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Tae technologies powers up with reliable control system
- 1. 1 TAE Technologies Powers Up with Reliable and Flexible Control System Rockwell Automation TechED | SanDiego | June 2018 R. Michel, A. Lednev, D.MacDonald Presented by ASibley
- 3. 3 Presentation Outline 1. TAEVision ofClean Fusion 2. C-2W Machine (Norman) 3. Vacuum Systems 4. Choice ofRockwell Automation products 5. Vacuum System Components 6. HardwareDesign 7. SoftwareDesign 8. HMIs 9. Integration with C-2W ControlSystem 10. Conclusions 11. Future ofClean Fusion
- 4. 4 TAE’s Vision of Clean Fusion • Formedin April 1998with theaim to investigatea “FieldReversed Configuration”which differsfrom thenormal Tokomakapproach(JET, ITER) • Machineis lineardevicewhich collidesplasmacompact toroidssustainedin a magnetic fieldandheatedby high energyNeutralBeams • Proposedfuelis p-B11 whichproducesnoneutronsunlike D-T reactions • Previousmachine(C-2U) demonstratedplasmasustainmentfor10ms limited by availablepower • C-2W (aka.Norman) is new andhasenhancedmagnetic, heatingandvacuum systems • Copernicusis in the planningstagesandwill demonstratelongpulse operationand reactorrelevantconditionsforboth D-T andp-B11 fuels Inner Divertor
- 5. 5 C-2W Machine (Norman) • 7 main Ultra High Vacuum chambers (15 in total) • DC magnetic field created along length • Deuterium gas injected in Formation section • High current Formation pulses makes plasma toroid • Plasma toroids accelerated into central • Plasma toroids combine into one • Neutral beams inject particles (H), plasma heated – temperature • Neutral beams fuel plasma — density • Circulating current generates field in plasma — confinement Neutral Beams Formation Central Vessel Outer Divertor Chamber Inner Divertor Chamber DC Magnets
- 6. 6 Why Rockwell Automation? • Reliabilityisessentialforourapplication,previoususe ofRockwellAutomationproducts hadno downtime • Downtimeverycostlyaswecannotoperate,noscienceoutput(est.at$100kperday) • R&Denvironmentnecessitatesusingnon-scheduledEtherNet/IPfordistributedI/O,SMC andFlex™IO(1794)– difficulttouseDeviceNet™orControlNet™ • Ease ofsoftwaredevelopmentusingstructuredtechniques – wemake maximumuse of UDTs,AOIsandAliasingtoensurecode is“self-documenting”andeasytofollow • Localsupportvitalforbothsystemdevelopmentand supply(OneSourceDist.)
- 7. 7 Vacuum System OVERVIEW AND SOFTWARE DESIGN
- 8. 8 Vacuum System Outer Divertor Formation Inner Divertor Central Vessel Chamber Gate Valves Vacuum • Ultra-high vacuum 1E-9 Torr • 15 large chambers • Over 300 gate valves • Over 24 Roughing pumps • Over 20 Turbo pumps • Over 60 vacuum gauges • LN2 Cryogenic systems • Thermocouples Hardware • Pneumatic valve control • Digital In for valve status • EtherNet/IP & Profibus • Fiber network for EMI Software • Structured design • Maximum use of Aliases • State machines • Auto pumpdown • Fault & recovery routines • Alarm handling • FactoryTalk® View SE Neutral Beams (8)
- 9. 9 Vacuum System Components Gate Valve Pneumaticactuatorand micro switches Turbo Pump Assembly TurboPump GateValve Angle Valve Pneumatics & Digital Input
- 10. 10 Network Infrastructure • Fibersystemsused(EMIresiliency)forallDIOcommunicationat 100Mb • UseredundantringtopologyusingNT24Kwithduplex fiberdrop tomediaconverterandequipment • Switchespredominantly100FXand 1000SXconnections • They’remonitoredviaCIPconnectionswithseparateL61 Controlleranddisplayedon FactoryTalk® ViewSE • DLRwascontemplatedinthedesignstage
- 11. 11 Software Design (1) 1. What’sthe firstthing we do? Startcoding? Understandthescopeand problem. 2. Knowthe scopeof what you’recontrollingfrom the P&ID. 3. Identifyareasof commonalitysoyou can codeonce – usemany. a) Gatevalve is the sameasanother. b) Gaugesareessentiallythesamebut may havedifferent Engineeringranges. c) Turbopumphasidenticalinterfaces. 4. Assemble“blocks of equipment”into structuredUDTsand AOIs. Thiscan be usedagainand againwithouthaving to domuch coding. 5. UseAliasingto linkControllerleveltags to Program Local Tags. 6. CreateProgramsto segregatecode mimicking the “blocks of equipment”. KeepalarmsandEvents with theobjectsthatproducethem. No separate faultroutines. 7. Try andbeconsistentacrossallPrograms andRoutines. 8. Choosetheright languagefor thesolution. Don’t make LadderLogic State Machines.
