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IT Technical Specifications

CWS case study specificationsThis document contains technical specifications for I&C to develop a comprehensive I&C use case illustrating PCDH and core CODAc standards. The use case is based on a cooling water loop derived from the CWS plant system (PBS 26)The purpose is: Illustration of Core CODAC tools and guidelines Illustration of PCDH standards and methods.Check of applicability of these standards and tools for real development by the industry.Get a feed back for improvement.

Approval Process Name Action AffiliationAuthor Journeaux J.- Y. 17 Jan 2013:signed IO/DG/COO/TED/MAG/SSACo-AuthorsReviewers Wallander A.

Yonekawa I. 05 Feb 2013:recommended25 Jan 2013:recommended

IO/DG/COO/SCOD/CSDIO/DG/COO/SCOD/CSD/PCI

Approver Thomas P. 24 Mar 2013:approvedDocument Security: Internal Use

RO: Wagner RyanRead Access LG: CODAC team, AD: ITER, AD: External Collaborators, AD: IO_Director-General, AD: EMAB, AD:

Auditors, AD: ITER Management Assessor, project administrator, RO, AD: OBS - Control System Division (CSD) - EXT, AD: OBS - CODAC Section (CDC) - EXT, AD: OBS - CODAC Section (CDC)

IDM UID

35W299VERSION CREATED ON / VERSION / STATUS

17 Jan 2013 / 3.4 / Obsolete

EXTERNAL REFERENCE / VERSION

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PDF generated on 21 Sep 2017DISCLAIMER : UNCONTROLLED WHEN PRINTED – PLEASE CHECK THE STATUS OF THE DOCUMENT IN IDM

Change Log

CWS case study specifications (35W299)

Version Latest Status Issue Date Description of Change

v1.0 Signed 09 Jul 2010

v1.1 Signed 09 Jul 2010 First draftv2.0 Signed 23 Jul 2010 Updated after discussion with Franck on PV namingv2.1 Signed 26 Jul 2010 Update of PV namesv2.2 Signed 30 Jul 2010 still under workv2.3 Signed 27 Aug 2010 Progress on control and simulationv2.4 Signed 27 Oct 2010 Complement for WDC, changes on variable and signal propertiesv2.5 Signed 02 Nov 2010 Vesrsion completed for the loop control. Included some inputs for HMI. Still

the cubicle configuration and the simulation section to complete,v2.6 Signed 03 Nov 2010 Version completed for the loop control and simulation. Included some inputs

for HMI. Still the cubicle configuration and HMI section to complete,

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v3.0 Signed 03 Jan 2011 New version for review in scope of PCDH v6.v3.1 Signed 05 Jan 2011 J Poole reviewv3.2 Signed 06 Jan 2011 Minor changes for PCDH v6 reviewv3.3 Approved 09 Feb 2011 Version issued after PCDH v6 external reviewv3.4 Approved 17 Jan 2013 Version updated in scope of PCDH v7 (CBS, ...)

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Document Revision History

Version Status Date Changes1.0 Draft 9/07/2010 Initial Version2.0 Draft 23/07/2010 Update for PV name including CBS and component ID2.1 Draft 26/07/2010 Update of PV names for states, and CBS level42.2 Draft 26/08/2010 Align PV names with new proposal of PV naming2.6 Draft 03/11/2010 Final for I&C part, still sections for cubicle configuration, PSH

configuration and guidelines for HMI to complete including archiving and alarming.

3.0 Draft 08/12/2010 PCDH satellite doc format3.1 Draft 05/01/2011 JP Review3.2 Draft 06/01/2011 Version for external review3.3 Final 20/11/2012 Version for PCDH v7: PCDH picture plus PV names updated

PBS updated and component names aligned

TABLE of CONTENTS1. Introduction.........................................................................................................................22. General presentation of the Cooling Water use case.......................................................33. Physical components for the CWS case study..................................................................44. Functions for the CWS case study.....................................................................................55. I&C Specifications as defined in PCDH ...........................................................................66. Tech. Specs for manufacture of the PHDL I&C system ...............................................187. Tech. Specs for manufacture of the PHDL simulator ...................................................318. Development and manufacture........................................................................................33ANNEX 1: CWS functional breakdown .................................................................................34ANNEX 2: CWS PBS ...............................................................................................................35

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1. Introduction1.1. Document purpose

Plant Control Design Handbook (PCDH) document defines standards for all ITER plant system instrumentation and control (I&C). These standards are essential in order to achieve an integrated, maintainable and affordable control system to operate ITER. This satellite document of PCDH, gives an illustration of technical specifications for I&C to develop a comprehensive use case for hardware and software based on a cooling water loop derived from the CWS plant system (PBS 26). See Figure 1.

Purpose is: - Illustration of Core CODAC tools and guidelines.- Illustration of PCDH standards: for example naming conventions.- Illustration of I&C technical specs as recommended in PCDH.- Check of applicability of these standards and tools for real development by the industry.- Get a feed-back for improvement.This use case has been implemented by CODAC team and is currently in production in IO premises

Core PCDH (27LH2V)Plant system control philosophyPlant system control Life CyclePlant system control specificationsCODAC interface specificationsInterlock I&C specificationSafety I&C specification

PCDH core and satellite documents: v7PS CONTROL DESIGN

Plant system I&C architecture (32GEBH)

Methodology for PS I&C specifications (353AZY)

CODAC Core System Overview (34SDZ5) INTERLOCK CONTROLS

Guidelines for PIS design (3PZ2D2)

Guidelines for PIS integration & config. (7LELG4)

Management of local interlock functions (75ZVTY)

PIS Operation and Maintenance (7L9QXR)

I&C CONVENTIONSI&C Signal and variable naming (2UT8SH)

ITER CODAC Glossary (34QECT)

ITER CODAC Acronym list (2LT73V)

PS SELF DESCRIPTION DATASelf description schema documentation (34QXCP)

CATALOGUES for PS CONTROLSlow controllers products (333J63)

Fast controller products (345X28)

Cubicle products (35LXVZ)

Integration kit for PS I&C (C8X9AE)

PS CONTROL INTEGRATIONThe CODAC -PS Interface (34V362)

PS I&C integration plan (3VVU9W)

ITER alarm system management (3WCD7T)

ITER operator user interface (3XLESZ)

Guidelines for PON archiving (B7N2B7)

PS Operating State management (AC2P4J)

Guidelines for Diagnostic data structure (354SJ3)PS CONTROL DEVELOPMENT

I&C signal interface (3299VT)

PLC software engineering handbook (3QPL4H)

Guidelines for fast controllers (333K4C)

Software engineering and QA for CODAC (2NRS2K)

Guidelines for I&C cubicle configurations (4H5DW6)


NUCLEAR PCDH (2YNEFU)

OCCUPATIONAL SAFETY CONTROLSGuidelines for PSS design (C99J7G)

Available and approved

Legend

This document

(XXXXXX) IDM ref.


Figure 1: PCDH documents for plant system I&C 1.2. Related documents

[RD1] Plant Control Design Handbook (PCDH) (27LH2V)[RD2] I&C signal and variable naming convention (2UT8SH),[RD3] Methodology for PS I&C specifications (353AZY),[RD4] PLC software engineering handbook (3QPL4H)OB

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2. General presentation of the Cooling Water use case The use case is a cooling loop derived from the Vacuum Vessel Primary Heat Transfer System (VV PHTS) of ITER.

