ITER and its Control System –Status and Perspectives

Ralph Lange

Control System Division
ITER Organization

Disclaimer:
Disclaimer:
TheTheviews
views
andandopinions
opinions
expressed
expressed
hereinhereindo donotnotnecessarily
necessarilyreflect
reflect
those
thoseof theof theITER
ITEROrganization.
Organization
KEK Seminar, 22 May 2017, Tsukuba© 2017, ITER Organization

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We forgot
there is aninterface
between A
and B
I forgot that I
need that inmy system

ITER A
Agreement
splitsproblems
the project in
bitMisinterpretedofinterface
Islandmentality
scope
procurement arrangements distributed
among the seven members

We changed
the design sothe interface
does not exist
anymoreThat shouldbe
implemented
in yoursystem, notmine

I did not know
the others are
doing thesame thing ina differentway

I do not carewhat theothers do. I
build mysystem.
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The ITER control system
performs thefunctional integration of the ITER plant
andenables integrated and automated operation

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Outline• Introduction and Architecture– System Breakdown, Networks, Structure– Key Parameters• CODAC Core System– Standardization: Specification, Hardware, Software, Support• CODAC Operation Applications• Infrastructure and Protection Systems• Schedule• Early Integration Approach
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Page 4KEK Seminar, 22 May 2017, Tsukuba© 2017, ITER Organization

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High Level Requirements
The ITER control system
performs thefunctional integration of the ITER plantandenables integrated and automated operation

KEK Seminar, 22 May 2017, Tsukuba© 2017, ITER Organization

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Architecture

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Architecture

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Page 8CBS 2CBS 1

CBS = Control Breakdown StructureArchitecture••••

Breakdown in 18 ITER control groups (CBS level 1) covering 28 PBS
An ITER control group contains many Plant System I&C, total no. 171 (CBS level 2)
A Plant System I&C is a deliverable from a procurement arrangement (IN-KIND)
A procurement arrangement delivers a part, one or many Plant System I&C
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Some Key Parameters (Quantities)
Parameter

Value

Total number of I&C cubicles/racks>5.000Total number of plant I&C signals (wires)>100.000

Total number of process variables (PV)>1.000.000

Total number of active operator stations

100

Physical size of ITER site

900*600 m

Number of buildings and plant areas with I&C equipment

90

Number of central-plant I&C interfaces330

I&C cables (sensors/actuators to controllers)

6000 kmMulti-core single mode fiber optic network cables

300 kmMulti-pair copper network cables

170 kmNumber of identified machine protection I&C functions

150

Number of identified nuclear safety I&C functions252

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Some Key Parameters (Performance)
Parameter

Value

Update rate per operator station (200 PVs)

5 Hz

Maximum sustained data flow on Plant Operation Network (PON)

50 MB/s

Total PON archive rate

25 MB/s

Total Data Archive Network (DAN) archive rate (initial)

2 GB/sTotal DAN archive rate (final)

50 GB/s

Total archive capacity90-2200 TB/day

Accuracy of time synchronization<50 ns RMS

Number of nodes on Synchronous Data Network (SDN)

100

Maximum latency asynchronous events

1 ms

Maximum latency sensor to actuator (SDN)

500 µsMaximum jitter sensor to actuator (SDN)

50 µs RMS

Maximum sustained data flow on SDN

25 MB/s

Maximum latency sensor to actuator for “slow” interlock

1 sec

Maximum latency sensor to actuator for “fast” interlock

1 ms

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Page 11Interfaces• Interface andintegrate 28 plants
supplied by 101
procurement
arrangements

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Page 1212

Standardization – Specifications
PCDH core and satellite documents: v7
INTERLOCK CONTROLS
Guidelines for PIS design (3PZ2D2)
Guidelines for PIS integration & config. (7LELG4)
Management of local interlock functions (75ZVTY)PIS Operation and Maintenance (7L9QXR)

