4This is the ITER Agreement This is the ITER agreement. The project has been broken down in vertical slices which have been distributed to the ITER member states. There are 140 vertical slices and 80 of those includes instrumentation and control.140 PA’s80 include I&C
5A bit of interface problems There are a lot of complex interfaces between all those vertical slices.
7Missing ItemsAnd then we have everything which was forgotten in the ITER agreement
8The control system can help to fix this Our claim is that the control system can help to fix this. Why?
9it identifies and may eliminate missing items It identifies and may eliminate missing items. Good examples are the missing instrumentation for vacuum vessel and thermal shields. This has been identified and corrective actions are now being taken.
10Control system is horizontal and connects almost everything Because it is horizontal
11it is involved in integration It integrates. It brings the vertical slices together again.
12and is the primary tool for operation And it is the primary tool for operation and must therefore resolve all interface problems.
13But this will work only if… …all these links workBut this will only work if all these links work
14That is why we, CODAC team, concentrate all our effort on standards (PCDH) and implementation of those standards (CODAC Core System)What is PCDH?Plant Control Design Handbook (PCDH) defines methodology, standards, specifications and interfaces applicable to all ITER plant systems I&C.PCDH is an annex to Project Requirements (PR) and applicable to all Procurement Arrangements with I&C.PCDH is released at regular interval throughout the construction phase of ITER.PCDH is reviewed by I&C IPT.On cost; Integration of compliant systems will be predictable and allow a tighter schedule. Receiving a multitude of black boxes will make integration completely unpredictable and therefore also the schedule. System compliant to standards will enable maintenance. As an experimental facility it is essential to be able to modify and improve systems with gained experience during operation. Only then can the full potential of ITER be explored. Standards also reduce the required number of spare parts as well as required amount of people supporting ITER.
15PCDH v6 scope Master document Master document: (27LH2V v6.1) ITER baseline document,Provides all rules, is contractually binding,Is summited to PCR
16PCDH v6 scope Satellite documents Satellite documents: Provide guidelines, recommendations and explanations, but no mandatory rules.
17PCDH v6 2011 release Why to standardize, PCDH ? Overview of ITER I&C ITER standards for I&CInterlock and Safety controlsI&C life-cycle and illustrationPCDH v6 status and v6/v5I&C IPT Kick-off Meeting
18Three vertical tiers, two horizontal layers I&C structureSegregation of ITERI&C into 3 vertical tiers and2 horizontal layersConventional ControlControl and monitoringfor all ITER PSInterlockProtects the investmentIndependent networkand I&CSafetyProtects personnel, andenvironment Independentnetwork and I&CTwo train systems
19Finite set of “Lego blocks”, which can be selected and connected as required
20Plant System I&Cis a deliverable by ITER member state (procurement arrangement).Set of standard components selected from catalogue.
21ITER Subsystemis a set of related plant system I&C.
23Plant System Hostis an IO furnished hardware and software component installed in a Plant System I&C cubicle. There is one and only one PSH in a Plant System I&C. PSH is mainly used to interface the PS I&C with CODAC
24Slow Controlleris a Siemens Simatic S7 industrial automation Programmable Logic Controller (PLC). There may be zero, one or many Slow Controllers in a Plant System I&C. A Slow Controller runs software and plant specific logic programmed on Step 7 and interfaces to either PSH or a Fast Controller using IO furnished interface. A Slow Controller has normally I/O and IO supports a set of standard I/O modules. A Slow Controller has no interface to HPN. A Slow Controller synchronizes its time using NTP over PON. A Slow Controller can act as supervisor for other Slow Controllers.
