Princeton University Cost & Schedule Review of NCSX May 1-4, 2007 WBS5 – Central Controls and Computing Paul Sichta

Princeton University Cost & Schedule Review

of NCSX May 1-4, 2007

WBS5 – Central Controls and Computing

Paul Sichta

WBS5 ElementsThe NCSX Central Controls and Computing will provide the equipment and services for: 1) integrated and remote control; 2) data acquisition, analysis, and storage; 3) facility timing and synchronization; 4) central safety and access control; 5) a control room; and 6) a networking and fiber optic infrastructure.

• Network and Fiber Optic Infrastructure (WBS 51)

• Central Instrumentation and Control (WBS 52)

• Data Acquisition and Facility Computing (WBS 53)

• Facility Timing and Synchronization (WBS 54)

• Real Time Plasma and Power Supply Control (WBS 55)

• Central Safety and Interlock System (WBS 56)

• Control Room Facility (WBS 57)

NCSX Contingency Risk Matrix

WBS 5 – Locations

Typical Shot Cycle(ignore details, slide borrowed from NSTX)

T(-140) T(0) T(+460)

NCSX Computing Overview

OPIsOPIsOPIsOPIs

OPIsOPIs

workstations

DIAGNOSTICS VLAN

NCSXMDSplus ServerSANTape

Archive

SERVERS VLAN

Timing & SyncSystems

Diagnostics:•Magnetics•Visible Camera•E-Beam

PPPLCore Switch &

Internal Firewalls

HIGH PERFORMANCE FIBER CHANNEL

Offices

CS VLAN

EPICS

EngineeringComputingSystems

NCSXPool

4/20/07 PS

PLC VLAN

PLC

ProgrammableLogic

Controllers

Budget Partition

WBS5 Resources

WBS5 Budget ~ $ 1.3 M WBS54 T&S

WBS53DAS

WBS55 PCS

WBS56CSIS

WBS52CI&C

WBS51Network

CSD/EE Engineers: 2.4 yearsElec/Mech/Drft Technicians: 1.6 years‘Materials & Services’: $ 207 K

Basis of Estimate

• Labor:– NSTX first plasma effort.– Input from others (e.g. Eric Perry).– Personal experience.– 30% ‘green’, mentored engineering talent.

• M&S – recent purchases of similar equipment.– input from others (e.g. network group).– catalog pricing.

WBS5 Schedule

2008

Scheduling Targets

Startup testing: 22 January 2009First Plasma : 11 March 2009

WBS5 Labor Profile

-160

0

160

320

480

hour

s

EA//SB

EC//EM

EC//TB

EE//EM

EE//TB

EM//TB

Poly. (EC//EM)

~full time

NSTX Run

Individual WBS Elements

WBS51 – Networking & Fiber Optic Infrastructure

• an infrastructure of fiber optic cables that connect the main experimental areas. All WBS can use this.

• conventional (tcp/ip) networking equipment such as switches and routers and wireless-access-points (WAP).

Fiber Optic Infrastructure

Computer Room NCSX

TestCell

Control Room

A

ESAT(Robicon)

PPLCC NSTXControl Room

& FCC

D-SITE•FCPC•Junction Area•MG Control Rm

1 * 121 * 24250C

1 * 121 * 2420D

1 * 121 * 4830A

1 * 121 * 4850B

Run Single Mode

62.5/125Length (m)

1 * 121 * 24250C

1 * 121 * 2420D

1 * 121 * 4830A

1 * 121 * 4850B

Run Single Mode

62.5/125Length (m)

B

futurefuture

D

C

Other PPPL & NSTX

VLANS, and the www

48

6012

NOTESexisting fiberControl Room = 90 x 30Computer Room = 18 * 18

Note: Shaded areas indicates external workscope.

Control Room Facility’s Underfloor Cable Trayfor fiber optic and twisted-pair media.

Up

74'-5 7/8"

Up

Door to Test Cell Platform


NCSX TEST CELL

NCSX Control Room

NCSXComputing

Center

text text text text

A/C Unit(out-of-service) AC Power

text

text

text

text text text text text text text text text text text text text text text text text text

6 ft. x 3 ft. 6 ft. x 3 ft.

6 ft. x 3 ft.6 ft. x 3 ft.

5 ft. 5.7 in. x 2 ft. 3.4 in.

6 ft. x 3 ft.

6 ft. x 3 ft.

C221A

C221B

C221C

C221D

C221EC221H

C221F/G

(shaded area – no raised floor)


AC

Pow

er

text

6 ft. x 3 ft.