PS CONTROL DESIGN
Plant system I&C architecture (32GEBH)
Methodology for PS I&C specifications (353AZY)
CODAC Core System Overview (34SDZ5)Core documentwith specification

Catalogues.
Mainstream industry COTS
technologies.
OCCUPATIONAL SAFETY CONTROLSCore PCDH (27LH2V)
Guidelines
for PSS-OS
designSpecial prices forITER
project
Plant system control philosophy
Guidelines
to help
Plant system control Life Cycle(C99J7G)

NUCLEAR PCDH (2YNEFU)

CATALOGUES for PS CONTROL
Slow controllers products (333J63)
Fast controller products (345X28)
Cubicle products (35LXVZ)
Integration kit for PS I&C (C8X9AE)

plant system I&C
suppliers
Plant system control specifications
CODAC interface specifications
Interlock I&C specification
Safety I&C specification

PS CONTROL DEVELOPMENT
I&C signal interface (3299VT)
PLC software engineering handbook (3QPL4H)
Guidelines for fast controllers (333K4C)
Software engineering and QA for CODAC (2NRS2K)
Guidelines for I&C cubicle configurations (4H5DW6)
CWS case study specifications (35W299)

I&C CONVENTIONS
I&C Signal and variable naming (2UT8SH)
ITER CODAC Glossary (34QECT)
ITER CODAC Acronym list (2LT73V)
PS SELF DESCRIPTION DATA
Self description schema documentation (34QXCP)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)LegendThis document
Available and approved(XXXXXX) IDM ref.

Full documentation set available on public web
KEK Seminar, 22 May 2017, Tsukuba© 2017, ITER Organization

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Standardization – Hardware
Slow controlüSiemens S7-300/400 products (1500 series soon)

üET200M and ET200S for remote I/OüCovering standard industrial systemsCubicles
üSchneider Electric productsü

Address floor standing andwall mounted cubicles

üAddress Standard andEMC protected.

Fast controlü

PCI Express. CPU and I/O segregatedü

Mainly National Instruments productsü

Covering acquisition and control > 50 Hz
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Standardization – Software• OS:
Red Release
Hat EnterpriseLinux (RHEL x86_64)
VersionChangeInfra2013
2014
2015201620172018
date real-times extensions on fast controllers
with MRG-R

2019

2020

2021

RHEL 6.3
4.0.0
2013-02-15
434400• MRG-R
Infrastructure:
EPICS,control
systemtool set used in hundreds of projects
4.0 4.1 4.2
4.3
Support300
2.14.1.0
2013-07-04
416
world-wide:
light sources, high energy
physics, fusion (KSTAR, NSTX)
200
EPICS
3.14

4.2.0

2014-02-14

455

100

6.5
• RHEL
CODAC
services
Studio used at many EPICS and other0
4.3.0
2014-07-07layer:
274Control System
MRG-R
4.0.0 4.1.0
5.
and 2015-02-20
including HMI,
archiving
etc.4.3.0 5.0.0
4.2.02.5sites
5.0 alarming,
5.2 5.3
5.4
Support
5.0.0
616
1
5.1.0 5.2.0
EPICS
5.3.0
5.4.0
5.1.0 specific2015-07-17
353 such as configuration (system description), state• 3.15ITER
softwarehandling,
drivers, networking,
etc.
5.2.0
2016-02-17
524
RHEL
7.x
enhancement
correc2ons
MRG-R
5.3.0
2016-01-01
6.0
6.1 needed),
6.2 extensive
6.3• x.xFixed
1 yearrelease280
cycle (maintenance releases
when
5.4.0
2017-02-21
EPICS
testing
procedures
7.x

357

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Standardization – I&C Integration Kits
Distributed for free to allplant system I&C (171)Contains:
o An industrial computer hosting:• Plant System Host• mini-CODAC
as virtual systems
o An industrial network switch to set-up
the local networko A cubicle monitoring systemo The interfaces boards to connect the fast controllers to High Performance
Networks (TCN/SDN/DAN)KEK Seminar, 22 May 2017, Tsukuba© 2017, ITER Organization

