PCDH v6
2011 release
•
•
•
•
•
•
Why to standardize, PCDH ?
Overview of ITER I&C
ITER standards for I&C
Interlock and Safety controls
I&C life-cycle and illustration
PCDH v6 status and v6/v5
PCDH v6 presentation – IO / Engage meeting - 18/02/2011
Page 1
PCDH v6
2011 release
•
•
•
•
•
•
Why to standardize, PCDH ?
Overview of ITER I&C
ITER standards for I&C
Interlock and Safety controls
I&C life-cycle and illustration
PCDH v6 status and v6/v5
PCDH v6 presentation – IO / Engage meeting - 18/02/2011
Page 2
This is ITER
PCDH v6 presentation – IO / Engage meeting - 18/02/2011
Page 3
This is the ITER Agreement
140 PA’s
80 include I&C
PCDH v6 presentation – IO / Engage meeting - 18/02/2011
Page 4
A bit of interface problems
PCDH v6 presentation – IO / Engage meeting - 18/02/2011
Page 5
A bit of interface problems
PCDH v6 presentation – IO / Engage meeting - 18/02/2011
Page 6
Missing Items
PCDH v6 presentation – IO / Engage meeting - 18/02/2011
Page 7
The control system can help to fix this
PCDH v6 presentation – IO / Engage meeting - 18/02/2011
Page 8
it identifies and may eliminate missing items
PCDH v6 presentation – IO / Engage meeting - 18/02/2011
Page 9
Control system is horizontal and connects
almost everything
PCDH v6 presentation – IO / Engage meeting - 18/02/2011
Page 10
it is involved in integration
PCDH v6 presentation – IO / Engage meeting - 18/02/2011
Page 11
and is the primary tool for operation
PCDH v6 presentation – IO / Engage meeting - 18/02/2011
Page 12
But this will work only if…
…all these links work
PCDH v6 presentation – IO / Engage meeting - 18/02/2011
Page 13
That 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.
PCDH v6 presentation – IO / Engage meeting - 18/02/2011
Page 14
PCDH v6 scope
Master document
Core PCDH (27LH2V)
Plant system control philosophy
Plant system control Life Cycle
Plant system control specifications
CODAC interface specifications
Interlock I&C specification
Safety I&C specification
Master document: (27LH2V v6.1)
• ITER baseline document,
• Provides all rules, is contractually binding,
• Is summited to PCR
PCDH v6 presentation – IO / Engage meeting - 18/02/2011
Page 15
PCDH v6 scope
Satellite documents
PCDH core and satellite documents: v6
INTERLOCK CONTROLS
Guidelines for the design of the PIS (3PZ2D2)
PIS, PS I&C and CIS integration
Guidelines for PIS configuration
Management of local interlock functions
Management of interlock data
PS CONTROL DESIGN
Plant system I&C architecture (32GEBH)
Methodology for PS I&C specifications (353AZY)
CODAC Core System Overview (34SDZ5)
I&C CONVENTIONS
I&C Signal and variable naming (2UT8SH)
ITER CODAC Glossary (34QECT)
ITER CODAC Acronym list (2LT73V)
OCCUPATIONAL SAFETY CONTROLS
Rules and guidelines for PSS design
Core PCDH (27LH2V)
Plant system control philosophy
Plant system control Life Cycle
Plant system control specifications
CODAC interface specifications
Interlock I&C specification
Safety I&C specification
NUCLEAR PCDH (2YNEFU)
CATALOGUES for PS CONTROL
Slow controllers products (333J33)
Fast controller products (345X28)
Cubicle products (35LXVZ)
Network products
PS CONTROL DEVELOPMENT
I&C signal interface (3299VT)
PLC software engineering handbook (3QPL4H)
Guidelines for fast controllers (333K4C)
CODAC software development environment (2NRS2K)
Guidelines for signal conditioning
Guidelines for I&C cubicle configurations
TEMPLATES and ILLUSTRATIONS
CWS case study specifications (35W299)
LCC and SCC prototypes
PS simulators: slow, fast, interlocks
PS SELF DESCRIPTION DATA
Self description schema documentation (34QXCP)
PS CONTROL INTEGRATION
The CODAC -PS Interface (34V362)
PS factory acceptance plan (3VVU9W)
ITER alarm system management (3WCD7T)
ITER operator user interface (3XLESZ)
Guidelines for archiving
Specifications for HPN
Specifications for time stamping
Legend
This document
Available and approved
Expected
(XXXXXX) IDM ref.
