Transcript sichta.ppt

Princeton University
Cost & Schedule Review
of NCSX
May 1-4, 2007
WBS5 – Central Controls and Computing
Paul Sichta
WBS5 Elements
The 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
HIGH PERFORMANCE
FIBER CHANNEL
Tape
Archive
NCSX
MDSplus
Server
SAN
NCSX
Pool
SERVERS VLAN
Offices
PPPL
Core Switch &
Internal Firewalls
PLC VLAN
CS VLAN
DIAGNOSTICS VLAN
PLC
workstations
OPIs
OPIs
OPIs
Diagnostics:
•Magnetics
•Visible Camera
•E-Beam
Timing & Sync
Systems
EPICS
Engineering
Computing
Systems
Programmable
Logic
Controllers
4/20/07 PS
WBS5 Resources
WBS5 Budget ~ $ 1.3 M
CSD/EE Engineers: 2.4 years
Elec/Mech/Drft Technicians: 1.6 years
‘Materials & Services’: $ 207 K
WBS54
T&S
WBS53
DAS
WBS52
CI&C
WBS55
PCS
WBS51
Network
WBS56
CSIS
Budget Partition
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
Scheduling Targets
Startup testing: 22 January 2009
First Plasma : 11 March 2009
2008
WBS5 Labor Profile
NSTX Run
480
320
EA//SB
hours
EC//EM
EC//TB
160
EE//EM
EE//TB
~full time
EM//TB
Poly. (EC//EM)
0
A
M
R
-160
FY
07
AP
R
FY
07
A
M
Y
07
FY
N
JU
FY
07
L
JU
FY
07
AU
G
07
FY
SE
P
07
FY
8
9
08
09
08
09
08
09
08
09
08
08
09
09
08
09
08
08
09
09
08 Y 0
09 Y 0
08
09
FY
FY
FY
FY
F
FY
F
FY
FY
FY
FY
FY
FY
FY
FY
FY
FY
FY
FY
FY
FY
FY
FY
FY
P
P
T
B
B
N
L
N
L
R
R
V
V
R
R
N
N
Y
Y
G
G
EC
EC
C
C
A
A
O
O
A
A
FE
JU
JU
SE
FE
JU
JU
SE
D
JA
D
JA
O
AP
O
AP
N
M
AU
N
M
AU
M
M
T
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
48
Other
PPPL & NSTX
VLANS,
and the www
PPLCC
NSTX
Control Room
& FCC
60
12
D-SITE
Computer Control
Room
Room
NCSX
Test
Cell
A
D
B
•FCPC
•Junction Area
•MG Control Rm
future
future
C
NOTES
existing fiber
Control Room = 90 x 30
Computer Room = 18 * 18
ESAT
(Robicon)
Run
Length (m)
62.5/125
Single
Mode
A
30
1 * 48
1 * 12
B
50
1 * 48
1 * 12
C
250
1 * 24
1 * 12
D
20
1 * 24
1 * 12
Note: Shaded areas indicates external workscope.
Control Room Facility’s Underfloor Cable Tray
for fiber optic and twisted-pair media.
NCSX TEST CELL
6 ft. x 3 ft.
Door to Test Cell
Platform
Space reserved for equipment racks
Door to Test Cell
Platform
text
text
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Hard
hats
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Hard
hats
6 ft. x 3 ft.
6 ft. x 3 ft.
6 ft. x 3 ft.
NCSX Control Room
6 ft. x 3 ft.
6 ft. x 3 ft.
6 ft. x 3 ft.
Up
Up
SS
C221E
C221H
C221D
text
(shaded area –
no raised floor)
C221B
text
5 ft. 5.7 in. x 2 ft. 3.4 in.
(shaded area –
no raised floor)
text
NCSX
Computing
Center
C221F/G
text
text
text
text
text
AC Power
A/C Unit
(out-of-service)
74'-5 7/8"
C221C
AC Power
C221A
Network Equipment
wireless
existing
PPPL & NSTX
Networks
1 Gbit
uplink
100 Mbit
uplink
100 Mbit
uplink
wireless
mixed VLANs
mixed VLANs
(NSTX-CS, Diag, PPPL)
(NSTX-CS, Diag, PPPL)
(24) TP
(24) TP, (8) FO
(24) TP
(24) TP, (8) FO
NCSX Control Room
& Computing Center
NCSX Test Cell
S1/ESAT (Robicon)
mixed VLANs
(NSTX-CS, PPPL)
(24) TP, (8) FO
Network
Port
Allocation
WBS51Cost & Schedule Detail
$K
hours
Activity Description
Duration
ECEM
WBS51 - Networking Infrastructure
Preliminary Design
Final Design
Procurement
30 days
60 days
60 days
30
30
20
Installation
Test
60 days
14 days
60
20
WBS51
ecem
ectb
emtb
easm
EMTB
EASB
EEEM
EETB
41MS
25
20
20
490
240
160
20
490
240
$
$
$
$
$
$
15.0
5.0
1.8
7.0
5.0
10.0
0
TOTAL
ECTB
$
43.8
Switches, etc..