25Not relevant for PBS 43-62-63-65 Fast Controlleris a dedicated industrial controller implemented in PCI family form factor and PCIe and Ethernet communication fabric. There may be zero, one or many Fast Controllers in a Plant System I&C. A Fast Controller runs RHEL and EPICS IOC. It acts as a channel access server and exposes process variables (PV) to PON. A Fast Controller has normally I/O and IO supports a set of standard I/O modules with associated EPICS drivers. A Fast Controller may have interface to High Performance Networks (HPN), i.e. SDN for plasma control and TCN for absolute time and programmed triggers and clocks. Fast Controllers involved in critical real-time runs a RT enabled (TBD) version of Linux on a separate core or CPU. A Fast Controller can have plant specific logic. A Fast Controller can act as supervisor for other Fast Controllers and/or Slow Controllers. The supervisor maintains Plant System Operating State.Not relevant for PBS
26High Performance Computer are dedicated computers (multi core, GPU) running plasma control algorithms.Not relevant for PBS
27High Performance Networks are physically dedicated networks to implement functions not achievable by the conventional Plant Operation Network. These functions are distributed real-time feedback control, high accuracy time synchronization and bulk video distribution.Not relevant for PBS
28Simplest possible Plant System I&C – Data flow CODAC System / Mini-CODAC send commands and, if required, publish data from other Plant System I&C to PSH using channel access protocolPSH receives absolute time from TCN (4). The absolute time on the Slow Controller can be set using NTP with PSH as NTP serverPSH publish data, alarms and logs to CODAC System / Mini-CODAC using channel access protocol.PSH and Slow Controller exchange data using standard interface provided by IO (3)The Slow Controller interfaces via signal interface to actuators and sensors and contains plant specific software and logic programmed on Step 7
29Not relevant for PBS 43-62-63-65 Simple Mixed Plant System I&C – Data flowCODAC System / Mini-CODAC may send commands and, if required, publish data from other Plant System I&C to Fast Controller using channel access protocol (6).Fast Controller may publish data, alarms and logs to CODAC System / Mini-CODAC using channel access protocol (7)PSH supervises Fast Controller (8) to manage COSNot relevant for PBSFast Controller could interface directly to Slow Controller using standard interface provided by IO (9) or indirectly through PSH by (8) and (3)SD: Plant System I&C Architecture (32GEBH v2.3)
30PCDH v6 2011 release Why to standardize, PCDH ? Overview of ITER I&C ITER standards for I&CInterlock and Safety controlsI&C life-cycle and illustrationPCDH v6 status and v6/v5Slow controllersFast controllersI&C cubiclesSignalsI&C IPT Kick-off Meeting
31ITER slow controllers: Selected products Next rackNext rackMedium range PLCsS7-300High range PLCsS7-400Fail safe SIL3 and high availability PLCsI/O interfaces are the same for high and medium ranges PLCs (ET200 products), only CPU and CPU chassis differ.I/O interfaces, CPUs and chassis are specific to this product line.
32ITER slow controllers: a large range of configurations for flexibility The simplest configuration with I/O cards within the S7-300 CPU rackConfiguration 2Generic architecture with remote IO racks connected in serial architecture.Next RackConfiguration 3Both serial and star configuration may be mixed.switchNext Rack
33ITER slow controllers: Network and software development NetworksEthernet 100 Mbits/s for S7 CPU to CODAC front-ends.PROFINET V2 for process interface within the S7.IEC for communication with equipments of power stations.Profisafe profile over Profinet for SIL-3 purposes.Software developmentSTEP 7 Professional version for user software development.Additional function block options if required for the plant system.Guidelines for software development included in PCDH v6.SD: Siemens S7 PLC Catalogue (333J63 v1.7)
34ITER slow controllers: e-ordering: implementation process Siemens S7 PLC Ordering process (3Q6UQ3 v1.0)