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Standardization – Distribution StatusoI&C Integration Kits Deliveries•102 kits (out of 171) shipped since 2013

oCODAC Core System (CCS) Distribution:•RedHat satellite since 2012 has distributed
RPMs to 64 registered institutions

KEK Seminar, 22 May 2017, Tsukuba© 2017, ITER Organization

CNEUINIOJAKORFUS

1122
6137111815

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Standardization – HMI Style Guide and Toolkit• Plant System operator VDU workstation: 3 VDU (terminals)– Ultra HD resolution as a minimum
3840 x 2160 (4K) at 60Hz
– 24 inches– Aspect ratio of 16:9

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CODAC Operation Applications
CODAC Operation Applications are ITER dedicated software packages
deployed on dedicated central servers
1. Preparation
Scheduling (PSPS)
Gateway (ORG)

2. Execution
Control (PCS)Supervision (SUP)

3. Analysis
Data handling
Data accesseXternal to POZ

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Page 19CODAC Operation Applications
o Pulse Schedule Preparation System (PSPS)••

Scheduler for schedule preparation and validation
Initial existing version allows editing, managing, saving and exportingconfiguration objects

o Operation Request Gateway (ORG)••Support remote participation by securely controlling and screening
interaction with the outside world
Initial existing version allows unidirectional mirroring of data from POZ
to XPOS and configuration requests transmission from XPOZ to POZ

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Page 20CODAC Operation Applicationso Supervision and Automation (SUP)••

Provides the infrastructure to execute a pulse schedule prepared byPSPS and to support automated operation and continuous monitoring
Initial existing version implements Plasma Operation State (POS)
sequence and Common Operational State (COS) aggregation andpartitioning functiono Plasma Control System (PCS)••

Performs the distributed real-time control and monitoring during thepulse
Final design of underlying real-time infrastructure frameworkcompleted. Preliminary design of physics algorithms completed.
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Page 21CODAC Operation Applicationso Data Handling••Provides the system to write, store, retrieve and visualize all data
produced during ITER commissioning and operation.
First implementation to store fast data in HDF-5 format and interface
to EPICS data archiving availableo Data Access••Provides a unified access to all data produced by ITER and APIs forselected preferred user processing and visualization software (e.g.
Matlab, MDSplus,…)First implementation of Unified Data Access API available

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Upgrade to EPICS 7EPICS 7 introduces a network protocol that supports structured data
• SUP (Supervision and Automation) will benefit from being able toconsistently read/write configuration for a complete system• PCS (Plasma Control System) will benefit from consistent control andmonitoring of real-time nodes• HMI will benefit from efficient image transfer across the network• The early plant systems’ I&C will be based on current EPICS V3 –EPICS 7 provides multiple interoperability options(more details in seminar this afternoon: 3rd bldg, 7F, meeting room, 1.30pm)

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Infrastructure
Control building

Neutral beam

Coil power supplies

Hot cellBackup controlbuilding

Tokamakcomplex

ElectricalCryoplant

KEK Seminar, 22 May 2017, Tsukuba© 2017, ITER Organization

ICH/ECH

Cooling water

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Infrastructure
Redundant dualstar configuration
All cables end up in
B71 and B24

Bill of Material•
173 cubicles•
175 passive network panels•
300 km multi-core single mode•
170 km multi-pair copper cables
Connecting thousands of plant system
I&C client cubicles via network panels
located in 28 buildings

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Page 25Machine Protection I&C

Final design completed
Manufacturing in progress

PIS• Different requirements on time
response and action complexity
lead to three architectures.
− Slow Interlock Architecture: slower than 0.3 sec− Fast Interlock Architecture: 100µs - 0.3 sec− Hardwired Loops : < 1µsCIS

