ITER_D_ 353AZY

Methodology for Plant System I&C Design

Abstract
This document completes the PCDH core document by focusing on methodology for plant system I&C design. It aims to give guidelines for the plant system I&C design; the recommended way to issue 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 are addressed and commented. Details on CAD tools and how to use them will be developed in a specific document.

Author Reviewers Approver

IDM Number: ITER_D_353AZY Name JY Journeaux Plant system ROs, I&C IPT ROs, A Wallanders, WD Klotz D. Bora

Date: 25th of January 2010 Affiliation CHD/CODAC IO CHD

Methodology for plant system I&C design v2.2

Page 1 of 30

ITER_D_ 353AZY

Records of revisions Revision 0 1 2.1 2.2 2.3 Date 04/09/2009 10/09/2009 21/09/2009 30/10/2009 25/01/2010 Description First draft First CODAC review comments included Second CODAC review comments included IO review comments included J Poole and IO review 2 to 9 2 to 14 2 to 14 2 to 14 Modified Pages

Methodology for plant system I&C design

Page 2 of 33

ITER_D_ 353AZY

TABLE of CONTENTS
1. INTRODUCTION.......................................................................................................................................... 5 1.1. 1.2. 1.3. 1.4. 1.5. 1.6. 1.7. 2. PCDH context .................................................................................................................................... 5 Document scope ............................................................................................................................... 5 Document identifiers......................................................................................................................... 6 Topics remaining to be addressed .................................................................................................. 6 Review, validation and thanks ......................................................................................................... 6 Acronyms ........................................................................................................................................... 7 Related documents ........................................................................................................................... 7

SUMMARY................................................................................................................................................... 8 2.1. 2.2. CAD tools involved in plant system I&C ......................................................................................... 8 Step1: Conceptual design of the plant system process. .............................................................. 8

2.3. Step2: Preliminary design of the plant system process and preliminary design of I&C functions. ........................................................................................................................................................ 9 2.4. 2.5. 2.6. 2.7. 2.8. 2.9. 3. 4. 5. 6. Step3: Detailed design of I&C functions. ........................................................................................ 9 Step4: Definition of FAT and SAT scenarios and of the plant system integration plan for I&C. 11 Step5: Detail design of HMI ............................................................................................................ 11 Summary of data directions involving CAD tools: ...................................................................... 12 Summary of other CAD features: .................................................................................................. 12 Summary of data directions between databases ......................................................................... 13

PCDH references ...................................................................................................................................... 14 General scheme for I&C design.............................................................................................................. 15 Approaches for plant system design including I&C ............................................................................ 16 I&C design, details ................................................................................................................................... 17 6.1. 6.2. 6.3. Step1 ................................................................................................................................................. 17 Step2 ................................................................................................................................................. 18 Step3 ................................................................................................................................................. 19

7. 8.

Requirements of tools for such a development process .................................................................... 21 Methodology for plant system I&C architecture definition ................................................................. 23 8.1. 8.2. What is proposed for plant system I&C architecture ? ............................................................... 23 The methodology for defining this I&C architecture ................................................................... 23

Example diagrams ............................................................................................................................................ 27

Methodology for plant system I&C design

Page 3 of 33

ITER_D_ 353AZY

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 _________________________________________ 10 Figure 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 0.4kV distribution and 22/0.4kV distribution _________________________________________ 32 Figure 22: Example of I&C functional analysis drawing _________________________________________ 33

Methodology for plant system I&C design

Page 4 of 33

ITER_D_ 353AZY

1. INTRODUCTION
1.1. PCDH context

The Plant Control Design Handbook (PCDH) [RD1] defines methodology, standards, specifications and interfaces applicable to ITER Plant Systems Instrumentation & Control (I&C) system life cycle. 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. PCDH comprises a core document which presents the plant system I&C life cycle and recaps the main rules to be applied to the plant system I&Cs for conventional controls, interlocks and safety controls. Some I&C topics will be explained in greater detail in dedicated documents associated with PCDH as presented in Figure 1. This document is one of them.

