ncsx ncsx preliminary design review ‒ october 7-9, 2003 g. oliaro 1 g. oliaro - wbs 5 central...

NCSX Preliminary Design Review‒October 7-9, 2003 G. Oliaro 1

NCSX

G. Oliaro - WBS 5 Central Instrumentation/Data Acquisition and Controls

Princeton Plasma Physics Laboratory

NCSX PDR

Princeton NJ 08543


NCSX

WBS 5 Project Elements

• WBS 5 will provide a computing and controls infrastructure for integrated NCSX operations.

• Includes distributed data acquisition, central controls, timing & shot cycle control, master control, real-time control systems, and central safety interlocks.

– WBS 51 TCP/IP network Infrastructure

– WBS 52 Central I&C

– WBS 53 Diagnostic Data Acquisition and Facility Computing

– WBS 54 Facility Timing and Synchronization

– WBS 55 Real Time Plasma and Power Supply Control System

– WBS 56 Central Safety and Interlock System

– WBS 57 Control Room Facility


NCSX

Primary Design Basis of WBS 5

• The NCSX Design Leverages the NSTX Technology and Experience Base and Provides a Low Risk - Cost Effective Implementation which requires essentially no new development.

• Commercial-Off-The-Shelf (COTS)

• Maximize Use of Open Source (Free) Software

• Just-In-Time Design & Purchase


NCSX

WBS 51TCP/IP network Infrastructure

• Provide the common 100Mbps backbone for all NCSX Data Communications using existing PPLnet and NSTX cable & hub infrastructure as much as possible.

• Provide a new Fiber Optic network infrastructure for machine platform environment

• Provide a total of ~24 new day 1 network drops for NCSX Facility at D-Site and C-Site

• Provide over 200 copper & fiber cables for Plasma Control, Central I&C, Interlocks Systems, Diagnostics and Timing and Synchronization


NCSX


Control RoomTest CellNBData Acquisition

C-Site RF

Junction AreaFCPC TF-Wing

MG Control Rm.MG High BayFCPC

FCPC Rm220

NSTX Control RoomPPLCC

DASS1

Disk ArchiverEng Hub

Fiber Optics

Eng Hub12 Strands

12 Strands

Fiber Optics

Fiber OpticsPPLCC

NSTX Cont Rm

FCPC

Fiber Optics

Eng Hub

Physics Hub-module

Eng Hub

MG

DAS

60 Strands

12 Strands

MG

48 Strands

S1

Fiber OpticsTest Cell

Fiber OpticsPPLCC

Fiber Optics

Fiber OpticsFCPC

DASFiber Optics

NSTX Cont RmFiber Optics

48 + 96 Strand plan

Fiber OpticsTest Cell

NCSX

Key

NCSX Network Infrastructureusing existing fiber and hub gear

(60 - 48 mm 12 sm)

(2/2/8)

(2s- PPLNet, 2s-Eng, 8s-avail)

(46 avail)

(2/2/8)

Fiber Optics

PC

T

T

T

T

T

DT

PC

T

Existing

New NCSX

Timing

Diagnostics

Plasma Control

Note: 2 Strands required per Ethernet circuit

PC

T

D

96- Strands for Diagnostics, 48- Strands for Network, (24- TC East, 24- TC West)

10-2-03 kwt

Physics Hub-module

Physics Hub-modulePhysics Hub

Physics Hub

Fiber OpticsD-Site

DASFiber Optics

60 + 60 Strands


NCSX


• Includes

– Engineering labor to design, configure, install & test

– Tech time for fiber pulls, optic and Copper terminations, AC Power

• Labor

– Engineering: 600 mhrs

– Tech: 1340 mhrs

– Drafting: 160 mhrs

• M&S

– Network hardware: $63.4K

– Fiber optic cable: $28.9K

• Estimate Basis: NSTX and PPLnet experience, catalog prices

• Start date: 3/06, Completion date: 2/07

• Contingency-low risk: 5%

• Total Estimated Cost: $417K


NCSX

WBS 52Central I&C

• Provide the infrastructure for remote control, monitoring, testing, trending, alarming, logging and coordination of engineering subsystems, including global-subsystem communications, through a common set of interfaces including web based interfaces.

