08 design methodology 353azy v2 0

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Methodology forPlant System I&C Design

Abstract

This document completes the PCDH core document by focusing on methodology for plant systemI&C design. It aims to give guidelines for the plant system I&C design; the recommended way toissue the for the design phase deliverables as mentioned in PCDH is commented in detail.

The CAD tools involved in the design and the links with the plant system configuration database areaddressed and commented. Details on CAD tools and how to use them will be developed in aspecific document.


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Records of revisions

Revision Date Description Modified Pages

0 04/09/2009 First draft

1 10/09/2009 First CODAC review comments included 2 to 9

2.1 21/09/2009 Second CODAC review comments included 2 to 14

2.2 30/10/2009 IO review comments included 2 to 14

2.3 25/01/2010 J Poole and IO review 2 to 14


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TABLE of CONTENTS

1.

INTRODUCTION .......................................................................................................................................... 5

1.1. PCDH context .................................................................................................................................... 5

1.2. Document scope ............................................................................................................................... 5

1.3. Document identifiers ......................................................................................................................... 6

1.4. Topics remaining to be addressed .................................................................................................. 6

1.5. Review, validation and thanks ......................................................................................................... 6

1.6.

Acronyms ........................................................................................................................................... 7

1.7. Related documents ........................................................................................................................... 7

2. SUMMARY ................................................................................................................................................... 8

2.1. CAD tools involved in plant system I&C ......................................................................................... 8

2.2. Step1: Conceptual design of the plant system process. .............................................................. 8

2.3. Step2: Preliminary design of the plant system process and preliminary design of I&Cfunctions. ........................................................................................................................................................ 9

2.4. Step3: Detailed design of I&C functions. ........................................................................................ 9

2.5. Step4: Definition of FAT and SAT scenarios and of the plant system integration plan for I&C.11

2.6. Step5: Detail design of HMI ............................................................................................................ 11

2.7. Summary of data directions involving CAD tools: ...................................................................... 12

2.8. Summary of other CAD features: .................................................................................................. 12

2.9. Summary of data directions between databases ......................................................................... 13

3. PCDH references ...................................................................................................................................... 14

4. General scheme for I&C design.............................................................................................................. 15

5. Approaches for plant system design including I&C ............................................................................ 16

6. I&C design, details ................................................................................................................................... 17

6.1. Step1 ................................................................................................................................................. 17

6.2. Step2 ................................................................................................................................................. 18

6.3. Step3 ................................................................................................................................................. 19

7. Requirements of tools for such a development process .................................................................... 21

8. Methodology for plant system I&C architecture definition ................................................................. 23

8 1 What is proposed for plant system I&C architecture ? 23


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FIGURES

Figure 1: PCDH documents structure _________________________________________________________ 5

Figure 2: Scheme for preliminary design of the plant system process ________________________________ 8

Figure 3: Scheme for detailed design of the plant system process ___________________________________ 9

Figure 4: Scheme for the plant system I&C architecture design and controller properties definition _______ 9

Figure 5: Scheme for controller hardware and cubicle configuration definition _______________________ 10

Figure 6: Scheme for preliminary design of I&C cabling _________________________________________ 10Figure 7: Scheme for state machines and drawings for HMI ______________________________________ 11

Figure 8: Summary of data directions with the plant system configuration database and ICP engineering

database. ________________________________________________________________ 13

Figure 9: plant system I&C life-cycle ________________________________________________________ 14

Figure 10: Generic scheme of ITER design for a functional design PA type. __________________________ 15

Figure 11: Example of step1 functional analysis: ICH case study __________________________________ 23

Figure 12: The ICH plant system with external interfaces ________________________________________ 24

Figure 13: Illustration of step 4 and 5 on ICH plant system (4 functions only) ________________________ 24

Figure 14: example of controller configurations ________________________________________________ 25

Figure 15: Illustration of the plant system I&C architecture and characterization of data communications __ 26

Figure 16: Example of PFD: Cryo-distribution system, main component and part of sensors are mentioned _ 27

Figure 17: PFD example on ACB, zoom ______________________________________________________ 28

Figure 18: In this schema, the PFD is used to illustrate the process description document (text) to identify

active components according to the operation mode ______________________________ 29

Figure 19: PID example on the ACB: details of instrumentation ___________________________________ 30

Figure 20: Example of electrical diagram for process description: MV 22/6.6 and 0.4kV distribution and

22/0.4kV distribution _______________________________________________________ 31

Figure 21: Example of electrical diagram for process description: detail of MV 22/6.6 and 0.4kVdistribution and 22/0.4kV distribution _________________________________________ 32

Figure 22: Example of I&C functional analysis drawing _________________________________________ 33


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1. INTRODUCTION

1.1. PCDH context

The Plant Control Design Handbook (PCDH) [RD1] defines methodology, standards, specifications andinterfaces applicable to ITER Plant Systems Instrumentation & Control (I&C) system life cycle.I&C standardsare 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.

