# Presentation: 948961

## NSTX Facility Ops & Management 

- NSTX Facility Ops & Management

- NSTX

- Presented by: Al von Halle

## NSTX Magnet Power Systems

-  NSTX utilizes the former TFTR Energy Conversion Systems and Infrastructure.
-  Systems have been refurbished, recommissioned, and are now maintained by the NSTX project

- D-Site Power Conversion and MG Buildings

## NSTX Magnet Power Systems

- Of the 39 power supplies (78 Sections) originally supplied for TFTR, NSTX is using 45 Sections.
- Each section is rated 1kV@24kA for 4 sec every 300 seconds.
- TF - 		4 PSS
- OH - 		12 PSS
- PF1a/b,U/L -	10 PSS
- PF2U/L - 	4 PSS
- PF3U/L - 	8 PSS
- PF5 -		3 PSS
- CHI - 		4 PSS

- Power supplies will be shared between NSTX/NCSX

## NSTX Magnet Power Systems

- Commutator structure of one of the two D-Site
- MG Sets

- NSTX presently uses
- MG #1.  MG#2 has been brought back into operating trim to allow shared operations.
- Each set, as supplied with ~600T flywheels, can store 4500MJ with 2250MJ usable from 90-60 Hz

## NSTX Neutral Beam Power Conversion

- Neutral Beam Modulator Regulators

- NSTX NBI uses three of the twelve tetrode-based power supplies.
- Each supply is rated for  120kV @ 65A and capable of precise regulation.
- Future possible uses on NSTX include an EBW upgrade and the addition of a 2nd NB.

## RF Capability

- RF Building and coaxial wave-guides to D-Site

- Power from six ICRF sources is brought to NSTX to operate the 6MW, 30Mhz HHFW system

## Instrumentation and Control 

- Instrumentation and Control

- Process Control and Monitoring (EPICS)
- 	Real Time Plasma Control Coordination
- 	Inter-System Communication and Data Transfer
- 	Safety Interlock and Access Control
- 	Master Timing and Synchronization
- Plasma Real Time Control  (PCS)
- Data Acquisition (MDSplus)
- 	Acquisition, Storage, and Display of Diagnostic Data
- 	Synchronization of Data Sampling
- Volume of data has increased significantly with the sophistication of diagnostic and control systems.

## Instrumentation and Control

- In 2003, NSTX acquired 300MB/Shot, a 50% increase over 2002
- On-line storage requirements are expected to increase each year by about 100MB/Shot.
- Majority of data travels to the primary control computers via six CAMAC highways:
- 	Three for Diagnostic Data
- 	Two for Facility Operations
- 	One for NBI
- Data acquisition utilizing PCI bus architecture has been developed that reproduces the functions of CAMAC.

## Instrumentation and Control

- MDSplus data presently managed by a VMS operating system:
- 	Cost of storage of VMS-based data is increasing as 		compared to LINUX-based systems (now < $10K/TB).
- 	1st NSTX LINUX-based system on line this year.
- NSTX participating in a multi-processor computing facility at PPPL (purchased 9 dual-processor LINUX-based units for the 140 unit cluster)
- 	Analysis software for MPTS now on that cluster.
- 	Decreased time to receive electron density /temperature 	profiles by X3.
- 	New diagnostic analysis tasks expected to move to the 	cluster over the next few years.

## Engineering Design Implementation

- Work Planning  	Web based work planning and approvals
-      (ENG-032)
- Design Verification	Documentation of design reviews
-      (ENG-033)		Calculations
- 			Chit Resolution
- Drawing Control	Engineering Change Notice
-      (ENG-010)		Software Change Notice
- Installation/Ops	Procedures and Approval Matrix
-      (ENG-030)		Record of Training
- 			Run Copy Control

## NSTX Training

- For Unrestricted Access into the NSTX test cell:
- 	General Employee training (GET)
- 	Radiation Safety Training
- 	Lockout/Tagout (Control of Energy Sources)
- 	Basic Electric Safety
- 	Knowledge of Administrative Procedures
- 		Conduct of Operations 		(OP-AD-39)
- 		Chain of Command 		(OP-AD-56)
- 		Work Permit System 		(OP-AD-09)
- 		Control of Temporary Mods 	(OP-AD-03)
- 		Control of Workplace Cleanliness 	(OP-AD-24)
- 		NSTX Access Controls 		(OP-AD-117)

## NSTX Training

- Operator Training Matrixes (OP-NSTX-12) developed for:
- 	Chief Operating Engineers (COEs)
- 	Machine Technicians
- 	Vacuum Technicians
- 	Water Technicians
- 	Field Coil Power Conversion Technicians
- 	Radio Frequency System Operators
- 		High Harmonic Fast-Wave Systems
- 		Electron Cyclotron Heating systems
- 	Neutral Beam Operators
- 		Ion Source Systems
- 		Cryogenic Systems
- 		Beam-line Vacuum ops
- 		Operations Shift Supervisor