Design phase I&C documents

CATALOGUES of I&C PRODUCTS Slow controllers products Fast controller products Cubicle products Other I&C components (wiring, PS) Plant system I&C networks products PS I&C DESIGN METHODOLOGY (33NC7K v1.1) Methodology for architecture and specifications CAD tools data export PS I&C ARCHITECTURE Templates of architecture Template of I&C controller topology Conv. / interl. controls relationship and interface I&C CONVENTIONS PV and signal naming Tables of signals naming CODAC INTERFACE CODAC INTERFACE (XXXXXX vY.Y) CODAC -PS Interface part-I Interface, Guidelines for alarm handling Guidelines for IOCs Guidelines for commands Guidelines for status Specifications for HPN Guidelines for HMI

PS SELF DESCRIPTION DATA Content Management Nuclear PCDH

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)

Legend This document Available and approved Expected

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

TEMPLATES and ILLUSTRATIONS Plant system case study: ICH LCC prototypes: slow, fast, interlocks PS simulators: slow, fast, interlocks

Figure 1: PCDH documents structure

1.2.

Document scope

This document completes the PCDH [RD2] core document by focusing on methodology for plant system I&C design, see Figure 1. The scope is plant system I&C design for conventional and protection controls: this document does not address Safety controls IEC61508 relevant. Three topics are considered in this document: The plant system process which defines the plant system functions, operation sequences and feedback controls. The plant system I&C which defines how the plant system process is controlled.

The plant system operation which defines how the plant system is operated through the plant system I&C and the supervisory system (CODAC). Hence, all of these three topics have to be considered for the plant system I&C design. As a general statement, the plant system I&C design shall be driven by the plant system process first and then by the plant system operation.

Methodology for plant system I&C design

Page 5 of 33

ITER_D_ 353AZY

Specific attention is given to the definition of the plant system process. Usually the process description is defined 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&C functions 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 database are 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, are detailed; 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 document as for the other PCDH satellite documents are mainly guidelines; some are rules, in such a case they are identified by a star symbol . As a general rule, the release of this document, like all the documents associated with PCDH mentioned in Figure 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 the user to understand the requirements. Table 1: Paragraph identifiers AD GL RD Applicable Document Glossary item 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 thanks

It 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 of the core PCDH, involving the I&C IPT team and other IO people involved in I&C activities. Thanks to the people who take the time for this review.

Methodology for plant system I&C design

Page 6 of 33

ITER_D_ 353AZY

1.6. Acronyms
Table 1 shows the acronyms used in this document. The relevant acronyms have been extracted from the complete list in PCDH . Acronym ANSI CAD CHD CODAC DA DO FAT HMI ICP I&C IO I/O IDef0 IPT LCC PCDH PFD PLC P&ID PIS PS PS OS PSH PSS PV RAMI SAT SCC SRD TBC TBD Item American National Standard Institute Computer-Aided Design CODAC & IT, Heating & Current Drive, Diagnostics COntrol, Data Access and Communication Domestic Agency Design Office Factory Acceptance Tests Human Machine Interface ITER Collaborative Platform Instrumentation & Control ITER Organization Inputs and Outputs Method Designed to model the organization of a system. Integrated Product Team Local Control Cubicle Plant Control Design Handbook Process Flow Diagrams Programmable Logic Controller Process and Instrumentation Diagram Plant Interlock System Plant System Plant system Operation State Plant System Host Plant Safety System Process Variable Reliability, Availability, Maintainability and Inspectability Site Acceptance Tests Signal Conditioning Cubicle System Requirement Document To Be Confirmed To Be Defined Table 2: Abbreviations and acronyms

1.7. Related documents

[RD1] [RD2] [RD3] [RD4] [RD5] [RD6] ITER Numbering System for Parts/Components (ITER_D_28QDBS) Plant Control Design Handbook (PCDH) (ITER_D_27LH2V v5.0) I&C signal and process variable naming convention (ITER_D_2UT8SH) Signal processing for I&C (ITER_D_3299VT) Room book for buildings CAD Manual - Section 14 - Diagram Guidelines (ITER_D_35CY6V)

Methodology for plant system I&C design

Page 7 of 33

ITER_D_ 353AZY

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 state machines 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 descriptions of 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 and industry 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 in following table. Drawings type Mechanical drawings PFD drawings P&ID drawings Electrical drawings Functional analysis drawings Cubicle configuration drawings IO standard tools CATIA V5 See System Design See System Design See System Design See System Design 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 this stage of the design. See Section 6.1 for details.