PCDH comprises a core document which presents the plant system I&C life cycle and recaps the main rules tobe applied to the plant system I&Cs for conventional controls, interlocks and safety controls. Some I&C topicswill be explained in greater detail in dedicated documents associated with PCDH as presented in Figure 1.This document is one of them.

Core PCDH

Plant system I&C life cycle

Plant system I&C specifications

Interface specification with central I&C

Interlock I&C specification

Safety I&C specification (C&A)

CATALOGUES of I&C PRODUCTS

Slow controllers products

Fast controller productsCubicle products

PS SELF DESCRIPTION DATA

Content

I&C SIGNAL PROCESSING

Plant system I&C cubicle configurations

I&C signal cabling configurations

I&C signal earthing and cabling practice for EMC

I&C signals standards

I&C signal conditioning

I&C cubicle wiring configurations

Available and approved

Expected

Legend

Template of I&C controller topology

Conv. / interl. controls relationship and interface

TEMPLATES and ILLUSTRATIONS

Plant system case study: ICH

Other I&C components (wiring, PS)

Plant system I&C networks products

PS I&C ARCHITECTURE

Templates of architecture

Design phase I&C documents

CODAC INTERFACE

CODAC -PS Interface, part-I

Guidelines for alarm handling

Guidelines for IOCs

Guidelines for commands

Guidelines for status

Specifications for HPN

Guidelines for HMI

I&C CONVENTIONS

PV and signal naming

This document

(33NC7K v1.1)PS I&C DESIGN METHODOLOGY

Methodology for architecture and specifications

CAD tools data export

Nuclear PCDH

Management

LCC prototypes: slow, fast, interlocksPS simulators: slow, fast, interlocks

(XXXXXX vY.Y)

Tables of signals naming

CODAC INTERFACE

CODAC -PS Interface

Figure 1: PCDH documents structure

1.2. Document scope


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Specific attention is given to the definition of the plant system process. Usually the process description isdefined by giving the way the plant system components are operated, using text documents and process flow

diagrams. This document proposes in addition, an approach based on a functional description of the I&Cfunctions for the definition of the plant system I&C architecture.

CAD tools are involved in the plant system I&C design; their links with the plant system configuration databaseare addressed and commented in order to clarify the specific features which may be required with these tools.Details of these tools and the way to use them will be developed in a specific document.

A five step method is proposed: the first three steps, which have to be performed as the first priority, aredetailed; the two last steps will be defined in specific documents.

Section 2 provides a summary of the method while details of steps 1 to 3 are to be found in section 6. Sections

3 to 5 provide background information on plant system I&C design.

1.3. Document identifiers

Table 1 provides the full list of identifiers used in this document. The recommendations raised in this documentas for the other PCDH satellite documents are mainly guidelines; some are rules, in such a case they areidentified by a star symbol.

As a general rule, the release of this document, like all the documents associated with PCDH mentioned inFigure 1, will be followed by an immediate update of the core PCDH so that the core PCDH is a single

document containing all the mandatory rules applicable to plant system I&C. In this way it will be easier for theuser to understand the requirements.

Table 1: Paragraph identifiers

AD Applicable Document

GL Glossary item

RD Reference Document

Rules referenced in core PCDH

1.4. Topics remaining to be addressed

The details of the of the following topics will be addressed in the next version of this document:

CAD tools data export

1.5. Review, validation and thanksIt is proposed this document is reviewed with the following objectives:

Check compliance with ITER need and configuration.

Check impact on manufacturing and technical optimisation.

As a reference document associated with PCDH, the validation process of this document is similar to that ofthe core PCDH involving the I&C IPT team and other IO people involved in I&C activities Thanks to the


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1.6. Acronyms

Table 1 shows the acronyms used in this document. The relevant acronyms have been extracted from thecomplete list in PCDH .

Acronym ItemANSI American National Standard Institute

CAD Computer-Aided Design

CHD CODAC & IT, Heating & Current Drive, Diagnostics

CODAC COntrol, Data Access and Communication

DA Domestic Agency

DO Design OfficeFAT Factory Acceptance Tests

HMI Human Machine Interface

ICP ITER Collaborative Platform

I&C Instrumentation & Control

IO ITER Organization

I/O Inputs and Outputs

IDef0 Method Designed to model the organization of a system.