The function of the VV PHTS is to provide cooling water to the ITER vacuum Vessel components.

Several simplifications have been applied to the ITER VV PHTS, for this use case, they are mainly:- A single pump instead of two whatever the operation state: baking or plasma operation.- A cold pressurizer operated with gaseous Nitrogen instead of a warm pressurizer operated

with steam. - No filters included.- 3 clients only so called client1, client2, client3 are interfaced for cooling services. No by-

pass valve.

What was kept:- The interface with the CCWS1 (Component Cooling Water System) for providing cold

water cooling.- The interface with CVCS (Chemical and Volume Control system) for adjustment of water

level in the pressurizer.See Figure 2 for the CWS case study PFD.

The CWS use case is operated in 2 main operating modes:- Baking operation.- Plasma operation.

Details are given in section 5.1.

26PHVV-VC-0001

26PHVV-PL-0001

26PHVV-PZ-0001

P

L

T

26PHVV-HX-0001

26PHVV-VC-0003

26PHVV-VC-0007

26PHVV-VC-0004

26PHVV-VC-0005

F

P-100

26PHVV-VC-0008

26PHVV-HT-0001

26PHVV-VC-0006

Water storage and treatment CVCS

GN2 gas

supply

T

F

T

T

CC

WS1

F

I-56

26PHVV-VC-0010

Client 1

26PHVV-VC-0013

26PHVV-VC-0014

Client 3

26PHVV-VC-0011

26PHVV-VC-0012

Client 2

26PHVV-VC-0009

P-111

26PHVV-VC-0002

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3. Physical components for the CWS case studyAll components of the CWS use case are defined in the PBS 26.PH.VV level 3. See the PBS breakdown in ANNEX 2: CWS PBS.

All the CWS use case physical components will be named using the official component naming convention with the PBS level 3 identifier: 26PHVV.

The physical components are shown on Figure 2 and are listed below:

Component description Physical component nameCirculating pump 26PHVV-PL-0001Electric heater 26PHVV-HT-0001Heat Exchanger 26PHVV-HX-0001Pressurizer 26PHVV-PZ-0001Heat Exchanger primary by pass valve 26PHVV-VC-0001Heat Exchanger primary outlet valve 26PHVV-VC-0002Pressurizer isolation valve 26PHVV-VC-0003Pressurizer GN2 inlet valve 26PHVV-VC-0004Pressurizer GN2 outlet valve 26PHVV-VC-0005CVCS water supply valve 26PHVV-VC-0006CVCS water exhaust valve 26PHVV-VC-0007Electric heater by pass valve 26PHVV-VC-0008Client 1 inlet 26PHVV-VC-0009Client 1 outlet 26PHVV-VC-0010Client 2 inlet 26PHVV-VC-0011Client 2 outlet 26PHVV-VC-0012Client 3 inlet 26PHVV-VC-0013Client 3 outlet 26PHVV-VC-0014Heat exchanger secondary T inlet sensor 26PHVV-MT-0001Heat exchanger secondary T outlet sensor 26PHVV-MT-0002Heat exchanger primary T inlet sensor 26PHVV-MT-0003Heat exchanger primary T outlet sensor 26PHVV-MT-0004Electric heater T outlet sensor 26PHVV-MT-0005Pressurizer P sensor 26PHVV-MP0001Pump delta P sensor 26PHVV-MP0002Pressurizer level sensor 26PHVV-ML0001Clients inlet flow sensor 26PHVV-MF0001LCC cubicle 26PHVV-CRC-0001Conventional controller 26PHVV-PCS-0001Interlock controller 26PHVV-PIC-0001Safety controller 26PHVV-PSC-0001PSH 26PHVV-PSH-0001OB

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4. Functions for the CWS case studyThe document referenced 2MTXAD provides the Functional Breakdown Structure for the CWS down to level 2. Official CBS function names are still to be determined.

CBS level 1 is equivalent to PBS level 1 (26) but named CWS.

CBS level2:This CBS introduces an CBS level 2 for the Tokamak Cooling Water Loops. It is proposed in this case study to name it PHTS as Primary Heat Transfer System. This name will be also the name of the plant system I&C. The full name of this function is then: CWS-PHTS. The PVs introduced at this level will use this CBS identifier.

CBS level 3:The CBS level 3 is not officially defined yet but PHTS is made of several water loops and it makes sense to define as many level 3 functions. The specific function dedicated to the vacuum vessel is named VV. The full name of this function is then: CWS-PHTS-VV. The PVs introduced at this level will use this CBS identifier.

CBS level 4:For I&C specifications purposes of the VV, we will introduce control functions at level 4. These functions are named in the I&C specifications documents and in the architecture of the user software, but will not be used for any other purpose. By convention, these control functions are implemented in a single I&C controller. They are as follows:

- Related to the VV process: VV master control: MTC. VV water flow control: WFC. VV water pressure control: WPC. VV pressurizer water level control: WLC. VV water temperature control: WTC. VV water distribution control: WDC. VV loop protection: LPC. VV loop safety: LSC.

- Related to the plant system I&C system: VV CODAC interface for conventional controls: LCI. VV I/O interface for conventional controls: LII. VV health monitoring: HTH

Specific control functions related in particular to the PSH role may also be introduced in addition. They may for example, be related to CODAC – PS I&C interface and PSOS management for example and are still to be introduced in the use case. OB

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5. I&C Specifications as defined in PCDHReferences to PCDH deliverables are given for information only. These deliverables as stand alone documents will not be issued in the scope of this case study: all contents are merged in this case study specification document.

5.1. General specifications for development and operation: PCDH input 1These specifications are defined in PCDH as part of design inputs for the plant system I&C. They are identified as I1: plant system operation and control philosophy. In order to illustrate what the content of this input may be, the following requirements are proposed:

- The case study shall implement all guidelines and rules expressed in PCDH v7.- The CWS case study will be designed as a fully automated system for baking

operation and plasma operation. - The CWS case study operation will be governed by a state machine implementing

COS and PSOS. The transition between all operating states will be fully controlled by a slow controller for normal operation and off-normal operation.

- All data required for monitoring and control in normal and off-normal operation including plant system failure analysis shall be made available at central I&C level.

- The CWS case study will be designed to be fully controlled and monitored from mini CODAC for conventional, interlock and safety controls.

- The CWS case study will be fully developed under the supervision and support of the CODAC team.

- All case study design and development deliverables shall be fully documented and referenced in IDM to be mentioned in PCDH v7.

5.2. Plant system I&C architecture: PCDH deliverable 1The plant system I&C architecture is detailed in the PCDH deliverable 1: This deliverable is split in 3 documents:

- D1A which provides the definition of the CBS level 2, see D1A at 2MTXAD in IDM.

- D1Bs provides the details for each CBS level 2. D1Bs are being defined in the scope of the plant system I&C design. For the specific configuration of the PBS26, an intermediate CBS level is introduced for each loop of the PHTS. Therefore the target of D1Bs will be the CBS level 3 functions. See section 5.2.1 for details.

