Machine Installation and Machine Installation and Construction ManagementConstruction Management

Erik D. Perry

Princeton Plasma Physics LaboratoryNSTX Upgrade Project

Office of Science ReviewLSB B318

October 2nd & 3rd, 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

NSTX-UNSTX-U NSTX Upgrade Project – Office of Science Review – October 2-3 ,, 2013 2

Topics

• Outage Planning• Outage Coordination• Installation Risks and Mitigations• Outage Progress in 2013• Remaining Structural Work• Work Once Centerstack is in NSTX Test Cell• Tasks to Prepare for Return to Operations

NSTX-UNSTX-U NSTX Upgrade Project – Office of Science Review – October 2-3 ,, 2013 3

Outage Planning

• Outage planning based on bottoms-up estimates from Engineering– Assumes just 5 days per week for almost all tasks

• Assigns technicians, by name, to critical scope to assure staffing requirements are met

• Adjust start dates of tasks to assure tasks in the same area are compatible

• Accelerate tasks that make other tasks safer or more efficient

• Work crews on opposite sides of vacuum vessel or on different shifts

• Daily / hourly coordination of all field work is critical

NSTX-UNSTX-U NSTX Upgrade Project – Office of Science Review – October 2-3 ,, 2013 4

Outage Coordination

• Use of Work Control Center (like TFTR D&D Project) to oversee and coordinate all activities in the NSTX Test Cell

• All work in the NSTX Test Cell being done with Engneering Work Packages (EWPs)

• Work Control Center reviews all EWPs for the field– Reviews removal/installation procedures– Reviews Job Hazard Analysis (JHA)– Attends pre-job and post-job briefs– Interfaces between Engineering and the field crews– Assures that the field work is done safely and correctly– Assures the field crews are used efficiently

NSTX-UNSTX-U NSTX Upgrade Project – Office of Science Review – October 2-3 ,, 2013 5

Outage Coordination

• Daily Plan-of-the-day meetings to coordinate activities between crews and fine tune technician assignments– Includes field crew leaders, QA, Safety, Health Physics, Industrial

Hygiene, DOE– Adjustments based on actual progress and manpower availability

• Flexibility for adjustments comes from– Second shift work– Multiple crews working on opposite sides of the vessel– Having many work packages ready for field work

• Safety and efficiency from– Temporary platforms to improve efficiency

– Trial fit-ups to verify handling techniques and minimize time spent on NSTX

– Temporary platforms to improve access and safety (inspected every shift)

– Plan work so crews are on opposite sides of machine

NSTX-UNSTX-U NSTX Upgrade Project – Office of Science Review – October 2-3 ,, 2013 6

Installation Risks and Mitigations

• Delays in getting parts delivered to installation crews– Re-schedule work sequence– Schedule work on two shifts once parts arrive

• Scope creep– Engineering Change Proposal process– Review of engineering estimates by division heads (WAF review)

• Fit-up of new centerstack– Estimate includes three fit-ups

NSTX-UNSTX-U NSTX Upgrade Project – Office of Science Review – October 2-3 ,, 2013 7

Outage Progress in 2013

• Install new umbrella legs / feet / slides• Install umbrella arch reinforcements

NSTX-UNSTX-U NSTX Upgrade Project – Office of Science Review – October 2-3 ,, 2013 8

Outage Progress in 2013

• Install reinforcements for TF to umbrella interface

NSTX-UNSTX-U NSTX Upgrade Project – Office of Science Review – October 2-3 ,, 2013 9

Outage Progress in 2013

• Replace PF2/3 clamp hardware and install additional PF2 clamps

• Install new PF4/5 supports and replace existing hardware (still in progress)

NSTX-UNSTX-U NSTX Upgrade Project – Office of Science Review – October 2-3 ,, 2013 10

Outage Progress in 2013

• Modify vacuum vessel legs to clear new TF turnbuckles

NSTX-UNSTX-U NSTX Upgrade Project – Office of Science Review – October 2-3 ,, 2013 11

Outage Progress in 2013

• Move two TF outer legs to new locations (to make room for other work)

• Install two new TF outer legs to replace ones taken out of service

NSTX-UNSTX-U NSTX Upgrade Project – Office of Science Review – October 2-3 ,, 2013 12

Outage Progress in 2013

• Re-silverplated leads on TF outer legs

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Outage Progress in 2013

• Installed new cable tray around top of machine– Walking surface included in top of tray

NSTX-UNSTX-U NSTX Upgrade Project – Office of Science Review – October 2-3 ,, 2013 14

Outage Progress in 2013

• Installed most of the TF outer leg upper support structure– Successfully proven out this very challenging installation procedure

NSTX-UNSTX-U NSTX Upgrade Project – Office of Science Review – October 2-3 ,, 2013 15

Remaining Structural Work

• Finish installing new PF4/5 supports and replace existing columns

• Install new TF outer leg lower supports

• Install new centerstack pedestal

• Install TF outer support turnbuckles

• Add extensions and anchors to vacuum vessel leg struts

NSTX-UNSTX-U NSTX Upgrade Project – Office of Science Review – October 2-3 ,, 2013 16

Work Once Centerstack is in NSTX Test Cell

• Lift centerstack casing over the OH/TF bundle

• Install PF1A upper coil

• Install kapton/G10 flash shields

• Lift centerstack into vacuum vessel

• Install TF flex bus support rings

• Install ceramic break assemblies

• Install organ pipes

• Install instrumentation cables to centerstack

• Install CHI flags

• Install edge tiles in-vessel

NSTX-UNSTX-U NSTX Upgrade Project – Office of Science Review – October 2-3 ,, 2013 17

Work Once Centerstack is in NSTX Test Cell

• Install bus inside umbrella and back to racks

• Install new TF flex bus

• Field measure space between centerstack and all TF flags

• Fabricate 72 unique centerstack to TF flag links

• Install umbrella lid support rings

• Install new umbrella lids

NSTX-UNSTX-U NSTX Upgrade Project – Office of Science Review – October 2-3 ,, 2013 18

Tasks to Prepare for Return to Operations

• Clean, photo and close the vacuum vessel

• Pumpdown

• Leak check

• Bakeout

All routine tasks at the end of an outage

NSTX-UNSTX-U NSTX Upgrade Project – Office of Science Review – October 2-3 ,, 2013 19

Summary

• The Upgrade Outage has been planned based on– Bottoms-up estimates from Engineering– Identifying staff to do the work– Scheduling work to avoid conflicts

• The plan is being continually worked– To improve safety and efficiency– To deal with delays in getting parts– To accelerate tasks to make full use of resources

• Coordination and Control– Provided by the Work Control Center– At the Plan-of-the-day meeting– Continuously by the Field Supervisors

• Successfully performing the outage (SPI= 0.97, CPI= 1.09)

– Will turn over NSTX to Operations in a fully ready condition