1. CERN
CIS
PLC/COTS based Interlock and protection systems 1-2 February CERN 2016 Ignacio Prieto Diaz - Riccardo Pedica 1
Combining safety and conventional
interfaces for interlock PLCs
Ignacio Prieto Diaz
Riccardo Pedica
PLC Based Interlock systems Workshop
1-2 February 2016 CERN

2. CERN
CIS
PLC/COTS based Interlock and protection systems 1-2 February CERN 2016 Ignacio Prieto Diaz - Riccardo Pedica 2
the way to new energy…

3. CERN
CIS
PLC/COTS based Interlock and protection systems 1-2 February CERN 2016 Ignacio Prieto Diaz - Riccardo Pedica
Hydrogen
Helium
Neutron
Energy

4. CERN
CIS
PLC/COTS based Interlock and protection systems 1-2 February CERN 2016 Ignacio Prieto Diaz - Riccardo Pedica4

5. CERN
CIS
PLC/COTS based Interlock and protection systems 1-2 February CERN 2016 Ignacio Prieto Diaz - Riccardo Pedica 5
The ITER Domestic Agencies are responsible for
implementing the procurement activities under
each Member’s responsibility
*
European
Union
CN
IN
RF
KO
JP
US

6. CERN
CIS
PLC/COTS based Interlock and protection systems 1-2 February CERN 2016 Ignacio Prieto Diaz - Riccardo Pedica
ITER
6

7. CERN
CIS
PLC/COTS based Interlock and protection systems 1-2 February CERN 2016 Ignacio Prieto Diaz - Riccardo Pedica
ITER Interlock Control System
7
Central I&C System
- CODAC
- Central Interlock System
- Central Safety Systems
Plant System I&C
- Plant Control System
- Plant Interlock System
- Plant Safety System

8. CERN
CIS
PLC/COTS based Interlock and protection systems 1-2 February CERN 2016 Ignacio Prieto Diaz - Riccardo Pedica
The CIS
8
#19 #100 #8

9. CERN
CIS
PLC/COTS based Interlock and protection systems 1-2 February CERN 2016 Ignacio Prieto Diaz - Riccardo Pedica
ICS – Complex architecture
9

10. CERN
CIS
PLC/COTS based Interlock and protection systems 1-2 February CERN 2016 Ignacio Prieto Diaz - Riccardo Pedica
Interlock PLC Software Architecture
PROGRAMMING
STRUCTURE
• Safety program
• Conventional
program
SCADA
INTERFACES
• Epics
• WinCC OA
COMMUNICATION
PROTOCOL
• SIEMENS S7
• SIEMENS TSPP
• Fail Safe
communication
HARDWARE
INTERFACES
• Digital I/O
• Analog AI
HEALTH
MONITORING
SYSTEM
• Critical HLM
• Conventional
HLM
PROTECTION
FUNCTION
• Local protection
function
• Central
protection
function

11. CERN
CIS
PLC/COTS based Interlock and protection systems 1-2 February CERN 2016 Ignacio Prieto Diaz - Riccardo Pedica
Integration
YOU ARE HERE

12. CERN
CIS
PLC/COTS based Interlock and protection systems 1-2 February CERN 2016 Ignacio Prieto Diaz - Riccardo Pedica
Integration tool
PIS configuration and integration
PLC software template
Control logic diagram tool
Mini-CIS
DESIGN
DEVELOP
TEST
INTEGRATION

13. CERN
CIS
PLC/COTS based Interlock and protection systems 1-2 February CERN 2016 Ignacio Prieto Diaz - Riccardo Pedica
Guidelines for PIS Configuration and
Integration
Guidelines for PIS Configuration and
Integration
It guides the plant system developer to the
configuration of the Plant Interlock Slow
Controller giving rules for
• Hardware naming convention
• Block naming and numbering convention
• Variables Naming convention
• Implementation of
• Safety program
• Core application
• Standard Program
• Implementation of the Safety program
• Version control
• Development process

14. CERN
CIS
PLC/COTS based Interlock and protection systems 1-2 February CERN 2016 Ignacio Prieto Diaz - Riccardo Pedica
PLC Software template
• General Structure of the program
• Communication interfaces
• TSPP
• S7
• Failsafe
• Command execution
• 3 Steps Overrides verification
• Hardware interfaces
• Health monitoring system
• Critical
• Non critical
• Runtime group organization
• F_ PROG
• Standard
• Safety
It provides the basic structure of a Plant System PLC Code

15. CERN
CIS
PLC/COTS based Interlock and protection systems 1-2 February CERN 2016 Ignacio Prieto Diaz - Riccardo Pedica
CLD – Control Logic Diagram tool
Common platform for I&C Design Management
Developed by the Central Safety System, extended to ITER I&C
 Database
 Functions
 Controllers
 Variables
 Logic Drawing Tool
 Report utility
 V&V

16. CERN
CIS
PLC/COTS based Interlock and protection systems 1-2 February CERN 2016 Ignacio Prieto Diaz - Riccardo Pedica
CLD – Control Logic Diagram tool
• Plant Breakdown Structure
• Central Functions
• Sub functions
• EVENT / CENTRAL / ACTION
• Central Interlock System
• Supervisor Module (SCADA server)
• Controllers
• Sub functions
• Logic Drawing tool
• Variables
• Plant Interlock Systems
• Controllers
• Local Functions / Sub functions
• Logic Drawing tool
• Variables
• Sensors and Actuators
• Reports
• Interface Data Sheets
• Controller Data sheet
• Custom reports

17. CERN
CIS
PLC/COTS based Interlock and protection systems 1-2 February CERN 2016 Ignacio Prieto Diaz - Riccardo Pedica
mini-CIS
The mini-CIS is an industrial computer, where the hardware and the software
components are designed to perform the main functionality of the CIS and permit the
FAT/SAT of Interlock Plant System.
Subsequent to the use of the mini-CIS, the integration of the corresponding PIS into the
real CIS should be immediate and free from errors.
• WinAC RTX
• NI PCIe FPGA card
• WinCC OA

18. CERN
CIS
PLC/COTS based Interlock and protection systems 1-2 February CERN 2016 Ignacio Prieto Diaz - Riccardo Pedica
Interfaces data sheet
The functional interface data between the
PLC and other plant Systems are
documented and managed through the IDS
(Interface Data Sheet)
There are five categories of functional
interfaces in the plant interlock controllers
• Critical automatic data
• CIS supervision on PIS
• Critical manual data
• Archiving interface
• Maintenance interface.
Automatic generated Electrical diagram
SEE Electrical expert.
An electrical tool used by ITER exchanges
information with PLC programming software
in order to automatically generate and
update Input/Output card layouts
And more…

19. CERN
CIS
PLC/COTS based Interlock and protection systems 1-2 February CERN 2016 Ignacio Prieto Diaz - Riccardo Pedica
Conclusions
The ITER Interlock System will most likely be the first machine protection system built
with most of its components provided in-kind from up to 36 different countries
A strong effort is being put in place to ensure that all actors around the globe
design, build and configure the parts of the puzzle to be properly integrated with the
central system
While a detailed design of the Central Interlock System has been already
performed, a strategy has been put in place to continuously monitor the progressive
growth the overall interlock system.

20. CERN
CIS
PLC/COTS based Interlock and protection systems 1-2 February CERN 2016 Ignacio Prieto Diaz - Riccardo Pedica
Thank you...
@ITERinterlocks