Satellite documents: Provide guidelines, recommendations
and explanations, but no mandatory rules.
PCDH v6 presentation – IO / Engage meeting - 18/02/2011
Page 16
PCDH v6
2011 release
•
•
•
•
•
•
Why to standardize, PCDH ?
Overview of ITER I&C
ITER standards for I&C
Interlock and Safety controls
I&C life-cycle and illustration
PCDH v6 status and v6/v5
PCDH v6 presentation – IO / Engage meeting - 18/02/2011
Page 17
Three vertical tiers, two horizontal layers
ITER I&C SYSTEM
Central I&C Systems
CODAC System
(PBS-45)
Central
Interlock System
(PBS-46)
Central
Safety Systems
(PBS-48)
Conventional Control
Control and monitoring
for all ITER PS
CODAC Networks
Central Interlock Network
Central Safety Networks
Plant System I&C
I&C Networks
Plant Conventional
Control System
Plant System
Host (PSH)
Plant System
Controller
Signal Interface
I&C structure
Segregation of ITER
I&C into 3 vertical tiers and
2 horizontal layers
Plant Interlock System
(PIS)
Plant Safety Systems
(PSS)
PIS Controller
PSS Controller
Signal Interface
Signal Interface
Interlock
Protects the investment
Independent network
and I&C
Safety
Protects personnel, and
environment Independent
network and I&C
Two train systems
PCDH v6 presentation – IO / Engage meeting - 18/02/2011
Page 18
Finite set of “Lego blocks”, which can
be selected and connected as required
PCDH v6 presentation – IO / Engage meeting - 18/02/2011
Page 19
Plant System I&C
is a deliverable by ITER member state (procurement arrangement).
Set of standard components selected from catalogue.
PCDH v6 presentation – IO / Engage meeting - 18/02/2011
Page 20
ITER Subsystem
is a set of related plant system I&C.
PCDH v6 presentation – IO / Engage meeting - 18/02/2011
Page 21
Plant Operation Network
PCDH v6 presentation – IO / Engage meeting - 18/02/2011
Page 22
Plant System Host
is 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
PCDH v6 presentation – IO / Engage meeting - 18/02/2011
Page 23
Slow Controller
is 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.
PCDH v6 presentation – IO / Engage meeting - 18/02/2011
Page 24
Fast Controller
is 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.
PCDH v6 presentation – IO / Engage meeting - 18/02/2011
Page 25
High Performance Computer
are dedicated computers (multi core, GPU) running plasma
control algorithms.
PCDH v6 presentation – IO / Engage meeting - 18/02/2011
Page 26
High 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.
PCDH v6 presentation – IO / Engage meeting - 18/02/2011
Page 27
Simplest 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 protocol
PSH receives absolute time from
TCN (4). The absolute time on the
Slow Controller can be set using NTP
with PSH as NTP server
PSH publish data, alarms and
logs to CODAC System / MiniCODAC 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
PCDH v6 presentation – IO / Engage meeting - 18/02/2011
Page 28
Simple Mixed Plant System I&C – Data flow
CODAC 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 COS
Fast 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)
PCDH v6 presentation – IO / Engage meeting - 18/02/2011
Page 29
PCDH v6
2011 release
•
•
•
•
•
•
Why to standardize, PCDH ?
Overview of ITER I&C
ITER standards for I&C
Interlock and Safety controls
I&C life-cycle and illustration
PCDH v6 status and v6/v5
•
•
•
•
Slow controllers
Fast controllers
I&C cubicles
Signals
PCDH v6 presentation – IO / Engage meeting - 18/02/2011
Page 30
ITER slow controllers:
Selected products
Next rack
Next rack
Medium range PLCs
High range PLCs
S7-300
S7-400
I/O interfaces are the same for high and
medium ranges PLCs (ET200 products),
only CPU and CPU chassis differ.
Fail safe SIL3 and high
availability PLCs
I/O interfaces, CPUs and chassis are
specific to this product line.
