1 NSTX-U NSTX Upgrade Project Office of Science Review May 2 nd 3 rd 2012 NSTX Centerstack Ancillary Systems Progress L. Dudek Princeton Plasma Physics Laboratory NSTX Upgrade Project Office of Science Review LSB B318 May 2 - 3, 2012 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, Jlich 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 NSTX Upgrade Project Office of Science Review May 2 nd 3 rd 2012 Outline Power Systems Diagnostics DCPS I & C Passive Plates Analysis Hardware Procurement Coordination 3 NSTX-U NSTX Upgrade Project Office of Science Review May 2 nd 3 rd 2012 Power Systems (Ramakrishnan) Requirements TF : kA, 1kV, ESW 7.08 sec every 2400 sec (7.05kA rms) ; OH : 24kA, ESW sec every 2400 sec ; 6kV PF1a: Eliminate Ripple reduction reactors Installation spec. has been written and work is in progress. About 30% of work completed in FCPC Building Power Cabling changes from Transition Area to NSTX Test Cell completed and tested One fiber-optic DCCT (+/-0 to 150kA) has been procured and installed to measure the TF current. For OH system, the old PLT TF coils have been tested & planned to be used as DC Current Limiting Reactors These are to be connected in the circuit and a PTP to be conducted 4 NSTX-U NSTX Upgrade Project Office of Science Review May 2 nd 3 rd 2012 Diagnostics (Kaita) Layout for Mirnov coils, Rogowski coils, and Langmuir probes complete & includes additional halo current sensors 5 NSTX-U NSTX Upgrade Project Office of Science Review May 2 nd 3 rd 2012 Diagnostic Layout Drawing 6 NSTX-U NSTX Upgrade Project Office of Science Review May 2 nd 3 rd 2012 Previous Review Recommended Halo Current Sensors Develop a plan for a set of diagnostics for measuring halo currents and vessel displacement to accommodate future installation by the DCPS final design review. Halo Measurement A plan was developed to measure Halo currents on the upgraded center stack using Shunt Tiles, B T sensors and a 2nd Poloidal Array. Mandrels were already available for the additional Mirnovs due to extra spares that were ordered for the base set. Tile designs for the new Mirnovs are completed. Shunt tile design is underway VV Displacements 8 FISO displacement sensors were saved from the existing NSTX instrumentation Electronics to support the sensors was also saved and available for the upgrade Tile Modified for 1D Mirnov 7 NSTX-U NSTX Upgrade Project Office of Science Review May 2 nd 3 rd 2012 Risks Identified and Addressed for Center Stack Diagnostics Supplier risk: availability of copper and thermocouple wires with specific material and insulation needs Specialized wire vendors identified Gauge and insulation meets space and durability requirements Most of wires delivered no delay expected in receiving remainder Manufacturing risk: fabrication and precision winding of small and delicate magnetic sensors (Mirnov coils) Local vendor and PPPL machine shop fabricated all mandrels Extra mandrels ordered due to low vendor price Reduced incremental cost for additional halo current sensors requested in chit from earlier review Vendor that wound original sensors preparing new sensors Delivery expected well before need date 8 NSTX-U NSTX Upgrade Project Office of Science Review May 2 nd 3 rd 2012 Controls (Sichta) ~3.5x longer pulse length drives upgrades for data acquisition, networking, and real-time controls. Design is complete. Procurement and fabrication scheduled for FY13. CAMAC upgrade & replacement activities started ahead of schedule: CAMAC memory module fab & test complete. PXI-based prototype 60% complete. COTS networked digitizer integration starts May Prototype real-time power supply control computer and I/O subsystem installed and being prepared for system development. NSTX-U NSTX Upgrade Project Office of Science Review May 2 nd 3 rd 2012 Controls (contd) Network upgrade and real-time control software efforts begin early FY13. EAC increased by $12K due to concerns for higher CAMAC replacement (PXI) and network equipment costs (FY13). 