ITER CODAC

F4E Industrial Colloquium Barcelona,Oct. 2008

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ITER CODAC

Wolf-Dieter Klotz

ITER Organization, Cadarache, France


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• ITER at a glance

•CODAC overall architecture

• ITER procurement model

•Standardization for

Instrumentation & Control (I&C)


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The Core of ITER

Toroidal Field CoilNb3Sn, 18, wedged

Central SolenoidNb3Sn, 6 modules

Poloidal Field CoilNb-Ti, 6

Vacuum Vessel9 sectors

Port Plug heating/current drive, test blanketslimiters/RHdiagnostics

Cryostat24 m high x 28 m dia.

Blanket440 modules

Torus Cryopumps, 8

Major plasma radius 6.2 m

Plasma Volume: 840 m3

Plasma Current: 15 MA

Typical Density: 1020 m-3

Typical Temperature: 20 keV

Fusion Power: 500 MW

Machine mass: 23350 t (cryostat + VV + magnets)- shielding, divertor and manifolds: 7945 t + 1060 port plugs- magnet systems: 10150 t; cryostat: 820 t

Divertor54 cassettes

29m

~28m


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Tokamak building

Tritium building

Cryoplant buildings

Magnet power convertors buildings

Hot cell

Cooling towers

The ITER Site

• Area about 60 ha• Buildings up to 60m high and 200m long


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ITER Site Preparation

Courtesy AIFCourtesy AIF

• The building construction permit was granted in April, 2008.

• Building construction will begin in 2009.

• The building construction permit was granted in April, 2008.

• Building construction will begin in 2009.


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International Cooperation

Seven Parties are involved in ITER Construction


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Construction Sharing

C

“Contributions in Kind”Major systems provided directly

by Parties

B

Residue of systems,jointly funded,purchased by

ITER Project Team

A

Systems suited only to Host Party industry- Buildings- Machine assembly- System installation- Piping, wiring, etc.- Assembly/installation labour

Overall cost sharing: EU 5/11, Others 6 Parties 1/11 each

Overall contingency up to 10% of total.

Total amount: 3577 kIUA (5079 M€-2007)

Overall costs shared according to agreed evaluation of A+B+C


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What makes ITER different?• Internationally exploited experiment

• “In-kind” procurement from 7 Parties

• Nuclear installation – new rules

• Reliability/availability higher than any

previous fusion project

• Continuous operation rather than pulsed

• Long timescale to construct, operate,

maintain


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Roles & Responsibilities for Roles & Responsibilities for ConstructionConstruction

ITER Organization Seven Parties

•Planning/Design •Integration / QA / Safety / Licensing / Schedule

•Installation •Testing + Commissioning

•Operation

•Detailing / Designing

•Procuring•Delivering•Support installation


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CODAC Architecture


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ITER seen by CODACControl, Data Access and

Communication

• ~150 ‘one off’ industrial plant systems • delivered ‘in-kind’ with corresponding

package• including

•science•diagnostics•plasma control•industrial control

• interconnected by dedicated networks

• ~150 ‘one off’ industrial plant systems • delivered ‘in-kind’ with corresponding

package• including

•science•diagnostics•plasma control•industrial control

• interconnected by dedicated networks


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3 Tier Segregation

CODAC PBS 4.5

Interlocks PBS 4.6

Nucl.Safety

PBS 4.8

Comm. overNetworks


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Remote AccessCODAC - 4.5

CIS - 4.6

CSS - 4.8

Plant Operation

Zone

Plant Operation

Zone


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A Different View

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CONTROL INTERLOCK SAFETY

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PLANT SYSTEMS

CODAC, CIS, CSSPBS 4.5, 4.6, 4.7

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80-100

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60-80

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<60

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unknown


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CODAC Integrates all Systems

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• Control room equipment

•Engineering and configuration workstations

•Scientific tools

•Remote control rooms management SW

•Mass data storage

•Configuration databases

•Central supervision system

•Central Alarm system

•Central timing system

•Plant interface systems

•Fast control systems

•Fast data acquisition systems

•Plant monitoring systems

•Slow control systems

•Industrial automation and control

• Process instrumentation

•Various type of networks

CODAC required equipment

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• Highly reliable and available PLC systems (SIL3 and class 2)

• Various type of transducers

• Various type of networks: TCP/IP, Safety field buses, monitored hardwired links

• Supervisory systems

• Long term safe data storage

• Safety operator’s desks

Interlock & Safety required equipment

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• I&C Support for plant systems