NCSX_TC WAP
media converters 6)
Terminations, F/O patch panels & cable mgmt., patch cables
Fiber Optic cable
misc.
Op. spares
43CC
10
37STK
35TRVL
4
Control Room Facility
NCSX TEST CELL
6 ft. x 3 ft.
Door to Test Cell
Platform
Space reserved for equipment racks
Door to Test Cell
Platform
text
text
text
text
text
text
text
text
text
text
text
Hard
hats
text
text
text
text
text
text
text
Hard
hats
6 ft. x 3 ft.
6 ft. x 3 ft.
6 ft. x 3 ft.
NCSX Control Room
6 ft. x 3 ft.
6 ft. x 3 ft.
6 ft. x 3 ft.
Up
Up
SS
C221E
C221H
C221D
text
(shaded area –
no raised floor)
C221B
text
5 ft. 5.7 in. x 2 ft. 3.4 in.
(shaded area –
no raised floor)
text
NCSX
Computing
Center
C221F/G
text
text
text
text
text
AC Power
A/C Unit
(out-of-service)
74'-5 7/8"
C221C
AC Power
C221A
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
NCSX
MDSplus
Servers
LabVIEW
Gateway
nstx:nstxpc09
Diagnostics
IOC
nstx:nstxioc1
LabVIEW
Systems
EPICS
Trending
nstx:epicsgate02
EPICS
Gateway
Tape
Archive
nstx:epicsgate01
SAN
Other PPPL VLAN’s
IOC
NSTX-DIAGNOSTICS VLAN
OPIs
OPIs
OPIs
OPIs
Engineering
workstations
OPIs
OPIs
OPIs
OPIs
EPICS ‘host:
FIREWALL
•development
•apps & databases
NSTX-CS VLAN
IOC
Central Clock
IOC
IOC
NCSX
IOC1
Thermocouple
PLC
OPC
Server/Client
Control PC’s:
•Gas Injection
•FCPC
Timing & Sync
Systems
(for PLC comm)
Note: Shaded areas indicates external workscope.
Test Cell Audio/Visual
WBS52 Cost & Schedule Detail
Activity Description
Duration
ECEM
WBS52 - Central I&C
Preliminary Design
Final Design
Procurement
EPICS Programming - Base
EPICS Programming - VDCT db editor
30 days
60 days
30 days
10 days
30 days
40
40
20
80
40
IOC Programming - MDSplus data & events
OPC - EPICS/PLC Interface
Programming - misc.
30 days
90 days
90 days
120
160
100
Installation
Test
60 days
14 days
40
40
WBS52
ecem
ectb
emtb
easm
EMTB
EASB
EEEM
$
$
$
$
$
$
$
3.0
5.0
3.0
10.0
6.0
8.0
7.0
$
42.0
41MS
43CC
37STK
17
2
100
240
120
NTC web cam (4)
PC - appl. TBD (2)
Linux soft IOC (2)
OPC client & server HW/SW/TRNG (for T/C)
EPICS server (use NSTX)
EPICS gateway
misc
Op. spares
EETB
18
760
100
240
0
0
TOTAL
ECTB
35TRVL
3
2
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
HIGH PERFORMANCE
FIBER CHANNEL
(future)
Tape
Archive
NCSX
MDSplus
Server
SAN
NCSX
(NSTX)
Pool
SERVERS VLAN
Diagnostics
IOC
LabVIEW
Gateway
PPPL
Core Switch &
Internal Firewalls
nstx:nstxioc1 nstx:nstxpc09
Offices
IOC
NSTX-DIAGNOSTICS VLAN
OPIs
OPIs
OPIs
OPIs
OPIs
OPIs
Physics
workstations
Diagnostics:
•E-Beam
•Magnetics
•Visible Camera
NSTX-CS VLAN
Timing & Sync
Systems
IOC
Central Clock
IOC
4/20/07 PS
Note: Shaded areas indicates external workscope.
WBS53 Cost & Schedule Detail
Activity Description
Duration
WBS53 - Data Acquisition & Management
Preliminary Design
Final Design
Procurement
Installation
MDSplus Installation
MDSplus Programming - Tree Design
MDSplus Programming - Shot Sync
MDSplus Programming - Dispatcher
MDSplus Programming - Acquisition
Programming - Misc.
Test
WBS53
ecem
ectb
easm
ECEM
EMTB
40
80
20
30 days
30 days
30 days
30 days
20 days
20 days
20 days
30 days
20 days
60 days
14 days
80
80
80
160
80
160
40
40
880
40
0
$
$
$
$
10.0
1.5
5.0
5.0
$
21.5
EASB
EEEM
EETB
41MS
17
40
0
TOTAL
ECTB
Linux MDSplus Server
SAN - disk space (500 GB)
misc.