35Not relevant for PBS 43-62-63-65 ITER fast controllers:I/O Bus and Industrial Form FactorsPCDH defines CODAC selection for I/O bus:PCI bus (parallel)PCI-Express (serialized, PCI functions as payload)PCDH defines CODAC selection of communication method for interconnected systems:EthernetThe definition covers extremely large selection of different industrial computers and form factorsCODAC Standards include and full support is given to:Conventional PCI and PCI Express boardsPICMG 1.3 SHB industrial computersPXI Express hybrid chassis for PXI, CompactPCI and PXI Express I/O boardsATCA shelf and blades for high end data acquisitionNot relevant for PBSQuestion: VME and VPX systems are much better! Why you have selected the PCI bus, it if for office computers !Answer: The CODAC team has experience and respect with the other bus standards. For better configuration management only one base standard needed to be chosen. The de-facto market dominance of the serialized PCI Express and Ethernet communication methods suggest long life time and good availability. Fast Controller Guideline document (referred later on) explains more about choices made.Fast Controllers for PCDH campaign
36Not relevant for PBS 43-62-63-65 ITER fast controllers:PCI Express for modularity and interoperabilityConnecting together different form factors of PCI and PCI Express based systemsI/O :- PXI / PXI Express- CompactPCI- PXIe Chassis (hybrid)4U PICMG 1.3 chassisHigh-end CPU (2 x Xeon)1 Gb/s EthernetBus ExtensionPCI-Express x46U CompactPCI Digitizer (not in catalogue)Conventional PCI / cPCI Bus ExtensionNot relevant for PBS10 Gb/s EthernetRead MoreQuestion: Can I plug anything I want anywhere I want?Answer: Yes.SD: Guideline for Fast Controllers (333K4C v1.3)Fast Controllers for PCDH campaign
37Not relevant for PBS 43-62-63-65 ITER fast controllers:Basic Fast Controller Configurations and IdeasSeparation in different physical units:CPU, network and – in some cases – solid state disksI/O cards and cablingExample: Simple, general purpose Fast ControllerI/O - PXI- CompactPCI- PXI ExpressPXIe Chassis2U PICMG 1.3 chassis1 Gb/s EthernetOptional 10 Gb/s EthernetBus ExtensionPCI-Express x1Not relevant for PBSQuestion: in the picture, I can see a CPU in the PXI chassis, is it a National Instruments CPU, can I run Windows and Labview?Answer: there is no CPU but a National Instruments MXI card to connect the PXI chassis with an external, PCI Express enabled computer. No, you cannot run Windows, nor LabView. Next slide explains more about the development environment and options.SD: ITER Catalogue of I&C Products – Fast Controllers (345X28 v1.3)Fast Controllers for PCDH campaign
38ITER I&C cubicles configurations Configuration1: The I/O interfaces of the I&C controllers are connected to PSEs through signal conditioning interfaces housed in an SCC.Configuration2: This configuration is similar to configuration 1, but LCC and SCC are merged in order to optimise the space allocation.
39ITER I&C cubicles configurations Configuration3: In this configuration, the I&C controller of LCC is configured with a remote I/O rack installed in the SCC. The link between the LCC controller and the remote I/O rack may be fibre optic in the case of a long distance connection, strong EMI issues or any voltage isolation issue. Preferred configuration for Tokamak building.Configuration4: In this configuration, the PSE are connected to the I&C controller by a plant system I&C field-bus. The medium may be fibre optic.Targets for cubicle standardization: All LCCs and SCCs cubicles whatever the plant system.
40e- configuration: http://www.iter-schneider-electric.com/ ITER I&C cubiclesSelected productsSD: SAREL cubicle catalogue for plant system I&C (35LXVZ v2.3)e- configuration:
42Signal interface Signal standards SensorsVoltage range: 0V to +10V unipolar, -5V to +5V bipolar, -10V to +10V bipolar.Current range: 4mA to 20mA (16mA span). Signal polarity: positive with respect to signal common.ActuatorsOutput Current: 4mA to 20mA (16mA span). Signal polarity: positive with respect to signal common. Load resistance: 500 max. Preferred 250 .Output voltage: 0V to +10V unipolar or: -10V to +10V bipolar.Digital signalsSignal logic: positive for process control, negative for fail safe logics.Range: 24V DC referenced to plant system I&C cubicle earth. Maximum current depends on the galvanic isolation interface.T sensorsResistance thermometers: Pt100, 4 wires.Thermocouples: type K, type N.A passive low-pass input filter may be recommended for any T sensor.Pneumatic signalsRange: 0.2 to 1 bar for the current / pressure converters of the pneumatic proportional control valves.0 to 6-8 bars for the non proportional control valves.
