page 1 iter control system – meeting – date © 2013, iter organization the control system of...
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Page 1ITER Control System – meeting – date
© 2013, ITER Organization
The Control System of ITER Overview, status and PS integration
CODAC teamITER IO
Page 2ITER Control System – meeting – date
© 2013, ITER Organization
What the ITER Control System is ?
Why do we need standards ?
What are these standards ?
How to get informed about ?
How to procure and use them ?
How to test and integrate the I&C systems ?
What is already done by IO and is expected ?
Everything you always wanted to know about ITER I&C but were afraid to ask
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© 2013, ITER Organization
Introduction toThe Control System of ITER
PCDH v7
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© 2013, ITER Organization
CODAC System (PBS-45)
Pla
nt
Sys
tem
I&C
CentralInterlock System
(PBS-46)
CentralSafety Systems
(PBS-48)
Central I&C Systems
CODAC NetworksCentral Interlock Network
Central Safety Networks
ITER I&C SYSTEM
Plant Conventional Control System
Plant System Controller
Signal Interface
Plant SystemHost (PSH)
Plant Interlock System(PIS)
PIS Controller
Plant Safety Systems(PSS)
PSS Controller
I&C Networks
Signal Interface Signal Interface
1. Conventional Controls
2. Interlock controls Investment protection
3. Safety controls Occupational, Nuclear
ITER Control System overview:Three vertical tiers with limited direct interface
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© 2013, ITER Organization
Plant system I&C
CODAC System (PBS-45)
Pla
nt
Sys
tem
I&C
CentralInterlock System
(PBS-46)
CentralSafety Systems
(PBS-48)
Central I&C Systems
CODAC NetworksCentral Interlock Network
Central Safety Networks
ITER I&C SYSTEM
Plant Conventional Control System
Plant System Controller
Signal Interface
Plant SystemHost (PSH)
Plant Interlock System(PIS)
PIS Controller
Plant Safety Systems(PSS)
PSS Controller
I&C Networks
Signal Interface Signal Interface
Central I&C
ITER Control System overview:Two horizontal layers interfaced with networks
Target: well identify functionalities and interfaces
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ITER Control System physical architecture
Data storage
I nterlock controller
Fast controller
Slow controller
Plant System Host
Plant system I &C: controllers + signal interf aces
Safety controller
Plant system equipment: sensors + actuators
Signals / field buses
Central I &C: servers + computers
Networks
As much as possible close to what is commonly in use for I&C
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ITER Control System functional architecture:
Made of a finite set of “Lego block” which can be selected and connected as required
Common architecture but versatile and scalable
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ITER Control System overview: Some figures
Parameter Value
Total number of computers 1.000
Total number of signals (wires) 100.000
Total number of process variables 1.000.000
Total number of active operator screens 100
Update rate per screen (200 PVs) 5 Hz
Maximum sustained data flow on PON 50 MB/s
Total engineering archive rate 5 MB/s
Total scientific archive rate 20 GB/s
Total scientific archive capacity Few PB/year
Accuracy of time synchronization 50 ns RMS
Maximum latency asynchronous events 1 ms
Maximum latency sensor to actuator (SDN) 500 µs
Maximum jitter sensor to actuator (SDN) 50 µs
Maximum sustained data flow on SDN 25 MB/s
ITER: a scientific facility made of COTS and specific systems
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The ITER standardsFor I&C systems
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I&C standards: why?
Main challenge for I&C systems is the integration
Statements:
1. Most of components or plant systems of ITER are procured “in-kind” from the seven ITER member partners.
2.These components will come with their own local control systems.
3. For integrated operation purpose, these local control system will be all interfaced to the Central I&C systems.
4.There will be a huge number of physical and functional interfaces.
5. After commissioning, ITER IO will have to maintain everything.
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© 2013, ITER Organization
I&C standards: Integration purpose
Target: Central I&C interfacesThe physical and functional interfaces with central I&C systems.The naming conventions and data format.Workflows and procedures for integration.
Data storage
I nterlock controller
Fast controller
Slow controller
Plant System Host
Plant system I &C: controllers + signal interfaces
Safety controller
Plant system equipment: sensors + actuators
Signals / field buses
Central I &C: servers + computers
Networks
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I&C standards: maintenance purpose
The I&C standards have been checked and tested for suitability
Target: Components of the plant system I&C
Products and technology (HW and SW) for controllers directly interfaced to central I&C systems.
Products for I&C cubicles enclosures.
