nstx-u transition to operations al vonhalle princeton plasma physics laboratory nstx upgrade project...

NSTX-U Transition to OperationsNSTX-U Transition to Operations

Al vonHalle

Princeton Plasma Physics LaboratoryNSTX Upgrade Project

Office of Science ReviewLSB B318

October 2nd & 3rd, 2013

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

NSTX-UNSTX-U NSTX Upgrade Project – Office of Science Review – October 2-3 ,, 2013 2

Operations Engineering on NSTX

Administrative systems utilized for NSTX start-up and operations were originally developed for the TFTR D-T campaign.

The procedures and controls described in this presentation were used in the initial commissioning of NSTX in February, 1999, and have been exercised for every restart after an extended outage or maintenance/upgrade period.


Activity Certification Committee

Concerns regarding personnel, environmental, and machine safety are being addressed early in the planning to start experimental operations.

NSTX-U maintains an Activity Certification Committee (ACC) comprised of representatives from PPPL Engineering, Research, Safety, and the DOE Princeton Area Office to review newly installed subsystems before commissioning. System reviews are performed at completion of construction activities.

The ACC review will include:Review of the revised Safety Assessment Doc. (SAD) – Nov. 2013A review of design review documentation and chit resolutionInterviews with cognizant engineer(s)Plans for pre-operational & integrated system testingReview of safety/interlock systemsPhysical walk-downs of equipmentReview resolution of remedial steps recommended by ACC.


Operational Readiness Assessment (ORA)

A PPPL QA Audit of NSTX-U Startup Documentation will begin in April 2014.

The DOE Princeton Site Office (PSO) is arranging for a Operational Readiness Assessment (ORA) before the project moves to start-up.

The ACC and QA Audit reports are delivered to the members of the ORA, and the ACC team is made available to interface with the ORA as required.

A Two Step ORA is being considered. The NBI Upgrade may be reviewed in late summer 2014, the Vessel, Coils, Centerstack and Balance of Project in the Fall of 2014.

Safety Certificates allowing Power and then Plasma Operation will be issued upon the recommendations of the ORA.


Test Cell Access Control

Approvals and training required for unescorted access into the NSTX test cell (per OP-NSTX-12):

General Employee training (GET)Radiation Safety TrainingLockout/Tagout (Control of Energy Sources)Basic Electric SafetyKnowledge 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)


Managing Work in the Test Cell

Work Permits, approved by the PPPL 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.


Subsystem Prep for Operations

Proper system operation is ensured by an approved set of operations procedures:

Preoperational Test Procedures describe the equipment, methods and steps to bring sub-systems to an operational state. This includes all vendor supplied and project-designed safety/interlock checks.

Integrated System Test Procedures describe the steps to test and document operation or interactions of multiple systems.

System Operations Procedures specify the prerequisites, requirements and actions for operating individual systems.

General Operating Procedures coordinate the operation of multiple systems.


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-U.

The 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 annually for each restart after an NSTX outage with configuration changes (currently working on Rev. #14)

The procedure concludes with full power combined field test shots per the electromagnetic ISTP, and the subsequent initiation of the 1st plasma of the run period.


OP-NSTX-02 Excerpts

2. SCOPEThis procedure defines the criteria for confirming the completion of the preoperational testing of those work elements associated with plasma operations on NSTX:

Torus Vacuum Pumping System (TVPS)Torus pumpdown and testingCoil systems and associated hardwareAC Power SystemsMotor Generator SetsWater SystemsBakeout SystemControl SystemsNTC Safety Interlock SystemsEnergy Conversion Systems (ECS)Diagnostic SystemsGlow Discharge Cleaning (GDC) SystemLithium SystemsRF Systems (HHFW & ECH)Neutral Beam Injection Systems

Preparation of the Machine AreasIntegrated System Testing


OP-NSTX-02 Excerpts

3. REFERENCES (SOME EXAMPLES)PTP-ECS-39 FCPC Dummy load testsPTP-ECS-45 ECS HiPot TestsPTP-NB-11 NB Long Pulse Ion Source Startup ProcedurePTP-RF-44 NSTX ECH-PI Pre-Operations testing PTP-WS-08 NSTX De-Ionized Water/ System Testing

OP-ECS-245 FCPC Daily Startup/Shutdown Procedure OP-VV-732 Leak Checking of NSTX

OP-NB-229 Startup/operations of the 1070W helium refrigerator OP-RF-140 HHFW System 1&2 Operating ProcedureOP-KK-26 ECS Kirk key TestOP-KK-27 MG CO2 Kirk Key TestOP-KK-28 NSTX SLD Kirk Key TestOP-KK-90 ICRF System 3&4 Kirk Key and Local E-Stop Test

OP-G-151 Daily Hi-Pot Test of the NSTX Inner/Outer Vacuum Vessel

OP-MG-07 D-Site MG Operation in support of NSTX

AP-ECS-01 FCPC System AccessAP-RF-01 ICRH Sources 1 & 2 Access Procedure


OP-NSTX-02 Excerpts

A.5. COIL ENERGIZATION TESTING 5.1 Vacuum Vessel Hi-Pot successfully completed (NSTX-OP-G-151)

ATI: ___________________________5.2 NSTX prepared for operations per the daily start-up procedure (OP-

NSTX-14)ATI: ___________________________

5.3 NSTX prepared for HPP operations (OP-NSTX-15)ATI: ___________________________

5.4 ECS start up and Hi-Pot of the NSTX Coil Systems completed (OP-ECS-245) ATI: ___________________________

HOLD POINT (Steps A.1 through A.5.4 must be completed before proceeding with coil energization tests)

The following committee has reviewed the completion of preparations for Individual Coil Energization and concur that systems and procedures are in place and ready.

NSTX Project Eng. __________________________

Head, NSTX Ops ___________________________

Head, Engineering & Infrastructure ______________________

Individual Coil Energization may proceed per (ISTP-NSTX-01)


Allowable Operating 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 multiple times 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 and Research groups. (see example on next slide)


Operator Training Matrix

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

Chief Operating Engineers (COEs)Machine TechniciansVacuum TechniciansWater TechniciansField Coil Power Conversion TechniciansRadio Frequency System Operators

High Harmonic Fast-Wave SystemsElectron Cyclotron Heating systems

Neutral Beam OperatorsIon Source SystemsCryogenic SystemsBeam-line Vacuum opsNB Operations Shift Supervisor


Maintenance/Repair Planning

Detailed procedures to safely access vessels, power equipment, diagnostics, etc. are developed before starting up equipment. A lab-wide Lockout/Tagout procedure defines how sources of hazardous energy are controlled.

Periodic Preventive Maintenance is performed on:Safety Interlock Systems (OP-KK-**, OP-NSTX-**)Control Systems (MP-CCD-**)Energy Conv. Systems (MP-MG-**, MP-ECS-**)AC Power Systems (MP-AC-***)Heating Systems (MP-NB-**, MP-RF-**)Water and Bake-Out Sys. (MP-WS-**)Vacuum and Gas Inj Sys. (MP-VAC-**)Machine Weld/Bolt Insp. (MP-TOR-**)


Summary

The ACC has not only proved effective in identifying potential system problems, but has done so in a timely fashion that allows these problems to be addressed more efficiently than if found just before start-up.

PPPL’s Administrative Procedures and Routines are well suited to help guide NSTX-U through a successful start-up and into experimental operations.

The NSTX technical procedures for pre-operational testing, start-up and control of operating parameters have been updated and exercised annually for each NSTX run campaign, and are now being updated for the NSTX-U configuration.