IPT Integrated Product Team

LCC Local Control CubiclePCDH Plant Control Design Handbook

PFD Process Flow Diagrams

PLC Programmable Logic Controller

P&ID Process and Instrumentation Diagram

PIS Plant Interlock System

PS Plant System

PS OS Plant system Operation State

PSH Plant System HostPSS Plant Safety System

PV Process Variable

RAMI Reliability, Availability, Maintainability and Inspectability

SAT Site Acceptance Tests

SCC Signal Conditioning Cubicle

SRD System Requirement Document

TBC To Be Confirmed

TBD To Be Defined

Table 2: Abbreviations and acronyms

1.7. Related documents

[RD1] ITER Numbering System for Parts/Components (ITER_D_28QDBS)


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2. SUMMARY

The plant system I&C design is performed in five steps, as follows:

- Step1: Conceptual design of the plant system process.

- Step2: Preliminary design of the plant system process and preliminary design of I&C functions.

- Step3: Detailed design of the plant system I&C functions, preliminary design of operation statemachines and HMI.

- Step4: Definition of FAT and SAT scenarios and of the plant system integration plan for I&C.

- Step5: Detailed Design of HMI functions and integration to plant wide operation.

For step 1 to 3 CAD tools are required. These CAD tools address electrical, mechanical and fluid descriptionsof the plant system; they are specified, selected and managed by the DO.

Examples of such drawings are given in Figure 16 to Figure 22.The CAD drawings will have to be updated throughout the whole life-cycle of the plant system. IO, DAs andindustry will be involved in this update process.

2.1. CAD tools involved in plant system I&C

These Cad tools are managed by IO Design Office (DO) and shall be used for any drawing type as listed infollowing table.

Drawings type IO standard toolsMechanical drawings CATIA V5PFD drawings See System DesignP&ID drawings See System DesignElectrical drawings See System Design

Functional analysis drawings See System DesignCubicle configuration drawings See Electrical Expert

2.2. Step1: Conceptual design of the plant system process.

This activity is fully integrated within the plant system design activity. The materials used are text documents,PFD CAD, Electrical CAD and mechanical CAD. There is no CODAC requirement on the CAD tools at thisstage of the design. See Section 6.1 for details.


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2.3. Step2: Preliminary design of the plant system process and preliminarydesign of I&C functions.

This activity is still fully integrated within the plant system design activity and is focused on the definition of theplant system instrumentation. The same CAD tools as for step 1 are used. In addition a P&ID CAD tool isrequired for definition of the plant system instrumentation. See Section 6.2 for details.

Figure 3: Scheme for detailed design of the plant system process

2.4. Step3: Detailed design of I&C functions.

This step is split into several tasks:- Detailed design of the plant system I&C architecture and definition of I&C controller properties.- Preliminary design of I&C cubicle configurations.- Preliminary design of I&C cabling for sensors and actuators.

- Preliminary design of the plant operation state machines and preliminary design of drawings for the HMI.

See section 6.3 for details.

2.4.1. Plant system I&C architecture and controller properties:

Details of this architecture design methodology are provided in Section 8. The general idea is to proceed to thefunctional analysis of the plant system process using drawings; define and characterize the plant system I&Cfunctions; then organize these I&C functions in order to group them according to those which are relevant tothe plant system process and those for I&C controller features (performance, location, ). These data arepushed to the plant system configuration database manually.


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2.4.2. I&C cubicle configuration:

The I&C controller properties are used as inputs to configure the controller hardware and the cubicle, using acubicle configuration CAD tool. The configuration data of the controllers are then exported to the engineeringstation to initiate software development for the I&C controllers; the software development is completed duringthe manufacturing phase of the plant system I&C. Compliance for data export between the cubicle CAD andthe software development station is mandatory. The same data are exported to the plant system configurationdatabase: in addition, an xml data export capability is mandatory. The cubicle configuration includes inaddition: definition of the space reservation and consumptions for the I&C architecture (cubicles footprint,volumes, power consumption, ).

Figure 5: Scheme for controller hardware and cubicle configuration definition

2.4.3. I&C cabling for sensors and actuators:

The objective of this task is the definition of the sensor/actuator cables and of their interfaces at bothextremities (i.e. the sensors/actuators and the I&C controllers). An electrical CAD tool is required and the bestsolution would be to use the electrical CAD tool used for steps 1 and 2. The work to be performed within thistask is an engineering task requiring inputs derived from the sensors/actuators properties (see outputs ofstep 2) and the architecture and controller properties (see previous task of step 3). After completion of thedefinition of I&C cabling, data needed for I&C controller configuration are exported from the electrical CAD toolto:

The plant system configuration database (xml format capability required) to complete the I&C signalproperties such as I&C controller channel number.

The I&C controller software engineering station for the same purpose (electrical CAD tool andsoftware development station compliance mandatory).

Process descrip.


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2.4.4. Preliminary design of plant operation state machines and drawings for HMI:

The conceptual design of the plant operation state machine is given in step1: the plant system operation statesare only listed. In step3 the preliminary design of theses state machines provides the details of the transitionsbetween the operation states when the links and conditions are determined. The detailed design of these statemachines is performed during the manufacturing phase.

