Progress to Date • CD-0 Approved February 2009 • The NSTX Upgrade Project organization formally established under the Associate Director for Engineering and Infrastructure. • Successful technical conceptual peer reviews. • Bottoms-up cost and schedule estimate prepared • Successful Independent CDR October 28 -29 th • CD-1 Documentation Prepared in compliance with DOE Order 413. 3 • Successful OFES (Lehman) Review December 15 th– 16 th • Value engineering has resulted in ~$5 M cost reductions in the coil support design /installation and NBI decontamination & refurbishment • Successful technical preliminary design peer review held March 3 rd for Neutral Beam #2 • Extensive iteration of project cost, schedule and scope with OFES • CD-1 Approved April 15 th • Peer Review April 21 st • CS Preliminary Design Peer Review April 29 th • NBI Decontamination PPPL Advisory Board Meeting May 2010 NSTX Upgrade – R. L. Strykowsky 1
2 nd Neutral Beam Decontamination in progress PPPL Advisory Board Meeting May 2010 NSTX Upgrade – R. L. Strykowsky 2
Plans for 2010 • Preliminary Design – FMEA analysis, Design models, stress, EM, & Thermal Analyses – Complete NBI Decontamination – R&D Activities (joint test, OH braze testing flex joint mockup) – Update GRD for CS – Updated CD-2 Estimates – Project comprehensive PDR June 23 rd – 24 th Outside reviewers All WBS elements included Includes Management assessment of CD-2 readiness • • Office of science review August 10 th-11 th Apply for CD-2 August 2010 CD-2 Approval September 2010 Begin Final Design after CD-2 approval PPPL Advisory Board Meeting May 2010 NSTX Upgrade – R. L. Strykowsky 3
Plans for 2011 • DOE Authorization to buy critical procurements – TF Inner Conductor (November Award) – TF Machining (April Award) • Begin NBI refurbishment (requires DOE authorization prior to CD-3) • • • CS and NBI final design and analysis CS and NBI Final Peer reviews mid-FY 2011 Final Design Review 3 rd quarter FY 2011 OFES (Lehman review) 4 th quarter FY 2011 CD-3 Approval Late FY 2011 • Complete Inner TF Fabrication (conductor machining, friction stir weld leads, procure OH conductor) PPPL Advisory Board Meeting May 2010 NSTX Upgrade – R. L. Strykowsky 4
Plans for 2012 • Begin TF/OH final assembly • CS tile procurement • NBI major procurements (duct, vessel cap, bellows, tiles) • NBI Services • Beamline relocation preparations (fixtures, procedures) • Removal procedures and re-installation design • Complete FY 12 operations campaign and begin outage • Start Diagnostics removals PPPL Advisory Board Meeting May 2010 NSTX Upgrade – R. L. Strykowsky 5
Project Cost and Schedule Range • Critical path through design, fabrication, installation and test of center TF/OH. • 41 month critical path from award of TF copper. Milestones • Requires early purchase of TF Copper Dec 2010 • $72 M being re-directed from within the NSTX Program • $3 M - $21 M Incremental funding required from DOE PPPL Advisory Board Meeting May 2010 NSTX Upgrade – R. L. Strykowsky 6
CD-4 Definition Demonstrated Performance at Completion Center Stack • First plasma with an ohmically heated discharge > 50 k. A at a toroidal magnetic field of > 1 k. G. Second neutral beam installed and; • The beamline has been pumped to a vacuum better than 10 m. Torr; • Beamline water, vacuum, cryogenics, and feedstock gas services have been attached to the beamline; • Three sources placed on alignment rails on the beamline source platform; • Power testing has demonstrated Accel High Voltage standoff to > 80 k. V through the high voltage enclosure; • A Torus Isolation Valve and duct interconnects the NSTX vacuum vessel and the neutral beamline; • Armor has been reconfigured in the vacuum vessel; • 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. PPPL Advisory Board Meeting May 2010 NSTX Upgrade – R. L. Strykowsky 7
Risks, Issues, Opportunities ▲ No significant jugular risk ~$3 M total at time of CD-1 review. ▲ Approx 43 open risk remaining - covered by mitigation plans and contingency ▲ No large or long lead procurements ─ ─ ─ PFC Tile $650 K & 4 mos. Cable installation $535 K and 8 mos. Rectangular bellows $400 K and 9 mos. NBI Cables $422 K and 5 mos. TF copper $242 K and 5 mos. ▲ 78% of project cost for in-house labor – under PPPL control ▼ DOE fiscal pressure results in backend loading funding profiles resulting ▼ Project not funded separately thus subject to annual competition of funds from within NSTX program. ► Purchase copper & machining desirable to leverage critical path PPPL Advisory Board Meeting May 2010 NSTX Upgrade – R. L. Strykowsky 8
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