PCDH v6 presentation – IO / Engage meeting - 18/02/2011
Page 31
ITER slow controllers:
a large range of configurations for flexibility
Configuration 1
Configuration 2
The simplest configuration with I/O
cards within the S7-300 CPU rack
Generic architecture with remote IO
racks connected in serial architecture.
Configuration 3
Both serial and star configuration
may be mixed.
switch
Next Rack
Next Rack
PCDH v6 presentation – IO / Engage meeting - 18/02/2011
Page 32
ITER slow controllers:
Network and software development
Networks
• Ethernet 100 Mbits/s for S7 CPU to CODAC front-ends.
• PROFINET V2 for process interface within the S7.
• IEC 61850 for communication with equipments of power stations.
• Profisafe profile over Profinet for SIL-3 purposes.
Software development
• STEP 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)
PCDH v6 presentation – IO / Engage meeting - 18/02/2011
Page 33
ITER slow controllers:
e-ordering: implementation process
Siemens S7 PLC Ordering process (3Q6UQ3 v1.0)
PCDH v6 presentation – IO / Engage meeting - 18/02/2011
Page 34
ITER fast controllers:
I/O Bus and Industrial Form Factors
• PCDH 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:
– Ethernet
• The definition covers extremely large selection of different
industrial computers and form factors
• CODAC Standards include and full support is given to:
– Conventional PCI and PCI Express boards
– PICMG 1.3 SHB industrial computers
– PXI Express hybrid chassis for PXI, CompactPCI and PXI Express
I/O boards
– ATCA shelf and blades for high end data acquisition
PCDH v6 presentation – IO / Engage meeting - 18/02/2011
Page 35
ITER fast controllers:
PCI Express for modularity and interoperability
Connecting together different form factors of PCI and PCI Express based systems
6U CompactPCI Digitizer (not in catalogue)
Conventional PCI / cPCI Bus Extension
1 Gb/s Ethernet
-4U PICMG 1.3 chassis
-High-end CPU (2 x Xeon)
10 Gb/s Ethernet
Bus Extension
PCI-Express x4
- PXIe Chassis (hybrid)
Read
More
I/O :
- PXI / PXI Express
- CompactPCI
SD: Guideline for Fast Controllers (333K4C v1.3)
PCDH v6 presentation – IO / Engage meeting - 18/02/2011
Page 36
ITER fast controllers:
Basic Fast Controller Configurations and Ideas
• Separation in different physical units:
– CPU, network and – in some cases – solid state disks
– I/O cards and cabling
• Example:
Simple,
general
purpose
Fast
Controller
1 Gb/s Ethernet
2U PICMG 1.3 chassis
Optional
10 Gb/s Ethernet
Bus Extension
PCI-Express x1
PXIe Chassis
I/O
- PXI
- CompactPCI
- PXI Express
SD: ITER Catalogue of I&C Products – Fast Controllers (345X28 v1.3)
PCDH v6 presentation – IO / Engage meeting - 18/02/2011
Page 37
ITER I&C cubicles
configurations
PSE1
1
A1
PSE2
SCC
LCC
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.
PSE1
1
A1
PSE2
LCC + SCC
PCDH v6 presentation – IO / Engage meeting - 18/02/2011
Page 38
ITER I&C cubicles
configurations
PSE1
1
A1
PSE2
SCC +
remote IO
LCC
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.
PSE1
1
A1
PSE2
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.
Field bus
LCC
Targets for cubicle standardization: All LCCs and SCCs
cubicles whatever the plant system.
PCDH v6 presentation – IO / Engage meeting - 18/02/2011
Page 39
ITER I&C cubicles
Selected products
SD: SAREL cubicle catalogue for
plant system I&C (35LXVZ v2.3)
e- configuration: http://www.iterschneider-electric.com/
PCDH v6 presentation – IO / Engage meeting - 18/02/2011
Page 40
Signal interface
Scope
PCDH
Mechanical
interface
Plant
system
I&C
Signal
conditioning
device
Plug
Sensor
/act.
Controller
rack
Cabling interface
PS
Cabling interface
PS
Signal interface
• IO cabling rules, (335VF9)
• IO cable catalogue (355QX2)
• ITER EMC policy (42FX5B)
PCDH v6 presentation – IO / Engage meeting - 18/02/2011
Page 41
Signal interface
Signal standards
Sensors
• Voltage 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.