- 12. 12 Software Design (2) Startby “whiteboarding”thesystemsmimickingtheP&ID. GATE VALVE TURBO PUMP TURBO CONTROLLER ANGLE VALVE GAUGE GAUGE BACKING PUMP PROFIBUS INTERFACE PNEUMATIC & DI AI & POWER AI & POWER PNEUMATIC & DI DIGITAL INPUT (DI) Gauge may not bepart ofthis block (Aliased)Good VacuumRough Vacuum GAUGE AI & POWER PLANT INTERFACES
- 13. 13 Software Design (3) Valve PermitProperties • Conditionsthatallowvalve to open • Couldbe poorvacuum one side • Differentialpressureeitherside • Turbonot ready(not at 45,000RPM) • Gauge fault • Downstreamconditions • Once valve is openpermitis ignored Valve Interlock Properties • Failuresthat needthe valve to close • Turbofault, dropin RPM • Poorvacuum detectedonexhaust • Poorvacuum inchamber • Backing pumpfault • SystemEmergency Stop Gate Valve Pneumatic &DI Open Close Open Contacts Closed Contacts Example of typicalgate valve controlwith 4-contactsper valve beingusedto monitorposition.
- 14. 14 Software Design (4) • Group DataTypes(e.g.BOOL)together • Giventhemmeaningfulnames • Alwaysadddescriptions • Includefaulttimers– they’reownedbythedevice • Stayconsistentwithnamingconventions • IncludeLocal/Remoteswitchingoptions • Inp_BOOLshavedatacopied intothemfromtheplantDI • Out_BOOLscopydatatoaplantDO Hints and Tips for Structuring UDT_VacuumValve (extract) Name Data Type Description Inp_OpenNO BOOL Contact closes whenvalve in open state Inp_OpenNC BOOL Contact opens whenvalve in open state Inp_ClosedNO BOOL Contact closes whenvalve in closed state Inp_ClosedNC BOOL Contact opens whenvalve in closed state OpenCmd BOOL Intenttooperatevalve Out_Open BOOL Output command tooperate pneumatics Open BOOL Valveis in openstate Closed BOOL Valveis in closed state Invalid BOOL Valveis in invalid state WiringFault BOOL A wiring fault has beendetected OpenFault BOOL Failureto open CloseFault BOOL Failureto close OpenFaultTMR TIMER Failureto reach open statetimer CloseFaultTMR TIMER Failureto reach closed state timer
- 15. 15 Software Design (5) AOIshowsinterfacingwithDI andDObox – one ofmany • 16portpneumaticvalves • 64digitalinputs • RemoteIOstructuredirectlyinterfaceswithAOI • JustinsertInputandOutputand that’sit! • AOIcontainsValvecontrol,status,faultlogic • LinkedtoControllerleveltagssothatnamesarereadable throughoutcode
- 16. 16 Software Design (6) • We arebuildingupthe“block of equipment”out of alreadydefinedUDTs to mimic the completeTurbopumping system • Note thereuseof UDTsforgauges andvalves • AliasProgram generictag to Controllerleveltag (e.g TurboaliasedtoTMP01) Youget nameconstructslike: Turbo.Drive.Rpm aliasedto…etc. TMP01.Drive.Rpm ; rpm reading TMP01.ExhaustPT.Eng ; 1.3E-4 Torr TMP01.Pump.AtSpeed ; Trueif at 45,000rpm TMP01.InletValve.Open ; Gate valve isopen Hints and Tips for Structuring UDT_Turbo (extract) Name Data Type Description RoughMode BOOL Turbo isinroughing mode RoughPermit BOOL Roughingmode permitted WaterFlowFault BOOL Waterflowinadequate InletPT UDT_GaugeAI Inlet pressuretransducer InletValve UDT_VacuumValve Inlet gate valve Pump UDT_VacuumPump Pump statesand interlocks Drive UDT_Profibus_Turbo Turbo controllerdata (RPMetc.) ExhaustPT UDT_GaugeAI Outletpressure transducer OutletValve UDT_VacuumValve Valve between turbo and backing BackingPT UDT_GaugeAI Backing pump pressuretransducer BackingPump UDT_BackingPump Backing pump Mode UDT_RemoteLocal Operatingmode Sequence UDT_RemoteLocal Sequence mode
- 17. 17 Software Design (7) • UseseparateProgramsfor blocksof equipment(littlepenaltyperformance wisebut claritybenefits) • KeepRoutinesconsistentand useAliaseswherepossibleconfiguredin Local Tags • Aim to copyandpastecodebetweenPrograms with no changesrequired • ArrangePrograms in logicalorderto mimic eithertheplantorprocessflow • KeepRoutinesconciseandwell documentedwith lengthabout3-4 pageslong • Gaugeshandledby otherTask Hints and Tips for Program Structuring