- D1C provides the final architecture of the PS I&C. See section 5.2.2 for details.

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5.2.1. CBS versus PBS for the case study

MTCWFC WPCWLCWTC WDC LPCLSC LCILII

VV XXXX

TCWS XXXX

CWS

XX VV

XX PH

26

PBS FBS

HTH

Figure 3: CBS breakdown and PBS breakdown for the case study

5.2.2. PS I&C architectureThe two following physical architecture are proposed for consideration in this case study. The one with the conventional controller only will be the first target for the prototype. In such a configuration, the LPC and LSC functions mentioned in section 4 will be implemented in this conventional controller.

Names of the physical components are defined in the section 3 of this document.

Interlock controller

Signal Interface

Signal Interface

Convent. controller

Plant System

Host

Plant system I&C v2

Safety controller

Mini CODAC

Network switch

PON

Signal Interface

Convent. controller

Plant System

Host

Plant system I&C v1

Mini CODAC

PON

Network switch

Figure 4: two physical architectures considered in this case study

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5.2.3. Distribution of the CBS level 4 control functions for VVThe distribution of the level 4 functions in the I&C controllers is given in the following table. It provides the link between the functional architecture and the physical architecture.

* in the conventional controller for the version 1 of the use case.

5.3. Controller configurations and performance specifications: PCDH deliverable 5

These are detailed in section 6.1.1.

CBS level 4 control functions Name Implementation inVV master control. MTC 26PHVV-PCS-0001VV water flow control. WFC 26PHVV-PCS-0001VV water pressure control. WPC 26PHVV-PCS-0001VV pressurizer water level control. WLC 26PHVV-PCS-0001VV water temperature control. WTC 26PHVV-PCS-0001VV water distribution control. WDC 26PHVV-PCS-0001VV loop protection. LPC 26PHVV-PIC-0001*VV loop safety. LSC 26PHVV-PSC-0001*VV - CODAC interface for conventional controls. LCI 26PHVV-PCS-0001VV - I/O interface for conventional controls. LII 26PHVV-PCS-0001VV health monitoring HTH 26PHVV-PCS-0001

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5.4. List of signals and associated properties: PCDH deliverable 6Signal properties

Component ID Comment Signal ID Signal type and range

Engineering value range

Available status

Power contactor command CZ1-CCC DO [0 -24 V] P On – Off FPower contactor status CY1-CCC DI [0 -24 V] P On - Off FElectric failure YT1-CCC DI [0 -24 V] N On - Off FSpeed command CS1-CCC AO [4-20 mA] P 0 – 100 % F

26PHVV-PL-0001

Speed measurement SY1-CCC AI [4-20 mA] P 0 – 100 % FPower contactor command CZ1-CCC DO [0 -24 V] P On - Off FPower contactor status CY1-CCC DI [0 -24 V] P On - Off FElectric failure YT1-CCC DI [0 -24 V] N On - Off FHIHI temperature TS1-CCC DI [0 -24 V] N On - Off F

26PHVV-HT-0001

Power level command CW1-CCC AO [4-20 mA] P 0 – 100 % F26PHVV-HX-0001 Not relevant: no signal expected, they are provided by other identified components26PHVV-PZ-0001 Not relevant: no signal expected, they are provided by other identified components26PHVV-VC-0001 Valve command TCVZ1-CCC AO [4-20 mA] P 0 – 100 % F26PHVV-VC-0002 Valve command TCVZ1-CCC AO [4-20 mA] P 0 – 100 % F

Valve command FVZ1-ICC DO [0 -24 V] P On - Off FValve open status FVY1-ICC DI [0 -24 V] P On - Off F26PHVV-VC-0003Valve close status FVY2-ICC DI [0 -24 V] P On - Off FValve command FVZ1-CCC DO [0 -24 V] P On - Off FValve open status FVY1-CCC DI [0 -24 V] P On - Off F26PHVV-VC-0004Valve close status FVY2-CCC DI [0 -24 V] P On - Off FValve command FVZ1-CCC DO [0 -24 V] P On - Off FValve open status FVY1-CCC DI [0 -24 V] P On - Off F26PHVV-VC-0005Valve close status FVY2-CCC DI [0 -24 V] P On - Off FValve command FVZ1-CCC DO [0 -24 V] P On - Off FValve open status FVY1-CCC DI [0 -24 V] P On - Off F26PHVV-VC-0006Valve close status FVY2-CCC DI [0 -24 V] P On - Off F

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Signal propertiesComponent ID Comment Signal ID Signal type

and rangeEngineering value range

Available status

Valve command FVZ1-CCC DO [0 -24 V] P On - Off FValve open status FVY1-CCC DI [0 -24 V] P On - Off F26PHVV-VC-0007Valve close status FVY2-CCC DI [0 -24 V] P On - Off FValve command FVZ1-CCC DO [0 -24 V] P On - Off FValve open status FVY1-CCC DI [0 -24 V] P On - Off F26PHVV-VC-0008Valve close status FVY2-CCC DI [0 -24 V] P On - Off FValve command FVZ1-CCC DO [0 -24 V] P On - Off FValve open status FVY1-CCC DI [0 -24 V] P On - Off F26PHVV-VC-0009Valve close status FVY2-CCC DI [0 -24 V] P On - Off FValve command FVZ1-CCC DO [0 -24 V] P On - Off FValve open status FVY1-CCC DI [0 -24 V] P On - Off F26PHVV-VC-0010Valve close status FVY2-CCC DI [0 -24 V] P On - Off FValve command FVZ1-CCC DO [0 -24 V] P On - Off FValve open status FVY1-CCC DI [0 -24 V] P On - Off F26PHVV-VC-0011Valve close status FVY2-CCC DI [0 -24 V] P On - Off FValve command FVZ1-CCC DO [0 -24 V] P On - Off FValve open status FVY1-CCC DI [0 -24 V] P On - Off F26PHVV-VC-0012Valve close status FVY2-CCC DI [0 -24 V] P On - Off FValve command FVZ1-CCC DO [0 -24 V] P On - Off FValve open status FVY1-CCC DI [0 -24 V] P On - Off F26PHVV-VC-0013Valve close status FVY2-CCC DI [0 -24 V] P On - Off FValve command FVZ1-CCC DO [0 -24 V] P On - Off FValve open status FVY1-CCC DI [0 -24 V] P On - Off F26PHVV-VC-0014Valve close status FVY2-CCC DI [0 -24 V] P On - Off F

26PHVV-MT-0001 Temperature sensor signal TT1-CCC AI [4-20 mA] P 0 – 100 C F26PHVV-MT-0002 Temperature sensor signal TT1-CCC AI [4-20 mA] P 0 – 100 C F26PHVV-MT-0003 Temperature sensor signal TT1-CCC AI [4-20 mA] P 0 – 250 C F

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Signal propertiesComponent ID Comment Signal ID Signal type

and rangeEngineering value range

Available status

Temperature sensor signal TT1-CCC AI [4-20 mA] P 0 – 250 C F26PHVV-MT-0004 HIHI temperature TSH1-ICC DI [0 -24 V] N On - Off F26PHVV-MT-0005 Temperature sensor signal TT1-CCC AI [4-20 mA] P 0 – 250 C F