PC appl. TBD
Op. spares
43CC
37STK
3
35TRVL
2
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
Encoder
Subsystem
Asynchronous
Timing Events
Pre-Programmed Ev en t s f o r S o f t war e,
Event Generator
n o t r eal -t ime
EPICS
Events
MDSplus
Events
Event Encoder
Manchester-Encoded Events
Control
Room
Distribution
Subsystem
Test
Cell
DARM
Powr
Conv
Program
A
Program
B
Program
C
Decoder
Subsystem
Event
Decoder
Event
Decoder
Event
Decoder
Event
Decoder
Digitizer Trigger, Enable Gate, Ignitron Trigger, Beam Dump, Frame Grabber
New Universal Networked
Timer
WBS54 Cost & Schedule Detail
Activity Description
Duration
ECEM
WBS54 - Facility Timing & Synch.
Preliminary System Design
Final SystemDesign
Preliminary Design - Clock Dist.
Final Design - Clock Dist.
30 days
40 days
20 days
30 days
40
40
20
20
Test - Clock Dist.
Procurement
UNT - Timing & Seq Emulation (FPGA Pgm)
UNT - Device Driver Prog (EPICS/MDSplus)
Central Clock (EPICS) Programming
40 days
90 days
90 days
120 days
30 days
20
40
160
80
Installation
Test
90 days
14 days
40
40
WBS54
ecem
ectb
emtb
easm
660
280
120
40
40 $
$
$
$
$
$
$
3.0
10.0
10.0
6.0
5.0
-
$
34.0
EMTB
EASB
EEEM
100
41MS
43CC
37STK
35TRVL
120
16
80
40
120
40
Central Clock (PC, timers, SW)
Complete prototype UNT (Universal Timer)
Design & fab proto fiber optic xmit
UNT Production (10 units)
Clock Distribution modules production (6 units)
misc.
Op. Spares
EETB
40
120
160
0
TOTAL
ECTB
14
4
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)
Facility
Clock
Engineering
Workstation in
Control Room
Timing & Sync
NSTX-CS VLAN
•Remote Control
•Software events
•Data Archival
triggers, gates, etc...
PC
running
LabVIEW
Scanning ADC
Multi-Channel
DAC
Digital I/O
Robicon
Power
Supplies
or
Gas Injector
WBS55 Cost & Schedule Detail
Activity Description
Duration
WBS55 - Real Time Control
FCPC - Preliminary Design
FCPC -Final Design
FCPC - Procurement
LabVIEW Programming
FCPC PLC Integration - EPICS Prog.
FCPC - Installation
FCPC -Test
GISRTC - Preliminary Design
GISRTC -Final Design
GISRTC - Procurement
LabVIEW Programming
GISRTC - Installation
GISRTC -Test
WBS55
ecem
ectb
emtb
easm
ECEM
40
80
20
120
40
40
40
40
20
20
120
20
20
30 days
60 days
60 days
30 days
30 days
60 days
14 days
30 days
60 days
60 days
30 days
60 days
14 days
EMTB
EASB
EEEM
$
$
$
$
12.0
12.0
2.0
-
$
26.0
20
24
PC/LabVIEW control of C-Site Power Supplies
PC/LabVIEW control of Gas Injection
misc.
Op. spares
EETB
41MS
43CC
37STK
35TRVL
6
7
1
6
5
1
40
20
620
60
0
0
0
TOTAL
ECTB
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
Robicon
Area
•(8) inputs
•(8) outputs
•(1) E-Stop input
HHFW
Area
•(8) inputs
•(8) outputs
•(1) E-Stop input
NBPC
Area
•(8) inputs
•(8) outputs
•(1) E-Stop input
future
Safety
I/O
Safety
I/O
future
Safety
I/O
D-Site
FCPC
future
Safety
I/O
DeviceNet Safety Communications
Safety
PLC
Programming
& Maintenance
Terminal
Computing Center
Safety
I/O
Control Room
COE Controls
•(16) Indicator controls
•(16) key/switches
•(buzzer)
•(16) inputs from EPICS
•(16) outputs to EPICS
•(1) E-Stop (loop) input
Safety
I/O
Test Cell
East Side
•(4) door mag sensor
•(2) magnetic strike
•(16) Indicator controls
•(8) key/switches
•(1) E-Stop (loop) input
Safety
I/O
Test Cell
West Side
(8) door mag sensor
(4) magnetic strike
(16) Indicator controls
(8) key/switches
(1) E-Stop (loop) input
4/20/07 PS
Safety PLC Equipment
WBS56 Cost & Schedule Detail
Activity Description
Duration
ECEM
WBS56 - Central Safety & Interlocks
Requirements, Codes&Standards
Preliminary Design
PLC Training
Final Design
Procurement
PLC Programming
60 days
30 days
60 days
30 days
60 days
90 days
40
40
80
140
40
120
Installation
Test
70 days
30 days
60
80
WBS56
ecem
ectb
emtb
easm
TOTAL
ECTB
EMTB
EASB
EEEM
EETB
5
5.0
5.0
17.0
10.0
42.0
43CC
37STK
35TRVL
2
20
80
40
480
240
600
80
480
240
$
$
$
$
$
$
41MS
travel & training
Kirk Locks, door sensors, e-stops
Safety Relays, enclosures
Small Safety PLC (possible, requires further design)
cabling & conduit
12
2
8
Summary
The 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.