NSTX Centerstack FabricationNSTX Centerstack Fabrication

James H. Chrzanowskiand the NSTX Upgrade Team

Princeton Plasma Physics LaboratoryNSTX Upgrade Project

Office of Science ReviewLSB B318

May 2 - 3, 2012

NSTX-UNSTX-U Supported by

Culham Sci CtrYork U

Chubu UFukui U

Hiroshima UHyogo UKyoto U

Kyushu UKyushu Tokai U

NIFSNiigata UU Tokyo

JAEAInst for Nucl Res, Kiev

Ioffe InstTRINITI

Chonbuk Natl UNFRI

KAISTPOSTECH

Seoul Natl UASIPP

CIEMATFOM Inst DIFFER

ENEA, FrascatiCEA, Cadarache

IPP, JülichIPP, Garching

ASCR, Czech Rep

Coll of Wm & MaryColumbia UCompXGeneral AtomicsFIUINLJohns Hopkins ULANLLLNLLodestarMITLehigh UNova PhotonicsOld DominionORNLPPPLPrinceton UPurdue USNLThink Tank, Inc.UC DavisUC IrvineUCLAUCSDU ColoradoU IllinoisU MarylandU RochesterU TennesseeU TulsaU WashingtonU WisconsinX Science LLC

NSTX-UNSTX-U NSTX Upgrade Project – Office of Science Review – May 2nd – 3rd 2012 2

Progress Since Last Review

• A great deal of work and accomplishments have been achieved since the last review.– TF Conductor Sub-assembly operations are underway– Solder trials for TF conductor have been completed– Centerstack Casing fabrication is underway– Area preparation for Centerstack fabrication has been completed– Tooling fabrication and procurement is underway– OH conductor has been shipped– Outer TF Coils procurement now underway– Final Centerstack Assembly on schedule for October 2013

completion

NSTX-UNSTX-U NSTX Upgrade Project – Office of Science Review – May 2nd – 3rd 2012 3

General Arrangement

3

TF Flex Bus and Support Structure

Centerstack Assembly

Outer TF CoilsMajor Centerstack Components

Umbrella Structure

Vacuum Vessel

NSTX-UNSTX-U NSTX Upgrade Project – Office of Science Review – May 2nd – 3rd 2012 4

TF Conductor Assembly

• Major Tool and Edison Welding Institute have successfully delivered to PPPL four (4) TF conductors.

• The balance of the conductors for first Quadrant will be delivered by mid May.

• Final development of the Friction Stir Welding (FSW) procedures and the necessary NDT testing has started slowly. However these delays have now ended and production has started.

NSTX-UNSTX-U NSTX Upgrade Project – Office of Science Review – May 2nd – 3rd 2012 5

TF Fabrication Sequence

Bars shipped to Major Tool

Bars shipped back to PPPL

Bars are shipped to Major Tool

Bars shipped to

EWI

Leads extensions are FSW to conductors

Bars inspected at Major Tool & preliminary machining performed

FSW joints are Non Destructively TestedFinal machining of TF Assemblies

NSTX-UNSTX-U NSTX Upgrade Project – Office of Science Review – May 2nd – 3rd 2012 6

TF Conductor Production Videos

TF Machining Video.movEWI Friction Stir Production.mov

NSTX-UNSTX-U NSTX Upgrade Project – Office of Science Review – May 2nd – 3rd 2012 7

TF Solder Trials

• Solder Trials:– Trials have been performed with the

assistance of Solder Consultant to verify materials and heating processes

– Successful heat runs w/actual TF bar

• Materials:– Solder paste- 96.5 Sn /3.5 Ag w/ GMS

based “R” flux [Glyceryl Mono-stearate, Terigitol (a detergent) and Cyclohexlamine Hydro-bromide]

• Solder Temperatures:– Liquidus ~221º C (430º F)– Soludus~ 246º C (475ºF)– TF solder temperature~ 270 degrees C

to ensure wetting

• Heating Method:– Power supply w/heating plate– Torch heat to complete process

• Begin production soldering first week of May

NSTX-UNSTX-U NSTX Upgrade Project – Office of Science Review – May 2nd – 3rd 2012 8

Centerstack Casing

• The contract for manufacturing the Inconel casing has been awarded to Martinez & Turliz in California.

• They have been making good progress in the manufacturing

– Raw material has all been received

– Main components have been rolled and welded

– Flanges have been machined

– Inconel forgings for the transition sections will arrive in mid May

• PPPL team will revisit in May

• Delivery scheduled 9-20-12

NSTX-UNSTX-U NSTX Upgrade Project – Office of Science Review – May 2nd – 3rd 2012 9

Area Setup- TF Fabrication

VPI Station

NSTX-UNSTX-U NSTX Upgrade Project – Office of Science Review – May 2nd – 3rd 2012 10

Safety Involvement

• The fabrication & assembly of the Centerstack will be performed by PPPL personnel at the laboratory.