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

Methodology for plant system I&C design

Page 8 of 33

ITER_D_ 353AZY

2.3.

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

This activity is still fully integrated within the plant system design activity and is focused on the definition of the plant system instrumentation. The same CAD tools as for step 1 are used. In addition a P&ID CAD tool is required 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 the functional analysis of the plant system process using drawings; define and characterize the plant system I&C functions; then organize these I&C functions in order to group them according to those which are relevant to the plant system process and those for I&C controller features (performance, location, ). These data are pushed to the plant system configuration database manually.

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

Methodology for plant system I&C design

Page 9 of 33

ITER_D_ 353AZY

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 a cubicle configuration CAD tool. The configuration data of the controllers are then exported to the engineering station to initiate software development for the I&C controllers; the software development is completed during the manufacturing phase of the plant system I&C. Compliance for data export between the cubicle CAD and the software development station is mandatory. The same data are exported to the plant system configuration database: in addition, an xml data export capability is mandatory. The cubicle configuration includes in addition: 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 both extremities (i.e. the sensors/actuators and the I&C controllers). An electrical CAD tool is required and the best solution would be to use the electrical CAD tool used for steps 1 and 2. The work to be performed within this task is an engineering task requiring inputs derived from the sensors/actuators properties (see outputs of step 2) and the architecture and controller properties (see previous task of step 3). After completion of the definition of I&C cabling, data needed for I&C controller configuration are exported from the electrical CAD tool to: The plant system configuration database (xml format capability required) to complete the I&C signal properties such as I&C controller channel number. The I&C controller software engineering station for the same purpose (electrical CAD tool and software development station compliance mandatory).

Process descrip. documents Signal properties for I&C controller configuration Signal properties for I&C controller configuration

P&ID CAD

Electrical CAD

Plant system configuration database

I&C controller dev. software

Mechanical CAD

Figure 6: Scheme for preliminary design of I&C cabling

Methodology for plant system I&C design

Page 10 of 33

ITER_D_ 353AZY

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 states are only listed. In step3 the preliminary design of theses state machines provides the details of the transitions between the operation states when the links and conditions are determined. The detailed design of these state machines is performed during the manufacturing phase. The drawings developed for the plant system design and available for mechanical, electrical and fluid descriptions may be used for mimic displays used for the HMI. In that case, a data export service for these drawings 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 system integration 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 an impact from the scenarios on the plant system architecture and on the topology of the I&C controllers.

2.6.

Step5: Detail design of HMI

Step 5 is dedicated to the detailed design of HMI functions to be implemented within CODAC. Details to be defined further in a specific document.

Methodology for plant system I&C design

Page 11 of 33

ITER_D_ 353AZY

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 data of I&C signals (list and properties). Xml format.

Plant system architecture CAD - Manual export of data related to controller properties (topology, name, ) towards the plant system 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 development stations (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 the components. - Templates of sensor/actuator properties provide guidelines for properties to be defined.

Methodology for plant system I&C design

Page 12 of 33

ITER_D_ 353AZY

2.9.

Summary of data directions between databases

Process name

P&ID CAD

I&C Function Analysis

Plant I&C Diagram

Plant System Configuration Database See System Design

Possible extraction

ICP Engineering Database

Cubicle configuration

Figure 8: Summary of data directions with the plant system configuration database and ICP engineering database. The philosophy is to get a central database (ICP) able to collect everything produced by the CAD tools as is done for the other engineering activities of ITER project. The data needed for plant configuration would be extracted from this central database to be imported in the CODAC plant system configuration database.

Methodology for plant system I&C design

Page 13 of 33

ITER_D_ 353AZY

3. PCDH references
A model of plant system I&C life cycle was defined in PCDH [RD2]. This model includes a design phase which foresees the following deliverables to be issued at completion of I&C design: [D1] Plant system I&C architecture. [D2] Plant system I&C boundary definition. [D3] Plant systems I&C integration plan. [D4] Plant system P&IDs, mechanical and electrical drawings needed for I&C specifications. [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 system I&C controllers. [D8] Configuration of I&C cubicles. [D9] Description of plant system state machines. Following inputs mentioned in PCDH are required to proceed to the I&C design: [I1] Plant system I&C operation and control philosophy. [I2] Plant system functional analysis. [I3] Plant system PFDs, mechanical and electrical drawings needed at conceptual design phase. [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 for the plant system I&C. [I7] List and specifications of the main protection functions to implement within the plant system or with respect to other plant systems. The specifications include a risk analysis to identify the interlock functions from amongst all of the protection functions [I8] List and specifications of the main safety functions to implement within the plant system or with respect to other plant systems.