Hardhats

Hardhats

SS

Space reserved for equipment racks

Network Equipment

existingPPPL & NSTX

Networks

(24) TP

mixed VLANs(NSTX-CS, PPPL)

mixed VLANs(NSTX-CS, Diag, PPPL)

mixed VLANs(NSTX-CS, Diag, PPPL)

NCSX Control Room& Computing Center

S1/ESAT (Robicon)

NCSX Test Cell

wireless wireless

(24) TP, (8) FO

(24) TP, (8) FO

1 Gbituplink

100 Mbituplink

100 Mbituplink

(24) TP, (8) FO(24) TP

Network Port

Allocation

WBS51Cost & Schedule Detail

Activity Description Duration ECEM ECTB EMTB EASB EEEM EETB 41MS 43CC 37STK 35TRVL

WBS51 - Networking InfrastructurePreliminary Design 30 days 30Final Design 60 days 30 Procurement 60 days 20 25 10 4

Installation 60 days 60 20 490 240Test 14 days 20 20

hours $K

WBS51ecem 160ectb 20emtb 490easm 240

15.0$ Switches, etc..5.0$ NCSX_TC WAP1.8$ media converters 6)7.0$ Terminations, F/O patch panels & cable mgmt., patch cables5.0$ Fiber Optic cable

10.0$ misc.0 Op. spares

TOTAL 43.8$

Control Room Facility

Up

74'-5 7/8"

Up



NCSX TEST CELL

NCSX Control Room

NCSXComputing

Center

text text text text

A/C Unit(out-of-service) AC Power

text

text

text

text text text text text text text text text text text text text text text text text text

6 ft. x 3 ft. 6 ft. x 3 ft.

6 ft. x 3 ft.6 ft. x 3 ft.

5 ft. 5.7 in. x 2 ft. 3.4 in.

6 ft. x 3 ft.

6 ft. x 3 ft.

C221A

C221B

C221C

C221D

C221EC221H

C221F/G



AC

Pow

er

text

6 ft. x 3 ft.

Hardhats

Hardhats

SS

Space reserved for equipment racks

WBS57 – Control Room Facility

A ‘normal’ Control Room Facility will not be supplied for CD-4/MIE. However, facilities such as lighting, power, fire suppression, HVAC, basic network communications, and telephones will be provided (not part of the NCSX workscope). The extent to which the Control Room Facility will be outfitted under GPP (as a general-use area) is unclear at this time. GPP planning is in-process.

• The Control Room will support PPPL physicists, engineers, and collaborators. The former PLT and PBX control rooms are approximately 2200 sq. ft. and will be used as the NCSX main control room.

– For CD-4/MIE, WBS 5 will provide approximately six surplus office-style tables and chairs.

• The Computing Center will hold the bulk of networking equipment, NCSX server computers, and will be a fiber optic cable hub location for the WBS51 fiber optic cable infrastructure. Approximately 1200 sq. ft. of the former PLT DAS computer area will be used as the NCSX Computing Center.

WBS52 – Central Instrumentation and Controls

• Like NSTX, will use the EPICS software.

• Supervisory and integrated control of NCSX engineering subsystems and diagnostics.

• System provides data trending, alarm logging, operator displays, and integrated process control and monitoring functions for NCSX.

• NCSX Test Cell audio and video support.

Central Instrumentation & Controls

OPIsOPIsOPIsOPIsOPIsOPIsOPIsOPIs


IOCIOC

EPICSTrending

EPICS ‘host:•development•apps & databases

nstx:epicsgate02

EPICSGateway

nstx:epicsgate01

Engineeringworkstations

Central ClockIOC

OPC Server/Client

(for PLC comm)

NCSXIOC1

IOC

DiagnosticsIOC

nstx:nstxioc1

LabVIEW Gateway

nstx:nstxpc09

NSTX-CS VLAN

NSTX-DIAGNOSTICS VLAN

FIREWALL

LabVIEWSystems

ThermocouplePLC

NCSXMDSplus Servers

SANTape Archive

Other PPPL VLAN’s

NCSXMDSplus Servers

SANTape Archive

Other PPPL VLAN’s

Test Cell Audio/Visual


Control PC’s:•Gas Injection•FCPC


WBS52 Cost & Schedule Detail


WBS52 - Central I&CPreliminary Design 30 days 40Final Design 60 days 40Procurement 30 days 20 18 17 3EPICS Programming - Base 10 days 80EPICS Programming - VDCT db editor 30 days 40

IOC Programming - MDSplus data & events 30 days 120OPC - EPICS/PLC Interface 90 days 160 2 2Programming - misc. 90 days 100

Installation 60 days 40 100 240 120Test 14 days 40


3.0$ NTC web cam (4)5.0$ PC - appl. TBD (2)3.0$ Linux soft IOC (2)

10.0$ OPC client & server HW/SW/TRNG (for T/C)6.0$ EPICS server (use NSTX)8.0$ EPICS gateway7.0$ misc

0 Op. spares

TOTAL 42.0$

WBS53 – Data Acquisition and Facility Computing

•Like NSTX, will use the MDSplus software.

