NSTX Supported by Vac Vsl Support Structures WBS
NSTX Supported by Vac Vsl & Support Structures WBS 1. 1. 2 College W&M Colorado Sch Mines Columbia U Comp. X 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 Princeton Plasma Physics Laboratory NSTX Upgrade Project Final Design Review LSB, B 318 June 22 -24, 2011 NSTX Upgrade Project – Final Design Review Culham Sci Ctr U St. Andrews York U Chubu U Fukui U Hiroshima U Hyogo U Kyoto 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 June 22 - 24, 2011 1
Outline • • • Design Overview Vessel Leg Reinforcement Pedestal Upgrade Umbrella Upgrades PF 2/3 Support Upgrades PF 4/5 Support Upgrades TF Outer Leg Support Upgrades Interconnections Cost & Schedule CHITs Open Items NSTX Upgrade Project – Final Design Review June 22 - 24, 2011 2
Design Overview New Umbrella Upper Lid Upper & Lower Umbrella Reinforcements Additional PF 2 Clamp, PF 2/3 Support Upgrades New TFO Leg Support Ring New (additional) PF 4/5 Supports Existing PF 4/5 Supports Upgraded New Clevis & Connecting Rods New Umbrella Lower Lid VV Foot Reinforcement New Pedestal NSTX Upgrade Project – Final Design Review June 22 - 24, 2011 3
Vessel Leg Reinforcement Horseshoe shaped foot reinforcement 1 reinforcement per set of VV supports. Epoxy anchor bolts attach to the concrete. NSTX Upgrade Project – Final Design Review June 22 - 24, 2011 4
Pedestal Upgrade Upper Pedestal Section New Pedestal Base Plate Lower Pedestal Section NSTX Upgrade Project – Final Design Review June 22 - 24, 2011 5
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. Fiducials provided for alignment. Base Plate distributes load and provides attachment point for equipment. NSTX Upgrade Project – Final Design Review June 22 - 24, 2011 6
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. NSTX Upgrade Project – Final Design Review June 22 - 24, 2011 7
Umbrella Upgrades Upper Lid and Crown Bolt Plate attachment (bolted) New Upper Lid Reinforcement Ring and Gussets (welded ) For installation, Upper Lid Reinforcement Ring is sectional. Upper Lid bolts to ring. Design provides access / clearance for equipment. NSTX Upgrade Project – Final Design Review June 22 - 24, 2011 8
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 NSTX Upgrade Project – Final Design Review June 22 - 24, 2011 9
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 NSTX Upgrade Project – Final Design Review June 22 - 24, 2011 10
Umbrella Upgrades Arch Reinforcement Ring (sectional & welded) To aid installation, reduce costs, and improve weld integrity the umbrella legs will be removed & replaced. Replacement Leg (1 fabricated part) Upper & Lower Umbrella Legs removed and replaced (welded). Replace foot hardware, capture and slide with Inconel parts. NSTX Upgrade Project – Final Design Review June 22 - 24, 2011 11
PF 2/3 Support Upgrades PF 2 mount PF 3 Clamp PF 3 mount Additional PF 2 Clamp Weld reinforcement on PF 3 mount. Remove PF 2/3 hardware and replace with ASTM A 193 B 8 M Class 2 Material. NSTX Upgrade Project – Final Design Review June 22 - 24, 2011 12
PF 4/5 Support Upgrades 4 of 6 existing PF 4/5 supports free to slide radially for thermal expansion. 2 of 6 existing PF 4/5 supports (180˚ apart) fixed radially. 6 New (additional) PF 4/5 Supports Modifications to existing PF 4/5 supports. NSTX Upgrade Project – Final Design Review June 22 - 24, 2011 13
PF 4/5 Support Upgrades Replace column. 2 part column with spacer for installation. Remove clevis. Replace hardware with ASTM A 193 B 8 M Class 2 Material. Studs used for installation. NSTX Upgrade Project – Final Design Review June 22 - 24, 2011 14
PF 4/5 Support Upgrades New (additional) PF 4/5 Support T-slot allows for relative motion between PF 4 and PF 5. Magna Plate low friction coating interface. NSTX Upgrade Project – Final Design Review June 22 - 24, 2011 15
TF Outer Leg Support Upgrades NSTX Upgrade Project – Final Design Review June 22 - 24, 2011 16
TF Outer Leg Support Upgrades Remove /replace VV clevis. Reinforce VV pad weld. Use In 718 pin. Shimmed around existing TFO leg clamp. Remove /replace TFOL clevis. Use In 718 pin. Remove and replace existing TFO Leg support turnbuckles. 26 kips shear load capacity. welded NSTX Upgrade Project – Final Design Review June 22 - 24, 2011 17
