NSTX-U Construction

Erik Perry

Princeton Plasma Physics Laboratory

NSTX Upgrade Readiness to Operate Review

LSB B318December 9-11, 2014

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

Content

• Outage Planning

• Outage Coordination

• Work Control Center

• Outage Adjustments

• Installation Risks and Mitigations

• Work Completed

• Remaining Work

Outage Planning• Outage planning was based on bottoms-up

estimates from Engineering

• Assigned technicians, by name, to critical scope to assure staffing requirements were met

• Adjusted start dates of tasks to assure tasks in the same area were compatible

• Accelerated tasks that made other tasks safer or more efficient

• Worked crews on opposite sides and two shifts

• Daily / hourly coordination was critical

Outage Coordination• Used 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 done with Engineering Work Packages (EWPs)

• EWPs included– Detailed procedure

– Job Hazard Analysis

– Permits required to perform the work

– Drawings required to perform the work

Work Control Center• Work Control Center reviewed all EWPs for the

field– Reviewed removal/installation procedures

– Reviewed Job Hazard Analysis (JHA)

– Attended pre-job and post-job briefs

– Interfaced between Engineering and the field crews

– Assured that the field work was done safely and correctly

– Assured the field crews were used efficiently

EWP Status• 248 Engineering Work Packages (EWPs) since

the start of the NSTX-U Outage

• 167 of these EWPs were for upgrade scope

• Of the upgrade scope EWPs there are 20 that still have work to be done

• There are 28 Operations EWPs that still have work to be done

• All closed-out EWPs are in the Ops Center

Outage Adjustments• Daily Plan-of-the-day meetings coordinated

activities between crews and fine tuned technician assignments– Included field crew leaders, QA, Industrial Hygiene, Health

Physics, DOE

• Twice a week meetings of the Work Control Center reviewed priorities, EWPs and hardware

• Flexibility for adjustments came from– Second shift work

– Multiple crews working on opposite sides

– Having many EWPs ready for field work

Installation Risks and Mitigations• Delays in getting parts delivered to field crews

– Facilitated parts fabrication

– Re-scheduled work sequence

– Scheduled work on two shifts once parts arrived

• Scope creep– Engineering Change Proposal process

– Review of engineering estimates by division heads (WAF review)

Work Completed

October 2011 October 2011

January 2012 April 2012

Work Completed

Work Completed

Work Completed

Work Completed

July 2013

Work Completed

Remaining Work• Install bus inside and outside of umbrellas

• Install gas injection inside umbrella structure

• Install kapton/G10 flash shields on centerstack

• Install TF flex bus and TF lead extensions

Remaining Work cont.

• Field measure space from lead extensions to TF outer leg flags

• Fabricate 72 custom TF flag links

• Install TF flag supports

• Install umbrella lid support rings

• Install new umbrella lids

• All remaining work is understood and is progressing well

Summary• The Upgrade Outage has been planned based

on– Bottoms-up estimates from Engineering

– Scheduling work to maximize safety / efficiency

• The plan is being continually worked– To deal with delays in getting parts

– To accelerate tasks to make full use of resources

• The remaining work is understood and is progressing well

Summary cont.

• 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– Will turn over NSTX to Operations at the completion of procedure

OP-NSTX-01: Preparation of Experimental Areas for Operations