• Safety is an important part of the PPPL culture • Safety is incorporated in all aspects of the development

program- carryover to production• Industrial Hygiene (IH) has participated in the planning and

setup of the coil area• Job Hazard Analysis (JHA’s) are being developed for each

procedure• Procedures: Clearly identify safety precautions for specific

operations• Personnel protective equipment (PPE’s) being used• Involvement of all safety groups

NSTX-UNSTX-U NSTX Upgrade Project – Office of Science Review – May 2nd – 3rd 2012 11

Tooling Fabrication and Procurement

• Inner TF Bundle- tooling– Soldering station- complete √– Grit blasting station complete √– Turn insulation station complete √– Oven commissioned- complete √– Quadrant mold- Delivery 1st. week of

May– Priming station complete √– VPI station- complete √– Full TF mold- Requisition in system

NSTX-UNSTX-U NSTX Upgrade Project – Office of Science Review – May 2nd – 3rd 2012 12

Tooling Fabrication and Procurement

• OH Solenoid- tooling– OH copper conductor has been

procured-delivery early May– OH conductor sandblasting & priming

will be sub-contracted –October 2012– Induction braze station has been

procured to support OH braze joints- delivery end of May

• Braze qualification program scheduled for this summer

РAquapour mold fabrication- complete å Trials have been scheduled for later

this summer– Tension unit & taping machines are

scheduled for fabrication this summer– OH Mold has been designed, but will not

be procured until October 2012– OH Winding station- winder delivered √

NSTX-UNSTX-U NSTX Upgrade Project – Office of Science Review – May 2nd – 3rd 2012 13

OH Solenoid Winding Facility

NSTX-UNSTX-U NSTX Upgrade Project – Office of Science Review – May 2nd – 3rd 2012 14

10.5”

92”

8.5”

15.788”

“Mock TF Bundle” with 3x Mold SegmentsCenter Stack Immediately Before Washing Aquapour

•Rolled Aluminum Cylinder Represents TF Bundle•Maintains true TF OD and clearance space at top and bottom•Will use actual mold segments and alignment pins•Will test:

1. Filling of Aquapour2. Curing of Aquapour with heating blankets3. Washing Out of Aquapour

TESTING OF AQUAPOUR FOR CENTER STACK FABRICATION

Trials will be performed this summer

NSTX-UNSTX-U NSTX Upgrade Project – Office of Science Review – May 2nd – 3rd 2012 15

Lehman Review Recommendation dispositon log

• 201110 - L02 from October 2011 Lehman Review– Item:2.2 Evaluate procuring spare

key fabrication tooling ( e.g. induction heater) to reduce schedule risk from failures prior to start of fabrication.

– Status: The project has procured induction braze unit- delivery end of May

– Spare parts: investigated purchase of spare parts. Parts are readily available so only spare work coil procured.

• A total of 24 production induction brazes are needed for OH solenoid

NSTX-UNSTX-U NSTX Upgrade Project – Office of Science Review – May 2nd – 3rd 2012 16

Plans Forward for Centerstack Components

• Inner TF Bundle– VPI first Quadrant- July 12, 2012– VPI Full Bundle- January 15, 2013

• OH Solenoid– Begin winding OH solenoid- March 20, 2013– VPI OH Solenoid- July 1, 2013

• Centerstack Casing– Delivery is scheduled for September 2012

• Outer TF Coils– Requisition has been submitted to

procurement– Delivery two (2) OTF coils- December 2012

NSTX-UNSTX-U NSTX Upgrade Project – Office of Science Review – May 2nd – 3rd 2012 17

Plans Forward- continued

• Inner Poloidal Field Coils– Place purchase order for PF coils- October 2012– Delivery spring/summer 2013

• TF buss and support components– Place requisitions in procurement- October 2012– > $946.0 k procurements

• Centerstack Assembly- – Assembly will occur between May to October 2013– Developing Assembly procedures

• Deliver completed Centerstack Assembly

October 2013

MT Torque-nut™

Flex-Bus (Cu-Cr-Zr)

NSTX-UNSTX-U NSTX Upgrade Project – Office of Science Review – May 2nd – 3rd 2012 18

Conclusion

• The risks associated with the production of the TF conductors have been addressed and conductors are being delivered

• The soldering trials have been completed and the first conductor is ready to be soldered

• The TF bundle manufacturing facility has been setup and ready to begin production– Awaiting delivery of molds and completion of procedures

• The Inconel casing has been ordered and is on schedule• The OH conductor has been shipped• Tooling for the OH winding has been developed. Some has been

delivered the balance will be ordered this summer

• The production of the Centerstack Assembly is ready to begin