- 18. 18 HMI Systems • PreviouslyusedRSView 32 andneededto migrate from WindowsXP to 2012R2 • LabVIEW notan optiondueto large behind-the-scenescoding requirement– some PLC datais displayedonLabVIEW via DDS • Neededseparatesystemforsafetyand reliabilityreasons • FactoryTalk® View SEoffersdistributedsystemandeasesroute to redundancy • VMware ESXi deploymentusing4 servers • Migrationfrom RSView 32 went smoothlyand gave usthe chanceto beautifyscreensand provideextrafunctions • Look andfeelsimilarto PlantPAX® FactoryTalk Directory Operator Work Stations Headless HMI Server Data Server MS SQL Server FactoryTalk™ View SE Clients · HMIs · Trend data · Alarms and Events · Secure login using RFID cards Trend data transferred to Science Server after 10-days
- 19. 19 Interfacing with DDS SEQUENCING VACUUM SYSTEM WITH SHOT CONTROL
- 20. 20 DDS Interfacing (1) • Majorityof the ControlsystemusestheData DistributionService (DDS) from RTI Inc. • LabVIEW codedsubsystemsauto-discoverandPublish/Subscribedatato/from anydevice • DDS is “battletested”andusedonmany large scaleprojectsincludingMilitary • We usetheDDS LabVIEW Toolkitand specificserverproductsfor: • Publishingandsubscribingto data(producersand consumers) • Trendingof data(turnondevice andif it publishesTrenddataitwill be captured) • Keepingcurrentvaluesavailableonthe DDS databus • Debugging DDS issuesand monitoringhealthof systemsincluding databases
- 21. 21 DDS Interfacing (2) • Vacuuminterfacedvia LabVIEW“Component”s/w • LabVIEWComponentisstandardacrossplantandinterfaceswithShotControl commandsetc. • LVdeveloperwritesspecificcodetocontrolplant • Over50 separateLabVIEWComponentscontrolthesequencingandoperationofC- 2W • Systemself-learnsaboutControlandPhysicsDiagnosticComponentsthatare operational • WriteandconfigureLabVIEWComponentandconnect–plugandplay • AutomaticallycapturesTrendandShotConfigurationdata fromdevices • Abilitytorecallover5000 settingsfromMySQLdatabase • Has provedveryreliableandflexibleinoperation
- 22. 22 Conclusions
- 23. 23 Conclusions Reliability • Choose hardwareand Distributed Input Output (DIO)hardware to match your expectations – we chose Rockwell Automation, ControlLogix® and EtherNet/IP – exceeded our expectations • Understand distributed networking challenges, the environment and impact of multiple devices using multicast • Build margininto designs and plan for expansion – after all we do R&D! • Monitor systems and learnfrom issues Flexibility • Abstraction of hardware using User Data Types (UDT) generates self documenting code • Build system so code can be modified without needing download • Build in AOI configuration to deal with different types of valves or gauges – limitcode sprawl • Use Aliasing so that youdon’t have to edit code when copying and pasting between Programs • Controller level tags allow different part of UDTs to be used in different programs
- 24. 24 Future of Clean Fusion
- 25. 25 The Next Step in Clean Fusion Designedto explorereactorrelevantconditions. • Highermagnetic fields,may usesuperconductingcoils • Much longerpulses(100sof seconds) • RealTime PlasmaControl • Developmentof ~600keVnegative ionneutralbeams • Developmentof multi megawattRadioFrequencyheatingsystems (IC/EC) • Controlanddatasystemsnumerousandcomplex(bothPLC and LabVIEW based) • Complexinterlockandplasmaprotectionsystems
- 26. 26 Thank You
- 27. 27 Share your Feedback • Download the Rockwell Automation Events App • Select Rockwell Automation TechED andlogin • Click on Session Surveys orSchedule in the main menu • Select the session you areattending • Click on the survey tab • Complete the survey and submit Pleasecompletea session survey on the mobileapp
- 28. www.rockwellautomation.com PUBLICPUBLIC Copyright © 2018 RockwellAutomation, Inc. All Rights Reserved. 2018 RockwellAutomation TechED™Event #ROKTechED #ROKTechED Thank you! Questions?