Pressure sensor signal PT1-CCC AI [4-20 mA] P 0 – 40 bar FLOLO pressure PSL1-ICC DI [0 -24 V] N On - Off F26PHVV-MP-0001HIHI pressure PSH1-ICC DI [0 -24 V] N On - Off F

26PHVV-MP-0002 Pressure sensor signal PT1-CCC AI [4-20 mA] P 0 – 10 bar FLevel sensor signal LT1-CCC AI [4-20 mA] P 0 – 100 % FLOLO level LSL1-ICC DI [0 -24 V] N On - Off F26PHVV-ML-0001HIHI level LSH1-ICC DI [0 -24 V] N On - Off FFlow sensor signal FT1-CCC AI [4-20 mA] P 0 – 100 % F26PHVV-MF-0001 LOLO flow FSL1-ICC DI [0 -24 V] N On - Off FFront door close status CY1-CCC DI [0 -24 V] N On - Off FRear door close status CY2-CCC DI [0 -24 V] N On - Off FTemperature sensor signal TT1-CCC AI [4-20 mA] P 0 – 100 C FHIHI temperature TSH1-CCC DI [0 -24 V] N On - Off FEarth current signal IT1-CCC AI [4-20 mA] P 0 – 100 mA F

26PHVV-CRC-0001

HIHI over earth current ISH1-CCC DI [0 -24 V] N On - Off F26PHVV-SM-0001 Emergency stop SM1-SCC DI [0 -24 V] N On - Off F

Signal type: P = positive logics, N = negative logics.Available status: F = failure, S = simulation, M = manual command mode (not under automatic control)OB

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5.5. List of controller Variables for CODAC interface: PCDH deliverable 7The following list of controller variables is derived from the signal list of the previous section. Additional variables not reflecting signals will be introduced along the detailed specifications definition, see section 6. Signals reflecting the states of the components are combined in the controller to define the component state as a single variable coded in an integer. The full scheme name of the controller variables will be: [complete CBS level 3]:[PV ID] then for the case study: 26-PHTS-VV for CBS level 3.The scheme of the variable name is:

[component ID]-[signal ID] for variables reflecting signals as compliant with PCDH guidelines. [Variable name] for variables not reflecting signals (internal variables).

See the following table for all variables of the case study:

Control function CBS name

Component involved Comment Associated controller

variable nameFormat Forced

statusNone VV operation stet configuration CONFVV W -None VV loop state VVSTATE W -None Pulse request PULSERQ B -VV master control. MTC

None COS for VV loop VVCOS W -WFC start/stop CWFC B -High speed request HSRQ B -Delta P pump set point, range [2- 6 bars]

PT2SP F -

Low flow set point, range [100- 400 m3/h]

LFSP F -

High flow set point, range [400- 800 m3/h]

HFSP F -

Stop state achieved STOPWFC B -Low flow state achieved LFST B -

None

High flow state achieved HFST B -Power contactor command PL1-CZ B FOPump state PL1-CY B FOPump electric failure PL1-YT B FOSpeed command PL1-CS F FO

26PHVV-PL-0001

Speed measurement PL1-SY F FO

VV water flow control WFC

26PHVV-VC-0008 Valve command VC8-FVZ B FO

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Valve state VC8-FVY I FO26PHVV-MP-0002 Pressure sensor signal MP2-PT F FO26PHVV-MF-0001 Flow sensor signal MF1-FT F FO



Variable nameFormat Forced

status

None VV pressure set point range [2-34 bars] PT1SP F FO

Valve command VC4-FVZ B FO26PHVV-VC-0004 Valve state VC4-FVY I FOValve command VC5-FVZ B FO26PHVV-VC-0005 Valve state VC5-FVY I FO

VV water pressure control WPC

26PHVV-MP-0001 Pressure sensor signal MP1-PT B FONone VV level set point LT1SP F FO

Valve command VC6-FVZ B FO26PHVV-VC-0006Valve state VC6-FVY I FOValve command VC7-FVZ B FO26PHVV-VC-0007Valve state VC7-FVY I FO

26PHVV-ML-0001 Sensor signal ML1-LT F FO

VV pressurizer water level control.

WLC

26CVVV Water draining and refilling OK CVDLOK B FO

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status

None VV loop temperature set-point target, range [20-200 C] TTSPTARGET F -

None VV loop temperature set-point for cooling and heating, range [20-200 C] TTSPCURRENT F -

None For cooling stop STOPCOOL B -None For heating stop STOPHEAT B -None To initiate a cooling state COOL B -None To initiate a heating state HEAT B -26CCC1 CCSW1 water loop OK CCSW1OK B FO26PHVV-VC-0001 Valve command VC1-TCVZ F FO26PHVV-VC-0002 Valve command VC2-TCVZ F FO

Power contactor command HT1-CZ B FOHeater state HT1-CY B FOHeater electric failure HT1-YT B FOHIHI temperature HT1-TS B FO

26PHVV-HT-0001

Power level command HT1-CW F FO26PHVV-MT-0001 Temperature measurement MT1-TT F FO26PHVV-MT-0002 Temperature measurement MT2-TT F FO26PHVV-MT-0003 Temperature measurement MT3-TT F FO26PHVV-MT-0004 Temperature measurement MT4-TT F FO

VV water temperature control. WTC

26PHVV-MT-0005 Temperature measurement MT5-TT F FOOBSOLETE

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statusNone Client 1 requested CLIENT1RQ B -None Client 2 requested CLIENT2RQ B -None Client 3 requested CLIENT2RQ B -None Client 1 connected CLIENT1CN B -None Client 2 connected CLIENT2CN B -None Client 3 connected CLIENT3CN B -None VV loop configured CLIENTCN B -

Valve command VC9-FVZ B FO26PHVV-VC-0009 Valve state VC9-FVY I FOValve command VC10-FVZ B FO26PHVV-VC-0010 Valve state VC10-FVY I FOValve command VC11-FVZ B FO26PHVV-VC-0011 Valve state VC11-FVY I FOValve command VC12-FVZ B FO26PHVV-VC-0012 Valve state VC12-FVY I FOValve command VC13-FVZ B FO26PHVV-VC-0013 Valve state VC13-FVY I FOValve command VC14-FVZ B FO

VV water distribution control. WDC

26PHVV-VC-0014 Valve state VC14-FVY I FO

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Component involved

Comment Associated controller Variable name

Format Forced status

None Heat load dissipation disabled POWERDSBL B -None Operator acknowledge OPRACK B -26PHVV-MF-0001 LOLO flow MF1-FSL B -

LOLO pressure MP1-PSL B -26PHVV-MP-0001 HIHI pressure MP1-PSH B -LOLO level ML1-LSL B -26PHVV-ML-0001 HIHI level ML1-LSH B -

26PHVV-MT-0004 HIHI temperature MT4-TSH B -Valve command VC3-FVZ B -

VV loop protection. LPC

26PHVV-VC-0003 Valve state VC3-FVY I -None Internal Vs None - -VV loop safety. LSC26PHVV-SM-0001 Emergency stop SM1-CY B -

VV - CODAC interface for conventional controls.

LCI

None Internal Vs

No specific variable in addition to those mentioned in the other control functions

- -

VV - I/O interface for conventional controls.

