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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F4E Industrial Colloquium Barcelona,Oct. 2008
The Core of ITER
Central Solenoid
Nb3Sn, 6 modules
29m
Cryostat
24 m high x 28 m dia.
Toroidal Field Coil
Nb3Sn, 18, wedged
Vacuum Vessel
9 sectors
Blanket
440 modules
Poloidal Field Coil
Nb-Ti, 6
Port Plug
~28m
heating/current drive, test
blankets
limiters/RH
diagnostics
Major plasma radius 6.2 m
Plasma Volume: 840 m3
Torus Cryopumps, 8
Plasma Current: 15 MA
Typical Density: 1020 m-3
Divertor
Typical Temperature: 20 keV
54 cassettes
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
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The ITER Site
Magnet power
convertors buildings
Cryoplant
buildings
Hot
cell
Tokamak building
Tritium building
•
•
Cooling towers
Area about 60 ha
Buildings up to 60m high and 200m long
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ITER Site Preparation
• The building construction permit was granted in
April, 2008.
• Building construction will begin in 2009.
Courtesy AIF
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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
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
B
Residue of systems,
jointly funded,
purchased by
ITER Project Team
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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
Construction
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 CODAC
Control, 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
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3 Tier Segregation
CODAC
PBS 4.5
Interlocks
PBS 4.6
Nucl.Safety
PBS 4.8
Comm. over
Networks
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Remote Access
CODAC - 4.5
Plant
Operation Zone
CIS - 4.6
CSS - 4.8
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A Different View
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CONTROL
INTERLOCK
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SAFETY
CODAC, CIS, CSS
PBS 4.5, 4.6, 4.7
PLANT SYSTEMS
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20
21
22
23
24
25
26
27
CODAC Integrates all Systems
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CODAC required equipment
• 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
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Interlock & Safety required equipment
• 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
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CODAC, Interlock & Safety required activities
• 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
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ITER IO Contract Strategy
2009
Q1
Q2
Q3
2010
Q4
Q1
Q2
Q3
2011
Q4
Q1
Q2
Q3
2012
Q4
Q1
Q2
Q3
2013
Q4
Q1
Q2
Q3
2014
Q4
Q1
Q2
Q3
2015
Q4
Q1
Q2
Q3
2016
Q4
Q1
Q2
Q3
2017
Q4
Q1
Q2
Q3
2018
Q4
Q1
Q2
Q3
2019
Q4
Q1
Q2
Q3
Q4
Start Integrated commissioning
Start of Tokamak assembly
First Plasma
I&C Support for Plant Systems
Assistance
Contracts
CODAC Support
Central Interlock and Safety Systems Support
Prototypesrealization
realization(x
(x10)
10)
Prototypes
CentralInterlock
InterlockSystems
Systemsrealization
realization(x(x
(x3)
3)
Central
Interlock
Systems
realization
3)
Central
CentralSafety
SafetySystems
Systemsrealization
realization(x(x(x3)
3)
Central
Safety
Systems
realization
3)
Central
CODAC
sub-systems
Development
CODAC
sub-systems
Development
CODAC
sub-systems
Development
CODAC
sub-systems
realization
(~x 10)
Procurement
Contracts
I&C
Plant
Systems
Development
I&C
Plant
Systems
Development
I&C
Plant
Systems
Development
I&C
Plant
Systems
realization
(~ x100)
In fund, contracts placed by ITER IO
In kind, contracts placed by ITER DAs
Task agreements, most probably no contracts with with Industry
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ITER Procurement
Model
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Fund versus In-Kind Procurement
IN FUND Procurement
IN KIND Procurement
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Procurement Allocation pg.1
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Procurement Allocation pg.2
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Procurement Allocation pg.3
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Procurement Allocation pg.4
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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
extracted form Integrated Project Schedule
IPS version 16-May-2008
•
•
YEAR
2008
2009
2010
2011
2012
No.
of
Procurements
13
32
22
11
6
Peak in preparing Procurement Arrangements: now to 2010
no new Procurement Arrangements after 2012
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CODAC Boundary
CODAC component
Provided to supplier
“Ambassador”
Procurement agreement
Factory-testing
Site acceptance
Commissioning
CODAC component
Provided to supplier
“Ambassador”
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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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Standards Requirements
Procurement cannot work without Standardization

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
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Standards ToBeDefined’s
Procurement 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 Sources
Procurement 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
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