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. NSTX Upgrade Project – Final Design Review June 22 - 24, 2011 18
Interconnections High friction interface: surface coating µstatic ≥ 0. 5 In 718 strain gage bolts Upper Crown-Lid Bolt Plate NSTX Upgrade Project – Final Design Review June 22 - 24, 2011 19
Interconnections High friction interface: surface coating µstatic ≥ 0. 5 In 718 strain gage bolts Lower Crown-Lid-Pedestal Bolt Plate NSTX Upgrade Project – Final Design Review June 22 - 24, 2011 20
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) : 1364 mn-hrs = $206 ($k) Total M&S is $688 ($k) Total ETC is $1, 411 ($k) NSTX Upgrade Project – Final Design Review June 22 - 24, 2011 21
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 PF 4/5 Supports. – Ground wire provided - Closed. – CHIT-18: Obtain approval for use of magnetic A 193 bolts. – Will receive approval or use Inconel bolts. – CHIT-19 a: Detailed analysis of bolted connections: (supports, pedestal, test cell floor). – Connections being analyzed in detail --- pending calculation completion. NSTX Upgrade Project – Final Design Review June 22 - 24, 2011 22
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 PF 4 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. NSTX Upgrade Project – Final Design Review June 22 - 24, 2011 23
Open Items • Analysis/Calculations: • Finalized and checked. • COG/CAM sign off. Recent open items • Contact vendor for high friction coating. • Contact vendor for In 718 strain gage bolts. • TFO Leg Support: – VV pad, clevis, rods, weldment, revised & validated. NSTX Upgrade Project – Final Design Review June 22 - 24, 2011 24
NSTX College W&M Colorado Sch Mines Columbia U Comp. X 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 Supported by Bus Bars & Supports WBS 1. 5. 5 Mark Smith and the NSTX Upgrade Team Princeton Plasma Physics Laboratory NSTX Upgrade Project Final Design Review LSB, B 318 June 22 -24, 2011 NSTX Upgrade Project – Final Design Review Culham Sci Ctr U St. Andrews York U Chubu U Fukui U Hiroshima U Hyogo U Kyoto 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 June 22 - 24, 2011 25
Outline • • • Description & Features Installation Layout CHI Ring Bus PF 1 a, b, c Bus OH Coaxial Bus TF Bus Cost & Schedule CHITs Open Items NSTX Upgrade Project – Final Design Review June 22 - 24, 2011 26
Description & Features • • Replace CHI Ring: accommodate new pedestal. New Upper and Lower PF 1 a, 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. – G 10 isolators, clamps, and supports. – SS supports NSTX Upgrade Project – Final Design Review June 22 - 24, 2011 27
Installation Layout Upper PF 1 Bus Tower TF Bus CHI Ring Bus NSTX Upgrade Project – Final Design Review June 22 - 24, 2011 28
Installation Layout Upper PF 1 Bus Tower TF Bus Lower PF 1 Bus OH Bus Pedestal CHI Ring Bus NSTX Upgrade Project – Final Design Review June 22 - 24, 2011 29
CHI Ring Bus Water cooled. Clamp G 10 spacer NSTX Upgrade Project – Final Design Review Support/mount June 22 - 24, 2011 30
PF 1 a, b, c Bus Tower Clamp Support/mount Upper PF 1 Bus Runs NSTX Upgrade Project – Final Design Review June 22 - 24, 2011 31
OH Coaxial Bus Connection to OH coil. Water cooled rectangular bus section. Air cooled Coaxial Bus section. G 10 spacer Support/mount NSTX Upgrade Project – Final Design Review June 22 - 24, 2011 32
TF Bus Tower Support/mount Water cooled section. G 10 spacer Support/mount NSTX Upgrade Project – Final Design Review June 22 - 24, 2011 33
TF Bus G 10 spacer Support/mount Water cooled section. Bus Tower G 10 spacer Support/mount NSTX Upgrade Project – Final Design Review June 22 - 24, 2011 34
Cost & Schedule • ETC completed. – 1 st 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. NSTX Upgrade Project – Final Design Review June 22 - 24, 2011 35
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. NSTX Upgrade Project – Final Design Review June 22 - 24, 2011 36
Open Items • Update models per calculations, FDR CHITs. • Update analysis. • Finalize design during field fit up / installation. NSTX Upgrade Project – Final Design Review June 22 - 24, 2011 37
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