LII None Internal Vs See guidelines for user software engineering - -

None Internal Vs None -Front door close status CRC1-CY1 B -Rear door close status CRC1-CY2 B -Temperature sensor signal CRC1-TT B -HIHI temperature CRC1-TSH B -Earth current signal CRC1-TT F -

VV health monitoring HTH 26PHVV-CRC-0001

HIHI over earth current CRC1-IT B -

Forced status: FO = variable mode: if FO is mentioned, the controller variable may be forced, see software development guidelines for implementation of the mechanism.

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5.6. Configuration of I&C cubicles: PCDH deliverable 8Requires the dedicated PCDH satellite document expected for PCDH v6. The I&C cubicle of the case study may be the target of the second task of the cubicle framework contract (first task is guidelines).

Cubicle enclosure configuration (still TBD)

5.7. CWS case study state machines: PCDH deliverable 9Is detailed in section 6.1.2OBSOLETE

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6. Tech. Specs for manufacture of the VV I&C system6.1. Detailed specifications for the controllers

6.1.1. Hardware configurationCPU rack

Reference Designation Qt.6ES7400-1JA11-0AA0 S7-400 chassis 16ES7407-0KA02-0AA0 Alimentation PS407 10A; 120/230V ca-> 5V/24V cc 16ES7416-3 PN 3ER05-0AB0 PLC 416-3 PN CPU card 16ES7971-0BA00 Lithium AA, 3.6 V/2.3 Ah 16ES7 952-1AS00-0AA0 16 MB RAM 16ES7971-0BA00 Lithium AA, 3.6 V/2.3 Ah 16GK7443-1EX20-0XE0 CP 443-1 Industrial Ethernet S7-400 1

Remote IO rack

Reference Designation Qt.6ES7195-1GA00-0XA0 Length:480mm: 19 “ mounting rail (Hot swapping function)6ES7 195-7HA00-0XA0 Bus extension for one power supply and an IM153-46ES7153-4AA01-0XB0 Active Bus backplane to Hot-Swap modules available; 16ES7953-8LF20-0AA0 Memory Card (64 KB)6ES7307-1EA01-0AA0 Power supply PS 307-1E; 120/230V ca 24V cc 5A 16ES7321-1BL00-0AA0 Digital Input Module SM 321 isolated (500 VDC), 32 DI, DC 24V 26ES7322-1BL00-0AA0 Digital output Module 32 DO, DC 24V, 0.5A isolated 1

6ES7331-7KF02-0AB0Analog Input Module 8 AI backplane isolated (500V), 14 bits+sign, configurable input range (current- voltage –thermocouple) 2

6ES7332-5HF00-0AB0Analog Output Module 8 AO 11/12 bits, backplane and channel isolated (500V), configurable output range (current- voltage) 1

6ES7390-1BC00-0AA0 Rail L=2000mm 1

6.1.2. User software specifications

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Details for I&C functions level 4 are given here:

VV master control: MTC

Emergency stop

Stop

Started

/SM1-CY

SM1-CY

(PLASMAVV + BAKEVV) * /SM1-CY

Plasma operation

Baking operation

STOPVV + SM1-CY

STOPVV + SM1-CY + PLASMAVV

BAKEVV * LFST * /SM1-CY

PLASMAVV * LFST * /SM1-CY

STOPVV + SM1-CY + BAKEVV

Figure 5: MTC state machineMTC function description: see MTC state machine on Figure 6. The VV operation configuration (STOPVV, PLASMAVV and BAKEVV) is defined by the single multistate variable CONFVV (values = respectively 1, 3, 4), except for the state EMERGENCY STOP:

Emergency stop: activated by the safety variable SM1-YT. The variables CWFC, COOL, HEAT, are set and forced to off. The VV loop can not be started. The variable VVSTATE is set to 0.

Stop: activated as defined in Figure 6. The VV loop can be started. The variables CWFC, COOL and HEAT are set and forced to off. VVSTATE is set to 1.

Started: activated as defined in Figure 6. The VV loop is started if there is no emergency stop request and CONFVV = 3 or 4:- The variable VVSTATE is set to 2.- The variables CWFC is set to on when the variable CLIENTCN is set to on by the

WDC function.- The variable TTSPTARGET is set to MT4-TT at initialisation of the started state and

the variable HEAT and COOL are set to the right value to get the TTSPTARGET.- The variable LT1SP is set to 50 %.- The variable PT1SP is set to the suitable value depending on MT4-TT, see baking

operation.

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Plasma operation: activated when CONFVV = 3, the low speed is achieved (LFST on), and there is no emergency stop request (SM1-CY off):- The variable VVSTATE is set to 3.- The variable TTSPTARGET is set to 120 C- The variable HEAT and COOL are set to the right value to get the TTSPTARGET. - The variable LT1SP is set to 20 %.- The variable PT1SP is set to 35 bars.- The PULSE command governs the variable CHSP by CHSP = PULSE.

Baking operation: activated when CONFVV = 4, the low speed is achieved (LFST on), and there is no emergency stop request (SM1-CY off):- The variable VVSTATE is set to 4.- The variable TTSPTARGET is set to 200 C- The variable HEAT and COOL are set to the right value to get the TTSPTARGET. - The variable LT1SP is set to 80 %.- The variable PT1SP is set to the value ((MT4-TT-100)/100)*29 + 5 to align the

pressure with the current loop temperature.

Just 3 out of 13 COS states are used in this case study These COS states are defined by the value of the variable VVCOS as follows:

COS state VVCOS value

Condition

READY 1 (VVSTATE=2) * CHSPFINAL PREPARATION 2 (VVSTATE=3) * CHSPRUN 3 (VVSTATE=3) * HFST

The links of MTC with other functions are shown in the sections below.

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VV water flow control: WFCWFC properties: conventional control requiring a response time of 200 ms for the whole control including the I/O interface.

26PHVV-PL-0001

F

26PHVV-MP-0002

26PHVV-VC-0008

F

26PHVV-MF-0001

Figure 6: P&ID of the WFCFigure 7: WFC state machineWFC function description:

The operation of WFC includes a pump start process and a pulsed operation synchronised by the master control MTC, see the state machine on Figure 7. At CWFC set to on and no pump failure, , the

pump contactor is switched on and the pump speed is ramped up to get the low flow set point. Then the delta P feed-back control using PL1-CS, MP2-PT and PT2SP is activated. The LFST state is set to on.

At HSRQ set to on, the delta P feed-back control is deactivated and the pump speed is ramped up again to get the high flow set point. Then the delta P feed-back is activated again. The LFST state is set to off, the HFST state is set to on.

At HSRQ set to off, the delta P feed-back control is deactivated and the pump speed is ramped down

to get the low flow set point. Then the delta P feed-back is activated again. The LFST state is set to on, the HFST state is set to off.

At CWFC set to off, the delta P feed-back control is deactivated and the pump speed is ramped down to 0. Then the pump contactor is switched off. The LFST and HFST states are set to off.

At pump failure (electric failure), the delta P feed-back control is deactivated and the pump speed is set to 0. Then the pump contactor is switched off. The LFST and HFST states are set to off.

The link of WFC with other functions is shown in Figure 8, while Table 1 provides a characterisation of these links.

