Princeton University Review of the NCSX Project, March 2008 WBS5 - Central Controls and Computing March 13,2008 WBS5 Manager: Paul Sichta

Princeton University Review of the NCSX Project, March 2008

WBS5 - Central Controls and Computing

March 13,2008 WBS5 Manager: Paul Sichta

NCSX EIR, WBS5 Central Controls and Computing Page2

WBS5 Elements

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 interlocks.

• 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 Computing Overview

OPIsOPIs

OPIs

workstations

Diagnostics VLAN

NCSXMDSplus ServerSANTape

Archive

PPPL Network

Timing & SyncSystems

Diagnostics:•Magnetics•Visible Camera•E-Beam

PPPLCore Switch &

Internal Firewalls

HIGH PERFORMANCE FIBER CHANNEL

Offices

Control Systems VLAN

EPICS

EngineeringComputingSystems

NCSXComputing

Pool

4/20/07 PS

PLC VLAN

PLC

ProgrammableLogic

Controllers

wwwoffsite

collaborators

PPPLFirewall


Budget Partition

WBS5 Resources

WBS5 Budget $ 2.1 M

WBS54 T&S

WBS53DAS

WBS55 PCS

WBS56CSIS

WBS52CI&C

WBS51Network

Softwr/Elec Engineers: 3.6 yearsElec/Mech/Draft Techs: 3.1 years‘Materials & Services’: $ 432 K


State of the Design

• WBS5 engineering begins in August, 2009.

• The WBS5 Preliminary Design Reviews and Final Design Reviews are pending. – The interfaces, performance, and functional

requirements have not been documented.


Basis of Estimate• Labor:

– NSTX first plasma effort.– personal experience.– +25% for ‘green’ engineering talent.– field estimates (e.g. Eric Perry).

• M&S – recent purchases of similar equipment.– catalog prices.

• Design Complexity & Maturity – The systems are generally based upon the existing NSTX design, so

complexity is relatively low. However, the current workscope has neither Preliminary or Final design, so the maturity is medium.


WBS 51 – Networking & Fiber Optic Infrastructure

• an infrastructure of fiber optic cables that connect the main experimental areas. Not just for networks; All WBS can use these.

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


WBS 51- Cost & Schedule Detail

Labor Engineering: 210 hoursTechnician: 1012 hours

M&S

Contingency & Risk

Design Maturity: Medium Design Complexity: LowUncertainty Range: -10%/+15%

M&S Details (Exp Class 41, 43, & 37):Switches, etc.. 21,000$ NCSX_TC WAP 7,500$ media converters (6) 2,500$ Terminations, F/O patch panels & cable 12,000$ Fiber Optic cable 7,000$ misc. 18,000$

Total M&S 68,000$


WBS 52 – Central Instrumentation and Controls

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

• Like NSTX, will use the EPICS software.

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

• NCSX Test Cell audio and video support.


WBS 52- Cost & Schedule DetailLabor Engineering: 1204 hours

Technician: 1128 hours

M&S

Contingency & Risk


M&S Details (Exp Class 41, 43, & 37):NTC web cam (4) 6,000$

PC - appl. TBD (2) 6,000$

Linux soft IOC (3) 4,500$

OPC client & server HW/SW/TRNG (for T/C) 10,000$

EPICS server 7,500$

EPICS gateway (Use NSTX) -$

network/PLC interfaces (6) 8,000$

CSIS discrete i/o i/f 2,000$

PA equipment 2,000$ software development tools 5,000$

misc 20,000$

Total M&S 71,000$

Travel/training 2,000$


WBS 53 – Data Acquisition and Facility Computing

•Automated pre-shot device configuration and post-shot data acquisition.•Like NSTX, will use the MDSplus software.•A software infrastructure to catalog and manage experimental data for subsequent retrieval and analysis. •An Applications Program Interface (API) for commonly used software, such as C, IDL, Matlab, LabVIEW, and EPICS.•A pool of computers for data analysis.




M&S

Contingency & Risk


M&S Details: K$Linux MDSplus Server 3,000$

SAN - disk space (0.5 TB) 6,000$

network i/f (3) 2,000$

misc. 5,000$

PC appl. TBD (2) 6,000$

Total M&S 22,000$


WBS 54 – 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.• Support 64 hardware events.• Timing signals are low voltage, high speed, and electrically isolated,

equivalent to TFTR and NSTX.

Generation_1 of the event decoder has been in use on NSTX for several years. Gen_2 prototype testing is expected in FY08.




M&S

Contingency & Risk

Design Maturity: Medium Design Complexity: Medium Uncertainty Range: -15%/+25%

M&S Details (Exp Class 41, 43, & 37): K$Central Clock (PC, timers, SW)Complete prototype UNT (Universal Timer) 3,000$ Design & fab proto fiber optic xmit 10,000$ UNT Production (24 units) 24,000$ Clock Distribution modules production (12 units) 12,000$ cabling & connections 2,000$ software development tools 5,000$ misc 15,000$

Total M&S 71,000$


WBS 55 – 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 determine the computer’s outputs.

• The design of the system will be duplicated from the NSTX-based control system. – There will be no Plasma Control algorithms, only open-loop

Power Supply Control.

– WBS4 will specify the detailed requirements and algorithms for power supply control. WBS2 will provide the detailed requirements for gas injection control.




M&S

Contingency & Risk


M&S Details (Exp Class 41, 43, & 37): Basis of M&S EstimateRealtime computer 20,000$ host server 5,000$ networking/comm cards 5,000$ fiber optic cables 5,000$ VME crates (5) 15,000$ Systran (4 links) 25,000$ SAD - digitizers (320 chans, 10 units) 25,000$ FIMM (5) 10,000$ FPDP I/O (6) 8,000$ Sample clock dist. (5) 5,000$ PCLIM (0) (no D-site) -$ misc 15,000$

Total M&S 138,000$


WBS 56 – 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) entity 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 into hazardous areas, such as 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.




M&S

Contingency & Risk

Design Maturity: Low Design Complexity: LowUncertainty Range: -15%/+25%

M&S Details (Exp Class 41, 43, & 37): $Safety PLC 5,000$ Safety Comm. Units 10,000$ Safety I/O (C-Site FCPC, GDC, MPTS) 10,000$ Access Control i/f (6) 6,000$ Enclosures, conduit, hardware 10,000$ Fiber & copper cabling & parts 10,000$ misc. 15,000$

Total M&S 66,000$

Training & Travel 4,000$


WBS 57 – Control Room Facility

• 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 NCSX 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.

A ‘normal’ Control Room Facility will not be provided 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.


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

provides confidence that WBS5 can effectively support the NCSX project.

•The remaining work has informally been assessed. The effort that leads to the Final Design Reviews will produce the best estimate. •The technology risks are fairly low; the schedule risk is contingent upon the availability of key technical personnel due to specialized software. – The engineering staff designated for WBS5-work is currently fully

committed to operating NSTX.

Documents

Princeton University Review of the NCSX Project, March 2008 WBS5 - Central Controls and Computing March 13,2008 WBS5 Manager: Paul Sichta