Figure 9: plant system I&C life-cycle

Methodology for plant system I&C design

Page 14 of 33

ITER_D_ 353AZY

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 and updated 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 the same milestones for reviews: Conceptual, preliminary and final design reviews.

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 Control Documents/Specifications Final Design Review

PA
Time

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

Methodology for plant system I&C design

Page 15 of 33

ITER_D_ 353AZY

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 assembly issues for the components of the plant system. The second is process function oriented to handle I&C specifications and architecture for hardware and 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 and maintenance 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. The third approach will be addressed in specific documents attached either to central I&C systems activities or to ITER plant operation activities

Methodology for plant system I&C design

Page 16 of 33

ITER_D_ 353AZY

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 to be adjusted to the particular plant system configuration since ITER is composed of so many different plant systems 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 performed within the conceptual design phase mentioned in Figure 10. The main objective is to issue the plant system I&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. The safety functions are mentioned in these documents but not detailed. There are no details of plant system protection functions in these documents at this stage of the design, but the ITER plant wide interlocks and safety functions are mentioned where the plant system is involved. The plant system operation 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 diagrams are issued through CAD tool dedicated to that purpose and configured specifically for ITER, see 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 include cabling and wiring related to I&C, but only electrical links between the plant system components for power 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 and configured specifically for ITER, see section 2.1. They are part of input [I2] mentioned in PCDH. Mechanical drawings and room book [RD5] are used to support the definition of the plant system layout 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 PFDs and 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 plant system normal operation states is added. To keep the design consistent, the work on text documents, PFDs and electrical diagrams shall be performed in parallel . 2. The analysis of component failures is performed. At this stage of design this analysis does not include the definition of failure detection but includes the definition of the plant system failure modes, consequences of the failure on the plant system operation and the way to recover from the failure. The impact of loss of utilities is considered in this analysis. RAMI analysis recommendations are used to include redundancy functions within the plant system. A risk analysis is performed to identify the interlocks for all of the plant system protection functions. Process description documents, PFDs and electrical diagrams are updated throughout the analysis process. 3. Safety functions and ITER plant wide interlock functions are added within the documents and diagrams. 4. A final review enables the consistency of all these documents to be checked. CAD tool access: By all people in charge of plant system I&C design within IO and DAs. Data exported to plant system configuration database at this step: The list of plant system operation states from the process description documents, but not description of the state machines, see step 3. Manual export process.

Methodology for plant system I&C design

Page 17 of 33

ITER_D_ 353AZY

6.2. Step2
Step 2 is dedicated to the preliminary design of the plant system process and the preliminary design of I&C functions. Thus this step focuses on definition of sensors, actuators and I&C signals. The main objective is to issue 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 the plant system. These documents are the documents mentioned in step1 but in their final version ready to be used for I&C design. They include details of plant system protections, interlocks and safety functions 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. These diagrams are the final version of PFDs mentioned in step1. Electrical diagrams for the electro-technical part of the process. These diagrams are final versions of the 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 of the 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 actuators of the plant system for conventional controls (includes plant system protection), interlock and safety functions. These diagrams are issued by a unique ITER standard CAD tool dedicated to that purpose and 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 type conventional/interlock/safety, accuracy, technology, acquisition rate, engineering conversion algorithms, filtering, signal, powering, electrical connections, mechanical connections, fluid connections, sensibility to perturbations, final property list still TBD) available within a sensor/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 determined case 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 and actuators used in P&IDs in addition to those mentioned in step1. This library is interfaced to the P&ID CAD 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 whole ITER plant. Templates for definition of sensor and actuator properties. These templates are implemented through the sensor/actuator database. Methodology to be applied: 1. Completion of the process description document, PFD and electrical diagrams by implementation of the same method as that proposed in step1: start with normal operation, complete with off normal operation. Include the plant system protections and interlocks (definition and details) and details for the ITER plant wide interlocks and safety functions mentioned in step1. 2. P&ID are produced in parallel to the completion of the process description documents and PFDs It should not be forgotten to include monitoring of the utilities and external information required to operate the plant system coming from the other plant system. 3. Sensor and actuator properties are to be defined in the database. CAD tool access: By all people in charge of plant system I&C design within IO and DAs. Data exported to plant system configuration database: The list of plant system I&C signals and a part of their properties (some related to cabling to I&C controllers are still missing). The list of data coming from other plant system and needed for the plant system I&C. The drawings and diagrams of CAD tools to be used for mimic displays used for HMI