The drawings developed for the plant system design and available for mechanical, electrical and fluiddescriptions may be used for mimic displays used for the HMI. In that case, a data export service for thesedrawings has to be performed by these CAD tools, details still TBD.

Figure 7: Scheme for state machines and drawings for HMI

2.5. Step4: Definition of FAT and SAT scenarios and of the plant systemintegration plan for I&C.

Details to be defined further in a specific document. This step may lead to a review of step3 if there is animpact from the scenarios on the plant system architecture and on the topology of the I&C controllers.


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2.7. Summary of data directions involving CAD tools:

These data exchanges are indicated by the red arrows in figures 2 to 7. They are: P&ID CAD:

- From P&ID database towards plant system configuration database: export of description dataof I&C signals (list and properties). Xml format.

Plant system architecture CAD

- Manual export of data related to controller properties (topology, name, ) towards the plantsystem configuration database.

- Manual export of same data towards cubicle CAD tool.

Cubicle CAD:

- Export of I&C controller hardware configurations towards I&C controller software developmentstations (STEP7 + fast controllers + )

- Export of the same data towards plant system configuration database. Xml format.

Electrical CAD:

- Export of signal properties related to cabling (board number and channel number) towards I&C

controller software development stations (STEP7 + fast controllers + )- Export of same data towards plant system configuration database. Xml format.

All CAD:

- Export of drawings data towards plant system configuration database. Xml format.

2.8. Summary of other CAD features:

PFD CAD:- An ITER library of unique symbols provides the plant wide standard representations of the

components.

- Application of naming conventions.

P&ID CAD:

- An ITER library of unique symbols provides the plant wide standard representations of thecomponents.

- Templates of sensor/actuator properties provide guidelines for properties to be defined.


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2.9. Summary of data directions between databases

Figure 8: Summary of data directions with the plant system configuration database and ICP engineeringdatabase.

The philosophy is to get a central database (ICP) able to collect everything produced by the CAD tools as isdone for the other engineering activities of ITER project. The data needed for plant configuration would beextracted from this central database to be imported in the CODAC plant system configuration database.

SeeSystemDesign

ICP

Engineering Database

P&ID CADProcessname

I&C FunctionAnalysis Plant I&CDiagram

Plant System

Configuration

Database

Possible e xtrac tion

Cubicleconfiguration


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3. PCDH references

A model of plant system I&C life cycle was defined in PCDH [RD2]. This model includes a design phasewhich foresees the following deliverables to be issued at completion of I&C design:

[D1] Plant system I&C architecture.

nition.

electrical drawings needed for I&C specifications.

em I&C controllers.

e machines.

ollowing inputs mentioned in PCDH are required to proceed to the I&C design:

nd electrical drawings needed at conceptual design phase.

r the plant system I&C.

t system or with

mplement within the plant system or with respect

[D2] Plant system I&C boundary defi

[D3] Plant systems I&C integration plan.

[D4] Plant system P&IDs, mechanical and

[D5] Plant system controller(s) performance and configuration requirements.

[D6] List of inputs and outputs (I/O) of the I&C controllers.

[D7] List of the Process Variables handled by the plant syst

[D8] Configuration of I&C cubicles.

[D9] Description of plant system statF

[I1] Plant system I&C operation and control philosophy.

[I2] Plant system functional analysis.

[I3] Plant system PFDs, mechanical a

[I4] A list and short description of main plant system operating states for plant system operation.

[I5] Plant system risk analysis and I&C RAMI requirements.

[I6] System Interface Control Documents (S-ICDs) relevant fo

[I7] List and specifications of the main protection functions to implement within the planrespect to other plant systems. The specifications include a risk analysis to identify the interlockfunctions from amongst all of the protection functions

[I8] List and specifications of the main safety functions to ito other plant systems.


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4. General scheme for I&C design

Plant system I&C design will follow the ITER model for design which defines the three following phases:conceptual design, preliminary design and final design.

Whichever phase is concerned, the deliverables listed above shall be addressed and shall be issued andupdated in compliance with the IO Design Office policy.

The plant system I&C design will follow in a parallel way with the full plant system design and will share thesame milestones for reviews: Conceptual, preliminary and final design reviews.

Figure 10: Generic scheme of ITER design for a functional design PA type.

Concept Design & Engineering studies

Concept Control Documents/Specifications

Concept Design Review

PA Documents (Main, Annex A & Annex B)

Signature of PA (Hand Off)

Preliminary Design & Engineering studies

Preliminary Control Documents/Specifications

Preliminary Design Review

Final Design & Engineering studies

Final Control Documents/Specifications

Final Design Review

PATime


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5. Approaches for plant system design including I&C

To perform the design of any plant system which includes I&C functions, several approaches are required:

The first one is component oriented to handle mechanics, fluids, electrics, location and assemblyissues for the components of the plant system.