43Signal interface EMC policy Single point earthing: For the Cryostat, the concept of single-point earthing has been selected and a loop Exclusion Zone (LEZ). Multipoint earthing: For other locations outside LEZ. Apply IECSignal transmission schemes are proposed for each signal type.Sensor configuration with differential amplifier at receiver levelSensor configuration with full differential configurationSD: I&C signal interface (3299VT v4.4)
44PCDH v6 2011 release Why to standardize, PCDH ? Overview of ITER I&C ITER standards for I&CInterlock and Safety controlsI&C life-cycle and illustrationPCDH v6 status and v6/v5Naming conventionSoftware engineeringHMI and alarm handlingCommon Operating StatesI&C IPT Kick-off Meeting
45Naming convention for variables 1/2 Signal Name = PS Component Identifier : Signal IdentifierVariable Name = PS Function Identifier : Variable IdentifierComponent identifier: ITER naming convention applies.Signal identifier: ITER naming convention based on ISA applies.Variable identifier: only guidelines are proposed by ITER, see SW HB
46Naming convention for variables 2/2 SD: Signal and plant system I&C variable naming conventions (2UT8SH v7.3)
47Software development guidelines SD: Software Engineering and Quality Assurance (2NRS2K v2.1)SD: PLC software engineering handbook (3QPL4H v1.3)PLC user software engineering:Software architecture.Coding language.Templates.ConventionsTargets are interfaces mainly.First doc addressing QA mainly. Second for PLC user software: Open the PLC doc and shortly commentI&C IPT Kick-off Meeting
48Human Machine Interface RD: (operation) ITER Human Factor Integration Plan (2WBVKU v1.1)SD: Philosophy of ITER Operator User Interface (3XLESZ v2.0)Operator User Interface Principles:Operator Tasks Analysis.Operator User Interface Detailed Design:Implementation.Operator User Interface Testing.Training.Expected: user manuals for HMI
49Expected: user manuals for alarm handling RD: ITER Human Factor Integration Plan (2WBVKU v1.1)SD: Philosophy of ITER Alarm System Management (3WCD7T v2.0)What is an Alarm?Alarm management lifecycle.Alarm philosophy principles.Key Design Principles for the alarm system.Alarm for redundant components.Alarms in case of dependant failures.Alarm Engineering Checklist.Rationalisation of the alarm system.Detailed Design of the alarm system.Expected: user manuals for alarm handling
50COS: alignment with Operation Handbook RD: Operations Handbook – 2 Operational States (2LGF8N v1.2).
51PCDH v6 2011 release Why to standardize, PCDH ? Overview of ITER I&C ITER standards for I&CInterlock and Safety controlsI&C life-cycle and illustrationPCDH v6 status and v6/v5I&C IPT Kick-off Meeting
54Interlocks: PIS guidelines Open the doc and shortly commentI&C IPT Kick-off Meeting
55Interlocks: PIS guidelines SD: Rules and Guidelines for the Design of the Plant Interlock System (PIS) (3PZ2D2 v1.2)PIS and PIN architecture.Redundancy sensors and actuators.Sharing of sensors and actuators between interlock and conventional control.Cabling rules for PIN.Powering rules for PIN.Rules for interfaces PIS – Conventional Control.Rules for interfaces PIS – Plant Safety System.Risk classification.etc…Open the doc and shortly commentI&C IPT Kick-off Meeting
56Safety: PCDH-NPlant Control Design Handbook for Nuclear control systems (2YNEFU v2.0)For all categories:IEC 61513, Nuclear power plants – Instrumentation and control for systems important to safety – General requirements for systems,IEC 60709, Nuclear Power Plants – Instrumentation and Control systems important to safety – Separation, except for some cabling rules which will be replaced by RCC-E rules,For Category A:IEC 60780, Nuclear power plants – Electrical equipment of the safety system –Qualification,IEC 60812, Technical Analysis for system reliability – Procedure for failure mode and effects analysis (FMEA),Seismic events : RCC-E adapted to ITER project,For Category B:IEC 60780,IEC 60987, Programmed digital computers important to safety for nuclear power stations,IEC 62138, Nuclear power plants – Instrumentation and control important for safety – Software aspects for computer-based systems performing category B or C functions,For Category C:IEC 62138,Open the doc and shortly commentI&C IPT Kick-off Meeting
57Nuclear safety: the main points to address Quality.PSS-N life-cycle.PSS-N safety requirements: safety class, single failure criterion, failsafe principle, power supplying, qualification to environmental conditions, seismic class, periodic tests, segregation rules.PSS-N functional specs.PSS-N architecture.Plant Control Design Handbook for Nuclear control systems (2YNEFU v2.0)Planned: Rules and Guidelines for the Design of the Plant Safety System (PSS)Open the doc and shortly commentI&C IPT Kick-off Meeting