Actuators
• Output 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 signals
• Signal 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
•
•
•
sensors
Resistance thermometers: Pt100, 4 wires.
Thermocouples: type K, type N.
A passive low-pass input filter may be recommended for any T sensor.
Pneumatic signals
• Range: 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.
PCDH v6 presentation – IO / Engage meeting - 18/02/2011
Page 42
Signal 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 IEC 61000-5-2.
• Signal transmission schemes are proposed for each signal type.
DC
Sensor
0v
+
Transmitter
I&C
controller
-
Sensor configuration with
differential amplifier at
receiver level
0v
0v
360° contacts
CBN
DC
CBN
0v
2 resistors 1 MΩ ± 1%
Sensor
+
Transmitter
I&C
controller
-
CBN
360° contacts
CBN
Sensor configuration with
full differential
configuration
0v
SD: I&C signal interface (3299VT v4.4)
PCDH v6 presentation – IO / Engage meeting - 18/02/2011
Page 43
PCDH v6
2011 release
•
•
•
•
•
•
Why to standardize, PCDH ?
Overview of ITER I&C
ITER standards for I&C
Interlock and Safety controls
I&C life-cycle and illustration
PCDH v6 status and v6/v5
•
•
•
•
Naming convention
Software engineering
HMI and alarm handling
Common Operating States
PCDH v6 presentation – IO / Engage meeting - 18/02/2011
Page 44
Naming convention for variables 1/2
Controller CPU
Signal interface
Signal
conditionner
Signal cable
Signal
Variable
Signal
P
PS sensor/
actuator
Signal Name = PS Component Identifier : Signal Identifier
Variable Name = PS Function Identifier : Variable Identifier
•
•
•
Component 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
PCDH v6 presentation – IO / Engage meeting - 18/02/2011
Page 45
Naming convention for variables 2/2
FBS
26PHDL-HT-0001
26PHDL-VC-0009
26PHDL-VC-0010
P-100
F
Client 1
26PHDL-VC-0002
CWS
T
T
T
F
26PHDL-VC-0011
26PHDL-VC-0012
I-56
Client 2
26PHDL-VC-0008
26PHDL-VC-0013
CCWS1
26PHDL-PL-0001 26PHDL-VC-0004
26PHDL-VC-0014
P-111
Client 3
26PHDL-VC-0001
F
GN2
gas
supply
L
P
26PHDL-VC-0005
26PHDL-HX-0001
26PHDL-PZ-0001
T
26PHDL-VC-0003
PHTS
XXXX
26PHDL-VC-0007
26PHDL-VC-0006
Water storage and
treatment CVCS
DLHT
XXXX
Remote IO
Signals
26PHDL-VC-0001:FCVZ-CRC
26PHDL-VC-0001:FCVY1-CRC
26PHDL-VC-0001:FCVY2-CRC
26PHDL-MT-0002:TT-CRC
Signal cable
variables
CWS-PHTS-DLHT:VC1-FCVZ
CWS-PHTS-DLHT:VC1-FCVY1
CWS-PHTS-DLHT:VC1-FCVY2
CWS-PHTS-DLHT:MT2-TT
SD: Signal and plant system I&C variable naming conventions (2UT8SH v7.3)
PCDH v6 presentation – IO / Engage meeting - 18/02/2011
Page 46
Software development guidelines
CODAC Core
System
PLC
2
SD: Software Engineering and
Quality Assurance (2NRS2K v2.1)
•
SD: PLC software engineering
handbook (3QPL4H v1.3)
CODAC interface
8
4
7
9
12
11
7
•
System
Monitoring
PLC Core
Application
6
10
13
PLC
Interface
Fast
Controller
Interface(s)
PLC(s)
Fast
Controller(s)
11
5
3
Hardware Outputs/Inputs Interface
Equipments
PIS
PSS
COTS
Simulator
PLC user software engineering:
• Software architecture.
• Coding language.
• Templates.
• Conventions
Targets are interfaces mainly.
PCDH v6 presentation – IO / Engage meeting - 18/02/2011
Page 47
Human 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
PCDH v6 presentation – IO / Engage meeting - 18/02/2011
Page 48
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
PCDH v6 presentation – IO / Engage meeting - 18/02/2011
Page 49
COS: alignment with Operation Handbook
RD: Operations Handbook – 2 Operational States (2LGF8N v1.2).