•A data management infrastructure to catalog and manage experimental results for subsequent retrieval and analysis.

•Automated pre-shot device configuration and post-shot data acquisition.

•A pool of computers for data analysis.

•An Applications Program Interface (API) for common data analysis software, such as C, IDL, Matlab, LabVIEW, and EPICS.

Data Acquisition and Facility Computing


OPIsOPIsOPIsOPIs

Physicsworkstations

NSTX-DIAGNOSTICS VLAN

NCSXMDSplus ServerSANTape

Archive

SERVERS VLAN


Diagnostics:•E-Beam•Magnetics•Visible Camera

PPPLCore Switch &

Internal Firewalls

HIGH PERFORMANCEFIBER CHANNEL

(future)

Offices

NSTX-CS VLAN

IOC

Central ClockIOC

IOC

DiagnosticsIOC

nstx:nstxioc1

LabVIEW Gateway

nstx:nstxpc09

NCSX(NSTX)Pool

4/20/07 PS




WBS53 - Data Acquisition & ManagementPreliminary Design 30 days 40Final Design 30 days 80Procurement 30 days 20 17 3 2Installation 30 days 40MDSplus Installation 20 days 80MDSplus Programming - Tree Design 20 days 80MDSplus Programming - Shot Sync 20 days 80MDSplus Programming - Dispatcher 30 days 160MDSplus Programming - Acquisition 20 days 80Programming - Misc. 60 days 160Test 14 days 40 40

WBS53ecem 880ectb 40easm 0

10.0$ Linux MDSplus Server 1.5$ SAN - disk space (500 GB)5.0$ misc. 5.0$ PC appl. TBD

0 Op. sparesTOTAL 21.5$

WBS54 – Timing and Synchronization

The Facility Timing and Synchronization System (T&S) will provide the hardware and software that facilitates the synchronization of hardware and equipment to the ‘microsecond’ degree, and computer programs on NCSX computers to the ‘seconds’ degree.

The T&S requirements include:• Local timing resolution of 100 nanoseconds, complex-wide

synchronism < 10 microseconds.• At least 64 hardware events.• Timing signals will be provided that are low voltage, high speed, and

electrically isolated, same as TFTR and NSTX.

• Generation_1 of the event decoder has been in use on NSTX for several years.

Facility Timing & Synchronization

Pre-ProgrammedEvent Generator

AsynchronousTiming Events

Event Encoder

Event Decoder

Event Decoder

Event Decoder

Event Decoder

ControlRoom

TestCell

PowrConvDARM

DistributionSubsystem

EncoderSubsystem

DecoderSubsystem

Digit izer Tr igger , Enabl e Gat e, Ignit r on Tr igger , Beam Dump, F r ame Gr abber

Manchester-Encoded Events

EPICSEvents

MDSplusEvents

ProgramA

ProgramB

ProgramC

Event s f or S of t war e,not r eal -t ime

New Universal Networked Timer



WBS54 - Facility Timing & Synch.Preliminary System Design 30 days 40Final SystemDesign 40 days 40Preliminary Design - Clock Dist. 20 days 20 40Final Design - Clock Dist. 30 days 20 120

Test - Clock Dist. 40 days 20 100 120Procurement 90 days 40 16 14 4UNT - Timing & Seq Emulation (FPGA Pgm) 90 days 160UNT - Device Driver Prog (EPICS/MDSplus) 120 days 160Central Clock (EPICS) Programming 30 days 80



40 -$ Central Clock (PC, timers, SW)3.0$ Complete prototype UNT (Universal Timer)

10.0$ Design & fab proto fiber optic xmit10.0$ UNT Production (10 units)6.0$ Clock Distribution modules production (6 units)5.0$ misc.-$

0 Op. SparesTOTAL 34.0$

WBS55 – Real Time Plasma and Power Supply Control

• For CD-4/MIE, the control system must provide synchronized control signals for the (approx.) seven NCSX power supplies, and one gas injector.

• The control methodology will be open-loop; no feedback will be used to modify the computer’s outputs.

• WBS4 will specify the detailed requirements for power supply control. WBS2 will provide the detailed requirements for gas injection control.

• A standard PC/LabVIEW-based system architecture will be used to fulfill the WBS55 systems.

