for NB2 12

13. NSTX Upgrade Project – Final Design Review June 22 - 24, 2011 Months 2 - 3 Continue removing racks to make room for NB2 Remove diagnostics from Bays J, K and L –Most congested work area for outage Coil up cables, tubing and fibers from Bays J, K and L –Do not remove cables etc – too costly and time consuming to replace 13

14. NSTX Upgrade Project – Final Design Review June 22 - 24, 2011 Months 4 - 6 Finish removing racks to make room for NB2 Remove diagnostics from Bays D, E, and F –Opposite side from Bays J, K and L –Coil up cables, tubing and fibers Remove diagnostics from Bays A, B, and C –Coil up cables, tubing and fibers Perform modifications to umbrella at Bays J, K and L –First modifications in primary work area Start modifications to umbrella at Bays D, E and F Start removing diagnostics to make room for NB2 –Diagnostics on platform away from vacuum vessel Start coil support mods in Bays J, K, and L Clean/sand tiles in-vessel to remove lithium 14

15. NSTX Upgrade Project – Final Design Review June 22 - 24, 2011 Months 7 - 9 Coil support mods in Bays J, K, and L Remove diagnostics from Bays A, B, C, G, H and I –Coil up cables, tubing and fibers Finish modifications to umbrella at Bays D, E and F, then start coil support mods there Remove Bay L pump duct Remove NW section of 109’ EL platform Finish removing diagnostics to make room for NB2 Remove passive plates, then trial fit and trim new passive plates and tiles Remove old centerstack 15

16. NSTX Upgrade Project – Final Design Review June 22 - 24, 2011 Months 10 - 11 Finish coil support mods in Bays D, E and F Perform modifications to umbrella at Bays A, B and C Vacuum vessel penetration cutting for NB2 at Bays J and K –Reinforce area prior to cutting –Protect surrounding areas –Significant crane usage Weld in “bay window” at Bays J and K –Protect surrounding areas –Significant crane usage 16

17. NSTX Upgrade Project – Final Design Review June 22 - 24, 2011 Months 12 - 13 Perform modifications to umbrella at Bays G, H and I Start coil support mods in Bays A, B, and C Vacuum vessel penetration cutting for diagnostics at Bay L –Protect surrounding areas –Significant crane usage Weld in nozzle for Bay L port –Protect surrounding areas –Significant crane usage 17

18. NSTX Upgrade Project – Final Design Review June 22 - 24, 2011 Months 14 - 17 Finish coil support mods in Bays A, B and C Move NB2 into NSTX test cell and seal enclosure –Protect surrounding areas –Significant crane usage Begin connections of services to NB2 Replace items in Bays D, E and F Final installation of new passive plates and tiles 18

19. NSTX Upgrade Project – Final Design Review June 22 - 24, 2011 Months 18 - 20 Coil support mods in Bays G, H and I Begin re-installation of items removed for NB2 installation Replace items in Bays A, B and C Continue NB2 installation 19

20. NSTX Upgrade Project – Final Design Review June 22 - 24, 2011 Months 21 - 23 Continue re-installation of items removed for NB2 installation Replace items in Bays G, H and I Continue NB2 installation Replace RF piping 20

21. NSTX Upgrade Project – Final Design Review June 22 - 24, 2011 Months 24 - 26 Install new center stack Continue re-installation of items removed for NB2 installation Replace items in Bays J, K and L Continue NB2 installation 21

22. NSTX Upgrade Project – Final Design Review June 22 - 24, 2011 Month 27 Finish re-installation of items removed for NB2 installation Finish NB2 installation Re-establish power in test cell Clean, photo, close and pump down vacuum vessel 22

23. NSTX Upgrade Project – Final Design Review June 22 - 24, 2011 Summary The NSTX Upgrade Outage has been planned based on –Bottoms-up estimates from Engineering –Identifying staff to perform the work –Scheduling work to avoid conflicts The plan is being worked –To reduce work required to remove/reinstall to gain access to areas –To improve efficiencies –Plan available to accelerate overall schedule by two months Coordination and Control –Provided by the Work Control Center –At the Plan-of-the-Day meeting –Continuously by the Field Supervisors Ready to successfully perform the outage 23

24. NSTX Upgrade Project – Final Design Review June 22 - 24, 2011 NSTX Upgrade Outage Successfully Completed 24