## NSTX Availability

- NSTX has typically operated at ~ 90% availability over scheduled run periods. (100% availability would be 1 plasma attempt every 15 minutes after the morning start-up/tests)

## NSTX Availability

- Additional run time scheduled to compensate for reductions in availability:
- FY’00 - Completed 15 Run weeks. Some reliability issues associated with power conversion systems corrected before resuming ops in FY’01
- FY’01 - Completed 15 Run weeks.  First TF water leaks corrected.  Repair of an insulation failure of the OH coil.
- FY’02 - Completed 13 Run weeks.  Some reduced availability due to electrical breakdowns during CHI experiments.
- FY’03 - 12 Run weeks scheduled.  Run ended in 5th week due to TF coil failure.  Redesign/repair in progress.

## TF Joint Elements

*24 Turn Outer Layer*

*12 Turn Inner Layer*

*Outer Tier Flags*

*Inner Tier Flags*

*Hub Assembly*

*Torque Collar*

*Connector*

*Flexible Link*

*Note: Original Design Shown*

## Problems with Original Design

- Design Factors
- hub stiffness not adequate to react moment
- communication of load from flag to hub uncertain with G10 shims
- bolt thread and shoulder engagement too small
- bolts necked down too far at threads, not enough on shaft
- dual shear/preload function of bolts
- lack of feature to facilitate joint resistance measurement w/o disassembly
- Quality Factors
- frequent manual reworking of contact surfaces
- non-planar flag surfaces
- shoulder bolt concentricity

- Hub

- Flag

- G10 Shims

- Bolts

## Improved Features of New Design

- Shear Shoes

- Flags Potted
- in Steel Boxes

- 3/8” Fasteners (studs)

- Washer Plate

- Design Improvements
- hub stiffness enhanced via Flag Boxes forming web of “I-beam”
- direct communication of load from flag to hub via potted flags in boxes
- larger diameter fasteners, 2x preload
- studs w/nuts instead of thru-bolts
- belleville washers
- separated shear/preload functions
- shear shoes added
- voltage taps added to facilitate joint resistance measurement w/o disassembly
- Quality Factors
- in-house fabrication, tight QC

## Comparison of Old/New Designs

## Managing the next weakest link

- Three highly critical areas in the NSTX design:
- TF Joints and associated support structure
- 	The new TF hub design will certainly reduce the stresses 	on the flag joints.
- TF inner bundle insulation shear stress due to OH
- 	Dissection of the failed TF inner bundle indicates that the 	TF insulation is fine after three years of operation.
- OH Solenoid at 6kV, based on size
- 	Although performing well, considering the manufacture 	of a spare OH.

## NSTX Failure Reporting

- An On-Line Failure Reporting system: http://nstxtr.pppl.gov/
- Developed from the General Atomics model and put into service in April 2001.
- Failures are categorized by group:
- 	Torus Systems (Vacuum, GIS, Water)
- 	Energy Conversion Systems (FCPC, MG)
- 	Control Systems
- 	Diagnostics
- 	Auxiliary Systems (Neutral Beam, HHFW, ECH)
- 	Facility Power Systems

## Preventive Maintenance

- Periodic Preventive Maintenance is performed on:
- 	Safety Interlock Systems 		(OP-KK-**, OP-NSTX-**)
- 	Control Systems 			(MP-CCD-**)
- 	Energy Conversion Systems 	(MP-MG-**, MP-ECS-**)
- 	AC Power Systems  		(MP-AC-***)
- 	Heating Systems 			(MP-NB-**, MP-RF-**)
- 	Water and He Bake-Out Systems  	(MP-WS-**)
- 	Vacuum and Gas Inj Systems 	(MP-VAC-**)
- An On-Line Preventive Maintenance Management System with automated electronic notifications has been developed and is currently being implemented.

## NSTX ES&H Representative (ES&H Division Head) reports to Project Director.
ES&H Resources
Electrical Safety
Radiation Protection
Industrial Hygiene
Industrial Safety
Laser & RF Safety
Environmental Protection
Waste Management

- NSTX ES&H Representative (ES&H Division Head) reports to Project Director.
- ES&H Resources
- Electrical Safety
- Radiation Protection
- Industrial Hygiene
- Industrial Safety
- Laser & RF Safety
- Environmental Protection
- Waste Management

- NSTX ES&H Support Highlights

## Other resources
ES&H Executive Board - senior Lab officials evaluate the effectiveness of PPPL’s ES&H Program.
Safety Review Committee - reviews/approves lab-wide safety documents and project safety assessment documents.
NSTX Activity Certification Committee (ACC) - conducts safety reviews of proposed NSTX operations and recommends issuance, revisions and constraints on the NSTX Safety Certificate.
The Safety Certificate outlines permissible NSTX operations and necessary constraints.
ACC appointed by ES&H Executive Board.
DOE-PAO staff participate as resource members of ACC.  