Stop

Low speed

High speed

CWFC * /PL1-YT

/CWFC + PL1-YT

CWFC * /PL1-YT * CHSP

/CWFC + PL1-YT + /CHSP

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CWS-TCWS-VV-MTC

Master control

CWS-TCWS-VV-WFC

Water flow control

CWS-TCWS-VV-LII

I/O interface

WFC-L1

WFC-L2

CWS-TCWS-VV-WFC

Table 1: Characterisation of WFC links.

Link ID Variable Resp. time * Direction Control type *PL1-CZ > LIIPL1-CY < LIIPL1-YT < LIIPL1-CS > LIIPL1-SY < LIIVC8-FVZ >LIIVC8-FVY < LIIMP2-PT < LII

WFC-L1

MF1-FT < LIICWFC < MTCHSRQ < MTCLFST > MTCWFC-L2

HFST

200 ms

> MTCC

onve

ntio

nal c

ontr

ols

* = inherited from the function properties

Figure 8: WFC relationship with other CBS level 4 functions.OBSOLETE

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VV water pressure control: WPCWPC properties: conventional control requiring a response time of 500 ms for the whole control including the I/O interface.

Figure 9: P&ID of the WPC

WPC function description:

The WPC function has a single state: active. There is no state machine. The opening of the two valves is governed by the VV pressure set point PT1SP with a dead band of 0.5 bar. PT1SP is provided by the MTC function: If MP1-PT > PT1SP + 0.5 bar then VC5 is opened and closed when MP1-PT <= PT1SP. If MP1-PT < PT1SP - 0.5 bar then VC4 is opened and closed when MP1-PT >= PT1SP.The set point PT1-SP is determined by the master control MTC depending on the VV operating mode and temperature.

On request by LPC, the valve VC4 is forced to closed state.

CWS-TCWS-VV-MTC

Master control

CWS-TCWS-VV-WPC

Water pressure control

CWS-TCWS-VV-LII

I/O interface

WPC-L1

WPC-L2

CWS-TCWS-VV-WPC

CWS-TCWS-VV-LPC

Water loop protection

WPC-L3

Figure 10: WPC relationship with other CBS level 4 functions.

Table 2: characterisation of the

WPC links

Link ID Variable Resp. time *

Direction Control type *

VC4-FVZ > LIIVC4-FVY < LIIVC5-FVZ > LIIVC5-FVY < LII

WPC-L1

MP1-PT < LIIWPC-L2 PT1SP < MTCWPC-L3 STOPWPC

500 ms

< LPC

Conventional

* = inherited from the function properties.

26PHDL-PZ-0001

P

26PHDL-MP-0001

26PHDL-VC-0004

26PHDL-VC-0005

GN2 gas

supply: PBS 65

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VV pressurizer water level control: WLCWLC properties: conventional control requiring a response time of 500 ms for the whole control including the I/O interface.

WLC function description:

The WLC function is active if the status of the CVCS system (26.CV.DL) is available (variable CVDLOK is on). If so:The opening of the two valves is governed by the VV level set point LT1SP with a dead band of 2%. LT1SP is provided by the MTC function: If ML1-LT > LT1SP + 2 % then VC7 is opened and closed when ML1-LT <= LT1SP. If ML1-LT < LT1SP – 2 % then VC6 is opened and closed when ML1-LT >= LT1SP.The set point LT1-SP is determined by the master control MTC depending on the VV operating mode.On request by LPC (WLC function failure), the two valves VC6 and VC7 are closed.

CWS-TCWS-VV-MTC

Master control

CWS-TCWS-VV-WLC

Water level control

CWS-TCWS-VV-LII

I/O interface

WLC-L1

WLC-L2

CWS-TCWS-VV-WLC

CWS-TCWS-VV-LPC


WLC-L3

Figure 12: WLC relationship with other CBS level 4 functions.

Figure 11: P&ID of the WLC

26PHVV-PZ-0001

L26PHVV-ML-0001

26PHVV-VC-0003

26PHVV-VC-0007 26PHVV-VC-0006

Water storage and treatment CVCS

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Table 3: characterisation of the

WLC links

VV water temperature control: WTCWTC properties: conventional control requiring a response time of 500 ms for the whole control including the I/O interface.

26PHVV-VC-0001

T

26PHVV-MT-0005

26PHVV-HX-0001

26PHVV-HT-0001

T

26PHVV-MT-0004

26PHVV-VC-0002

F

26PHVV-MT-0002

T

26PHVV-MT-0001

CC

WS

1

T

26PHVV-MT-0003

Figure 13: P&ID of the WTCWTC function description:The WTC function governs the loop temperature from the TTSP temperature set-point: The TTSP value is set to TTbakingSP or to TTplasmaSP by MTC function depending on the VV operating state.WTC function is split in two sub functions:

• Cooling with heat exchanger HX1 and associated components including CCWS1 loop.• Heating with heater HT1 and associated components.

In order to avoid any overlap of control, both sub-functions are controlled by the WTC state machine, itself under MTC control, see Figure 14.

Figure 14: WTC state machine

Link ID Variable Resp. time *

Direction Control type *

VC6-FVZ > LIIVC6-FVY < LIIVC7-FVZ > LIIVC7-FVY < LII

WLC-L1

ML1-LT < LIIWLC-L2 LT1SP < MTCWLC-L3 STOPWLC

500 ms

< LPC

Conventional

Stop

Cool Heat

Cool

T control

/Cool

Heat

/Heat

Tcontrol

/Tcontrol

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This state machine introduces four states for WTC:• Stop: Heater 26PHVV-HT-0001switch off, PHVV-VC-002 valve closed and PHVV-VC-

001 valve opened.• Cooling: On request by MTC if CCWS1 loop is available, see MTC for details. If the

variable CCWS1 is on, then the position of the PHVV-VC-002 valve is controlled by a feed-forward controller function block of the 26PHVV-PCS-0001 controller, provided there is no stop request by LPC, see LPC function for details. The primary measurement is MT4-TT, the secondary measurement is MT3-TT, the manipulated variable is VC2-TCVZ, the T set-point is TTSPCURRENT, see Figure 15 for details. TTSPCURRENT set-point is initiated to MT4-TT value at the entering of the cool state and then ramped down to TTSPTARGET at the rate of 100 C / h. The VC1-TCVZ variable is value is determined by the law: 100 % - VC2-TCVZ. On request by LPC the TTSPCURRENT ramp down is held on. If the variable CCWS1 is off the valve PHVV-VC-002 is closed and the valve PHVV-VC-001 is open (100 %).

• Heating: On request by MTC, see MTC for details. Then, the heater 26PHVV-HT-0001 switch on, PHVV-VC-002 valve closed and PHVV-VC-001 valve opened, provided there is no stop request by LPC, see LPC function for details. The power level of the heater is controlled by a controller function block of the 26PHVV-PCS-0001 controller. The measurement is MT5-TT, the manipulated variable is HT1-CW and the T set-point is TTSPCURRENT. TTSPCURRENT set-point is initiated to MT5-TT value at the entering of the heat state and then ramped up to TTSPTARGET at the rate of 100 C / h. At heater electric failure and HIHI temperature, the heater is switched off. On request by LPC the TTSPCURRENT ramp up is held on.