58PCDH v6 2011 release Why to standardize, PCDH ? Overview of ITER I&C ITER standards for I&CInterlock and Safety controlsI&C life-cycle and illustrationPCDH v6 status and v6/v5I&C IPT Kick-off Meeting
59PS I&C life cycle from PCDH This life cycle is aligned with the ITER model for plant system life cycle.Deliverables are proposed at completion of each phase.I&C IPT Kick-off Meeting
60I&C tech specs = I&C scope + I&C rules & guidelines I&C techs specsIn generalI&C tech specs = I&C scope + I&C rules & guidelinesI&C Scope = PS dependent, implemented by PCDH deliverables of the design phase.I&C rules & guidelines = PCDH rules and guidelines for the full life-cycle.ITER design review procedure: what to review, when and with which maturity level.The I&C specifications as defined by PCDH are incorporated in the new version.At FDR the tech specs should be ready for manufacture by the industry.Design Review Procedure (2832CF v1.12) (current) (to be updated soon by v2.0)I&C IPT Kick-off Meeting
61PS design activities Scheme for pure functional PA type Concept Design & Engineering studiesConcept Control Documents/SpecificationsPA Documents (Main, Annex A & Annex B)Concept Design ReviewSignature of PA (Hand Off)Preliminary Design & Engineering studiesPreliminary Control Documents/SpecificationsPreliminary Design ReviewFinal Design & Engineering studiesFinal Design ReviewPATimeIODAResponsibilityPA annex B + PCDHI&C scopeI&C specsA collaborative work involving DAs and IO is required to get the most suitable specifications for both parties
62I&C techs specsDetails as specified in Standard design ProcessSee: sdp working instructions content & maturity of main design engineering dataI&C tech spec deliverableDocument typePCDH IDPlant system I&C architecture.I&CD1Plant system I&C boundary definition.ISD2Plant systems I&C integration plan.Installation planD3Plant system P&IDs, and electrical drawings and diagrams.P&ID, cabling diagramsD4Controller(s) performance and configuration requirements.D5List of inputs and outputs (I/O) of the I&C controllers.D6List of the Process Variables handled by the I&C controllers.I&C, ISD7Configuration of I&C cubicles.D8Description of plant system state machines.Operation sequenceD9
63Deliverables for I&C specifications How to proceed for I&C architecture (D1) Develop control diagrams for each plant system function.Starting point: the FBS.Characterize the control functions with properties as: I/O, RT, SIL, ..
64Deliverables for I&C specifications How to proceed for D1 Build the I&C architecture with all controllers + PSH. Follow PCDH rules / architectureIO interfaceI&C fct4I&C fct3I&C fct2I&C fct1CODAC interfaceControllerAssign control functions to controllers in a consistent way / properties and PS operation.
65I&C technical specifications I&C architecture: status for PBS 62,63,65,43D1A: PS functional break down, general requirements for I&C including operation considerations.CCS-SA5-02-Reinforced Concrete I&C Overview (3G38L3 v1.3) (current)CCS-SA Steel Frame Buildings (PBS63) - Plant System I&C Overview (3QTG8V v1.2) (current)Liquid_Gas_Distribution_PBS65_IC_Overview (35ETBE v1.1) (current)SSEN & PPEN I&C Overview (33L9QV v3.4) (current)D1B: Text + diagrams to elaborate on control function to be implemented, plus control function properties. As many D1Bs as required. Specific D1Bs for N- safety functions. Are in progress at IO, need to be reviewed by DAs.D1C: Text + diagrams, the complete functional and physical architecture.
66I&C technical specifications Other deliverablesD2: PS I&C boundary, implemented by Interface Sheets (IS). Is derived from D1. Is not I&C specific.D3: I&C Integration plan, guidelines available for I&C FAT (3VVU9W v1.2). Should be integrated to the PA/PS integration plan.D4: P&ID, electrical diagrams, see CIE/DO. Is not I&C specific.D5: Controller performance and configuration requirements: is derived from D1. Is I&C specific.D6: List of controller I/O; normally derived from P&IDs and electrical diagrams. Is I&C specific.D7: List of Process Variables; is implemented by IS 45-XX. CODAC template available at (3NTEU3 v1.0). Is I&C specific.D8: Cubicle configuration; is derived from D1 and D5. Guidelines will be provided soon. Is I&C specific.D9: Plant System state machines: see Operation Handbook (2LGF8N v1.2).