Methodology for plant system I&C design

Page 18 of 33

ITER_D_ 353AZY

6.3. Step3
Step 3 is dedicated to the detailed design of I&C functions: definition of the plant system I&C architecture, specification of I&C controllers, preliminary design of I&C cabling and I&C cubicles and the description of state machines for the plant system operation states. In addition, a preliminary design of HMI is made. The main deliverables are: Functional analysis diagrams of the plant system I&C showing the breakdown in plant system I&C functions. A CAD tool is required for the diagrams. See section 8 for details. Characterisation of these I&C functions (location, response time, conventional/interlock/safety type, availability requirement, local control requirement, .). This characterisation may be supported by Microsoft 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 CAD tool is required for diagrams. The P&IDs mentioned in STEP2 may be updated during the progress of this I&C architecture. Preliminary definition of I&C cubicle hardware configuration to distribute the I&C controller racks within the I&C cubicles (LCC) and clarify the need for signal conditioning cubicles (SCC). A CAD tool is required. 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 the I&C controllers. Preliminary definition of I&C cabling showing the connection of the sensors/actuators to the I&C controllers including the junction boxes if any (and location of these boxes), the earthing scheme to clarify the need for insulation, the powering scheme to clarify the need for power distribution, the routing of the cables within the building and the specification of the cables. Details of cabling for sensors/actuators and I&C cubicles is defined during the manufacturing phase. An electrical CAD tool is required. Plant system operation state machines defined using the software development environment dedicated to the slow or fast controller, which may be the software engineering station or any other compatible tool. This tool is specified by CODAC. Preliminary design of HMI is performed in addition: still TBD. Minimum list of standards required at this step of design: Guidelines for I&C controller topology. Catalogues of hardware products for the I&C controllers and I&C cubicles. See PCDH catalogues. Guidelines for I&C cubicle design. Rules and guidelines for signal processing including EMC and radiation protection issues. [RD4] Rules for I&C controller addresses (TBD). Methodology to be applied: Proceed in the sequence following the order mentioned above for the deliverables : start with the functional analysis and complete with I&C cabling. The state machine may be defined separately. 1. The functional analysis and the characterization of the I&C functions, see details in section 8. 2. Deduce the plant system I&C architecture. Guidelines for I&C controller topology are applicable. 3. Make the preliminary design of the I&C cubicle hardware configuration. Guidelines for cubicle design (still TBD) are applicable.

Methodology for plant system I&C design

Page 19 of 33

ITER_D_ 353AZY

4. Perform the preliminary design of I&C cabling: it must show the need for signal conditioning or junction cubicle/boxes, if any. Rules for signal processing, EMC, and radiation protection issues (TBD) are applicable. 5. Develop the plant system operation state machine. CAD tool access: By all people in charge of plant system I&C design within IO and DAs. Data exported to plant system configuration database and software development stations: Some controller properties (name, type, topology, IP address, location of racks, I&C functions, ). The data export mechanism may be manual from the documents mentioned in this step of design. Some plant system I&C properties (details TBD). The data export mechanism may be manual from the documents mentioned in this step of design. The definitive address of the I/O within the controller will be defined during the I&C manufacture phase, 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 controller user software would be developed during the manufacturing phase.

