NSTX Centerstack Fabrication StatusNSTX Centerstack Fabrication Status

James H. Chrzanowskiand the NSTX Upgrade Team

Princeton Plasma Physics LaboratoryNSTX Upgrade Project

Office of Science ReviewLSB B318

December 11-12, 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 – December 11-12, 2012 2

Progress Since Last Review

• A great deal of work and accomplishments have been achieved since the last review.– TF Conductor Sub-assembly procurement is proceeding smoothly– Soldering of cooling tubes in TF conductor (Full TF Bundle) is nearly

complete– Centerstack Casing fabrication is nearly complete– Coil manufacturing area for Centerstack is in full operation– Final tooling fabrication and procurement for OH is underway– OH and PF conductor has been completed– Completed testing of the Aquapour– Outer TF Coils procurement has been awarded – Inner PF coil contract requisition has been submitted– Delivery of Centerstack Assembly is scheduled for February 2014

NSTX-UNSTX-U NSTX Upgrade Project – Office of Science Review – December 11-12, 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 – December 11-12, 2012 4

Critical Path Schedule

NSTX-UNSTX-U NSTX Upgrade Project – Office of Science Review – December 11-12, 2012 5

TF Conductor Assembly

• Major Tool and Edison Welding Institute are manufacturing the TF conductor assemblies.

• Initially a slow start due to the final development of the Friction Stir Welding (FSW) procedures and the necessary NDT testing, but production is now moving smoothly.

• 36 conductors required for the full TF bundle have been delivered• Quadrant #5 conductors in January• Quadrant #6 conductors in February.

NSTX-UNSTX-U NSTX Upgrade Project – Office of Science Review – December 11-12, 2012 6

TF Solder Operations

• From Solder Trials to Operations:– Solder trials were successfully completed

at PPPL with assistance of a Solder Consultant

– Solder operations are now moving along smoothly

– 29 conductors have already been soldered

• 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~ 270-300 degrees

C to ensure wetting

NSTX-UNSTX-U NSTX Upgrade Project – Office of Science Review – December 11-12, 2012 7

Area Setup- TF Fabrication

VPI Station

NSTX-UNSTX-U NSTX Upgrade Project – Office of Science Review – December 11-12, 2012 8

Safety Involvement

• The fabrication & assembly of the Centerstack is being 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 – December 11-12, 2012 9

Tooling Fabrication and Procurement

• Inner TF Bundle- Tooling and Fabrication– Operations are moving ahead smoothly– All stations are in full operation

• Post solder bake √

• Sandblast √

• Priming and cure √

• Application of turn insulation √

• Install conductors in mold √

• Align conductors and complete assembly of mold- In process– Awaiting lid for Quadrant mold

• Vacuum Pressure Impregnation of TF Quadrant- January 2013

– Full TF bundle mold has been awarded to Reno Machining- delivery in late January

NSTX-UNSTX-U NSTX Upgrade Project – Office of Science Review – December 11-12, 2012 10

TF Conductor Preparation

Sandblasting

PrimingTurn Insulation

Post Solder Bake

NSTX-UNSTX-U NSTX Upgrade Project – Office of Science Review – December 11-12, 2012 11

TF Quadrant Assembly

• Install conductors into mold

NSTX-UNSTX-U NSTX Upgrade Project – Office of Science Review – December 11-12, 2012 12

VPI Operations

• Developed procedures and tooling for VPI operations• Trial VPI was successful

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VPI Process Cycle

NSTX-UNSTX-U NSTX Upgrade Project – Office of Science Review – December 11-12, 2012 14

J.H. Chrzanowski 9/7/12

NSTX-U Center Stack Coils VPI Cycle [CTD-425]

3024 45 7562520

Coil Fill Period [Fill/soak & remove lines]

Cure Time

Ramp down Period

Ramp up period

Post Cure Time

Ramp up period

15 hours

24 hours

10 hours

Ramp up 6 hours @ 10 ° C / hour

Ramp down 13 hours @ 10 ° C per hour

Hours

Temperature degrees C

10

20

30

40

60

50

70

80

90

130

100

110

140

0

120

150

160

170

10

20

30

40

60

50

70

8090

130

100

110

140

0

120

150

160

170

Ramp up 7 hours @ 10 ° C per hour

Temperature degrees C

NSTX-UNSTX-U NSTX Upgrade Project – Office of Science Review – December 11-12, 2012 15

