NSTX-U Engineering Operations January 28, 2015 NSTX-U Engineering Operations Al vonHalle January 28, 2015 NSTX-U Supported by Culham Sci Ctr York U Chubu

NSTX-UNSTX-U Engineering Operations January 28, 2015

NSTX-U Engineering Operations

Al vonHalle

January 28, 2015

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


Assessing Readiness to Operate

• A Readiness for Operations review by a committee from GA, Culham, ORNL, MIT, JLAB, Brookhaven & CCFE was held in December. In general, the committee believed that NSTX-U was on track to begin operations and could meet its design goals. There are corrective items:– Revise the SAD to clearly define the NSTX-U Safety Envelope– Identify external experts to review our FMEA– Develop a schedule identifying commissioning tests– Develop burn-in requirements for critical electronics (DCPS)– Develop a plan for ongoing verification of DCPS algorithms– Revise procedures to detail the D-Site chain of command– Revise governing documents for “sustainability” of training– Review muliple responsibilities and succession planning – PPPL implementation of DOE 422.1 (Conduct of Operations)– Further formalize the ACC process. Link to Eng. Procedures

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Activity Certification Committee

• The NSTX-U ACC addresses concerns regarding personnel, environmental, and machine safety very early in the planning to start experimental operations.

• The ACC is comprised of representatives from PPPL Engineering, Research, Safety, and DOE PSO and has been conducting ongoing reviews of technical and safety systems.

• The Committee will present its findings to the PPPL Executive Safety Board in mid-March with recommendations on the issuance of the NSTX-U Safety Certificate establishing the operational allowables for the first plasma and subsequent FY15 run.

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Configuration Control• Work Planning Web based work planning system for work (ENG-032) authorization and approvals.

• Design Verification Documentation of design reviews

(ENG-033) Calculations

Chit Resolution

• Drawing Control Engineering Change Notice

(ENG-010) Software Change Notice

• Installation/Ops Technical Procedures and Approval Matrix

(ENG-030) Record of Training

Run Copy Control

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Managing Work in the Test Cell

• Work Permits, approved by the D-Site Shift Supervisor, ensure that Test Cell configuration control and proper work practices are maintained.• Defines location of work, tools req’d and responsible workers

• Verifies proper procedures are used (Job specific, Lift, etc.)

• Checks permit requirements (confined space, radiological, etc.)

• Provides record for work for checks before resuming ops

• A Job Hazard Analysis (JHA) is performed for each task to help identify existing and potential workplace hazards, and to find ways to control these hazards. The safety controls/equipment needs are defined on the JHA, and reviewed with staff as part of the pre-job brief.

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Test Cell Access Control

Approvals and training required for unrestricted access into the NSTX-U 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 Modifications (ENG-036)

Control of Workplace Cleanliness (OP-AD-24)

NSTX Access Controls (OP-AD-117)

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Operator Training Matrix• Operator Training Matrixes (OP-NSTX-12) developed for:

NSTX-U Chief Operating Engineers (COEs)

Machine Technicians

Vacuum Systems Operator

Water Systems Operator

Field Coil Power Conversion (FCPC) Operator

Motor Generator (MG) Operator

Radio Frequency System Operators

High Harmonic Fast-Wave Source Operator

Electron Cyclotron Heating systems

Neutral Beam Operators

NB Operations Shift Supervisor (NBOS)

Ion Source Operator

Helium refrigerator Operator

Beam-line Subsystem Operator

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Overall Start-Up Procedure

• An Administrative procedure (OP-NSTX-02) is used to list the sub-system and integrated system procedures used to start-up and operate NSTX.

• This procedure is managed by the NSTX Chief Operating Engineer (COE), who will get sign-offs from the appropriate cognizant engineers upon the completion of each procedure.

• Prerequisites and the order of completion are specified, and “Hold Points” are included when management approvals are needed.

• This procedure was used for the initial commissioning of NSTX, and has been revised/used for each restart (Currently using Rev. #14)

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Overall Start-Up Procedure

The OP-NSTX-02 procedure is separated into five sections:

1. Pump down, Test Cell Prep, and Initial Bake out.

2. Preparation and authorization for ISTP-001.

3. Preparation and authorization for NSTX-U CD-4 milestone.

4. Preparation and authorization for the Neutral Beam CD-4 milestone

5. Preparations/Approvals for subsystems used for NSTX-U plasma operations.

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Allowable Magnet Parameters

• The electromagnetic ISTP (ISTP-001) defines protection system settings and necessary test shots for any changes to the NSTX electromagnetic configuration and/or operating envelope.