Data storage
I nterlock controller
Fast controller
Slow controller
Plant System Host
Plant system I &C: controllers + signal interf aces
Safety controller
Plant system equipment: sensors + actuators
Signals / fi eld buses
Central I &C: servers + computers
Networks
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Plant Operation Network (PON): Industrial EthernetSynchronous Databus Network (SDN): UDP multicast on 10 Gb EthernetTime Communication Network (TCN): PTP, IEEE 1588Audio-Video Network (AVN): 10 Gb EthernetData Archiving Network (DAN): 10 Gb EthernetCentral Interlock Network (CIN): Industrial EthernetCentral Safety Network (CSN): Industrial Ethernet + Hard Wires
I&C standards - Physical interfaces: Networks
I nterlock controller
Fast controller
Signal I nterface
Slow controller
Plant System Host
PON
Safety controller
SDNTCNDANAVN
CSN
CIN
NETWORK PANEL
Signal I nterface
Signal I nterface
Signal I nterface
PLANT SYSTEM I &C
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I&C standards - physical interfaces: Network interfaces
IO provides for free one integration kit for each plant system I&C. Others Network interfaces shall be ordered separately by the suppliers.
The “Integration Kit” is gathering everything the suppliers need as HW
interface for Central I&C systems. See: Integration Kit for PS I&C (C8X9AE)
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Are implemented in CODAC Core Systems (CCS) for:Plant system I&C supervisory control and monitoring (HMI).Data archiving retrieval and display.Event handling and synchronization.Configuration management (plant systems and plant)
• CODAC is responsible for defining and providing the solution and tools for implementation.
• Based on EPICS Channel Access protocol for PON interface. EPICS (Experimental Physics and Industrial Control System)
• Other CODAC solutions: see CODAC Core Systems v4.0 * documentation at: https://www.iter.org/org/team/chd/cid/codac/Pages/CoreSystem.aspx
I&C standards - Functional interfaces
CODAC team provides required tools and assistance services (training + support) for user configuration and integration
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CODAC Core System distribution: today status
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CODAC Core System distribution: today status
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I&C standards - products: Slow controllers
Slow controllers are addressing
industrial controls, fail safe controls
and redundant controls.
See:
ITER catalogue for I&C products - Sl
ow controllers PLC (333J63)
Are Siemens S7-300 and S7-400 products
Are ET200M and ET200S for Remote IO Are covering standard ITER signals
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I&C standards - technology: Fast controllers
Fast controllers are addressing controls not implementable in slow
controllers.
See: ITER Catalog of I&C products - Fast Contollers (345X28)
SW supported by CCS
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I&C standards: products details: I&C cubicle enclosures
ITER standards enclosures are suited to interface the cable trays and are monitored by a standard system.
See:
ITER catalogue for I&C products - Cubicles (35LXVZ)
Are Schneider Electric products Address floor standing and wall mounted
cubicles Address Standard and EMC protected.
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I&C standards: I&C design data and deliverables
CODAC Core System generates automatically the functional interfaces
I&C design data, see: Methodology for Plant System I&C specifications (353AZY)
Address design phase and manufacture phases for I&C I&C design data: what we need to initiate the integration
process I&C deliverables: What to deliver at manufacture.
From design to manufacture
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How to get informed and trained about
ITER solutions for I&C ?
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I&C standards repository = 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.
All major project reviews are required to show that PCDH standards are followed.
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Publicly available at https://www.iter.org/org/team/chd/cid/codac/Pages/PlantControlHandbook.aspx
PCDH access: public access
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PCDH access: IDM access
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
PCDH core and satellite documents: v7PS CONTROL DESIGN
Plant system I&C architecture (32GEBH)
Methodology for PS I&C specifications (353AZY)
CODAC Core System Overview (34SDZ5) INTERLOCK CONTROLS
Guidelines for PIS design (3PZ2D2)
Guidelines for PIS integration & config. (7LELG4)
Management of local interlock functions (75ZVTY)
PIS Operation and Maintenance (7L9QXR)
I&C CONVENTIONS
I&C Signal and variable naming (2UT8SH)
ITER CODAC Glossary (34QECT)
ITER CODAC Acronym list (2LT73V)
PS SELF DESCRIPTION DATA
Self description schema documentation (34QXCP)
CATALOGUES for PS CONTROL
Slow controllers products (333J63)
Fast controller products (345X28)
Cubicle products (35LXVZ)
Integration kit for PS I&C (C8X9AE)
PS CONTROL INTEGRATION
The CODAC -PS Interface (34V362)
PS I&C integration plan (3VVU9W)
ITER alarm system management (3WCD7T)
ITER operator user interface (3XLESZ)
Guidelines for PON archiving (B7N2B7)
PS Operating State management (AC2P4J)
Guidelines for Diagnostic data structure (354SJ3)PS CONTROL DEVELOPMENT
I&C signal interface (3299VT)
PLC software engineering handbook (3QPL4H)
Guidelines for fast controllers (333K4C)
Software engineering and QA for CODAC (2NRS2K)
Guidelines for I&C cubicle configurations (4H5DW6)
CWS case study specifications (35W299)
NUCLEAR PCDH (2YNEFU)
OCCUPATIONAL SAFETY CONTROLS
Guidelines for PSS-OS design (C99J7G)
Available and approved
Legend
This document
(XXXXXX) IDM ref.