• Temperature control: On request by MTC, see MTC for details. This function is similar to heat and cool at the same time but with a T set-point derived from TTSPTARGET with following law:

- T set-point for cooling = TTSPTARGET + 1 C- T set-point for heating = TTSPTARGET - 1 C

Figure 15: Schema of the feedforward controller

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CWS-TCWS-VV-MTC

Master control

CWS-TCWS-VV-WTC

Water temperature control

CWS-TCWS-VV-LII

I/O interface

WTC-L1

WTC-L2

CWS-PHTS-DLHT-WTC

CWS-TCWS-VV-LPC


WTC-L3

Figure 16: WTC relationship with other CBS level 4 functions.Link ID Variable Resp. time

*Direction Control type *

VC1-TCVZ > LIIVC2-TCVZ > LIIHT1-CZ > LIIHT1-CY < LIIHT1-YT < LIIHT1-TS < LIIHT1-CW > LIIMT1-TT < LIIMT2-TT < LIIMT3-TT < LIIMT4-TT < LII

WLC-L1

MT5-TT

500 ms

< LII

Conventional

TTSPTARGET < MTCCOOL < MTC

WLC-L2 HEAT < MTCSTOPCOOL < LPCWLC-L3STOPHEAT

500 ms

< LPC

Conventional

VV water distribution control: WDCWDC properties: conventional control requiring a response time of 500 ms for the whole control including the I/O interface. The water is circulating from the left hand to right hand on Figure 17.

26PHVV-VC-0010

Client 1

26PHVV-VC-0013

26PHVV-VC-0014

Client 3

26PHVV-VC-0011

26PHVV-VC-0012

Client 2

26PHVV-VC-0009

P-111

Figure 17: P&ID of the WDC

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WDC function description:The internal variables CLIENT1RQ, CLIENT2RQ, CLIENT3RQ define the configuration request of the water distribution:

Opening the valves: The valves (VC-0009; VC0010), (VC-0011; VC0012), (VC-0013; VC0014), are opened when the water loop is stopped (STOP variable set to on) and the configuration request variable is on, with the following sequence: open the client outlet valve first and open the client inlet valve when the client outlet state is open. The state variables CLIENT1CN, CLIENT2CN, CLIENT3CN are set to on when the two associated valve states are open.

Closing the valves: The valves (VC-0009; VC0010), (VC-0011; VC0012), (VC-0013; VC0014), are closed when the water loop is stopped (STOP variable set to on) and the configuration request variable is off, with the following sequence: close the client inlet valve first and close the client outlet valve when the client outlet state is closed. The state variables CLIENT1CN, CLIENT2CN, CLIENT3CN are set to off as soon as one of the valves is no longer open.

VV configuration state: the variable CLIENTCN is set to on when the CLIENT configuration is matching the requested configuration.

CWS-TCWS-VV-MTC

Master control

CWS-TCWS-VV-WDC

Water distribution control

CWS-TCWS-VV-LII

I/O interface

WDC-L1

WDC-L2

CWS-TCWS-VV-WDC

Figure 18: WDC relationship with other CBS level 4 functions

Link ID Variable Resp. time * Direction Control type *

WDC-L2 CLIENTCN < MTCVC9-FVZ > LIIVC9-FVY < LIIVC10-FVZ > LIIVC10-FVY < LIIVC11-FVZ > LIIVC11-FVY < LIIVC12-FVZ > LIIVC12-FVY < LIIVC13-FVZ > LIIVC13-FVY < LIIVC14-FVZ > LII

WDC-L1

VC14-FVY

500 ms

< LII

ConventionalOBSOLETE

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VV loop protection: LPCLPC properties: interlock control requiring a response time of 500 ms for the whole control including the I/O interface.

Some protection functions are already implemented in conventional control functions as WFC and WTC: they are not considered as interlock controls: Only 3 interlock controls are considered in this case study:

1. The protection of clients against LOLO flow, LOLO and HIHI pressure and HIHI temperature. In case of MF1-FSL + MP1-PSL + MP1-PSH + MT4-TSH = 1 then POWERDSBL is set to 1 and reset on OPRACK = 1.

2. The protection of the water cooling loop against HIHI pressure. In case of MP1-PSH = 1 then STOPWLC and is set to 1 and reset on OPRACK = 1.

3. The protection of the water cooling loop against LOLO and HIHI level. In case of ML1-LSH = 1 then STOPWPC and STOPHEAT are set to 1 and reset on OPRACK = 1. In case of ML1-LSL = 1 then STOPWPC and STOPCOOL are set to 1 and reset on OPRACK = 1

The variable OPRACK is reset by the EPICS IOC as a simple command.

VV loop safety: LSCLSC properties: Safety control requiring a response time of 500 ms for the whole control including the I/O interface.

The emergency stop is a hardwired safety control acting on the 6 distribution valves, the pump, the heater and the master control MTC:

- The 6 valves are closed and locked in closed state.- The pump and heater are switched off and locked in switched off state.- MTC control is set and locked in EMERGENCY state.

VV - CODAC interface for conventional controls: LCISee PLC user software guidelines

VV - I/O interface for conventional controls; LIISee PLC user software guidelines

VV health monitoring: HTHSee PLC user software guidelines

Rules and guidelines to apply for software development:See PLC user software guidelines.

6.2. Detailed specifications for the PSH configuration

Scope: - The IOC configuration through SDD: details still TBD.

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- The PS I&C health monitoring: details still TBD

Rules and guidelines to apply: still TBD

6.3. Detailed specifications for the HMI configuration

HMI specifications:The VV HMI will be organised into two set of mimics:

Those dedicated to loop operation. Those dedicated to loop maintenance.

Loop operation:The organisation of the display for operation will be organised in two levels:The first level will be a display of the VV loop organised in three parts:

First part to display the process status as Figure 2 plus operation state. Second part an alarm box to display the ten last alarms. Third part to display the curves of loop pressure, flow and temperature.

No command accessible on this display, only buttons to call the second level of display for operation and the first level for maintenance.

A specific display where all configuration variables may be adjusted. A specific display for each function: MTCWFC, WPC, WLC, WTC and WDC showing

the P&ID figures and state machine as defined in this document.

Loop maintenance:From the first level of the HMI for operation, the organisation of the display for maintenance will be organised in two levels:

A picture of the controller for whole PLC health monitoring, details still TBD. Details for each PLC board for to display the status of each I/O board for value and state.

Rules and guidelines to apply: still TBD

6.4. Other CODAC functions

- Scope: o The IOC configuration through SDD: details to be completed.o The PS I&C health monitoring: details still to be completed.o Archiving and alarming: details still to be completed.OB

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7. Tech. Specs for manufacture of the VV simulatorThe VV loop simulator may be implemented as an autonomous software module of the PLC which is fed by output PVs and which provide simulated value of the input PVs.

Another way is to connect an external simulator (e.g. PXI) to the PLC inputs/outputs.

Solution to select is to be discussed. Whatever the solution, the algorithms to implement in the simulator are given below, depending on component type:

All kn parameters mentioned will be determined during the test of the simulator. t designates the time in s starting from the beginning of the simulation.