– As on NSTX, use Experimental Physics and Industrial Control System (EPICS)

– Well Established DCS, World Wide User Community– Scales to hundreds of thousands of points

– Multi-Platform & OS Base

– open source


NCSX

WBS 52Central I&C

• Support for 5 Baseline Engineering Subsystems• WBS 21 Fueling Systems

• WBS 22 Vacuum Pumping Systems

• WBS 43 Magnet Power Systems

• WBS 62 Water Systems

• WBS 63 Cryogenic Systems


NCSX

WBS 52Central I&C

• Includes

– Engineering labor to design and configure EPICS, implement & test 5 engineering subsystems

• Labor


– Tech: 600 mhrs

• M&S

– PCs, IOCs, EPICS Hosts: $108.0K

• Estimate Basis: NSTX actual experience, catalog prices


• Contingency-low risk: 10%



NCSX

WBS 53Diagnostic Data Acquisition and Facility

Computing

• Provide hardware and software for distributed data acquisition, data analysis, display, and archival of shot based data. This WBS will be responsible for data management of Terabytes of data for the life of NCSX.

– Design Objectives

• All Data Available Online for Life of Machine

• Redundancy– High availability computer architecture

– Archive 3 Copies of Raw & Processed Data (same as NSTX)

• As on NSTX, use MDSplus (MIT) Set of Tools


NCSX


Computing

• Support 2 baseline diagnostics, Magnetics and Field Mapping

• Deploy Primary UNIX Based MDSplus Data Acquisition Server with small data store of under 1TB

• After the first year of operations augment PPPL Facility Tape Backup and Compute Cluster


NCSX


Computing

• Includes

– Engineering labor to design, configure & test the data acquisition system, initial diagnostic acquisition hardware, and master control

• Labor


• M&S

– Data acquisition hardware: $57.7K

• Estimate Basis: NSTX actual experience, catalog prices


• Contingency: 16%



NCSX

WBS 54Facility Timing and Synchronization

• Provide timing information (10MHz clock base) to all facility and diagnostic subsystems and provide the configuration control for the event driven shot cycle.

• A new PCI based Timing And Synchronization System designed for NSTX will be deployed for NCSX.

• Xilinx 200,000 logic gate FPGA

• Each board has 6 multi-function timing channels which mirror NSTX/TFTR functionality


NCSX

WBS 54Facility Timing and Synchronization

• Includes

– Engineering to design clock encoder and repeaters, deploy master shot cycle timing system

– Tech time for testing and construction

• Labor


– Tech: 700 mhrs

• M&S

– Timing system hardware: $24.8K

• Estimate Basis: NSTX actual experience


• Contingency: 14%



NCSX

WBS 55Real Time Plasma and Power Supply Control

System

• Provide real time power supply and plasma feedback control systems

– Use Existing SKY Computer Hardware and Software System In Use on NSTX

– Clone Software With Parameter Changes for NCSX

– Add 64 Digitizer Channels in NCSX Test Cell in Two Crates for real time data acquisition


