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NSTX-U Coll of Wm & Mary Columbia U Comp. X General Atomics FIU INL NSTX-U Coll of Wm & Mary Columbia U Comp. X 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 Supported by Project Overview Ron Strykowsky, J. Chrzanowski, L. Dudek, E. Perry, T. Stevenson LSB B 318 January 3, 2013 Culham Sci Ctr York U Chubu U Fukui U Hiroshima U Hyogo U Kyoto 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

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

Neutral Beam Progress NSTX-U Neutral Beam Progress NSTX-U

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

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

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

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

VV Modification Bay JK weldments repaired in Tech Shop… • Bay JK and port 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… Stevenson NSTX-U

Neutral Beam Summary NBI BL 2 Upgrade GRD Requirements achieved General Arrangement maintained by Neutral Beam Summary NBI BL 2 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… Stevenson NSTX-U 9

Construction Progress NSTX-U Construction Progress NSTX-U

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

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

Outer TF Coils -Repair • Removal of TF outer legs that need to be Outer TF Coils -Repair • 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 NSTX-U 1

Outer TF Coils -NEW • The contract for fabricating (2) Outer TF coils was 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 NSTX-U 1

Machine structural improvements well underway Dudek NSTX-U 1 Machine structural improvements well underway Dudek NSTX-U 1

Hardware Status Dudek NSTX-U 1 Hardware Status Dudek NSTX-U 1

Plan for January 2013 • Ex-vessel set-up for cutting at bay L – Installing 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 NSTX-U 1

Plan for December 2012 – March 2013 • • Complete modifications to umbrella and 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 NSTX-U 1

Outage Planning for Diagnostic Calibrations • Diagnosticians have listed the calibrations they would like Outage Planning for Diagnostic Calibrations • Diagnosticians have listed the calibrations they would like prior to restarting 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 NSTX-U 1

Construction Summary • The plan is being continuously worked – To improve safety and 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 NSTX-U 2

Center Stack Progress NSTX-U Center Stack Progress NSTX-U

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

Center Stack First Quadrant ready for final assembly Conductor progress 4 quadrants of 9 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 NSTX-U

Full TF Mold • The full TF mold is being manufactured by Reno Machine Full TF Mold • The full TF mold is being manufactured by Reno Machine (Conn. ) – – Scheduled for February delivery Chrzanowski NSTX-U 2

TESTING OF AQUAPOUR FOR OH CONDUCTOR WINDING • Rolled Aluminum Cylinder wrapped with epoxy/glass TESTING OF AQUAPOUR FOR OH CONDUCTOR WINDING • 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 √ Chrzanowski NSTX-U 2

OH Winding Station Induction braze station (Complete) OH winding support tooling complete Tension unit OH Winding Station Induction braze station (Complete) OH winding support tooling complete Tension unit being fabricated in house Taping machines complete Turning fixture delivered Chrzanowski NSTX-U 2

Tooling Fabrication and Procurement • OH Solenoid- tooling – OH copper conductor has been 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 NSTX-U

Centerstack Casing • • The Centerstack Inconel casing is being manufactured by Martinez & 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 NSTX-U

Plans Forward for Centerstack Components • Inner TF Bundle – VPI first Quadrant- January 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 NSTX-U

Plans Forward- continued • Inner Poloidal Field Coils – Requisition has been submitted to Plans Forward- continued • Inner Poloidal Field Coils – Requisition has been submitted to procurement- RFQ – Delivery summer 2013 MT Torque-nut™ • 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 Flex-Bus (Cu-Cr-Zr) NSTX-U Chrzanowski

Center Stack Summary • The risks associated with the production of the TF conductors 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 NSTX-U

Cost and Schedule NSTX-U Cost and Schedule NSTX-U

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

Lehman Review Dec 11 -12 -Conclusions 1. Construction efforts are being executed safely. 2. 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. NSTX-U

Lehman Review Dec 11 -12 - Recommendations 1. 2. Assign adequate personnel to assure Lehman Review Dec 11 -12 - Recommendations 1. 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. NSTX-U Develop a comprehensive facility readiness plan and schedule including both project and non-project items. Present plan at the next review. Prepare a plan for startup readiness that is acceptable to by the Site Office prior to the next review.

NSTX Upgrade Summary • The project has maintained a safe working environment. • The 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. NSTX-U

Supplemental NSTX-U 3 Supplemental NSTX-U 3

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

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

Second Neutral Beam Safely relocated ahead of schedule • • • Beam box = Second Neutral Beam Safely relocated ahead of schedule • • • 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 NSTX-U 40 4

Performance metrics good • Cost – CPI = 1. 00 CV = +199 K Performance metrics good • Cost – CPI = 1. 00 CV = +199 K • 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 – CD-4 Project Baseline (Early Finish) – CD-4 DOE Milestone (Late Finish) = August 4, 2014 = September 2015 • BAC =$82. 7 EAC= $83. 9 TPC =94. 3 M • Cost to date = $44. 1 M 54% complete • Free balance contingency 31 -33% remaining risk and uncertainty) (27% NSTX-U ($11. 8 M remaining consistent with at CD-2)

Risk & Opportunities Risk OH Fab Inner TF bundle fab Serious injury stand-down Late Risk & Opportunities Risk OH Fab Inner TF bundle fab Serious injury stand-down Late vendor delivery on critical path Other I&C add’l capacity Diagnostic re-installation Hardware fit up issues Mgmt direct allocations Critical skill lost Total open $1, 290 k FY 13 $544 k FY 13 $400 k FY 14 $250 k/mo FY 14 $391 k FY 14 $200 k FY 14 $294 k FY 14 $427 k FY 14 $216 k FY 14 $137 k FY 14 $4, 149 Opportunities PPPL Overhead rates (baselined at conservative levels) Schedule acceleration (by applying 2 shifts to critical path) NSTX-U 4 42