NSTX-U

1. NSTX-U Supported by NSTX Centerstack Ancillary Systems Progress 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 L. Dudek 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, Jülich IPP, Garching ASCR, Czech Rep Princeton Plasma Physics Laboratory NSTX Upgrade Project Office of Science Review LSB B318 May 2 - 3, 2012 NSTX Upgrade Project – Office of Science Review – May 2nd – 3rd 2012 NSTX-U

2. Outline • Power Systems • Diagnostics • DCPS • I & C • Passive Plates • Analysis • Hardware Procurement Coordination NSTX Upgrade Project – Office of Science Review – May 2nd – 3rd 2012 NSTX-U

3. Power Systems (Ramakrishnan) • Requirements • TF : 129.8 kA, 1kV, ESW 7.08 sec every 2400 sec (7.05kA rms) ; • OH : 24kA, ESW 1.474 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 NSTX Upgrade Project – Office of Science Review – May 2nd – 3rd 2012 NSTX-U

4. Diagnostics (Kaita) • Layout for Mirnov coils, Rogowski coils, and Langmuir probes complete & includes additional halo current sensors NSTX Upgrade Project – Office of Science Review – May 2nd – 3rd 2012 NSTX-U

5. Diagnostic Layout Drawing NSTX Upgrade Project – Office of Science Review – May 2nd – 3rd 2012 NSTX-U

6. 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 MeasurementA plan was developed to measure Halo currents on the upgraded center stack using Shunt Tiles, BT 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 NSTX Upgrade Project – Office of Science Review – May 2nd – 3rd 2012 NSTX-U

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

8. 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 2012. • Prototype real-time power supply control computer and I/O subsystem installed and being prepared for system development. NSTX Upgrade Project – Office of Science Review – May 2nd – 3rd 2012 NSTX-U

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

10. DCPS Status (Hatcher) Replace RED bullets and summarize the changes “Why” • 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 NSTX Upgrade Project – Office of Science Review – May 2nd – 3rd 2012 NSTX-U

11. 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) Internal View of DCPS Computer with I/O cards installed Prototype DCPS Computer In FCC Rack NSTX Upgrade Project – Office of Science Review – May 2nd – 3rd 2012 NSTX-U

12. Passive Plate Upgrade (Atnafu) • Progress: Calculation is complete • Disruption analysis of the Passive Plates was performed (Refer Calculation #NSTXU-CALC-12-01-01). NSTX Upgrade Project – Office of Science Review – May 2nd – 3rd 2012 NSTX-U

13. Passive Plate Upgrade • Progress: Drawings released for Fabrication Fabrication and Installation Drawings are complete (Refer #C-ED-1319-ECN, #E-ED-1322 and E-ED-1321). NSTX Upgrade Project – Office of Science Review – May 2nd – 3rd 2012 NSTX-U

14. Passive Plate Upgrade • Procurement is complete • The Inconel bushings have been received and heat treated. • The bolts have been received. NSTX Upgrade Project – Office of Science Review – May 2nd – 3rd 2012 NSTX-U

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

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

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

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