From: Timothy N. Stevenson Sent: Friday, September 24, 2004 10:59 AM To: George H. Neilson Cc: Wayne T. Reiersen; Joseph M. Carson; Alfred von Halle; Ronald L. Strykowsky; Lawrence E. Dudek; Gary J. Gibilisco; Jerome Siegel; MWILLIAMS Subject: C site NBI status 2004 Hutch, Ron requested that I write an update covering NBI work and status of hardware for the C site NBI system. During FY 2003 and 2004 significant progress has been made in resurrecting the PBXM NBI system for NCSX use. The following summarizes work and status for our future reference. PROJECT MANAGEMENT The NCSX NBI Cost Estimate, Schedule, and Technical Scope received thorough attention in adapting to each project requirement change. Interfaces were thoroughly explored and mapped into other WBSs also. Procedures have been developed to accomplish work safely in compliance with Laboratory policy and procedure, including work planning, job hazard analysis, Directive ES&H 5008, and others. Key procurements for equipment have been identified and costed for project consideration. Layout and routing plans have been made and identified to the project for all major NBI requirements. Engineering work for design elements of the NBI WBS have been started or conceptualized to the point were design work could begin when scheduled. Changes to the interconnecting duct have been identified to allow for clearances needed for the NBI duct, and Torus Interface Valve. Physics requirements have been discussed as needed to keep pace with project needs. POWER The AC Power System received much needed maintenance in the C site yard, including breakers, cabling, transformers, and insulation. The Pole Transformers for two systems were also rebuilt. The AC system was cleaned, tested, and then energized up to and including the NBI rectifiers. The rectifiers were exercised using the existing phase controls in the C site MG building adjacent to the rectifier cabinet. The ignitron rectifiers were cleaned and hipotted individually prior to system testing. The rectifiers pulsed properly into an open circuit. To accomplish this stage of testing, the local rectifier water system was reassembled, tested and operated. The Modulator cabinets were investigated and pressurized with deionized water. Several weak points were identified and redesigned using better technology borrowed from NSTX ion source water systems. all of the High Voltage Switch Tubes were checked and two identified as probably operable. The systems were high voltage tested. Many electronics repairs were accomplished also to support testing. The High Voltage Transmission Line concept has been explored and solutions to this critical need identified and evaluated. Significant improvements over the previous design have been achieved. The C site NBI Dummy Load was disassembled and moved from its storage location and relocated nearer to the Modulator vault area where it will see duty during construction, system testing, and for operations and maintenance during the life of the project. BEAMLINES All 4 PBXM beamlines were removed to the ESAT building for evaluation and storage during NCSX construction. Two beamlines have known leaks from prior use. Two were leakchecked and brought to operating vacuum. Cryopanels were also tested. Some refurbishment of seals has also taken place. After testing, the beamline most likely to see first duty was disassembled to evaluate the front box cryopanel installation and to correct calorimeter drive problems. The beamlines are stored in the ESAT Building pit Mechanical shop. DUCT Several key problems were identified and eliminated in the project layout models. First, the Torus Interface Valve modeled did not account for orientation and space precluded using the previous TIV in its required orientation. A replacement valve was identified and costed. Significant changes to the NBI duct ensued. Dimensions for bellows, electrical break, flanges, and the new TIV were submitted to careful analysis. Beamline, source, and flange centerlines were noted to be corrected on project drawings. Beam trajectory aiming lines and alignment techniques were explored to insure correct field of fire in the stellarator plasma. More work is needed in this area when the design of the duct is undertaken more formally. SOURCES A total of five sources exist for NCSX, one returned from Culham Lab, England and four from PBXM. Two have known leaks and problems. Two have been leakchecked. One of these has been identified as needing a water line repair leaving one source thought to be operable in its present state. The returned source is still awaiting evaluation. Filament procedures to make new source filaments are started. The sources are stored in the NBI shop in the Mockup Building, D site. CONTROLS Significant strides have been made in updating the controls scheme to modern technology. A computer and electronic interface input/output systems have been identified and evaluation begun to develop a LabView based controls platform. No technical hurdles have been encountered so far that would preclude the use of this scheme and some foundational implementation has been completed. Fault detection and telemetry schemes have been developed borrowing heavily on TFTR NBI technology now in use on NSTX. This approach will save many engineering, equipment, and testing dollars while taking advantage of the electronics repair capability presently supporting NSXT NBI. SERVICES Water, vacuum, cryogenics, and other services have received due attention in their respective design phases. The necessary auxiliary services envelope has been provided for in the NBI project and in the appropriate system interfaces in other WBSs. DRAFTING An extensive effort has been undertaken to update as built prints and old drawings that are fast approaching an unreadable state due to their age. Drafting has provided much support to take care of these ancient drawings and has nearly finished this phase of NBI drafting requirements. Naturally, many new drawings will be needed in the future for the NBI design as it develops, but a solid foundation has been established on which to build. In summary, the C site NBI system has been evaluated and prepared for adaptation to NCSX use. The system is ready for redesign where needed for project requirements. The NBI system is ready for reassembly at the pleasure of the NCSX project . Regards, Tim Tim Stevenson Principal Electrical Engineer Head of Experimental Heating Systems and NBI Operations PPPL Engineering and Technical Infrastructure Dept. LSB 316 Telephone (609) 243-2657