Full TF Mold

• The full TF mold is being manufactured by Reno Machine (Conn.) –

– PPPL is planning a visit in December– Scheduled for February delivery

NSTX-UNSTX-U NSTX Upgrade Project – Office of Science Review – December 11-12, 2012 16

Tooling Fabrication and Procurement

• OH Solenoid- tooling– OH copper conductor has been received

– OH conductor sandblasting & priming requisition in system

– Induction braze station OH braze joints- is being commissioned

• OH joint braze qualification program will begin in January

– Tension unit & taping machines are in fabrication

– OH Mold will be out for bids in January

NSTX-UNSTX-U NSTX Upgrade Project – Office of Science Review – December 11-12, 2012 17

OH Solenoid Winding Facility

NSTX-UNSTX-U NSTX Upgrade Project – Office of Science Review – December 11-12, 2012 18

OH Winding Station

Tension unit being fabricated in house

Taping machines complete

OH winding support tooling complete

Turning fixture delivered

Induction braze station (Complete)

NSTX-UNSTX-U NSTX Upgrade Project – Office of Science Review – December 11-12, 2012 19

•Rolled Aluminum Cylinder wrapped with epoxy/glass insulation represents TF Bundle•Maintains true TF OD and clearance space at top and bottom•Will use actual mold segments and alignment pins•Tested:

1. Filling of Aquapour √2. Curing of Aquapour with heating blankets √3. Washing Out of Aquapour √

TESTING OF AQUAPOUR FOR CENTER STACK FABRICATION

NSTX-UNSTX-U NSTX Upgrade Project – Office of Science Review – December 11-12, 2012 20

Centerstack Casing

• The Centerstack Inconel casing is being manufactured by Martinez & Turek located in California.

• They have been making good progress

– PPPL visited facility in November just prior to final welding

• Delivery is scheduled for December 2012

NSTX-UNSTX-U NSTX Upgrade Project – Office of Science Review – December 11-12, 2012 21

Centerstack Casing

• Upon arrival of the casing 500 Inconel studs will added to the outside surfaces (original casing shown below)

• 696 Tiles with diagnostics will then be mounted

3.4 3.4

5.8

5.8

NSTX-UNSTX-U NSTX Upgrade Project – Office of Science Review – December 11-12, 2012 22

Plans Forward for Centerstack Components

• Inner TF Bundle– VPI first Quadrant- January 2013

– VPI Full Bundle- May 2013

• OH Solenoid– Begin winding OH solenoid- July 2013

– VPI OH Solenoid- October 2013

• Centerstack Casing– Delivery is scheduled for December 2012

• Centerstack Assembly- – Final assembly will occur between November

2013 to February 2014

– Developing Assembly procedures

NSTX-UNSTX-U NSTX Upgrade Project – Office of Science Review – December 11-12, 2012 23

Plans Forward- continued

• Inner Poloidal Field Coils– Requisition has been submitted to

procurement- RFQ

– Delivery summer 2013

• TF buss and support components– Purchase Order has been placed with Zenox

Corp. (TF Flexes)

– Super-nuts in procurement February 2013

– OTF Lead extensions (January procurement)

• Deliver completed Centerstack

Assembly - February 2014

MT Torque-nut™

Flex-Bus (Cu-Cr-Zr)

NSTX-UNSTX-U NSTX Upgrade Project – Office of Science Review – December 11-12, 2012 24

Outer TF Coils

• The contract for fabricating (2) Outer TF coils was awarded to Everson-Tesla.– Soldering of the cooling tubes has started

– February 2013 delivery

NSTX-UNSTX-U NSTX Upgrade Project – Office of Science Review – December 11-12, 2012 25

Conclusion

• The risks associated with the production of the TF conductors have been addressed (Major Tool/Edison Welding)

• The soldering trials have been completed and production nearly complete (Retired risk)

• The TF bundle manufacturing facility is in full operation– Awaiting delivery of molds and completion of procedures

• The R&D and procedures for VPI are complete & first VPI is scheduled for January

• The Aquapour trials are complete• Tooling for the OH solenoid is being fabricated• The OH conductor sandblast/priming contract is awaiting bids• The Inconel casing is scheduled for delivery in December• Contract for the OTF has been awarded • Requisition for Inner PF coils is in procurement

• The production of the Centerstack Assembly has begin