10 NSTX-U NSTX Upgrade Project Office of Science Review May 2 nd 3 rd 2012 DCPS Status (Hatcher) Project DCPS scope reviewed and changed (initiated by NSTX project Engineer) The original plan required an algorithm look ahead feature which was overly complicated for what was required to protect the hardware - it was eliminated. The stress analysis on the OH coil revealed it was unnecessary to predict internal coil temperatures and gradients to protect the coils - the requirement was eliminated and replaced by a coil coolant temperature measurement. By incorporating fail safe techniques in the hardware and software it was possible to eliminate the redundant DCPS hardware requirement. Added PDP timer functionality - to prevent pulse rates from exceeding what can safely be handled in the FCPC cabling system. It also helped to eliminate the redundant DCPS hardware requirement above. DCPS algorithms added to NSTX power supply real-time controller functionality which will aid in troubleshooting problems and help is simulating shot plans for the development of XPs. New DCPS requirements document reviewed and signed New WAF completed, reviewed, and approved New resource loaded schedule generated Requirements documents being written for individual scopes Analysis Calculations updated with new currents and loads (including disruption contribution) from Design Point Spreadsheet More than 40 Calculations Completed and filed Many with DCPS Algorithms (Summer intern selected to assemble these into a requirements document, will check for completeness and will exercise simpler ones) Simplified method of computing post-disruption currents (without look ahead feature) was used with 96 equilibrium scenarios to qualify TF torsional shear Replace RED bullets and summarize the changes Why 11 NSTX-U NSTX Upgrade Project Office of Science Review May 2 nd 3 rd 2012 Prototype DCPS Computer In FCC Rack Internal View of DCPS Computer with I/O cards installed DCPS (contd) Water System PLC Initial scoping studies completed Requirements document started Candidate hardware (PLC and I/O) selected Existing system as built verification ongoing Hardware/Software Documentation of Junction Area as built configuration ongoing Selected Red Hawk (Red Hat derivative) for real-time OS and software development tools Purchased prototype DCPS computer with analog and digital I/O cards with custom drivers Installed prototype DCPS computer and I/O cards in NSTX FCC (added to eng network) Preparing DCPS software FDR (scheduled for early July 2012) NSTX-U NSTX Upgrade Project Office of Science Review May 2 nd 3 rd 2012 Passive Plate Upgrade (Atnafu) Progress: Calculation is complete Disruption analysis of the Passive Plates was performed (Refer Calculation #NSTXU-CALC ). 13 NSTX-U NSTX Upgrade Project Office of Science Review May 2 nd 3 rd 2012 Passive Plate Upgrade Progress: Drawings released for Fabrication Fabrication and Installation Drawings are complete (Refer #C-ED ECN, #E-ED-1322 and E-ED-1321). NSTX-U NSTX Upgrade Project Office of Science Review May 2 nd 3 rd 2012 Passive Plate Upgrade Procurement is complete The Inconel bushings have been received and heat treated. The bolts have been received. 15 NSTX-U NSTX Upgrade Project Office of Science Review May 2 nd 3 rd 2012 Passive Plates Upgrade Installation work has started IP, JHA, Work Permit and other necessary documentation has been prepared. The grafoil has been cut. The passive plates have been taken out of the vacuum vessel Machining of the passive plates has commenced. Re-installation of the shims has been completed. Installation of the passive plates is underway and will complete early May, 2012. 16 NSTX-U NSTX Upgrade Project Office of Science Review May 2 nd 3 rd 2012 Analysis Analysis to support the design (over 50 calculation packages) have been completed and checked per PPPL procedures As design engineers complete the final detail drawings the calculations receive one final review to ensure final design detail changes are incorporated Calculations are posted on internal website where they are accessible by project 17 NSTX-U NSTX Upgrade Project Office of Science Review May 2 nd 3 rd 2012 Hardware Procurement Coordination Hardware is being fabricated in-house or through Procurement, via standard requisition or Blanket Purchase Agreements (BPA) An evaluation is made based on the type, size and schedule requirements for the the work. In-house fabrications examples: VV Clevis, OTF Support Clips OH Belleville support asm Umbrella structure reinforcement rings BPA Procurements OTF Clevis Bushings, Umbrella Structure Legs OTF Rod Ends and turnbuckles, Umbrella block reinforcements CS Torque Rings and Compression Washers Standard Requisition OTF Support Structure 18 NSTX-U NSTX Upgrade Project Office of Science Review May 2 nd 3 rd 2012 Summary Ancillary systems fabrication is well underway Fabrication and Procurement of hardware is being managed to bring parts to the Test Cell in a timely manner Recommendations from the previous SC review has been addressed Risks are being actively managed