princeton university cost & schedule review of ncsx may 1-4, 2007 wbs5 – central controls and...
TRANSCRIPT
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
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)
(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
Door to Test Cell Platform
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)
(shaded area – no raised floor)
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
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
Timing & SyncSystems
Control PC’s:•Gas Injection•FCPC
Note: Shaded areas indicates external workscope.
WBS52 Cost & Schedule Detail
Activity Description Duration ECEM ECTB EMTB EASB EEEM EETB 41MS 43CC 37STK 35TRVL
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
WBS52ecem 760ectb 100emtb 240easm 0
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
OPIsOPIsOPIsOPIsOPIsOPIsOPIsOPIs
OPIsOPIsOPIsOPIs
Physicsworkstations
NSTX-DIAGNOSTICS VLAN
NCSXMDSplus ServerSANTape
Archive
SERVERS VLAN
Timing & SyncSystems
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
Note: Shaded areas indicates external workscope.
WBS53 Cost & Schedule Detail
Activity Description Duration ECEM ECTB EMTB EASB EEEM EETB 41MS 43CC 37STK 35TRVL
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 Cost & Schedule Detail
Activity Description Duration ECEM ECTB EMTB EASB EEEM EETB 41MS 43CC 37STK 35TRVL
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
Installation 90 days 40 80 120 40Test 14 days 40 40
WBS54ecem 660ectb 280emtb 120easm 40
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
WBS55ecem 620ectb 60emtb 0easm 0
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 Cost & Schedule Detail
Activity Description Duration ECEM ECTB EMTB EASB EEEM EETB 41MS 43CC 37STK 35TRVL
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
Installation 70 days 60 80 480 240Test 30 days 80 40
WBS56ecem 600ectb 80emtb 480easm 240
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.