67FAT plans Plant System Factory Acceptance Plan (3VVU9W v1.2) Configuration#1: the procurement only concerns equipment with sensors and actuators, without any I&C hardware.Configuration#2: procurement concerns equipment with I/Os chassis and boards, without CPU.Configuration#3: procurement concerns equipment with conventional and possibly interlock controllers (i.e. I/Os and CPUs), without PSH and mini-CODAC.Configuration#4: procurement concerns equipment, conventional and possibly interlock controllers and PSH + mini-CODAC .Campaigns split in scenarios depending on PS conf.PS full plan to be defined depending on configurationOpen the doc and shortly commentI&C IPT Kick-off Meeting
68CODAC Standards illustrations Specification of Cooling Water loop I&C use case (35W299 v3.2)Open the doc and shortly commentTargets: I&C specs + standard illustrationDevelopment in progress (I&C + core CODAC)I&C IPT Kick-off Meeting
69PCDH v6 2011 release Why to standardize, PCDH ? Overview of ITER I&C ITER standards for I&CInterlock and Safety controlsI&C life-cycle and illustrationPCDH v6 status and v6/v5I&C IPT Kick-off Meeting
70PCDH v6 status 10th Jan 2011: External review announcement: IO + DAs 10th Jan - 28th Jan 2011: Review period8th Feb 2011: Review report – answer to comments – update the doc.PCR initiated.End Feb 2011: PCDH 6.1 and satellite docs release.IO I&C expertsDA I&C contact personsIO PS RO
71PCDH v6 set of documents document updated / v5 Baseline document: PCDH (27LH2V v6.1) provides all rules, is contractually binding, is summited to PCR.Satellite documents: provide guidelines, recommendations and explanations, but no mandatory rules. Updaded documents / v5.Plant System I&C Architecture (32GEBH v2.3)Methodology for Plant System I&C specifications (353AZY v3.3)Signal and plant system I&C variable naming conventions (2UT8SH v7.3)Self-description schema documentation (34QXCP v2.1)The CODAC – Plant System Interface (34V362 v2.0)Guideline for Fast Controllers, I/O Bus Systems and Com. (333K4C v1.3)I&C signal interface (3299VT v4.4)Siemens S7 PLC Catalogue (333J63 v1.7)ITER Catalogue of I&C Products – Fast Controllers (345X28 v1.3)Plant Control Design Handbook for Nuclear control systems (2YNEFU v2.1)
72PCDH v6 set of documents new documents Satellite documents: provide guidelines, recommendations and explanations, but no mandatory rules. New documents / v5.CODAC Core System Overview (34SDZ5 v2.5)ITER CODAC Glossary (34QECT v1.2)ITER CODAC Acronyms (2LT73V v2.2)Plant System Factory Acceptance Plan (3VVU9W v1.5)Philosophy of ITER Alarm System Management (3WCD7T v2.0)Philosophy of ITER Operator User Interface (3XLESZ v2.0)Specification of Cooling Water loop I&C use case (35W299 v3.3)Software Engineering and Quality Assurance (2NRS2K v2.1)PLC software engineering handbook (3QPL4H v1.3)SAREL cubicle catalogue for plant system I&C (35LXVZ v2.3)Rules and Guidelines for the Design of the Plant Interlock System (PIS) (3PZ2D2 v2.4)All are available on IDM except the master doc.All have been submitted to the external review.
73PCDH v6 / v5I&C technical specs: Alignment with new version on design review procedure.New naming convention for variables: introduction of functional description.COS: Alignment with Operation Handbook.New sections for HMI and alarm handling guidelines.HW standards: Cubicle catalogue (recommended products).Signal interface: Alignment with EMC policy and cabling rules.Software development: New guidelines.Interlocks: new guidelines for PIS design.Safety: Simplification of PCDH-N.FAT: guidelines for I&C scenarios.Case studies: improvement on ICH and new CWS Case Study, illustration only
74Thank you for your attention What is important for I&CCompliance with PCRD requirements for:The plant system I&C architecture rules.The interface with CODAC systems: physical and functional.The HW standards: PLC, fast control technologies, cubicles, signal format.The SW standards: PLC, fast controls, EPICS, CODAC systems, …The naming conventions: components, signals, variables, …ITER EMC and radiation policy applicable to I&C equipment.Applicable standards for nuclear safety controls.The jointly IO/DA work along the I&C life-cycleThank you for your attention