Methodology for plant system I&C design

Page 20 of 33

ITER_D_ 353AZY

7. Requirements of tools for such a development process

CAD tools: All the CAD tools used at IO are defined and managed by the Design Office (DO). Refer to the DO for further documentation. This section gives additional information concerning use for I&C design scope only. It is assumed in this document that the drawings and data issued by the plant system suppliers would comply with these CAD tools. PFD CAD tool: This tool is dedicated to the plant system process design, step1 and step2. CODAC requirements: - 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 of the sensors and actuators needed for the plant system operation for everything: automatic&manual controls, conventional&interlock&safety controls, indicatorsThis tool is the main source of I&C signal information for the plant system. The best would be to get a CAD tool which includes a signal database able to determine all the properties of the sensors/actuators and associated I&C signals, with an xml data export capability. CODAC requirements: - Xml data export capability towards plant system configuration database and to be a unique reference 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 performed periodically; 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 export capability towards the CODAC software to build process mimics. - Description of cabling for I&C signals. The tool shall be able to complete the sensor/actuator data related to electrical connections, cable type, cable routing, cable identification from the sensors/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 cable routing diagrams for cable installation, cabling diagrams for connection and signal processing loop diagrams for maintenance. CODAC requirements: data export capability towards plant system 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 be performed 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. The data exports towards plant system configuration database and the software development stations are manual. Cubicle hardware configuration CAD tool: This tool is used to configure the I&C cubicle for all components in the cubicles: I&C controller hardware, cabling interface, power supply, the cubicle itself, HVAC devices, Configuration means selection of the hardware from predefined lists of ITER standard products and definition of the location of the product within the cubicle including I&C controller hardware configuration. After completion, this I&C controller hardware configuration shall be extracted and pushed to the I&C controller software development tools and to the plant system configuration database. Some consistency checking with the I&C controller source codes, plant system configuration database and the electrical CAD tool configuration shall be performed periodically; the way and tool used to perform such controls is still TBD.

Methodology for plant system I&C design

Page 21 of 33

ITER_D_ 353AZY

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. The completion of the user software will only be performed through the STEP 7 afterwards. Some consistency checking between STEP 7 source codes, plant system configuration database and the cubicle CAD tool configuration shall be performed periodically; the way and tools to perform such controls are still TBD. Fast controllers: still TBD CODAC (mimics): still TBD

Methodology for plant system I&C design

Page 22 of 33

ITER_D_ 353AZY

8. Methodology for plant system I&C architecture definition

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 system I&Cs. A characterization of the I&C functions. A definition of software functions and hardware architecture of the I&C controllers.

An architecture of the full plant system I&C including the details of data communication. All these topics shall be addressed in the deliverable [D1] mentioned in PCDH, see Section 3 of that present document.

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-deliverables of [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.

Figure 11: Example of step1 functional analysis: ICH case study Extract from SRD-51 Ion Cyclotron Heating: System Basic Configuration The ICH&CD system is composed of the antenna port plugs, the matching systems, the transmission line systems, the RF power sources, plus auxiliary sub-systems and services such as decoupling units, control systems and test facilities.

Methodology for plant system I&C design

Page 23 of 33

ITER_D_ 353AZY

Step2. Add oriented arrows between functions to show the I&C interfaces between the plant system internal functions and with other functions outside the plant system. (the former have to be defined with the plant system, the latter are defined in the SRD). See illustration in Figure 12. Step3. Define several plant system I&Cs as quasi autonomous I&C function of the plant system if possible.
Cooling Water System (PHTS) AC distribution class II, class IV (SSEPN) 43.AC PS power supplies 51.IC 26.PH

RF Hot Cell facility 51.HC

22 kV AC distribution (PPEN) 43.AE

HV Power Supply 42.IC

RF source 51.RS

Transmission line 51.TL

Matching system 51.MS

Antenna 51.AN

Other services (compressed air, dry nitrogen...) 65.00

High power load system 51.LS

RF port plug facility 51.TF

Cooling Water System (CCWS) 26.CC

Vacuum system (primary and services) 31.IC

ICH & CD antenna plant system Process functional breakdown Physical links with potential I&C issue

Figure 12: The ICH plant system with external interfaces Step4. Step5. Add feedback control, plant system protection and interlocks. Name functions and links. Function names may be PBS level 2. See illustration in Figure 13.