Architecture and Technologies

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Machine Protection I&C – Slow Interlock
PLC based using
Siemens S7-400 F/FH

Example function:
Event: Loss of one LN2 plant
Action: Coil power permitsremoved, next pulse inhibited

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Machine Protection I&C – Fast Interlock
FPGA based using
Customized NI compactRIO
Example function:
Hardwired CIN

CIS

KEK Seminar, 22 May 2017, Tsukuba© 2017, ITER Organization

Event: Diagnostics detect
Neutral Beam shine-throughAction: Neutral Beam is stopped

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Machine Protection I&C – Hardwired Loops
Current loops based on
Custom design (CERN derived)

Discharge Loop Interface Box (DLIB)

Example function:
Event: Magnet detects quench
Action: Fast Discharge Unit isactivated

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Nuclear Safety I&C
Architecture and Technologies•

Safety functions are classified
in four categories;− SIC 1 cat A and SIC 2 cat B
Hardwired HIMA Planar 4− SIC 2 cat C and SR cat C
Siemens S7-400 F/H•

Number of inputs/outputs
estimated to 29.000•

Project Change Request
transfers the scope of most
PSS-N to Central TeamFinal design in progress
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Occupational Safety I&C
Architecture and Technologies• S7-400 H and S7-300 F
technologies

Final design suspended for lack of inputs
and project schedule

PSS-OS x n

CSS-OS• Safety functions are classified inthree categories; SIL 1, 2 or 3

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Page 31Schedule
ITER 2016 baseline approved by ITER Council in November 2016
Underpinned with detailed resource loading
Staged approach

FP FinishedFirst Plasma and Start ofAssembly II(FP)
Jun. 2026
Dec. 2025

EngineeringOperation(SC Magnets)(6 Months)

Assembly II(24 Months)

End ofAssembly II
Jun. 2028

Start of PreFusion PowerOperation-I(SP)Dec. 2028

Integrated
Comm. II (6Months)

add 46
plant system I&C

End of PreFusion PowerOperation-I
and Start ofAssembly III
Jun. 2030

Pre-Fusion
Power
Operation-I (18Months)

End ofAssembly III
Sep. 2031

Assembly III (15Months)

Pre-Fusion
Power
Operation-II(TP)
Jun. 2032

Integrated
Comm. III (9Months)

add 29plant system I&C
KEK Seminar, 22 May 2017, Tsukuba© 2017, ITER Organization

End of PreFusion PowerOperation-II andStart of PreNuclear
Shutdown for
Assembly IV
Mar. 2034

Pre-Fusion
Power OperationII (21 Months)

End of PreFusion Power
Nuclear
Shutdown for Operation
Assembly IV (DT)Dec. 2035
Mar. 2035

Assembly IV(12 Months)

Integrated
Comm. IV (9Months)

add 18plant system I&C
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Schedule

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Schedule

Control building (B71)
postponed 4 years!

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Mitigation: Temporary Control RoomsRequirements•••

The central infrastructure and services must be available soon
Human Machine Interfaces must be provided for plant system I&C integration
Migration of all plant systems I&C control to B71 must be achieved within 18 months

Implementation•••

Create temporary local autonomous “islands” in strategic buildings,
providing central services and Human Machine Interfaces
Connect islands with temporary cables to provide inter building connectivity
Maximize emulation of final system to simplify migration to B71

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Temporary Control Rooms
1.

Install central servers in existing
CODAC hutch cubicles

2.

Standard HMI stations in suitableroom3.

Add CIS and CSS whenapplicable (local test tools)

4.

Cover all Plant Systems for First
Plasma (before Control Buildingavailability) by six Temporary
Control Rooms

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Conclusions• ITER 2016 baseline schedule approved by Council– Resource loaded, using staged approach• CODAC Core System stabilizing– Plant system design tool set in place• CODAC Operation Applications under development– Integrating important EPICS developments• Integration effort begins this year
– Using local control rooms as control room building is delayed

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Thank you

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