NCSX

G. Oliaro - WBS 5 Central Instrumentation/Data Acquisition and Controls Princeton Plasma Physics Laboratory NCSX PDR 5/22/02 Princeton NJ 08543

NCSX

Project Design Review ‒ October 7-9, 2003

G. Oliaro 1

WBS 5 Project Elements

NCSX

• • • • • • • WBS 51 TCP/IP network Infrastructure WBS 52 Central Facilities 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

Project Design Review ‒ October 7-9, 2003

G. Oliaro 2

Primary Design Basis of WBS 5

NCSX

• The NCSX Design Leverages the NSTX Technology and Experience Base and Provides a Low Risk - Cost Effective Implementation.

– Commercial-Off-The-Shelf (COTS) – – – Maximize Use of Open Source (Free) Software Just-In-Time Design & Purchase Steer Current NSTX Upgrades to Benefit NCSX • Network • • • CAMAC Replacement to CPCI & PCI Synchronization System Plasma Control (FIMM) – CAMAC Instrumentation Will Not Be Used In Design

NCSX

Project Design Review ‒ October 7-9, 2003

G. Oliaro 3

WBS 51

NCSX

• •

TCP/IP network Infrastructure

Common Backbone For All NCSX Data Communications Minimum 100Mbps with possible 1Gbps uplinks – Cost Base – Experience Base • • • • Use existing PPLnet backbone for Physics requirements Extend existing NSTX Engineering Network to lower costs Utilize existing firewall protection for Engineering network Provide Fiber Optic network infrastructure for machine platform environment • Provide a total of 12-24 new day 0 network drops for NCSX Facility at D-Site and C-Site

NCSX

Project Design Review ‒ October 7-9, 2003

G. Oliaro 4

WBS 51 TCP/IP network Infrastructure

NCSX

• Hub and Fiber Patch Point modifications in 5 PPPL Locations – D-Site FCPC, D-Site MG, C-Site S1, C-Site NCSX Control Room, PPLCC, and NSTX Control Room • • Use Existing Network C-Site to D-Site Fiber Optic Runs Share Engineering Subnet with NSTX to Allow Seamless Sharing of Common Resources • 2X60 fibers C-Site/D-Site for Plasma Control/Utility I&C, Timing and Synchronization • 96 Diagnostic Fiber Optic Cables Between Test Cell and Control Room

NCSX

Project Design Review ‒ October 7-9, 2003

G. Oliaro 5

WBS 52 Central Facilities I&C

NCSX

• Experimental Physics and Industrial Control System (EPICS) Distributed Control System (DCS) • Well Established World Wide User Community • Multi-Platform & OS Base • Scales to hundreds of thousands of points • Multiple I/O Capability – PLCs – – – Native EPICS Input Output Controller (IOC) VME, PCI, CPCI, … Interfaces to • Standard DCS Capabilities – Trending – – Alarms & Alarm Logging Graphical Mimics, Control & Monitoring

NCSX

Project Design Review ‒ October 7-9, 2003

G. Oliaro 6

WBS 52 Central Facilities I&C

NCSX

• NCSX/NXTX EPICS Parameter Comparison

NCSX Day 0 I/O Points Access to PLC I/O Points Internal/External EPICS records Number of Subsystems Control, Monitoring & Test Pages & Mimics Display Stations 200 100 500(?) 5 20 4 Current NSTX 2000 3000 8000+ 15 150 22 NCSX

Project Design Review ‒ October 7-9, 2003

G. Oliaro 7

WBS 52 Central Facilities I&C

NCSX

• • Support for 5 Day 0 Engineering Subsystems • • • • • WBS 21 Fueling Systems WBS 22 Vacuum Pumping Systems WBS 43 Magnet Power Systems WBS 62 Water Systems WBS 63 Cryogenic Systems Support for additional Subsystems after 1 st • • • • WBS 23 First Wall Conditioning, Thermocouples for Bakeout, GDC WBS 24 RF Heating Systems, ICH WBS 25 Neutral Beam Heating Systems WBS 42 Motor Generators year

NCSX

Project Design Review ‒ October 7-9, 2003

G. Oliaro 8

WBS 53 Diagnostic Data Acquisition and Facility Computing

NCSX

• Design Objectives – All Data Available Online for Life of Machine – – Access to All Engineering Process Control Data Redundancy • All Data on RAID 5 • • • Battery Backup Cache Dual Power Supply Auto Configured Hot Spare RAID 5 Disk – Archive 3 Copies of Raw & Process Data • Nightly Backup of Local Data Acquisition Computer & Central Data Server • Data continuously Maintained on Central RAID 5 Storage Array

NCSX

Project Design Review ‒ October 7-9, 2003

G. Oliaro 9

WBS 53

NCSX

Diagnostic Data Acquisition and Facility Computing

• • • • MDSplus (MIT) Set of Tools – Setup, Data Acquisition, Post-Processing Analyses, and Display – Pulsed Mode Experiments MDSplus is becoming “standard” in fusion research throughout the world Rich interface to platforms and languages – MDSplus Ported to VMS, Windows, UNIX – API’s for FORTRAN, C, Java, IDL, Visual Basic, and LabView.