PCDH v6 presentation – IO / Engage meeting - 18/02/2011
Page 50
PCDH v6
2011 release
•
•
•
•
•
•
Why to standardize, PCDH ?
Overview of ITER I&C
ITER standards for I&C
Interlock and Safety controls
I&C life-cycle and illustration
PCDH v6 status and v6/v5
PCDH v6 presentation – IO / Engage meeting - 18/02/2011
Page 51
INTERLOCK at ITER
Machine
(investment)
Integrity
≡
Design &
Operation
+
Interlocks
=
Investment
protection
≠
Instrumented
Machine
Protection
Nuclear
Safety
Personnel
Safety
Environmen
tal Safety
Access
PCDH v6 presentation – IO / Engage meeting - 18/02/2011
Page 52
The Interlock Control System (ICS)
ICS
PCDH v6 presentation – IO / Engage meeting - 18/02/2011
Page 53
Interlocks: PIS guidelines
PCDH v6 presentation – IO / Engage meeting - 18/02/2011
Page 54
Interlocks: 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…
PCDH v6 presentation – IO / Engage meeting - 18/02/2011
Page 55
Safety: PCDH-N
Plant 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,
• Seismic events : RCC-E adapted to ITER project,
• 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,
PCDH v6 presentation – IO / Engage meeting - 18/02/2011
Page 56
Nuclear 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)
PCDH v6 presentation – IO / Engage meeting - 18/02/2011
Page 57
PCDH v6
2011 release
•
•
•
•
•
•
Why to standardize, PCDH ?
Overview of ITER I&C
ITER standards for I&C
Interlock and Safety controls
I&C life-cycle and illustration
PCDH v6 status and v6/v5
PCDH v6 presentation – IO / Engage meeting - 18/02/2011
Page 58
PS I&C life cycle from PCDH
PS I&C Life Cycle: from design to operation & maintenance
PS design phase
Inputs for
I&C design
EDH
PCDH
PS manufacturing phase
PS I&C
design
PS
design
review
PCDH
PCDH
PS
manufacture
including I&C
PS integration phase
PS FAT
including
I&C
PCDH
PS on site
Installation
including
I&C
PCDH
PCDH
PS SAT
including
I&C
PS integrated
commissioning
Operation and
maintenance phase
PCDH
Operation &
maintenance
•
•
This life cycle is aligned with the ITER model for plant system life cycle.
Deliverables are proposed at completion of each phase.
PCDH v6 presentation – IO / Engage meeting - 18/02/2011
Page 59
I&C techs specs
In general
I&C tech specs = I&C scope + I&C rules & guidelines
I&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)
PCDH v6 presentation – IO / Engage meeting - 18/02/2011
Page 60
PS design activities
Scheme for pure functional PA type
Concept Design & Engineering studies
Concept Control Documents/Specifications
PA Documents (Main, Annex A & Annex B)
Concept Design Review
Signature of PA (Hand Off)
Preliminary Design & Engineering studies
Preliminary Control Documents/Specifications
Preliminary Design Review
Final Design & Engineering studies
Final Design Review
PA
Responsibility
I&C specs
IO
PA annex B + PCDH
Time
DA
I&C scope
A collaborative work involving DAs and IO is required to
get the most suitable specifications for both parties
PCDH v6 presentation – IO / Engage meeting - 18/02/2011
Page 61
I&C techs specs
Details as specified in Standard design Process
See: sdp working instructions content & maturity of main design engineering data
I&C tech spec deliverable
Document type
PCDH
ID
Plant system I&C architecture.
I&C
D1
Plant system I&C boundary definition.
IS
D2
Plant systems I&C integration plan.
Installation plan
D3
Plant system P&IDs, and electrical drawings and
diagrams.
P&ID, cabling
diagrams
D4
Controller(s) performance and configuration
requirements.
I&C
D5
List of inputs and outputs (I/O) of the I&C controllers.
I&C
D6
List of the Process Variables handled by the I&C
controllers.
I&C, IS
D7
Configuration of I&C cubicles.
I&C
D8
Description of plant system state machines.