Editor's Notes
- This is a somewhat simplified explanation of what happens! There are about 50 subsystems on this machine (depending on the configuration) and the Vacuum PLC system is just one of them. We have 20% PLC controlled the remainder is LabVIEW using some National Instruments hardware for acquisition, critical timing and control functions. The Vacuum system using ControlLogix L85 is a good example of how to engineer a very complex system and to use creative programming techniques to simplify a complex problem. The 7 chambers are under an ultra high vacuum system with pressures around the 1E-9 Torr. We accomplish this by using a variety of pumping techniques including cryogenic and Titanium evaporation. The Vacuum PLC is therefore critical in the control and monitoring of a large number of systems to maintain the high quality vacuum and to deal with fault scenarios. A DC magnetic field is created along the vessel. Deuterium gas is injected into the Formation section and a sequence of high current discharges first ionizes the gas and then traps magnetic energy in the plasma creating a football shaped toroid. Both Toroids are propelled towards the center of the machine where they are held captive by Mirror fields. Neutral Beam injectors – basically high energy particle injectors – inject neutral 15keV hydrogen into the vessel where the atoms are ionized and create a circulating current in the Toroid. This current mains the internal magnetic fields and confines the plasma. If the beams terminate then the plasma disappears after a few 100us. So far we have sustained the plasma for 10ms limited by the stored energy on site. The current experiment is operating and had reached its Phase 1 goals. We’re currently operating on initial Phase 2 work in flaring the magnetic field lines into the Inner Divertor Chamber.
- 7 main vessel chambers 8 Neutral Beam chambers Over 20 turbo pumps: 2 turbo on each divertor and central vessel (10) 1 turbo on each Formation and 8 NBI (10) Additional Turbo pumps used for some vacuum facing Diagnostic systems Vacuum control is distributed throughout the machine with about 40 pneumatic and analog input boxes connected via a fiber network to a ring system of 24-port predominately fiber switches. A single L85 controller and Ethernet modules is housed in a rack located in the server room. The Vacuum system has it’s own EtherNet/IP subnet for DIO and a connection onto the main control network for HMI and programming access.
- Photos show the type of Gate Valves we control and monitor as well as Turbo Pumps and smaller angle valves. The Pneumatic system uses and SMC EX600 manifold and we also use their DI blocks to save on space. Gate Valves – Interfaced with pneumatics and DI Turbo pump – interfaced with TD20 Controller and Profibus via EtherNet/IP Gauges are power via 24V DC and interfaced to AI (0-10V)
- Correct network design is critical to reliability. As we use predominately fiber optics to communicate to equipment we selected: N-Tron NT24K rack mount switch with 100FX and 1000SX fiber modules Handles EtherNet/IP without issue (as many manufactures do) Ring system at 1Gb allows for about 60 drops to equipment Pay attention to the number of IGMP groups on the subnet Server room switch interfaces to the Cisco core switches 1G/10G, VMware clusters and storage systems Vacuum system uses 192.168.0.0/24 for DIO but has separate HMI interface to main machine network
- TODO
- Although I cannot detail ALL of the plant I’m going to discuss one block of equipment – Turbo pump set. Gate valve is pneumatically operated with CDA and has open and close ports Open and close states are checked with SPDT microswitches providing 4-wire monitoring Angle valves have subset of these functions and so common code AOI can be reconfigured Turbo pumps runs at up to 45,000 RPM, risk of damage to equipment The Controller provides VFD power to Turbo and monitors states and faults Turbo Controller interfaced to the PLC using Profibus (AnyBus module) Gauges are power from +24V and output 0-10V in log scale (1-9V is valid) Gauge types used to configure logic to correctly scale engineering units Out of range detection used to signify gauge fault and this is used to check for gauge function before operating equipment Backing pump operation monitored by gauge Backing pump can also be monitored for faults using DI
- TODO
- Mention reliability and flexibility.