The second is process function oriented to handle I&C specifications and architecture for hardwareand software.

The third one is operation oriented for the HMI issues and organisation of operation.

These three approaches are needed and may be implemented sequentially.

One important feature for successful integration with ITER plant is that the future plant system operation andmaintenance must drive the design of the plant system I&C:

At every stage of the design the impact on operation and maintenance shall be considered.

This document addresses the integration of the first two above-mentioned approaches for I&C design. Thethird approach will be addressed in specific documents attached either to central I&C systems activities or toITER plant operation activities


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6. I&C design, details

The following scheme is proposed for I&C design. It has to be considered as a generic scheme which needs tobe adjusted to the particular plant system configuration since ITER is composed of so many different plantsystems from I&C point of view.This is a step by step scheme to reach the final design before going to manufacture.

6.1. Step1

Step 1 is dedicated to the conceptual design of the plant system process. This step is typically performedwithin the conceptual design phase mentioned in Figure 10. The main objective is to issue the plant systemI&C inputs required for the design. See PCDH for the input list.

The main deliverables are:

Text documents to describe the process for normal and off-normal operation of the plant system. Thesafety functions are mentioned in these documents but not detailed. There are no details of plantsystem protection functions in these documents at this stage of the design, but the ITER plant wideinterlocks and safety functions are mentioned where the plant system is involved. The plant systemoperation states are defined, but not the state machines. All these materials are the inputs [I1], [I3],

[I6], [I7], and [I8] mentioned in PCDH.

Process Flow Diagrams (PFD) to support the process description for fluids processes. These diagramsare issued through CAD tool dedicated to that purpose and configured specifically for ITER, see

ents for

for ITER, see section 2.1. They are part of input [I2] mentioned in PCDH.

nt system normalents, PFDs and

all be performed in parallel .

section 2.1. They are part of input [I2] mentioned in PCDH.

Electrical diagrams for the electro-technical part of the process.. These diagrams do not includecabling and wiring related to I&C, but only electrical links between the plant system componpower and earth at this stage of design. They are part of input [I2] mentioned in PCDH.

Mechanical drawings to support the process description for the mechanical part of the process. These

diagrams are issued through a unique ITER standard CAD tool dedicated to that purpose andconfigured specifically

Mechanical drawings and room book [RD5] are used to support the definition of the plant systemlayout in order to get the location of the plant system I&C components.

List of standards applicable at this step of I&C design:

An ITER library of symbols provides the IO standard representation of the components used in PFDsand electrical diagrams. This library is interfaced to the CAD tools.

The ITER naming convention for components [RD1].

Methodology to be applied:1. The description of the plant system process is initiated by the definition of plant system operation

states for normal operation first; then the definition of the transition between these plaoperation states is added. To keep the design consistent, the work on text documelectrical diagrams sh

2. The analysis of component failures is performed. At this stage of design this analysis does not includeth d fi iti f f il d t ti b t i l d th d fi iti f th l t t f il d


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6.2. Step2

Step 2 is dedicated to the preliminary design of the plant system process and the preliminary design of I&Cfunctions. Thus this step focuses on definition of sensors, actuators and I&C signals. The main objective is toissue the deliverables [D4] and [D6] mentioned in PCDH.

Main deliverables are:

Text documents to provide further details about the process for normal and off-normal operation of theplant system. These documents are the documents mentioned in step1 but in their final version readyto be used for I&C design. They include details of plant system protections, interlocks and safetyfunctions and details of feedback controls (algorithms, response time). The transitions between the

plant system operation states are detailed.

Process Flow Diagrams (PFD) to support the process description for the fluids processes. Thesediagrams are the final version of PFDs mentioned in step1.

Electrical diagrams for the electro-technical part of the process. These diagrams are final versions ofthe diagrams mentioned in step1. They still do not include electrical links for I&C signals.

Mechanical drawings for the mechanical part of the process. These drawings are the final versions ofthe diagrams mentioned in step1.

Process and Instrumentation Diagrams (P&ID) are issued to support the process description and to

initiate the design of the plant system I&C. These diagrams will mention all the sensors and actuatorsof the plant system for conventional controls (includes plant system protection), interlock and safetyfunctions. These diagrams are issued by a unique ITER standard CAD tool dedicated to that purposeand configured specifically for ITER. They are part of deliverable [D4] mentioned in PCDH.