Operation sequence
D9
PCDH v6 presentation – IO / Engage meeting - 18/02/2011
Page 62
Deliverables for I&C specifications
How to proceed for I&C architecture (D1)
51
ANT2
ANT1
TEST
51
HVPS
HVPS
HVRF
SPLR
FAFB
PROT
TLMN
MATC
PPTF
HPLS
51.ANT1.HVPS.MESM.L2
51.RS.1
51.ANT1.HVRF
51.ANT1.HVRF.MESM.L2
51.ANT1.FAFB.RFPW.L1
51.ANT1.HVRF.MESM.L1
High Volt control &
mgmnt
51.ANT1.FAFB.PROT.L2
51.ANT1.HVPS
51.ANT1.HVRF.INTF.L1
HVPS control &
mgmnt
51.ANT1.FAFB.PROT.L1
Amplitude
Mearement
Develop control diagrams for
each plant system function.
3.
Characterize the control
functions with properties as:
I/O, RT, SIL, ..
TEST
51.ANT1.PROT.OVRV.L1
51.RS.1
51.ANT1.HVPS.MESM.L1
2.
ANT1
51.HV.1
51.ANT1.HVCM.L1
Starting point: the FBS.
RF source
HVPS
51.ANT1.CONF.PARA.L1
HVDL
ANT2
51.HV.1
51.ANT1.CONF.PARA.L4
CORD
CONF
1.
Amplitude
Mearement
51.RS.1
51.ANT1.FAFB.CORD.L1
ICH fast feedback
Controller
51.ANT1.FAFB
51.ANT1.PCS.FAFB.L1
Amplitude
ICH coordination
CONF
CORD
51.ANT1.HVPS.PROT.L1
51.ANT1.FAFB.CORD.L2
HVPS
PROT interlock control FAFB
HVRF
SPLR
TLMN
MATC
HVDL
PPTF
HPLS
51.ANT1.PROT
51.ANT1.CORD
51.ANT1.FAFB.MONI.L3
Amplitude
monitoring
51.ANT1.FAFB.MONI.L1
51.ANT1.PCS.CORD.L1
51.ANT1.MON1
51.ANT1.MON1.L1
PCS
CODAC
47
45
PCDH v6 presentation – IO / Engage meeting - 18/02/2011
Page 63
Deliverables for I&C specifications
How to proceed for D1
CIS
CODAC
CODAC
CIS
Interlock
controller
Plant
System
Host 1
Plant
System
Host 1
Interlock
controller
Slow
controller
Signal
Interface
Signal
Interface
Slow
controller
Master
PS
coordination
Signal
Interface
Signal
Interface
Plant system I&C 2
Plant system I&C 1
PLANT SYSTEM
HVPS
RF source
51.HV.1
Amplitude
Mearement
51.ANT1.HVPS.MESM.L2
51.RS.1
51.ANT1.HVRF.MESM.L2
Amplitude
Mearement
51.ANT1.FAFB.CORD.L1
ICH fast feedback
Controller
I&C fct2
I&C fct3
51.ANT1.PROT
51.ANT1.CORD
51.ANT1.FAFB.MONI.L3
Amplitude
monitoring
I&C fct4
51.ANT1.FAFB.MONI.L1
51.ANT1.PCS.CORD.L1
4.
Assign control functions to
controllers in a consistent
way / properties and PS
operation.
5.
Build the I&C architecture
with all controllers + PSH.
Follow PCDH rules /
architecture
CODAC interface
51.ANT1.FAFB
Amplitude
interlock control
51.ANT1.HVPS.PROT.L1
51.ANT1.FAFB.CORD.L2
Controller
I&C fct1
51.RS.1
51.ANT1.PCS.FAFB.L1
ICH coordination
51.ANT1.PROT.OVRV.L1
51.ANT1.HVRF
51.ANT1.FAFB.RFPW.L1
51.ANT1.HVRF.MESM.L1
51.ANT1.HVPS
High Volt control &
mgmnt
51.ANT1.FAFB.PROT.L2
51.ANT1.HVPS.MESM.L1
HVPS control &
mgmnt
51.ANT1.FAFB.PROT.L1
51.ANT1.CONF.PARA.L1
51.ANT1.HVCM.L1
51.ANT1.HVRF.INTF.L1
51.HV.1
51.ANT1.CONF.PARA.L4
51.RS.1
HVPS
51.ANT1.MON1
51.ANT1.MON1.L1
PCS
CODAC
47
IO interface
45
PCDH v6 presentation – IO / Engage meeting - 18/02/2011
Page 64
I&C technical specifications
I&C architecture: status for PBS 62,63,65,43
•
D1A: PS functional break down, general requirements for I&C including
operation considerations.
