1 ITER Standardization for Integration of local and central interlocks Riccardo Pedica PLC Based Interlock systems Workshop 4-5 December 2014 – ITER Organization Headquarters - St Paul-lez-Durance-France

CERN CIS PLC Based Interlock System Workshop 4-5 December 2014 Riccardo Pedica Standardization for Integration 2 The standardization Includes procedure and guidelines to ensure that all the element of the project are properly integrated. Why managing the standardization ? Manage the development of the Plant systems Reduce integration problems and delays Involve the plant system developer early and often Identify the problems/solutions early Use relevant experience as early as possible.

CERN CIS PLC Based Interlock System Workshop 4-5 December 2014 Riccardo Pedica PLC Integration Requirement 3 Flexibility. During integration and commissioning, all interfaces may be not available. The application should allow some signals to be forced, or the partial simulation of the missing interface. Maintainability Sufficient system information should be provided. The PLC application should be modular so that modifications have only local impact. Ability to be tested. Unit testing of PLC Control Blocks should be easy. Control systems software should be tested independently from the system. The idea is to test the control system when it is connected to a simulator rather than the system. Readability Every information transformation in the data flow should be easy to track.

CERN CIS PLC Based Interlock System Workshop 4-5 December 2014 Riccardo Pedica The Plant Control Design Handbook (PCDH) 4 The Plant Control Design Handbook (PCDH) defines the methodology, standards, specifications and interfaces applicable to the whole life cycle of ITER plant instrumentation & control (I&C) systems. I&C standards are essential for ITER to: Integrate all plant systems into one integrated control system. Maintain all plant systems after delivery acceptance. Contain cost by economy of scale. Some I&C topics are explained in greater detail in dedicated documents associated with PCDH as presented in Figure.

CERN CIS PLC Based Interlock System Workshop 4-5 December 2014 Riccardo Pedica Guidelines for PIS Configuration and Integration 5 Multiproject strategy Hardware Configuration Software Configuration Slow controller naming convention + interlock variables naming Version control and repository management Development tool versioning Development process.

CERN CIS PLC Based Interlock System Workshop 4-5 December 2014 Riccardo Pedica Multiproject Strategy 6 The multi-project functionality of SIMATIC PCS 7 provides the option of a flexible and performance- oriented configuration of plants. The main emphasis is placed on parallel and time saving processing of projects which can be managed, divided and merged with system support. Siemens Multiproject Project specific setup Testing and configuring is possible entirely within the project with Automation Station and Operator Station. The work procedure during the project engineering and commissioning is the same. It is possible to copy entire subsystems including the update of the OS objects. There is a uniform view in the plant hierarchy which includes AS and OS in a project. Division without the network With this variant you divide the multiproject including master data library and the project which is to be engineered After retrieving on the decentralized ES, remove the no longer required projects from the multiproject and delete them. When you have processed the project on the decentralized ES, it is removed from the multiproject, archived and reintegrated into the original multiproject on the engineering server.

CERN CIS PLC Based Interlock System Workshop 4-5 December 2014 Riccardo Pedica Hardware configuration 7 Guidelines for CPU Configuration CP Configuration Remote I/O Rack Configuration I/O Module configuration Network Configuration Naming convention Configuration settings

CERN CIS PLC Based Interlock System Workshop 4-5 December 2014 Riccardo Pedica Naming convention 8 Hardware component Naming convention Software component Naming convention Variables Naming convention Internal step 7 variables Variables Interfaced with central systems (CODAC –CIS) Based On [RD1] CODAC Naming Convention(HTSSFH) Signal and plant system I&C Variable Naming Convention (2UT8SH) But with some differences due to. Fail safe variables. Safety related logic. Interface with WinCC OA. Critical Interlock logging System.