• Intended to be repeated as the operating envelope is adjusted to support the experimental program.

• Verifies that planned polarities, power levels and pulse lengths are consistent with design allowables.

• Documents, exercises and tests protection circuits, and prescribes test shot levels.

• Each iteration approved by Engineering, Research, and Project Management.

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Coil Protection

• AC System Protective Relaying

• Rectifier Fault Detector Overcurrent

– Set to produce a Level 1 Fault if current exceeds 10% of the PSRTC setting

• Digital Coil Protection System (Redundant)

– Junction Area DCPS. Set to produce a Level 1 Fault if current exceeds 5% of the PSRTC setting, or 1% over the I2T level of the FCC DCPS

– FCC DCPS. Set to suppress & bypass rectifiers if current exceeds 2% of the PSRTC setting, or reaches the I2T level

• Pulse Duration & Period (PDP) trip protection

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ISTP-001 Test Shots

• ISTP-001 prescribes individual magnet coil set test shots to test and set coil protection features.

• Important prerequisites for this procedure include:

– that the DCPS be tested and configured per OP-DCPS-779 to verify, exercise, and set protection algorithms.

– that the Power Supply Fault Detectors and AC Protective Relaying be configured/tested per OP-PC-734 (Reactivation of individual rectifiers) and PTP-ECS-39 (individual Rectifier Dummy Load Tests).

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ISTP-001 Test Shots

• A “portfolio” of test shots will be generated and archived (under a test data sheet #) for each coil set to be qualified for use:

–Test Shots performed at the 10%, 50% & 100% of the planned operating level, and induced Voltage & Magnetic Diagnostic calibration measurements taken as prescribed.–Exercise the overcurrent and I2T trips of the redundant DCPS’s at nominal 10% and 90% of the desired operating level, and the Rectifier Fault Detector Overcurrent and Overtime trips at the 90% level. –Set and document the DCPS and Rectifier Fault Detector protection settings at prescribed “headrooms” as defined in ISTP-001 for coil operation at 100% of the planned operating level.–Record that coil set’s allowable operating level and protection settings on the summary Test Plan Data Sheet.

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ISTP-001 Test Shots

• Select appropriate levels for the daily 50% and 100% test shots, and record on the summary Test Plan Data Sheet.

• Obtain approvals of the Test Plan Plan Data Sheet results and the daily test shot level selections as shown on the following test plan template.

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NSTX-UNSTX-U Engineering Operations January 28, 2015 15

ISTP-001 Test Plan Data Sheet

Example: Test Plan Template


Status of Power Systems• D-MG#1 has been fully restored to operation

• Rectifier reactivation (open circuit testing) is complete

• Rectifier Dummy Load testing is ready to start

– Will concentrate on systems needed for the CD4 plasma (TF, OH, PF3U/L, PF5)

• Expect to be ready to start ISTP-001 on March 23rd

• SPA’s, HF power supply (SPA primary power) will be recommissioned following CD4

• CHI Cap Bank is being restored to previous ops levels

– Control System will have to be re-evaluated

– CHI Handiscope is being recommissioned. MOV’s re-installed

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Status of Control Systems• Control Room is adequate to resume operations

– Workstation upgrades are pending

• Clock System, EPICS, MDSplus and networks are ready

• Junction Area DCPS & PCS/PSRTC are almost ready– The FCC DCPS integration will follow shortly (needed for ISTP-01)

• Magnetics and FCPC data acquisition ready

• T/C data acq software ready. Instrumentation cal pending

• NB data acq ready. NB T/C and NB timing soon

• Awaiting Diagnostics want/need list

• Test Cell network patch cables ready soon

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Status of Neutral Beams

• NB2 is preparing for the CD4 milestone– NB2 is under vacuum and ion sources are installed

– The He refrigerator is operating and making liquid

– Expect to be ready to cool down NB2 in late Feb.

– Low level ion source conditioning in early March, followed by beam conditioning and CD4 injection (late March as test cell access allows

• NB1 will not be recommissioned until after CD4

– NB1 is under vacuum and ion sources are installed

– Plan to cool down NB1 in parallel with NB2

– Expect to condition the NB1 ion sources during the vessel bake

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