- Other resources
- ES&H Executive Board - senior Lab officials evaluate the effectiveness of PPPL’s ES&H Program.
- Safety Review Committee - reviews/approves lab-wide safety documents and project safety assessment documents.
- NSTX Activity Certification Committee (ACC) - conducts safety reviews of proposed NSTX operations and recommends issuance, revisions and constraints on the NSTX Safety Certificate.
- The Safety Certificate outlines permissible NSTX operations and necessary constraints.
- ACC appointed by ES&H Executive Board.
- DOE-PAO staff participate as resource members of ACC.

- NSTX ES&H Support Highlights

## Other resources
A Safety Assessment Document (SAD) is maintained for NSTX.
Describes NSTX structures, systems and components.
Identifies hazards.
Addresses design features & administrative controls to mitigate hazards.
Includes detailed failure modes and effects analyses of NSTX systems.
Periodic Management Safety Walkthroughs are conducted of the NSTX facility.  Special safety walkthroughs are conducted by ACC and others for new or modified installations with safety implications.

- Other resources
- A Safety Assessment Document (SAD) is maintained for NSTX.
- Describes NSTX structures, systems and components.
- Identifies hazards.
- Addresses design features & administrative controls to mitigate hazards.
- Includes detailed failure modes and effects analyses of NSTX systems.
- Periodic Management Safety Walkthroughs are conducted of the NSTX facility.  Special safety walkthroughs are conducted by ACC and others for new or modified installations with safety implications.

- NSTX ES&H Support Highlights

## CY 2001
No away from work lost work cases.
Recordable Injury Case Rate: 5.62 (6 cases)
Lost Work Case Rate: 4.68 (5 cases)

CY 2002
No away from work lost work cases.
Recordable Injury Case Rate: 5.61 (5 cases)
Lost Work Case Rate: 3.37 (3 cases)

NSTX received a special NJ State award in 2003 for working 2 consecutive years without an away from work case.

- CY 2001
- No away from work lost work cases.
- Recordable Injury Case Rate: 5.62 (6 cases)
- Lost Work Case Rate: 4.68 (5 cases)
- CY 2002
- No away from work lost work cases.
- Recordable Injury Case Rate: 5.61 (5 cases)
- Lost Work Case Rate: 3.37 (3 cases)
- NSTX received a special NJ State award in 2003 for working 2 consecutive years without an away from work case.

- NSTX SAFETY RECORD: 2001-2002

## 
Access to NSTX Test Cell and work involving radioactive components are controlled by Radiation Work Permits (RWPs).
Radiological monitoring (gammas, neutrons, tritium) is performed for NSTX.
Maximum estimated annual dose to the public (at Site Boundary) from NSTX operations is <0.02 mrem per year.
Collective occupational dose for all PPPL (including NSTX) in CY 2002 was 3.7 person-rem.

- Access to NSTX Test Cell and work involving radioactive components are controlled by Radiation Work Permits (RWPs).
- Radiological monitoring (gammas, neutrons, tritium) is performed for NSTX.
- Maximum estimated annual dose to the public (at Site Boundary) from NSTX operations is <0.02 mrem per year.
- Collective occupational dose _for all PPPL_ (including NSTX) in CY 2002 was 3.7 person-rem.

- NSTX Radiological Safety

- NSTX Radiological Safety

- Criteria for the NSTX Radiological Monitoring Plan

## Quality Assurance

- The Quality Assurance Division provides the expertise, guidance, and oversight to assure quality and help link the principles of ISM to work performance and processes.
- QA Policies were modeled after Requirements for Nuclear Facility Applications (NQA-1-1997) and tailored to the risks present at PPPL:
- 	P-006	Conduct of Operations
- 	P-013	Use of Procedures
- 	P-052	Special Processes
- 	P-063	Handling, Shipping, and Storage
- 	P-075	Configuration Management
- 	P-079	Identification & Control of Materials
- 	P-086	Calibration of Measurement and Test Equipment
- 	P-037	Software Quality Assurance

## Quality Assurance

- The Quality Assurance organization reports to the Director’s Office via the ES&H/Infrastructure Support Department.
- QA responsibilities include:
- 	QA Plan, developing quality related policies & procedures
- 	Inspections - AWS Certified Weld Inspector
- 	Procurement Quality Assurance
- 	Audits - Both internal and suppliers
- 	Tracking open audit/inspection findings