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NSTX

NSTX. Supported by. Vac Vsl & Support Structures WBS 1.1.2. College W&M Colorado Sch Mines Columbia U CompX General Atomics INEL Johns Hopkins U LANL LLNL Lodestar MIT Nova Photonics New York U Old Dominion U ORNL PPPL PSI Princeton U Purdue U SNL Think Tank, Inc. UC Davis

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NSTX

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  1. NSTX Supported by Vac Vsl & Support Structures WBS 1.1.2 College W&M Colorado Sch Mines Columbia U CompX General Atomics INEL Johns Hopkins U LANL LLNL Lodestar MIT Nova Photonics New York U Old Dominion U ORNL PPPL PSI Princeton U Purdue U SNL Think Tank, Inc. UC Davis UC Irvine UCLA UCSD U Colorado U Illinois U Maryland U Rochester U Washington U Wisconsin Mark Smith and the NSTX Upgrade Team Culham Sci Ctr U St. Andrews York U Chubu U Fukui U Hiroshima U Hyogo U Kyoto U Kyushu U Kyushu Tokai U NIFS Niigata U U Tokyo JAEA Hebrew U Ioffe Inst RRC Kurchatov Inst TRINITI KBSI KAIST POSTECH ASIPP ENEA, Frascati CEA, Cadarache IPP, Jülich IPP, Garching ASCR, Czech Rep U Quebec Princeton Plasma Physics Laboratory NSTX Upgrade Project Final Design Review LSB, B318 June 22-24, 2011 1

  2. Outline Design Overview Vessel Leg Reinforcement Pedestal Upgrade Umbrella Upgrades PF2/3 Support Upgrades PF4/5 Support Upgrades TF Outer Leg Support Upgrades Interconnections Cost & Schedule CHITs Open Items 2

  3. Design Overview New Umbrella Upper Lid Upper & Lower Umbrella Reinforcements Upper & Lower Umbrella Reinforcements Additional PF2 Clamp, PF2/3 Support Upgrades New TFO Leg Support Ring New (additional) PF4/5 Supports Existing PF4/5 Supports Upgraded New Clevis & Connecting Rods New Umbrella Lower Lid VV Foot Reinforcement New Pedestal 3

  4. Vessel Leg Reinforcement Horseshoe shaped foot reinforcement Epoxy anchor bolts attach to the concrete. 1 reinforcement per set of VV supports. 4

  5. Pedestal Upgrade Upper Pedestal Section New Pedestal Base Plate Lower Pedestal Section 5

  6. Pedestal Upgrade Design provides access / clearance for equipment. Attachments for lower crown bolt plate and umbrella lower lid. Bolt slots provide for alignment. Gap allows for height adjustment via shims. Epoxy anchor bolts attach to the concrete. Grouted base allows for leveling. Base Plate distributes load and provides attachment point for equipment. Fiducials provided for alignment. 6

  7. Umbrella Upgrades Upper & Lower Umbrellas Internal Reinforcement adjacent to Al Blocks (2 part & welded). Block threaded rods replaced. Upper & Lower Umbrellas External Reinforcement on Al Blocks (bolted). Corner bolts replaced. 7

  8. Umbrella Upgrades Upper Lid and Crown Bolt Plate attachment (bolted) New Upper Lid Upper Lid bolts to ring. Upper Lid Reinforcement Ring and Gussets (welded ) Design provides access / clearance for equipment. For installation, Upper Lid Reinforcement Ring is sectional. 8

  9. Umbrella Upgrades New Lower Lid (sectional & bolted) Lower Lid-Pedestal attachment (bolted) bolted welded Standoff ensures TF flex strap clearance. Sectional lower lid aids in installation and allows maintenance access. Slots allow adjustment. welded 1 water jet part 9

  10. Umbrella Upgrades Inner Reinforcement to Umbrella Legs and Arches (perimeter and plug welds). Outer Reinforcement to Umbrella Legs (perimeter and plug welds). Previous Reinforcement Scheme 10

  11. Umbrella Upgrades To aid installation, reduce costs, and improve weld integrity the umbrella legs will be removed & replaced. Arch Reinforcement Ring (sectional & welded) Replacement Leg (1 fabricated part) Upper & Lower Umbrella Legs removed and replaced (welded). Replace foot hardware, capture and slide with Inconel parts. 11

  12. PF2/3 Support Upgrades PF2 mount PF3 mount PF3 Clamp Additional PF2 Clamp Weld reinforcement on PF3 mount. Remove PF2/3 hardware and replace with ASTM A193 B8M Class2 Material. 12

  13. PF4/5 Support Upgrades 4 of 6 existing PF4/5 supports free to slide radially for thermal expansion. 2 of 6 existing PF4/5 supports (180˚ apart) fixed radially. 6 New (additional) PF4/5 Supports Modifications to existing PF4/5 supports. 13

  14. PF4/5 Support Upgrades Replace column. 2 part column with spacer for installation. Remove clevis. Replace hardware with ASTM A193 B8M Class2 Material. Studs used for installation. 14

  15. PF4/5 Support Upgrades New (additional) PF4/5 Support T-slot allows for relative motion between PF4 and PF5. Magna Plate low friction coating interface. 15

  16. TF Outer Leg Support Upgrades 16

  17. TF Outer Leg Support Upgrades Remove /replace VV clevis. Reinforce VV pad weld. Use In718 pin. Shimmed around existing TFO leg clamp. Remove /replace TFOL clevis. Use In718 pin. Remove and replace existing TFO Leg support turnbuckles. welded 26 kips shear load capacity. 17