Use IDM references. See: http://www.iter.org/getaccount for IDM account creation
PCDH v7 to be released by April 2013 is the final version
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CODAC Core System training
Subscriptions: http://www.iter.org/org/team/chd/cid/codac/CoreSystemTraining
To get started on ITER solutions for I&C. Scheduled every month in ITER premises. Address all users of ITER solutions for I&C. One to 4 days training depending on
scope. Free of charge for the trainees.
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How to procure and useITER standards for I&C ?
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Standard Procedure to apply for orderingStrategic
agreement in place
CODAC Core Systems
http://www.iter.org/org/team/chd/cid/codac/coresystem
No, CCS subscription required only, free of charge
Slow controllers
Siemens S7 PLC ordering process for EU DA - IO standards for I&C products
Yes with Siemens including a special ITER discount
Cubicles http://www.iter-schneider-electric.com/ Yes with Schneider-Electric including a special ITER discount
Fast controllers
Check product references in the catalogue: Fast Contollers (345X28) and order to the right supplier.
In preparation
How to procure ITER standards for I&C
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How to use ITER standards for I&C: A set of guidelines as how to applicable to I&C systems
Guidelines for ITER operator user interface (3XLESZ)
Guidelines for ITER alarm system management (3WCD7T)
Guidelines for PON archiving (B7N2B7)
Guidelines for Plant system operating state management (AC2P4J)
PLC software engineering handbook (3QPL4H)
Guidelines for diagnostic data structure and plant system status information (354SJ3)
Guidelines for fast controllers (333K4C)
Guidelines for I&C signal interface (3299VT),
Guidelines for I&C cubicle configuration (4H5DW6)
Guidelines for PIS design (3PZ2D2)
Guidelines for PIS integration and configuration (7LELG4)
Guidelines for PSS design (C99J7G)PCDH guidelines are IO recommendations for implementing IO standards
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How to use ITER standards for I&C: Some illustrations: Signal interface, cubicle configuration, PLC SW
engineering
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How to test and integrate I&C system at ITER ?
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How to test and integrate I&C systems ?Model of Life-Cycle in use at ITER:
1.Manufacture is ended with FAT in supplier premises.
2.Integration on ITER site is ended with SAT and hand-over.
3.Integrated commissioning under IO responsibility.
4.Operation under IO responsibility.Focus on phases 1 and 2 with following principles:
1.Get an approved design which includes I&C standards requirements.
2.Full compliance to the approved design checked during manufacture.
3.Central I&C interfaces tested at the earliest (FAT) using CODAC solution and CODAC support: mini-CODAC systems delivered for that purpose.
4.Integration on ITER site is checked and supported by CODAC team for the connection to the CODAC infrastructure.
Details are still TBD, but draft scenarios addressed in:
Plant system I&C Integration plan (3VVU9W)
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Already done by IO for I&C
Selection of ITER solutions for I&C. Endorsement of our partners for these solutions. Test and validation of ITER solutions on simulated use cases. Set up training sessions open to all users. Implementation of ITER solutions on real use cases in IO: (SSEN,
B55) Implementation of ITER solutions on real use cases in partners:
(KSTAR)
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ITER project has Selected I&C standard solutions, architectures and interfaces for risk reduction and cost saving at procurement integration.
The suitability of these solutions has been checked against user reviews and real use cases implementation.
ITER CODAC is now offering support and training services for helping the suppliers and users in implementing these solutions.
Opportunities for the industry shall be investigated mainly with the procurement suppliers and with IO for procurement integration.
Conclusion
ITER IO is ready for dealing with I&C business for
the detailed design and manufacture phases