nstx-u fwp 2015 budget planning meeting-nstx upgrade status- ron strykowsky – 4/10/2013 1 nstx...

NSTX-UNSTX-U FWP 2015 Budget Planning Meeting-NSTX Upgrade Status- Ron Strykowsky – 4/10/2013 1

NSTX UpgradeNSTX UpgradeProgress OverviewProgress Overview

Ron StrykowskyErik Perry, Tim Stevenson, Larry Dudek, Steve Langish, Tom

Egebo, Mike Williamsand the NSTXU Project Team

FWP FY2015 Budget Planning Meeting April 10, 2013

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


• Technical Progress

• Cost, schedule, risks

Outline


• Excellent safety record• On schedule and cost

Significant progress in the last year• Excellent safety record• On schedule and cost


Neutral beam installation ahead of schedule

TIV valve installed on the front of the Neutral Beam

40 ton Neutral Beam move into the NSTX TC

New vacuum vessel port installed

Neutral Beam in final position

Ready for connecting

duct


Center Stack Fabrication & Assembly Proceeding WellCooling tube soldered into inner

TF conductor (completed )

Conductor being wrapped with fiberglass insulation

Insulated conductor being placed into mold

Assembled TF mold ready for Vacuum Pressure Impregnation (VPI)

First Quadrant successfully VPI !


Centerstack casing delivered

• Forms the inner part of the vacuum vessel and houses the inner TF/OH magnet.

• 500 Inconel studs will added to the outside surfaces.

• 696 Tiles with diagnostics will then be mounted.


Plans Forward for Centerstack Components• Components & Hardware

– Flex connectors delivered– PF 1b,a,c coils- Awarded. Delivery July, August, October

– PFC Tiles-delivered and being machined– Casing delivered

• Inner TF Bundle– VPI first Quadrant- Completed– VPI Full Bundle- July 2013

• OH Solenoid– OH Conductor delivered– Begin winding OH solenoid- September 2013– OH Mold Award. Delivery August– VPI OH – December 2013

• Centerstack Assembly- – Delivery to NSTX TC April 2014


New CS Installation one year away!

• Completed center-stack assembly being lifted into the vacuum vessel

• Planned for April 2014


Machine modifications making good progress

Umbrella Legs and Arch Reinforcement

TF Outer Leg Supports

Umbrella/TF Reinforcements


TF Coil Flag Replacement

Machine modifications continued

Neutral Beam Bay J/K Port Cap MPTS Bay L Port


Other Field work progressing well

• Davis-Bacon Services and Electrical work being bid• NB High Voltage Enclosures (HVE’s) being prepared for transport to the Test Cell• Cable tray installations on the north wall and labyrinth underway.• Fabrication and leak checking of NB LHe cryo lines underway.• Installation of new gas injection ports underway• Fabrication of NB/TVPS duct components underway.

Re-installation of cable trays and racks underway

2 New Outer TF Coils being fabricated

Conductor

Mold


• Cost – CPI = 0.99

• Schedule– SPI = 1.00 – Total float = 1 week to early finish PLUS 12 months to late finish CD-4

• Completion– Forecast = September 22, 2014– CD-4 Project Baseline (Early Finish) = September 30, 2014– CD-4 DOE Milestone (Late Finish) = September 2015

• BAC =$83.5 EAC= $ 84.8 TPC =94.3M

• Cost to date = $50.9 M 60% complete

• Contingency balance = 30% ($10.0M remaining) (27% at CD-2)

Performance metrics good (1)

(1) Through February 2013


Project Budget Consistent with CD-2 Plans and EAC

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Plan

Budget Profile

Actual Cost

NSTX-U Cost and Budget

Plan (excl contingency)

FY 2009 | FY 2010 | FY 2011 | FY 2012 | FY 2013 | FY 2014 |FY 2015

($K) ($K)


Project on Track for September 2014 Completion


Transition into operations- Planning underway

Pre-operational test of subsystems (PTP’S)

Activity Certification Committee (ACC) review

DOE Readiness assessment (RA)

Integrated system test procedure (ISTP) (per OP-NSTX-02 rev 14)

Commence Operations and

run XP’s

CD-4 DemonstratedPerformance

NSTX-U ISTP, Commissioning, and Startup will follow the same process as NSTX initial commissioning and startup from February 1999.


Near Term Risks & UncertaintiesSCHEDULE – 1.Center Stack Assembly

• Planning workshop conducted. Increased fabrication times offset with 2 shift operations.

2.Vendor deliveries (e.g. Outer TF coils, PF 1 coils, OH mold)3.Funding uncertainties and impact of a potential reduction in force on project schedule.

TECHNICAL – 1.Centerstack VPI operations . First VPI successful! 5 more to follow.


NSTX Upgrade Summary

• Project risks identified and being worked

• The project continues to make good technical progress.

• The project is on schedule and cost.

• Planning for start-up underway

• Project risks identified and being worked

• The project continues to make good technical progress.

• The project is on schedule and cost.

• Planning for start-up underway


SUPPLEMENTAL MATERIAL


Level MilestoneDOE

Commitment Date

PMB (early finish) Baseline

Forecast Actual

Level I Receive CD-2 Approval Jan-11 Dec-10 Dec-10

Level II Project FDR Jun-11 Jun-11 Jun-11Level I Receive CD-3 Approval Jan-12 Sep-11 Dec-11

Level II Receive First Delivery Machined Inner Tf Conductor Jun-12 May-12 Apr-12

Level II Nstx Complete Operations Jul-12 Mar-12 Sep-11

Level II Begin Upgrade Outage Aug-12 Apr-12 Sep-11

Level II Award Neutral Beam (NB) Vessel Cap Jun-13 Oct-12 Feb-11

Level II Begin Inner Tf Quadrant Fab (Apply Turn Insul #1 Apr-13 Oct-12 Jun-12

Level II Complete Assy and Pot Of 4th Inner TF Quadrant Oct-13 Mar-13 Jun-13

Level II Complete Fabricate & Test Inner TF/OH Coil Assy Jun-14 Oct-13 Jan-14

Level II NB Cap Installed Oct-14 Jan-14 Jan-13

Level II Lift In New Centerstack Jan-15 Mar-14 Apr-14

Level II Complete ISTP Aug-15 Sep-14 Sep-14

Level II Resume Operations Sep-15 Sep-14 Sep-14

Level I CD-4 Sep-15 Sep-14 Sep-14

Project Milestones

nstx-u fwp 2015 budget planning meeting-nstx upgrade status- ron strykowsky – 4/10/2013 1 nstx...

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