CERN CIS PLC Based Interlock System Workshop 4-5 December 2014 Riccardo Pedica Variable Naming applied to a function CODAC NAMING CONVENTIONINTERLOCK NAMING CONVENTION

CERN CIS PLC Based Interlock System Workshop 4-5 December 2014 Riccardo Pedica Hardware configuration: Example 10 In the text field, introduce details as mentioned below Name: Name of controller as per ITER naming guidelines (Ref: ITER_D_2FJMPY). ITER_D_2FJMPY Plant Designation: Details of PIS. Local Designation: Location of Cubicle housing controller ( ITER Rooms Location) Comments: Detail information about Controller and PIS.

Software Configuration 11 [11] 11 Software Configuration Block numbering convention PLC core application Reset Overrides Permit inhibit Threshold management System health monitoring Implementation of interfaces BlocksDescriptionCODAC Preferred Numbers Interlock prototype OBSiemens Default UDT System1..99 N.A. CODAC Reserved Application Specific DB CODAC Reserved Shared1..49 Siemens Default Instance Siemens Default Application Specific Shared Instance Siemens Default FC SystemSiemens Default:1..99 Siemens Default CODAC Reserved Siemens Default Application Specific FB SystemSiemens Default:1..99 Siemens Default CODAC Reserved Siemens Default Application Specific SFC Siemens Default SFB Siemens Default

CERN CIS PLC Based Interlock System Workshop 4-5 December 2014 Riccardo Pedica Software Configuration 12

CERN CIS PLC Based Interlock System Workshop 4-5 December 2014 Riccardo Pedica Interfaces with WinCC OA

CERN CIS PLC Based Interlock System Workshop 4-5 December 2014 Riccardo Pedica Version Control and repository management 14 In order to assure a correct version control management of the software and configuration files used in the development of the PIS, CODAC Subversion repository will be used to store Software developed or used by PIS. Plant system-specific software configuration files. PIS-CODAC interface configuration file. The Repository is located on The folder used to store the PIS I&C projects will be ev/units/ ev/units/ 1)m- / (CBSL1,CBSL2Name of the PIS project.) ├ branches/ ├ tags/ └ trunk/ └ src/ └ main/ ├ epics/ ├... └ plc/ (common folder for PLC stuff) ├ sdd/ (interface files generated by SDD) │ └ / (one folder per PLC) │ └ └ step7/ (folder for STEP7 projects; an empty folder created by maven) └ (folder layout according to STEP7 rules) └ (folder dedicated to store the Interlock project)

Development Process 15 [11] 15 Several development tools are involved into the development of PIS runtime Application. SDD tool is used to generate the configuration files for CODAC Interfacing STEP 7 is used to develop the Core Application of the PIS Winn CC OA to implement the archiving and the monitoring of the PIS from CIS Desk MINI CODAC to implement the core application that permit the monitoring and archiving from the CODAC control room CSS to generate the HMI screen used to monitor the PIS from the CODAC Control room.

PIS-CIS Integration 16 PIS software integration with the CIS can be achieved in several way, 4 cases of development scenario could be mentioned Development and stand-alone test (FAT/SAT) of the PIS off-site by the supplier/DA independently from IO. First connection of a new PIS (one or several PLCs) to the CIS Update of at PIS configuration (hardware and/or software) not affecting central functions/monitoring/etc. Update of at PIS configuration (hardware and/or software) affecting central functions/monitoring/etc.

CERN CIS PLC Based Interlock System Workshop 4-5 December 2014 Riccardo Pedica Questions 17 Is there an automatic code generation tool available for safety PLCs? Automatic generation of CODE for conventional Systems -The need of ‘Generation Tool’ was found mandatory developing a ‘Plant System Prototype’. The prototype had 300 variables when a Real Plant System will have ‘Primitive Generation Tool’ : -Generated : HW Interface, PLC Core App Framework -The generation of code was modular. -Standardize Features : Forcing, Anti-Noise, Scaling for AI …. -Foreseen to create : -HMI, Health Monitoring. -Advantages : -All the processes inside the ‘Software Architecture’ are standard and easy to track. -Match ‘Naming convention’, ‘Software programming rules’ and ‘Software configuration table’.

CERN CIS PLC Based Interlock System Workshop 4-5 December 2014 Riccardo Pedica 18 Thank