List of plant system sensors and actuators and properties (name, location, range, unit, control typeconventional/interlock/safety, accuracy, technology, acquisition rate, engineering conversionalgorithms, filtering, signal, powering, electrical connections, mechanical connections, fluidconnections, sensibility to perturbations, final property list still TBD) available within asensor/actuator database which may be supported by the P&ID CAD tool. Text documents, PFDs and

electrical diagrams are used as inputs for sensor and actuator definition (name, type, range, ..);mechanical drawings and room book are used to define location. Other properties are determinedcase by case. This list is the deliverable [D6].

List of standards required at this step of design:

An ITER library of symbols provides the plant wide standard representations of the sensors andactuators used in P&IDs in addition to those mentioned in step1. This library is interfaced to the P&IDCAD tool.

The standard naming convention for I&C signals [RD3].

Some standards for sensors and actuators at least within the plant system, but better for the wholeITER plant.

Templates for definition of sensor and actuator properties. These templates are implemented throughthe sensor/actuator database.

Methodology to be applied:

1. Completion of the process description document, PFD and electrical diagrams by implementation of


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6.3. Step3

Step 3 is dedicated to the detailed design of I&C functions: definition of the plant system I&C architecture,

lysis diagrams of the plant system I&C showing the breakdown in plant system I&CD tool is required for the diagrams. See section 8 for details.

power distribution, theg and the specification of the cables. Details of cabling for

m operation state machines defined using the software development environmentthe software engineering station or any other

esign of HMI is performed in addition: still TBD.

pology.

specification of I&C controllers, preliminary design of I&C cabling and I&C cubicles and the description of statemachines for the plant system operation states. In addition, a preliminary design of HMI is made.

The main deliverables are:

Functional anafunctions. A CA

Characterisation of these I&C functions (location, response time, conventional/interlock/safety type,availability requirement, local control requirement, .). This characterisation may be supported byMicrosoft Word documents (template to be provided).

Plant system I&C architecture diagrams showing:

- The I&C controllers,

- The plant system field-buses,

- The topology of the controllers (location of racks, connection of the racks),

- The connections to CODAC architecture and specification of the controllers properties for type(fast/slow),

- I&C functions handled,

- I&C controller input/output definition (signal type, number, location)- Controller network addresses.

Specific attention will be given to the definition of interfaces with other plant system I&Cs and CODAC,to the definition of the plant system protections and interlocks and to the feedback controls. A CADtool is required for diagrams. The P&IDs mentioned in STEP2 may be updated during the progress ofthis I&C architecture.

Preliminary definition of I&C cubicle hardware configuration to distribute the I&C controller racks withinthe I&C cubicles (LCC) and clarify the need for signal conditioning cubicles (SCC). A CAD tool isrequired. This CAD tool will support the definition of the whole I&C controller hardware configuration in

order to get a comprehensive configuration to be exported in the software development stations for theI&C controllers.

Preliminary definition of I&C cabling showing the connection of the sensors/actuators to the I&Ccontrollers including the junction boxes if any (and location of these boxes), the earthing scheme toclarify the need for insulation, the powering scheme to clarify the need forrouting of the cables within the buildinsensors/actuators and I&C cubicles is defined during the manufacturing phase. An electrical CAD toolis required.

Plant systededicated to the slow or fast controller, which may becompatible tool. This tool is specified by CODAC.

Preliminary d

Minimum list of standards required at this step of design:

Guidelines for I&C controller to


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4. Perform the preliminary design of I&C cabling: it must show the need for signal conditioning or junctioncubicle/boxes, if any. Rules for signal processing, EMC, and radiation protection issues (TBD) areapplicable.

t system operation state machine.

CAD tool access:By all people in charge of plant system I&C design within IO and DAs.

ions, ). Theism may be manual from the documents mentioned in this step of design.

troller user software would be developed during

5. Develop the plan

Data exported to plant system configuration database and software development stations:

Some controller properties (name, type, topology, IP address, location of racks, I&C functdata export mechan

Some plant system I&C properties (details TBD). The data export mechanism may be manual from thedocuments mentioned in this step of design.

The definitive address of the I/O within the controller will be defined during the I&C manufacturephase, but the allocation to controller boards may be done at this level of design.

It is assumed in this model of design that the I&C conthe manufacturing phase.


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7. Requirements of tools for such a development process

CAD tools:

All the CAD tools used at IO are defined and managed by tdocumentation. This section gives additional information

he Design Office (DO). Refer to the DO for furtherconcerning use for I&C design scope only. It is

rs would comply with

: automatic&manual

system. The best would be to get a CAD tool which includes a signaldatabase able to determine all the properties of the sensors/actuators and associated I&C signals, withan xml data export capability. CODAC requirements:

- Xml data export capability towards plant system configuration database and to be a uniquereference of data used by IO, DAs and industry for P&ID activities.- Support an ITER library of unique symbols (ANSI) providing the plant wide standard

representations of the components.- P&ID diagrams update: Some consistency checking between the I&C controller source codes,

plant system configuration database and the P&ID CAD tool diagrams shall be performedperiodically; the way and tool to perform such controls is still TBD.