NCSX


System

SB

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rate

Con

tro

ller

SB

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isk

Dri

ve

Clo

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FP

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Mer

lin

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AD

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AD

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Sys

tran

Fib

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tree

m

Clo

ck R

ecei

ver

FP

DP

Bre

ako

ut

Mer

lin

9421

AD

C

Sys

tran

Fib

reX

tree

m

Clo

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ver

FP

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lin

9421

AD

C

Sys

tran

Fib

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tree

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SB

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rate

Con

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SB

S D

isk

Dri

ve

Clo

ck R

ecei

ver

FP

DP

Bre

ako

ut

Mer

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C

Sys

tran

Fib

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tree

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For

ce C

rate

Co

ntro

ller

PC

Lin

k In

terf

ace

Mo

dule

T &

S M

odu

le

Sys

tran

Fib

reX

tree

m

Sys

tran

Fib

reX

tree

m

Mer

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9421

AD

C

Mer

lin

9421

AD

C

FP

DP

Bre

ako

ut

FIM

M

FIM

M

Sk

y II

Sk

y II

NSTX TEST CELL NCSX TEST CELL

JUNCTION AREA

ADC Clock ADC Clock

ADC Clock ADC Clock

Data

Data

Data

Data

FPDP

FPDP

FPDP

FPDP

FPDP

FPDP

FPDP

FPDP FPDP

FPDP

FPDP

Sys

tran

VM

E B

us

Ext

end

er

Sys

tran

VM

E B

us

Ext

end

er

Sys

tran

VM

E B

us

Ext

end

er

Sys

tran

VM

E B

us

Ext

end

erS

ystr

an V

ME

Bu

s E

xten

der

GasInjectionSystem

Class 4

Class 2i/3

Shared Plasma Control SystemNSTX/NCSX

R J Marsala02-26-02

Class 3

Class 2

New Puchaseor Fabrication


NCSX


System

• Includes

– Engineering design software & hardware reconfiguration

– Tech time wiring, construction, testing

• Labor


– Tech: 1200 mhrs

• M&S

– Real time communications hardware: $53.2K



• Contingency: 8%



NCSX

WBS 56Central Safety and Interlock System

• Includes

– Multi Site Fail Safe Design • Access Control at 2 Doors

• Door Interlocks for 6-8 doors

• E-Stop

• Interfaces to all day 1 subsystems

• Labor


– Tech: 1200 mhrs

• M&S

– PLC, badge readers, Kirk Hardware: $57K



• Contingency: 8%



NCSX

WBS 57Control Room Facility

• Includes– Installation of 4 workstation

tables wired for network and power for day 1 operations

– Installation of 12-15 equipment racks wired for day 1 network and power requirements

– Test Cell PA system

– Wireless Ethernet for the Physics network to support visitors and laptop computers

• Labor– Engineering: 320 mhrs

– Tech: 500 mhrs

• M&S– M&S: $10.5K



• Contingency: 3%



NCSX

WBS 57Control Room Facility

Isle

Ro

utin

g

NCSX Diag. Rack Area

Network Hubs&Fiber OpticPatch Panels

We

b C

as

ting

Eq

uip

/ PA

Sy

ste

m

Display Wall System

Ste

p D

ow

n

Ste

p D

ow

n

Ste

p D

ow

n

Ex

pa

ns

ion

Storage

OfficeM

ee

ting

Are

a

Removable

Note:

Main Platform Entrance NCSX Test Cell

PLC Area

NBIControlRoom

5-15-02 kwt

C-Wing Hallway

NCSX Diag. Rack AreaNCSX Diag. Rack Area

Future seats

Proposed Control Room Layout – Day 1 and future


NCSX

WBS 5 Cost & Schedule

Central I&C (WBS 5) cost summary by year of expenditure (WBS Level 2)

WBS Level 2 (k$) FY03 FY04 FY05 FY06 FY07 TOTAL51 - TCP/IP Infrastructure Systems $13 $13 $199 $193 $41752 - Central Instrumentation & Control $221 $353 $57453 - Data Acquisition & Facility Computing $184 $221 $40554 - Facility Timing & Synchronization $186 $158 $34455 - Real Time Plasma & Power $66 $223 $29056 - Central Safety Interlock $46 $353 $39957 - Control Room Facility $46 $71 $1175 - Central Instrumentation and Control $0 $13 $13 $947 $1,573 $2,546

ncsx ncsx preliminary design review ‒ october 7-9, 2003 g. oliaro 1 g. oliaro - wbs 5 central...

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