• Eng. support for CODAC

• Eng. support for Interlock&Safety

• Technical specifications

• Engineering Design

• Detailed Design

• Prof-of-concept with prototypes

• Procurement of equipment

• SW programming

• HW assembly

• HW and SW integration

• Factory testing

• Installation and Commissioning

CODAC, Interlock & Safety required activities


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I&C Support for Plant Systems

CODAC Support

Central Interlock and Safety Systems Support

I&C Plant Systems DevelopmentI&C Plant Systems DevelopmentI&C Plant Systems DevelopmentI&C Plant Systems realization (~ x100)

CODAC sub-systems DevelopmentCODAC sub-systems DevelopmentCODAC sub-systems DevelopmentCODAC sub-systems realization (~x 10)

Central Safety Systems realization (x 3)

Central Interlock Systems realization (x 3)

In fund, contracts placed by ITER IOIn kind, contracts placed by ITER DAsTask agreements, most probably no contracts with with Industry

Assistance Contracts

Central Safety Systems realization (x 3)Central Safety Systems realization (x 3)

Central Interlock Systems realization (x 3)Central Interlock Systems realization (x 3)

Start Integrated commissioning

First Plasma

Procurement Contracts

Start of Tokamak assembly

Prototypes realization (x 10)Prototypes realization (x 10)

ITER IO Contract Strategy


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ITER Procurement Model


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Fund versus In-Kind Procurement

IN KIND - Procurement

IN FUND - Procurement


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Procurement Allocation pg.1


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Plant System I&C Costs• Assume CODAC + Plant System I&C is 7% of total cost

• low end of typical range

• amounts to about ➟ 317M€

• CODAC (the supervisory part) + CIS + CSS is funded at ➟ 75M

• needs to be verified if CSS can be included

• A first (top-down) estimate of Plant System I&C inside procurement arrangements is therefore the remaining ➟ 242M€

• EU has ~32.9% of procurement, and probably a greater fraction (~42.2%) of Plant System I&C ➟ 102M€

• ~75% is dominated by engineering costs ➟ 76.8M€, rather than component costs ➟ 25.2M€


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Procurement Schedule

YEAR 2008 2009 2010 2011 2012

No.of

Procurements13 32 22 11 6

extracted form Integrated Project ScheduleIPS version 16-May-2008

• Peak in preparing Procurement Arrangements: now to 2010• no new Procurement Arrangements after 2012


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CODAC BoundaryCODAC componentProvided to supplier“Ambassador”

CODAC componentProvided to supplier“Ambassador”

Procurement agreementFactory-testingSite acceptanceCommissioning

Procurement agreementFactory-testingSite acceptanceCommissioning




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The Procurement Chain


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Integrated Project Teams in the DAs

• There is need for efficient communication between CODAC and the Domestic Agency.

• A model is suggested based on expert centers in the DAs.

• Experts from the different DAs could spend time in Cadarache to develop a full understanding of CODAC, while at the same time contributing to the development of CODAC itself.

• When in their Participant Teams, their knowledge can be passed on to the domestic industries or research institutions which, in turn, enhance the contact with the end-suppliers.


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Standardization for Instrumentation &

Control


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Reliability, Availability and Serviceability (RAS) Open Standards Conservative Solutions Commercial off-the-shelf (COTS) Minimize New Development Very easy to use Low Risk Fast Delivery Low Total cost per channel Bottom Up and Top Down Engineering to PLC

Standards RequirementsProcurement cannot work without Standardization


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Standards ToBeDefined’sProcurement cannot work without Standardization

• Plant System Controllers• PLCs• PCs/PCI• Chassis based systems: Compact PCI, PXI, ATCA, AMC, μTCA

• Open Software• Operating Systems (LINUX distribution)• SCADA frameworks: EPICS, TANGO• RT-OS

• Development Methodologies/Frameworks• PLC programming• Application IDEs: Eclipse, Control Studio, ...

• Network Standards based on Gbit Ethernet• Protocols over IP and TCP


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Standards How To - 3 SourcesProcurement cannot work without Standardization

• Plant System Host - will be provided by CODAC• works as gateway between Plant System and CODAC• contains communication middleware• maps plant data and protocols to a universal CODAC format

• miniCODAC - will be provided by CODAC• works as portable system for plant design and SAT (may be FAT as well)• contains SCADA tools to set up autonomous plant control systems

• Plant Control Design Handbook - is provided by CODAC• is the reference for mandatory and recommended standards


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The End

ITER CODAC

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