  18. TF Outer Leg Support Upgrades Spherical rod ends allow alignment. Length adjustment via opposite threads. Remove /replace connecting rods. Jam nuts lock position. Wrench feature for installation. 4 special rods provide clearance around VV support legs. 18

  19. Interconnections High friction interface: surface coating µstatic ≥ 0.5 In718 strain gage bolts Upper Crown-Lid Bolt Plate 19

  20. Interconnections High friction interface: surface coating µstatic ≥ 0.5 In718 strain gage bolts Lower Crown-Lid-Pedestal Bolt Plate 20

  21. Cost & Schedule • ETC has been updated. • Man power EAEM (analyst): 960 mn-hrs = $170 ($k) • Man power EADM (designer): 986 mn-hrs = $170 ($k) • Man power EMEM (CAM) : 1364mn-hrs = $206 ($k) • Total M&S is $688 ($k) • Total ETC is $1,411 ($k) 21

  22. CHITs • PDR 6/2010 • CHIT-07 TF Outer Leg Support Bolted Joint: • Are dielectric breaks (insulated joints) required? • Physics checked current loops, No breaks needed – Closed. • How is a shear load carried? • Design accommodates shear load – Closed. • Peer Review 5/2011 • CHIT-5: Electrically Ground new PF4/5 Supports. • Ground wire provided - Closed. • CHIT-18: Obtain approval for use of magnetic A193 bolts. • Will receive approval or use Inconel bolts. • CHIT-19a: Detailed analysis of bolted connections: (supports, pedestal, test cell floor). • Connections being analyzed in detail --- pending calculation completion. 22

  23. CHITs • Peer Review 5/2011 • CHIT-38: Analysis indicates PF 4/5 supports not stiff enough. • Titus to provide updated analysis and/or ppt slides. • CHIT-40: Confirm PF4 T-slide material & required travel length to prevent lock up. • Magna Plate low friction surface specified. • T-slide length increased. • Confirmation of design pending calculation completion. • CHIT-44: Ensure tolerances, friction and pinned connections consistent with analysis assumptions. • Confirmation pending calculation completion. 23

  24. Open Items • Analysis/Calculations: • Finalized and checked. • COG/CAM sign off. Recent open items • Contact vendor for high friction coating. • Contact vendor for In718 strain gage bolts. • TFO Leg Support: • VV pad, clevis, rods, weldment, revised & validated. 24

  25. NSTX Supported by Bus Bars & Supports WBS 1.5.5 College W&M Colorado Sch Mines Columbia U CompX General Atomics INEL Johns Hopkins U LANL LLNL Lodestar MIT Nova Photonics New York U Old Dominion U ORNL PPPL PSI Princeton U Purdue U SNL Think Tank, Inc. UC Davis UC Irvine UCLA UCSD U Colorado U Illinois U Maryland U Rochester U Washington U Wisconsin Mark Smith and the NSTX Upgrade Team Culham Sci Ctr U St. Andrews York U Chubu U Fukui U Hiroshima U Hyogo U Kyoto U Kyushu U Kyushu Tokai U NIFS Niigata U U Tokyo JAEA Hebrew U Ioffe Inst RRC Kurchatov Inst TRINITI KBSI KAIST POSTECH ASIPP ENEA, Frascati CEA, Cadarache IPP, Jülich IPP, Garching ASCR, Czech Rep U Quebec Princeton Plasma Physics Laboratory NSTX Upgrade Project Final Design Review LSB, B318 June 22-24, 2011 25

  26. Outline Description & Features Installation Layout CHI Ring Bus PF 1a, b, c Bus OH Coaxial Bus TF Bus Cost & Schedule CHITs Open Items 26

  27. Description & Features • Replace CHI Ring: accommodate new pedestal. • New Upper and Lower PF1a,b,c Bus • New Coaxial OH Bus & Standard Bus • Replace existing TF cables with solid bus bar. • Oxygen free copper • 2 mil Kapton, Fiberglass wrap, Epoxy Coated • Bolted Connections: silver plated flat surfaces, bevel washers, minimum contact pressure @ 2 ksi. • G10 isolators, clamps, and supports. • SS supports 27

  28. Installation Layout Upper PF1 Bus Bus Tower TF Bus CHI Ring Bus • 28 28

  29. Installation Layout Upper PF1 Bus Bus Tower TF Bus Lower PF1 Bus OH Bus CHI Ring Bus Pedestal 29

  30. CHI Ring Bus Water cooled . Clamp Support/mount G10 spacer 30

  31. PF 1a, b, c Bus Bus Tower Clamp Support/mount Upper PF1 Bus Runs • 31 31

  32. OH Coaxial Bus Connection to OH coil. Water cooled rectangular bus section. Air cooled Coaxial Bus section. G10 spacer Support/mount 32

  33. TF Bus Bus Tower Support/mount G10 spacer Water cooled section. G10 spacer Support/mount Support/mount 33

  34. TF Bus G10 spacer Support/mount Water cooled section. Bus Tower G10 spacer Support/mount • 34 34

  35. Cost & Schedule • ETC completed. • 1st pass analysis is completed. • Assembly and detailed drawings mostly completed. • Note: Since bus runs are field fit, design finalization & validation occurs during installation. • M&S = $109 ($k) • ETC = $ 995 ($k) includes installation. 35

  36. CHITs • Peer Review 5/2011 • CHIT-20: Prepare designs for the bus supports for all new bus runs. • Supports already included, modifications per updated analysis - Closed. • CHIT-21: Prepare designs for the cooling water of new bus runs. • Designs to be prepared. • CHIT-29: Fault modes required when analyzing bus bar supports. • Future analysis will include fault modes. 36

  37. Open Items Update models per calculations, FDR CHITs. Update analysis. Finalize design during field fit up / installation. 37

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