PPPL will have a strong base of UNIX based MDSplus experience for NCSX design and startup requirements

NCSX

Project Design Review ‒ October 7-9, 2003

G. Oliaro 10

WBS 53 Diagnostic Data Acquisition and Facility

NCSX

•

Computing

Deploy 2 remote Data Acquisition I/O Processors (VME, CPI, CPCI) – 32 channels of magnetics sensors -16 bit,100KHz – – – E-Beam Measurements, 32 channels – 16 bit, 10 KHz 32-64 channels of digital input & output points One frame grabber • 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 System to 0.5 -1.0 PB – Augment PPPL Facility Compute Cluster

NCSX

Project Design Review ‒ October 7-9, 2003

G. Oliaro 11

WBS 54 Facility Timing and Synchronization

NCSX

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

– Xilinx XC2S200, Spartan II, 200,000 logic & RAM gate FPGA – – CeSys PCI XC2S board ~$400 Each board has 6 multi-function channels • Timing • • • • Timed Gate Time Interval Counter Clock Generator Timing & Sequencing – A Signal Conditioning and Interface board has been designed to allow full output capabilities, (TTL, transformer & opto isolated)

NCSX

Project Design Review ‒ October 7-9, 2003

G. Oliaro 12

WBS 54 Facility Timing and Synchronization

NCSX

• Single Clock Generator with Multiple Receiver System Guaranteed Simultaneity Event Codes Resolution NCSX 1us 256 100ns (10MHz) NSTX (TFTR 1970s) 20 us-1ms 16 1us (1MHz)

NCSX

Project Design Review ‒ October 7-9, 2003

G. Oliaro 13

WBS 55 Real Time Plasma and Power Supply Control System

NCSX

• • Use Existing Hardware and Software System In Use For NSTX – Two Merlin 4 333MHz PPC Boards (20+ GFLOPS Total) – Clone Software With Parameter Changes for NCSX • Power Supply RTC (PSRTC) Software • GA Plasma Control System (PCS) Software Add 64 Digitizer Channels in NCSX Test Cell in Two Crates – Systran FiberExtreme Fiber Channel (1 Gbps) to Power Supply Building – DMA (160MBps) Into Array Processor Using PPPL Developed FPDP Input Multiplexing Module (FIMM)

NCSX

Project Design Review ‒ October 7-9, 2003

G. Oliaro 14

WBS 56 Central Safety and Interlock System

NCSX

• Multi Site – Access Control at 2 Doors – – – Door Interlocks E-Stop Inputs from all Day 0 subsystems • Fail Safe Design – PLC monitoring and display – – – Outboard Mechanical Watch Dog Timers Hard Wire Backup – Planned At This Time UPS (?) • EPICS Monitoring

NCSX

Project Design Review ‒ October 7-9, 2003

G. Oliaro 15

WBS 57 Control Room Facility

NCSX

• 3200 sq.ft. Main Control Room & 600 sq.ft. Diagnostic Rack Space (Only a small portion of this will be used for Day ) operations) – Installation of 4 dual workstation tables wired for network and power.

– – – Installation of 12-15 equipment racks wired for network and power.

Test Cell PA system Wireless Ethernet for the Physics network to support visitors and laptop computers

NCSX

Project Design Review ‒ October 7-9, 2003

G. Oliaro 16

Conclusions

NCSX

• The NCSX Design Leverages the NSTX Technology and Experience Base and Provides a Low Risk - Cost Effective Implementation .

– Schedule Mirrors Actual NSTX Experience – – – Backend Loading Saves Cost and Optimizes Technology Choices PPPL IT Infrastructure Upgrades Today Will Benefit NCSX Technology Empowers Small (<10) Experienced NSTX Team

NCSX

Project Design Review ‒ October 7-9, 2003

G. Oliaro 17

WBS 5 Cost & Schedule

NCSX Central I&C (WBS 5) cost summary by expense class (WBS Level 3)

Total Estimated Cost ($k) excluding contingency Sum of cost CAT 2) Title I & II 2) Title I & II Total 3) Fabrication/Assembly (incl title III) 3) Fabrication/Assembly (incl title III) Total Grand Total expcl Labor/Other Labor/Other M&S WBS3 510 $38 $38 $257 $123 $379 $417 Pivot Table Key CAT - Cost Category WBS3 - Work Breakdown Structure Category(Level 3) expcl - Expense Class 520 $122 $122 $308 $145 $453 $574 530 $122 $122 $206 $77 $284 $405 540 $91 $91 $220 $33 $253 $344 550 $24 $24 $194 $72 $265 $290 560 $49 $49 $273 $77 $350 $399

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

WBS Level 2 (k$) 51 - TCP/IP Infrastructure Systems 52 - Central Instrumentation & Control 53 - Data Acquisition & Facility Computing 54 - Facility Timing & Synchronization 55 - Real Time Plasma & Power 56 - Central Safety Interlock 57 - Control Room Facility 5 - Central Instrumentation and Control FY03 $0 FY04 $13 $13 FY05 $13 $13 FY06 $199 $221 $184 $186 $66 $46 $46 $947 FY07 $193 $353 $221 $158 $223 $353 $71 $1,573 TOTAL $417 $574 $405 $344 $290 $399 $117 $2,546 570 Grand Total $24 $469 $24 $78 $469 $1,536 $14 $93 $117 $541 $2,076 $2,546

NCSX

Project Design Review ‒ October 7-9, 2003

G. Oliaro 18