Electrical diagrams CAD tool: used for three purposes:

- Description of cabling for power distribution or the equivalent of PFD and P&ID diagrams for

the electro-technical part of the plant system process. CODAC requirements: xml data exportcapability towards the CODAC software to build process mimics.

- Description of cabling for I&C signals. The tool shall be able to complete the sensor/actuatordata related to electrical connections, cable type, cable routing, cable identification from thesensors/actuators up to the I&C controller including the controller and channel identification,through SCC and other connection boxes. The diagrams which have to be produced are cablerouting diagrams for cable installation, cabling diagrams for connection and signal processingloop diagrams for maintenance. CODAC requirements: data export capability towards plantsystem configuration database and the software development station databases for controller

and channel identification of the I&C signals in order to complete what is exported from P&IDs.

- Electrical diagram update: Some consistency checking with the I&C controller source codes,plant system configuration database and the cubicle CAD tool configuration shall beperformed periodically; the way and tool to perform such controls is still TBD.

I&C functional analysis and I&C architecture diagrams tool: See step 3. Multi-purpose CAD tool. Thedata exports towards plant system configuration database and the software development stations are

assumed in this document that the drawings and data issued by the plant system suppliethese CAD tools.

PFD CAD tool: This tool is dedicated to the plant system process design, step1 and step2. CODACrequirements:

- Xml data export capabilities towards the CODAC software to build process mimics.- Support an ITER library of unique symbols (ANSI) providing the plant wide standard

representations of the components.

P&ID CAD tool: Used for fluids processes mainly, see step 2. This tool is dedicated to the definition ofthe sensors and actuators needed for the plant system operation for everythingcontrols, conventional&interlock&safety controls, indicatorsThis tool is the main source of I&C signalinformation for the plant


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Software development tools:

PLC: The software development tool is the engineering station running STEP 7. The idea is to initiate

the user software development with hardware configurations provided by the cubicle CAD tool. Thepletion of the user software will only be performed through the STEP 7 afterwards. Some

ollers: still TBD

comconsistency checking between STEP 7 source codes, plant system configuration database and thecubicle CAD tool configuration shall be performed periodically; the way and tools to perform suchcontrols are still TBD.

Fast contr

CODAC (mimics): still TBD


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8. Methodology for plant system I&C architecture definition

system I&Cs.

C functions.

s and hardware architecture of the I&C controllers.

An architecture of the full plant system I&C including the details of data communication.

ll these topics shall be addressed in the deliverable [D1] mentioned in PCDH, see Section 3 of that presentocument.

8.2. The methodology for defining this I&C architecture

The methodology approach is functional and the starting point is the plant system SRD. The sub-deliverablesof [D1] are:

[D1]-1. A diagram of the plant system I&C functions.

[D1]-2. A list of I&C functions to be performed by the plant system I&C and properties of these functions.

[D1]-3. A distribution of these I&C functions in I&C controllers and a topology of these controllers.[D1]-4. A diagram of the architecture of the full plant system I&C with identification of the data exchange

within the plant system I&C and with CODAC.

[D1]-5. A distribution of the controller racks in I&C cubicles.

A 12 step method is proposed:

Sub-deliverable 1: the diagram of the plant system I&C functions:

Step1. Translate the plant system functional description of SRD (text) into a drawing, keep I&C

related functions only. IDef0 formalism is proposed with IGE-XAO software. See Figure 11.

8.1. What is proposed for plant system I&C architecture ?

A schema of plant system I&C functions including internal and external links.

A definition of the plant

A characterization of the I&

A definition of software function

Ad


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Step2. Add oriented arrows between functions to show the I&C interfaces between the plant systinternal functions and with other functions outside the plant system. (the former have to be defin

emed

with the plant system, the latter are defined in the SRD). See illustration in Figure 12.

of the plant system ifStep3. Define several plant system I&Cs as quasi autonomous I&C functionpossible.

42.IC

Supply

HV Power

51.RS

RF source

51.TL

line

Transmission

51.AN

Antenna43.AE

(PPEN)

22 kV AC

distribution

ICH & CD antenna plant system

Process functional breakdownPhysical links with potential I&C issue

43.AC

(SSEPN)

AC distributionclass II, class IV

65.00

Other services

(compressed air,

dry nitrogen...)

26.CC

Sy

Cooling Water

stem (CCWS)51.LS

High power

load system

51.MS

system

Matching

51.TF

RF port plug

facility

51.HC

facility

RF Hot Cell

31.IC

Vacuum system

(primary and

services)

Cooling Water

System

(PHTS)

26.PH

51.IC

supplies

PS power

e ICH plant system with external interfaces

Step4. Add feedback control, plant system protection and interlocks.