 620000-CCS-SA5-02-Reinforced Concrete I&C Overview (3G38L3 v1.3) (current)
 630000-CCS-SA5-01 - 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 Nsafety functions. Are in progress at IO, need to be reviewed by DAs.
•
D1C: Text + diagrams, the complete functional and physical architecture.
PCDH v6 presentation – IO / Engage meeting - 18/02/2011
Page 65
I&C technical specifications
Other deliverables
•
D2: 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).
PCDH v6 presentation – IO / Engage meeting - 18/02/2011
Page 66
FAT 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 configuration
PCDH v6 presentation – IO / Engage meeting - 18/02/2011
Page 67
CODAC Standards illustrations
Specification of Cooling Water loop I&C use case (35W299 v3.2)
26PHDL-HT-0001
26PHDL-VC-0009
26PHDL-VC-0010
P-100
F
Client 1
26PHDL-VC-0002
T
T
T
F
26PHDL-VC-0011
26PHDL-VC-0012
I-56
Client 2
26PHDL-VC-0008
26PHDL-VC-0013
CCWS1
26PHDL-PL-0001 26PHDL-VC-0004
26PHDL-VC-0014
P-111
Client 3
26PHDL-VC-0001
F
GN2
gas
supply
L
P
26PHDL-VC-0005
26PHDL-HX-0001
26PHDL-PZ-0001
T
26PHDL-VC-0003
26PHDL-VC-0007
26PHDL-VC-0006
Water storage and
treatment CVCS
• Targets: I&C specs + standard illustration
• Development in progress (I&C + core CODAC)
PCDH v6 presentation – IO / Engage meeting - 18/02/2011
Page 68
PCDH v6
2011 release
•
•
•
•
•
•
Why to standardize, PCDH ?
Overview of ITER I&C
ITER standards for I&C
Interlock and Safety controls
I&C life-cycle and illustration
PCDH v6 status and v6/v5
PCDH v6 presentation – IO / Engage meeting - 18/02/2011
Page 69
PCDH v6 status
• 10th Jan 2011: External review announcement: IO + DAs
• 10th Jan - 28th Jan 2011: Review period
• 8th 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 experts
Bastien.Boussier@iter.org;
Jerry.Goff@iter.org;
David.Hamilton@iter.org;
Denis.Henry@iter.org;
Paul.Holik@iter.org;
Oleg.Kazachenko@iter.org;
Fabienne.Kazarian@iter.org;
Victor.Komarov@iter.org
Robin.LeBarbier@iter.org;
Supriya.Nair@iter.org;
Dharmesh.Purohit@iter.org;
Rene.Raffray@iter.org;
Felix.Rodriguez-Mateos@iter.org
Fabio.Somboli@iter.org;
Lennart.Svensson@iter.org;
George.Vayakis@iter.org;
Axel.Winter@iter.org;
Han.Xie@iter.org;
Yu.Yang@iter.org
DA I&C contact persons
djc@ornl.gov;
raju@ipr.res.in;
kawano.yasunori@jaea.go.jp;
mkpark@nfri.re.kr;
Harshad.Pujara@iter.org;
Filippo.Sartori@f4e.europa.eu;
i.semenov@iterrf.ru;
wusq@iterchina.cn;
IO PS RO
PCDH v6 presentation – IO / Engage meeting - 18/02/2011
Page 70
PCDH 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)
PCDH v6 presentation – IO / Engage meeting - 18/02/2011
Page 71
PCDH 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.
PCDH v6 presentation – IO / Engage meeting - 18/02/2011
Page 72
PCDH v6 / v5
• I&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
PCDH v6 presentation – IO / Engage meeting - 18/02/2011
Page 73
What is important for I&C
Compliance 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-cycle
Thank you for your attention
PCDH v6 presentation – IO / Engage meeting - 18/02/2011
Page 74