Real Time Plasma and Power Supply Control (and Gas Injection)

PCrunning

LabVIEW

Scanning ADC

Multi-Channel DAC

Digital I/O

Timing & Sync

FacilityClock

NS

TX

-CS

VL

AN

triggers, gates, etc...

RobiconPower

Suppliesor

Gas Injector

•Remote Control•Software events•Data Archival

EngineeringWorkstation in Control Room

WBS55 Cost & Schedule DetailActivity Description Duration ECEM ECTB EMTB EASB EEEM EETB 41MS 43CC 37STK 35TRVL

WBS55 - Real Time ControlFCPC - Preliminary Design 30 days 40FCPC -Final Design 60 days 80FCPC - Procurement 60 days 20 6 7 1LabVIEW Programming 30 days 120FCPC PLC Integration - EPICS Prog. 30 days 40FCPC - Installation 60 days 40 40FCPC -Test 14 days 40 20GISRTC - Preliminary Design 30 days 40GISRTC -Final Design 60 days 20GISRTC - Procurement 60 days 20 6 5 1LabVIEW Programming 30 days 120GISRTC - Installation 60 days 20 20 24GISRTC -Test 14 days 20


12.0$ PC/LabVIEW control of C-Site Power Supplies12.0$ PC/LabVIEW control of Gas Injection2.0$ misc.-$

0 Op. sparesTOTAL 26.0$

WBS56 – Central Safety and Interlock System

The Central Safety Interlock System (CSIS) will provide system wide coordination of personnel and hardware interlocks.

• Each NCSX high-energy (or otherwise hazardous) subsystem will interface with the CSIS. The high-energy subsystem will be responsible for ensuring that the design of its (local) interlocks and safety features are adequate.

• The CSIS will provide a global E-Stop system, permitting individuals the ability to shutdown all hazardous equipment using E-Stop pushbuttons located throughout the NCSX complex.

• An access control system will be incorporated to control access to the Test Cell. Entry into these areas while “unsafe” will cause an automatic E-Stop.

• The CSIS will provide the NCSX Chief Operation Engineer (COE) with a centralized point of control to enable/disable, arm/disarm, and shutdown each NCSX high-energy (or otherwise hazardous) subsystem

• The CSIS M&S costs estimates are based on a cursory review of online pricing. A system configuration, parts list, and price quotes have not been developed.

Central Safety and Interlock System

Programming& MaintenanceTerminal

SafetyPLC

SafetyI/O

Test Cell East Side•(4) door mag sensor•(2) magnetic strike•(16) Indicator controls•(8) key/switches•(1) E-Stop (loop) input

DeviceNet Safety Communications

SafetyI/O

Test Cell West Side(8) door mag sensor(4) magnetic strike(16) Indicator controls(8) key/switches(1) E-Stop (loop) input

SafetyI/O

Control RoomCOE Controls•(16) Indicator controls•(16) key/switches•(buzzer)•(16) inputs from EPICS•(16) outputs to EPICS•(1) E-Stop (loop) input

SafetyI/O

futureSafety

I/O

future Safety

I/O

Robicon Area•(8) inputs•(8) outputs•(1) E-Stop input

HHFWArea•(8) inputs•(8) outputs•(1) E-Stop input

NBPC Area•(8) inputs•(8) outputs•(1) E-Stop input

Computing Center

future Safety

I/O

D-SiteFCPC

4/20/07 PS

Safety PLC Equipment



WBS56 - Central Safety & InterlocksRequirements, Codes&Standards 60 days 40Preliminary Design 30 days 40PLC Training 60 days 80 2 2Final Design 30 days 140Procurement 60 days 40 20 12 8PLC Programming 90 days 120



5$ travel & training5.0$ Kirk Locks, door sensors, e-stops5.0$ Safety Relays, enclosures

17.0$ Small Safety PLC (possible, requires further design)10.0$ cabling & conduit

TOTAL 42.0$

SummaryThe similarity to NSTX’s central controls and computing and the availability of an experienced and diverse staff affords

confidence that WBS5 will support the NCSX project.

•The remaining work has generally been identified. The effort that leads to the Final Design Reviews will produce the best estimate.

•The current contingency values (8-14%) were developed based upon the 2003 Preliminary Design Review’s values.

•Simultaneously supporting two ‘large’ machines is ‘new ground’ for the computer engineering staff. This situation presents a potential for impacting WBS5 schedule performance.

•The WBS5 workscope and cost have been substantially reduced since the CDR and PDR. Although the M&S costs could be further reduced, doing so would lessen the effectiveness of the staff which would tend to increase the labor costs.

Documents

Princeton University Cost & Schedule Review of NCSX May 1-4, 2007 WBS5 – Central Controls and Computing Paul Sichta