Step5. Name functions and links. Function names may be PBS level 2. See illustration in Figure 13.

Figure 12: Th


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Sub-deliverable 2:the diagram of the plant system I&C functions:

Step6. Detail the I&C functions and the links by determining I&C properties

Description Type Response IO / data loc.

(conventional/interlock/safety function or link, response time, IO volume and characterization, timeresolution, data resolution, location, redundancy, .)

I&Cfunction

IDC, I, S time ms

PLANT SYSTEM power supply 51.IC

ICHPS1 Driver DC anode control C 100 ms 10DI, 5DO, 5AI, 2AO Room1

ICHPS2 SSEPN monitoring C 100 ms ICH2 Room1

HV power supply 42.IC

ICHHV1 Final stage DC anode control C 100 ms 10DI, 5DO, 5AI, 2AO Room2

RF source 51.RS

ICHRF1 Ancillaries controls C 100 ms 30DI, 20DO, 10AI, 5AO Room3

ICHRF2 Fast failure event detection I 10 s 30DI, 1DO Room3

ICHRF3 Fast feedback controls C 1 ms 20DI, 10DO, 10AI, 2AO Room3

I&C link

ICH2 SSEPN status C 100 ms 1 boolean CODAC

ICH16 Fast shut down command I 10 s 1 digital command PLANTSYSTEMI&C

Etc.

Table 3: example of I&C function characterisation, list of propertie

Sub-deliverable 3: distribution of these I&C function in I&C controllers.

Step7. Distribute the I&C functions in I&C controllers. The criteria for thi slo /fast,plant system I&C ct the controller topologytype, and name the controllers. The distribution of I&C functions within the I&C controllers is a critical

t have to be taken in account in

ll be a separate one if a re-allocation to another plant system I&C forimproved consistency of the future operation is envisaged.

s still TBD

s distribution are: wlink, IO volume, location, redundancy, other criteria. Sele

phase: optimization of performance, of plant system operation and cos

the distribution process. One rule has to be considered: Within a controller, the I/Os related to the same I&C function shall be connected to the samecontroller rack. This rack sha

Power su l slow controller: ICHPSC


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Sub-deliverable 4: diagram of the architecture of the full plant system I&C.

Step8. Determine the plant system I&C architecture type: (PCDH plant system I&C type)

Step9. Link the controllers with plant system field-buses to show data communication; issue adiagram as illustrated in Figure 15.

Step10. Add RAMI requirements if any.

Step11. Check with procurement scenario for FAT, final adjustment to optimize and issue finalarchitecture.

ICHPSCICHRFC1 ICHRFC3

ICHRFC2

Master control

PSH

21

3 4 5 6

CODAC

7

PSH

Antenna 1 control

Antenna 2 control + test

facilities

Figure 15: Illustration of the plant system I&C architecture and characterization of data communications

Table 5: identification of data links

Connectnb.

Link ID

1 ICH1 to ICH9,

2 ICH1 to ICH9,

3 ICH1 to ICH9, ICH10, ICH11,

4 ICH1 to ICH9, ICH10, ICH11, ICH12, ICH17

. ..


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Methodology for plant system I&C design v2.2 Page 27 of 30

Figure 16: Example of C ion system, main component and part of sensors are mentioned

PFD: ryo-distribut

Example diagrams

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Methodology for plant system I&C design Page 28 of 33

Figure 17: PFD example on ACB, zoom

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Figure 18: In this schema, the PFD is used to illustrate the process description document (text) to identify active components according to the operation mode


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Figure 19: PID example on the ACB: details of instrumentation

Methodology for plant system I&C design Page 30 of 33Methodology for plant system I&C design Page 30 of 33

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Figure 20: Example of electrical diagram for process description: MV 22/6.6 and 0.4kV distribution and 22/0.4kV distribution


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Figure 21: Example of electrical diagram for process description: detail of MV 22/6.6 and 0.4kV distribution and 22/0.4kV distribution

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42.IC

HV Power

Supply

I&C

51.RS

RF source

I&C

51.TL

Transmission

line I&CICH10ICH12

43.AE

22 kV AC

distribution(PPEN)

ICH & CD antenna plant system

I&C functional breakdown

ICH5

43.AC

AC distribution

class II, class IV

(SSEPN)

65.00

Other services

(compressed air,

dry nitrogen...)

26.CC

Cooling Water

System (CCWS)

ICH8

ICH3

ICH6

ICH9

ICH7

ICH1

51.IC

PS power

supplies

I&C

ICH11

ICH2

ICH4

ICH17

ICH18

ICH16

Figure 22: Example of I&C functional analysis drawing