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

Methodology for plant system I&C design

Page 24 of 33

ITER_D_ 353AZY

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 (conventional/interlock/safety function or link, response time, IO volume and characterization, time resolution, data resolution, location, redundancy, .) I&C Description function ID PLANT SYSTEM power supply 51.IC ICHPS1 ICHPS2 ICHHV1 ICHRF1 ICHRF2 ICHRF3 I&C link ICH2 ICH16 Etc. Table 3: example of I&C function characterisation, list of properties still TBD SSEPN status Fast shut down command C I 100 ms 10 s 1 boolean 1 digital command CODAC PLANT SYSTEM I&C Driver DC anode control SSEPN monitoring Final stage DC anode control Ancillaries controls Fast failure event detection Fast feedback controls Type C, I, S Response time ms IO / data loc.

C C C C I C

100 ms 100 ms 100 ms 100 ms 10 s 1 ms

10DI, 5DO, 5AI, 2AO ICH2 10DI, 5DO, 5AI, 2AO

Room1 Room1 Room2

HV power supply 42.IC RF source 51.RS 30DI, 20DO, 10AI, 5AO Room3 30DI, 1DO Room3 20DI, 10DO, 10AI, 2AO Room3

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 this distribution are: slow/fast, plant system I&C link, IO volume, location, redundancy, other criteria. Select the controller topology type, and name the controllers. The distribution of I&C functions within the I&C controllers is a critical phase: optimization of performance, of plant system operation and cost have to be taken in account in 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 same controller rack. This rack shall be a separate one if a re-allocation to another plant system I&C for improved consistency of the future operation is envisaged.

Power supply slow controller: ICHPSC ICHPS1 ICHPS2 ICHHV1 10DI, 5DO, 5AI, 2AO 1DI, 2AI 10DI, 5DO, 5AI, 2AO Room1 Room1 Room2

RF source fast controller: ICHRFC2 ICHRF2 20DI, 10DO, 10AI, 2AO Room3
Figure 14: example of controller configurations

Table 4: Functions performed by the controller

Methodology for plant system I&C design

Page 25 of 33

ITER_D_ 353AZY

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 a diagram as illustrated in Figure 15. Step10. Add RAMI requirements if any. Step11. Check with procurement scenario for FAT, final adjustment to optimize and issue final architecture. CODAC
PSH PSH Master control

7 1 2

ICHPSC

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

Sub-deliverable 5: A distribution of the controller racks in the I&C cubicles. Step12. Use the cubicle CAD tool for this distribution. Comply with the signal processing document [RD4] for the controller topology and use [RD5] for cubicle location.

ICHRFC1

Connect nb. 1 ICH1 to ICH9, 2 3 4 . ICH1 to ICH9,

4 ..

ICHRFC3

Antenna 1 control

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

Table 5: identification of data links

Link ID

Methodology for plant system I&C design

6
ICHRFC2

Antenna 2 control + test facilities

Page 26 of 33

ITER_D_ 353AZY

Example diagrams

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

Methodology for plant system I&C design v2.2

Page 27 of 30

ITER_D_ 353AZY

Figure 17: PFD example on ACB, zoom

Methodology for plant system I&C design

Page 28 of 33

ITER_D_ 353AZY

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

Methodology for plant system I&C design

Page 29 of 33

ITER_D_ 353AZY

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

Methodology for plant system I&C design

Page 30 of 33

ITER_D_ 353AZY

Figure 20: Example of electrical diagram for process description: MV 22/6.6 and 0.4kV distribution and 22/0.4kV distribution
Methodology for plant system I&C design

Page 31 of 33

ITER_D_ 353AZY

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

Methodology for plant system I&C design

Page 32 of 33

ITER_D_ 353AZY

AC distribution class II, class IV (SSEPN) 43.AC

ICH2

ICH1

ICH18

ICH4

PS power supplies I&C 51.IC

ICH11

22 kV AC distribution (PPEN) 43.AE

ICH3

ICH5 ICH6

HV Power Supply I&C 42.IC

ICH7

ICH10

RF source I&C 51.RS

ICH12

Transmission line I&C 51.TL

Other services (compressed air, dry nitrogen...) 65.00

ICH17 ICH16

ICH8

Cooling Water System (CCWS) 26.CC

ICH9

ICH & CD antenna plant system I&C functional breakdown

Figure 22: Example of I&C functional analysis drawing

Methodology for plant system I&C design

Page 33 of 33