Open/close valves, contactors of pump and heater:Simulation of valve, pump and heater states: Initial state = off - closed, excepted for VC0008 = openXXY=1, 2 seconds after XXZ is ON (valve opened)XXY=2, 2 seconds after XXZ is OFF (valve closed)Simulation of electric failure from HMI on request.

WFC measurements:The model is PL1-CS is adjusted to get PT2SP by the control function WFC. Then in sequence:

For the pump speedInitial value = 0SY = k1 * , k1 to be adjusted during first simulation. dtSYCS )(

For the delta P of the pump:Initial value = 0[a] MP2-PT = k2 * PT1-SYFor the water flow:Initial value = 0[b] MF1-FT = k3 * PTMP2

WPC measurementsInitial value of MP1-PT = 2.0 barWhen VC5-FVY=1 (valve opened) then set MP1-PT0 to the current value of MP1-PT and execute:MP1-PT = MP1-PT0 + k4 * dtPTMP ).160(Until VC5-FVY=1

When VC4-FVY=1 (valve opened) then set MP1-PT0 to the current value of MP1-PT and execute:MP1-PT = MP1-PT0 - k4 * dtPTMP ).1(Until VC4-FVY=1

WLC measurementsInitial value of ML1-LT = 20 %

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When VC6-FVY=1 and VC3-FVY=1 (valves opened) then set ML1-LT0 to the current value of ML1-LT and execute:ML1-LT = ML1-LT0 + k5 * tUntil VC6-FVY=1 and VC3-FVY=1

When VC7-FVY=1 and VC3-FVY=1 (valves opened) then set ML1-LT0 to the current value of ML1-LT and execute:ML1-LT = ML1-LT0 - k5 * tUntil VC7-FVY=1 and VC3-FVY=1

When VC6-FVY=0 and VC7-FVY=0 and VC3-FVY=1 then set ML1-LT0 to the current value of ML1-LT, then set MT5-TT0 to the current value of MT5-TT and execute:[c] ML1-LT = ML1-LT0 + k6 * (MT5-TT – MT5-TT0)

WTC measurementsInitial value of all temperature sensors to 20 C, when the simulator is started.The MT1-TT keeps constant at 20 C- W1 is the amount of power exchanged in HX1- W2 is the amount of power provided by the heater.- W3 is the amount of power coming from clients.

[d] W1 = k7 * VC2-TCVZ * (MT3-TT - MT1-TT) = k8 * (MT2-TT - MT1-TT)[e] W2 = k9* HT1-CW = k10 * MF1-FT * (MT5-TT - MT4-TT)[f] W3 = a pulse of + 10 MW 400s during the plasma and - 1 MW permanently without plasma due to heat losses on 80 K thermal shields. W3 = k11 * MF1-FT * (MT3-TT - MT5-TT).

MT4-TT is determined by the mix of water coming from the HX at MT1-TT and flow = MF1-FT * VC2.TCVZ and water bypassed by VC1 at MT3-TT and flow = MF1-FT * VC1.TCVZ. Hence:[g] MT4-TT = VC2.TCVZ * MT1-TT + VC1.TCVZ * MT3-TT

Heating mode- VC1-TCVZ is forced to 100 % and VC2-TCVZ to 0 by the controller.- MT5-TT = TTSPCURRENT- 1.- HT1-CW is determined by the controller depending MT5-TT.- From [d] MT2-TT = MT1-TT.- Use [f] to determine MT3-TT with W3 = - 1 MW.- From [g] MT4-TT = MT3-TT (VC2 is closed); W1 = 0

Cooling mode: - MT4-TT = TTSPCURRENT + 1.- Heater is switched off, W2 = 0 then [e] gives MT5-TT = MT4-TT.- Use [f] to determine MT3-TT.- Use [d] to determine MT2-TT.

WDC measurementsOnly state variables to simulate, see generic rules for valves.OB

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8. Development and manufactureThe hardware including the fully assembled I&C cubicles, the I&C controllers, PSH and MiniCODAC may be procured through the framework contracts being set up or expected to be set up by end of 2011.

The user software for PLC, configurations of PSH and miniCODAC will be developed through a specific sub task of the task order number 3 of the I&C support contract.

The actors: PLC expert and CWS case study project leader: B Evrard. Acting as the PS I&C RO and CODAC PSEG for CWS: JY Journeaux. CODAC support for CODAC interface: S Pande. HMI, alarming, archiving support: N Utzel. Acting as the DA supplier for software development (PLC, IOC, HMI, …): TCS HW Integration for cubicles, miniCODAC and PSH: the cubicle, miniCODAC, PSH

framework contracts through PMI and JYJ.

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ANNEX 1: CWS functional breakdown

PBS26 - Cooling Water System

31

Vacuum pumping and

Fuelling

11

Mangnets

18

Fueling & Wall Conditioning

34

Cryogenics

32

Tritium Plant

51

ICH & CD

52

ECH & CD

27

Thermal Shields

41

Coil power supply and distribution

53

NBH and CD

54

LHH and CD

43

SSEN

65

Liquid & Gas Distribution

61

Water Disposal System

31

Vacuum Pumping98

External Services

15

Vacuum Vessel

56

Test Blanket Modules

17

Divertor

55

Diagnostic

26.CC.C1

CCWS1

26.CC.C2

CCWS2

26.CH.H1

CHWS1

26.HR

HRS

26.CH.H2

CHWS2

26.PH.B1/B2/B3

FWBKT PHTS

26.PH.NB

NBI PHTS

26.PH.DL

DIV/LIM PHTS

26.PH.V1/V2

VV PHTS

26.CV

Chemical Volume Control

26.DR

Draining

26.DY

Drying

16

Blanket

Plant System I&C Process Functional Breakdown

Plant System Cooling Water System

Revision Date Prepared By Reviewed By Approved By REV

April 2010 DCI FSI, JYJ ABC 0

Cooling Water System Block Diagram with Interface Details PBS Level 26.00.00 SHEET 1 of 1

Figure 19: the VV PHTS within the CWS

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ANNEX 2: CWS PBS

PBS level 1

PBS level 2 PBS level 3

PLANT BREAK-DOWN STRUCTURE: CWS

PRODUCT (COMPONENT) NAME26 Cooling Water System 26.PH PHTS 26.PH.BD IBED PHTS 26.PH.VV VV PHTS 26.PH.NB NBI PHTS 26.CV CVCS 26.CV.BD CVCS for IBED PHTS 26.CV.NB CVCS for NBI PHTS 26.DR Draining & Refilling 26.DR.00 Draining Refilling 26.DY Drying 26.DY.00 Drying 26.CC Component Cooling Water 26.CC.C1 CCWS-1 26.CC.2A CCWS-2A (for CU) 26.CC.2B CCWS-2B (for AL) 26.CC.2C CCWS-2C 26.CC.2D CCWS-2D 26.CH Chilled Water 26.CH.H1 CHWS-H1(SIC) 26.CH.H2 CHWS-H2(non-SIC) 26.HR Heat Rejection 26.HR.00 Heat Rejection

Highlighted in yellow, the components involved in the VV function

OBSOLETE

cws case study specifications k ^k> d - static.iter.orgstatic.iter.org/codac/pcdh7/folder...

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